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摘要: 以45#钢和TC4钛合金为基体材料，采用等离子喷涂方法制备了钨（W）及钨合金涂层，并在不同烧蚀条件下进行了烧蚀实验，比较了涂层的抗烧蚀性能，探讨了涂层烧蚀破坏机理。结果表明：基体材料喷涂W涂层后，提高了抗烧蚀性能。烧蚀温度为2600 ℃时，烧蚀11 s，涂层存在氧化，基本无烧蚀现象；烧蚀温度为3400 ℃时，烧蚀6 s，涂层有了明显的烧蚀，存在基体熔化现象，说明热量传递到基体，导致基体温度超过了自身熔点。W+Al2O3和W+ZrO2复合涂层可减缓热量从涂层表面向基体的传递速率，提高了基体材料的抗烧蚀性能。W+Al2O3和W+ZrO2复合涂层测力曲线呈锯齿状下降，不抗冲刷，但涂层的抗烧蚀时间相对较长。Abstract: Tungsten (W) and tungsten alloy coatings were prepared by plasma spraying on 45# steel and TC4 titanium alloys. Ablation tests were carried out under the different ablation conditions. The ablation resistance of the coatings was compared, and the ablation failure mechanism of the coatings was discussed. The results show that, the ablation resistance of the base materials is improved by spraying W coatings. When the ablation temperature is 2600 ℃ for 11 s, the coatings are oxidized, and there is no ablation phenomenon. When the ablation temperature is 3400 ℃ for 6 s, the coatings have the obvious ablation, indicating that the heat is transferred to the matrix, resulting in the matrix temperature exceeding the own melting point. The W+Al2O3 and W+ZrO2 composite coatings slow down the heat transfer rate from the coating surface to the substrate, and improve the ablative resistance of the substrate materials. The dynamometer curves of W+Al2O3 and W+ZrO2 composite coatings show the zigzag decline and do not resist the erosion, but the coating ablative resistance time is relatively long.
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Key words:
- plasma spraying /
- W coatings /
- composite coatings /
- ablation resistance properties
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图 1 喷涂纯W涂层45#钢烧蚀后表面形貌：（a）未烧蚀；（b）2600 ℃、烧蚀6 s；（c）2600 ℃、烧蚀11 s；（d）3400 ℃、烧蚀3 s；（e）3400 ℃、烧蚀6 s
Figure 1. Surface morphology of the pure W-coated 45 # steels after ablation: (a) unablated; (b) ablated at 2600 ℃ for 6 s; (c) ablated at 2600 ℃ for 11 s; (d) ablated at 3400 ℃ for 3 s; (e) ablated at 3400 ℃ for 6 s
图 2 纯W涂层在不同烧蚀情况下微观形貌及元素分布：（a）未烧蚀；（b）2600 ℃、烧蚀11 s；（c）3400 ℃、烧蚀6 s
Figure 2. Morphology and element distribution of the pure W coatings under different ablative conditions: (a) unablated; (b) ablated at 2600 ℃ for 11 s; (c) ablated at 3400 ℃ for 6 s
图 3 不同基体材料及涂层烧蚀表面形貌：（a）45#钢、W涂层；（b）45#钢、W+Al2O3涂层；（c）45#钢、W+ZrO2涂层；（d）钛合金、W+ZrO2涂层
Figure 3. Ablative surface morphology of the coatings on the different substrate materials: (a) 45# steels, W coatings; (b) 45# steels, W+Al2O3 coatings; (c) 45# steels, W+ZrO2 coatings; (d) Ti alloys, W+ZrO2 coatings
图 4 W+ZrO2复合涂层烧蚀后表面X射线衍射图谱
Figure 4. XRD patterns of the W+ZrO2 composite coatings after ablation
图 5 45#钢表面喷涂复合涂层烧蚀后微观形貌及元素分析：（a）W+Al2O3涂层；（b）W+ZrO2涂层
Figure 5. Ablative morphology of the composite coatings on 45# steels: (a) W+Al2O3 coating; (b) W+ZrO2 coatings
图 6 不同涂层材料发动机测力试验曲线：（a）纯W涂层；（b）W+ZrO2涂层；（c）W+Al2O3涂层
Figure 6. Dynamometer curves of the engines with the different coatings: (a) pure W coatings; (b) W+ZrO2 coatings; (c) W+Al2O3 coatings
图 7 不同材料涂层试车后的微观形貌：（a）纯W涂层；（b）W+ZrO2涂层；（c）W+Al2O3涂层
Figure 7. Microstructure of different materials coating after test：(a) pure W coating; (b) W+ZrO2 coating; (c) W+Al2O3 coating
表 1 ZrO2粉末化学成分（质量分数）
Table 1. Chemical composition of the ZrO2 powders
% ZrO2 Y2O3 SiO2 Fe2O3 Al2O3 TiO2 92.25 7.48 ＜0.02 ＜0.02 ＜0.01 ＜0.01 
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表 2 Al2O3粉末化学成分（质量分数）
Table 2. Chemical composition of the Al2O3 powders
% Al2O3 Fe2O3 Na2O SiO2 99.00 0.07 0.18 0.14
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表 3 等离子喷涂工艺参数
Table 3. Plasma spraying process parameters
材料 Ar流量 / (m3∙h‒1) He流量 / (m3∙h‒1) 电流 / A 送粉量 / (g∙min‒1) 功率 / kW 纯W涂层 2.83 1.13 780 49.8 28 W+ZrO2涂层 2.83 0.85 800 40.2 27 W+Al2O3涂层 2.83 0.85 750 34.8 25
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