摘 要

本文研究了鋁合金的硬質(zhì)陽極氧化工藝。為了使鋁活塞能在高性能全鋁發(fā)動機(jī)缸體中得到應(yīng)用，解決鋁活塞耐磨性問題，試驗獲得了能有效提高鋁活塞表面硬度的工藝參數(shù)和電解液配方。
鋁活塞硬質(zhì)陽極氧化處理的任務(wù)包括：ZL108鋁活塞制造技術(shù)要求的制定，前處理工藝的確定，氧化處理裝置及掛具的設(shè)計，專用電解液的研制。試驗檢測了硬度、膜層厚度等參數(shù)值并且分析了各項參數(shù)之間的關(guān)系。本文分析了國內(nèi)外鋁硅合金在室溫下的硬質(zhì)陽極氧化電解液成分，并且建立了兩組配方。通過對比研究，試驗確定了最終的電解液配方為：A酸40g/L，B酸30g/L，D膜層改善劑20g/L，E促進(jìn)成膜劑8g/L；通過對各項參數(shù)之間相互作用的分析，試驗確定了最終的工藝參數(shù)為：溫度T=12～15℃，電流密度i=4A/dm2，時間t=20min，獲得了黑褐色、光潔度高、膜層厚度為12～13μm的氧化膜，完全符合預(yù)留尺寸，膜層顯微硬度為HV0.01>500，達(dá)到設(shè)計需求。
通過鋁活塞的臺架強(qiáng)化試驗，其結(jié)果表明此次鋁活塞耐磨處理是成功的，各項參數(shù)均滿足實際要求。


關(guān)鍵詞：活塞、鋁合金、硬質(zhì)陽極氧化、硬度















ABSTRACT

A hard anodizing process on aluminum was researched in this paper, In order to make aluminum piston can be applied in the all-aluminum alloy cylinder of high performance engine and solve the wear resistance problem of aluminum piston, the trial get the processing parameters and electrolyte formula that was able to effectively improve the surface hardness of the piston aluminum.
The tasks of the hard anodizing process of aluminum piston include: The formulation of ZL108 aluminum piston manufacturing technology requirements, the determination of process before oxide treatment, the designing of oxide treatment plant and suspension, the development of electrolyte. The trial has tested the hardness, thickness and other parameters and analysis of the relationship between the various parameters. This paper analysised of the hard anodizing electrolyte composition of Al-Si alloys at home and abroad at room temperature, and established the two formulations. By comparing the research, the ultimate formula for the electrolyte has been determined by the trial: A acid 40g/L, B acid 30g/L, D improve a coating additives 20g/L, E promote a coating additives 8g/L; through the analysis of interaction among various parameters, the ultimate parameters has been determined by the trial: temperature T = 12~15 ℃, the current density i = 4A/dm2, time t = 20min, got the dark brown, high-quality finish, thickness of 12~13μm of the oxide coating in full compliance with the reserve size, for the coating microhardness HV0.01> 500, to meet the design requirements.
Through the platform test of aluminum piston, the results show that the aluminum piston wear resistant treatment is successful, the parameters are to meet actual demand.


Key words：Piston, Aluminum alloy, Hard anodizing, Degree of hardness








目 錄

中文摘要 Ⅰ
ABSTRACT Ⅱ
1 緒論 1
1.1 鋁合金活塞表面強(qiáng)化處理的意義 1
1.2 鋁合金活塞表面強(qiáng)化處理的研究現(xiàn)狀 2
1.3 陽極氧化電解液的配制 4
1.3.1 硫酸電解 4
1.3.2 有機(jī)酸電解 5
1.3.3 混合電解 5
1.4 本課題的研究目的、研究內(nèi)容及技術(shù)指標(biāo) 7
2 試驗準(zhǔn)備 9
2.1 活塞制備 9
2.1.1 材料選取 9
2.1.2 尺寸要求 9
2.1.3 銳角處理 10
2.2 試驗藥品 10
3 試驗過程 11
3.1 試驗裝置 11
3.2 硬質(zhì)陽極氧化工藝流程 11
3.3 前處理 11
3.3.1 機(jī)械處理 12
3.3.2 除油 12
3.3.3 活化沖洗出光 13
3.3.4 水洗 13
3.4 上裝夾 13
3.5 鋁合金室溫硬質(zhì)陽極氧化操作方法 14
3.6 封閉后處理 14
4 鋁活塞硬質(zhì)陽極氧化工藝 15
4.1 鋁活塞室溫硬質(zhì)氧化液組成設(shè)計 15
4.2 鋁活塞室溫硬質(zhì)氧化工藝參數(shù)的影響 16
4.2.1 膜層改善劑D對膜層顯微硬度的影響 16
4.2.2 促進(jìn)成膜劑E對膜層的影響 17
4.2.3 電流密度對終電壓的影響 19
4.2.4 溫度對終電壓的影響 20
4.2.5 電流密度對膜層厚度的影響 20
4.2.6 電流密度對膜層外觀質(zhì)量的影響 21
4.3 鋁活塞室溫硬質(zhì)氧化工藝參數(shù)的優(yōu)化確定 21
5 臺架強(qiáng)化試驗 24
6 硬質(zhì)陽極氧化工藝探討 25
6.1 鋁合金硬質(zhì)陽極氧化原理 25
6.2 硬質(zhì)氧化溶液的發(fā)熱和氧化膜再溶解問題 26
6.3 局部保護(hù) 27
6.4 硬質(zhì)陽極氧化膜的特點 27
6.5 硬質(zhì)陽極氧化常見故障原因及其排除方法 28
7 結(jié)論 29
參考文獻(xiàn) 30
致謝 32