CN115505816B - 一种抗空蚀Fe基高熵合金粉末、涂层及其制备方法 - Google Patents
一种抗空蚀Fe基高熵合金粉末、涂层及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种抗空蚀Fe基高熵合金粉末、涂层及其制备方法。该粉末以原子百分比计，其成分组成为Fe粉末：余量、Cr粉末：25～35％，Ni粉末：7‑13％，Al粉末：3～8％，Ti粉末：3～8％，Nb粉末：0.5～10％。以该配方为原料，通过激光熔覆或热喷涂使粉末熔覆在需要解决空蚀问题的工件表面，最终形成0.5～3mm的涂层。该涂层致密均匀，与基体呈冶金结合，稀释率低，具有优异抗空蚀性能。本发明的生产成本低，制备方法工艺可靠，性能稳定，用于解决水轮机、水泵等过流部件的空蚀问题。
Description
技术领域
本发明涉及一种抗空蚀Fe基高熵合金粉末、涂层及其制备方法，适合在水轮机、水泵等水力装备的过流部件上应用。
背景技术
空蚀对水力机械的破坏是材料界一直难以解决的关键问题。它不同于腐蚀，也不同于磨损、磨损腐蚀等。在流动的液体中，当局部区域的压力因某种原因而突然下降至与该区域液体温度相应的汽化压力以下时，部分液体汽化，溶于液体中的气体逸出，形成液流中的气泡(或称空泡)，这一过程称为空化。空泡随液流进入压力较高的区域时，失去存在的条件而突然溃灭，原空泡周围的液体运动使局部区域的压力骤增。如果液流中不断形成、长大的空泡在固体壁面附近频频溃灭，壁面就会遭受巨大压力的反复冲击，从而引起材料的疲劳破损甚至表面剥蚀，这就叫空化剥蚀，简称空蚀。
水泵、水轮机是水力机械的关键装备。水泵、水轮机中的过流部件在高速转动过程中，极易产生水空泡的空蚀，大大降低了水力机械的性能和使用寿命。全国水电站有46758座、泵站424451座，其中规模以上水电站数有22190座、泵站89063座。其中30％～40％的水轮机、水泵等水力装备受到空蚀侵害问题十分突出。其过流部件长期处于流速较高、压力较低的工况下，极易发生空蚀。由于空蚀现象的存在，造成过流部件表面材料大面积疲劳剥落，出现小凹坑，随着空蚀的加剧，形成了连片的、有突起和穴孔的蜂窝状表面，进而发展成海绵状，严重的可在过流部件表面形成大片的凹坑，深度可达20mm。空蚀破坏了过流部件原有的翼形曲线，大大降低了设备出力和效率。空蚀还造成材料大量剥落，过流部件变薄，在高水头冲击下极易发生断裂。空蚀不仅大大缩短了机组的检修周期，增加了机组维修的复杂性，严重影响发电效率，还严重影响电站的运行安全。
目前国内外解决空蚀防范主要有：提高母材韧性，涂覆有机涂层、渗碳渗氮、表面喷丸纳米化、超音速火焰喷涂等手段来提高水力装备的抗空蚀性能。但以上方法均解决水力机械的空蚀问题的效果不佳。
高熵合金具有独特的合金相结构、优异的性能，如高熵合金具有高强度与硬度、良好的耐磨性、良好的塑性和韧性、耐腐蚀性等优点。这为解决水力装备叶片空蚀提供了新思路。高熵合金经历了几个阶段的发展使其越来越“接地气”，从实验室研究走向了产业化应用，并解决了一些以往难以解决工程实践问题。在第一阶段，设计高熵合金主要以等原子比为主，这个阶段也主要以实验室研究为主，人们期望应用场景主要是航空航天领域。再到第二阶段，这时高熵合金的设计主要要求是控制每种主要元素的原子分数在5％～35％之间。在这个阶段，人们对高熵合金的认识得到了进一步深化，并且发现以往已运用于工程实践材料中已存在高熵合金材料。近阶段，学者及工程师对高熵合金有了更加深刻的理解，对成分比例的限制进一步放宽，更多只是强调多主元，注重运用其“四大效益”，而非拘束某种定义。现在人们正在利用高熵合金及其效应解决一些工程实践中以往难以解决材料问题，如空蚀问题等。
发明内容
本发明的目的在于针对水泵、水轮机等水力机械的关键装备的过流部件在高速运转时易产生空蚀现象，从而导致过流部件涂层性能下降的问题，提供一种抗空蚀Fe基高熵合金粉末、涂层及其制备方法，具有优异的抗空蚀性能。
本发明所采用的技术方案如下：
