CN104593720A - 航空发动机压气机叶片抗沙尘冲蚀复合涂层及其制备方法 - Google Patents

航空发动机压气机叶片抗沙尘冲蚀复合涂层及其制备方法 Download PDF

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CN104593720A
CN104593720A CN201510033549.5A CN201510033549A CN104593720A CN 104593720 A CN104593720 A CN 104593720A CN 201510033549 A CN201510033549 A CN 201510033549A CN 104593720 A CN104593720 A CN 104593720A
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aero
engine compressor
compressor blade
shot peening
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何卫锋
李应红
张金
王冠
张翼飞
龙霓东
李玉琴
杨竹芳
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Aerospace Engineering School Of Chinese People's Liberation Army Air Force Engineering University
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Abstract

本发明公开了一种航空发动机压气机叶片抗沙尘冲蚀复合涂层及其制备方法，包括由下到上依次分布的喷丸影响层、Ti结合层及若干TiN层，其中，相邻两个TiN层之间均设有Ti层。本发明所述的涂层与航空发动机压气机叶片的结合力强，硬度高，韧性好，并且制备方法简单。

Description

航空发动机压气机叶片抗沙尘冲蚀复合涂层及其制备方法
技术领域
本发明属于航空发动机叶片制备与防护涂层技术领域，涉及一种航空发动机压气机叶片抗沙尘冲蚀复合涂层及其制备方法。
背景技术
直升机在起飞和降落的过程中或近地飞行时，产生的高速气流将尘土、砂粒等吸入发动机，这些砂尘会对压气机叶片进行冲击、磨损等作用，导致叶片产生变形、凹坑、缺口等损伤，破坏叶片表面完整性，甚至导致发动机故障；同时，叶片表面粗糙度增大、前缘弯曲、弦长变短、厚度减小等，使得压气机的增压比、效率、以及流通能力降低，引起发动机性能衰减，功率下降、耗油率增加、涡轮前燃气温度升高等，严重影响发动机的使用和维护。例如，某直升机在普通环境下飞行，发动机寿命可达2000h，但在砂尘环境下飞行，仅能持续100h。
为了提高叶片抗冲蚀损伤性能，可以采用粒子分离器、更换材料、优化叶片型面设计、防护涂层等方法。粒子分离器只能对一定尺寸、一定速度的砂粒进行分离，还有很多细小砂粒依然会进入压气机；更换材料和优化叶片型面设计需要较长的周期，短时间内无法实现。而防护涂层不会改变叶片的基体设计和材料、不影响叶片的气动性，同时可显著提高抗冲蚀性能，是一种成本较低、效果较好的方法。
航空发动机压气机叶片常用钛合金材料，由于钛合金硬度较低，抗冲蚀性能较差，因此，在钛合金叶片表面制备一层硬质涂层可提高叶片抗砂尘冲蚀性能，TiN、ZrN、TiC等涂层具有很高的硬度，可显著降低叶片在砂尘小角度冲击引起的磨蚀。当冲击角度较大时，叶片表面的涂层还需要承受大的冲击载荷，单一的TiN、ZrN、TiC等涂层韧性较差，在冲击载荷的作用下，容易产生脆性开裂，因此增加硬质涂层的韧性是提高涂层抗冲蚀性能的迫切需求。采用金属-陶瓷涂层可以充分利用陶瓷层的硬度和耐磨性，同时可通过韧性较好的金属层提高涂层抵抗大角度冲击时脆性裂纹和剥落，从而提高涂层的综合性能。
