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Extreme high-speed laser cladding (EHLA) technology was used to prepare Al2O3-316L coatings on Ti6Al4V rods. The effects of scanning speed, powder feeding rate on single-track coating quality, and 316L powder content on multi-track coating quality and corrosion resistance were explored. Results show that with the following optimum process parameters, including scanning speed of 250 mm/s and powder feeding rate of 8 g/min, the coating can present superior quality with the 316L powder in a mass fraction of 20%. It is shown that all Al2O3-316L coatings exhibit superior corrosion resistance compared to the substrate. As 316L content increases, the corrosion resistance of coatings increases followed by decline. With 316L powder in a mass faction of 20%, the electrochemical impedance of the coating is 2.27 times that of the substrate.

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使用超高速激光熔覆技术在Ti6Al4V棒材表面制备Al2O3-316L涂层。研究了扫描速度和送粉速度对单道熔覆涂层质量的影响,以及316粉末含量对多道熔覆涂层质量和耐腐蚀性能的影响。结果表明,制备涂层的适宜工艺参数为:扫描速度250 mm/s、送粉速度8 g/min。当316L粉末含量(质量分数)为20%时,涂层质量最佳。所有Al2O3-316L涂层的耐腐蚀性能都优于基体,且随着316L粉末含量增加,其耐腐蚀性能先上升后下降,当316L粉末含量为20%时,涂层的电化学阻抗为基体的2.27倍。

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魏祥(1988—),男,湖南安化人,副教授,主要研究方向为高性能耐磨材料。E-mail:
陈志国(1969—),男,湖南临澧人,教授,主要研究方向为新材料的微观组织设计与制备。E-mail:
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石锋(1998—),男,浙江宁波人,硕士研究生,主要研究方向为超高速激光熔覆涂层。E-mail:

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石锋(1998—),男,浙江宁波人,硕士研究生,主要研究方向为超高速激光熔覆涂层。E-mail:

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(a)350 mm/s;(b)300 mm/s;(c)250 mm/s;(d)200 mm/s

, figureFileSmall=fhwlIfFOEopcX3E8KlVc5g==, figureFileBig=95/FE3yrMhvgdkRregdWuA==, tableContent=null), ArticleFig(id=1241327778415571363, tenantId=1146029695717560320, journalId=1235980550691926019, articleId=1241321696616051208, language=EN, label=Fig.2, caption=Cross-sectional morphology of single-track cladded coatings at different powder feeding speeds, figureFileSmall=gcxGCRRxqLbUat0iAThG5w==, figureFileBig=3wuuQvsYRwSa5lFThVJtFA==, tableContent=null), ArticleFig(id=1241327778524623268, tenantId=1146029695717560320, journalId=1235980550691926019, articleId=1241321696616051208, language=CN, label=图2, caption=不同送粉速度下的单道熔覆涂层横截面形貌

(a)12 g/min;(b)10 g/min;(c)8 g/min;(d)6 g/min

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(a)A1涂层;(b)A2涂层;(c)A3涂层;(d)A4涂层

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(a)A1涂层;(b)A2涂层;(c)A3涂层;(d)A4涂层

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316L powder content in cladding powder for each coating

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涂层编号316L粉末含量(质量分数)/%
A110
A220
A330
A440
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各涂层熔覆粉末中316L粉末含量

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涂层编号316L粉末含量(质量分数)/%
A110
A220
A330
A440
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Chemical composition of cladding powder for each coating

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名称SiOCrMoNiFeAl
A10.0342.301.600.151.307.01余量
A20.0837.603.310.332.2514.11余量
A30.1032.944.930.493.4021.05余量
A40.2128.236.630.654.5428.04余量
), ArticleFig(id=1241327780886016434, tenantId=1146029695717560320, journalId=1235980550691926019, articleId=1241321696616051208, language=CN, label=表2, caption=

各涂层熔覆粉末化学成分(质量分数)

