CN106061655B - 热阻挡涂层和方法 - Google Patents
热阻挡涂层和方法 Download PDFInfo
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- CN106061655B CN106061655B CN201580007489.8A CN201580007489A CN106061655B CN 106061655 B CN106061655 B CN 106061655B CN 201580007489 A CN201580007489 A CN 201580007489A CN 106061655 B CN106061655 B CN 106061655B
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- coating
- oxide
- thermal barrier
- barrier coating
- adhesive coatings
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- 238000000034 method Methods 0.000 title claims abstract description 76
- 239000012720 thermal barrier coating Substances 0.000 title claims abstract description 37
- 238000000576 coating method Methods 0.000 claims abstract description 173
- 239000011248 coating agent Substances 0.000 claims abstract description 135
- 230000011218 segmentation Effects 0.000 claims abstract description 37
- 239000000463 material Substances 0.000 claims description 33
- 239000000853 adhesive Substances 0.000 claims description 31
- 230000001070 adhesive effect Effects 0.000 claims description 31
- 239000000843 powder Substances 0.000 claims description 28
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 claims description 25
- 229910001928 zirconium oxide Inorganic materials 0.000 claims description 25
- 239000007921 spray Substances 0.000 claims description 19
- 230000003647 oxidation Effects 0.000 claims description 18
- 238000007254 oxidation reaction Methods 0.000 claims description 18
- SIWVEOZUMHYXCS-UHFFFAOYSA-N oxo(oxoyttriooxy)yttrium Chemical compound O=[Y]O[Y]=O SIWVEOZUMHYXCS-UHFFFAOYSA-N 0.000 claims description 17
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 16
- 238000005336 cracking Methods 0.000 claims description 12
- VQCBHWLJZDBHOS-UHFFFAOYSA-N erbium(iii) oxide Chemical compound O=[Er]O[Er]=O VQCBHWLJZDBHOS-UHFFFAOYSA-N 0.000 claims description 12
- IATRAKWUXMZMIY-UHFFFAOYSA-N strontium oxide Chemical compound [O-2].[Sr+2] IATRAKWUXMZMIY-UHFFFAOYSA-N 0.000 claims description 12
- MRELNEQAGSRDBK-UHFFFAOYSA-N lanthanum(3+);oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[La+3].[La+3] MRELNEQAGSRDBK-UHFFFAOYSA-N 0.000 claims description 11
- 239000000395 magnesium oxide Substances 0.000 claims description 8
- 239000003963 antioxidant agent Substances 0.000 claims description 7
- 230000003078 antioxidant effect Effects 0.000 claims description 7
- 235000006708 antioxidants Nutrition 0.000 claims description 7
- 229910000420 cerium oxide Inorganic materials 0.000 claims description 6
- 238000000280 densification Methods 0.000 claims description 6
