CN112501607A - 一种含铬耐磨防腐蚀涂层的制备方法 - Google Patents
一种含铬耐磨防腐蚀涂层的制备方法 Download PDFInfo
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Abstract
本发明公开了一种含铬耐磨防腐蚀涂层的制备方法,具体步骤为:(1)用激光技术对基材工件上进行激光清洗,除去锈斑以及污染颗粒;(2)采用激光熔覆技术在清洁的工件表面熔覆耐磨防腐蚀涂层,涂层材料成分包括:Fe、Ni、Si、C、B、Cr、Mn、W、Mo、Co、Yb、Zr;(3)控制激光功率、光斑大小、扫描速度、多道搭接率以及送粉方式和速度对工件进行激光熔覆含铬耐磨防腐蚀涂层,涂层与基体形成冶金状的致密结合,结合强度高,工件长期运转情况下不易脱落,同时合适调节铬含量可以使涂层达到实际工况对工件所要求的耐磨性能和防腐蚀性能。本发明提高了含铬涂层与基体的结合强度提高了生产效率,减少了环境污染,应用前景广阔。
Description
技术领域
本发明属于涂层技术领域,具体涉及一种含铬耐磨防腐蚀涂层的制备方法。
背景技术
近年来由于经济的飞速发展,在石油开采、海洋船舶、矿山机械以及电力工程等行业,对零部件尤其是轴类部件的要求越来越高,这个部件的重要特性是具有优异的耐磨性和抗腐蚀性能,这决定着整个器件的使用寿命,零件的磨损和锈蚀不仅影响生产进度,还会进一步增加成本,甚至导致资源的浪费。近年来,发展起来的各种耐磨、抗腐蚀的合金材料中,铬是不可缺少的重要合金元素,铬有着优秀的高温抗氧化性能,镀硬铬层不仅具有高的熔点和良好的化学稳定性,而且其硬度高,能抵抗长期工作引起的磨损和变形。目前工业上较常用的电镀铬层尽管成本低,铬层硬度好、均匀,但镀硬铬层与基体材料的结合基本上是物理结合,结合力差,长期使用容易造成气泡、氧化、龟裂等使镀层失效,同时电镀铬也存在对环境污染较为严重的现象。
激光熔覆技术是采用激光束在工件表面指定区域熔覆一层特殊性能的涂层,以改善工件表面性能的工艺,通过自动送粉器将合金粉末同步添加到激光熔池中,按照预设轨迹完成熔覆过程。激光熔覆涂层较为成熟的工艺是对合金粉末的熔覆,熔覆层的硬度、耐磨、抗腐蚀性能以及热学性能都比较好,且节省原料,无污染,与电镀铬或者镍等技术相比具有绿色环保、熔覆层致密、与基材结合强度高等优势,激光熔覆的一个显著特点是熔覆层与基材可以达到冶金状的结合,可以最大程度地减少熔覆层的裂纹和孔隙,增强了熔覆层和基材的结合强度,大大提高零部件的使用寿命,同时合金粉末中加入一定含量的铬,不仅节约了对镀纯铬的需求量,而且在保障熔覆层硬度满足需求的同时提高抗腐蚀能力和与基材的结合强度,本发明提出的在铁基或镍基合金粉中加入一定量的Si、C、B、Cr、Mn、W、Mo、Co、Yb、Zr元素,通过控制铬粉含量在14.2wt%-25.2wt%之间,不仅能与钢基材有很好衔接和过渡,还能增加涂层的耐磨和抗腐蚀性能,铬的含量如果过高会在熔覆的过程中产生裂纹,铬含量过低容易使最终熔覆层的硬度下降,同时增加稀土元素如Yb或Zr,可以充分吸收激光能量催化涂层的形成过程,提高生产效率。
发明内容