, figureFileSmall=null, figureFileBig=null, tableContent=
名称SiOCrMoNiFeAl
A10.0342.301.600.151.307.01余量
A20.0837.603.310.332.2514.11余量
A30.1032.944.930.493.4021.05余量
A40.2128.236.630.654.5428.04余量
), ArticleFig(id=1241327780948930995, tenantId=1146029695717560320, journalId=1235980550691926019, articleId=1241321696616051208, language=EN, label=Table 3, caption=

Process parameters in tests

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序号扫描速度/(mm·s-1送粉速度/(g·min-1
135010
230010
325010
420010
525012
625010
72508
82506
), ArticleFig(id=1241327781003456948, tenantId=1146029695717560320, journalId=1235980550691926019, articleId=1241321696616051208, language=CN, label=表3, caption=

实验工艺参数

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序号扫描速度/(mm·s-1送粉速度/(g·min-1
135010
230010
325010
420010
525012
625010
72508
82506
), ArticleFig(id=1241327781070565813, tenantId=1146029695717560320, journalId=1235980550691926019, articleId=1241321696616051208, language=EN, label=Table 4, caption=

Fitting values of polarization curves for coatings with different 316L contents and Ti6Al4V substrate

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样品名称自腐蚀电位Eccor(VSCE自腐蚀电流Icoor/(A·cm-2
A1涂层-0.2271.106×10-6
A2涂层-0.1941.211×10-6
A3涂层-0.2337.269×10-7
A4涂层-0.2142.146×10-6
Ti6Al4V基体-0.5956.651×10-6
), ArticleFig(id=1241327781150257590, tenantId=1146029695717560320, journalId=1235980550691926019, articleId=1241321696616051208, language=CN, label=表4, caption=

不同316L粉末含量涂层和基体的极化曲线拟合值

, figureFileSmall=null, figureFileBig=null, tableContent=
样品名称自腐蚀电位Eccor(VSCE自腐蚀电流Icoor/(A·cm-2
A1涂层-0.2271.106×10-6
A2涂层-0.1941.211×10-6
A3涂层-0.2337.269×10-7
A4涂层-0.2142.146×10-6
Ti6Al4V基体-0.5956.651×10-6
), ArticleFig(id=1241327781225755063, tenantId=1146029695717560320, journalId=1235980550691926019, articleId=1241321696616051208, language=EN, label=Table 5, caption=

Fitting values of electrochemical impedance spectroscopy data in equivalent circuit

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样品名称Rs/(Ω·cm2CPE1/(Ssn·cm-2npRt/(Ω·cm2
Ti6Al4V基体4.1978.02×10-50.75010 232
A1涂层9.6175.92×10-50.6537 081
A2涂层9.0869.38×10-50.62723 228
A3涂层11.912.85×10-40.66412 242
A4涂层14.824.14×10-40.6146 179
), ArticleFig(id=1241327781297058232, tenantId=1146029695717560320, journalId=1235980550691926019, articleId=1241321696616051208, language=CN, label=表5, caption=

电化学阻抗谱数据在等效电路中的拟合值

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样品名称Rs/(Ω·cm2CPE1/(Ssn·cm-2npRt/(Ω·cm2
Ti6Al4V基体4.1978.02×10-50.75010 232
A1涂层9.6175.92×10-50.6537 081
A2涂层9.0869.38×10-50.62723 228
A3涂层11.912.85×10-40.66412 242
A4涂层14.824.14×10-40.6146 179
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超高速激光熔覆Al2O3-316L涂层工艺优化及耐腐蚀性能研究
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石锋 1 , 魏祥 2 , 陈志国 3 , 李沛扬 1 , 谢宝军 1 , 夏敬尧 2
矿冶工程杂志 | 材料 2025,45(2): 178-182
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矿冶工程杂志 | 材料 2025, 45(2): 178-182
超高速激光熔覆Al2O3-316L涂层工艺优化及耐腐蚀性能研究
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石锋1 , 魏祥2 , 陈志国3 , 李沛扬1, 谢宝军1, 夏敬尧2
作者信息
  • 1.中南大学 材料科学与工程学院,湖南 长沙 410083
  • 2.湖南人文科技学院 能源与机电工程学院,湖南 娄底 417000
  • 3.湖南开放大学 智能制造学院,湖南 长沙 410004
  • 石锋(1998—),男,浙江宁波人,硕士研究生,主要研究方向为超高速激光熔覆涂层。E-mail:

