高承载下Al2O3-GdAlO3(GAP)非晶陶瓷涂层的摩擦磨损性能

doi:10.15541/jim20250016

无机材料学报 ›› 2025, Vol. 40 ›› Issue (10): 1111-1118.DOI: 10.15541/jim20250016

高承载下Al₂O₃-GdAlO₃(GAP)非晶陶瓷涂层的摩擦磨损性能

艾伊昭彤¹(), 任九龙², 强林芽³, 张小珍³, 杨凯²(), 高彦峰²

¹ 中国科学院上海硅酸盐研究所, 中国科学院特种无机涂层重点实验室, 上海 201899
² 上海大学材料科学与工程学院, 上海 200444
³ 景德镇陶瓷大学材料科学与工程学院, 景德镇 333403

收稿日期:2025-01-13 修回日期:2025-02-17 出版日期:2025-03-25 网络出版日期:2025-03-25
通讯作者: 杨凯, 研究员. E-mail: kaiyang_yk@shu.edu.cn
作者简介:艾伊昭彤(1993-), 女, 工程师. E-mail: aiyizhaotong@mail.sic.ac.cn

Friction and Wear Properties of Al₂O₃-GdAlO₃ (GAP) Amorphous Ceramic Coatings under High Load Capacity

AI Yizhaotong¹(), REN Jiulong², QIANG Linya³, ZHANG Xiaozhen³, YANG Kai²(), GAO Yanfeng²

¹ Key Laboratory of Inorganic Coating Materials CAS, Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai 201899, China
² School of Materials Science and Engineering, Shanghai University, Shanghai 200444, China
³ School of Materials Science and Engineering, Jingdezhen Ceramic University, Jingdezhen 333403, China

Received:2025-01-13 Revised:2025-02-17 Published:2025-03-25 Online:2025-03-25
Contact: YANG Kai, professor. E-mail: kaiyang_yk@shu.edu.cn
About author:AI Yizhaotong (1993-), female, engineer. E-mail: aiyizhaotong@mail.sic.ac.cn

摘要/Abstract

摘要：

针对高承载、高温、富氧及宽温域交变热冲击等苛刻工况的航空航天动力装置关键部件, 对材料的力学性能、热稳定性及抗氧化能力提出了极高要求。传统热喷涂技术制备的Al₂O₃涂层凭借高硬度、良好的耐磨性、优异的抗氧化能力及较好的热稳定性, 已在航空航天、能源及机械等领域得到了广泛应用。然而, 热喷涂Al₂O₃涂层以亚稳态γ-Al₂O₃为主晶相, 力学及导热性能弱于α-Al₂O₃相, 这限制了其在更高承载极端工况下的应用效果。为解决上述问题并提升涂层的综合性能, 本研究采用大气等离子体喷涂(Atmospheric Plasma Spraying, APS)技术, 制备了厚度约350 µm的Al₂O₃-GdAlO₃(GAP)非晶涂层。通过设计磨损试验(载荷2000 N、转速500 r/min、时间1 h), 对涂层的摩擦磨损行为及力学性能进行了系统考察。实验结果表明, 由于涂层中高比例的非晶相及优化的微观结构, Al₂O₃-GAP涂层在高速重载摩擦测试中表现出优异的耐磨性和抗裂纹扩展能力, 显著优于传统多晶Al₂O₃涂层。此外, Al₂O₃-GAP涂层的摩擦系数较低且稳定, 摩擦表面温度明显降低, 减缓了高温氧化及热损伤的发生, 缓解了应力集中效应。综上所述, Al₂O₃-GAP非晶涂层在高载荷、高速摩擦工况下具有显著优势, 为航空航天动力装置关键部件的防护提供了一种高性能、可靠服役的涂层解决方案。

关键词: 大气等离子体喷涂, Al₂O₃-GdAlO₃(GAP), 非晶陶瓷涂层, 高承载耐磨性能

Abstract:

Key components of aerospace power systems operating under extreme conditions, such as high loads, elevated temperatures, oxygen-rich environments, and wide-temperature-range alternating thermal shocks, impose stringent requirements on material mechanical properties, thermal stability, and oxidation resistance. Conventional thermally sprayed Al₂O₃ coatings, characterized by high hardness, excellent wear resistance, superior oxidation resistance, and good thermal stability, have been widely applied to aerospace, energy, and mechanical engineering fields. However, these coatings primarily consist of metastable γ-Al₂O₃ as the dominant crystalline phase, which exhibits inferior mechanical and thermal conductivity properties compared to α-Al₂O₃. This limitation hinders their effectiveness under extremely high-load conditions. To address this issue and enhance the overall coating performance, atmospheric plasma spraying (APS) was employed to fabricate Al₂O₃-GdAlO₃ (GAP) amorphous coating with a thickness of approximately 350 µm. The friction and wear behavior, along with the mechanical properties of the coating, were systematically investigated through a designed wear test under a load of 2000 N, a rotational speed of 500 r/min, and a duration of 1 h. Experimental results indicate that due to the high proportion of the amorphous phase and the optimized microstructure, the Al₂O₃-GAP coating exhibits excellent wear resistance and superior crack propagation resistance under high-speed and heavy-load friction conditions, significantly outperforming conventional polycrystalline Al₂O₃ coatings. Furthermore, the Al₂O₃-GAP coating demonstrates a lower and more stable friction coefficient, effectively reducing frictional surface temperature. This mitigates high-temperature oxidation and thermal damage while alleviating stress concentration effects. In summary, the Al₂O₃-GAP amorphous coating demonstrates remarkable advantages under high-load, high-speed friction conditions, providing a high-performance and reliable coating solution for the protection of critical aerospace power system components.

