金属陶瓷涂层/碳基薄膜复合体系的设计构筑及磨蚀机理研究

Diamond-like carbon-based films have excellent tribological properties and corrosion resistance in seawater environments, so they are ideal marine corrosion-wear resistant surface protection material. However, there are some common problems in traditional carbon-based films, such as insufficient bearing capacity, obdurability and corrosion-wear resistant. This project intends to synergize the performance advantages of cermet coating and carbon-based nanomultilayers，and construct a coating/film composite protective system with high load bearing bottom coating, tough and corrosion-wear resistant superficial film as well as strong interface between them by breaking through key technology of heterogeneous interface matching between coating and film. Through systematically optimizing the interface matching design，the structure design principle for the composite system with strongly bonded phase interface and low stress will be established, and the interface matching mechanism between the cermet coating and the carbon-based film will be clarified. The interaction mechanism of corrosion and wear as well as the functional cooperation mechanism of coating and film will be revealed by investigating the electrochemical behavior, tribological behavior and the quantitative relationship between corrosion and wear of the composite system in seawater environments. This project will promote the composite application of cermet coating and carbon-based film in marine environments, and provide new ideas and new approaches for developing coating/film composite system for marine applications.

类金刚石碳基薄膜在海水环境中兼具优异的摩擦学性能与耐腐蚀性能，是理想的海洋耐磨蚀表面防护材料。然而，传统碳基薄膜普遍存在承载能力不足、强韧性与耐磨蚀性有待进一步提升的共性问题。本项目拟协同金属陶瓷涂层与碳基纳米多层膜的性能优势，突破涂层与薄膜异质界面匹配关键技术，构筑出底部涂层高承载、涂层-薄膜强结合、表层薄膜高强韧与耐磨蚀一体化的涂层/薄膜复合防护体系。通过对复合体系进行系统的界面匹配优化设计，建立各相界面强结合、低应力的结构设计准则，阐明金属陶瓷涂层与碳基薄膜界面匹配调控机制；研究复合体系在海水环境磨蚀过程中的电化学行为、摩擦学行为及腐蚀-磨损量化关系，揭示其腐蚀-磨损交互损伤机理与涂层/薄膜功能协同机制。本项目的实施将推动金属陶瓷涂层与碳基薄膜在海洋环境中的复合应用，并为发展海洋耐磨蚀涂层/薄膜复合防护体系提供新思路和新途径。

为解决传统碳基薄膜承载能力不足、强韧性与耐磨蚀性能有待进一步提升的共性问题，项目基于金属陶瓷涂层与碳基纳米多层膜性能优势协同的设计思想，在突破涂层与薄膜异质界面匹配关键技术的基础上，发展了一种底部涂层高承载、涂层-薄膜强结合、表层薄膜高强韧与耐磨蚀一体化的涂层/薄膜复合防护体系。首先，在第一性原理计算和有限元模拟分析的基础上，优选复合体系材料组分及整体结构设计方案，通过磁控溅射工艺精细化调控获得了纳米尺度下兼具逐层梯度过渡与多元复合梯度过渡结构的“双模式梯度过渡层”，借助其硬度、模量及热膨胀系数梯度实现了金属陶瓷涂层与碳基薄膜的界面匹配。其次，系统研究了金属陶瓷涂层成分配比及厚度对复合体系机械性能及摩擦学性能的影响，并从调制比与调制周期两方面对碳基纳米多层膜进行了致密化与强韧化微纳结构调控，揭示了其强韧化机制与减磨抗磨机理，探明了复合体系结构与性能间的构效关系。最后，对比研究了金属陶瓷涂层、碳基纳米多层膜及涂层/薄膜复合体系在人工海水环境中的电化学行为、摩擦学行为及腐蚀磨损行为，重点探究了复合体系腐蚀磨损过程中腐蚀与磨损交互损伤机理与涂层/薄膜功能协同机制。研究结果表明，相较于单层碳基薄膜，金属陶瓷涂层/碳基薄膜复合体系的承载能力、耐腐蚀性能及摩擦学性能均显著提升，抗腐蚀磨损性能提升近10倍。研究成果可为重载、腐蚀、磨损等多因素耦合苛刻工况下高性能涂层/薄膜复合防护体系的设计构筑提供指导。