等离子喷涂层微观成形过程数值模拟研究现状  

Research Status on Numerical Simulation of Plasma Spraying Coating in Micro-forming Process

作　　者：丁述宇 马国政 徐滨士[1] 王海斗[1] 陈书赢 何鹏飞 王译文 DING Shuyu;MA Guozheng;XU Binshi;WANG Haidou;CHEN Shuying;HE Pengfei;WANG Yiwen(National Key Laboratory for Remanufacturing,Army Academy of Armored Forces,Beijing 100072;National Key Laboratory of Human Factors Engineering,China Astronaut Research and Training Center,Beijing 100094)

机构地区：[1]陆军装甲兵学院装备再制造技术国防科技重点实验室,北京100072 [2]中国航天科研训练中心人因工程重点实验室,北京100094

出　　处：《材料导报》2019年第11期1889-1896,1918,共9页Materials Reports

基　　金：国家自然科学基金(51675531;51535011);北京市自然科学基金(3172038)~~

摘　　要：等离子喷涂具有焰流温度高、粒子速度快、能量密度高等特点,是零件表面强化和再制造常用的表面工程技术之一,在耐磨、防腐、热障等诸多领域具有重要应用。涂层的质量往往决定零件的服役性能和使用寿命。等离子喷涂层的成形质量受众多喷涂要素和工艺参数的交叉耦合作用。传统优化喷涂工艺的方法是依据实践经验确定主要工艺参数的可行域,然后反复进行工艺参数调节和涂层性能验证来获得相对合适的工艺参数,这种方式存在成本高、效率低、可靠性差的缺陷。数值模拟作为一种新兴的科学研究方法,在等离子喷涂领域不仅有助于优化喷涂工艺参数,而且有助于深入理解喷涂成形原理和涂层微观构筑过程。研究者们借助数值模拟手段,探究等离子喷涂过程的微观机理,模拟实验中无法观测瞬时、高速的现象,并且指导优化喷涂工艺参数,改善喷枪机械结构,在提升涂层质量与性能上发挥重要作用。本文总结了数值模拟中有限元模拟的研究步骤,综述了近年来国内外数值模拟在等离子喷涂层微观成形过程应用的研究现状。在等离子射流形成的数值模拟中,研究领域从单一物理场转化为多物理场耦合,能较为准确地把握等离子喷枪中复杂的物理现象;其数值模拟范围主要包括等离子射流的温度场模拟、湍流模拟与电磁特性模拟等。在喷涂粒子与射流交互作用数值模拟中,研究者结合实验探究喷涂粒子与大气物性参数对飞行过程的影响,获取最佳的喷涂距离、送粉管角度等工艺参数;其数值模拟范围包括等离子射流中粒子加速过程模拟、加热过程模拟、飞行轨迹和空间分布模拟。在喷涂粒子铺展凝固过程的数值模拟中,将瞬时、高速的铺展凝固过程形象化,掌握基体与大气物性参数对该过程的影响。其数值模拟范围包括粒子撞击铺展过程模拟与凝固Plasma spraying is characterized by the high temperature of flame flow, fast particle velocity and high energy density, which is one of the common surface engineering techniques for surface strengthening and remanufacturing of parts and has important applications in many fields, such as wear-resisting, anti-corrosion and thermal barrier. The service performance and life of the product is often determined by the quality of the coating. The forming quality of plasma spraying coating is determined by the cross-coupling of many spray elements and process parameters. The traditional method of optimizing spraying process is to determine the feasible region of main process parameters according to practical experience, which has to adjust the progress parameters and test the performance of the coating over and over again. This method has the disadvantage of high cost, low efficiency and poor reliability. Numerical simulation is a high-efficiency, low-cost scientific research method. In the field of plasma spraying, it can not only optimize the spraying process parameters, but also help deeply understand the principle of spray forming and the process of coating microcosmic construction. With the help of numerical simulation, the researchers have explored the microscopic mechanism of the plasma spraying process, the transient and high-speed phenomena which could not be observed in experiment. What’s more, it can also guide the optimization of spray process parameters, improve the mechanical structure of the spray gun, and play an important role in improving the coating quality and performance. This paper summarizes the research steps of finite element simulation in numerical simulation and reviews the micro-forming process of plasma sprayed coating in recent research state of numerical simulation. As for the numerical simulation of plasma jet formation, the research field has transformed from a single physics field to a multi-physics coupling. By this mean, it can accurately grasp the complex physical phenomena in plasma

关 键 词：等离子喷涂 涂层成形 数值模拟 飞行粒子 传热传质 

分 类 号：TG148[一般工业技术—材料科学与工程]