Preparation method and device of amorphous alloy-MoS2 composite coating

Abstract

The invention provides a preparation method and device of an amorphous alloy-MoS2 composite coating. According to the preparation method of the amorphous alloy-MoS2 composite coating, the technical bottleneck that amorphous alloy cannot be compounded with MoS2 through a traditional coating process can be broken through, the amorphous alloy-MoS2 composite coating with wear resistance, friction reduction and corrosion resistance can be prepared without pretreatment coating, the comprehensive performance of the coating is remarkably improved, and the preparation cost is reduced.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of thermal spraying / cold spraying composite coating preparation, and particularly relates to a preparation method and device of amorphous alloy-MoS2 composite coating. BACKGROUND

[0002] As an important functional material in the field of surface engineering, MoS2 coating is widely used in aerospace, precision machinery and automobile industry, etc. which have comprehensive demand for friction reduction, wear resistance and corrosion resistance. In the related art, a preparation system of multiphase composite coating is constructed through the collaborative work of thermal spraying and cold spraying. Specifically, this technical system covers the whole process from material selection, process parameter control to structure design, including the composite of Ni-based binder phase and MoS2 lubricating phase, the introduction of chemical plating coating process, and the key links such as spraying path planning and collaborative control of manipulator. With the development of surface protection technology, MoS2 has become the core component of self-lubricating coating due to its excellent solid-state lubrication performance, but its poor thermal stability and brittleness have always limited its application expansion in wear and corrosion resistance fields.

[0003] However, in the existing MoS2 coating preparation method, pure MoS2 powder is directly used for thermal spraying, which leads to a significant decrease in the content of lubricating phase and deterioration of coating performance due to the easy loss of sulfur and oxidation decomposition at high temperature. Based on this, the existing technology usually uses Ni, NiCr alloy as the binder phase, and carries out coating treatment on MoS2 through electrodeposition, agglomeration sintering and other processes to improve its thermal stability and bonding strength. However, such coated powders have problems such as complex process, high cost, limited wear and corrosion resistance, and it is especially difficult to realize the composite structure of amorphous alloy as the binder phase. Although amorphous alloy has high hardness and excellent corrosion resistance, it cannot be combined with MoS2 through traditional coating process, which limits the development and application of high-performance composite coating. SUMMARY

[0004] The present application aims to at least solve one of the technical problems in the related art to some extent.

[0005] To this end, a first object of the present application is to provide a preparation method of amorphous alloy-MoS2 composite coating.

[0006] A second object of the present application is to provide a preparation device of amorphous alloy-MoS2 composite coating.

[0007] To achieve the above object, the first aspect of the present application provides a preparation method of amorphous alloy-MoS2 composite coating, comprising: S1, spraying amorphous alloy powder and MoS2 powder by using a thermal spraying system and a cold spraying system respectively, wherein the thermal spraying system is used to form a splat structure of amorphous alloy binder phase on the surface of the substrate, and the cold spraying system is used to deposit MoS2 particles on the splat structure; S2, offsetting the trajectories of the thermal spraying manipulator and the cold spraying manipulator by programming control, so that the amorphous alloy phase and the MoS2 phase are alternately deposited according to a preset arrangement structure, and the arrangement structure comprises a chessboard type, a field type or a honeycomb type structure; S3, calculating and setting the TCP point position and the spraying path of the spraying manipulator according to the shape of the substrate and the spraying process parameters, so as to ensure that the amorphous alloy phase and the MoS2 phase form a continuous and stable composite structure in the coating.

[0008] In an embodiment of the present application, the spraying of amorphous alloy powder and MoS2 powder by using the thermal spraying system and the cold spraying system respectively, wherein the thermal spraying system is used to form a splat structure of amorphous alloy binder phase on the surface of the substrate, and the cold spraying system is used to deposit MoS2 particles on the splat structure, further comprises: S11, the thermal spraying system adopts a plasma spraying process, the powder feeding speed is 60-80 g / min, the current is 300-400 A, the mixing gas ratio of Ar and H2 is 8:2, and the spraying distance is 30-50 mm, so as to ensure that the amorphous alloy powder forms a splat structure with a thickness of 3 μm and a width of 10 mm after impacting the surface of the substrate; S12, the cold spraying system adopts a solid deposition mode, the powder feeding speed is 20-40 g / min, the gas pressure is 3-5 MPa, the spraying distance is 10-20 mm, and the movement speed of the spray gun is consistent with that of the thermal spraying system, so as to realize the uniform embedding of MoS2 particles on the amorphous alloy splat structure.

[0009] In an embodiment of the present application, the offsetting of the trajectories of the thermal spraying manipulator and the cold spraying manipulator by programming control, so that the amorphous alloy phase and the MoS2 phase are alternately deposited according to a preset arrangement structure, and the arrangement structure comprises a chessboard type, a field type or a honeycomb type structure, further comprises: S21, the programming control is realized by using ABB Rapid language, the TCP point starting positions Phome1 and Phome2 of the two manipulators are symmetrically distributed at 180°, and the trajectory offset is realized by using Offs instruction, so as to realize the alternate deposition of the amorphous alloy phase and the MoS2 phase; S22, when the preset arrangement structure is a honeycomb type structure, a column of MoS2 phase is inserted between every two columns of amorphous alloy phase, and continuous amorphous alloy columns are arranged on both sides of the amorphous alloy phase, so as to enhance the support and bonding strength of the MoS2 phase.

[0010] In one embodiment of the present application, the calculation and setting of the TCP point position and spraying path of the spraying manipulator according to the substrate shape and spraying process parameters to ensure that the amorphous alloy phase and the MoS2 phase form a continuous and stable composite structure in the coating further comprises: S31, the calculation uses the formula RPS x pi x D = 2VS, wherein RPS is the number of revolutions per second of the rotary table, D is the diameter of the workpiece, and VS is the surface moving speed of the spray gun, and the speed of the rotary table is determined according to the formula to match the spraying speed and ensure the uniformity of the coating; S32, the spraying path is set to be in a spiral distribution of the TCP point trajectories of the hot spraying manipulator and the cold spraying manipulator on the cylindrical substrate, and the distance between adjacent trajectory lines is 10 mm, so as to realize the continuous and alternating deposition of the amorphous alloy phase and the MoS2 phase.

[0011] In one embodiment of the present application, further comprising: S4, when the preset arrangement structure is a plow type structure, every 8 amorphous alloy phases are deposited around 1 MoS2 phase to avoid the angle contact between the MoS2 phases, thereby improving the compactness and bonding strength of the coating; S5, the MoS2 phase of the plow type structure is wrapped by the amorphous alloy phase in the normal direction to form a three-dimensional support structure, thereby enhancing the wear resistance and anti-peeling performance of the coating.

[0012] To achieve the above object, the second embodiment of the present application proposes an amorphous alloy-MoS2 composite coating preparation device, comprising: a spraying execution module for spraying amorphous alloy powder and MoS2 powder by using a hot spraying system and a cold spraying system respectively, wherein the hot spraying system is used to form a splat structure of an amorphous alloy binder phase on the surface of a substrate, and the cold spraying system is used to deposit MoS2 particles on the splat structure; a trajectory control module for controlling the trajectory offset of the hot spraying manipulator and the cold spraying manipulator by programming to make the amorphous alloy phase and the MoS2 phase be deposited alternately according to a preset arrangement structure, wherein the arrangement structure comprises a chessboard type, a plow type or a honeycomb type structure; a path planning module for calculating and setting the TCP point position and the spraying path of the spraying manipulator according to the substrate shape and the spraying process parameters to ensure that the amorphous alloy phase and the MoS2 phase form a continuous and stable composite structure in the coating.

[0013] The method and device of the embodiments of the present application can break through the technical limitation that amorphous alloy is difficult to coat MoS2, realize the composite structure of amorphous alloy and MoS2 by an alternating spraying process, significantly improve the wear resistance, friction reduction and corrosion resistance of the coating, and simplify the preparation process and reduce the material cost.

[0014] Additional aspects and advantages of the present application will be made apparent by the following description. BRIEF DESCRIPTION OF DRAWINGS

[0015] The above and / or additional aspects and advantages of the present application will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which: Figure 1 is a flow chart of a preparation method of an amorphous alloy-MoS2 composite coating according to an embodiment of the present application; Figure 2 is an international chessboard pattern with the highest MoS2 phase proportion according to an embodiment of the present application; Figure 3 is a pattern of a single pass spraying of MoS2 phase completely wrapped by amorphous alloy phase according to an embodiment of the present application; Figure 4 is a honeycomb pattern of a single pass spraying of MoS2 phase with only the upper and lower two corners in contact, and the whole being completely wrapped by amorphous alloy phase according to an embodiment of the present application; Figure 5 is a diagram of preparation of amorphous-MoS2 coating using a hot spraying, a cold spraying double mechanical arm and a two-axis turntable according to an embodiment of the present application; Figure 6 is a diagram of starting point and route of hot spraying and cold spraying TCP point trajectory according to an embodiment of the present application; Figure 7 is a cross-sectional image of a coating prepared according to an international chessboard pattern according to an embodiment of the present application; Figure 8 is a cross-sectional image of a coating prepared according to an international chessboard pattern according to an embodiment of the present application; Figure 9 is a cross-sectional image of a coating prepared according to a honeycomb pattern according to an embodiment of the present application; Figure 10 is a structure diagram of a preparation device of an amorphous alloy-MoS2 composite coating according to an embodiment of the present application. DETAILED DESCRIPTION

[0016] It should be noted that the embodiments in the present application and the features in the embodiments can be combined with each other without conflict. The technical solutions in the embodiments of the present application will be described in detail below with reference to the drawings and in combination with the embodiments.

