DEVELOPMENT OF COMPOSITE FUNCTIONAL MATERIALS WITH HIGH PERFORMANCE AND THEIR PROCESSING TECHNOLOGY

该项目的目的是与韩国启明大学的研究人员合作，研究和开发高性能复合功能材料及其加工技术。本文从四个方面进行了研究，取得了以下成果：(1)高性能耐磨铸造合金的合金设计、凝固工艺和耐磨性。设计了三种合金的强碳化物形成元素Cr、Mo、W和V的总量为200/0，使每种合金中各有两种不同类型的合金共存。根据碳平衡参数测定其含碳量。合金的化学成分和共存碳化物分别为：Fe - 3%C- 10%Cr-5%Mo -5% w （M_7C_3+M_6C，合金1）、Fe - 3%C- 10% V -5%Mo -5% w （MC+M_2C，合金2）和Fe - 3.5%C - 17% Cr- 3%V （M_7C_3+(MC)，合金3）。各合金的凝固顺序如下：各合金的耐磨性依次为均质态（AH）、铸态（as）、淬硬回火态（AHFT）和淬硬态（AHF）。在铸态和均质化状态下，合金2的耐磨性最高，合金3的耐磨性最低。在淬火和回火状态下，合金2的耐磨性大大提高或最大，其次是合金3和合金1。结果表明，具有极高硬度的MC碳化物、以马氏体或回火马氏体和残余奥氏体为基体的基体是提高材料耐磨性的重要相。(2)离子束对材料表面的改善。MgO薄膜已被广泛应用于等离子体显示面板（PDP）的电极或荧光粉保护膜，其电阻效率的提高是实现PDP长寿命所不可缺少的。采用快速原子束溅射法测定了薄膜对能量为2.0keV的快速原子轰击的抵抗能力。PDP中原子与等离子体粒子之间的能量差和动量差必须考虑到对等离子体暴露电阻的精确估计；如果需要进行相对估计，则可以方便地进行快速估计。通过附着在试样上窗口前的小电极监测试样表面被轰击的原子数量，并测量二次电子的电流。经等量原子辐照后，用Dektak3测量溅射区与未溅射区之间的间隙，并覆盖小玻璃板。采用EB沉积法制备MgO样品；厚度在200 ~ 500 nm之间，用薄膜x射线衍射系统对其衍射谱图进行了验证。这些试样在热处理后和原位沉积时的制备条件略有不同，但它们之间没有差异。对抗快原子束轰击性能的估计结果总结如下：(1) MgO镀膜试样的电阻优于未镀膜的溅射玻璃试样。(2)未热处理的游离MgO的耐蚀性能优于热处理试样。(3)原因(2)并没有从x射线衍射图的结果和AFM对试样表面的观察中得到澄清，但通过测量这些薄膜的硬度有望弄清楚。(3)橡胶、塑料与无机材料的复合。采用聚酰胺/铝颜料复合物代替铝用于汽车轮帽，不仅可以降低成本，而且由于消除了使用有毒有机溶剂的涂层过程而带来的环境问题。为防止尼龙黄度升高和物理性能下降，在尼龙/无机颜料复合材料中掺入抗氧剂或分散剂，并对抗氧剂的最佳用量进行了研究。与不含抗氧化剂的样品相比，加入抗氧化剂的样品黄度较低。在125℃烘箱老化试验中发现，加入抗氧剂后试样的抗拉强度下降速度比未加入抗氧剂的试样慢得多。在添加的抗氧化剂中，Irganox i098和b11711对尼龙6体系具有较好的抗氧化剂效果。为了使铝颜料在尼龙6中得到良好的分散，丙烯酸蜡和铝偶联剂等添加剂是有效的。(4)复合多组分白口铸铁的磨损性能研究。制备了含O、2、5和I O质量% Co的复合多组分白口铸铁（Fe-5%Cr-5%Mo-5%W-5%V-2%C-Co），研究了钴含量和热处理条件对硬度和摩擦滑动磨损性能的影响。在铸态和退火状态下，随着钴含量的增加，铸铁的硬度降低，而在回火状态下，硬度反而升高。从Suga型磨损试验机的测试结果中发现，无论钴含量如何，随着硬度的增加，耐磨性降低。在销盘式磨损试验中，随着钴含量的增加，铸铁的滑动耐磨性增加，并在3 ~ 4 m/s的滑动速度范围内表现得最大。认为滑动磨损性能与磨损过程中氧化膜的性能有关。少

The purpose of this project is to research and develop the composite functional materials with high performance and their processing technique by cooperating with researchers of Keimyung University in Korea. The research was curried out on four themes and the following results were obtained :(1) Alloy design, solidification process and wear resistant of high functional wear resistant cast alloys.Three kind of alloys were designed to have totally 200/0 of strong cabide forming elements such as Cr, Mo, W and V so that two different types of each special coexist in each alloy. The carbon content was determinated referring to the parameter of carbon balance. Chemical composition and coexisting cabides of alloys are, Fe - 3%C- 10%Cr-5%Mo -5%W (M_7C_3+M_6C, alloy 1), Fe - 3%C - 10% V - 5% Mo - 5%w, (MC+M_2C, alloy 2) and Fe - 3.5%C - 17% Cr - 3%V (M_7C_3+(MC), alloy 3)Solidification sequence of each alloy is as follows,In all the specimens, the abrasion wear resistance was found to increase … More in the order of homogenized (AH), as-cast (AS), hardened and temped (AHFT) and as-hardened (AHF) states. In as-cast and homenized states, the highest wear resistance was obtained in alloy 2 and lowest one was alloy 3. In hardened and tempered states, the wear resistance of alloy 2 was greatly increased or greatest and it followed with difference by the order of alloy 3 and alloy 1. From these results, MC cabide having extreme hardness and matrix with martensite or tempered martensite and some retained austenite were found to be significant phases to improve the abrasion wear resistance.