CN113151772A - Novel high-temperature corrosion-resistant thermal barrier coating with double ceramic layer structure and preparation method thereof - Google Patents
Novel high-temperature corrosion-resistant thermal barrier coating with double ceramic layer structure and preparation method thereof Download PDFInfo
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
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- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/134—Plasma spraying
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
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- C23C4/073—Metallic material containing MCrAl or MCrAlY alloys, where M is nickel, cobalt or iron, with or without non-metal elements
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
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- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
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Abstract
The invention relates to the technical field of material processing and preparation, in particular to a high-temperature-resistant thermal barrier coating with a double-ceramic-layer structure and a preparation method thereof2O3The top ceramic layer is made of an LZO material, so that the heat insulation performance and the thermal shock performance of the thermal barrier coating can be improved, and the service life of the thermal barrier coating is prolonged; the ceramic transition layer adopts YSZ (La)2O3) The thermal mismatch stress between the two layers can be relieved, and the bonding strength of the two layers is improved. The invention provides the thermal barrier coating withThe ceramic material has the characteristics of stable phase, high bonding strength, long service life under high-temperature service conditions, high bonding strength between double-layer ceramics and high bonding strength between a ceramic layer and a metal bonding layer.
Description
Technical Field
The invention relates to the technical field of material processing and preparation, in particular to a high-temperature corrosion-resistant thermal barrier coating with a double-ceramic-layer structure and a preparation method thereof.
Background
The thermal barrier coating is a ceramic coating with high temperature resistance and good heat insulation performance sprayed on the surface of the hot end component, has good heat insulation, high temperature oxidation resistance and corrosion resistance, and can obviously improve the service temperature and service life of the hot end component. As the temperature before the turbine of the modern gas turbine engine is continuously increased due to the pursuit of higher thermal efficiency and thrust-weight ratio, the temperature before the turbine of the modern advanced high-performance aircraft engine reaches more than 2350K, but the service temperature of the turbine blade still far exceeds the limit temperature (1423K) which can be borne by the traditional nickel-based superalloy material. Therefore, the preparation of the thermal barrier coating with excellent heat insulation performance and stable high-temperature service performance is the key for improving the performance of the engine blade.
The thermal barrier coating material widely used at present is mainly Zr02-8%Y203(yttria-stabilized zirconia, 8YSZ for short), the material has low thermal conductivity, and the thermal expansion coefficient of the material is matched with that of a metal base material. It has been proposed in the patent (CN 109706418A) to use conventional plasma and high energy plasma to prepare such thermal barrier coatings, and the texture of the thermal barrier coatings prepared using this method is a layered structure. According to related experiments and researches, when the service temperature of YSZ is 1100 ℃ for a long time, a series of phase changes can occur, so that cracks are generated in the coating, and the failure of the coating is accelerated; and when the service temperature is higher than 1100 ℃, the high-speed diffusion of oxygen causes the oxidation of the metal bonding layer, and the oxidation is the main reason for the failure of the thermal barrier coating. Therefore, finding a new thermal barrier coating structure is an important technical approach to replace YSZ materials.
Disclosure of Invention
The invention aims to provide a high-temperature-resistant thermal barrier coating with a double-ceramic-layer structure and a thermal barrier coating thereofThe preparation method overcomes the defects of the prior art and adopts LZO + YSZ (La)2O3) The double-ceramic-layer structure reduces the growth of TGO through the ceramic transition layer and the top ceramic layer, reduces the existence of semi-molten or non-molten particles in the coating, improves the bonding strength and the thermal shock resistance of the coating, prolongs the thermal cycle life and plays a role in prolonging the working life.
In order to achieve the purpose, the technical scheme of the invention is as follows:
the technical scheme is as follows: the high-temperature-resistant thermal barrier coating with the double-ceramic-layer structure is characterized in that the thermal barrier coating is of a composite structure, a metal bonding layer, a ceramic transition layer and a top ceramic layer are sequentially arranged on the surface of a metal substrate from bottom to top, the metal substrate is a nickel-based high-temperature alloy, the metal bonding layer is a nickel-based alloy, and the ceramic transition layer is YSZ + La2O3The material, top layer ceramic layer is the LZO material.