多层涂层的专利主要用于刀具、磨具等，例如，在授权号为CN1256326 A、名称为“多层涂层”的发明专利中，所发明的多层涂层包括镍层、锡和镍合金层、钛或钛合金层，夹层为钛或钛合金层交替设置的钛化合物(TiN)或钛合金化合物(TiZrN)等，可保护基体材料的磨损和腐蚀，该涂层主要用于装饰及对日常用品的防护。但是该涂层结构复杂，韧性和硬度没有兼顾考虑，不适合砂尘环境下工作的叶片的防护。
在授权号为CN 102575345 A、名称为“多层涂层、制作多层涂层的方法及其应用”的发明专利中，采用的是二氧化钛和氧化铝涂层，用于保护基体材料不受环境的化学元素腐蚀的影响，不适用于砂尘冲蚀环境。
在授权号为CN 102092159 A、名称为“用于压气机叶轮、叶片的ZrN/TiMo复合涂层及制备方法”的发明专利中，用于压气机叶轮、叶片的ZrN/TiMo复合涂层由TiMo粘结层和TiAlN面层组成，粘结层TiMo的制备，采用磁控溅射制备工艺；ZrN面层的制备，采用多弧离子镀制备工艺。主要用于600℃高温下抗热循环能力、抗热盐腐蚀能力和抗冲刷磨损的能力。该涂层主用用于高温抗腐蚀，且制备方法涉及到两种设备，加工复杂，且韧性难以控制，不能用于沙尘环境下提高叶片的抗冲蚀能力。
发明内容
本发明的目的在于克服上述现有技术的缺点，提供了一种航空发动机压气机叶片抗沙尘冲蚀复合涂层及其制备方法，该涂层与航空发动机压气机叶片的结合力强，硬度高，韧性好，并且制备方法简单。
为达到上述目的，本发明所述的航空发动机压气机叶片抗沙尘冲蚀复合涂层包括由下到上依次分布的涂覆有喷丸影响层、Ti结合层及若干TiN层，其中，相邻两个TiN层之间均设有Ti层。
所述喷丸影响层、Ti结合层、TiN层及Ti层的总层数为n，且4≤n≤20。
所述TiN层与Ti层的厚度比值为m，且1≤m≤35。
所述喷丸影响层的厚度小于0.2mm，喷丸影响层表面的粗造度小于Ra0.6微米。
所述待处理的航空发动机压气机叶片基体为不锈钢或钛合金材料。
所述喷丸影响层、Ti结合层、TiN层及Ti层的总厚度大于25微米，且Ti结合层的厚度、TiN层的厚度及Ti层的厚度均小于6微米。
所述TiN层内添加有Al元素及Zr元素。
本发明所述的航空发动机压气机叶片抗沙尘冲蚀复合涂层的制备方法包括以下步骤：
1)对待处理的航空发动机压气机叶片基体进行清洗；
2)对清洗后的待处理的航空发动机压气机叶片基体表面进行喷丸，形成喷丸影响层；
3)对步骤2)得到的喷丸影响层进行振动抛光；
4)清洗步骤3)得到的振动抛光后的喷丸影响层；
5)在清洗后的喷丸影响层上采用磁控溅射的方法制备Ti结合层；
6)采用磁控溅射的方法在Ti结合层上制备Ti层及TiN层，得航空发动机压气机叶片抗沙尘冲蚀复合涂层。
步骤1)的具体操作为：将待处理的航空发动机压气机叶片基体依次进行去油、超声波清洗、去离子水漂洗及烘干，其中，在超声波清洗的过程中采用2000mL的丙酮为清洗液清洗15min。
步骤5)的具体操作为：将抛光后的喷丸影响层先通过超声波去除表面的污渍及残留的磨料，然后通过等离子体冲击喷丸影响层表面。
本发明具有以下有益效果：
本发明所述的航空发动机压气机叶片抗沙尘冲蚀复合涂层及其制备方法在制备过程中，通过给振动抛光及清洗后的喷丸影响层上采用磁控溅射的方法制备Ti结合层，从而有效的提高涂层与航空发动机压气机叶片的结合力，然后再给Ti结合层上制备TiN层及Ti层，从而制备出来的航空发动机压气机叶片抗沙尘冲蚀复合涂层具体高硬度及良好的韧性的特点，并且制备方法简单、有效。
附图说明
图1为本发明的结构示意图；
图2为本发明的实施实例中与钛合金叶片表面结合牢固的TiN层4和/Ti层5的截面的SEM图。
图3为本发明的实施实例中制备的涂层与钛合金叶片的结合力测试与结果图。
其中，1为待处理的航空发动机压气机叶片基体、2为喷丸影响层、3为Ti结合层、4为TiN层、5为Ti层。
