Effect of Spraying Process on Microstructure and Tribological Properties of Ta2O5 In Situ Composite Nanocrystalline Ta-Based Coatings

doi:10.11900/0412.1961.2020.00242

Acta Metall Sin

2021, Vol. 57

Issue (2): 237-246 DOI: 10.11900/0412.1961.2020.00242

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Effect of Spraying Process on Microstructure and Tribological Properties of Ta₂O₅ In Situ Composite Nanocrystalline Ta-Based Coatings

LI Xiaoqian¹^,², WANG Fuguo¹, LIANG Aimin¹^,²(

)

^1.Key Laboratory of Science and Technology on Wear and Protection of Materials, Lanzhou Institute of Chemical Physics, Chinese Academy of Sciences, Lanzhou 730000, China
^2.Center of Materials Science and Optoelectronics Engineering, University of Chinese Academy of Sciences, Beijing 100049, China

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LI Xiaoqian, WANG Fuguo, LIANG Aimin. Effect of Spraying Process on Microstructure and Tribological Properties of Ta₂O₅ In Situ Composite Nanocrystalline Ta-Based Coatings. Acta Metall Sin, 2021, 57(2): 237-246.

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Abstract

In the fields of aviation, aerospace, and military, Ta-based coatings are of wide prospects in applications owing to their remarkable characteristics. Compared with other preparation methods, plasma spraying has obvious technical advantages in preparing Ta-based coatings. In this work, Ta₂O₅ in situ composite nanocrystalline Ta-based coatings via plasma spraying were fabricated. Effects of the spraying power, main gas (Ar) flow rate, and spraying mode on the fine surface microstructure and friction, as well as on the wear properties of Ta-based coatings, were investigated using several techniques. Such techniques included SEM, micro-beam XRD, fretting friction and wear test, and computational analysis. Moreover, related rules and causes were discussed. Results indicated that the Ta₂O₅ content at the surface of Ta-based coatings initially decreased and then increased with an increase in the spraying power. Conversely, the crystal size and lattice distortion of α-Ta at the coating surface initially increased and then decreased. With an increase in the Ar flow rate, the Ta₂O₅ content decreased in general and reached the lowest value when the flow rate was 2.17×10^-3-2.33×10^-3 m³/s. A negative correlation between the variation of the crystal size and lattice distortion with Ar flow rate has been observed. The Ta₂O₅ content, crystal size, and lattice distortion slightly decreased due to intermittent spraying. Moreover, a significant correlation between the Ta₂O₅ content and coating microhardness was observed. Under dry friction, the wear rate is closely related to both the oxide content and crystal size. Low oxide content and large crystal size results in high wear rate. Under boundary lubrication, coatings with higher levels of hardness exhibit better anti-wear and friction-reducing performance in the same series of Ta-based coatings. The coating exhibiting the best tribological properties can be achieved via intermittent spraying. Mechanical properties of Ta-based coating are significantly correlated with their fine microstructure characteristics. Aside from microhardness, the grain size, lattice distortion, and oxide content of the coatings can be utilized as important indexes to control the coating quality.

Key words: Ta-based coating nanocrystal plasma spraying Ta₂O₅ crystal size wear rate

Received: 22 July 2020

ZTFLH:

TG178

Fund: Armament Pre-research Project (Cultivation Project)(0711)

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	Xiaoqian LI
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https://www.ams.org.cn/EN/10.11900/0412.1961.2020.00242 OR https://www.ams.org.cn/EN/Y2021/V57/I2/237

Table 1 Main plasma spraying process parameters of Ta-based coatings

Fig.1 SEM image (a), EDS (b), and XRD spectrum (c) of Ta powders

Fig.2 XRD spectrum of Ta-based coating

Fig.3 Surface SEM images of No.1 (a), No.2 (b), No.3 (c), No.4 (d), No.5 (e), No.6 (f), and No.7 (g) Ta-based coatings

Fig.4 Surface roughnesses of No.1-No.7 Ta-based coatings

Fig.5 Surface micro-beam XRD spectra (a) and columnar chart of I $T a 2 O 5 (001)$ /I $T a (110)$ (b) of No.1-No.7 Ta-based coatings (I $T a 2 O 5 (001)$ and I $T a (110)$ —intensities of XRD peaks of Ta₂O₅(001) and α-Ta(110) crystal planes, respectively)

Coating	I $T a 2 O 5 (001)$ /I $T a (110)$	I $T a 2 O 5 (001)$ /I $T a (200)$	I $T a 2 O 5 (001)$ /I $T a (211)$	I $T a 2 O 5 (110)$ /I $T a (110)$	I $T a 2 O 5 (110)$ /I $T a (200)$	I $T a 2 O 5 (110)$ /I $T a (211)$
No.1	0.044	0.416	0.156	0.053	0.500	0.188
No.2	0.036	0.286	0.114	0.045	0.357	0.143
No.3	0.031	0.308	0.111	0.031	0.308	0.111
No.4	0.047	0.417	0.152	0.066	0.583	0.212
No.5	0.035	0.035	0.114	0.053	0.462	0.176
No.6	0.036	0.036	0.118	0.054	0.462	0.176
No.7	0.035	0.035	0.118	0.045	0.385	0.147

Table 2 Intensity ratios of XRD peaks of two phases in surface layers of No.1-No.7 Ta-based coatings

Fig.6 Variation of crystal size (D) and lattice distortion (Δd/d) of α-Ta in Ta-based coatings with spraying power (a), and their positive correlation with spraying power (b), and variations of D and Δd/d with Ar flow rate (c) and spraying mode (d)

Fig.7 Columnar chart of average microhardness of Ta-based coatings (a), and variation of average microhardness and surface Ta₂O₅ content of the coatings with spraying power (b), Ar flow rate (c), and spraying mode (d)

Fig.8 Variation curves of friction coefficients of No.1-No.7 Ta-based coatings with time under unlubr-ication (a) and paraffin lubrication (b) condition, respectively (μ₁, μ₂—average friction coefficients under unlubrication and paraffin lubrication conditions, respectively)

Table 3 Average friction coefficients of No.1-No.7 Ta-based coatings

Fig.9 Variations of wear rate of Ta-based coatings under unlubricated and paraffin lubricated conditions with spraying power (a), Ar flow rate (b), and spraying mode (c), respectively

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