The thickness of the bonding layer is 150-160 mu m, and the transition layer YSZ (La) is2O3) The thickness is 100-110 μm, and the thickness of the ceramic top layer LZO is 180-200 μm.
The bonding layer is made of NiCoCrAlY, the surface roughness Ra of the bonding layer is 3-6 mu m, the Rz is 20-45 mu m, the RSm is 100-150 mu m, and the Rsk is 0.20-0.45.
The ceramic transition layer is a nano-structure coating, the porosity of the ceramic transition layer is 5% -10%, and the number of unmelted particles is less than 3.
The top ceramic layer is a nano-structure coating, wherein the porosity is 5% -15%, and the number of unmelted particles is 1-5.
The second technical proposal is that: a preparation method of a high-temperature-resistant thermal barrier coating with a double-ceramic-layer structure is characterized by comprising the following specific operation steps:
step (1), preparing and pretreating a substrate, namely soaking the nickel-based high-temperature alloy substrate in acetone for 0.5-1h, taking out, naturally airing, and performing sand blasting treatment on the substrate to enable the surface roughness of the substrate to reach Ra <6 mu m;
step (2), spraying and preparing a NiCoCrAlY bonding layer on the metal matrix;
step (3) of preparing YSZ (La) by spraying on the bonding layer2O3) The bonding layer is prepared by a PS-PVD method on the ceramic transition layer, and the specific technological parameters are as follows: the spraying distance is 330-360 mm, the powder feeding rate is 10-15 g/min, the pressure of a working cabin is 190-200 Pa, the preheating temperature is 800-900 ℃, and the current is 2500-2700A;
and (4) adopting LZO nano-agglomeration-plasma densification powder on the ceramic transition layer, preparing an LZO ceramic top layer of the nano-structure coating by using an atmospheric plasma process APS, setting the spraying distance to be 80-90 mm, the powder feeding speed to be 15-25 g/min, the transverse moving speed of a spray gun to be 300-350 mm/s, the spraying voltage to be 60-70V, the current to be 650-700A, preheating the matrix to 300-320 ℃, and the thickness of the sprayed ceramic top layer to be 200-230 mu m, wherein the porosity is 11.2-13.5%.
In the step (3), the surface of the metal bonding layer needs to be preheated before the ceramic transition layer is sprayed, and the temperature is 850-880 ℃.
In the step (4), the substrate is preheated at the temperature of 300-350 ℃ before the top layer ceramic is sprayed.
Compared with the prior art, the technical scheme of the invention has the beneficial effects that:
(1) the invention has a double ceramic layer structure LZO + YSZ (La)2O3) The advanced PS-PVD spraying technology is adopted and the design of the coating structure is optimized, so that the bonding strength, the thermal shock resistance and the thermal cycle life of the thermal barrier coating are improved.
(2) The bonding layer prepared by the PS-PVD process is of a typical feather-shaped columnar structure, holes are almost not formed, molten particles are spread on the substrate more completely and flatly, the compact bonding layer can protect the substrate metal more effectively, and the corrosion resistance of the metal is effectively improved.
(3) The LZO top layer ceramic is introduced on the ceramic transition layer, and the coating has stability at high temperature, high wear resistance and low thermal conductivity, so that the coating can be used for designing and preparing a novel high-temperature thermal barrier coating material at the use temperature of below 1600 ℃ in an oxygen-enriched environment. LZO as the top layer of the coating reacts with CMAS by La to produce dense apatite (Ca)2La8(SiO4)6O2) The blocking effect of the composite can effectively reduce the CMAS infiltration, inhibit the instability of the internal 8YSZ,the corrosion resistance of the coating is improved.
(4) Compared with the traditional single-layer YSZ coating, the invention adopts YSZ (La)2O3) The coating of the composite material can not only increase the yield strength and the fracture toughness of a system, but also prevent the growth and the phase change of crystal grains, thereby enhancing the hot corrosion resistance and the high-temperature oxidation resistance. On LZO coating and YSZ (La)2O3) Under the double obstruction, the oxygen is effectively prevented from permeating, the growth of the thermal growth oxide TGO is obstructed, and the service life of the coating is obviously prolonged. Adding an appropriate amount of La into YSZ2O3The thermal mismatch stress between the two layers can be relieved, and the bonding strength of the two layers is improved.
(5) The product of the invention can be widely used on various hot end parts such as aerospace, gas turbine blades and the like.