为了解决现有技术的问题,本发明的目的在于提出一种含铬耐磨防腐蚀涂层的制备方法,具体为:一种含铬耐磨防腐蚀涂层的制备方法,其特征在于:将工件进行激光清洗后,以金属合金粉末为原料进行激光熔覆耐磨防腐蚀涂层,涂层原料成分和含量为:Si:0.5-1.3wt%、C:0.1-0.2wt%、B: 0.1-0.15wt%、Cr:14.2-25.2wt%、Mn:0.1-0.4wt%、W:1-5wt%、Mo 1-20wt%、 Co:0-5wt%、Yb:0-1wt%、Zr:0-0.5wt%,余量为Fe;Si:0.5-1.3wt%、C: 0.1-0.2wt%、B:0.1-0.15wt%、Cr:14.2-25.2wt%、Mn:0.1-0.4wt%、W:1-5wt%、 Mo:1-20wt%、Co:0-5wt%、Yb:1wt%、Zr:0.5wt%,余量为N;控制激光功率、光斑大小、扫描速率、搭接率以及送粉方式和送粉速率对工件进行激光熔覆含铬耐磨防腐蚀致密涂层。
优选的,所述金属合金粉末粉由雾化制得,雾化包括气流雾化和水雾化,采用气流雾化压力范围为0.5-5MPa,水雾化压力范围在3-300MPa,最终制得的金属合金粉末粒径范围48-160μm。
优选的,所述金合金粉末可根据需要进行高能球磨后加入粘结剂等进行造粒,使微观颗粒均匀细小,提高熔覆层与基材的结合强度;所述基材为碳素钢、合金钢。
优选的,所述金合金粉末可根据需要调节加入稀土元素Yb、Zr。
优选的一种含铬耐磨防腐蚀涂层的制备方法步骤如下:
(1)激光清洗:先采用激光除锈,控制激光能量密度达到锈蚀层的烧蚀阈值实现清洗作用,激光功率密度范围5×106W/cm2到5×108W/cm2,同时去除亚微米级的污染颗粒,然后用去污剂对工件表面进行清洁并去除油污;也可在激光清洗的同时加入还原性强的物质,如碳粉、铜粉等,以促进彻底清洗;
(2)激光熔覆:激光熔覆过程的激光功率控制在1200-3000W,光斑大小3-10mm,多道熔覆搭接率范围45%-60%,扫描速率5-18mm/s;激光熔覆过程采用重力送粉法或氩气同步送粉法,熔覆厚度为0.-0.8mm,可根据工件厚度需求采用机床精加工至目标厚度。
优选的,调节激光熔覆耐磨防腐蚀涂层的各元素成分的含量可以得到性能不同的熔覆层。
优选的,所述激光熔覆涂层硬度在60以上,激光熔覆涂层在未精加工时的平均粗糙度在3.5-8.5μm之间。
本发明的有益效果是:
熔覆层厚度为0.8mm,可根据工件厚度需求采用机床精加工至目标厚度。所得熔覆层具有耐磨性能,硬度可达60以上,所形成的熔覆层较为致密,且与45号钢基材结合强度高,适合轴类等零部件在各种工况下使用,长期工作不易氧化脱落,起到抗腐蚀的作用,此法具有工艺简单、成本低廉、快速高效、环保无污染、能耗低等特点,适合大规模工业化应用。
附图说明
图1激光熔覆含铬涂层技术流程图;
图2部分激光熔覆含铬涂层的实际工件。
具体实施方式
下面将结合本发明中的附图,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
