Diffusion and Friction Dissipation Mechanisms in Wide-temperaturerange of Cu in NiCrAlY-Cu Coating by Plasma Sprayed

FANG Ziwen, HE Nairu, JIA Junhong, YANG Jie, LIU Ning

China Surface Engineering ›› 2023, Vol. 36 ›› Issue (2) : 65-78.

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China Surface Engineering ›› 2023, Vol. 36 ›› Issue (2) : 65-78. DOI: 10.11933/j.issn.1007-9289.20220512002

Diffusion and Friction Dissipation Mechanisms in Wide-temperaturerange of Cu in NiCrAlY-Cu Coating by Plasma Sprayed

  • FANG Ziwen, HE Nairu, JIA Junhong, YANG Jie, LIU Ning
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Abstract

Soft metal-containing composite coatings exhibit favorable tribological properties owing to extremely low shear strength. However, the soft metal dissipates during the friction process at elevated temperatures, resulting in the failure of such coatings. Recent studies have identified dissipation mechanisms of soft metals based on the effect of temperature. However, research on the dissipation mechanisms of soft metals by the synergetic effect of the load and temperature during the friction process at elevated temperatures has not yet been explored. NiCrAlY-Cu coatings were prepared using air plasma spraying technology to study the diffusion and dissipation mechanisms of soft metal lubrication in the composite coating by the synergetic effect of load and temperature. Heat treatment and tribological tests of the NiCrAlY-Cu coatings were carried out over a wide temperature range. The wear mechanisms of the NiCrAlY-Cu coatings are also discussed. The compositions and morphologies of the NiCrAlY-Cu coatings and worn tracks were determined using X-ray diffraction (XRD), scanning electron microscopy (SEM), and energy-dispersive X-ray spectroscopy (EDS).The Cu content of the NiCrAlY-Cu coating was calculated and compared after heat treatment and tribological tests over a wide temperature range. The diffusion mechanisms of Cu at elevated temperatures and the dissipation mechanisms of Cu during the friction process were studied using compositional and morphological analyses. The results showed that Cu was uniformly distributed with a lamellar structure in the NiCrAlY-Cu coatings. According to the Gibbs-Thomson effect and Ostwald ripening theory, soft metal would diffuse vertically under the influence of temperature, which is consistent with Cu vertical diffusion to the coating surface. Meanwhile, the diffusion intensified as the temperature increased. Furthermore, Cu diffused in parallel and was dispersedly distributed in the NiCrAlY-Cu coating at 1 000 ℃. At low and moderate temperatures, the shear strength of Cu decreased with increasing temperature, resulting in a gradual decrease in the friction coefficients of the NiCrAlY-Cu coatings. However, fatigue spalling on the worn surface of the NiCrAlY-Cu coating caused by the lamellar distribution of Cu led to an obvious increase in the wear rate. The friction coefficient and wear rate of the NiCrAlY-Cu coatings were 0.401 and 2.49×10?3 mm3 / (N·m) at 400 °C, respectively. The wear mechanism at 400 °C is mainly severe fatigue wear. With a further increase in temperature, the intensification of Cu diffusion and oxidation in the NiCrAlY-Cu coating resulted in an increase in the friction coefficients and decrease in the wear rates. During the friction process from 25 to 1 000 °C, owing to the synergetic effect of the temperature and load, Cu diffused vertically to the coating surface according to the analysis of the Gibbs-Thomson effect, Ostwald ripening theory, and Fick’ s first law. This was further confirmed by the EDS mapping results. Moreover, Cu diffused in parallel from the inside to the outside of the worn track owing to the effect of the load. At low and moderate temperatures, the main driving force for Cu diffusion was the load effect. With a further increase in temperature, the main driving force of Cu diffusion was the temperature effect. Simultaneously, the enrichment of Cu on the worn surface gradually dissipated in the form of wear debris during the friction process. In this paper, the diffusion and dissipation mechanisms of soft metal in a soft metal-containing adaptive coating under the synergetic effect of load and temperature during the friction process over a wide temperature range are proposed, which provide a theoretical basis for solving the problem of lubrication failure of the soft metal-containing adaptive coating.

Key words

plasma spraying； NiCrAlY-Cu coating； tribological properties in wide-temperature-range； diffusion mechanism； friction dissipation mechanism

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FANG Ziwen, HE Nairu, JIA Junhong, YANG Jie, LIU Ning. Diffusion and Friction Dissipation Mechanisms in Wide-temperaturerange of Cu in NiCrAlY-Cu Coating by Plasma Sprayed[J]. China Surface Engineering, 2023, 36(2): 65-78 https://doi.org/10.11933/j.issn.1007-9289.20220512002

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Supported by National Natural Science Foundation of China (51905325).
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