喷涂道次对 Q245R碳素钢表面 Fe基涂层组织结构与性能的影响

Effect of the number of spray passes on microstructure and properties of Fe-based coating on Q245R carbon steel surface

摘要

[目的]为解决核电废液存储工况下 Q245R 碳素钢储罐的耐腐蚀与脆性劣化问题，依托低压冷喷涂的现场施工优势，开展核电专用防腐涂层的工程化工艺研究。[方法]采用低压冷喷涂技术在 Q245R 碳素钢上制备不同道次(1、2、3 和 4 道)的 Fe 基涂层，通过扫描电子显微镜(SEM)、维氏显微硬度测试、动电位极化曲线测量及静态浸泡试验，研究了喷涂道次对涂层微观组织、力学性能及耐蚀性的影响。[结果]随着喷涂道次增加，涂层结构越来越致密，颗粒间的结合状态逐渐改善。与 1 道次涂层相比，4 道次涂层实现了充分致密化，孔隙率从 2.4%降至 0.8%，表面粗糙度( Ra)由 3.7 μm 降至 2.1 μm，显微硬度提升约 55.6%，达到 223.7 HV _0.2。电化学测试显示 4 道次涂层耐蚀性最优，其腐蚀电流密度比 1 道次涂层降低 25%，腐蚀电位正移了 349 mV，表明该涂层的极化电阻显著增大，可有效阻碍涂层/基体界面的电荷传递，抑制基体的腐蚀反应。4 道次涂层在 3.5% NaCl 溶液浸泡过程中，其表面腐蚀产物从松散絮状逐步演变为连续致密覆盖层，该致密覆盖层可进一步增大涂层极化电阻，减少电荷转移通道，阻碍腐蚀过程中的电荷传递，有效减缓涂层内部 Fe 相及 Q245R 基体的腐蚀进程，为基体提供了稳定、可靠的腐蚀保护。[结论]4 道次为制备高性能纯 Fe 涂层的最优工艺参数。本研究明确了喷涂道次在涂层沉积与抗腐蚀中的关键作用，为冷喷涂铁基防护涂层的工艺优化提供了实验依据。

Abstract

[Objective] To address the corrosion resistance and embrittlement issues of Q245R carbon steel storage tanks under the storage conditions of waste liquid from nuclear power plants, an engineering process study on a dedicated anticorrosion coating for nuclear power applications was conducted based on the on-site application advantages of low-pressure cold spraying technology. [Method] Fe-based coatings with different spray passes (1, 2, 3, and 4) were prepared on Q245R carbon steel by low-pressure cold spraying. The effect of the number of spray passes on the microstructure, mechanical properties, and corrosion resistance of the coatings were studied by scanning electron microscopy (SEM), Vickers microhardness testing, potentiodynamic polarization measurement, and static immersion test. [Result] As the number of spray passes increased, the coating structure became denser and the inter-particle bonding gradually improved. Compared with the 1-pass coating, the 4-pass coating achieved full densification, with porosity decreasing from 2.4% to 0.8%, surface roughness ( Ra) reducing from 3.7 μm to 2.1 μm, and the microhardness increasing by approximately 55.6% to reach 223.7 HV _0.2. Electrochemical tests showed that the 4-pass coating exhibited the optimal corrosion resistance, with a corrosion current density reduced by 25% and a corrosion potential shifted positively by 349 mV as compared with the 1-pass coating, suggesting a significant increase in polarization resistance that effectively hinders the charge transfer at the coating/substrate interface and suppresses the corrosion of the substrate. During the immersion in 3.5% NaCl solution, the corrosion products on the 4-pass coating surface gradually evolved from a loose flocculent structure to a continuous compact covering layer. This compact layer further enhanced the polarization resistance of the coating, reduce the charge transfer channels, and effectively hindered the charge transfer process, thereby slowing the corrosion progression of both the Fe phase within the coating and the Q245R substrate, providing stable and reliable corrosion protection for the substrate. [Conclusion] Four passes was identified as the optimal process parameter for preparing high-performance pure Fe coatings by cold spraying in this work. This study clarifies the key role of the number of spray passes in coating deposition and corrosion resistance of carbon steel, providing experimental evidence for process optimization of cold-sprayed iron-based protective coatings.

关键词

碳素钢 / 冷喷涂 / 喷涂道次 / 显微硬度 / 耐蚀性

Key words

carbon steel / cold spraying / number of spray passes / microhardness / corrosion resistance

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基金资助

国家自然科学基金(52265049)

甘肃省联合科研基金项目(24JRRA833)