CN110699682A - Method for preparing cavitation erosion resistant coating by using cold spraying and laser remelting composite process - Google Patents
Method for preparing cavitation erosion resistant coating by using cold spraying and laser remelting composite process Download PDFInfo
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/02—Coating starting from inorganic powder by application of pressure only
- C23C24/04—Impact or kinetic deposition of particles
- C23C24/045—Impact or kinetic deposition of particles by trembling using impacting inert media
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
- C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
- C23C24/103—Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides
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- Organic Chemistry (AREA)
- Other Surface Treatments For Metallic Materials (AREA)
Abstract
The invention relates to the technical field of cavitation erosion resistant coatings, and discloses a method for preparing a cavitation erosion resistant coating by using a cold spraying and laser remelting composite process, which comprises the following steps: (1) preparing a metal ceramic composite coating on the substrate by utilizing cold spraying; (2) and (3) carrying out laser remelting treatment on the metal ceramic composite coating in the step (1). The invention adopts the cold spraying and laser remelting composite process to treat the surface of the material, forms a metal ceramic composite coating on the surface of the material by the cold spraying technology, and then treats the surface of the cold sprayed metal ceramic by the laser remelting process. Under the high-density energy of laser, the surface of the metal ceramic coating is remelted to form a new structure, the coating structure performance is enhanced after cooling, the cavitation erosion resistance of the coating is greatly improved, and the metal ceramic coating can be widely applied to equipment which is easy to be damaged by cavitation erosion, such as a propeller, a water turbine blade and the like, and the service time of the equipment is prolonged.
Description
Technical Field
The invention relates to the technical field of cavitation erosion resistant coatings, in particular to a method for preparing a cavitation erosion resistant coating by utilizing a cold spraying and laser remelting composite process.
Background
Cavitation erosion is also called cavitation erosion, and cavitation erosion refers to that under the condition of high-speed multiphase flow, local pressure change in a liquid medium causes cavitation bubbles to form and collapse, the high-speed liquid contains the cavitation bubbles, so that abrasion and corrosion are serious, and the material is continuously impacted by high-pressure and high-speed micro jet to damage the surface of metal. Therefore, the protective film on the metal surface is damaged to a certain extent, the metal particles are torn to a certain extent, the surface of the metal is broken, the corrosion occurs, and finally, dense and deep holes are formed on the surface of the metal, and the surface is rough. Metal cavitation often occurs in equipment such as pump impellers and hydraulic turbines, which causes the material performance to be sharply reduced, and the service life and the use quality of the equipment are seriously influenced.
At present, the treatment for resisting cavitation erosion of metal materials can be generally to plate a coating on the surface of the metal materials to strengthen the cavitation erosion resistance, and the corresponding surface treatment technology comprises the following steps: the laser surface modification technologies such as laser surface cladding, laser surface alloying and laser surface fusing are based on the action of high-energy laser irradiation heat, and different cavitation erosion resistant coatings are prepared on the surface of a material, but the surface treatment technologies have the characteristics of expensive instruments and equipment, high cost and complex operation, and are difficult to popularize and apply in the practical process.
The laser remelting is to melt the surface by laser beam without adding any metal element to improve the surface structure, and the laser remelting can release impurities, pores and compounds, and simultaneously, the crystal grains are refined due to rapid cooling, so that the structure has a higher coating. However, when a ceramic coating is applied to a substrate by laser remelting alone, ceramic particles tend to settle down on the surface of the substrate.
In addition, the method for improving the cavitation erosion resistance of the material also comprises a plasma surface modification technology, a thermal spraying technology, a surface nitriding treatment technology and the like, wherein the thermal spraying technology has the characteristics of small heat influence on a matrix, small deformation, high production efficiency and the like and is widely concerned, but a coating prepared by the thermal spraying technology has the defects of micropores and microcracks, and further improvement is needed to obtain a coating with higher production efficiency and higher uniformity and lower porosity. The cold spraying refers to that at normal temperature or lower temperature, supersonic gas and solid two-phase gas flow are used for hitting coating powder to a substrate to form a dense coating, and the cold spraying technology does not have the effect of heating coating material powder particles at high temperature, namely, the effect of influencing the coating performance such as high-temperature oxidation, gasification, melting, crystallization and the like does not exist. Compared with the traditional thermal spraying technology, the cold spraying technology has the advantages of less oxidation of spraying materials, small residual stress, no need of a high-temperature heat source, adjustable coating thickness and the like, but the obtained coating also has the defects of micropores and microcracks of the technology.