实施例1,将45号钢材质的工件进行激光清洗、除锈,控制激光能量密度达到锈蚀层的烧蚀阈值实现清洗作用,激光功率密度为10×107W/cm2,同时去除亚微米级的污染颗粒,然后用去污剂对工件表面进行清洁处理并去除油污,备用;将工件固定在激光熔覆工作台上,以金属合金粉末为原料进行激光熔覆耐磨防腐蚀涂层,涂层原料成分和含量为:Si:1.2wt%、C:0.2wt%、 B:0.12wt%、Cr:20.2wt%、Mn:0.1wt%、W:2wt%、Mo:15wt%、Co:1wt%、 Yb:1wt%,余量为Fe,采用氩气吹粉同步送粉进行激光熔覆,控制激光功率 3000W、光斑大小为10mm×10mm、扫描速率10mm/s、搭接率60%,对工件进行激光熔覆含铬耐磨防腐蚀致密涂层。熔覆层厚度为0.8mm,可根据工件厚度需求采用机床精加工至目标厚度。所得熔覆层具有耐磨性能,硬度为 62,所形成的熔覆层较为致密,且与45号钢基材结合强度高。图1是激光熔覆含铬涂层流程图,图2是多道激光熔覆含铬涂层,光亮部分是熔覆后经过车床加工的,其余部分熔覆后未加工。
实施例2,将工件进行激光清洗、除锈,控制激光能量密度达到锈蚀层的烧蚀阈值实现清洗作用,激光功率密度为10×107W/cm2,同时去除亚微米级的污染颗粒,然后用去污剂对工件表面进行清洁处理并去除油污,备用;将工件固定在激光熔覆工作台上,以金属合金粉末为原料进行激光熔覆耐磨防腐蚀涂层,涂层原料成分和含量为:Si:1.2wt%、C:0.2wt%、B:0.12wt%、 Cr:18.2wt%、Mn:0.1wt%、W:2wt%、Mo:15wt%、Co:1wt%、Yb:1wt%,余量为Fe,采用氩气吹粉同步送粉进行激光熔覆,控制激光功率3000W、光斑大小为7mm×7mm、扫描速率10mm/s、搭接率45%,对工件进行激光熔覆含铬耐磨防腐蚀致密涂层。熔覆层厚度为0.5mm,可根据工件厚度需求采用机床精加工至目标厚度。所得熔覆层具有耐磨性能,硬度为61。
实施例3,将工件进行激光清洗、除锈,控制激光能量密度达到锈蚀层的烧蚀阈值实现清洗作用,激光功率密度为10×107 W/cm2,同时去除亚微米级的污染颗粒,然后用去污剂对工件表面进行清洁处理并去除油污,备用;将工件固定在激光熔覆工作台上,以金属合金粉末为原料进行激光熔覆耐磨防腐蚀涂层,涂层原料成分和含量为:Si:1.2 wt%、C:0.2wt%、B:0.12wt%、Cr:20.2wt%、Mn:0.1 wt%、W:2wt%、Mo:15 wt%、Co:1wt%、Yb:1wt%、 Zr:0.5wt%,余量为Ni,采用氩气吹粉同步送粉进行激光熔覆,控制激光功率3000W、光斑大小为10mm×10mm、扫描速率10mm/s、搭接率60%,对工件进行激光熔覆含铬耐磨防腐蚀致密涂层。熔覆层厚度为0.8mm,可根据工件厚度需求采用机床精加工至目标厚度。所得熔覆层具有耐磨性能,硬度为65,所形成的熔覆层较为致密,且与45号钢基材结合强度高。
实施例4,将工件进行激光清洗、除锈,控制激光能量密度达到锈蚀层的烧蚀阈值实现清洗作用,激光功率密度为10×107 W/cm2,同时去除亚微米级的污染颗粒,然后用去污剂对工件表面进行清洁处理并去除油污,备用;将工件固定在激光熔覆工作台上,以金属合金粉末为原料进行激光熔覆耐磨防腐蚀涂层,涂层原料成分和含量为:Si:1.2 wt%、C:0.2wt%、B:0.12wt%、 Cr:18.2wt%、Mn:0.1 wt%、W:2wt%、Mo:15 wt%、Co:1wt%、Yb:1wt%、Zr:0.5wt%,余量为Ni,采用氩气吹粉同步送粉进行激光熔覆,控制激光功率3000W、光斑大小为7mm×7mm、扫描速率10 mm/s、搭接率45%,对工件进行激光熔覆含铬耐磨防腐蚀致密涂层。熔覆层厚度为0.5mm,可根据工件厚度需求采用机床精加工至目标厚度。所得熔覆层具有耐磨性能,硬度为62。
