| 引用本文: | 郭鹏,陈仁德,李昊,杨葳,西村一仁,柯培玲,汪爱英.海洋环境PVD抗磨蚀防护涂层的研究进展[J].中国表面工程,2024,37(6):1~20 |
| GUO Peng,CHEN Rende,LI Hao,YANG Wei,NISHIMURA Kazuhito,KE Peiling,WANG Aiying.Research Progress of PVD Anti-tribocorrosion Coatings UnderMarine Environment[J].China Surface Engineering,2024,37(6):1~20 |
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| 海洋环境PVD抗磨蚀防护涂层的研究进展 |
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郭鹏，陈仁德，李昊，杨葳，西村一仁，柯培玲，汪爱英
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中国科学院宁波材料技术与工程研究所海洋关键材料重点实验室 宁波 315201
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| 摘要: |
| 先进表面涂层防护技术是海工装备关键金属运动系统磨损与腐蚀防护、保障海工装备高性能长寿命可靠服役的关键途径。其中，物理气相沉积（PVD）抗磨蚀防护涂层材料兼具耐老化、耐磨性、耐腐蚀等优势，特别是可满足深海或远海机械系统相关精密运动部件的高可靠性与稳定性要求，是抗磨蚀防护的有效技术手段之一。围绕海洋环境PVD 抗磨蚀防护涂层材料及应用技术发展现状，重点介绍现有防护涂层材料体系，碳基、氮基涂层因优异耐磨及耐腐蚀性能而获得较多关注，改善膜基界面结合强度及涂层致密性等是提升其抗磨蚀性能的关键因素，而高熵涂层及过渡金属二硫属化物（TMD）涂层磨蚀防护性能也成为基础及应用研究的热点。总结主要的涂层磨蚀评价方法，目前在外加电位下开展涂层磨蚀测试性能评价的应用较多，引入理论计算研究涂层磨蚀性能及相关失效机理已逐渐开展。围绕疲劳 / 重载下磨蚀防护需求，介绍PVD 复合喷涂、微弧氧化、热处理等兼具高承载、长寿命的复合强化抗磨蚀防护涂层材料技术的新进展。列举PVD 抗磨蚀涂层在海水传动液压马达和液压泵、船舶低速柴油机柱塞、水下安全阀、钻井泵阀体阀座以及涉海直升机操纵杆等核心涉海装备部件上的典型应用，并对海洋环境PVD 抗磨蚀防护涂层的未来发展方向进行思考与展望，为进一步发展高性能海洋抗磨蚀涂层材料技术提供参考。 |
| 关键词: 海洋环境 物理气相沉积(PVD)涂层 磨蚀性能 评价方法 典型应用中 |
| DOI：10.11933/j.issn.1007-9289.20231228003 |
| 分类号:TG156；TB114 |
| 基金项目:国家重点研发计划（2022YFB3706205）；国家自然科学基金杰出青年基金（52025014）；宁波市重点研发计划（2023Z009，2023Z021） |
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| Research Progress of PVD Anti-tribocorrosion Coatings UnderMarine Environment |
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GUO Peng，CHEN Rende，LI Hao，YANG Wei，NISHIMURA Kazuhito，KE Peiling，WANG Aiying
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Key Laboratory of Advanced Marine Materials, Ningbo Institute of Materials Technology and Engineering,Chinese Academy of Sciences, Ningbo 315201 , China
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| Abstract: |
| Tribocorrosion is a material-degradation phenomenon resulting from interactive effects between wear and corrosion. Forvarious marine equipment, their key metal motion systems are typically affected by the combined effect of mechanical wear andchemical corrosion under the harsh marine environment, which can directly limit their stability and safety. Thus, comprehensiveinvestigations into tribocorrosion behavior is critical for the design of appropriate engineering materials under the marine environment.Advancing marine exploration and deep-sea development necessitates surface and coating techniques to ensure favorableanti-corrosion and anti-wear performances for moving mechanical components. Many conventional techniques have been used to prepare protective coatings, such as spraying, high-energy beam surface modification, and physical vapor deposition (PVD). Amongthe diverse developed protective coatings, those realized via PVD exhibit favorable properties, including high corrosion resistance andexcellent mechanical performance, which can effectively protect precision moving components used in deep-sea or offshoremechanical systems; thus, they are one of the most effective strategies in this field. This article focuses primarily on the developmentof anti-tribocorrosion coatings achieved via PVD and technologies used in the marine environment, in addition to the main scientificand technical issues encountered in the field. First, the tribocorrosion performance of carbon-based, nitride-based, high-entropy alloy,and transition metal dichalcogenide coatings are introduced, and the role of components and multilayer / nano-multilayer /nanocomposite / gradient structures on their tribocorrosion performance and related failure mechanism are summarized. Themultilayer interface in coatings achieved via PVD not only significantly improves their hardness by hindering dislocation movementbut also improves their corrosion resistance by hindering the diffusion of H2O, O2, Cl?, and Na+ corrosives. To evaluate thetribocorrosion performance of coatings, electrochemical and tribological tests are primarily conducted in early research; currently,tribocorrosion tests are performed using a tribometer equipped with a three-electrode