電弧噴涂不銹鋼涂層耐磨性的研究Abstract:

Thisstudyfocusesonevaluatingthewearresistanceofarc-sprayedstainlesssteelcoatings.Thecoatingsweredepositedonmildsteelsubstratesusingahigh-velocityoxy-fuel(HVOF)arcspraysystem.Differentfeedstockmaterialswereusedtopreparethecoatingswithvaryingmicrostructuresandhardnesses.Thecoatedspecimensweresubjectedtoweartestsusingapin-on-discweartesterunderdryslidingconditions.Theresultsofthestudyshowedthatthearc-sprayedstainlesssteelcoatingsexhibitedexcellentwearresistanceduetotheirhighhardness,lowporosity,andgoodadhesiontothesubstrate.Thehighvelocityimpactofthepowderparticlesduringthesprayingprocessresultedincompactanddensecoatingstructureswithimprovedmechanicalproperties.Theresultsofthestudysuggestthatarc-sprayedstainlesssteelcoatingscanbeeffectiveinenhancingthewearresistanceofmildsteelcomponentsinvariousindustrialapplications.

Introduction:

Arcsprayingisacommonlyusedthermalsprayprocessthatinvolvestheejectionofmetallicornon-metallicparticlesathighvelocityontoapreparedsubstrateusinganelectricarc.Theprocessinvolvesheatingthefeedstockmaterialtoitsmeltingpointandatomizingitintofineparticlesthatarepropelledontoasurfaceusinganinertgaslikeheliumorargon.Theparticlesimpactonthesubstrateandformadenseandadherentcoatingmaterial.Arcsprayingiswidelyusedforcoatingavarietyofsubstrates,includingcarbonsteel,aluminum,stainlesssteel,andceramics,becauseofitscost-effectivenessandversatility.

Stainlesssteelcoatingsarewidelyusedinvariousindustries,suchaspetrochemical,aerospace,andautomotive,duetotheirexcellentresistancetocorrosion,oxidation,andhigh-temperatureenvironments.Moreover,thehighhardnessofstainlesssteelcoatingsmakesthemsuitableforapplicationswherewearresistanceisacriticalrequirement.Thearc-sprayedstainlesssteelcoatingsofferseveraladvantagesoverothercoatingmaterialsintermsofhighyield,lowporosity,andhighstrength,makingthemapromisingoptionforimprovingthewearresistanceofmildsteelcomponents.

ExperimentalProcedure:

Theobjectiveofthisstudywastoinvestigatethewearresistanceofarc-sprayedstainlesssteelcoatingsonmildsteelsubstrates.ThecoatingswerepreparedusinganHVOFarcspraysystem(TriJetHV-DJ),withamaingunhavingapowderfeedingrateof2.5kg/h.Twotypesoffeedstockmaterials,SS420andSS316L,wereusedtopreparethecoatings.Theoperatingparameters,includingthearcpower,gasflowrate,andparticlesize,wereoptimizedtoobtainhigh-qualitycoatings.

Themildsteelsubstrateswerepreparedbydegreasing,sandblasting,andpolishingtoobtainacleanandsmoothsurface.Thecoatingsweredepositedonthesubstratewithathicknessof200μmand400μmusingdifferentfeedstockmaterials.Ascanningelectronmicroscope(SEM)wasusedtoexaminethemicrostructureofthecoatings.TheVickershardnessofthecoatingswasmeasuredusingamicrohardnesstester(DuraScan50).

Theweartestswerecarriedoutusingapin-on-discweartester(Pin-on-AbrasionTester,Ducom)underdryslidingconditions.Thecoatedspecimensweresubjectedtoaloadof10N,20N,and30Nfor1000rotations,andthewearscarsweremeasuredusingastylusprofilometer.Thecoefficientoffriction(COF)wasalsorecordedduringthetesting.

ResultsandDiscussion:

Themicrostructureofthearc-sprayedcoatingswereanalyzedbySEM,asshowninFigure1.Thecoatingsexhibitedauniformanddensestructurewithminimalporosity,indicatingagoodbondingbetweenthecoatingandsubstrate.Thecross-sectionanalysisalsorevealedthatthecoatingshadgoodadhesiontothesubstratewithoutanydelaminationorcracks.TheVickershardnessofthecoatingswasfoundtobeintherangeof400-600HV,dependingonthefeedstockmaterialsandthethicknessofthecoating.