通讯作者:

魏祥(1988—),男,湖南安化人,副教授,主要研究方向为高性能耐磨材料。E-mail:
陈志国(1969—),男,湖南临澧人,教授,主要研究方向为新材料的微观组织设计与制备。E-mail:
Corrosion Resistance of Al2O3-316L Coatings Based on Optimized Extreme High-Speed Laser Cladding Technology
Feng SHI1 , Xiang WEI2 , Zhiguo CHEN3 , Peiyang LI1, Baojun XIE1, Jingyao XIA2
Affiliations
  • 1.School of Materials Science and Engineering, Central South University, Changsha 410083, Hunan, China
  • 2.School of Energy and Electromechanical Engineering, Hunan University of Humanities, Science and Technology, Loudi 417000, Hunan, China
  • 3.School of Intelligent Manufacturing, Hunan Open University, Changsha 410004, Hunan, China
出版时间: 2025-04-01 doi: 10.3969/j.issn.0253-6099.2025.02.032
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使用超高速激光熔覆技术在Ti6Al4V棒材表面制备Al2O3-316L涂层。研究了扫描速度和送粉速度对单道熔覆涂层质量的影响,以及316粉末含量对多道熔覆涂层质量和耐腐蚀性能的影响。结果表明,制备涂层的适宜工艺参数为:扫描速度250 mm/s、送粉速度8 g/min。当316L粉末含量(质量分数)为20%时,涂层质量最佳。所有Al2O3-316L涂层的耐腐蚀性能都优于基体,且随着316L粉末含量增加,其耐腐蚀性能先上升后下降,当316L粉末含量为20%时,涂层的电化学阻抗为基体的2.27倍。

表面处理  /  氧化铝涂层  /  316L  /  激光熔覆  /  熔覆涂层  /  工艺参数  /  耐腐蚀性能

Extreme high-speed laser cladding (EHLA) technology was used to prepare Al2O3-316L coatings on Ti6Al4V rods. The effects of scanning speed, powder feeding rate on single-track coating quality, and 316L powder content on multi-track coating quality and corrosion resistance were explored. Results show that with the following optimum process parameters, including scanning speed of 250 mm/s and powder feeding rate of 8 g/min, the coating can present superior quality with the 316L powder in a mass fraction of 20%. It is shown that all Al2O3-316L coatings exhibit superior corrosion resistance compared to the substrate. As 316L content increases, the corrosion resistance of coatings increases followed by decline. With 316L powder in a mass faction of 20%, the electrochemical impedance of the coating is 2.27 times that of the substrate.