具体实施方式
下面结合附图对本发明做进一步详细描述：
参考图1及图2，本发明所述的航空发动机压气机叶片抗沙尘冲蚀复合涂层包括由下到上依次分布的喷丸影响层2、Ti结合层3及若干TiN层4，其中，相邻两个TiN层4之间均设有Ti层5，喷丸影响层2、Ti结合层3、TiN层4及Ti层5的总层数为n，且4≤n≤20，TiN层4的厚度与Ti层5的厚度的比值为m，且1≤m≤35，喷丸影响层2的厚度小于0.2mm，喷丸影响层2表面的粗造度小于Ra0.6微米，待处理的航空发动机压气机叶片基体1为不锈钢或钛合金材料，Ti结合层3、TiN层4及Ti层5的总厚度大于25微米，且Ti结合层3的厚度、TiN层4的厚度及Ti层5的厚度均小于6微米，TiN层4内添加有Al元素及Zr元素。
本发明所述的航空发动机压气机叶片抗沙尘冲蚀复合涂层的制备方法包括以下步骤：
1)对待处理的航空发动机压气机叶片基体1进行清洗；
2)对清洗后的待处理的航空发动机压气机叶片基体1表面进行喷丸，形成喷丸影响层2；
3)对步骤2)得到的喷丸影响层2进行振动抛光；
4)清洗步骤3)得到的振动抛光后的喷丸影响层2；
5)在清洗后的喷丸影响层2上采用磁控溅射的方法制备Ti结合层3；
6)采用磁控溅射的方法在Ti结合层3上制备TiN层4及Ti层5，得航空发动机压气机叶片抗沙尘冲蚀复合涂层。
步骤1)的具体操作为：将航空发动机压气机叶片基体1依次进行去油、超声波清洗、去离子水漂洗及烘干，其中，在超声波清洗的过程中采用2000mL的丙酮为清洗液清洗15min。
步骤5)的具体操作为：将抛光后的喷丸影响层2先通过超声波去除表面的污渍及残留的磨料，然后通过等离子体冲击喷丸影响层2表面。
实施实例：
1)对采用丙酮溶液清除钛合金叶片表面的油污，并擦拭干净；
2)将钛合金叶片放入超声波清洗机中，加入丙酮2000ml，对叶片进行进一步清洗，清洗时间为20min，其清洗过程为：超声波粗洗→超声波精洗→去离子水漂洗→烘干，超声波清洗参数为：功率密度为0.5W/cm2，超声波频率为40Hz，清洗温度30℃，清洗后放入真空室备用；
3)对清洗后的钛合金叶片的叶身表面进行喷丸，喷丸参数为：BZ30玻璃丸，喷丸强度0.15A，覆盖率200％，气压0.2MPa；
4)将喷丸后的钛合金叶片进行振动抛光处理，振动抛光机型号为VB-100LB，磨料为1-20mm的形状多样的树脂，放水清洗磨料3-5分钟，打开排水阀门待水漏干90％后，加入YMY-2研磨液，振动抛光60分钟。
5)采用与步骤2)相同的方法对钛合金叶片进行超声清洗，然后进行氩气等离子体清洗，真空度30Pa，氩气流量80ml/min；
6)对钛合金叶片的表面进行磁控溅射。(1)将磁控溅射炉腔内的灰尘等清洗干净；(2)将钛靶安装在溅射靶台上；(3)将经过预先处理、待镀膜的叶片等构件安装在磁控溅射炉腔内并固定在转动工作台上；(4)在以下的条件下进行磁控溅射镀膜，炉腔内真空度6×10-3pa，温度为300℃±5℃，铬靶的直流电压为400V、功率为2.4kW，转台匀速转动速度3r/min，叶片偏压为-300V，镀膜时间45min；(5)保持铬靶的直流电压、电流值不变，开启氮气管、氮气瓶，使氮气流经离子源，向炉腔内充入氮气，当氮气流量达120cm3/min时，保持氮流量恒定，在叶片表面沉积TiN结合层，钛合金叶片所加的偏压为-150V，沉积120min后关闭氮气；(6)关闭氮气开关，按步骤(4)所述的过程和条件进行镀膜，然后交替3次，制备7层Ti层5/TiN层4；(7)关闭氩气瓶，打开炉盖，开炉取出叶片，放置在洁净环境中；(8)采用WS-92自动划痕测试仪测试TiN层4/Ti层5与基体的结合力；采用JSM-6700F场发射扫描电镜分析薄膜截面及其表面形貌特征；采用MH-5显微硬度计测量薄膜的显微硬度；采用M03XHF22型X射线衍射仪对薄膜金相结构进行分析，参考图3。