(2) Surface improvement of materials using ion beam. MgO thin films have been widely used for protecting film of electrodes or phosphors in Plasma Display Panel (PDP), and the improvement of the efficiency of resistance has been required, because it is indispensable to achieve the long life of PDP. Fast Atom Beam Sputtering Method has been applied in order to estimate the resistance of these thin films against the fast atom bombardment with the energy of 2.0keV. The difference of energy and the momentum between the atoms and plasma particles in PDP must be considered in case of making exact estimation of resistance against plasma exposure ; rapid estimation is convenient if the relative estimation is required. The amount of the atoms that were bombarded upon the surface of the specimen was monitored by small electrode attached just in front of the upper specimen window and the current of the secondary electron were measured. After the irradiation by the same amount of atoms, the gap between sputtered area and un-sputtered area, which that was covered with small glass plate, were measured by Dektak3. MgO specimens were prepared by means of EB deposition method in Keimyong University ; of which thickness were 200 to 500 nm and these X-ray diffraction pattem were confirmed by thin film X-ray diffraction system. There were no differences between these specimens although the preparation conditions of them were slightly different in heat treatment after and in-situ deposition.The results of estimation of the resistance against fast atom beam bombardment were summarized as follows ;(1) MgO coated specimen shows better resistance than that of the uncoated glasses that were sputtered in the same way as to get the standard value.(2) The resistance of the non-heat-treatment free MgO shows better performance than that of heat-treated specimens.(3) The reason (2) has not been cleared from the results of X-ray diffraction pattern and the observation of the surfaces of the specimens by AFM, but to measer the hardness of these films have been expected to making it clear.(3) Compounding of rubber, plastic and inorganic materials. The use of polyamide/aluminium pigment compounds instead of aluminium for automobile wheel cap will bring the reduction of cost and the environmental problems because of the elimination of coating process using toxic organic solvents. To prevent the increase of yellowness and decrease of the physical properties of nylon, Nylon6/inorganic pigments composites mixed with antioxidants or dispersion agents were prepared, and optimum amount of the antioxidants was investigated. Samples mixed with antioxidants showed less yellowness than a sample free of antioxidants. For the aging test in the 125'C oven, it was found that much slower decrease of the tensile strength occurred in the antioxidants added samples compared with those without antioxidants. Among antioxidants added, Irganox I 098 and B 1 1 7 1 were better antioxidants for Nylon6 systems. To get good dispersion of aluminium pigment in the Nylon6, it was found that the additives such as acrylic acid wax and Al coupling agent were effective. (4) Study of abrasion wear properties of composite multi-component white cast irons.Composite multi-component white cast irons(Fe-5%Cr-5%Mo-5%W-5%V-2%C-Co) containing O, 2, 5 and I O mass % Co were prepared to clear the effects of cobalt content and heat treatment condition on hardness and properties of abrasion and sliding wears. The hardness of the cast irons decreased with an increase in cobalt content in as-cast and annealed states, but it increased conversely in the tempered state. It was found from the tests results using Suga type wear tester that the abrasion wear resistance lowered with an increase in hardness regardless of cobalt content. In the case of Pin on disk type wear test, the sliding wear resistance of the cast iron increased with increasing cobalt content and showed greatest in the sliding speed ranging from 3 to 4 m/s. It is considered that the sliding wear resistance could relate to the properties of oxide film produced during wear. Less