摘要
轴作为机械传动系统中用于支撑旋转并传递扭矩的关键部件,其磨损将直接影响系统传动精度与工作性能,严重时还会导致设备停机。电刷镀技术因高效、便捷的特性,被广泛应用于轴类零件的维护与修复领域。近年来纳米颗粒复合电刷镀液技术逐渐兴起,相较于传统电刷镀技术,纳米复合电刷镀层具有更优异的硬度、耐磨损和耐腐蚀等性能。然而,目前关于电刷镀技术修复磨损轴件的应用与作用机制、工艺参数和纳米颗粒对轴修复效果的影响以及轴磨损后电刷镀修复性能评价缺乏系统性总结。主要介绍电刷镀技术的工作原理及应用范围,探讨电刷镀技术在轴磨损修复中的应用及作用机制,并分析不同刷镀工艺参数对修复效果的影响。重点阐述磨粒磨损、黏着磨损、氧化磨损和疲劳磨损等轴磨损常见形式,依据常见轴件失效形式,分析关键工艺参数(如刷镀温度、电流密度和刷镀速度)和纳米颗粒对修复效果和性能指标的影响,同时进一步探究镀层强化机理并综述轴磨损后电刷镀修复性能评价。研究表明,电刷镀技术在轴修复领域展示出巨大的应用潜力。电流密度、刷镀速度和镀液温度等关键电刷镀工艺参数直接影响轴修复效果。纳米颗粒通过细化晶粒尺寸、阻碍位错等机制优化镀层微观结构,进而增强电刷镀层硬度、耐磨损和耐腐蚀等性能。目前传统电刷镀技术虽然成熟,但仍存在使用试错法探寻工艺参数最佳组合、镀液成分设计不精准、人工刷镀精度波动较大等问题。综述相关研究现状不仅可以指出电刷镀技术在实际轴修复应用中的不足及未来研究的方向,还可为工业应用中高性能轴修复提供有利参考。
The shaft is a crucial component in mechanical transmission systems,responsible for supporting rotation and transmitting torque.However,over time,wear can significantly affect both the accuracy and operational performance of the system,potentially leading to equipment failure.Brush plating technology has become widely used for the maintenance and repair of shaft components due to its effectiveness and convenience.Recently,nano-particle composite brush plating solutions have emerged as a new advancement.Compared to traditional brush plating,nano-composite coatings offer improved hardness,wear resistance,and corrosion resistance.However,comprehensive reviews are lacking that address the mechanisms of electro-brush plating technology in shaft repair,the critical process parameters,the effects of nanoparticles on the functionality of brush plating coatings,and the assessment of repair outcomes.This study primarily investigates the use and operational principles of electro-brush plating technology for shaft wear repair and provides an analysis of how different process parameters affect repair efficacy.It begins by introducing the fundamental principles and applications of electro-brush plating technology,focusing on the common types of shaft wear:abrasive,adhesive,oxidative,and fatigue.The analysis then explores how key process parameters,such as brush plating temperature,current density,and brush plating speed,along with nanoparticles,influence repair performance indicators.In addition,it examines the mechanisms behind coating strengthening and reviews the evaluation of electro-brush plating in repairing worn shafts.Research demonstrates that electro-brush plating technology enables rapid repairs due to its straightforward process and wide applicability.It can also be adapted for localized and on-site operations,thus demonstrating its significant potential for shaft repair.Extensive studies have analyzed how process parameters,including current density,brush plating speed,and temperature,affect the properties of the brush plating coating.These parameters influence not only hardness,wear resistance,corrosion resistance,coating adhesion,and hydrogen embrittlement of the coating but also the deposition rate and nanoparticle distribution uniformity during the electro-brush plating process.Nano-composite brush plating coatings exhibit high hardness,excellent wear resistance,and superior contact fatigue resistance.The hardness and wear resistance of a material largely depend on the quantity of doped particles and the substrate’s hardness.Mechanisms such as the Hall-Petch effect,Orowan mechanism,and hindrance of dislocation movement by nanoparticles can significantly enhance coating hardness through grain refinement and dispersion strengthening.The addition of nanoparticles increases the number of nucleation sites,which promotes the formation of new grains.During grain growth,mutual contact and hindrance among grains further refine grain size.Nanoparticles impede grain growth by constraining the movement of grain boundaries,facilitating grain refinement during growth and recrystallization.A uniform distribution and optimal size of nanoparticles improve the inhibition of grain boundary movement,leading to finer grain structures,which in turn enhance coating hardness and mechanical properties such as impact strength,tensile strength,and toughness.The nano-composite coating demonstrates resilience to alternating loads and exhibits favorable contact fatigue resistance.Depositing insoluble nano-ceramic particles at crystal defects creates a structure akin to“barrier piles”,which prevents lattice slip,increases hardness and wear resistance,improves internal stress conditions,and enhances fatigue resistance.On the other hand,poorly dispersed nanoparticles or aggregates can lead to crack formation,reducing fatigue resistance.This issue may arise from insufficient dispersion,inadequate wetting of particle surfaces,or insufficient plating solution quantity.Despite the advancements in traditional electro-brush plating technology,challenges remain,such as the lack of experimental optimization of process parameters,imprecision of plating solution compositions,and significant variability in manual brush plating precision.Finally,this study summarizes the limitations of electro-brush plating technology in practical applications and outlines future research directions,providing valuable insights for achieving high-performance shaft repairs in industrial settings.
作者
侯天朋
段海涛
黄素玲
段林林
李文轩
刘炼
贾丹
HOU Tianpeng;DUAN Haitao;HUANG Suling;DUAN Linlin;LI Wenxuan;LIU Lian;JIA Dan(State Key Laboratory of Special Surface Protection Materials and Application Technology,China Academy of Machinery Wuhan Research Institute of Materials Protection Co.,Ltd.,Wuhan 430030,China)
出处
《中国表面工程》
北大核心
2025年第2期132-147,共16页
China Surface Engineering
基金
国家重点研发计划(2023YFB4604803)
国家自然科学基金面上项目(52275208)
国家自然科学基金青年项目(52105203)。
关键词
电刷镀
轴
磨损机理
修复机理
工艺参数
electro-brush plating
shaft
wear mechanism
repair mechanism
process parameter
