电流密度对柔性摩擦辅助脉冲电沉积 Ni–Co–Al ₂O ₃ 复合镀层性能的影响

Properties of Ni–Co–Al ₂O ₃ composite coating prepared by flexible friction-assisted pulse electrodeposition at different current densities

摘要

[目的]针对火炮身管内膛在使用过程中易发生烧蚀磨损的问题，通过柔性摩擦辅助脉冲电沉积技术在炮钢表面制备 Ni–Co–Al ₂O ₃ 复合镀层，系统研究平均脉冲电流密度对镀层组织结构及性能的影响，以提升火炮身管的耐蚀性与使用寿命。[方法]采用机械球磨法制备了纳米 Al ₂O ₃ 颗粒均匀分散的氨基磺酸盐体系复合镀液，然后以炮钢 PCrNi3MoVA 为基体，利用自主研制的柔性摩擦辅助电沉积装置，在平均脉冲电流密度 2 ~ 10 A/dm 2、频率 400 Hz、占空比 0.3 的条件下制备 Ni–Co–Al ₂O ₃ 复合镀层。通过扫描电子显微镜(SEM)、能谱仪(EDS)、X 射线衍射仪(XRD)、显微硬度计及电化学工作站，分别对镀层的表面与截断面形貌、元素组成、物相结构、显微硬度及耐蚀性能进行表征。[结果]柔性摩擦辅助可有效减少 Al ₂O ₃ 颗粒团聚，令 Ni–Co–Al ₂O ₃ 复合镀层组织更致密。随着平均脉冲电流密度从 2 A/dm 2 增至 10 A/dm 2，镀层表面孔隙减少，致密性提高；Al ₂O ₃ 颗粒复合量呈先增后降趋势，在 6 A/dm 2 时达到最大(3.1%)；Ni–Co–Al ₂O ₃ 复合镀层均由面心立方固溶体相组成，平均晶粒尺寸在 6 A/dm ² 时细化至 9.3 nm，显微硬度达 585.4 HV，较基体提高约 39.4%。电化学测试结果表明，Ni–Co–Al ₂O ₃ 复合镀层耐蚀性随电流密度增大而增强，在 10 A/dm 2 时腐蚀电位最正，腐蚀电流密度最低，电荷转移电阻最高，耐蚀性最优。[结论]柔性摩擦辅助脉冲电沉积可制备出组织致密、晶粒细小、颗粒分布均匀的 Ni–Co–Al ₂O ₃ 复合镀层。通过调整平均电流密度可优化镀层的颗粒复合量、显微硬度及耐蚀性。本研究为火炮身管内膛表面防护提供了可行的技术途径。

Abstract

[Objective] To address the issue of ablation wear that readily occurs in gun barrel bores during service, a Ni–Co–Al ₂O ₃ composite coating was prepared on gun steel surface by flexible friction-assisted pulse electrodeposition. The effect of average pulse current density on the microstructure and properties of the coating was systematically studied, aiming to improve the corrosion resistance and service life of gun barrels. [Method] A sulfamate-based plating bath containing uniformly dispersed nano-Al ₂O ₃ particles was prepared by mechanical ball milling. Using self-developed flexible friction-assisted electrodeposition equipment, Ni–Co–Al ₂O ₃ composite coatings were deposited on PCrNi3MoVA gun steel substrate at average pulse current densities of 2-10 A/dm ², a frequency of 400 Hz, and a duty cycle of 0.3. The surface and cross-sectional morphologies, elemental composition, phase structure, microhardness, and corrosion resistance of the coatings were characterized by scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), X-ray diffraction (XRD), microhardness testing, and electrochemical measurement. [Result] Flexible friction assistance effectively reduced the agglomeration of Al ₂O ₃ particles, resulting in a denser microstructure of Ni–Co–Al ₂O ₃ composite coating. As the average pulse current density increased from 2 A/dm ² to 10 A/dm ², the surface porosity decreased and the compactness improved. The incorporation content of Al ₂O ₃ particles initially increased and then decreased, reaching a maximum of 3.1% at 6 A/dm ². All Ni–Co–Al ₂O ₃ composite coatings consisted of a face-centered cubic solid solution phase. The average grain size was refined to 9.3 nm at 6 A/dm ², and the microhardness reached 585.4 HV, which was approximately 39.4% higher than that of the substrate. Electrochemical test results indicated that the corrosion resistance of the coatings improved with increasing current density, with the coating deposited at 10 A/dm ² exhibiting the most positive corrosion potential, the lowest corrosion current density, and the highest charge-transfer resistance, demonstrating optimal corrosion resistance. [Conclusion] A Ni–Co–Al ₂O ₃ composite coating with compact microstructure, fine grains, and uniformly distributed particles can be obtained by flexible friction-assisted pulse electrodeposition. The incorporation content of Al ₂O ₃ particles, microhardness, and corrosion resistance can be optimized by adjusting the average current density. This study provides a feasible technical approach for surface protection of gun barrel bores.

关键词

脉冲电沉积 / 柔性摩擦辅助 / 氨基磺酸盐 / 镍−钴−氧化铝复合镀层 / 电流密度 / 微观结构 / 显微硬度 / 耐蚀性

Key words

pulse electrodeposition / flexible friction assistance / sulfamate / nickel–cobalt–alumina composite coating / current density / microstructure / microhardness / corrosion resistance

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基金资助

辽宁省科技厅应用基础研究计划项目(2023JH2/101300214)

2023 年辽宁省教育厅基本科研项目(JYTMS20230191)

沈阳理工大学“光选计划”人才资助项目(SYLUGXRC14)

沈阳理工大学“科研团队”资助项目(SYLUGXTD5)