- BMMGVYCKOGBVEV-UHFFFAOYSA-N oxo(oxoceriooxy)cerium Chemical compound [Ce]=O.O=[Ce]=O BMMGVYCKOGBVEV-UHFFFAOYSA-N 0.000 claims description 6
- 229910001938 gadolinium oxide Inorganic materials 0.000 claims description 5
- 229940075613 gadolinium oxide Drugs 0.000 claims description 5
- CMIHHWBVHJVIGI-UHFFFAOYSA-N gadolinium(iii) oxide Chemical compound [O-2].[O-2].[O-2].[Gd+3].[Gd+3] CMIHHWBVHJVIGI-UHFFFAOYSA-N 0.000 claims description 5
- 229910000449 hafnium oxide Inorganic materials 0.000 claims description 5
- PLDDOISOJJCEMH-UHFFFAOYSA-N neodymium(3+);oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[Nd+3].[Nd+3] PLDDOISOJJCEMH-UHFFFAOYSA-N 0.000 claims description 5
- WIHZLLGSGQNAGK-UHFFFAOYSA-N hafnium(4+);oxygen(2-) Chemical compound [O-2].[O-2].[Hf+4] WIHZLLGSGQNAGK-UHFFFAOYSA-N 0.000 claims description 4
- 238000010438 heat treatment Methods 0.000 claims description 3
- NYWITVDHYCKDAU-UHFFFAOYSA-N oxygen(2-) yttrium(3+) zirconium(4+) Chemical compound [O--].[O--].[Y+3].[Zr+4] NYWITVDHYCKDAU-UHFFFAOYSA-N 0.000 claims description 2
- 229910052769 Ytterbium Inorganic materials 0.000 claims 2
- GEZAXHSNIQTPMM-UHFFFAOYSA-N dysprosium(3+);oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[Dy+3].[Dy+3] GEZAXHSNIQTPMM-UHFFFAOYSA-N 0.000 claims 2
- NAWDYIZEMPQZHO-UHFFFAOYSA-N ytterbium Chemical compound [Yb] NAWDYIZEMPQZHO-UHFFFAOYSA-N 0.000 claims 2
- 239000010410 layer Substances 0.000 description 19
- 239000002245 particle Substances 0.000 description 14
- 239000007789 gas Substances 0.000 description 11
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 10
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 10
- 229910052726 zirconium Inorganic materials 0.000 description 10
- 239000000758 substrate Substances 0.000 description 9
- 230000008859 change Effects 0.000 description 7
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 6
- 238000001694 spray drying Methods 0.000 description 6
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 5
- 229910052786 argon Inorganic materials 0.000 description 5
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 5
- 230000004888 barrier function Effects 0.000 description 5
- 239000001257 hydrogen Substances 0.000 description 5
- 229910052739 hydrogen Inorganic materials 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 5
- 239000001301 oxygen Substances 0.000 description 5
- 229910052760 oxygen Inorganic materials 0.000 description 5
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 4
- 238000005516 engineering process Methods 0.000 description 4
