等离子增强高速电弧喷涂Fe基涂层：喷涂功率对涂层组织、摩擦学性能和耐腐蚀性能的影响

doi:10.3901/JME.2025.10.066

机械工程学报 ›› 2025, Vol. 61 ›› Issue (10): 66-74.doi: 10.3901/JME.2025.10.066

• 特邀专栏：高端装备表面强化防护与再制造 • 上一篇

扫码分享

等离子增强高速电弧喷涂Fe基涂层：喷涂功率对涂层组织、摩擦学性能和耐腐蚀性能的影响

高瑞^1,2, 刘明², 范薇³, 黄艳斐², 金国¹, 张寒冰², 马国政², 王海斗^1,4

1. 哈尔滨工程大学材料科学与化学工程学院哈尔滨 150001;
2. 陆军装甲兵学院再制造技术国家重点实验室北京 100072;
3. 中北大学能源与动力工程学院太原 030051;
4. 陆军装甲兵学院机械产品再制造国家工程研究中心北京 100072

收稿日期:2024-10-07 修回日期:2025-01-09 发布日期:2025-07-12
作者简介:高瑞，男，1997年出生，博士研究生。主要研究方向为表面工程。E-mail：gr14791773310@163.com;王海斗(通信作者)，男，1969年出生，博士，教授，博士研究生导师。主要研究方向为机械工程、表面工程及摩擦学。E-mail：whaidou2021@163.com
基金资助:
国家自然科学基金资助项目(52075542，52130509，52205225)。

Plasma-enhanced High-speed Arc Spraying of Fe-based Coatings：Effect of Spraying Power on Coating Organization, Tribological Properties, and Corrosion Resistance

GAO Rui^1,2, LIU Ming², FAN Wei³, HUANG Yanfei², JIN Guo¹, ZHANG Hanbing², MA Guozheng², WANG Haidou^1,4

1. College of Material Science and Chemical Engineering, Harbin Engineering University, Harbin 150001;
2. National Key Laboratory for Remanufacturing, Army Academy of Armored Forces, Beijing 100072;
3. School of Energy and Power Engineering, North University of China, Taiyuan 030051;
4. National Engineering Research Center for Remanufacturing, Army Academy of Armored Forces, Beijing 100072

Received:2024-10-07 Revised:2025-01-09 Published:2025-07-12

摘要/Abstract

摘要： 海工装备服役过程中关键件长期处于腐蚀-磨损交互作用的复杂环境，致使其表面损伤严重，影响设备运行的安全性和可靠性。对工件表面进行处理形成结合良好的热喷涂涂层是解决这一问题的有效途径。利用等离子增强高速电弧喷涂技术(Plasma-enhanced high-speed arc technology,PE-HAS)成功制备出Fe基涂层，并研究喷涂功率对涂层微观组织、力学性能及耐磨耐腐蚀性能的影响。研究结果表明，涂层的物相组成主要为奥氏体和马氏体。当喷涂功率不足或过大时，涂层的组织结构会变差，从而导致其摩擦学和耐腐蚀性能变差。当喷涂电流优化至500 A时，可以提供优良的组织结构，从而提升涂层的力学性能、摩擦学和耐腐蚀性能。综上，等离子增强高速电弧喷涂过程中控制喷涂功率对丝材熔化很重要，从而影响涂层的组织结构致密性。