CN 104213065A discloses a method for preparing a glass ceramic coating by a thermal spraying-laser original taste reaction composite process, which comprises the steps of preparing a CrFeAlTiC thermal spraying coating by a thermal spraying mode, then carrying out laser remelting treatment, and carrying out Cr, Fe, Al and Ti elements in composite powder and O in the laser remelting process2、N2The glass ceramic coating is generated through reaction, the coating has good interface bonding performance, a smooth surface and high comprehensive quality, and the thickness (5-300 mu m) and the overall quality of the glass ceramic coating generated through in-situ reaction can be controlled by adjusting parameters such as laser power, spot size, scanning speed and the like, the component proportion of the CrFeAlTiC composite powder and the components of reaction gas. But the hardness of the coating finally obtained by the adopted CrFeAlTiC coating materialNot good, it is difficult to achieve better cavitation erosion resistance.
Tungsten carbide (WC) has very high hardness, which is beneficial to improving the cavitation erosion resistance of the coating, but the melting point of WC particles is too high, the existing technologies such as spraying, sintering and the like are difficult to form a compact coating from pure WC, so that the pure WC coating has the defects of micropores and microcracks, and the cavitation erosion pit grows along the defects of the coating, so that the pure WC coating formed by spraying, sintering and the like is not beneficial to cavitation erosion resistance. Therefore, the technical difficulty in the art is to obtain a coating with good cavitation erosion resistance.
Disclosure of Invention
The invention aims to provide a method for preparing a cavitation erosion resistant coating, which effectively solves the problem of downward deposition in the direct laser cladding process of ceramic particles by utilizing a cold spraying and laser remelting composite process and obtains a metal ceramic composite coating with excellent cavitation erosion resistance.
In order to achieve the purpose, the invention adopts the technical scheme that:
a method for preparing a cavitation erosion resistant coating by using a cold spraying and laser remelting composite process comprises the following steps:
(1) preparing a metal ceramic composite coating on the substrate by utilizing cold spraying;
(2) and (3) carrying out laser remelting treatment on the metal ceramic composite coating in the step (1).
The method can be used on various substrates such as nickel-aluminum bronze, AISI316, 0Cr13Ni5Mo, CrMnN stainless steel, Ni-Ti alloy or 20SiMn low alloy steel and the like.
A layer of thicker metal ceramic composite coating is deposited on the surface of the matrix by using a cold spraying technology, and then the coating is subjected to laser remelting treatment, so that a novel cavitation erosion resistant structure with ceramic as an exoskeleton and metal and ceramic alloy as a buffer layer is formed on the surface of the coating, and the cavitation erosion resistance of the coating is greatly improved. And a transition layer is formed between the coating after laser remelting and cold spraying, so that the stress of the laser remelting coating is dispersed, and the probability that the laser remelting coating is easy to fall off integrally due to huge stress is greatly reduced.
The substrate can be pretreated before cold spraying; the pretreatment comprises the following steps: at least one of rust removal, oil stain removal and sand blasting coarsening, the surface of the matrix can be cleaned through pretreatment, impurities, oil stains and the like can be removed, and the subsequent combination of the spraying material and the matrix is facilitated.
In the invention, the pretreatment is to firstly utilize ethanol, acetone and the like to clean dirt on the surface of the matrix, and then to carry out sand blasting coarsening by using a sand blasting machine after drying, wherein the process parameters of the sand blasting coarsening are as follows: the air pressure is 0.3-1.0 MPa, the sand blasting time is 10 s-2 min, and the grain diameter of sand for sand blasting is 40-200 meshes.
The material for cold spraying is a mixture of metal powder and ceramic powder. The ceramic powder can be used as a hard phase to improve the hardness and strength of the coating, the metal powder can be used as a connecting phase to connect the ceramic powder into a compact coating, so that the defects of large pores and weak cavitation erosion resistance of the coating prepared by independently using the ceramic powder can be overcome, and the problem of poor hardness of the coating prepared by independently using the metal powder can be solved; the cold spraying material comprises the following components in parts by volume: 25-80 parts of metal powder and 10-70 parts of ceramic powder.