[0017] In order for those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings and in combination with the embodiments. Obviously, the described embodiments are only a part of the embodiments of the present application, not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor should belong to the scope of protection of the present application.

[0018] The amorphous alloy-MoS2 composite coating preparation method and device according to the embodiments of the present application will be described below with reference to the drawings.

[0019] Example 1 Figure 1 is a flow chart of the preparation method of the amorphous alloy-MoS2 composite coating according to an embodiment of the present application.

[0020] As shown in Figure 1 , the method comprises the following steps: S1, spraying amorphous alloy powder and MoS2 powder by using a thermal spraying system and a cold spraying system respectively, wherein the thermal spraying system is used to form a splat structure of amorphous alloy binder phase on the surface of the substrate, and the cold spraying system is used to deposit MoS2 particles on the splat structure.

[0021] Specifically, the step sprays amorphous alloy powder and MoS2 powder by using a thermal spraying system and a cold spraying system respectively, wherein the thermal spraying system is used to form a splat structure of amorphous alloy binder phase on the surface of the substrate, and the cold spraying system is used to deposit MoS2 particles on the splat structure. This step is a key process link for realizing the structure of the composite coating according to the present application, and the technical implementation principle is based on the synergistic effect of the two deposition mechanisms of thermal spraying and cold spraying.

[0022] In terms of technical implementation, the thermal spraying system heats the amorphous alloy powder to a molten or semi-molten state by a high-temperature heat source (such as plasma or flame), and then impacts the surface of the substrate at high speed to form a splat with amorphous structure. Since the amorphous alloy has high cooling rate sensitivity, it solidifies rapidly after impacting the substrate to form a binder layer with no grain boundary and high density. The splat structure serves as a carrier for the subsequent cold spraying of MoS2 particles, providing mechanical support and interfacial bonding force. The cold spraying system accelerates the powder particles to supersonic speed (usually 500-1200 m / s) by high-pressure gas (such as nitrogen or helium) without melting the MoS2 particles, so that plastic deformation occurs when they impact the surface of the splat, realizing solid-state deposition. During the cold spraying process, the deposition efficiency and bonding strength of the MoS2 particles depend on the critical deposition velocity (CDV), which is usually between 600-800 m / s for MoS2. The gas pressure (0.8-1.2 MPa) and powder feeding rate (10-30 g / min) need to be adjusted to ensure the deposition quality.

[0023] In terms of parameter indicators, the thermal spraying system needs to control the powder feeding speed (10-20 g / min), the spray gun moving speed (100-300 mm / s), the spraying distance (80-120 mm), the current (200-400 A), and the gas composition (Ar 90%+H2 10%) to ensure that the size of the amorphous alloy splat is controlled within 10 mm wide and 3 μm high. The cold spraying system needs to set the gas pressure (1.0 MPa), the gas flow (20-30 L / min), the powder feeding speed (15-25 g / min), and the spraying distance (20-40 mm) to achieve uniform deposition of MoS2 particles on the splat structure, and the single-pass thickness can reach 3-5 μm. In addition, in order to realize specific structures such as chessboard, checkered pattern, or honeycomb, the spraying path and overlap step of the two systems need to be precisely controlled by programming the mechanical hand to ensure that the distribution ratio (0-50%) and arrangement mode of MoS2 phase in the amorphous alloy binder phase are controllable.

[0024] In application scenarios, this step is suitable for the preparation of composite coatings on complex curved surfaces (such as cylindrical workpieces) and planar workpieces. Through the coordinated control of the double mechanical hands, different structure types of coatings can be realized, such as chessboard structure for high friction reduction demand and honeycomb structure for enhanced wear resistance and bonding strength. This method does not need to prepare coated composite powders in advance, simplifies the process flow, reduces production costs, and at the same time improves the retention rate of MoS2 and the stability of coating performance.

[0025] The technical effect of this step is that through the synergistic effect of thermal spraying and cold spraying, in-situ composite of amorphous alloy and MoS2 is realized, solving the problems of complexity, high cost, and performance limitation of traditional coated powders. Amorphous alloy as a binder phase not only provides excellent wear resistance and corrosion resistance, but also effectively fixes MoS2 particles through its high bonding strength to prevent them from falling off or slipping during use, thereby significantly improving the comprehensive performance of the composite coating.

[0026] Further, S1 comprises: S11, the thermal spraying system adopts a plasma spraying process, the powder feeding speed is 60-80 g / min, the current is 300-400 A, the mixed gas ratio of Ar and H2 is 8:2, and the spraying distance is 30-50 mm to ensure that the amorphous alloy powder forms a splat structure with a thickness of 3 μm and a width of 10 mm after impacting the substrate surface.

[0027] Specifically, the thermal spraying system in the present application adopts a plasma spraying process, the core of which is to form a splat structure with specific geometric characteristics on the surface of the substrate by precisely controlling the spraying parameters, so as to provide structural support and interface bonding basis for the subsequent cold spraying of MoS2 phase. In some implementations, the powder feeding speed of this step is set to 60-80 g / min, the current is controlled to 300-400 A, the working gas is a mixed gas of Ar and H2 with a volume ratio of 8:2, and the spraying distance is set to 30-50 mm. The setting of these parameters is based on the balance relationship between energy input, powder melting state and thermodynamic response of the substrate surface in the plasma spraying process.

[0028] Plasma spraying forms a high-temperature plasma in the spray gun through a high-frequency arc, heats the amorphous alloy powder to a molten or semi-molten state, and sprays it at high speed to the surface of the substrate. The powder feeding speed directly affects the coating deposition rate and thickness uniformity, and a powder feeding speed of 60-80 g / min can ensure that the powder is heated sufficiently in the plasma without overheating and decomposition. The current parameter determines the plasma temperature and energy density, and a current range of 300-400 A can maintain the plasma temperature at about 10,000-15,000 K, which is sufficient to quickly melt the amorphous alloy powder and maintain its amorphous structure. The mixed gas of Ar and H2 has a ratio of 8:2, in which Ar provides a stable spraying environment as an inert gas, and H2 helps to improve the thermal efficiency of the plasma and the uniformity of powder melting.

[0029] The spraying distance is 30-50 mm, which can ensure that the molten particles have sufficient flight time to spread before hitting the substrate, while avoiding overheating of the substrate or uneven structure of the coating due to too close distance. The final splat structure has a thickness of 3 μm and a width of 10 mm, which meets the typical characteristics of thermal spraying single-layer deposition, and provides good interface matching and mechanical embedding conditions for the subsequent cold spraying of MoS2.

[0030] This step is suitable for surface pretreatment of cylindrical or planar workpieces, especially in cases where alternating spraying of amorphous alloy and MoS2 is required to form a composite functional coating. The amorphous alloy splat structure formed by this step can serve as a mechanical anchor point for MoS2 particles, improving the overall coating's bonding strength and structural stability.

[0031] The technical effect of this step is to precisely control the plasma spraying parameters to ensure that the amorphous alloy powder forms a uniform and dense splat structure on the surface of the substrate, providing structural support for the subsequent cold spraying of MoS2, thereby achieving efficient and stable preparation of amorphous alloy-MoS2 composite coating, and solving the technical bottleneck of high cost, complex process and limited performance of traditional coated powder preparation.

[0032] S12, the cold spraying system adopts a solid-state deposition method, the powder feeding speed is 20-40 g / min, the gas pressure is 3-5 MPa, the spraying distance is 10-20 mm, and the spray gun moving speed is consistent with the thermal spraying system, so as to realize uniform embedding of MoS2 particles on the amorphous alloy splat structure.

[0033] Specifically, in some implementations, the cold spraying system adopts a solid-state deposition method, the powder feeding speed is 20-40 g / min, the gas pressure is 3-5 MPa, the spraying distance is 10-20 mm, and the spray gun moving speed is consistent with the thermal spraying system, so as to realize uniform embedding of MoS2 particles on the amorphous alloy splat structure. The technical implementation of this step is based on the solid-state deposition mechanism of the cold spraying process, and the core principle is to accelerate the MoS2 powder to the critical deposition speed (usually 300-800 m / s, depending on the material hardness and ductility) through high-speed airflow, and to realize the mechanical embedding and dense accumulation of the particles by plastic deformation when the particles hit the substrate or the surface of the deposited amorphous alloy splat without melting the particles.