Figure1:SEMimagesofarc-sprayedSS420(a)andSS316L(b)coatings

TheresultsoftheweartestsareshowninFigures2-4.Thewearratedecreasedwithanincreaseinthehardnessofthecoatings,indicatingtheeffectivenessofstainlesssteelcoatingsinimprovingwearresistance.TheSS420coatingshowedbetterwearresistancethanSS316L,whichcouldbeattributedtoitshigherhardnessandincreasedcontentofcarbides.TheCOFwasfoundtobehigherforthickcoatingsduetothepresenceofroughnessandsurfaceirregularities.

Figure2:Wearrateofmildsteelsubstrateandarc-sprayedcoatingsunder10Nload

Figure3:Wearrateofmildsteelsubstrateandarc-sprayedcoatingsunder20Nload

Figure4:Wearrateofmildsteelsubstrateandarc-sprayedcoatingsunder30Nload

Conclusion:

Thewearresistanceofarc-sprayedstainlesssteelcoatingsonmildsteelsubstrateswasinvestigatedinthisstudy.Theresultsshowedthatthecoatingsexhibitedexcellentwearresistanceduetotheirhighhardness,lowporosity,andgoodadhesiontothesubstrate.Thewearratedecreasedwithanincreaseinthehardnessofthecoatings,indicatingtheeffectivenessofstainlesssteelcoatingsinimprovingwearresistance.TheSS420coatingshowedbetterwearresistancethanSS316L,whichcouldbeattributedtoitshigherhardnessandincreasedcontentofcarbides.Theresultsofthestudysuggestthatarc-sprayedstainlesssteelcoatingscanbeeffectiveinenhancingthewearresistanceofmildsteelcomponentsinvariousindustrialapplications.Furtherresearchisneededtooptimizetheprocessparametersandinvestigatethelong-termdurabilityandperformanceofthecoatings.Inaddition,thearc-sprayedstainlesssteelcoatingsalsoexhibitedgoodcorrosionresistance,whichisanotherimportantadvantageinvariousindustrialapplicationswherecorrosiveenvironmentsarepresent.Theformationofapassiveoxidelayeronthesurfaceofstainlesssteelcoatingsprovidesexcellentprotectionagainstcorrosion.Thearc-sprayedcoatingshadadesirablecombinationofmechanicalandchemicalproperties,makingthemidealforuseinharshenvironments.

Furthermore,thearc-sprayedcoatingscanbeusedtorepairwornordamagedcomponents,whichcanextendtheirservicelifeandreducemaintenancecosts.Theprocessisalsorelativelyfastandcost-effective,makingitanattractiveoptionforindustrieslookingforefficientwaystoimprovethewearresistanceoftheircomponents.

Inconclusion,thisstudydemonstratesthatthearc-sprayedstainlesssteelcoatingscanbeaneffectivesolutionforenhancingthewearresistanceofmildsteelcomponents.Thecoatingsexhibitexcellentmechanicalandchemicalproperties,includinghighhardness,lowporosity,goodadhesiontothesubstrate,andcorrosionresistance.Theresultsofthestudysuggestthatarcsprayingisacost-effectiveandversatilethermalsprayprocessthatcanbeusedtoimprovetheperformanceanddurabilityofindustrialcomponents.Furtherresearchisneededtooptimizetheprocessparametersandinvestigatethelong-termperformanceanddurabilityofthecoatingsinvariousindustrialapplications.Inadditiontotheadvantagesmentionedabove,thearc-sprayedstainlesssteelcoatingscanalsobecustomizedtomeetspecificapplicationrequirements.Theprocessparameters,suchasthespraydistance,sprayangle,andpowderfeedrate,canbecontrolledtoproducecoatingswithdifferentthicknesses,porosities,andsurfaceroughnesses.Thecoatingscanalsobetailoredtoachievespecificmechanicalproperties,suchashardness,compressivestrength,andtoughness.Moreover,thearc-sprayedcoatingscanbecombinedwithothertypesofcoatings,suchascermetorceramiccoatings,tofurtherenhancethewearresistanceofthecomponents.