electrochemical system. By adopting in-situatomic force microscopy (AFM) and an AFM-based “image-wear-image” tribology method, researchers are currently investigatingsubnanoscale and nanoscale wear, the tribocorrosion phenomenon, as well as the oxide growth mechanism of metallic materials. Foradvanced synergistic wear-corrosion models, a novel two-dimensional predictive model has been developed for predicting thesynergetic wear-corrosion reliability of Ni / GPL and steel. Additionally, a combined experimental and computational investigationhas been performed using Al single crystals to develop a crystal-based tribocorrosion modeling framework that considers the effects oflattice reorientation and dislocations on surface corrosion. Additionally, new strategies that combine PVD with othersurface-protection technologies have been developed, for example, duplex coating systems formed via the PVD of CrN orcarbon-based coatings and thermal layer spraying using a high-velocity oxyfuel. Using these methods, material losses due to thesynergistic effects of wear and corrosion can be reduced. In particular, hydrogenated carbon-based coatings present hightribocorrosion resistances under low loads due to their high hardness and excellent corrosion resistance; however, they exhibitcatastrophic delamination under heavy loads, whereas hydrogen-free carbon-based coatings exhibit better tribocorrosion performanceowing to their gradual shearing characteristic. Additionally, carbon-based coatings can enhance the anti-corrosion properties ofmicroarc oxidation (MAO) coatings on magnesium alloys. The superior low-friction and anti-corrosion properties of carbon-basedcoatings / MAO render them preferable as protective coatings on magnesium alloys. Cr layers achieved via thermal diffusionmetallization and CrN coatings deposited via PVD are used to strengthen the surface of 45 steel, thus improving its surface hardnessand abrasion resistance. By implementing ion implantation and Al / AlN / CrAlN / CrN / MoS2 gradient duplex coatings, both theanti-wear and anti-corrosion properties of AM60 magnesium alloy are improved. For AISI 4140 steel, plasma nitriding applied beforethe coating significantly improves the corrosion and tribocorrosion resistances of PVD CrN, TiN, and AlTiN coatings. Typicalapplications of anti-tribocorrosion coatings achieved via PVD include seawater-pump plungers, hydrostatic slipper bearings, ball valves, and components of a helicopter-cockpit instrument panel. Hydrogenated diamonds coated with Cr and WC as transition layersare prepared on the plunger of marine diesel engines. These coatings can significantly improve the hardness and elastic modulus whiledecreasing the friction factor under heavy-diesel-oil environments. After a bench test is performed, the wear marks on the surface ofthe plunger with coating are extremely narrow and shallow. For drill pump valves, implementing TiN coatings can increase theirservice life by three times. In the cockpit of a helicopter, multigradient nano-black coatings achieved via PVD are thin and thethickness tolerance is low; additionally, these coatings satisfy the requirements of the salt spray test. Finally, the development andapplication of anti-tribocorrosion coatings achieved via PVD under the marine environment are proposed. Machine-learning andbig-data sharing services should be used to comprehensively understand the damage mechanism; the optimization and design of thesuitable coating should account for the actual operating conditions, such as deep sea, nearshore, and shallow sea; advanced coatingequipment should be developed for the inner wall of certain pipelines; and in-situ evaluations and bench experiments should beperformed to evaluate the service life of metal mechanical components and coating materials. This review presents a comprehensiveand systematic report pertaining to anti-tribocorrosion coatings achieved via PVD for marine applications. |
| Key words: marine environment physical vapor deposition (PVD) coating tribocorrosion properties evaluation method typicalapplications |
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