Xu Binshi

Characterization and anti-friction on the solid lubrication MoS2 film prepared by chemical reaction technique

Abstract To develop a new way to produce the molybdenum disulfide (MoS2) solid lubrication film, the following two-step chemical reaction technique was attempted. Firstly, a Mo film was prepared by multi-arc ion plating technique, and secondly the Mo film was sulfurized by a low temperature ion sulfuration technique to obtain the MoS2 solid lubrication film. This MoS2 film was a composite film consisted of MoS2 and Mo. The lubricant MoS2 is dominant in the surface and metal Mo is dominant in the deep layer. It is an ideal frictional surface. The tribological properties showed that the solid lubrication MoS2 film possessed an excellent anti-friction property.

Metal magnetic memory signals from surface of low-carbon steel and low-carbon alloyed steel

In order to investigate the regularity of metal magnetic signals of ferromagnetic materials under the effect of applied load, the static tensile test of Q235 steel and 18CrNiWA steel plate specimens were conducted and metal magnetic memory signals of specimens were measured during the test process. The influencing factors of metal magnetic memory signals and the relationship between axial applied load and signals were analyzed. The fracture and microstructure of the specimens were observed. The results show that the magnetic signals corresponding to the measured points change linearly approximately with increasing axial load. The microstructure of Q235 steel is ferrite and perlite, whereas that of 18CrNiWA steel is bainite and low-carbon martensite. The fracture of these two kinds of specimens is ductile rupture; carbon content of specimen materials and dislocation glide give much contribution to the characteristics of magnetic curves.

Failure analysis used for remanufacturing of steel rolling components

The guide-pieces, used in the process line of steel rolling, were the important components. The guidepieces, which were slide contacting with the rolled-piece, had a high temperature and high speed. The wear was very serious. The results from failure analysis showed that there were three failure forms in the guide-pieces: the first was the wear during heat friction, the second was the heat fatigue under the cycle of deep heating and deep cooling, and the third was the impact rupture. Among them, the wear was the main reason. To the wear of guidepieces, there were four mechanisms, namely abrasive wear, adhesive wear, fatigue wear and corrosion wear. The failure analysis to the guide-piece laid the foundation for its remanufacturing.

Excellent vacuum tribological properties of Pb/PbS film deposited by RF magnetron sputtering and ion sulfurizing.

Soft metal Pb film of 3 μm in thickness was deposited on AISI 440C steel by RF magnetron sputtering, and then some of the Pb film samples were treated by low-temperature ion sulfurizing (LTIS) and formed Pb/PbS composite film. Tribological properties of the Pb and Pb/PbS films were tested contrastively in vacuum and air condition using a self-developed tribometer (model of MSTS-1). Scanning electron microscopy (SEM), X-ray diffraction (XRD) and X-ray photoelectron spectroscopy (XPS) were adopted to analyze the microstructure and chemical construction of the films and their worn surfaces. The results show that a mass of Pb was changed to PbS during the process of LTIS. In air condition, owing to the severe oxidation effect, pure Pb film showed relatively high friction coefficients (0.6), and Pb/PbS composite film also lost its friction-reduction property after sliding for a short time. In a vacuum, the average friction coefficients of Pb film were about 0.1, but the friction coefficient curve fluctuated obviously. And the Pb/PbS composite film exhibited excellent tribological properties in vacuum condition. Its friction coefficients keep stable at a low value of about 0.07 for a long time. If takes the value of friction coefficients exceeding 0.2 continuously as a criterion of lubrication failure, the sliding friction life of Pb/PbS film was as long as 3.2 × 10(5) r, which is 8 times of that of the Pb film. It can be concluded that the Pb/PbS film has excellent vacuum tribological properties and important foreground for applying in space solid lubrication related fields.

Residual stresses in coating-based systems, part I: Mechanisms and analytical modeling

Thin films and multi-layered coatings comprised of different classes of materials are often used for various functional devices. The thermo-mechanical integrity of these systems is becoming a major concern and is strongly related to the residual stresses because of the fabrication processes. In this paper, the sources of the residual stresses in the coating-based systems and the concept of “misfit strain” were briefly reviewed. Analytical models were developed to predict the residual stresses in multi-layered film structures or coating-based systems using the force and moment balances. In addition, the residual stress distributions in the functionally and compositionally graded coatings were also analyzed.

