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涂层疲劳损伤声发射特征参数及损伤机理

     

摘要

使用超音速等离子喷涂设备在1045钢基体上制备了铁基合金涂层.以球盘式接触疲劳试验机为平台,研究了涂层接触疲劳损伤过程中声发射特征参数的变化规律,并分析了涂层的接触疲劳损伤机理.结果表明,在转速为2500r/min和应力水平为1.58GPa实验条件下,点蚀是涂层的主要失效形式,表现为在涂层磨痕轨迹范围内出现大量的点蚀坑,点蚀坑深度为20~30μm.涂层表面粗糙的微凸体与轴承球滚压接触产生黏着磨损,以及涂层、磨粒、滚动轴承三者形成三体磨料磨损是点蚀失效产生的主要原因.声发射幅值、有效值(Root Mean Square,RMS)、能量、计数和平均频率对涂层表面粗糙微凸体去除、弹塑性变形、裂纹萌生、裂纹稳定扩展和失稳扩展过程比较敏感,并且在不同的疲劳损伤阶段具有不同的信号反馈特点.%Fe-based alloy coating was deposited on 1045 steel by a supersonic plasma spraying device.The variation regularities of acoustic emission characteristic parameters in the process of contact fatigue damage were researched using a ball-disk contact fatigue tester,and the contact fatigue damage mechanism of as-sprayed coating was analyzed.The results show that pitting is main failure mode of the coating under the experimental conditions of the 1.58GPa contact press and 2500r/min.Many pitting pits were observed on the wear track,and depth of the pitting pits was in the range from 20μm to 30μm.The pitting failure was closely associated with adhesive wear caused by rolling contact between rough salient on coating surface and bearing balls,and three-body abrasive wear among the coating,abrasives and rolling bearings within the contact region.Acoustic emission characteristic parameters,such as amplitude,root mean square (RMS),energy,count and average frequency are sensitive for rough salient removal on coating surface,elastic and plastic deformation,crack initiation,crack stable growth and unstable growth,and which are different during different fatigue damage stages.

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