surface treatment  /  alumina coating  /  316L  /  laser cladding  /  cladding coating  /  process parameter  /  corrosion resistance
石锋, 魏祥, 陈志国, 李沛扬, 谢宝军, 夏敬尧. 超高速激光熔覆Al2O3-316L涂层工艺优化及耐腐蚀性能研究. 矿冶工程杂志, 2025 , 45 (2) : 178 -182 . DOI: 10.3969/j.issn.0253-6099.2025.02.032
Feng SHI, Xiang WEI, Zhiguo CHEN, Peiyang LI, Baojun XIE, Jingyao XIA. Corrosion Resistance of Al2O3-316L Coatings Based on Optimized Extreme High-Speed Laser Cladding Technology[J]. Mining and Metallurgical Engineering, 2025 , 45 (2) : 178 -182 . DOI: 10.3969/j.issn.0253-6099.2025.02.032
在高盐雾、强腐蚀介质及动态载荷耦合作用下,Ti6Al4V合金的抗腐蚀性能与长期服役稳定性面临劣化风险,严重制约其在工程中的实际应用[1]。在Ti6Al4V合金表面制备涂层已成为增强其耐腐蚀性的主要方法[2-3]。激光熔覆技术可以实现涂层与基体之间的冶金结合[4],在生产耐腐蚀和耐磨涂层方面具有巨大的潜力[5]。超高速激光熔覆技术通过重新设计同轴送粉喷嘴,使得大部分能量作用于粉末颗粒上[6]。相较于传统的激光熔覆技术,超高速激光熔覆技术制备的涂层表面粗糙度更低、加工效率更高、涂层晶粒更加细小,在一定程度上提高了涂层性能[7]。然而,由于冷却速度过快,涂层中可能出现裂纹和孔隙等缺陷[8]。腐蚀介质可通过这些裂纹和孔隙渗入涂层,导致涂层合金耐腐蚀性能显著下降[9]。减少涂层中裂纹和孔隙数目是增强其耐腐蚀性能的有效方法。研究表明,合适的扫描速度和送粉速度可以降低涂层中的残余应力[10-11],从而降低裂纹产生的概率,制备出低缺陷、高密度的熔覆涂层。Al2O3涂层具有优异的耐腐蚀性能,但容易出现开裂和剥落等问题,316L粉末具有良好的熔焊性和成型性,有望改善Al2O3涂层开裂的问题。因此,本文采用超高速激光熔覆技术在Ti6Al4V棒材上制备Al2O3-316L涂层,研究送粉速度和扫描速度对涂层质量的影响,并研究316L粉末含量对涂层耐腐蚀性能的影响。
实验选用Ti6Al4V棒材作为基体,其尺寸为Φ50 mm(外径)×220 mm(长度),实验前先对基体材料进行精车,然后用无水乙醇清洗其表面。熔覆粉末为Al2O3-316L混合粉末,各涂层熔覆粉末中316L粉末质量分数见表1,各涂层熔覆粉末化学成分如表2所示,Al2O3粉末粒径75~100 μm,316L粉末粒径35~45 μm。实验前,将Al2O3粉末和316L粉末用球磨机均匀混合,球料比为1∶1(其中Φ9 mm球、Φ5 mm球、Φ3 mm球质量比为2∶5∶3)。然后将熔覆粉末置于100 ℃干燥箱中干燥1 h。
采用移动式激光熔覆设备,以A2涂层材料制备不同送粉速度和扫描速度的单道熔覆涂层,工艺参数如表3所示。筛选出合适的送粉速度和扫描速度后,使用该参数制备不同316L粉末含量(质量分数,下同)的多道熔覆涂层。
采用电火花切割技术从棒材表面切割出尺寸为10 mm×10 mm×10 mm的Al2O3-316L涂层样品,使用Leica DM4M金相显微镜观察单道涂层和多道涂层截面显微组织;采用D/Max2550 X射线衍射仪表征涂层物相;采用Multi Autolab/M204电化学工作站测定室温下涂层的耐腐蚀性能,并使用其自带的软件进行数据分析,工作站由标准三电极体系组成,以铂电极为辅助电极,以饱和甘汞电极(SCE)为参比电极,待测试样为工作电极。腐蚀液为质量分数3.5%的NaCl溶液。开路电位测试时间为15 min,极化曲线测试范围为开路电位(OCP)处±0.5 V,扫描速度为0.5 mV/s。电化学阻抗谱测试在OCP附近进行,频率范围为10-2~105Hz,电压振幅为±5 mV。