Drawings
FIG. 1 is a schematic cross-sectional structure of a coated product of the present invention;
FIG. 2 is a cross-sectional profile of a tie layer made using APS technology;
FIG. 3 is a cross-sectional profile of a bond coat made using PS-PVD in an embodiment of the invention;
FIG. 4 is a graph comparing the number of thermal cycles of the present invention with a single layer YSZ coating;
FIG. 5 is a graph comparing the CMAS corrosion resistance of different coatings on aircraft blades according to embodiments of the present invention.
In the figure: 1-metal matrix, 2-bonding layer, 3-ceramic transition layer and 4-top ceramic layer.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only illustrative and are not intended to limit the present invention.
The embodiment of the invention relates to a preparation method of a high-temperature-resistant thermal barrier coating with a double-ceramic-layer structure, which comprises the following specific operation steps:
step (1): preparing and pretreating a substrate, selecting a nickel-based high-temperature alloy, wherein the nickel-based high-temperature alloy comprises the components (Ni =61%, Cr =16%, Co =8.5% and La = 3.4%), ultrasonically cleaning the alloy substrate by using acetone with the concentration of 99.7% and absolute ethyl alcohol with the concentration of 99.8%, taking out after 0.5h, cleaning to remove surface grease, and drying by using a drying oven. And after drying, carrying out sand blasting treatment on the surface of the matrix by using 50# brown corundum sand grains, wherein the sand blasting angle is 45-60 degrees, the sand blasting treatment is carried out until the surface of the matrix is uniform in color and has no metallic luster, and high-pressure air is used for blowing off residual sand grains on the surface after the sand blasting is finished.
Step (2): preparing a bonding layer by a PS-PVD method, wherein metal alloy powder mainly comprising NiCoCrAlY is selected for preparing the bonding layer, the particle size range of the powder is 20-45 mu m, the spraying distance is set to be 350mm, the powder feeding speed is 10g/min, the transverse moving speed of a spray gun is 500mm/s, and the argon flow is 110m3The current was 1650A, the thickness of the sprayed bond coat was 150 μm, the roughness RSm was 180 μm and the Rsk was 0.34.
And (3): preparation of nano-structure ceramic transition layer YSZ (La) by PS-PVD method2O3) The main component of the preparation material of the nano-structure ceramic transition layer is YSZ (La)2O3) The particle size range of the nano powder is 20-60 mu m, the set spraying distance is 950mm, the powder feeding speed is 10g/min, the transverse moving speed of a spray gun is 800mm/s, the spraying current is 2600A, and the argon flow is 35m3H, helium flow rate of 60m3And h, preheating the substrate to 850 ℃ by using plasma in the spraying process, wherein the thickness of the sprayed ceramic transition layer is 100 mu m, and the porosity is 3.26%.
And (4): preparing LZO on the top layer of the nano-structure ceramic by using atmospheric plasma, wherein the main component of the top layer of the nano-structure ceramic is nano-agglomeration-plasma densification powder of the LZO, the granularity range of the powder is 10-30 mu m, the set spraying distance is 80mm, the powder feeding speed is 10g/min, the transverse moving speed of a spray gun is 300mm/s, the spraying voltage is 60V, the current is 650A, the substrate is preheated to 300 ℃, the thickness of the top layer of the sprayed ceramic is 200 mu m, and the porosity is 12.2%.
The bonding layer and the ceramic transition layer are prepared by adopting a plasma-physical vapor deposition technology (PS-PVD technology), and the high-power plasma spray gun (180 KW) is used for spraying in an ultra-low pressure environment (50-150 Pa), so that the plasma jet velocity is extremely high, and the occurrence of inclusions and oxides in the bonding layer can be avoided. Under the action of extremely high plasma jet velocity, the molten particles can be fully spread after impacting the matrix, the combination with the metal matrix is tighter, and the obtained coating is also denser. The use of a high-power plasma spray gun can enable the raw materials to be more fully melted and greatly reduce the existence of semi-molten or non-molten particles in the coating.