关键词: 等离子增强高速电弧喷涂, 喷涂功率, 组织结构, 力学性能, 摩擦学性能, 耐腐蚀性能

Abstract: In the service process of offshore equipment, key components are subjected to a complex environment characterized by corrosion-wear interactions over extended periods. This exposure results in significant surface damage, compromising the safety and reliability of equipment operation. Treating the surface of the workpiece to achieve a robust thermal spray coating is an effective solution to this issue. In this study, iron-based coatings were successfully prepared using plasma-enhanced high-speed arc technology (PE-HAS). The impact of spraying power on the microstructure, mechanical properties, and wear and corrosion resistance of the coatings was thoroughly investigated. The results indicate that the primary physical phase composition of the coating consists of austenite and martensite. When the spraying power is either insufficient or excessive, the structure of the coating deteriorates, leading to a decline in its tribological and corrosion resistance properties. Optimizing the spraying current to 500 A results in an excellent microstructural configuration, thereby enhancing the mechanical properties, tribological performance, and corrosion resistance of the coating. In conclusion, controlling the spray power during PE-HAS is crucial for wire melting, which significantly influences the densification of the coating's microstructure.

Key words: PE-HAS, spraying power, organizational structure, mechanical properties, tribological properties, corrosion resistance

中图分类号:

TG178

高瑞, 刘明, 范薇, 黄艳斐, 金国, 张寒冰, 马国政, 王海斗. 等离子增强高速电弧喷涂Fe基涂层：喷涂功率对涂层组织、摩擦学性能和耐腐蚀性能的影响[J]. 机械工程学报, 2025, 61(10): 66-74.

GAO Rui, LIU Ming, FAN Wei, HUANG Yanfei, JIN Guo, ZHANG Hanbing, MA Guozheng, WANG Haidou. Plasma-enhanced High-speed Arc Spraying of Fe-based Coatings：Effect of Spraying Power on Coating Organization, Tribological Properties, and Corrosion Resistance[J]. Journal of Mechanical Engineering, 2025, 61(10): 66-74.