- 229910052735 hafnium Inorganic materials 0.000 description 4
- UZLYXNNZYFBAQO-UHFFFAOYSA-N oxygen(2-);ytterbium(3+) Chemical compound [O-2].[O-2].[O-2].[Yb+3].[Yb+3] UZLYXNNZYFBAQO-UHFFFAOYSA-N 0.000 description 4
- 238000002360 preparation method Methods 0.000 description 4
- 229910003454 ytterbium oxide Inorganic materials 0.000 description 4
- 229940075624 ytterbium oxide Drugs 0.000 description 4
- 229910052727 yttrium Inorganic materials 0.000 description 4
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 description 4
- ZSLUVFAKFWKJRC-IGMARMGPSA-N 232Th Chemical compound [232Th] ZSLUVFAKFWKJRC-IGMARMGPSA-N 0.000 description 3
- ODINCKMPIJJUCX-UHFFFAOYSA-N Calcium oxide Chemical compound [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 3
- 229910052776 Thorium Inorganic materials 0.000 description 3
- 229910052770 Uranium Inorganic materials 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- 230000002902 bimodal effect Effects 0.000 description 3
- VNNRSPGTAMTISX-UHFFFAOYSA-N chromium nickel Chemical compound [Cr].[Ni] VNNRSPGTAMTISX-UHFFFAOYSA-N 0.000 description 3
- 239000011247 coating layer Substances 0.000 description 3
- 238000009826 distribution Methods 0.000 description 3
- -1 dysposia Chemical compound 0.000 description 3
- 230000004927 fusion Effects 0.000 description 3
- 239000012535 impurity Substances 0.000 description 3
- 238000005259 measurement Methods 0.000 description 3
- 238000002844 melting Methods 0.000 description 3
- 230000008018 melting Effects 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 229910001120 nichrome Inorganic materials 0.000 description 3
- 229910052759 nickel Inorganic materials 0.000 description 3
- 229910052702 rhenium Inorganic materials 0.000 description 3
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N titanium dioxide Inorganic materials O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 3
- JFALSRSLKYAFGM-UHFFFAOYSA-N uranium(0) Chemical compound [U] JFALSRSLKYAFGM-UHFFFAOYSA-N 0.000 description 3
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 2
- 229910000943 NiAl Inorganic materials 0.000 description 2
- NPXOKRUENSOPAO-UHFFFAOYSA-N Raney nickel Chemical compound [Al].[Ni] NPXOKRUENSOPAO-UHFFFAOYSA-N 0.000 description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 2
- 239000000919 ceramic Substances 0.000 description 2
- 229910052681 coesite Inorganic materials 0.000 description 2
- 229910052593 corundum Inorganic materials 0.000 description 2