[0034] In terms of parameter setting, the powder feeding speed is controlled at 20-40 g / min, ensuring that the number of MoS2 particles deposited per unit time is moderate, avoiding uneven particle accumulation or nozzle blockage due to too fast powder feeding, and ensuring controllable coating thickness. The gas pressure is set to 3-5 MPa, and nitrogen or helium is usually used as the carrier gas to provide sufficient acceleration capability to make the MoS2 particles reach the required deposition speed. The spraying distance is 10-20 mm, which can effectively balance the particle kinetic energy and heat input, prevent the particles from being heated and decomposed or oxidized due to too close distance, and avoid the deposition efficiency from being reduced due to too far distance.

[0035] The spray gun moving speed consistent with the thermal spraying system is a key control point for realizing the alternating deposition of MoS2 and amorphous alloy splat structure and forming a composite coating. In the spraying process of the cylindrical workpiece, through the coordinated control of the double mechanical hands, the thermal spraying and the cold spraying are accurately aligned in the spatial path, so as to realize the uniform distribution of MoS2 particles between the amorphous alloy layers in the microscale. This step realizes the accurate lap and offset of the spraying path through programmed control (such as ABB Rapid or Robot Studio offline programming), ensuring the interface bonding strength and structural continuity between different coating layers.

[0036] The step is suitable for surface treatment of workpieces with complex curved surfaces or rotationally symmetric structures in practical applications, such as surface strengthening of wear-resistant and friction-reducing parts such as shafts and pipes. By embedding MoS2 particles in the amorphous alloy splat structure through cold spraying, the oxidation and decomposition of MoS2 during high-temperature spraying can be effectively avoided, and the high hardness and corrosion resistance of the amorphous alloy are used as a binder phase to significantly improve the overall performance of the composite coating. The technical scheme realizes the composite deposition of MoS2 and amorphous alloy without powder pre-coating treatment, reduces the preparation cost, improves the process flexibility and the adjustability of coating performance, and has significant engineering application value.

[0037] S2, by programming controlling the trajectory offset of the hot spraying manipulator and the cold spraying manipulator, the amorphous alloy phase and the MoS2 phase are deposited alternately according to a preset arrangement structure, and the arrangement structure includes a chessboard type, a field type or a honeycomb type structure.

[0038] Specifically, by programming controlling the trajectory offset of the hot spraying manipulator and the cold spraying manipulator, the amorphous alloy phase and the MoS2 phase are deposited alternately according to a preset arrangement structure (such as a chessboard type, a field type or a honeycomb type), which is the core process step of realizing the composite coating structure design in the present application. Based on the accurate control of the spraying trajectory and the logical planning of the deposition phase, the movement path of the two manipulators is programmed and offset during spraying, so as to form an amorphous alloy-MoS2 composite layer system with a specific spatial distribution on the substrate surface.

[0039] In some implementations, the step uses an ABB manipulator system to plan the trajectory through Rapid language or Robot Studio offline programming software. The hot spraying manipulator and the cold spraying manipulator carry amorphous alloy powder and MoS2 powder respectively, and the starting positions (Phome1 and Phome2) of the TCP (tool center point) are set, and the trajectory offset is set according to the spraying distance, the spraying gun moving speed and other parameters. For example, when preparing a chessboard type structure on a cylindrical sample, the trajectories of the two manipulators are arranged symmetrically in the circumferential direction by 180°, and in the axial direction, the hot spraying point is set to be higher than the cold spraying point by | VS |, i.e. the moving distance per second, based on the surface moving speed VS of the spraying gun, so as to ensure that the two phases are deposited alternately in space without overlapping.

[0040] Further, the control of trajectory offset in this step needs to meet specific arrangement logic, for example, in the chessboard structure, the MoS2 phase (yellow brick) and the amorphous alloy phase (green brick) need to be strictly alternated to avoid direct contact between MoS2 phases to prevent interlayer sliding or peeling caused by brittleness. In the field structure, each MoS2 deposition layer is surrounded by 8 amorphous alloy layers to form a stable "field" shaped support structure, thereby improving the overall bonding strength and wear resistance of the coating. In the honeycomb structure, the MoS2 phase is embedded between the amorphous alloy phase in a diagonal manner, while forming continuous amorphous alloy columns in the normal direction, acting like "reinforcing steel" to enhance the function.

[0041] The key parameters involved in this step include the movement speed of the spray gun (VS), the powder feeding rate, the spraying distance, the gas pressure (such as the supply pressure of N2 or He in cold spraying, usually 2-4 MPa), the plasma current in thermal spraying (such as 100-200 A), and the powder feeding gas flow (such as the Ar / H2 mixed gas flow of 10-20 L / min). In addition, the trajectory offset needs to be adjusted according to the phase distribution ratio of the coating design, for example, in the chessboard structure, the MoS2 phase accounts for up to 50%, while in the field structure, it is controlled at about 11.1% to ensure the balance between structural stability and functional performance.

[0042] This step is suitable for surface treatment of cylindrical or planar workpieces in practical applications, especially in mechanical parts, aerospace structural parts, and high-temperature sliding interfaces that require simultaneous friction reduction, wear resistance, and corrosion resistance. The phase control achieved through trajectory programming not only avoids the high cost and process complexity of traditional coated powder preparation, but also optimizes the distribution and bonding mode of the MoS2 phase through structural design, thereby significantly improving the overall performance of the coating.

[0043] Further, S2 comprises: S21, the programming control is realized by ABB Rapid language, the TCP point starting positions Phome1 and Phome2 of the two robots are set to be symmetrically distributed at 180°, and the trajectory offset is realized by Offs instruction to realize the alternate deposition of amorphous alloy phase and MoS2 phase.

[0044] Specifically, in some implementations, the programming control is realized by ABB Rapid language, the TCP (Tool Center Point) point starting positions Phome1 and Phome2 of the two robots are set to be symmetrically distributed at 180°, and the trajectory offset is realized by Offs instruction to realize the alternate deposition of amorphous alloy phase and MoS2 phase. This step is the core control logic for realizing the design of composite coating structure in the present application, and its technical implementation is based on the accurate planning of the spraying path and the coordinated motion control of the robot.

[0045] From the technical implementation level, this step first defines the TCP points of two independent robots in the ABB robot system, corresponding to the center positions of the spray guns of the thermal spraying system and the cold spraying system. Phome1 and Phome2 are arranged symmetrically at 180° on the circumference of the cylindrical workpiece, ensuring that the coverage areas of the two spraying systems on the workpiece surface do not overlap, while having good lap relationship. During the spraying process, the TCP points are controlled by the Offs instruction in the Rapid language to realize the layer-by-layer alternative offset of the spraying trajectory. For example, after the thermal spraying robot completes a layer of amorphous alloy coating, the cold spraying robot offsets a certain step (such as 0.5 mm) in the circumferential direction through the Offs instruction, and deposits MoS2 phase in the adjacent area, thereby forming an alternating layered structure.

[0046] In the parameter index layer, the offset amount of the TCP point needs to be dynamically adjusted according to the workpiece diameter D, the spraying speed VS and the rotary table speed RPS, following the formula RPS x π x D = 2 x VS, to ensure that the deposition rates of the two spraying systems on the workpiece surface are consistent. In addition, the spraying step is usually set to 0.5-1.0 mm to ensure that the interlayer lap rate is above 80% to avoid uncovered areas. The spraying distance parameters need to be set separately, with the thermal spraying system generally being 100-150 mm and the cold spraying system being 200-250 mm to adapt to the requirements of different processes for particle deposition state.

[0047] In the application scenario layer, this step is suitable for alternating spraying processes of cylindrical or planar workpieces, and has a significant advantage in realizing uniform distribution of amorphous alloy and MoS2 phase in the composite coating structure. By programming the symmetrical distribution and trajectory offset of the TCP points of the two robots, various coating structures such as chessboard, checkered pattern, honeycomb, etc. can be flexibly realized, thereby adjusting the volume fraction of MoS2 phase (0-50%) and optimizing the friction reduction, wear resistance and corrosion resistance of the coating.

[0048] The technical effect of this step is that without the need for pre-prepared coated composite powder, the spraying path can be controlled online or offline to realize in-situ alternating deposition of amorphous alloy and MoS2, thereby constructing a composite coating with excellent interfacial bonding strength and structural stability. By accurately controlling the symmetrical distribution and offset amount of the TCP points, direct contact between MoS2 phases can be effectively avoided, reducing the risk of interlayer sliding and peeling, and improving the overall mechanical properties and service life of the coating.

[0049] S22, when the preset arrangement structure is a honeycomb structure, a column of MoS2 phase is inserted between every two columns of amorphous alloy phase, and continuous amorphous alloy columns are arranged on both sides of the amorphous alloy phase to enhance the support and bonding strength of the MoS2 phase.

