基于制造与再制造领域的Fe基非晶涂层的制备及性能研究

Corrosion and wear seriously influence the stability of the mechanical components to work effectively, and bring great losses to the national economy. Fabricating Fe-based amorphous coatings with excellent corrosion and wear resistance is an effective way to solve the problem. However, the fundamental questions such as the independent design of Fe-based amorphous powder compositions, the fabrication of high quality coatings, the interface bonding mechanism of the coating and substrate, and the corrosion mechanism and wear mechanism of coatings are unsolved, which become the main bottlenecks restricting the popularization and application of this technology. In this application, Fe-based amorphous compositions are optimized and designed, the powder is prepared and the amorphous coatings are fabricated. The basic scientific research on the interface bonding mechanism of the coating and substrate, the corrosion mechanism and wear mechanism of coatings are proposed to conduct. The concrete contents are as follows. Amorphous powder of Fe-Cr-Ni-P-C-B-Si system will be developed, which is suitable for thermal spraying with low cost and high amorphous forming ability. Based on stainless steel, alloy steel and carbon steel, amorphous coatings will be fabricated by high velocity oxygen fuel technology, the microstructure of the coating, and the interface bonding mechanism of the coating and substrate will be studied. The thermal stability, mechanical properties, corrosion and friction wear properties of coatings will be studied. The mechanism of corrosion resistance and wear mechanism will be revealed. This subject is of great theoretical significance for accelerating the application of Fe-based amorphous alloys in manufacturing and remanufacturing.

腐蚀和磨损严重影响机械组件的稳定高效运行，给国民经济带来巨大损失，制备优异耐蚀耐磨性能的Fe基非晶涂层成为解决该问题的有效途径。然而，Fe基非晶粉末成分的自主设计、优质涂层的制备及涂层和基体的界面结合机理、涂层的耐蚀机理和磨损机制等基础问题尚未解决，成为制约该项技术推广应用的主要瓶颈。本申请优化设计Fe基非晶合金成分并制备非晶粉末，进而制备非晶涂层并对涂层和基体的界面结合机理、涂层的耐蚀机理和磨损机制进行基础科学研究。具体内容包括：开发适用于热喷涂用的低成本、强非晶形成能力的Fe-Cr-Ni-P-C-B-Si体系非晶粉末；以不锈钢、合金钢、碳素钢等为基体，利用超音速火焰喷涂技术制备非晶涂层，研究涂层的微观组织结构及涂层和基体的界面结合机理；研究涂层的热稳定性、力学性能、腐蚀及摩擦磨损性能，揭示耐蚀机理和磨损机制。本课题对于加快Fe基非晶合金在制造及再制造领域的应用具有重要的理论指导意义。

随着工业的快速发展，油气钻探、火电、煤电、核发电、钢铁厂、海陆空交通、医药化工等领域的设备部件，长期满负荷在恶劣环境下运行，极易因腐蚀和磨损而失效破坏，给国民经济带来巨大损失。Fe基非晶涂层在腐蚀、磨损等严苛工矿中能表现出优异的性能，能有效地延长工件的使用寿命、降低设备维护成本，在制造与再制造业倍受关注。然而，Fe基非晶粉末成分的自主设计、优质非晶涂层的制备及涂层和基体的界面结合机理、涂层的耐蚀机理和磨损机制等是推广Fe基非晶涂层在制造和再制造业的应用进而体现其在国民经济中的价值急需解决的关键基础问题。. 本研究通过非晶合金成分优化设计、气雾化制粉、HVOF制备涂层，XRD和TEM结构分析、涂层界面SEM观察、腐蚀实验和摩擦磨损实验等对Fe基非晶粉末开发、非晶涂层制备及涂层和基体的界面结合机理、涂层的耐蚀机理和磨损机制等基础科学问题进行系统研究。主要研究内容和结论为：(1)从成分设计出发，通过室温力学性能和腐蚀性能的测定，优化制备出了适合于热喷涂的低成本、强非晶形成能力、高耐腐蚀和耐磨性能的新型的Fe基非晶合金粉体，拓展了国内制造与再制造领域用Fe基非晶粉体成分体系。(2)以A32船体用钢、304不锈钢为基体，利用HVOF技术制备出了优质的Fe基非晶涂层，获得了制备高质量Fe基非晶涂层的HVOF技术工艺参数，研究了涂层界面的微观组织结构，明确了具有非晶结构的涂层和具有晶体结构的基体的界面结合机理，为解决Fe基非晶涂层的界面问题提供了理论支撑。(3)研究了涂层在实际工况下的腐蚀性能和摩擦磨损性能，揭示了耐蚀机理和磨损机制，为Fe基非晶涂层应用于制造和再制造领域工艺的制定和优化提供理论支持和可行性方案。. 研究结果拓展了我国具有自主知识产权的性能优异的涂层用Fe基非晶合金成分体系；为深入研究Fe基非晶涂层的界面结合机理、耐蚀机理和磨损机制并优化制备工艺提供了理论指导；为推广Fe基非晶涂层在制造及再制造领域的应用奠定了坚实的理论基础并提供了应用指导。