- 229910052906 cristobalite Inorganic materials 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- 230000001965 increasing effect Effects 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- JKQOBWVOAYFWKG-UHFFFAOYSA-N molybdenum trioxide Chemical compound O=[Mo](=O)=O JKQOBWVOAYFWKG-UHFFFAOYSA-N 0.000 description 2
- 238000010422 painting Methods 0.000 description 2
- 239000000377 silicon dioxide Substances 0.000 description 2
- KKCBUQHMOMHUOY-UHFFFAOYSA-N sodium oxide Chemical compound [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 description 2
- 229910001948 sodium oxide Inorganic materials 0.000 description 2
- 238000005507 spraying Methods 0.000 description 2
- 229910052682 stishovite Inorganic materials 0.000 description 2
- 229910052905 tridymite Inorganic materials 0.000 description 2
- 229910001845 yogo sapphire Inorganic materials 0.000 description 2
- RUDFQVOCFDJEEF-UHFFFAOYSA-N yttrium(III) oxide Inorganic materials [O-2].[O-2].[O-2].[Y+3].[Y+3] RUDFQVOCFDJEEF-UHFFFAOYSA-N 0.000 description 2
- 229910052688 Gadolinium Inorganic materials 0.000 description 1
- 229910052779 Neodymium Inorganic materials 0.000 description 1
- 208000037656 Respiratory Sounds Diseases 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 230000004523 agglutinating effect Effects 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 238000009388 chemical precipitation Methods 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 238000010891 electric arc Methods 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 230000003628 erosive effect Effects 0.000 description 1
- 238000007667 floating Methods 0.000 description 1
- UIWYJDYFSGRHKR-UHFFFAOYSA-N gadolinium atom Chemical compound [Gd] UIWYJDYFSGRHKR-UHFFFAOYSA-N 0.000 description 1
- VBJZVLUMGGDVMO-UHFFFAOYSA-N hafnium atom Chemical compound [Hf] VBJZVLUMGGDVMO-UHFFFAOYSA-N 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- FZLIPJUXYLNCLC-UHFFFAOYSA-N lanthanum atom Chemical compound [La] FZLIPJUXYLNCLC-UHFFFAOYSA-N 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 239000003595 mist Substances 0.000 description 1
- QEFYFXOXNSNQGX-UHFFFAOYSA-N neodymium atom Chemical compound [Nd] QEFYFXOXNSNQGX-UHFFFAOYSA-N 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 238000009738 saturating Methods 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 238000004544 sputter deposition Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000005382 thermal cycling Methods 0.000 description 1
Classifications
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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
- C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