Further, the metal powder is pure nickel, and the particle size is 5-50 mu m; the ceramic powder is tungsten carbide (WC) powder, and the particle size is 5-100 mu m. Because cavitation jet flow can generate instantaneous high temperature and accelerate the conduction of oxygen, so that the material is accelerated to corrode, the metal nickel has good high-temperature resistance, a stable oxidation film can be formed on the surface of the metal nickel in a humid environment, the WC has very high hardness, the high hardness is favorable for improving the cavitation corrosion resistance of the coating, and the corrosion condition of the material under the cavitation corrosion condition can be relieved. The nickel in the coating is used as a binding phase, and the WC is used as a hard phase, so that the formed metal ceramic composite coating has excellent cavitation erosion resistance.
However, the density difference between the ceramic and the metal is huge, so that the direct mixing can cause the condition of uneven mixing, therefore, the equipment used for cold spraying adopts a co-feeding system, the problem can be effectively solved, meanwhile, the damage to the powder caused by mechanical mixing can be avoided, the porosity of the coating after cold spraying is low, and the coating is well combined with the matrix.
The cold spraying parameters are set as follows: the carrier gas is high-purity nitrogen or argon, the pressure of the carrier gas is 0.4-6 MPa, the temperature of the sprayed material is 350-750 ℃ before the sprayed material enters the nozzle, the distance between the matrix and the nozzle outlet is 5-60 mm, and the moving speed of the spray gun is 15-50 mm/s. Other parameters were those conventionally used in the art. High-purity nitrogen or argon is inert gas, is difficult to react with materials under conventional conditions, and can play a role of protecting gas and isolating air by utilizing the inertia of the high-purity nitrogen or argon. Within the above parameters, the overall performance of the coating is best.
When the cold spray coating described employs a co-feed system, the ceramic powder and metal powder are fed to the spray gun from separate hoppers, and the feed rates are controlled so that the desired ratio of the cermet composite powder coating to the substrate can be deposited.
Setting the parameters of laser remelting: the power is 200-3000 w, the diameter of a light spot is 0.3-3 mm, the moving speed of the light spot is 100-500 mm/min, the pressure of protective gas: 0.2-1.2 MPa, the flow rate is 3-12L/min, and other parameters are parameters conventionally used in the field.
More preferably, the protective gas is inert gas such as high-purity nitrogen or argon, and the oxidation of the coating is prevented.
The parameters of cold spraying and laser remelting can be adjusted according to different proportions of coating materials.
When the materials for cold spraying comprise the following components in parts by volume: when 30-60 parts of metal powder and 30-70 parts of ceramic powder are adopted, the cold spraying parameters are as follows: the carrier gas is high-purity nitrogen or argon, the pressure of the carrier gas is 0.4-6 MPa, the temperature of the sprayed material is 500-750 ℃ before the sprayed material enters the nozzle, the distance between the matrix and the nozzle outlet is 5-20 mm, and the moving speed of the spray gun is 15-50 mm/s;
setting the parameters of laser remelting: the power is 300-1200 w, the diameter of a light spot is 0.5-1 mm, the moving speed of the light spot is 150-300 mm/min, and the pressure of protective gas is as follows: 0.4-0.8 MPa, and the flow rate is 4-8L/min. With such parameters, the obtained coating has the best cavitation erosion resistance.
The method disclosed by the invention can be applied to the blades of propellers, water turbines and the like, the service time of equipment is prolonged, the maintenance frequency of the equipment due to cavitation erosion damage is greatly reduced, and the service efficiency of the equipment is improved. The method can also be applied to the repair of equipment such as propellers, water turbine blades and the like.
Compared with the prior art, the invention has the following beneficial effects:
(1) compared with the coating prepared by directly laser cladding the ceramic material, the method of the invention eliminates the problem of ceramic powder sedimentation on the surface of the matrix.
(2) The method can deposit a thicker metal ceramic composite coating on the substrate by using a cold spraying technology, and then forms a transition layer by using the coating after laser remelting treatment and the coating after cold spraying, so that the stress of the laser remelting coating is dispersed, and the problem that the laser remelting coating is easy to fall off integrally due to huge stress is greatly reduced.
(3) The coating prepared by the method of the invention adopts a novel anti-cavitation structure with ceramic as an exoskeleton and metal and ceramic alloy as a buffer layer, reduces the porosity of the coating, overcomes the defects of micropores and microcracks of the direct cold-sprayed coating, and greatly improves the anti-cavitation property of the coating.