参考文献

[1] 李梦璇，丁昊昊，安博洋，等. U71Mn钢轨在工业与海洋大气环境下腐蚀与磨损行为研究[J]. 机械工程学报，2024，60(19)：132-143.LI Mengxuan，DING Haohao，AN Boyang，et al. Corrosion and wear behavior of steel rails in industrial and marine atmospheric environments[J]. Journal of Mechanical Engineering，2024，60(19)：132-143.
[2] GAO R，Huang Y F，ZHOU X Y，et al. Material system and tribological mechanism of plasma sprayed wear resistant coatings：Overview[J]. Surface and Coatings Technology，2024，483：130758.
[3] 周琼，岗志远，黄彪，等. 退火温度对DLC和Si-DLC涂层微观结构和摩擦学性能的影响[J]. 中国表面工程，2024，37(4)：206-217.ZHOU Qiong，GANG Zhiyuan，HUANG Biao，et al. Effect of annealing temperature on microstructure and tribological properties of DLC and Si-DLC coatings[J]. China Surface Engineering，2024，37(4)：206-217.
[4] 王秀雨，程江波，葛云云，等. 镁合金表面再制造AlCoTi非晶涂层组织及力学性能研究[J]. 机械工程学报，2023，59(7)：367-374，388.WANG Xiuyu，CHENG Jiangbo，GE Yunyun，et al. Study on the organization and mechanical properties of remanufactured AlCoTi amorphous coating on the surface of magnesium alloy[J]. Journal of Mechanical Engineering，2023，59(7)：367-374，388.
[5] WU S，TANG Y，GU J，et al. Controllable preparation of metal-based lubrication coatings in extreme environmental applications[J]. Materials & Design，2024，241：112922.
[6] 何东青，梁瑞瑞，冯子涵，等. 中间层厚度对Cr₃C₂-NiCr/ DLC复合涂层腐蚀磨损行为的影响[J/OL]. 中国表面工程. https://link.cnki.net/urlid/11.3905.tg.20241217.1919.029. HE Dongqing，LIANG Ruirui，FENG Zihan，et al. The influence of interlayer thicknesses on the tribo-corrosion behaviors of Cr₃C₂-NiCr/DLC duplex coatings[J/OL]. China Surface Engineering. https://link.cnki.net/urlid/11.3905.tg.20241217.1919.029.
[7] WANG G，PENG Y，ZHU Z，et al. A multi-physics coupling analysis to predict stress corrosion characteristics of wires in rope under wear damage[J]. Simulation Modelling Practice and Theory，2024，131：102882.
[8] RALLS A M，BALDWIN C，SHE Y，et al. Assessing the tribo-corrosion resistance of surface nanostructured stainless-steel[J]. Surface and Coatings Technology，2024，483：130755.
[9] SUN J，WANG W，LIU Z，et al. Study on selective laser melting 316L stainless steel parts with superhydrophobic surface[J]. Applied Surface Science，2020，533：147445.
[10] TIAN H，WANG C，GUO M，et al. Influence of Ni and Cr on the high-temperature wear resistance of FeNiCrAl coatings[J]. Results in Physics，2019，12：959-969.
[11] PEI W，PEI X，XIE Z，et al. Research progress of marine anti-corrosion and wear-resistant coating[J]. Tribology International，2024，198：109864.
[12] DRMOSH Q A，AL-MUHAISH N A，Al-WAJIH Y A，et al. Surface composite and morphology tuning of tungsten oxide thin films for acetone gas sensing[J]. Chemical Physics Letters，2021，776：138659.
[13] LIM J，JANANI G，CHOE J，et al. Mechanism of enhanced flowability/spreadability in 3D printed Ni alloy powder[J]. Powder Technology，2023，415：118198.
[14] TAILOR S，MODI A，MODI S C. Thermally sprayed thin copper coatings by W-HVOF[J]. Journal of Thermal Spray Technology，2019，28(1)：273-282.
[15] MILLER F，WINTZHEIMER S，PRIESCHL J，et al. A supraparticle based five level identification tag that switches information upon readout[J]. Advanced Optical Materials，2021，9(4)：2001972.
[16] GAO J，HANIF M B，ZHANG H，et al. Recent advances in microstructural control via thermal spraying for solid oxide fuel cells[J]. Chemical Engineering Journal，2023：147352.
[17] HE J，HE Z，QIN Y，et al. A review of TiCN coating prepared by reaction plasma spraying[J]. Journal of Thermal Spray Technology，2022，31(8)：2280-2299.
[18] TAO X，ZHANG Z，Zhang B，et al. Plasma sprayed CoNiCrMoNb (BSi) high-entropy amorphous alloy coating：The effect of spraying power on microstructure，mechanical and tribological properties[J]. Materials Chemistry and Physics，2024，314：128887.
[19] WANG Y，HAN Y，LIN C，et al. Effect of spraying power on the morphology of YSZ splat and micro-structure of thermal barrier coating[J]. Ceramics International，2021，47(13)：18956-18963.
[20] LIU Y，MA G，ZHU L，et al. Effects of Al₂O₃ powder characteristics on microstructure，mechanical and tribological properties of Inconel 625-Al₂O₃ non-skid coatings prepared by plasma enhanced high-velocity arc spraying[J]. Tribology International，2024，199：110033.
[21] LIU Y，ZHU L，MA G，et al. Effects of Al₂O₃ content on the microstructure and performance of Inconel 625-xAl₂O₃ composite non-skid coatings by plasma enhanced high-velocity arc spraying[J]. Surface and Coatings Technology，2024，485：130929.
[22] LI Y T，FU H G，MA T J，et al. Microstructure and wear resistance of AlCoCrFeNi-WC/TiC composite coating by laser cladding[J]. Materials Characterization，2022，194：112479.
[23] YANG Q，XU Z，LI L，et al. Microstructure and performance research on ceramic-enhanced Inconel 718 matrix composite using laser additive manufacturing[J]. Metals，2023，13(9)：1525.