In the embodiment, the heat conductivity of the ceramic top layer LZO coating is smaller than that of YSZ, and can reach 0.8W/(m.K) at least, so the LZO has good heat insulation performance. The LZO coating is effective to prevent the penetration of oxygen and thereby prevent the coating from failing and falling off due to the generation of Thermally Grown Oxides (TGO). To mix La2O3The doping can not only improve the high-temperature phase stability of the YSZ and reduce the thermal conductivity to 1.70-1.84W/(m.K) (800-; and under high temperature conditions, La2O3The doping of (a) may inhibit the densification process of the coating and may produce a significant amount of nanostructured pores. While La in the coating2O3The "pinning" effect of the particles also inhibits ZrO4The grain boundary migration and growth of the crystal grains lead the crystal grains to be refined, the density of the grain boundary to be increased and the deformation to be more uniform. Therefore, the cracking probability of the coating is reduced, and the bending strength, the hardness and the fracture toughness of the coating are greatly improved.
FIG. 1 is a schematic cross-sectional structure of a coated product of the present invention, wherein a metal substrate 1 is sequentially provided with a bonding layer 2, a ceramic transition layer 3 and a top ceramic layer 4, and a high temperature corrosion resistant double ceramic layer thermal barrier coating is formed on the metal substrate 1.
Fig. 2 and 3 are cross-sectional profiles of bonding layers prepared by different technologies. As can be seen in fig. 2; a large number of holes are present in the adhesive layer. This is related to the jet velocity and jet temperature of APS preparations, the lower jet temperature leading to the presence of unmelted or semi-melted particles during the spraying process, thereby creating crater sites on the coating surface. When the pit cannot be completely filled, a hole is created. Whereas the bonding layer prepared with PS-PVD had almost no voids, as shown in fig. 3. In one aspect, PS-PVD has a high power plasma torch, under which conditions the powder particles are sufficiently heated to a molten state and deposited onto the substrate; on the other hand, the plasma jet velocity of PS-PVD is much higher than that of APS, and the molten particles impact the substrate at high velocity under the action of the plasma jet, and the molten particles spread more completely and smoothly on the substrate. Therefore, the bonding layer prepared using PS-PVD is more dense.
Fig. 4 is a graph comparing the number of thermal cycles of the present invention with a single layer YSZ coating. By incubating and cooling at 1300 c, the thermal cycle resistance of the present invention is shown to be superior to that of single layer YSZ.
FIG. 5 is a graph comparing the CMAS corrosion resistance of different coatings on aircraft blades according to embodiments of the present invention. By resisting CMAS corrosion under the same conditions, it can be seen that the corrosion resistance of the present invention is superior to that of single layer YSZ.
The process of the invention can be operated in an environment below 2mbar using a high energy plasma torch and can deposit coatings by a variety of methods, such as: the molten powders are deposited in liquid form to form a layered structured coating and the coating formed by vapor deposition may also have a novel unique microstructure. A PS-PVD process is used to obtain a columnar grain structure thermal barrier coating and a coating of uniform thickness can be deposited. The thermal barrier coating prepared by the PS-PVD technology has excellent thermal insulation and thermal shock resistance, so that the thermal barrier coating becomes one of the most promising technologies for preparing future advanced aeroengine thermal barrier coatings.
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and it is therefore intended that all such changes and modifications as fall within the true spirit and scope of the invention be considered as within the following claims.
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Cited By (6)
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| CN113913730A (en) * | 2021-10-31 | 2022-01-11 | 中国人民解放军国防科技大学 | Thick thermal barrier coating with high thermal cycle life and preparation method thereof |
| CN114411085A (en) * | 2021-11-25 | 2022-04-29 | 矿冶科技集团有限公司 | Preparation method of dense thick thermal barrier coating |
| CN114561613A (en) * | 2022-03-09 | 2022-05-31 | 内蒙古科技大学 | 700 ℃ ultra supercritical power station is with two tubular structures of coating |
| CN114671686A (en) * | 2022-04-21 | 2022-06-28 | 昆明理工大学 | Preparation method of anti-permeation ceramic material capable of rapidly reacting with low-melting-point oxide |
| CN114908311A (en) * | 2022-06-28 | 2022-08-16 | 北京理工大学 | Thermal protection coating and preparation method and application thereof |
| CN116477970A (en) * | 2023-03-05 | 2023-07-25 | 广西大学 | A preparation method for in-situ generation of rare earth apatite phase dense reaction layer resistant to CMAS corrosion |
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