尽管上述实施例描述了本发明的优选实施方式,但是这些实施方式仅作为示例提供。本领域普通技术人员应理解,在不脱离本发明权利要求书所限定的发明构思和范围的情况下,可以对本发明做出若干变形和改进。
Claims (7)
1.一种含铬耐磨防腐蚀涂层的制备方法,其特征在于:将工件进行激光清洗后,以金属合金粉末为原料进行激光熔覆耐磨防腐蚀涂层,涂层原料成分和含量为:Si:0.5-1.3wt%、C:0.1-0.2wt%、B:0.1-0.15wt%、Cr:14.2-25.2wt%、Mn:0.1-0.4wt%、W:1-5wt%、Mo 1-20wt%、Co:0-5wt%、Yb:0-1wt%、Zr:0-0.5wt%,余量为Fe;Si:0.5-1.3wt%、C:0.1-0.2wt%、B:0.1-0.15wt%、Cr:14.2-25.2wt%、Mn:0.1-0.4wt%、W:1-5wt%、Mo 1-20wt%、Co:0-5wt%、Yb:1wt%、Zr:0.5wt%,余量为Ni;控制激光功率、光斑大小、扫描速率、搭接率以及送粉方式和送粉速率对工件进行激光熔覆含铬耐磨防腐蚀致密涂层。
2.根据权利要求1所述的一种含铬耐磨防腐蚀涂层的制备方法,其特征在于:所述金属合金粉末粉末由雾化制得,雾化包括气流雾化和水雾化,采用气流雾化压力范围为0.5-5MPa,水雾化压力范围在3-300MPa,最终制得的金属合金粉末粒径范围48-160μm。
3.根据权利要求1所述的一种含铬耐磨防腐蚀涂层的制备方法,其特征在于:所述合金粉末可根据需要进行高能球磨后加入粘结剂等进行造粒,使微观颗粒均匀细小,提高熔覆层与基材的结合强度的同时提高熔覆层的致密性;所述基材为碳素钢、合金钢。
4.根据权利要求1所述的一种含铬耐磨防腐蚀涂层的制备方法,其特征在于:所述金属合金粉末可根据需要调节加入稀土元素Yb、Zr;Yb元素可吸收激光能量催化反应进行,实现涂层的自蔓延生长;Zr元素可以提高涂层的耐腐蚀性。
5.根据权利要求1所述的一种含铬耐磨防腐蚀涂层的制备方法,其特征在于步骤如下:
(1)激光清洗:先采用激光除锈,控制激光能量密度达到锈蚀层的烧蚀阈值实现清洗作用,激光功率密度范围5×106W/cm2到5×108W/cm2,同时去除亚微米级的污染颗粒,然后用去污剂对工件表面进行清洁并去除油污;也可在激光清洗的同时加入还原性强的物质,用于在激光高功率清洗的同时使之与氧等发生反应,促进高效彻底清洗,可选用碳粉、铜粉;
(2)激光熔覆:激光熔覆过程的激光功率控制在1200-3000W,光斑大小3-10mm,多道熔覆搭接率范围45%-60%,扫描速率5-18mm/s;激光熔覆过程采用重力送粉法或氩气同步送粉法,熔覆厚度为0.1-0.8mm,可根据工件厚度需求采用机床精加工至目标厚度。
6.根据权利要求1所述的一种含铬耐磨防腐蚀涂层的制备方法,其特征在于:调节激光熔覆耐磨防腐蚀涂层的各元素成分的含量可以得到硬度和耐腐蚀性能不同的熔覆层。
7.根据权利要求1所述的一种含铬耐磨防腐蚀涂层的制备方法,其特征在于:所述激光熔覆涂层硬度在60以上,激光熔覆涂层在未精加工时的平均粗糙度在3.5-8.5μm之间。
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