[0050] Specifically, when the preset arrangement structure is a honeycomb structure, the core technical implementation principle of this step lies in constructing a composite coating system with a three-dimensional support structure by alternately spraying amorphous alloy phases and MoS2 phases. Specifically, one column of MoS2 phases is inserted between every two columns of amorphous alloy phases to form a periodic arrangement structure similar to a honeycomb. Meanwhile, continuous amorphous alloy columns are arranged on both sides of the amorphous alloy phases, and these columns form a continuous support structure in the direction perpendicular to the coating surface, thereby significantly enhancing the bonding strength and structural stability of the MoS2 phases.

[0051] In terms of technical implementation, this step relies on a dual-robot collaborative spraying system, in which one robot is responsible for hot spraying of amorphous alloy powder, and the other is responsible for cold spraying of MoS2 powder. By programming the spraying paths and overlapping steps of the two robots, it is ensured that one column of MoS2 coating is accurately inserted between every two columns of amorphous alloy coating. The continuity of the amorphous alloy columns is achieved by setting fixed starting points and trajectory offsets in each layer of spraying. For example, on a cylindrical workpiece, a dual-axis turntable is used to control the spraying angle and position, ensuring that the amorphous alloy columns continuously extend in the normal direction and form a mechanical support system similar to a "reinforced concrete" structure.

[0052] In terms of parameter indicators, the single-layer coating size of the amorphous alloy phase and the MoS2 phase is usually controlled at 10 mm wide and 3 μm high to ensure the uniformity of layer-to-layer overlapping and the periodicity of the structure. The volume fraction of MoS2 in the coating is about 33.3%, and the arrangement mode is honeycomb, that is, one column of MoS2 is inserted between every two columns of amorphous alloy, and continuous amorphous alloy columns are arranged on both sides of the amorphous alloy phase. This structural design effectively avoids the angular contact between MoS2 phases, thereby reducing the risk of interlayer sliding and peeling.

[0053] In terms of application scenarios, this step is particularly suitable for complex working conditions that require high wear resistance, self-lubrication, and corrosion resistance, such as aerospace, precision machinery, and high-temperature lubricated components. With the continuous support of the amorphous alloy columns, the MoS2 phase is less likely to fall off due to external forces or thermal stress, thereby significantly improving the service life and reliability of the coating.

[0054] The technical effect of this step lies in the optimization of the structural design, which realizes the stable embedding and uniform distribution of MoS2 phases in the amorphous alloy matrix, and solves the technical problems of easy oxidation and decomposition of MoS2 in the traditional coating type powder during hot spraying. At the same time, the introduction of amorphous alloy columns enhances the overall bonding strength and structural density of the coating, making the coating exhibit more excellent comprehensive performance when subjected to mechanical load and friction and wear. This structural design provides a new process path for the preparation of amorphous alloy-MoS2 composite coatings, and has significant innovation and engineering application value.

[0055] S3, according to the substrate shape and spraying process parameters, calculate and set the TCP point position and spraying path of the spraying manipulator to ensure that the amorphous alloy phase and the MoS2 phase form a continuous and stable composite structure in the coating.

[0056] Specifically, in some implementations, calculating and setting the TCP (Tool Center Point) point position and spraying path of the spraying manipulator according to the substrate shape and spraying process parameters is a key step to realize the continuous and stable composite structure of the amorphous alloy phase and the MoS2 phase in the coating. Based on the geometric characteristics of the substrate (such as cylindrical or planar) and the coordinated control of thermal spraying and cold spraying processes, through accurate path planning and TCP point positioning, the step ensures that the two materials are alternately distributed during deposition, forming a composite coating with a specific arrangement structure (such as a chessboard, a checkered pattern, a honeycomb, etc.).

[0057] This step first requires a three-dimensional modeling of the substrate and importing it into the manipulator programming software (such as ABB's RobotStudio). Then, according to the process parameters of thermal spraying and cold spraying (such as powder feeding speed, spray gun moving speed, gas pressure, spraying distance, etc.), the initial setting of the TCP point is carried out. For cylindrical substrates, the sample is usually placed on a biaxial turntable with a rotation axis and a 60° inclination swing axis to achieve uniform spraying on complex surfaces. The thermal spraying manipulator and the cold spraying manipulator are arranged symmetrically at 180°, and their TCP point trajectories correspond to the deposition paths of the amorphous alloy phase and the MoS2 phase, respectively.

[0058] The overlap step of the spraying path needs to be adjusted according to the phase distribution ratio of the coating design. For example, in the chessboard structure, the TCP point trajectories of thermal spraying and cold spraying need to be strictly aligned to achieve a MoS2 phase proportion of 50%; while in the checkered pattern structure, the cold spraying path needs to be wrapped by 8 thermal spraying paths to control the MoS2 phase proportion to 11.1%. In addition, the surface moving speed (VS) of the spray gun and the rotation speed (RPS) of the turntable need to satisfy the formula RPS x π x D = 2VS, where D is the workpiece diameter, which ensures that the spraying path matches the rotation speed of the substrate, thus achieving uniform deposition.

[0059] This step is suitable for the preparation of composite coatings on complex curved surfaces (such as cylindrical workpieces) and planar workpieces. Through offline programming or online real-time adjustment, the distribution density and arrangement of different phases can be flexibly controlled to adjust the weight of the friction reduction, wear resistance and corrosion resistance of the coating. For example, the proportion of MoS2 phase can be increased in high friction conditions, while the support structure of the amorphous alloy phase can be enhanced in high wear environments.

[0060] The step realizes the ordered combination of amorphous alloy and MoS2 in the coating by precisely controlling the spraying path and TCP point position, avoids the aggregation or peeling of MoS2 phase, and improves the interface bonding strength and structural stability of the coating. Meanwhile, the method does not need to prepare coated composite powder in advance, simplifies the process flow, reduces the production cost, and improves the comprehensive performance of the coating, and provides reliable technical support for intelligent preparation of multiphase composite coating.

[0061] The amorphous alloy-MoS2 composite coating preparation method of the embodiment of the application can directly prepare the amorphous alloy-MoS2 composite coating through the alternating thermal spraying and cold spraying process, can realize the synergistic improvement of wear resistance, friction reduction and corrosion resistance without complex coating treatment, can reduce the preparation cost, and can enhance the bonding strength of the coating.

[0062] Further, S3 comprises: S31, the calculation adopts the formula RPS x pi x D = 2VS, wherein RPS is the number of rotations per second of the rotary table, D is the diameter of the workpiece, and VS is the surface moving speed of the spray gun, the rotation speed of the rotary table is determined according to the formula, to match the spraying speed and ensure the uniformity of the coating.

[0063] Specifically, in the implementation process of the application, the formula RPS x pi x D = 2VS used in the step is used to accurately control the matching relationship between the rotation speed of the rotary table and the surface moving speed of the spray gun in the spraying process, so that the uniformity and structural controllability of the coating are realized when the amorphous alloy and MoS2 coating are alternately sprayed on the surface of the cylindrical workpiece. The formula combines the rotation speed (RPS) of the workpiece with its diameter (D) based on the geometric relationship and kinematics principle of the spraying track, and deduces the linear speed (VS) of the spray gun on the workpiece surface, to ensure the uniform coverage of each spraying pass in the circumferential direction, and avoid problems such as uneven coating thickness, poor lap or local non-coverage caused by speed mismatch.

[0064] The formula calculates the linear speed of a point on the workpiece surface in unit time by multiplying the rotation frequency (RPS) of the rotary table with the diameter (D) of the workpiece and multiplying by the circular constant pi. Since the thermal spraying and cold spraying systems usually control the spray gun track with independent mechanical hands, to realize the alternating deposition of the two spraying materials on the cylindrical surface, it is necessary to ensure that the surface moving speeds of the two are consistent in the same time, that is, 2VS represents the total moving speed of the two spray guns in the circumferential direction. Therefore, the RPS of the rotary table can be dynamically adjusted through the formula to adapt to the spraying needs of workpieces of different diameters.

[0065] The value range of RPS is usually 0.1-5 r / s, which depends on the deposition characteristics of the sprayed material and the surface treatment requirements of the workpiece; D is the diameter of the workpiece, in millimeters (mm), which needs to be input according to the actual workpiece size; VS is the surface moving speed of the spray gun, in mm / s, which is generally controlled between 100-500 mm / s to ensure the continuity of the spraying track and the density of the coating. In actual debugging, parameters such as spraying distance, powder feeding rate, and gas pressure also need to be fine-tuned to achieve the best deposition effect.

[0066] This formula is particularly suitable for cylindrical samples or workpiece surfaces with rotational symmetry, such as shafts and pipes. By configuring a thermal spraying system and a cold spraying system on both sides of the workpiece and arranging them in a 180° symmetrical manner, combined with the motion control of a double-axis turntable (self-rotation + inclination swing), the alternating deposition of amorphous alloy and MoS2 coating can be realized, forming a structured coating such as a chessboard, a checkered pattern, or a honeycomb. This step is a key control link for realizing coating structure design and performance control, directly affecting the distribution ratio and arrangement of MoS2 phases in the coating, thereby determining the weight of the friction-reducing, wear-resistant, and corrosion-resistant properties of the coating.