送粉速度10 g/min,以A2为涂层材料,不同扫描速度下的单道熔覆涂层横截面形貌如图1所示。扫描速度350 mm/s时,部分熔融粉末包裹着未熔化的Al2O3粉末沉积在基体表面,被包裹的粉末颗粒无法继续受到激光能量作用以颗粒的形式存在于涂层内部,导致涂层结合力变差,涂层出现了大量剥落。扫描速度300 mm/s时,粉末与激光有更多时间接触,从而均匀地受热熔化沉积在基体表面,但在涂层中还是出现了较多的剥落,其原因是涂层凝固速度较快,基体和涂层内部产生较大的热应力,导致裂纹产生。扫描速度250 mm/s时,粉末熔融充分,熔池稳定形成,涂层中热应力释放充分,未产生较大的宏观剥落。扫描速度200 mm/s时,熔融粉末沉积较慢,基体可以接受更多激光能量,从而引起熔池扩大,降低涂层质量。适宜的扫描速度为250 mm/s。
扫描速度250 mm/s,以A2为涂层材料,不同送粉速度下的单道熔覆涂层横截面形貌如图2所示。送粉速度12 g/min时,涂层中出现了较大剥落,这是由于送粉速度较高,粉末数量过多而激光能量不足,未能完全将粉末熔化,粉末与基体之间的结合力较差,从而出现了较大剥落。送粉速度10 g/min时,涂层剥落现象明显减少,仅在涂层中出现少量的剥落和气孔。送粉速度为8 g/min时,可以观察到涂层中仅存在一条垂直裂纹,没有明显的气孔和剥落现象,说明工艺参数适配,制备的涂层质量好。送粉速度6 g/min时,涂层表面出现了不完整剥落以及少量裂纹和孔洞,涂层表面的剥落是送粉量不够导致此处粉末分布不均匀产生的。适宜的送粉速度为8 g/min。
图3为不同316L粉末含量多道熔覆涂层的表面形貌。A1涂层表面出现了宏观裂纹,A2、A3涂层表面宏观质量较好,没有观察到裂纹和宏观剥落的现象,A4涂层表面未出现宏观剥落和裂纹,但表面出现了黑色块状物质,用毛刷刷掉后,内部涂层形貌较差,高低不平。
图4为不同316L粉末含量多道熔覆涂层的截面形貌。宏观剥落与截面形貌相对应,A1涂层截面形貌呈现出一片空洞,A2涂层厚500.3 μm,A3涂层厚424.2 μm。相较于A3涂层,A2涂层裂纹和孔洞较少。A4涂层存在剥落现象,但相较于A1涂层,其剥落情况较轻,仅有少量区域发生了剥落。综合涂层剥落情况以及裂纹和孔洞可以看出,316L粉末含量为20%时,涂层质量很好。
图5为不同316L粉末含量涂层的XRD图谱。由图5可知,涂层主要由Al1.98Cr0.02O3以及TiO2、V2O5组成。在熔覆过程中,当温度升高到1 050 ℃时,Al2O3与316L粉末中的Cr元素发生反应生成Al1.98Cr0.02O3相,Al1.98Cr0.02O3相能提高陶瓷涂层的结合强度[12],并且在激光熔覆过程中,Al2O3会完全转变为稳定的α-Al2O3相。部分基体上的Ti元素和V元素与粉末中的O元素发生反应,生成TiO2、V2O5等氧化物,这些氧化物分布在涂层中,可提升涂层硬度。其中A4涂层的衍射峰强最低,这是因为当316L粉末含量增大到40%时,Fe元素含量增大,涂层中Fe与Al2O3发生反应,在涂层表面形成了氧化膜,该氧化膜与涂层结合不紧密,会完全脱落,其衍射峰强度最低,且由于大部分O元素会与Fe发生反应,TiO2和V2O5衍射峰强度也有所下降。
图6为不同316L粉末含量涂层和Ti6Al4V基体的极化曲线。从图6可以看出,添加了316L粉末的涂层自腐蚀电位都大于基体,这说明涂层相较于基体更不容易被腐蚀。这主要是因为316L粉末受热熔化后均匀地分散在整个液相中,可以作为缓冲区降低Al2O3粉末和Ti6Al4V基体之间的热物理性质差异,减少裂纹和孔洞的产生,使得涂层具有更好的质量。但是在A1、A2、A3、A4涂层极化曲线中仍能观察到点蚀现象的发生,其原因可能是涂层中存在微裂纹,裂纹处发生了点蚀。本文选用Tafel外推法[13]来计算涂层的自腐蚀电位和自腐蚀电流,计算结果如表4所示。A1、A2、A3、A4涂层的自腐蚀电位均高于Ti6Al4V基体,而自腐蚀电流均低于Ti6Al4V基体。自腐蚀电位越高,自腐蚀电流越低,说明涂层的耐腐蚀性能越好。