Claims (10)

1.一种航空发动机压气机叶片抗沙尘冲蚀复合涂层，其特征在于，包括由下到上依次分布的喷丸影响层(2)、Ti结合层(3)及若干TiN层(4)，其中，相邻两个TiN层(4)之间均设有Ti层(5)。
2.根据权利要求1所述的航空发动机压气机叶片抗沙尘冲蚀复合涂层，其特征在于，所述TiN层(4)及Ti层(5)的总层数为n，且4≤n≤20。
3.根据权利要求1所述的航空发动机压气机叶片抗沙尘冲蚀复合涂层，其特征在于，所述TiN层(4)与Ti层(5)的厚度比值为m，且1≤m≤35。
4.根据权利要求1所述的航空发动机压气机叶片抗沙尘冲蚀复合涂层，其特征在于，所述喷丸影响层(2)的厚度小于0.2mm，喷丸影响层(2)表面的粗造度小于Ra0.6微米。
5.根据权利要求1所述的航空发动机压气机叶片抗沙尘冲蚀复合涂层，其特征在于，所述航空发动机压气机叶片基板(1)为不锈钢或钛合金材料。
6.根据权利要求1所述的航空发动机压气机叶片抗沙尘冲蚀复合涂层，其特征在于，所述喷丸影响层(2)、Ti结合层(3)、TiN层(4)及Ti层(5)的总厚度大于25微米，Ti结合层(3)的厚度、TiN层(4)的厚度及Ti层(5)的厚度均小于6微米。
7.根据权利要求1所述的航空发动机压气机叶片抗沙尘冲蚀复合涂层，其特征在于，所述TiN层(4)内添加有Al元素及Zr元素。
8.一种航空发动机压气机叶片抗沙尘冲蚀复合涂层的制备方法，其特征在于，包括以下步骤：
1)对待处理的航空发动机压气机叶片基体(1)进行清洗；
2)对清洗后的航空发动机压气机叶片基体(1)表面进行喷丸，形成喷丸影响层(2)；
3)对步骤2)得到的喷丸影响层(2)进行振动抛光；
4)清洗步骤3)得到的振动抛光后的喷丸影响层(2)；
5)在清洗后的喷丸影响层(2)上采用磁控溅射的方法制备Ti结合层(3)；
6)采用磁控溅射的方法在Ti结合层(3)上制备TiN层(4)及Ti层(5)，得航空发动机压气机叶片抗沙尘冲蚀复合涂层。
9.根据权利要求8所述的航空发动机压气机叶片抗沙尘冲蚀复合涂层的制备方法，其特征在于，
步骤1)的具体操作为：将待处理的航空发动机压气机叶片基体(1)依次进行去油、超声波清洗、去离子水漂洗及烘干，其中，在超声波清洗的过程中采用2000mL的丙酮为清洗液清洗15min。
10.根据权利要求8所述的航空发动机压气机叶片抗沙尘冲蚀复合涂层的制备方法，其特征在于，
步骤5)的具体操作为：将抛光后的喷丸影响层(2)先通过超声波去除表面的污渍及残留的磨料，然后通过等离子体冲击喷丸影响层(2)表面。
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