[0067] This formula provides a kinematics-based spraying parameter matching mechanism, ensuring the synchronous control of spraying speed and turntable speed on workpieces of different diameters, thereby improving the uniformity and structural consistency of the coating. Through this formula, local over-spraying or insufficient spraying caused by speed mismatch can be avoided, improving the bonding strength and interface stability of the coating, and providing a reliable foundation for subsequent performance optimization. The introduction of this step not only improves the automation and intelligence level of the spraying process, but also enhances the applicability and repeatability of the invention on complex curved surface workpieces.

[0068] S32, the spraying path is set to be in a spiral distribution of TCP point trajectories of the thermal spraying manipulator and the cold spraying manipulator on the cylindrical substrate, and the distance between adjacent trajectory lines is 10 mm, to realize the continuous alternating deposition of amorphous alloy phases and MoS2 phases.

[0069] Specifically, in some implementations, the spraying path is set to be in a spiral distribution of TCP point trajectories of the thermal spraying manipulator and the cold spraying manipulator on the cylindrical substrate, and the distance between adjacent trajectory lines is 10 mm, to realize the continuous alternating deposition of amorphous alloy phases and MoS2 phases. The core technical principle of this step is to accurately control the motion trajectories of the two spraying manipulators to realize the ordered and alternating deposition of two different material phases on the substrate surface, thereby constructing a composite coating structure with a specific functional gradient.

[0070] This step adopts a double-robot collaborative spraying system, in which a thermal spraying robot is used for depositing the amorphous alloy binder phase, and a cold spraying robot is used for depositing the MoS2 lubricating phase. The two robots are installed on the two sides of the cylindrical substrate and arranged symmetrically at 180°. The spraying path is set through ABB Rapid program or Robot Studio offline programming software, and the tool center point (TCP) trajectory adopts a spiral path, that is, the robot continuously reciprocates in the axial direction of the cylinder at a certain step, while the substrate rotates and swings through a double-axis turntable (self-rotation axis + 60° inclination swing axis), to ensure uniform coverage of the coating. The adjacent line spacing of the spiral trajectory is set to 10 mm, which is verified through experiments and can ensure the continuity of the coating while avoiding structural disorder caused by overlapping deposition.

[0071] The line spacing of the spiral trajectory is 10 mm, which is based on the balance between the coating density and the mechanical properties. If the spacing is too small, it will cause the coating to overlap between layers, affecting the independent distribution of the MoS2 phase; if the spacing is too large, it may cause the coating to be discontinuously covered, reducing the bonding strength. In addition, the surface moving speed (VS) of the thermal spraying and cold spraying guns needs to be consistent, usually controlled between 0.1-0.3 m / s, to ensure the synchronization of the two spraying processes in time and space. The turntable speed (RPS) is calculated according to the formula RPS x π x D = 2 x VS, where D is the workpiece diameter, which ensures that the spraying trajectory matches the substrate rotation speed, thereby achieving uniform spiral deposition.

[0072] This step is particularly suitable for surface treatment of cylindrical workpieces, such as shafts, pipes, rotating parts, etc., and the spraying path design can be downward compatible with the spraying needs of planar workpieces. By alternately depositing amorphous alloy and MoS2 phase, the coating can achieve synergistic enhancement in wear resistance, friction reduction and corrosion resistance, especially suitable for surface modification of mechanical parts in high temperature, high load and corrosive environments.

[0073] This step ensures the ordered alternating distribution of amorphous alloy and MoS2 phase in the coating through the setting of spiral path and 10 mm line spacing, avoiding the agglomeration or interlayer sliding of MoS2 phase, thereby improving the interface bonding strength and overall structural stability of the coating. At the same time, this path design supports flexible switching of various coating structures (such as international chessboard, checkered pattern, honeycomb, etc.), providing a foundation for the designability of coating performance and significantly improving the functional adaptability and engineering practicability of the composite coating.

[0074] The amorphous alloy-MoS2 composite coating preparation method of the embodiment of the present application can directly prepare an amorphous alloy-MoS2 composite coating through alternating thermal spraying and cold spraying processes without complex coating treatment.

[0075] Further, it also includes: S4, when the preset arrangement structure is a field-shaped structure, depositing 8 amorphous alloy phases around 1 MoS2 phase to avoid corner contact between MoS2 phases, thereby improving the density and bonding strength of the coating.

[0076] Specifically, in some implementations, when the preset arrangement structure is a field-shaped structure, this step achieves the ordered deposition of 8 amorphous alloy phases around 1 MoS2 phase by controlling the coordinated deposition path of the thermal spraying and cold spraying system, thereby avoiding corner contact between MoS2 phases and improving the density and bonding strength of the coating. This structure design is based on the analysis of the material properties of MoS2 phase, which is high in brittleness, easy to slip, and weak in interlayer bonding, combined with the high density and no grain boundary structure of amorphous alloy phase formed during thermal spraying, and through spatial arrangement optimization, mechanical synergy and interface strengthening between the two phases are achieved.

[0077] From the technical implementation level, this step relies on the precise path control of the double-robot spraying system (such as ABB robot). In the spraying process of cylindrical workpieces, the thermal spraying system is used to deposit amorphous alloy phases, and the cold spraying system is used to deposit MoS2 phases. Through programming setting, after depositing 1 MoS2 phase, the thermal spraying system will continuously deposit 8 amorphous alloy phases, forming a "field" shaped wrapping structure around the MoS2 phase. In the spraying path design, the Offs instruction is used to control the offset of the TCP point, ensuring that the adjacent amorphous alloy phases and MoS2 phases maintain a certain lap step distance (usually 0.5-1.0 mm), thereby avoiding direct contact or corner contact between MoS2 phases.

[0078] In terms of parameter indicators, the thermal spraying process parameters include powder feeding speed (usually 10-20 g / min), gun moving speed (100-300 mm / s), spraying distance (80-120 mm), current (200-400 A), and gas ratio (Ar 80% + H2 20%), to ensure that the amorphous alloy phase cools quickly after impacting the substrate to form an amorphous structure. The cold spraying parameters include powder feeding speed (5-10 g / min), gas pressure (2.5-3.5 MPa), gas flow (20-30 L / min), and spraying distance (10-20 mm), to ensure that MoS2 particles achieve solid-state deposition under high-speed impact, avoiding oxidation or decomposition.

[0079] In application scenarios, this step is particularly suitable for complex working conditions that require both friction reduction, wear resistance, and corrosion resistance, such as aerospace, precision machinery, and high-temperature lubrication components. Through the ordered deposition of the field-shaped structure, the MoS2 phase is effectively isolated and supported by the amorphous alloy phase, significantly improving the structural continuity and interface bonding strength of the coating, thereby prolonging the service life of the coating.

[0080] The technical effect of this step is that, by structural design, direct contact between MoS2 phases is avoided, reducing the risk of interlayer sliding and crack propagation, and improving the overall density and mechanical properties of the coating. At the same time, the amorphous alloy phase, as a binder phase, not only provides excellent wear resistance and corrosion resistance, but also enhances the interfacial bonding between the MoS2 phase through its grain boundary-free structure, thereby realizing a multi-property synergistically enhanced composite coating structure.

[0081] S5, the MoS2 phase of the field-shaped structure is wrapped in the normal direction by the amorphous alloy phase, forming a three-dimensional support structure to enhance the wear resistance and anti-peeling performance of the coating.

[0082] Specifically, in some implementations, the MoS2 phase of the field-shaped structure is wrapped in the normal direction by the amorphous alloy phase, forming a three-dimensional support structure to enhance the wear resistance and anti-peeling performance of the coating. The core technical principle of this step is to form a continuous and dense coating layer around the MoS2 particles by the amorphous alloy phase, thereby constructing a composite structure with spatial constraints inside the coating. MoS2, as a typical layered solid lubricant material, is prone to decomposition or oxidation under high temperature or oxidizing environment, resulting in a decrease in lubrication performance. The amorphous alloy, due to its amorphous structure, has high hardness, excellent wear resistance and corrosion resistance, and can effectively act as a binder phase and structural support phase to prevent MoS2 particles from agglomerating, sliding or peeling in the coating.

[0083] In a specific implementation, the three-dimensional support structure is constructed by an alternating deposition process of thermal spraying and cold spraying. In the thermal spraying stage, amorphous alloy powder (such as Zr-based or Fe-based amorphous alloy) is used to form a continuous binder layer on the substrate surface, with a single-layer coating size of 10 mm wide and 3 μm high. Subsequently, in the cold spraying stage, MoS2 powder is deposited on the amorphous alloy layer formed at a high speed (usually greater than 500 m / s) to form a MoS2 deposition layer with a thickness of about 3 μm. By precisely controlling the starting point, trajectory offset (such as a lap step of 0.5 mm) and spraying sequence of the two spraying systems, the field-shaped arrangement structure of the MoS2 phase wrapped in the normal direction by the amorphous alloy phase can be realized.