- C23C4/11—Oxides
-
- 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
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
- C23C28/32—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer
- C23C28/321—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer with at least one metal alloy layer
- C23C28/3215—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer with at least one metal alloy layer at least one MCrAlX layer
-
- 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
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
- C23C28/34—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates
- C23C28/345—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer
- C23C28/3455—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer with a refractory ceramic layer, e.g. refractory metal oxide, ZrO2, rare earth oxides or a thermal barrier system comprising at least one refractory oxide layer
-
- 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
- C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
-
- 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
- C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
-
- 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
- C23C4/12—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
- C23C4/18—After-treatment
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
- F01D5/288—Protective coatings for blades
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Plasma & Fusion (AREA)
- Physics & Mathematics (AREA)
- Inorganic Chemistry (AREA)
- Ceramic Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Coating By Spraying Or Casting (AREA)
- Application Of Or Painting With Fluid Materials (AREA)
- Laminated Bodies (AREA)
- Turbine Rotor Nozzle Sealing (AREA)
- Other Surface Treatments For Metallic Materials (AREA)
Abstract
本发明描述了用多孔分段热阻挡涂层涂覆的制品。所述涂层具有小于理论密度的约88%的密度。本发明还描述了多层制品和施用所述热阻挡涂层到制品的方法。
Description
相关申请的交叉引用
本申请要求2014年2月21日提交的美国临时专利申请号61/942,984的权益,其公开内容通过引用明确地结合到本文中。
技术领域
本发明通常所属的技术领域为热喷雾工艺涂层。
背景
热喷雾为其中将各种材料以加热或熔融形式喷雾到表面上的涂覆方法。所述涂覆材料通常通过电等离子体或电弧加热。所使用的涂覆材料尤其包括例如金属、合金和陶瓷的物质。根据预定用途,涂层品质一般通过例如密度、孔隙度、抗烧结性、导热率、耐应变性等要点测量。许多要点可影响这些及其他涂层性质,例如所使用的涂覆材料的细节、所使用的等离子体气体的细节、流速、功率水平、喷嘴距离(torch distance)、基材的细节等。由于其性质,这些类型的涂层通常用于保护结构材料免受高温、腐蚀、侵蚀、磨损等。因此,持续探求改进用于这些用途以及其他用途的这些涂层的性质和性能的方式。
本文所述的方法和材料满足上述挑战,包括改进的涂层性质和性能等其它要点。
概要
本发明描述了施用热阻挡涂层到制品的方法,其包括将等离子体加热的颗粒涂覆材料热喷雾到所述制品的表面上,以产生具有小于理论密度的约88%的密度的多孔分段热阻挡涂层。