Erosion-corrosion behaviors of high velocity arc sprayed Fe−Al/Cr3C2 coating

Iron aluminide intermetallic coatings were prepared from Fe−Al/Cr3C2 cored wires using High Velocity Arc Spraying (HVAS) technology. Erosion and corrosion properties of HVAS sprayed Fe−Al/Cr3C2 coatings were investigated. Results show that the erosion at impingement angle of 30° is more than that of 90°. The erosion resistance of coatings was enhanced with the increase of temperature. Coatings had a better erosion resistance than substrates. The erosion changed from ductile behaviors to brittle behaviors above 450°C. At high temperature, the erosion resistances were superior to those at low temperature and room temperature. Coatings had much higher corrosion properties than substrates. The temperature had a little effect on the corrosion resistance of coatings; The corrosion losing of coatings increased slowly with the increase of corrosion time. The HVAS-sprayed Fe−Al/Cr3C2 coatings exhibited a high bond strength and hardness.

Sand-wear resistance of brush electroplated nanocomposite coating in oil and its application to remanufacturing

Sand-wear resistance of nano scale alumina particle reinforced nickel matrix composite coating (n-Al2O3/Ni) prepared by brush electroplating technique was investigated via wear tests in sand-contaminated oil lubricant, comparing with that of AISI1045 steel and brush electroplated Ni coating. Effects of testing load, sand content and sand size on worn volume of the three materials, and also coating surface roughness on worn volume of the brush electroplated coatings were accessed. Results show that the worn volume of all the three materials increases with increasing of testing load, sand content and sand size. In the same conditions, n-Al2O3/Ni composite coating has the smallest worn volume while AISI1045 steel has the largest because of the n-Al2O3 particle effects. As to n-Al2O3/Ni and Ni coatings, the surface-polished coatings have obviously lower worn volume than the as-plated coatings. The brush electroplated n-Al2O3/Ni composite coating was employed to remanufacture the sand-worn bearing seats of a heavy vehicle and good results were gained.

Residual stresses within sprayed coatings

Some important developments of residual stress researches for coating-based systems were studied. The following topics were included the sources of residual stresses in coatings: error analysis of Stoney’s equation in the curvature method used for the measurement of coating residual stress, the modeling of residual stress and some analytical models for predicting the residual stresses in coatings. These topics should provide some important insights for the fail-safe design of the coating-based systems.

Automatic brush-plating technology for component remanufacturing

An automatic brush-plating system was developed for component remanufacturing. With this system, Ni/nano-alumina composite coatings from an electrolyte containing 20 g/L nano-alumina particles were prepared. Microstructure, surface morphology, microhardness and wear resistance of automatically plated coating and manually plated coatings were investigated comparatively. The results show that the automatically plated coatings are relatively dense and uniform and have lower friction coefficient of 0.089 under lubricant condition, when compared with manually plated coatings with friction coefficient of 0.14.

INVESTIGATION OF STRUCTURAL INTEGRITY AND LIFE TIME PREDICTION OF THE THERMAL SPRAYED ALLOY COATING FOR REMANUFACTURING

Thermal spray technique is one of the key techniques in remanufacture engineering. The thermal sprayed coatings are commonly used in remanufacturing applications,their initial performance and service lifetime are critical to the success of remanufacturing.In the present paper, structural integrity,lifetime and failure mechanism of plasma sprayed coatings were investigated.The influences of hydrogen gas flow,spraying powder and powder feed rate on porosity in coatings and their mechanical properties were described.The rolling contact fatigue(RCF) experiment was conducted to develop a method of life time prediction and to reveal the failure mechanism for plasma sprayed coatings.The results show that the structural integrity of coatings can be obviously influenced by spraying process and an optimal design of spraying process can remarkably promote the coating performance. For this purpose,the S-N curve was established based on the large sample space to be used to easily predict coating lifetime.It is found that corrosive pitting,spalling and hierarchical failure are the main failure modes,those results from asperity contact,subsurface defect propagation and shear stress distribution,respectively.