一种抗空蚀Fe基高熵合金粉末，以原子百分比计，其成分组成为：Fe粉末：余量、Cr粉末：25～35％、Ni粉末：7-13％、Al粉末：3～8％、Ti粉末：3～8％、Nb粉末：0.5～10％。
基于上述粉末的高熵合金涂层，由激光熔覆或热喷涂方法制备而成。
其制备方法包括如下步骤：
步骤1：将Fe粉末、Cr粉末、Ni粉末、Al粉末、Ti粉末、Nb粉末按原子百分比进行配制，粉末制备方法可采用机械混合法、喷雾干燥法、气雾化法制备。制备的高熵合金粉末颗粒尺度为10～105μm；高熵合金粉末中以原子百分比计，各成分占比为，Fe粉末：余量、Cr粉末：25～35％、Ni粉末：7-13％、Al粉末：3～8％、Ti粉末：3～8％、Nb粉末：0.5～10％。步骤2：将Fe基高熵合金粉末分开放置平铺，放在保温箱内进行烘干，保温温度为100～120℃，烘干时间为2～4小时；
步骤3：用丙酮或酒精将喷涂基材表面清洗干净，并放于保温箱内50～60℃烘干，除去其表面油渍污物；
步骤4：设置激光熔覆或热喷涂工艺，制备抗空蚀Fe基高熵合金涂层。
激光熔覆抗空蚀Fe基高熵合金涂层的厚度为0.5～3mm。
激光熔覆工艺参数：光斑直径为5mm，激光功率为2.5～4KW，搭接率：50％，熔覆头扫描速度：6～20mm/s，送粉率：15～100g/min。
本发明的有益效果是：
本发明制备了Fe基高熵合金抗空蚀涂层，尤其是通过激光熔覆方法制得的涂层的硬度相对水轮机、水泵常用抗空蚀不锈钢ZG05Cr13Ni5Mo硬度提高30％左右；抗空蚀性能达到了ZG05Cr13Ni5Mo的5～15倍，抗空蚀性能非常突出；抗磨损性能ZG05Cr13Ni5Mo相当；涂层与基体是冶金结合力，结合非常好。本发明解决了水轮机、泵等过流部件高速运转时产生空蚀现象，从而导致过流部件涂层性能下降等问题。本发明的生产成本低，制备方法工艺可靠，性能稳定，不仅适合在淡水环境下的水轮机和水泵等水利机械的过流部件，还适合汽轮机、洋流发电、船舶等海洋设施的过流部件上大规模应用。本发明的高熵合金粉末除了用激光熔覆方法制备涂层外，还可以用热喷涂方法制备，如超音速热喷涂方法制备。
附图说明
图1是本发明实施例1-3制得的-FeCrNiAlTiNb高熵合金涂层XRD图谱；
图2是1#高熵合金涂层与基体空蚀对比图；
图3是2#高熵合金涂层与基体空蚀对比图；
图4是3#高熵合金涂层与基体空蚀对比图。
具体实施方式
以下结合实例对本发明做进一步说明。
1、激光熔覆抗空蚀Fe基高熵合金涂层实施方式
本发明实施例中喷涂基体可采用45钢、Q345钢等碳钢；ZG06Cr13Ni5Mo钢、2205不锈钢、304、316L等不锈钢。
实施例1
(1)按原子比取各组份Fe粉末：余量、Cr粉末：25％粉末：Ni粉末：7％、Al粉末：3％，Ti粉末：3％，Nb粉末：1.3％，制备出Fe基高熵合金涂层粉末；
(2)将Fe基高熵合金粉末分开放置平铺，放在保温箱内进行烘干，保温温度为100～120℃，烘干时间为2～4小时；
(3)用丙酮或酒精将喷涂基材表面清洗干净，并放于保温箱内50～60℃烘干，除去其表面油渍污物；
(4)激光熔覆工艺参数：激光功率为2.5KW，搭接率：50％，熔覆头扫描速度：8mm/s，送粉率：20g/min。
(5)制备的FeCrNiAlTiNb高熵合金涂层的硬度402HV0.2。在相同的空蚀条件下，FeCrNiAlTiNb高熵合金涂层抗空蚀性能是基体ZG06Cr13Ni5Mo不锈钢的12.3倍(同等实验检测条件下，基体表面的失重是高熵合金涂层的12.3倍)。试样的物相结构以及基体与空蚀对比图见附件。
实施例2
(1)按原子比取各组份Fe粉末：余量、Cr粉末：30％粉末：Ni粉末：20％、Al粉末：5％，Ti粉末：5％，Nb粉末：2.6％，制备出Fe基高熵合金涂层粉末；
(2)将Fe基高熵合金粉末分开放置平铺，放在保温箱内进行烘干，保温温度为100～120℃，烘干时间为2～4小时；
(3)用丙酮或酒精将喷涂基材表面清洗干净，并放于保温箱内50～60℃烘干，除去其表面油渍污物；
(4)激光熔覆工艺参数：激光功率为3.2KW，搭接率：50％，熔覆头扫描速度：10mm/s，送粉率：40g/min。