另外的实施方案包括:上述方法,其中所述涂覆材料用级联等离子体枪或常规热喷雾等离子体枪如9M或F4枪施用;上述方法,其中所述涂覆材料用例如SinplexPro™等离子体枪或TriplexPro™等离子体枪的级联电弧枪技术施用;上述方法,其中氩气作为初次等离子体气体使用;上述方法,其中氢气作为二次等离子体气体使用;上述方法,其中等离子体焓为约14,000KJ/Kg-约24,000KJ/Kg;上述方法,其中所述等离子体焓为约18,000KJ/Kg;上述方法,其中氩气与氢气的比率为约6:1至约18:1;上述方法,其中氩气与氢气的比率为约9:1至约12:1;上述方法,其中所述涂覆材料的进料速率为约30g/min至约180g/min;上述方法,其中所述进料速率为约60g/min至约120g/min;上述方法,其中平均喷雾颗粒温度为约2700℃-约3300℃;上述方法,其中平均喷雾颗粒温度为约2700℃-约3300℃;上述方法,其中平均喷雾颗粒速度为约180m/s-约280m/s;上述方法,其中权利要求30的方法,其中平均喷雾颗粒速度为约190m/s-约250m/s;上述方法,其中涂层具有等于或小于约4.9g/cc的密度;上述方法,其中所述涂层具有约4.2g/cc-约4.9g/cc的密度;上述方法,其中所述涂层具有约3.0g/cc-约5.5g/cc的密度;上述方法,其中所述涂层具有至少约5个宏观裂纹/线性英寸;上述方法,其中所述涂层具有约5-约60个宏观裂纹/线性英寸;上述方法,其中所述涂层具有大于约5体积%、优选高达20体积%且可高达25体积%的孔隙度;上述方法,其中所述涂覆材料包含用氧化镁、氧化铈、氧化钇、氧化镱、dysposia、氧化钆、氧化铒、氧化钕、氧化镧和/或氧化锶中的一种或多种稳定的氧化锆,其量一般为约5-约75重量%、优选为约5-约50重量%且更优选为约5-约15重量%;上述方法,其中氧化铪代替至少部分(或所有)的氧化锆。上述方法,其中所述涂覆材料为氧化钇稳定的氧化锆。
另外的实施方案还包括:上述方法,其包括在所述制品上施用至少一个抗氧化粘合涂层;上述方法,其中其包括在所述粘合涂层的顶部施用致密的传统氧化钇稳定的氧化锆层;上述方法,其包括在所述粘合涂层的顶部施用致密分段的氧化钇稳定的氧化锆层;上述方法,其包括在所述粘合涂层的顶部施用至少一个中间涂层;上述方法,其包括在所述粘合涂层的顶部施用至少一个顶涂层;上述方法,其中所述中间涂层包括传统多孔氧化钇稳定的氧化锆、致密涂层、多孔分段涂层和/或致密分段涂层中的至少一个层;上述方法,其中所述顶涂层包括传统多孔氧化钇稳定的氧化锆、致密涂层、多孔分段涂层和/或致密分段涂层中的至少一个层;上述方法,其包括施用至少一个多孔分段涂层作为中间涂层;上述方法,其包括施用至少一个多孔分段涂层作为顶涂层;上述方法,其中所述粘合涂层的厚度达到约200微米;上述方法,其中所述中间涂层的厚度达到约400微米;上述方法,其中所述中间涂层的厚度为约50微米-400微米;上述方法,其中所述顶涂层的厚度达到约800微米;上述方法,其中所述顶涂层的厚度为约100微米-约800微米;上述方法,其中所述中间涂层包括耐应变涂层的至少一个层;上述方法,其中所述粘合涂层包含MCRAlY,其中M为Ni、Co和/或Fe;上述方法,其中所述粘合涂层为NiCr、NiAl和/或NiCrAlY;上述方法,其中所述粘合涂层另外含有少量、例如痕量至0.6重量%的Re、Hf和/或Si;上述方法,其中所述涂层具有在与传统氧化锆热阻挡涂层相比较时减小的导热率、在与传统氧化锆热阻挡涂层相比较时高的耐应变性、在与传统氧化锆热阻挡涂层相比较时高的抗烧结性和/或改进的热循环寿命;上述方法,其中所述颗粒具有约10微米-约176微米的粒度;上述方法,其中所述涂覆材料或粉末的表观密度为约1.0克/立方厘米-约3.0克/立方厘米;上述方法,其中在所述颗粒中的总氧化物杂质小于约0.5重量%;上述方法,其中所述氧化物来自包括但不限于SiO2、Al2O3、氧化铁、氧化钠、CaO、MgO和/或TiO2的组;上述方法,其中在所述颗粒中的总氧化物杂质小于约0.15重量%;上述方法,其中所述粉末含有小于约0.05重量%的铀和/或钍;上述方法,其中所述粉末含有小于约0.02重量%的铀和/或钍;上述方法,其中所述粉末包含含有约75重量%等离子体致密化的颗粒和约25重量%喷雾干燥的粉末的双峰分布;上述方法,其中所述等离子体致密化的粉末的直径为约11µm-约75µm且所述喷雾干燥的粉末的直径为约75µm-约180µm。另外,所述粉末可为等离子体致密化的粉末、团聚并烧结的粉末、熔合并粉碎的粉末或喷雾干燥的粉末或以变化百分数的这些粉末的任何组合。
还描述了用多孔分段热阻挡涂层涂覆的制品,其中所述涂层具有小于理论密度的约88%的密度。
另外的实施方案包括:上述制品,其中所述涂层具有约3.0g/cc-约5.5g/cc的密度、约5个宏观裂纹/线性英寸-约60个微观裂纹/线性英寸和约5体积%至高达约25体积%的孔隙度;上述制品,其中所述涂层包含用氧化镁、氧化铈、氧化钇、氧化镱、dysposia、氧化钆、氧化铒、氧化钕、氧化镧和/或氧化锶中的一种或多种稳定的氧化锆;上述制品,其中氧化铪代替至少部分的氧化锆;上述制品,其中所述涂层包含氧化钇稳定的氧化锆;上述制品,其包括在所述制品上的至少一个抗氧化的粘合涂层;上述制品,其包括在所述粘合涂层的顶部的致密传统或分段的氧化钇稳定的氧化锆层;上述制品,其包括在所述粘合涂层的顶部的至少一个中间涂层;上述制品,其包括在所述粘合涂层的顶部的至少一个顶涂层;上述制品,其包括至少一个多孔分段涂层作为中间或顶涂层。
本发明的其他例示性实施方案和优势可通过回顾本公开和附图来确定。
附图简述
本发明在以下详述中参照所提到的多个附图通过本发明的例示性实施方案的非限制性实施例进一步描述,且其中:
图1A、1B和1C示出如本文所述的各种涂覆制品的示意图;
图2示出典型的热阻挡涂层;
图3示出如本文所述的典型的热阻挡涂层。
详述
在此示出的特例作为例示且仅出于说明性讨论本发明的各种实施方案的目的,并且以提供认为是本发明的原理和概念方面的最有用且易于理解的描述的原因而呈现。在这方面,除了为基本理解本发明所必需的外,不曾试图更详细地显示本发明的细节,说明书使得本领域技术人员显而易见的是本发明的几种形式是怎样在实际中体现的。
现在将参考更详细的实施方案描述本发明。然而,本发明可以不同形式体现且不应将其视为局限于本文所阐述的实施方案。相反,提供这些实施方案从而使本公开更加透彻且完整,且将对本领域的技术人员充分表达本发明的范围。