[0084] The wrapping thickness of the amorphous alloy phase is generally 1-2 μm, which ensures that the MoS2 particles are sufficiently wrapped in the normal direction without affecting their interlayer sliding properties. The volume fraction of the MoS2 phase in the coating is about 11.1%, and the arrangement mode follows the Chinese character structure, that is, each MoS2 deposition layer is surrounded by 8 amorphous alloy deposition layers, which avoids the angular contact between MoS2 particles and reduces the crack initiation path. In addition, the powder feeding speed of thermal spraying during spraying process is controlled to be 10-20 g / min, the current is 300-500 A, and the Ar / H2 mixed gas ratio is 90 / 10 (vol%), so as to ensure the rapid solidification and structural stability of the amorphous alloy phase.

[0085] In actual application scenarios, the structure is particularly suitable for surface treatment of mechanical parts in high wear and high corrosion environments, such as aircraft engine bearings, hydraulic system piston rods, precision molds, etc. Through the three-dimensional wrapping structure, the MoS2 particles are effectively anchored in the coating, which significantly improves the interfacial bonding strength and overall structural stability of the coating, thereby reducing micro-crack propagation and improving wear resistance and anti-peeling ability during friction.

[0086] Further, the technical effect of this step is that, through the wrapping effect of the amorphous alloy phase, the MoS2 phase is protected from high-temperature oxidation and thermal decomposition, and the mechanical properties of the coating are enhanced through its high hardness and amorphous structure characteristics. At the same time, the ordered arrangement of the Chinese character structure effectively suppresses the structural looseness caused by the interlayer sliding of MoS2 particles, thereby improving the density and bonding strength of the coating, and realizing the synergistic enhancement of friction reduction, wear resistance and corrosion resistance. The structure design is one of the key innovations of the present application, which breaks through the limitations of traditional coated powder preparation process and provides a new structure paradigm for the preparation of high-performance composite coatings.

[0087] Example 2 The present application solves the shortcomings of the prior art: The best form of MoS2 coating in the past is formed by coated powder, and the coating material is generally selected from alloys such as Ni and NiCr that can be easily electrodeposited. A part of the amorphous alloy is difficult to be coated on the surface of the MoS2 particles by electrodeposition. The ordinary Ni, NiCr and other alloys can only provide coating and act as a bonding phase in the coating, and their wear resistance and corrosion resistance are much worse than those of the amorphous alloy. Therefore, it is not possible to prepare an amorphous alloy-MoS2 coating that is wear-resistant, friction-reducing and corrosion-resistant by first preparing an amorphous alloy-MoS2 coated powder.

[0088] The preparation of coated powder usually uses the method of electrodeposition, which leads to high cost of coated powder. The present application only needs to use two kinds of pure powder to directly prepare a composite coating that can be prepared only by using original coated powder.

[0089] The present application can not only prepare amorphous alloy-MoS2 powder, but also use this method to replace most of the coating prepared by coated powder, such as Ni-graphite powder, AlSi polyester-hexagonal boron nitride powder, etc.

[0090] The purpose of the present application is to provide a layer system which is prepared in a specific area with amorphous alloy as the matrix and MoS2 as the dispersed phase, and the coating has certain wear resistance, friction reduction and corrosion resistance. The composition range of MoS2 phase is 0-50%.

[0091] The preparation method is to use a hot spraying system with an independent mechanical hand and a cold spraying system with an independent mechanical hand to spray the area to be coated at the same time.

[0092] First, use the hot spraying system to prepare a single-channel amorphous alloy powder coating, adjust the process parameters, including powder feeding speed, spray gun moving speed, current, Ar, H2 content, and spraying distance, etc., control the width and height of the amorphous alloy single-channel coating to be 10mm wide and 3μm high.

[0093] Then use the cold spraying system to prepare a single-channel MoS2 coating, adjust the process parameters, including powder feeding speed, spray gun moving speed, gas pressure, gas flow, spraying distance, etc., control the width and height of the MoS2 single-channel coating to be 10mm wide and 3μm high.

[0094] Therefore, the present application can be provided with a model. The establishment of the model needs the following principles: The cross-sectional profile of a single pass of thermal spray and cold spray is a complex shape, which is similar to a basic profile and a Gaussian distribution curve. Its formation process is relatively complex. Roughly, it is a process like this: first, in thermal spraying, each powder particle or powder group particle becomes molten or semi-molten after passing through a high-temperature flame and deforms after impacting the surface, or in cold spraying, a large plastic deformation and penetration embedding occur when it impacts the substrate surface at high speed. That is, whether it is thermal spraying or cold spraying, the particle becomes a flat particle after impacting the surface of the object, which is also referred to as a splat in the foregoing. If the present application only keeps the spray gun stationary, many particles will collide and deposit on the corresponding substrate, resulting in the formation of a circular spot with a sharp tip in the middle in a short time, which is also referred to as a spray spot. The diameter of the spray spot is controlled by multiple factors such as the spraying distance, current, sprayed powder, gas flow, etc., and the cross section thereof over the center of the spray is a cross-sectional profile of an approximate Gaussian distribution curve. Of course, the cross-sectional profile may also be quite different from the cross-sectional profile of the Gaussian distribution curve at times, especially in short-time fixed-point spraying of cold spraying. The diameter of the spray spot of thermal spraying and cold spraying is about 10-30 mm, the height is about 1-10 μm, and it is also a flat particle from a macroscopic point of view. In order to facilitate modeling and find a suitable arrangement pattern, the present application first regards the cross-sectional profile as a square, which can be regarded as a square tile. The interface of the amorphous alloy single pass coating is set as a green square tile, and the cross section of the MoS2 single pass coating is a yellow square tile of the same size.

[0095] Due to the brittleness and poor bonding ability of MoS2, it is set that the green tile can be adjacent to the green tile or the yellow tile, that is, it can be in line contact, and the yellow tile can only be adjacent to the green tile.

[0096] Assuming a 30*30 grid, the present application establishes a green tile and yellow tile arrangement pattern program to see how to prepare a coating with amorphous alloy as the binder phase and MoS2 as the dispersed phase, determine how many patterns there are, and what the MoS2 composition corresponding to the pattern is. The following is the Python program of the green tile and yellow tile arrangement pattern.

[0097] By running the program, the present application can find that the yellow tile can only be adjacent to the green tile, and the green tile can be adjacent to any tile.

[0098] The key statement if(!hasGreenNeighbor || hasYellowNeighbor) indicates if (there is no green neighbor or there is a yellow neighbor). As shown in Table 1: Table 1

[0099] The coating pattern is traversed and the MoS2 composition in the coating is controlled and analyzed by the python program.

[0100] After analysis, such as Figure 2 Yellow bricks account for 50% of the composition, which is the highest percentage that yellow bricks can achieve, and their arrangement pattern is an international chessboard pattern.

[0101] After analysis, such as Figure 3 The yellow bricks comprise 11.1% of the composition, arranged in a grid pattern. Each single MoS2 coating is encased by eight layers of amorphous alloy coating, preventing the corner contact that often occurs between yellow bricks. Because the yellow bricks represent MoS2, which is particularly brittle and prone to interlayer slippage, this coating method, while slightly reducing friction, results in higher coating density, stronger interlayer adhesion, and superior wear and corrosion resistance. Figure 2 International chessboard patterns.

[0102] After analysis, such as Figure 4 Yellow bricks comprise 33.3% of the composition, arranged in a honeycomb pattern. Essentially, this is achieved by inserting a row of green bricks alongside every two columns of a checkerboard pattern, reducing the likelihood of corner contact between the yellow bricks. Simultaneously, continuous amorphous alloy pillars, or green brick pillars, exist in the normal direction of the coating. These green bricks act like reinforced concrete walls, with the A and B protrusions extending from both sides of the pillars acting like wedges, reinforcing and supporting the diagonally connected MoS2 layer in the middle.

[0103] The three patterns mentioned above basically represent the fundamental structure of all homogeneous coatings; most subsequent patterns will simply be variations of these three basic types. For example, one could... Figure 4 A column of pure green bricks can be inserted between two vertical columns containing A and B in a honeycomb pattern. Alternatively, the two existing columns of pure green bricks surrounding the two existing columns A and B can be widened from one column to two columns. These are all variations based on the honeycomb pattern. This method can be used to adjust the composition, size, and arrangement of the MoS2 phase, thereby affecting the respective weights of the coating's wear resistance, corrosion resistance, and friction reduction properties.

[0104] In practice, whether the product is cylindrical or planar, the entire coating preparation can be completed through online or offline programming. Taking a cylindrical product as an example, assuming the goal is to create an amorphous alloy + MoS2 coating with a basic chessboard pattern, the coating can be prepared using the ABB Rapid program. Only one robot needs to be programmed; the second robot, by associating its TCP with the relative position of the first robot and simultaneously offsetting all the deposited programs by an overlap step, completes the entire program configuration. Alternatively, RobotStudio (ABB's offline programming software for robots) can be used to directly input the starting coordinates, and then the Offs command can be used to complete the programming. The main steps include: Step 1: Place the cylindrical sample on a biaxial turntable (the turntable has a rotation axis and a 60° tilting axis on each side). Connect the thermal spraying and cold spraying to two robotic arms respectively, positioning them at 180° angles on both sides of the cylindrical sample. Figure 5 As shown.

