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摘要: 采用紧耦合气雾化技术制备热喷涂NiCrAlY合金粉末，对NiCrAlY合金粉末的物理性能、粒度分布、粉末形貌、微观结构和物相组成等进行了分析。结果表明，粉末以球形和近球形颗粒为主，85%粉末粒径小于150 μm。粉末显微组织主要由树枝晶和胞状晶组成，粒径25～250 μm的粉末凝固冷速大约在4000～67000 K·s−1。粒径尺寸小于50 μm的粉末内部结构致密，少量尺寸大于50 μm的颗粒内部出现凝固缩孔和空心缺陷。粉末晶界和晶内存在Y、Si元素偏析，粉末物相结构主要由γ'-Ni3Al、γ-Ni固溶体相组成。
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关键词:
- 紧耦合气雾化 /
- NiCrAlY合金粉末 /
- 热喷涂 /
- 显微组织 /
- 粉末性能
Abstract: NiCrAlY alloy powders used for the thermal spraying were fabricated by the closed-coupled gas atomization technology. The physical properties, particle size distribution, powder morphology, internal microstructure, and phase composition of the NiCrAlY alloy powders were investigated. The results show that, most of powders are spherical or nearly spherical particles, the particle size of 85% powders is less than 150 μm. The powder microstructures are mainly composed of dendrites and cellular crystals, and the solidification cooling rate of the powders with the particle size of 25～250 μm is about 4000～67000 K·s−1. The inner structure of the powders with the particle size less than 50 μm is dense, and a small number of particles with the particle size larger than 50 μm show the solidification shrinkage pore and hollow defects. There are Y and Si segregation in the crystal boundary and intracrystalline, and the powder phases are mainly composed of γ'-Ni3Al and γ-Ni solid solution phases. -
图 2 NiCrAlY合金粉的粒度分布
Figure 2. Cumulative particle size distribution (volume fraction) and the particle size of the NiCrAlY powders
图 3 不同粒度NiCrAlY合金粉显微形貌：（a）＜20 μm；（b）25～38 μm；（c）45～90 μm；（d）120～200 μm
Figure 3. SEM images of the NiCrAlY powders with the different particle size: (a) <20 μm; (b) 25~38 μm; (c) 45~90μm; (d) 120~200 μm
图 4 不同粒度NiCrAlY合金粉末断面显微组织：（a）250 μm；（b）160 μm；（c）80 μm；（d）30 μm
Figure 4. Cross-section microstructure of NiCrAlY powders with different particle size: (a) 250 μm; (b) 160 μm; (c) 80 μm; (d) 30 μm
图 5 粒径为45～106 μm的NiCrAlY粉末断面扫描电镜背散射电子形貌：（a）粉末显微组织；（b）无缺陷颗粒；（c）凝固缩孔颗粒；（d）空心颗粒
Figure 5. SEM-BSE images of the NiCrAlY powders in the cross-section with the particle size of 45～106 μm: (a) overall microstructure of the powders; (b) featureless structure powder; (c) solidification shrinkage; (d) hollow defects
图 6 NiCrAlY合金粉末断面能谱分析
Figure 6. EDS mapping of the NiCrAlY powders in the cross-section
图 7 NiCrAlY粉末内部凝固组织和元素能谱分析：（a）粒径为120 μm左右的粉末颗粒；（b）图7（a）中B点能谱分析；（c）图7（a）中C点能谱分析
Figure 7. Solidification microstructure and EDS spectrum of the NiCrAlY powders: (a) microstructure of powders with the particle size of 120 μm; (b) EDS spectrum of spot B in Fig.7(a); (c) EDS spectrum of spot C in Fig.7(a)
图 8 不同粒度NiCrAlY粉末X射线衍射图谱
Figure 8. XRD patterns of the NiCrAlY powders with the different particle sizes
表 1 不同粒径NiCrAlY合金粉的物理性能
Table 1. Physics properties of the NiCrAlY powders with the different particle sizes
粒径 / μm 松装密度 / (g·cm−3) 流动性 / [s·(50g)−1] 质量分数 / % O N 106～297 4.089 18.50 0.0078 0.0043 45～106 4.063 17.37 0.0057 0.0045 25～38 3.850 — 0.0231 0.0047 
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表 2 不同粒度NiCrAlY粉末的晶间距和冷速
Table 2. Grain spacing and cooling rate of the NiCrAlY powders with different particle sizes
粉末粒度 / μm 晶间距 / μm 颗粒冷速 / (K·s−1) 251.5 3.144 4020 145.9 2.456 8400 72.9 1.500 37000 40.6 1.350 51000 25.5 1.229 67000
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表 3 图7（a）中各点能谱分析
Table 3. EDS analysis of each spots in Fig.7(a)
位置 质量分数 / % Al Si Y Cr Mn Ni 能谱面扫A 6.42 0.57 0.48 28.06 — 64.47 晶内B 9.05 0.21 0.29 27.15 — 63.30 晶界C 5.63 1.02 1.65 27.02 0.75 63.93 晶间D 6.65 0.67 0.58 27.74 0.39 63.96 名义含量 7.82 0.32 0.57 25.70 — 65.59
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