ZM6镁合金表面冷喷涂铝基复合涂层的耐磨性

Wear resistance of cold-sprayed aluminum-based composite coating on ZM6 magnesium alloy surface

摘要

[目的] 航空发动机ZM6镁合金机匣在振动、腐蚀等恶劣工况下极易发生磨损失效，传统冷喷涂铝基涂层虽可提供一定保护，但硬度和耐磨性仍有不足，引入不规则硬质颗粒制备复合涂层有望提升其综合性能。[方法] 以ZM6镁合金为基体，采用冷喷涂技术分别制备6061Al单相涂层和6061Al–Al ₂O ₃复合涂层。利用白光干涉仪、场发射扫描电镜、能谱仪、显微硬度计和X射线残余应力分析仪对涂层的表面粗糙度、微观组织、显微硬度及残余应力进行表征。通过球−盘式滑动干摩擦磨损试验对比了ZM6镁合金、6061Al涂层和6061Al–Al ₂O ₃复合涂层的耐磨性，并结合磨痕形貌与元素分析探讨磨损机理。[结果] 两种涂层都均匀致密，与基体结合良好。6061Al–Al ₂O ₃复合涂层的平均显微硬度和平均残余压应力分别为121.2 HV和−96.4 MPa，均高于6061Al涂层(78.9 HV和−37.6 MPa)。在5 N载荷下摩擦磨损后，6061Al涂层和6061Al–Al ₂O ₃复合涂层的磨损率较ZM6镁合金基体分别降低22.2%和82.1%，在10 N载荷下则分别降低18.6%和66.0%。[结论] 在冷喷铝基涂层中引入合适的硬质颗粒有助于提升涂层的耐磨性，本文的研究结果为镁合金表面高耐磨冷喷涂涂层的设计提供了思路。

Abstract

[Objective] The ZM6 magnesium alloy casing of aero-engines is highly susceptible to wear failure under severe service conditions such as vibration and corrosion. Although conventional cold-sprayed aluminum-based coatings can provide certain protection, their hardness and wear resistance remain insufficient. Introducing irregular hard particles to prepare composite coatings is expected to enhance their overall performance. [Method] The surface roughness, microstructure, microhardness, and residual stress of the coatings were characterized by white light interferometry, field emission scanning electron microscopy, energy dispersive spectroscopy, microhardness tester, and X-ray residual stress analyzer. The wear resistance of ZM6 magnesium alloy, 6061Al coating, and 6061Al–Al ₂O ₃ composite coating was compared through ball-on-disc dry sliding friction and wear tests, and the wear mechanisms were discussed based on the morphologies and elemental compositions of the wear tracks. [Result] Both coatings were uniform and compact with good adhesion with the substrate. The average microhardness and average residual compressive stress of 6061Al–Al ₂O ₃ composite coating were 121.2 HV and –96.4 MPa, respectively, which were higher than those of 6061Al coating (78.9 HV and –37.6 MPa). After friction and wear test under a load of 5 N, the wear rates of 6061Al coating and 6061Al–Al ₂O ₃ composite coating decreased by 22.2% and 82.1%, respectively, compared with the ZM6 substrate; under a load of 10 N, the decreases were 18.6% and 66.0%, respectively. [Conclusion] Introducing suitable hard particles into cold-sprayed aluminum-based coatings helps to improve their wear resistance. The findings of this work provide a strategy for the design of highly wear-resistant cold spray coatings on magnesium alloy surfaces.

关键词

镁合金 / 冷喷涂 / 铝基涂层 / 氧化铝 / 显微组织 / 耐磨性

Key words

magnesium alloy / cold spray / aluminum-based coating / alumina / microstructure / wear resistance

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基金资助

中国航发航空齿轮制造技术创新中心基金项目(AGMTIC-KFKT-202401)

江西省自然科学基金项目(CA202401448)

江西省航空材料表面技术工程中心基金项目(EB202301428)

中国航发中传机械有限公司研究项目(GK202401087)