除非另作定义,否则本文所用的所有技术和科学术语都具有与本发明所属领域的技术人员通常理解的含义相同的含义。在本文中在本发明的说明书中使用的术语只是出于描述特定实施方案的目的,并非旨在限制本发明。除非在上下文中明确地指出,否则如在本发明的描述和随附权利要求中所使用,单数形式“一个/种”和“所述”还旨在包括复数形式。本文提到的所有出版物、专利申请、专利及其他参考文献都通过引用以其整体明确地结合到本文中。
除非另外指出,否则在说明书和权利要求中使用的表达成分的量、反应条件等的所有数值在所有情况下都应该理解为由术语“约”修饰。因此,除非指出相反情况,否则以下说明书和随附权利要求中陈述的数值参数都是近似值,其可根据设法通过本发明获得的所要性质而改变。最起码的是,而且并不试图限制与本权利要求的范围等效的原则的应用,应该根据有效数字的数目且通过普通舍入方法解释各数值参数。
尽管陈述本发明的广泛范围的数值范围和参数是近似值,但应尽可能准确地报道在具体实施例中陈述的数值。然而,任何数值内在地含有由其相应试验测量中见到的标准偏差必要地产生的某些误差。在本说明书中给出的每一数值范围均包括落入这一较宽数值范围内的每一较窄数值范围,如同这个较窄数值范围在本文中全部明确地写出一样。
本发明的额外优势将在随后的描述中部分地陈述,且在某种程度上将自该描述而显而易见或可为通过实施本发明来学习。应理解上述概述与以下详述两者都只是例示性和说明性的,且并非限制如所要求保护的本发明。
热阻挡涂层是众所周知的,其包括具有垂直裂纹的那些。存在公开具有垂直裂纹的热阻挡涂层的许多出版物和专利。然而,这些涂层一般具有致密的微观结构。例如,Taylor的美国专利5,073,433号和Taylor等人的美国专利8,197,950号公开了具有大于理论密度的88%的5.47g/cc (克/立方厘米)-5.55g/cc的密度的分段涂层。这些美国专利各自的公开内容通过引用以其整体明确地结合到本文中。
本文描述涂层和制备这种涂层的方法,其中所述涂层有利地高度耐应变且具有低导热率。所述涂层还有利地为用于高温应用的抗烧结热阻挡涂层,其可保护金属部件且利用一个或多个抗氧化粘合涂层。
图1A示出如本文所述的基本结构,其中基材材料(10)用也如本文所述的热阻挡顶涂层(11)涂覆。在图1B和1C中示出的其他选项包括多层形式,包括在基材上增加粘合涂层(12)和任选的中间层(13)。
图2示出如例如在Advances in Thermal Spray Coatings for Gas Turbines and Energy Generation: A Review, Journal of Thermal Spray Technology,第22卷(第5期),第564-576页,2013年6月中描述的典型致密的垂直开裂的热阻挡涂层(TBC)涂层,其公开内容通过引用以其整体明确地结合到本文中。参考图2,示出用热阻挡涂层(22)涂覆的基材材料(21)。还可以看到孔(23)和宏观裂纹(24)。
图3示出根据本发明且具有约20%的孔隙度和每英寸约35个垂直宏观裂纹的多孔且分段的等离子体喷雾的氧化锆-氧化钇(YSZ)涂层的抛光横截面。参考图3,示出用热阻挡涂层(32)涂覆的基材材料(31)。还可以看到孔(33)和宏观裂纹(34)。
将有利地制备具有小于理论密度的88%的涂层密度的空气等离子体喷雾的分段涂层。这类涂层可通过控制颗粒熔融状态和应力水平以增加涂层的孔隙度来制备。增加的孔隙度可有利地增加涂层抗烧结性,降低导热率并促进耐应变性增强,特别是在与垂直裂纹组合时。
本文所述的制品包括与现有涂层相比具有减小的导热率、较高耐应变性、较高抗烧结性和改进的抗热循环疲劳性的热阻挡涂层。可制备所述热阻挡涂层,其具有多孔且垂直分段的微观结构。该涂层可例如有利地为氧化钇稳定的氧化锆(YSZ)涂层,其具有4.2g/cc-4.9g/cc范围的典型密度或者其中所述涂层具有约3.0g/cc-约5.5g/cc的密度,且具有约5-约60个宏观裂纹/线性英寸的垂直裂纹密度。这些涂层一般具有比传统致密分段热阻挡涂层高1.4-1.6倍的热循环寿命。所述涂层可使用常规热喷雾技术和如本文所述改进的设备等离子体喷雾。
根据本发明制备的涂层的非限制性实施例包括以下内容。
实施例
多孔分段氧化钇稳定的氧化锆热阻挡涂层通过等离子体喷雾YSZ球状粉末形成。YSZ粉末由7重量%氧化钇和余量的氧化锆组成,其具有5µm-180µm且优选11µm-125µm范围的粒度。可能的双峰分布可利用75重量%的等离子体致密化的材料(粒度为11µm-75µm范围)以及25重量%的喷雾干燥的材料(粒度为75µm-180µm范围)。可能的径直材料可利用具有粒度11µm-110µm的等离子体致密化的YSZ粉末。将YSZ粉末径向注入等离子体喷枪中。在实施方案中,等离子体喷枪利用级联枪技术且可为TriplexPro™-210等离子体枪、SinplexPro™等离子体枪或甚至常规等离子体枪,例如由Oerlikon Metco制备的F4枪或9MB枪。当涂层在金属或陶瓷复合基材的顶部施用时,优选利用级联枪技术的等离子体枪。
在等离子体喷雾期间,应该控制等离子体喷雾参数,使得一些颗粒完全熔融,而一些颗粒将仅部分地熔融或保持未熔融。一般地,应该在基材上施用涂层之前将基材预热到约500℃。
以此方式施用的YSZ涂层可有利地具有合乎需要的孔隙度且由完全熔融的溅射物(splat)以及部分熔融和未熔融的颗粒构成。该YSZ涂层也可有利地具有约4.2g/cc-约4.9g/cc范围(即,小于理论密度的88%)的密度,且可包括沿平行于基材表面的线测量的约5-约60个垂直宏观裂纹/线性英寸。还可预期该YSZ涂层表现出合乎需要的性质,例如低导热率、大大改进的抗烧结性和增强的耐应变性。
在上述实施例中,已经证实利用7-8重量% (wt%) YSZ材料且通过已知OerlikonMetco HOSP方法制备的涂层。然而,本发明不受此限制且可扩展到使用各种粉末制造方法的许多不同氧化锆热阻挡体系。