(4) And a co-feeding system is adopted during cold spraying, so that the difficulty in mixing ceramic powder and metal powder due to different densities is avoided, and the damage to the powder during mechanical mixing is also avoided.
(5) The coating prepared on the surface of the substrate by the method has very good cavitation erosion resistance, can be applied to equipment such as a propeller, a water turbine blade and the like which are easy to be damaged by cavitation erosion, can prolong the service time of the equipment, greatly reduces the maintenance frequency of the equipment damaged by cavitation erosion and improves the service efficiency of the equipment.
Drawings
FIG. 1 is a scanning electron microscope image of the surface of the cavitation erosion resistant coating prepared in example 1.
FIG. 2 is a scanning electron microscope image of a cross section of the cavitation erosion resistant coating prepared in example 1.
FIG. 3 is a scanning electron micrograph of the surface of the cavitation erosion resistant coating prepared in example 1 after 10 hours of ultrasonic cavitation erosion.
Figure 4 is a plot of cumulative cavitation loss versus volume after 10 hours of ultrasonic cavitation erosion of the cavitation resistant coated 316 stainless steel prepared in example 1 and untreated 316 stainless steel.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is further described in detail with reference to the following embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention. Those skilled in the art should understand that they can make modifications and equivalents without departing from the spirit and scope of the present invention, and all such modifications and equivalents are intended to be included within the scope of the present invention.
Example 1
In this embodiment, the substrate material is 316 stainless steel, and the step of preparing the cavitation erosion resistant coating on the surface thereof includes:
(1) cleaning dirt on the surface of a substrate by using ethanol, and after drying, blasting sand on the surface of the substrate by using 60-mesh brown corundum sand for coarsening, wherein the air pressure of the blasting sand is 0.5MPa, and the sand blasting time is 45 seconds, so that the roughness of the substrate meets the spraying requirement;
(2) preparing the metal ceramic composite coating on the matrix subjected to sand blasting by cold spraying: using WC powder with the grain size of 45 +/-15 microns and nickel powder with the grain size of 50 +/-25 microns as raw materials through a co-feeding system, respectively feeding the raw materials into a spray gun through a separate hopper, and adjusting the speed of the co-feeding system to ensure that the volume ratio of the WC powder to the nickel powder is 45: 55; the carrier gas of cold spraying is argon, the pressure of the carrier gas is 4MPa, the temperature of the gas is 700 ℃, the spacing distance between the matrix and the nozzle outlet is set to be 7mm, and the moving speed of the spray gun is 35 mm/s;
(3) carrying out laser remelting treatment on the matrix subjected to cold spraying treatment in the step (2): the parameters of laser remelting are as follows: the laser power is 300W, the diameter of a laser spot is 0.5mm, the moving speed of the laser spot is 250mm/s, the repetition rate of a laser path is 50%, high-purity nitrogen is used for side blowing, the pressure of protective gas is 0.5MPa, and the flow is 6L/min.
Finally, a cavitation erosion resistant coating is prepared on the surface of 316 stainless steel by a cold spraying and laser remelting composite process, the treated cavitation erosion resistant coating is subjected to electron microscope scanning, and the result is shown in fig. 1 and fig. 2, and it can be seen from fig. 1 that the cavitation erosion resistant coating prepared by the cold spraying and laser remelting composite process has a uniform, flat and compact surface and small pores. As can be seen from fig. 2, the cross section of the cavitation erosion resistant coating is divided into an upper part and a lower part, the part with darker color at the lower part is nickel and WC which are sprayed on by cold spraying, wherein the brighter white blocks are WC particles; the part with lighter color on the upper part is the coating after laser remelting treatment, so that WC particles become tiny and are completely compatible with nickel, the surface structure of the coating is compact, and the cavitation erosion resistance of the matrix is greatly improved.
Performing cavitation erosion resistance test on the 316 stainless steel treated by the steps and the untreated 316 stainless steel, wherein the test is as follows: the substrate or the surface of the substrate after treatment was subjected to a grinding and polishing treatment with 2000-mesh sandpaper, and the cavitation erosion resistance of the material was tested by an ultrasonic cavitation erosion apparatus in accordance with ASTM-G32-2010 standard.