等离子增强高速电弧喷涂Fe基涂层：喷涂功率对涂层组织、摩擦学性能和耐腐蚀性能的影响

Plasma-enhanced High-speed Arc Spraying of Fe-based Coatings：Effect of Spraying Power on Coating Organization, Tribological Properties, and Corrosion Resistance

PDF

可视化

摘要/Abstract

引用本文

使用本文

参考文献

相关文章 15

编辑推荐

Metrics

本文评价

[1]	钦兰云, 袁溪涟, 赵朔, 杨光, 王向明. 电弧模式对Ti/Al异质合金直接增材制造界面组织与力学行为影响研究[J]. 机械工程学报, 2025, 61(9): 199-210.
[2]	刘元铭, 刘延啸, 申宏卓, 王振华, 王涛. Mg/Al复合板波纹轧变形特点与微观组织演变[J]. 机械工程学报, 2025, 61(8): 85-97.
[3]	韩静, 石玗, 李广, 张航, 陆刚. 非均匀激光热源焊接铜/钢接头的组织及力学性能研究[J]. 机械工程学报, 2025, 61(6): 151-159.
[4]	米高阳, 蒋熠鸣, 王春明, 张铭洋, 胡溢洋, 肖永康, 翟春成, 欧阳求保. 激光摆动焊接7075铝合金接头的成形、组织和力学性能[J]. 机械工程学报, 2025, 61(4): 86-95.
[5]	李涌泉, 郝清锐, 梁国栋, 王存喜, 高阳. TiAl合金表面Al-Y渗层的组织及高温抗氧化性能[J]. 机械工程学报, 2025, 61(4): 137-146.
[6]	崔冰, 江涛, 赵卫星, 傅玉灿, 杜全斌. Ti₃AlC₂构建梯度界面对Cu-20Sn-10Ti合金钎料钎焊金刚石磨粒磨削性能的影响[J]. 机械工程学报, 2025, 61(4): 156-166.
[7]	杨纯攀, 王小伟, 李雪松, 杨东青, 黄勇, 彭勇, 王克鸿. 超声冲击辅助电弧增材制造18Ni-350马氏体时效钢组织性能研究[J]. 机械工程学报, 2025, 61(2): 162-171.
[8]	吴贯之, 陈楠楠, 石华兵, 刘坤山, 孔谅, 王敏. 摆动激光填丝焊工艺参数对碳钢搭接角焊缝成形与力学性能的影响[J]. 机械工程学报, 2025, 61(2): 172-180.
[9]	石佳东, 马国政, 李国禄, 李振, 赵海朝, 王海斗. 典型工况环境中类金刚石薄膜摩擦学性能研究进展[J]. 机械工程学报, 2025, 61(10): 19-35.
[10]	杨超雄, 张兆栋, 沙禹垚, 刘黎明. 倾斜基板铝合金增材制造尺寸规律及性能研究[J]. 机械工程学报, 2025, 61(1): 326-334.
[11]	孔玲, 王玉辉, 杨浩坤, 彭艳. Fe-Mn-Al-C系奥氏体基低密度钢使役性能研究进展[J]. 机械工程学报, 2024, 60(8): 34-47.
[12]	任志英, 黄子豪, 方荣政, 王秦伟, 莫继良, 秦红玲. 金属橡胶无序式网格互穿结构的热力学性能研究[J]. 机械工程学报, 2024, 60(8): 165-175.
[13]	陈伟, 赵杰, 朱利斌, 曹海波. 增材制造低活化钢研究现状及展望[J]. 机械工程学报, 2024, 60(7): 312-333.
[14]	郑洋, 赵梓昊, 刘伟, 余政哲, 牛伟, 雷贻文, 孙荣禄. 高性能镁合金增材制造技术研究进展[J]. 机械工程学报, 2024, 60(7): 385-400.
[15]	鲍鑫宇, 麻永林, 程桥, 苏怡卉, 王杰, 邢淑清. 脉冲磁场熔体处理对Al-Si-Mg-Cu-Ni合金DC铸造凝固组织和力学性能的影响[J]. 机械工程学报, 2024, 60(6): 279-286.