图7为不同316L粉末含量涂层和基体的电化学阻抗谱及其等效电路图。Rs为电解液电阻,Rt为恒相位元件CPE1的电荷转移电阻,反映涂层中电子转移的难易程度。涂层表面具有一定粗糙度,且涂层表面不均匀,容易出现多种电化学过程并存的情况(如电荷传递、扩散等),因此引入恒相位元素CPE1可以更准确模拟实际电化学的阻抗行为,使得ECM模型与实验数据更贴切。表5为对应等效电路中元器件的拟合数据,高阻抗代表涂层耐腐蚀性能好。结果表明,掺杂316L粉末后,部分涂层阻抗低于Ti6Al4V基体,这与自腐蚀电位和自腐蚀电流观察到的结果不一致。阻抗表示电荷在涂层中转移的难度,A1、A4涂层表面分布有裂纹,在这些裂纹处电荷转移难度小,因此A1、A4涂层的电化学阻抗小于基体;而A2、A3涂层致密,缺陷少,当涂层表面发生腐蚀时,316L粉末中Cr、Mo、Ni等元素会在涂层表面形成氧化膜,阻止电荷转移,电荷转移难度大,因此,A2、A3涂层的电化学阻抗大于基体。其中A2涂层的电化学阻抗最高,是基体的2.27倍。
1)扫描速度250 mm/s、送粉速度8 g/min时,熔池稳定性显著改善,涂层内部热应力有效释放,缺陷(裂纹、孔洞)数量较少,表明该参数组合为制备涂层适宜的工艺参数。
2)316L粉末含量为20%时,涂层中Al1.98Cr0.02O3相的生成有效缓解了Al2O3基体的脆性开裂倾向,同时TiO2、V2O5等氧化物均匀分布,显著提升涂层致密性,此时涂层厚度达500.3 μm,裂纹与剥落现象少,涂层质量优。
3)Al2O3-316L涂层的腐蚀倾向低于基体Ti6Al4V棒材,涂层的自腐蚀电位均高于Ti6Al4V基体,电化学阻抗在6 179~23 228 Ω·cm2之间。A2涂层的电化学阻抗最高,是基体的2.27倍。
  • 湖南省自然科学基金(2025JJ80339)
  • 湖南省“双一流”学科建设项目(湘教通2018-469号)
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2025年第45卷第2期
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doi: 10.3969/j.issn.0253-6099.2025.02.032
  • 接收时间:2024-09-27
  • 首发时间:2026-03-19
  • 出版时间:2025-04-01
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  • 收稿日期:2024-09-27
基金
湖南省自然科学基金(2025JJ80339)
湖南省“双一流”学科建设项目(湘教通2018-469号)
作者信息
    1.中南大学 材料科学与工程学院,湖南 长沙 410083
    2.湖南人文科技学院 能源与机电工程学院,湖南 娄底 417000
    3.湖南开放大学 智能制造学院,湖南 长沙 410004

通讯作者:

魏祥(1988—),男,湖南安化人,副教授,主要研究方向为高性能耐磨材料。E-mail:
陈志国(1969—),男,湖南临澧人,教授,主要研究方向为新材料的微观组织设计与制备。E-mail:
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2种不同金属材料的力学参数

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species
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鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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