The frequency of the ultrasonic cavitation equipment is set to be 20KHz, the amplitude is +/-50 mu m, the distance between the ultrasonic cavitation head and the surface of the sample is 1mm, the cavitation head is immersed in water for 23 +/-2 mm, the test solution is deionized water, and the water temperature is kept at 25 +/-2 ℃.
A scanning electron microscope of the coating after 10h of ultrasonic cavitation erosion is shown in FIG. 3, and only a small amount of small holes are formed. A comparison graph of the cumulative cavitation loss volume of the 316 stainless steel with the cavitation erosion resistant coating after ultrasonic cavitation erosion for 20 hours and the cumulative cavitation loss volume of the untreated 316 stainless steel after ultrasonic cavitation erosion for 10 hours is 4mm, as shown in FIG. 43While the cumulative cavitation loss volume of 316 stainless steel with cavitation erosion resistant coating is 1.9mm3The cavitation erosion resistance is improved by 2.1 times, and the cavitation erosion resistance is greatly improved.
Claims (9)
1. A method for preparing a cavitation erosion resistant coating by using a cold spraying and laser remelting composite process comprises the following steps:
(1) preparing a metal ceramic composite coating on the substrate by utilizing cold spraying;
(2) and (3) carrying out laser remelting treatment on the metal ceramic composite coating in the step (1).
2. The method for preparing the cavitation erosion resistant coating by using the cold spraying and laser remelting combined process according to claim 1, wherein the substrate is nickel aluminum bronze, AISI316, 0Cr13Ni5Mo, CrMnN stainless steel, Ni-Ti alloy or 20SiMn low alloy steel.
3. The method for preparing a cavitation erosion resistant coating by using a cold spraying and laser remelting combined process as claimed in claim 1, wherein the substrate is pretreated before cold spraying; the pretreatment comprises the following steps: at least one of rust removal, oil stain removal and sand blasting coarsening.
4. The method for preparing the cavitation erosion resistant coating by using the cold spraying and laser remelting combined process as claimed in claim 3, wherein the process parameters of the sand blasting coarsening are as follows: the air pressure is 0.3-1.0 MPa, the sand blasting time is 10 s-2 min, and the grain diameter of sand for sand blasting is 40-200 meshes.
5. The method for preparing the cavitation erosion resistant coating by using the cold spraying and laser remelting combined process as claimed in claim 1, wherein the material for cold spraying is a mixture of metal powder and ceramic powder; the cold spraying material comprises the following components in parts by volume: 25-80 parts of metal powder and 10-70 parts of ceramic powder.
6. The method for preparing the cavitation erosion resistant coating by using the cold spraying and laser remelting composite process as claimed in claim 5, wherein the metal powder is pure nickel with the particle size of 5-50 μm; the ceramic powder is tungsten carbide powder, and the particle size is 5-100 mu m.
7. The method for preparing the cavitation erosion resistant coating by using the cold spraying and laser remelting combined process as claimed in claim 1, wherein the parameters of the cold spraying are as follows: the carrier gas is high-purity nitrogen or argon, the pressure of the carrier gas is 0.4-6 MPa, the temperature of the sprayed material is 350-750 ℃ before the sprayed material enters the nozzle, the spacing distance between the substrate and the nozzle outlet is 5-60 mm, and the moving speed of the spray gun is 15-50 mm/s.
8. The method for preparing the cavitation erosion resistant coating by using the cold spraying and laser remelting combined process as claimed in claim 1, wherein the parameters of the laser remelting are as follows: the power is 200-3000 w, the diameter of the light spot is 0.3-3 mm, and the moving speed of the light spot is 100-500 mm/min.
9. The method for preparing the cavitation erosion resistant coating by using the cold spraying and laser remelting combined process as claimed in claim 5, wherein when the materials for cold spraying comprise, by volume: 30-60 parts of metal powder and 30-70 parts of ceramic powder,
the cold spraying parameters are set as follows: the carrier gas is high-purity nitrogen or argon, the pressure of the carrier gas is 0.4-6 MPa, the temperature of the sprayed material is 500-750 ℃ before the sprayed material enters the nozzle, the distance between the matrix and the nozzle outlet is 5-20 mm, and the moving speed of the spray gun is 15-50 mm/s;
setting the parameters of laser remelting: the power is 300-1200 w, the diameter of a light spot is 0.5-1 mm, the moving speed of the light spot is 150-300 mm/min, and the pressure of protective gas is as follows: 0.4-0.8 MPa, and the flow rate is 4-8L/min.
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