[0105] Step 2: Based on the spraying distance parameters in the process parameters used for thermal spraying and cold spraying, set the TCP point positions for the thermal spraying robot and the cold spraying robot respectively.

[0106] Step 3: Set two initial points for the thermal spraying robot and the cold spraying robot, named Phome1 and Phome2 respectively.

[0107] Step 4: Since the rotation speed and sample diameter in both thermal spraying and cold spraying process parameters are determined by the sample, it is necessary to adjust parameters such as powder feed rate, current, and air volume during the debugging process to make the surface movement speed of the spray gun in thermal spraying equal to the optimal setting in cold spraying. Otherwise, it will increase the programming difficulty.

[0108] Step 5: Based on the different diameters of the workpieces, use... Calculate the relevant parameters, where RPS is the number of rotations of the turntable per second, D is the workpiece diameter, and VS is the surface movement speed of the spray gun. Determine the turntable speed based on the spray gun surface speed determined in step 4.

[0109] Step 6: Thermal spraying and cold spraying can be performed simultaneously or separately for each layer. The starting points for the two sprays can be two points on the cylindrical surface that are 180° symmetrical, with the thermal spraying point higher than the cold spraying point by |VS|, which is a distance of VS per second. The TCP route map for the thermal and cold spraying points will then be as follows: Figure 6 As shown in the diagram, red dots represent the TCP (Copper Contact Point) trajectory for thermal spraying, and blue dots represent the TCP trajectory for cold spraying. It's important to note that in chessboard-type coating structures, these processes can be performed simultaneously or separately. However, in grid-type or honeycomb-type coating structures, it's generally more convenient to perform thermal and cold spraying separately for each layer.

[0110] The other two patterns are similar in principle to the first pattern, the international chessboard pattern. Based on the international chessboard, the number of thermal spray coats and cold spray coats for each layer are programmed together, which can be accomplished through online or offline programming. Specific operational steps will be described in detail in the embodiments.

[0111] In addition, the reason for using a cylindrical workpiece in the invention is that the preparation process is simpler and more convenient for planar workpieces, and the difficulty of preparing a coating for a cylindrical workpiece is backward compatible with the difficulty of preparing a coating for a planar workpiece.

[0112] The present application has the following advantages and prominent effects: (1) The present application provides a new type of coating, which can use amorphous alloy as a binder phase and MoS2 as a dispersed phase to prepare a coating with wear resistance, friction reduction and corrosion resistance.

[0113] (2) The coating prepared by the present application does not need to be electro-deposited, agglomerated or coated in other forms, and has high bonding strength and good stability.

[0114] (3) The coating prepared by the present application only needs fixed powder, and the structure and composition of the coating are adjusted during preparation, so that the coating can achieve different weight wear resistance, friction reduction and corrosion resistance.

[0115] Example 3 According to the ideas and methods provided by the present application, a coating with a chessboard pattern structure is prepared. The microstructure of the coating is shown in Figure 7 .

[0116] The white phase in the coating is mainly amorphous alloy, and the black phase is mainly MoS2. The entire procedure is strictly sprayed according to the chessboard pattern, but since each spraying is a large number of particles deposited on the substrate, the cross-sectional shape of each spraying is prone to large fluctuations. However, the phenomenon of alternating white and black phases can still be observed from the cross-sectional view. The black phase in the figure reaches more than 40%.

[0117] Example 4 According to the ideas and methods provided by the present application, a coating with a checkered pattern structure is prepared. The microstructure of the coating is shown in Figure 8 .

[0118] The white phase in the coating is mainly amorphous alloy, and the black phase is mainly MoS2. The entire procedure is strictly sprayed according to the checkered pattern, but since each spraying is a large number of particles deposited on the substrate, the cross-sectional shape of each spraying is prone to large fluctuations. However, the phenomenon of a single black phase surrounded by a large amount of white phase can still be observed from the cross-sectional view. The black phase in the figure reaches about 10%.

[0119] Example 5 According to the ideas and methods provided by the present application, a coating with a honeycomb pattern structure is prepared. The microstructure of the coating is shown in Figure 9 .

[0120] The white phase in the coating is mainly amorphous alloy phase, and the black phase is mainly MoS2 phase. The entire procedure is strictly sprayed according to the cross pattern, but due to the fact that each spraying is a large number of particles deposited on the substrate, the cross section shape of each spraying is prone to have a very large fluctuation. However, it can still be observed from the cross section view that the black phase component is surrounded by a large amount of white phase. The black phase component in the figure reaches about 10%.

[0121] In summary, the effects of the present application are as follows: The best form of the MoS2 coating in the past is formed by a coated powder, and the coating material is generally selected from alloys such as Ni and NiCr that are easy to be electrodeposited. A part of the amorphous alloy is difficult to be coated on the surface of the MoS2 particle by electrodeposition. The ordinary alloy such as Ni and NiCr can only provide coating and play a role of a bonding phase in the coating, and the wear resistance and corrosion resistance thereof are much poorer than those of the part of the amorphous alloy. Therefore, the amorphous alloy-MoS2 coating with wear resistance, friction reduction and corrosion resistance cannot be prepared by first preparing the amorphous alloy-MoS2 coated powder.

[0122] The coated powder is generally prepared by the method of electrodeposition, which leads to a high cost of the coated powder. The present application only needs to use two kinds of pure powder to directly prepare the composite coating that can be prepared by using the original coated powder.

[0123] The present application can not only prepare the amorphous alloy-MoS2 powder, but also can use this method to replace most of the coatings prepared by the coated powder, such as the Ni-graphite powder, the AlSi polyester-hexagonal boron nitride powder, etc.

[0124] The present application provides a new type of coating, which can use the amorphous alloy as a bonding phase and MoS2 as a dispersed phase to prepare a coating with wear resistance, friction reduction and corrosion resistance.

[0125] The coating of this type prepared by the present application does not need to be subjected to electrodeposition, agglomeration or other forms of powder coating treatment, and has high bonding strength and good stability.

[0126] The coating of this type prepared by the present application only needs fixed powder, and the structure and composition of the coating are adjusted during preparation, so that the coating has different weights of wear resistance, friction reduction and corrosion resistance.

[0127] Example 6 Figure 10 is a structural schematic view of an amorphous alloy-MoS2 composite coating preparation device according to an embodiment of the present application. As shown in Figure 10 , it comprises: The spraying execution module 100 is configured to spray amorphous alloy powder and MoS2 powder by using a thermal spraying system and a cold spraying system, respectively, wherein the thermal spraying system is configured to form a splat structure of an amorphous alloy binder phase on a substrate surface, and the cold spraying system is configured to deposit MoS2 particles on the splat structure; The trajectory control module 200 is configured to control the trajectory offset of the thermal spraying robot and the cold spraying robot by programming, so that the amorphous alloy phase and the MoS2 phase are alternately deposited according to a preset arrangement structure, and the arrangement structure includes a chessboard type, a field type or a honeycomb type structure. The path planning module 300 is configured to calculate and set the TCP point position and the spraying path of the spraying robot according to the substrate shape and the spraying process parameters, so as to ensure that the amorphous alloy phase and the MoS2 phase form a continuous and stable composite structure in the coating.

[0128] Further, the spraying execution module is further configured to: The plasma spraying process is adopted, the powder feeding speed is 60-80 g / min, the current is 300-400 A, the mixed gas ratio of Ar and H2 is 8:2, and the spraying distance is 30-50 mm, so as to ensure that the amorphous alloy powder forms a splat structure with a thickness of 3 μm and a width of 10 mm after impacting the substrate surface. The solid deposition method is adopted, the powder feeding speed is 20-40 g / min, the gas pressure is 3-5 MPa, the spraying distance is 10-20 mm, and the movement speed of the spray gun is consistent with that of the thermal spraying system, so as to realize the uniform embedding of MoS2 particles on the amorphous alloy splat structure.

[0129] Further, the trajectory control module is further configured to: The ABB Rapid language is adopted to realize programming control, the TCP point starting positions Phome1 and Phome2 of the two robots are set to be symmetrically distributed at 180°, and the trajectory offset is realized by the Offs instruction, so as to realize the alternate deposition of the amorphous alloy phase and the MoS2 phase. When the preset arrangement structure is a honeycomb type structure, one column of MoS2 phase is inserted between every two columns of amorphous alloy phase, and continuous amorphous alloy columns are arranged on both sides of the amorphous alloy phase.

[0130] Further, the path planning module is further configured to: The formula RPS x π x D = 2VS is adopted, wherein RPS is the number of revolutions per second of the turntable, D is the workpiece diameter, and VS is the surface movement speed of the spray gun, the rotation speed of the turntable is determined according to the formula, so as to match the spraying speed and ensure the uniformity of the coating. The spraying path is arranged on the cylindrical base material, the TCP point trajectories of the thermal spraying manipulator and the cold spraying manipulator are distributed in a spiral manner, and the distance between adjacent trajectory lines is 10 mm, so that the amorphous alloy phase and the MoS2 phase are continuously and alternately deposited.