Key words: atmospheric plasma spraying, Al₂O₃-GdAlO₃(GAP), amorphous ceramic coating, high-load wear resistance

中图分类号:

TQ174

艾伊昭彤, 任九龙, 强林芽, 张小珍, 杨凯, 高彦峰. 高承载下Al₂O₃-GdAlO₃(GAP)非晶陶瓷涂层的摩擦磨损性能[J]. 无机材料学报, 2025, 40(10): 1111-1118.

AI Yizhaotong, REN Jiulong, QIANG Linya, ZHANG Xiaozhen, YANG Kai, GAO Yanfeng. Friction and Wear Properties of Al₂O₃-GdAlO₃ (GAP) Amorphous Ceramic Coatings under High Load Capacity[J]. Journal of Inorganic Materials, 2025, 40(10): 1111-1118.

图/表 11

表1 NiCr合金黏结层和Al2O3-GAP陶瓷层的喷涂工艺参数

Table 1 Spray coating parameters for NiCr bondcoat and Al2O3-GAP ceramic topcoat

Sample	Arc current/A	Primary plasma gas (Ar)/slpm	Secondary plasma gas (Ar)/slpm	Power/ kW	Carrier gas (Ar)/slpm	Powder feed rate/(g·min^-1)	Spray distance/cm
NiCr bondcoat	590-610	55-60	7.5-8.0	40-50	3.5	10	120
Al₂O₃-GAP topcoat	640-660	45-50	8.5-9.0	45-50	4.0	30	110

图1 摩擦磨损实验原理示意图

Fig. 1 Schematic diagram of the principle of the friction and wear test

图2 不同粉体的形貌图

Fig. 2 Morphologies of different powder samples (a, b) SEM images of Al2O3 spray powder prepared by the melting and crushing method; (c, d) TEM images of mixed powder composed of nanoscale or submicron Al2O3 and Gd2O3 raw materials; (e, f) SEM images of sprayed Al2O3/Gd2O3 powder after heat treatment at 900 ℃

图3 喷涂粉体和喷涂态Al2O3-GAP非晶涂层的XRD图谱

Fig. 3 XRD patterns of the feedstock and as-sprayed Al2O3-GAP amorphous coating

图4 喷涂态Al2O3-GAP非晶涂层的形貌与EDS分析

Fig. 4 Morphology and EDS analysis of as-sprayed Al2O3-GAP amorphous coating (a, b) Surface morphology of the coating; (c, d) Cross-sectional morphology of the coating; (e, f) EDS elemental analysis of the coating

图5 喷涂态Al2O3涂层和Al2O3-GAP非晶涂层在2000 N@500 r/min条件下的摩擦系数(a)和磨损表面温度(b)

Fig. 5 Coefficients of friction (a) and wear surface temperatures (b) of sprayed Al2O3 coating and Al2O3-GAP amorphous coating under conditions of 2000 N@500 r/min

表2 Al2O3和Al2O3-GAP涂层的摩擦系数和磨损表面温度

Table 2 Coefficients of friction and wear surface temperatures of Al2O3 and Al2O3-GAP coatings

Coating system	Coefficient of friction			Wear surface temperature/℃
Coating system	Average	Maximum	Minimum	Average	Maximum
Al₂O₃	0.236	0.305	0.127	513.14	553.80
Al₂O₃-GAP	0.146	0.213	0.067	438.54	464.20

图6 Al2O3涂层在2000 N@500 r/min条件下的磨损表面形貌及EDS分析

Fig. 6 Wear surface morphology and EDS analysis of Al2O3 coating under conditions of 2000 N@500 r/min (a) SEM image of the overall worn surface of coating wear ring; (b) Magnified view of a worn region in (a); (c, d) EDS elemental analysis

图7 Al2O3-GAP非晶涂层在2000 N@500 r/min条件下的磨损表面形貌

Fig. 7 Wear surface morphology of Al2O3-GAP amorphous coating under conditions of 2000 N@500 r/min (a) A typical wear scar region of the coating; (b) Magnified view of an abrasive wear characteristic region selected from (a); (c) Magnified view of a typical dark ‘scratch’ region selected from (b); (d) Further magnified view of the region in (c)

图8 Al2O3-GAP涂层/石墨在2000 N@500 r/min条件下产生磨屑的形貌及EDS分析

Fig. 8 Morphology and EDS analysis of wear debris from Al2O3-GAP/graphite under conditions of 2000 N@500 r/min (a-c) SEM images of wear debris with different sizes and shapes; (d) EDS elemental analysis of the wear debris in (c)

图9 Al2O3涂层和Al2O3-GAP涂层在2000 N@500 r/min条件下磨损前后的三维应力云图

Fig. 9 3D stress maps of Al2O3 coating and Al2O3-GAP coating before and after wear under conditions of 2000 N@500 r/min

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高承载下Al₂O₃-GdAlO₃(GAP)非晶陶瓷涂层的摩擦磨损性能

Friction and Wear Properties of Al₂O₃-GdAlO₃ (GAP) Amorphous Ceramic Coatings under High Load Capacity

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