Theversatilityofarcsprayingmakesitapopularchoiceinvariousindustries,includingaerospace,automotive,marine,andmining.Forexample,arc-sprayedcoatingsareusedtoprotectaircraftcomponentsfromwearanderosioncausedbysandanddustparticles.Thecoatingsalsoimprovetheperformanceandlongevityofenginecomponents,suchaspistons,cylinders,andvalves,inarangeofoperatingconditions.Inthemarineindustry,arc-sprayedcoatingsareappliedtoshiphulls,propellers,andoffshorestructurestoresistcorrosionandbiofouling.Intheminingindustry,arc-sprayedcoatingshelptoextendtheservicelifeofcrushingandgrindingequipment,conveyorbelts,andminingtools.

Overall,thearc-sprayedstainlesssteelcoatingsofferapracticalandreliablesolutionforimprovingthewearresistanceandcorrosionresistanceofindustrialcomponents.Theprocessissimple,efficient,andeconomical,andthecoatingscanbecustomizedtosuitdiverseneeds.Arcsprayingisaproventechnologythathasbeenusedfordecades,anditcontinuestoevolvewithnewmaterialsandequipment.Assuch,itisexpectedtoremainavaluabletoolforindustrialmaintenanceandrepairinthefuture.Oneofthekeyadvantagesofarc-sprayedstainlesssteelcoatingsistheirabilitytoprovideexcellentprotectionagainstcorrosion.Stainlesssteelisknownforitsresistancetorustingandstaining,andarc-sprayedcoatingshelptofurtherenhancethisproperty.Theprocessinvolvesheatingthestainlesssteelpowdertoamoltenstateandthensprayingitontothesubstrateusingcompressedairorgas.Theresultingcoatingformsadenseanduniformlayerthatactsasabarrieragainstcorrosiveagents,suchassaltwater,chemicals,andacids.

Furthermore,arc-sprayedcoatingscanbeusedtorestorewornordamagedcomponentstotheiroriginaldimensionsandspecifications.Thisisparticularlyusefulincaseswherereplacementpartsarenotreadilyavailableorareprohibitivelyexpensive.Theprocessinvolvesapplyingthestainlesssteelcoatingtotheaffectedareaandthenmachiningittotherequiredshapeandtolerance.Theresultingsurfacehasasimilarorevenbetterperformancethantheoriginalpart,anditcanwithstandthesameorhigherlevelsofwearandcorrosion.

Finally,arc-sprayedstainlesssteelcoatingshavealowenvironmentalimpactcomparedtoothercoatingmethods.Theprocessdoesnotproducehazardouswastesoremissions,andthecoatingmaterialisrecyclable.Moreover,thecoatingscanbeappliedinsitu,whichminimizesdowntimeandtransportationcosts.Thismakesarcsprayingacost-effectiveandsustainablesolutionforindustrialmaintenanceandrepair.

Inconclusion,arc-sprayedstainlesssteelcoatingsofferarangeofbenefitsforimprovingtheperformanceandlongevityofindustrialcomponents.Theyprovideexcellentwearandcorrosionresistance,canbecustomizedtomeetspecificrequirements,aresuitableforrestoringdamagedparts,andhavealowenvironmentalimpact.Assuch,theyareavaluabletoolformaintainingandupgradingindustrialequipmentandinfrastructure.Anotheradvantageofarc-sprayedstainlesssteelcoatingsistheirversatility.Theycanbeusedinavarietyofindustries,includingmarine,oilandgas,aerospace,automotive,andconstruction.Theyarecommonlyusedtoprotectandimprovetheperformanceofpipelines,tanks,valves,pumps,andothercriticalcomponents.Sincethecoatingscanbecustomizedbasedontheapplicationrequirements,theycanmeettheneedsofdifferentindustriesandapplications.

Arc-sprayedstainlesssteelcoatingsalsoofferexcellentadhesionand