Optimization Of Anti-Wear Coating Formula Based On Response Surface Methodology

Aeroengine fuel pump side plates,bearings and other components need to meet the requirements of high-speed,heavy-duty,high temperature and other harsh application conditions which routine grease lubrication is difficult to perform.Research on solid lubricant coating technology has important theoretical and application value.In order to prolong the life of the solid lubricant coating under harsh working conditions,a wear-resistant coating formulation was developed and the corresponding research process was prepared.Firstly,according to the data summary and test screening,the binding system and lubricant components of the bonded solid lubricant coating were established,and the dosage of formula ingredients was studied by response surface methodology(RSM).With the help of Design Expert 10.0.4 software,the mathematical model between the components and wear life was established and analyzed,resulting in the best formula design.The experimental results show that the wear life of the newly formulated coating reaches 380 minutes under 500N and 200r/min conditions,which is in line with the predicted value and much higher than that of similar mature products in the market.Then through the test,formulated the preparation process parameters for the new formula,including the number of sandpaper used in the pretreatment stage for rust removal,ultrasonic degreasing,surface modification treatment of solid additives,the procedure for coating preparation,spray gun diameter,spraying distance,and curing Temperature and time.The physical and chemical properties of the prepared coating such as appearance,film thickness and adhesion were tested,a and all the indicators were in compliance with the requirements.Finally,the tribological performance of the coating was tested by M-2000 ring-block contact friction and wear tester,and the wear mechanism of the coating was explored by means of SEM and EDS.The effects of matrix materials(Fe,Cu,12Cr),matrix hardness,and oil environment on the coefficient of friction and wear of the coating were investigated.The results show that the coating with 12Cr as the substrate has a low coefficient of friction and minimal wear.High hardness materials can reduce wear;the newly developed coatings have excellent wear resistance in oil environments.The tribological properties and wear mechanisms of the coatings under different loads were analyzed.With increasing load,the friction coefficient showed a downward trend,while the wear amount increased gradually.The wear patterns of the coatings are respectively slight abrasive wear,abrasive wear and adhesive wear,abrasive wear and sticky oxidation wear,and glue wear.In this paper,the composition selection and dosage optimization of the coating formulation were systematically performed,the corresponding preparation process was formulated and its tribological properties were characterized,which provided theoretical and experimental support for the design and application of the coating.