(5)制备的FeCrNiAlTiNb高熵合金涂层的硬度521HV0.2。在相同的空蚀条件下，FeCrNiAlTiNb高熵合金涂层抗空蚀性能是基体ZG06Cr13Ni5Mo不锈钢的13.8倍(同等实验检测条件下，基体表面的失重是高熵合金涂层的13.8倍)。试样的物相结构以及基体与空蚀对比图见附件。
实施例3
(1)按原子比取各组份Fe粉末：余量、Cr粉末：30％粉末：Ni粉末：20％、Al粉末：6.5％，Ti粉末：9％，Nb粉末：3.9％，制备出Fe基高熵合金涂层粉末；
(2)将Fe基高熵合金粉末分开放置平铺，放在保温箱内进行烘干，保温温度为100～120℃，烘干时间为2～4小时；
(3)用丙酮或酒精将喷涂基材表面清洗干净，并放于保温箱内50～60℃烘干，除去其表面油渍污物；
(4)激光熔覆工艺参数：激光功率为3.8KW，搭接率：50％，熔覆头扫描速度：15mm/s，送粉率：65g/min。
(5)制备的FeCrNiAlTiNb高熵合金涂层的硬度435HV0.2。在相同的空蚀条件下，FeCrNiAlTiNb高熵合金涂层抗空蚀性能是基体ZG06Cr13Ni5Mo不锈钢的8.6倍(同等实验检测条件下，基体表面的失重是高熵合金涂层的8.6倍)。
实施例1、实施例2、实施例3中制备的FeCrNiAlTiNb高熵合金涂层分别记为1#、2#、3#，对应的XRD图如图1：
实施例1、实施例2、实施例3中制备的FeCrNiAlTiNb高熵合金涂层与基体(ZG06Cr13Ni5Mo)空蚀对比图，分别如图2、图3、图4。在图2、图3、图4中，左边的试样是基体，右边的试样是本发明制得的高熵合金涂层，同样实验条件下，基体被空蚀剥落的面积均明显大于高熵合金涂层表面。基体表面和高熵合金涂层表面失重量的倍数关系如实施案例1、2、3所述。
Claims (2)
1.一种抗空蚀Fe基高熵合金涂层，其特征在于，该涂层是以粉末为原料，由激光熔覆制备而成；制备方法包括如下步骤：
步骤1：将Fe粉末、Cr粉末、Ni粉末、Al粉末、Ti粉末、Nb粉末按原子百分比进行配制，制备的高熵合金粉末颗粒尺度为10~105μm；高熵合金粉末中以原子百分比计，各成分占比为，Fe粉末：余量、Cr粉末：25~35%、Ni粉末：7-13%、Al粉末：3~8%，Ti粉末：3~8%，Nb粉末：0.5~10%；
步骤2：将Fe基高熵合金粉末分开放置平铺，放在保温箱内进行烘干，保温温度为100~120℃，烘干时间为2~4小时；
步骤3：用丙酮或酒精将喷涂基材表面清洗干净，并放于保温箱内50~60℃烘干，除去其表面油渍污物；
步骤4：设置激光熔覆工艺，制备抗空蚀Fe基高熵合金涂层；激光熔覆工艺参数为：光斑直径为5mm，激光功率为2.5~4KW，搭接率：50%，熔覆头扫描速度：6~20mm/s，送粉率：15~100g/min；制得抗空蚀Fe基高熵合金涂层的厚度为0.5~3mm。
2.制备如权利要求1所述的一种抗空蚀Fe基高熵合金涂层的方法，其特征在于，包括如下步骤：
步骤1：将Fe粉末、Cr粉末、Ni粉末、Al粉末、Ti粉末、Nb粉末按原子百分比进行配制，制备的高熵合金粉末颗粒尺度为10~105μm；高熵合金粉末中以原子百分比计，各成分占比为，Fe粉末：余量、Cr粉末：25~35%、Ni粉末：7-13%、Al粉末：3~8%，Ti粉末：3~8%，Nb粉末：0.5~10%；
步骤2：将Fe基高熵合金粉末分开放置平铺，放在保温箱内进行烘干，保温温度为100~120℃，烘干时间为2~4小时；
步骤3：用丙酮或酒精将喷涂基材表面清洗干净，并放于保温箱内50~60℃烘干，除去其表面油渍污物；
步骤4：设置激光熔覆工艺，制备抗空蚀Fe基高熵合金涂层，激光熔覆工艺参数为：光斑直径为5mm，激光功率为2.5~4KW，搭接率：50%，熔覆头扫描速度：6~20mm/s，送粉率：15~100g/min，制得抗空蚀Fe基高熵合金涂层的厚度为0.5~3mm。
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