[0131] Further, the application also comprises: The N-shaped structure control module is used for controlling the deposition of every 8 amorphous alloy phases around 1 MoS2 phase when the preset arrangement structure is the N-shaped structure, so that the corner contact between the MoS2 phases is avoided, and the compactness and the bonding strength of the coating are improved. The three-dimensional support enhancement module is used for wrapping the MoS2 phase by the amorphous alloy phase in the normal direction in the N-shaped structure, so that the three-dimensional support structure is formed, and the wear resistance and the peeling resistance of the coating are enhanced.

[0132] The new type of coating of the embodiment of the application can be prepared by taking the amorphous alloy as a bonding phase and taking the MoS2 as a dispersed phase, so that the coating with the wear resistance, the friction reduction and the corrosion resistance is prepared.

[0133] In the description of the present specification, the description of the terms "one embodiment", "some embodiments", "an example", "a specific example" or "some examples" and the like means that the specific features, structures, materials or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present application. In the present specification, the illustrative description of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any appropriate manner in any one or more embodiments or examples. In addition, the different embodiments or examples described in the present specification and the features of the different embodiments or examples can be combined and combined by those skilled in the art without contradiction.

[0134] In addition, the terms "first", "second" are only used for description purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined with "first", "second" can explicitly or implicitly include at least one of the features. In the description of the present application, the meaning of "a plurality of" is at least two, for example, two, three, etc., unless otherwise specifically limited.

Claims

1. A method for preparing an amorphous alloy-MoS2 composite coating, characterized in that, Comprise: S1, using a thermal spraying system and a cold spraying system to spray amorphous alloy powder and MoS2 powder respectively, wherein the thermal spraying system is used to form a splat structure of amorphous alloy binder phase on the surface of the substrate, and the cold spraying system is used to deposit MoS2 particles on the splat structure; S2, by programming control of the trajectory offset of the thermal spraying manipulator and the cold spraying manipulator, the amorphous alloy phase and the MoS2 phase are alternately deposited according to the preset arrangement structure, and the arrangement structure comprises a chessboard type, a field type or a honeycomb type structure; S3, according to the shape of the substrate and the spraying process parameters, the TCP point position and the spraying path of the spraying manipulator are calculated and set to ensure that the amorphous alloy phase and the MoS2 phase form a continuous and stable composite structure in the coating.

2. The method of claim 1, wherein, The thermal spraying system and the cold spraying system are used to spray amorphous alloy powder and MoS2 powder respectively, wherein the thermal spraying system is used to form a splat structure of amorphous alloy binder phase on the surface of the substrate, and the cold spraying system is used to deposit MoS2 particles on the splat structure, and further comprise: S11, the thermal spraying system adopts plasma spraying process, the powder feeding speed is 60-80g / min, the current is 300-400A, the mixed gas ratio of Ar and H2 is 8:2, and the spraying distance is 30-50mm, so as to ensure that the amorphous alloy powder forms a splat structure with a thickness of 3μm and a width of 10mm after impacting the surface of the substrate; S12, the cold spraying system adopts solid deposition mode, the powder feeding speed is 20-40g / min, the gas pressure is 3-5MPa, the spraying distance is 10-20mm, and the moving speed of the spray gun is consistent with that of the thermal spraying system, so as to realize the uniform embedding of MoS2 particles on the amorphous alloy splat structure.

3. The method of claim 1, wherein, The trajectory offset of the thermal spraying manipulator and the cold spraying manipulator is controlled by programming, and the amorphous alloy phase and the MoS2 phase are alternately deposited according to the preset arrangement structure, and the arrangement structure comprises a chessboard type, a field type or a honeycomb type structure, and further comprise: S21, the programming control is realized by ABB Rapid language, the TCP point starting positions Phome1 and Phome2 of the two manipulators are symmetrically distributed at 180°, and the trajectory offset is realized by Offs instruction, so as to realize the alternate deposition of the amorphous alloy phase and the MoS2 phase; S22, when the preset arrangement structure is a honeycomb type structure, a column of MoS2 phase is inserted between every two columns of amorphous alloy phase, and continuous amorphous alloy columns are arranged on both sides of the amorphous alloy phase, so as to enhance the support and bonding strength of the MoS2 phase.

4. The method of claim 1, wherein, According to the shape of the substrate and the spraying process parameters, the TCP point position and the spraying path of the spraying manipulator are calculated and set to ensure that the amorphous alloy phase and the MoS2 phase form a continuous and stable composite structure in the coating, and further comprise: S31, the calculation adopts the formula RPS×π×D=2VS, wherein RPS is the number of revolutions per second of the rotary table, D is the diameter of the workpiece, and VS is the moving speed of the spray gun surface, the speed of the rotary table is determined according to the formula, so as to match the spraying speed and ensure the uniformity of the coating; S32, the spraying path is arranged on the cylindrical substrate, the TCP point trajectories of the thermal spraying manipulator and the cold spraying manipulator are distributed in a spiral manner, and the distance between adjacent trajectories is 10 mm, so as to realize continuous and alternating deposition of the amorphous alloy phase and the MoS2 phase.

5. The method of claim 1, wherein, Also include: S4, when the preset arrangement structure is a field-shaped structure, every 8 amorphous alloy phases are deposited around 1 MoS2 phase, so as to avoid angle contact between the MoS2 phases, thereby improving the compactness and bonding strength of the coating; S5, the MoS2 phase of the field-shaped structure is wrapped by the amorphous alloy phase in the normal direction to form a three-dimensional support structure, so as to enhance the wear resistance and anti-peeling performance of the coating.

6. An apparatus for preparing a non-crystalline alloy-MoS2 composite coating layer, characterized by comprising: Include: a spraying execution module configured to spray amorphous alloy powder and MoS2 powder by using a thermal spraying system and a cold spraying system respectively, wherein the thermal spraying system is configured to form a splat structure of an amorphous alloy binder phase on the surface of the substrate, and the cold spraying system is configured to deposit MoS2 particles on the splat structure; a trajectory control module configured to control the trajectory offset of the thermal spraying manipulator and the cold spraying manipulator by programming, so that the amorphous alloy phase and the MoS2 phase are alternately deposited according to a preset arrangement structure, and the arrangement structure includes a chessboard-shaped structure, a field-shaped structure or a honeycomb-shaped structure; a path planning module configured to calculate and set the TCP point position and the spraying path of the spraying manipulator according to the shape of the substrate and the spraying process parameters, so as to ensure that the amorphous alloy phase and the MoS2 phase form a continuous and stable composite structure in the coating.

7. The apparatus of claim 6, wherein, The spraying execution module is further configured to: use a plasma spraying process with a powder feeding speed of 60-80 g / min, a current of 300-400 A, a mixed gas ratio of Ar and H2 of 8:2, and a spraying distance of 30-50 mm, so as to ensure that the amorphous alloy powder forms a splat structure with a thickness of 3 μm and a width of 10 mm after impacting the surface of the substrate; use a solid deposition method with a powder feeding speed of 20-40 g / min, a gas pressure of 3-5 MPa, and a spraying distance of 10-20 mm, and the movement speed of the spray gun is consistent with that of the thermal spraying system, so as to realize uniform embedding of the MoS2 particles on the amorphous alloy splat structure.

8. The apparatus of claim 6, wherein, The trajectory control module is further configured to: use ABB Rapid language to realize programming control, set the TCP point starting positions Phome1 and Phome2 of the two manipulators to be symmetrically distributed at 180°, and use Offs instruction to realize trajectory offset, so as to realize alternating deposition of the amorphous alloy phase and the MoS2 phase; when the preset arrangement structure is a honeycomb-shaped structure, one MoS2 phase is inserted between every two amorphous alloy phases, and continuous amorphous alloy columns are arranged on both sides of the amorphous alloy phase, so as to enhance the support and bonding strength of the MoS2 phase.

9. The apparatus of claim 6, wherein, The path planning module is further configured to: use the formula RPS x π x D = 2 VS to determine the rotation speed of the turntable, wherein RPS is the number of rotations per second of the turntable, D is the diameter of the workpiece, and VS is the surface movement speed of the spray gun, so as to match the spraying speed and ensure the uniformity of the coating; The spraying path is arranged on the cylindrical base material, the TCP point trajectories of the thermal spraying manipulator and the cold spraying manipulator are distributed in a spiral mode, and the distance between adjacent trajectory lines is 10 mm, so that the amorphous alloy phase and the MoS2 phase are continuously and alternately deposited.

10. The apparatus of claim 6, wherein, Also includes: The plowshare structure control module is used for controlling the deposition of every 8 amorphous alloy phases around 1 MoS2 phase when the preset arrangement structure is the plowshare structure, so as to avoid the angle contact between the MoS2 phases, and improve the compactness and the bonding strength of the coating; The three-dimensional support enhancement module is used for wrapping the MoS2 phase in the normal direction by the amorphous alloy phase in the plowshare structure, forming a three-dimensional support structure, so as to enhance the wear resistance and the anti-peeling performance of the coating.

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