在非限制性实施例中,可利用许多类型的材料体系,例如:用氧化镁、氧化铈、氧化钇、氧化镱、dysposia、氧化钆、氧化铒、氧化钕、氧化镧、氧化锶的一种或多种组合稳定的氧化锆体系。氧化铪可代替部分或全部的氧化锆。
另外,可使用许多类型的材料制造方法,例如如下制造方法:其利用喷雾干燥的粉末制造路径或工艺(0-100重量%预合金化或0-100重量%未反应的组成)以及有机粘合剂;喷雾干燥并烧结的材料;喷雾干燥并等离子体致密化的材料;以及各种制造路径中的两种或更多种的化学沉淀共混物。还可利用根据这三种制造路径中的一种或多种制备的熔合并粉碎的材料的共混物。
在非限制性实施例中,粉末性质可包括下列:约10-约176微米的粒度;约1.0g/cc-约3.0g/cc的表观密度;如下纯度,其中例如SiO2、Al2O3、氧化铁、氧化钠、CaO、MgO和TiO2的氧化物的总杂质低于0.5重量%且优选小于0.15重量%;如下放射性,小于0.05重量%铀和钍且优选小于0.02重量%;可能的双峰分布,其可利用75重量%的等离子体致密化的材料(粒度为11µm-75µm范围)以及25重量%的喷雾干燥的材料(粒度为75µm-180µm范围)。
在非限制性实施例中,所述涂层可为利用抗氧化粘合涂层和多孔分段顶涂层的双层体系,或利用在抗氧化粘合涂层的顶部的7-8重量% YSZ的致密传统体系或甚至致密分段YSZ的多层体系。所述涂层也可为具有变化涂层微观结构的多层涂层,其包括在抗氧化粘合涂层基材上的一个或多个中间涂层和一个或多个顶涂层。所述中间涂层可为传统多孔YSZ涂层、致密涂层、多孔分段涂层、致密分段涂层或其任何组合的一层或数层。所述一个顶涂层或多个顶涂层可为传统多孔YSZ涂层、致密涂层、多孔分段涂层、致密分段涂层或其任何组合的一层或数层。在多层涂层应用中,所述一个或多个多孔分段涂层可至少表现为中间涂层或顶涂覆层。典型的涂层厚度可包括至多200微米的粘合涂层、约50-400微米的中间涂层和约100-约800微米的顶涂层。
在非限制性实施方案中,粘合涂覆层一般可为NiCr、NrAl、NiCrAlY或其他含MCRAlY的材料,其中M代表Ni、Co和/或铁的组合。所述MCrAlY材料还可含有痕量的Re、Hf、Si。
所产生的涂覆制品具有多孔分段热阻挡涂层,其中所述涂层具有小于理论密度的约88%的密度。另外的非限制性实施方案包括:上述制品,其中所述涂层具有等于或小于约4.9g/cc的密度;上述制品,其中所述涂层具有约4.2g/cc-约4.9g/cc的密度;上述制品,其中所述涂层具有约3.0g/cc-约5.5g/cc的密度;上述制品,其中所述涂层具有至少约5个宏观裂纹/线性英寸;上述制品,其中所述涂层具有约5-约60个宏观裂纹/线性英寸;上述制品,其中所述涂层具有大于约5体积%、优选高达20体积%且可高达25体积%的孔隙度;上述制品,其中所述涂层包含用氧化镁、氧化铈、氧化钇、氧化镱、dysposia、氧化钆、氧化铒、氧化钕、氧化镧和/或氧化锶中的一种或多种稳定的氧化锆;上述制品,其中氧化铪代替至少部分的氧化锆;上述制品,其中所述涂层为氧化钇稳定的氧化锆。
另外的非限制性实施方案还包括:上述制品,其包括在所述制品上的至少一个抗氧化的粘合涂层;上述制品,其包括在所述粘合涂层的顶部的致密传统7-8重量%的氧化钇稳定的氧化锆层;上述制品,其包括在所述粘合涂层的顶部的致密分段的氧化钇稳定的氧化锆层;上述制品,其包括在所述粘合涂层的顶部的至少一个中间涂层;上述制品,其包括在所述粘合涂层的顶部的至少一个顶涂层;上述制品,其中所述中间涂层包括传统多孔氧化钇稳定的氧化锆、致密涂层、多孔分段的涂层和/或致密分段的涂层中的至少一个层;上述的制品和方法,其中所述中间层可为:1) 传统5-10重量%的YSZ涂层结构,2) 具有小于5%孔隙度的致密YSZ或3) 致密分段的YSZ;上述制品,其中所述顶涂层包括传统多孔氧化钇稳定的氧化锆、致密涂层、多孔分段涂层和/或致密分段涂层中的至少一个层;上述制品,其包括至少一个多孔分段涂层作为中间涂层;上述制品,其包括至少一个多孔分段涂层作为顶涂层;上述制品,其中所述粘合涂层的厚度达约200微米;上述制品,其中所述中间涂层的厚度达约400微米;上述制品,其中所述中间涂层的厚度为约50微米-400微米;上述制品,其中所述顶涂层的厚度高达约800微米;上述制品,其中所述顶涂层的厚度为约100微米-约800微米;上述制品,其中所述中间涂层包括耐应变涂层的至少一个层;上述制品,其中所述粘合涂层包含MCRAlY,其中M为Ni、Co和/或Fe;上述制品,其中所述粘合涂层为NiCr、NiAl和/或NiCrAlY;上述制品,其中所述粘合涂层另外含有少量、例如痕量至0.6重量%的Re、Hf和/或Si;上述制品,其中所述涂层具有在与传统氧化锆热阻挡涂层相比较时减小的导热率、在与传统氧化锆热阻挡涂层相比较时高的耐应变性、在与传统氧化锆热阻挡涂层相比较时高的抗烧结性和/或改进的热循环寿命。
应注意到这类粉末制造方法可影响涂层微观结构。粉末纯度、粉末粒度、输入粉末的热以及在粉末与喷雾参数之间的内在关系可影响涂层微观结构以及构造成实现最佳微观结构,例如多孔且分段的TBC。
另外,应该注意到捕获在热阻挡涂层内用于降低导热率、改进抗烧结性和增加热循环寿命的半熔融和未熔融的金属氧化物颗粒的重要性。
根据本发明的一个有利的实施方案,多孔分段涂层可通过利用具有9mm喷雾嘴的SinplexPro™等离子体枪形成。氩气和氢气分别作为初次等离子体气体和二次等离子体气体使用。所使用的等离子体焓可为14000KJ/Kg(千焦耳/千克)-24000KJ/Kg范围,优选为18000KJ/Kg。氩气与氢气的比率可为6-18,优选为9-12。进料速率可为30g/min(克/分钟)-180g/min,优选为60g/min-120g/min范围。平均颗粒温度和速度可分别为2700℃-3300℃、180m/s(米/秒)-280m/s范围。优选平均温度为2700℃-3000℃且平均速度为190m/s-250m/s。
应注意到上述实施例仅出于解释的目的提供且无论如何也不被视为限制本发明。虽然已经参照例示性实施方案描述了本发明,但是应当理解本文使用的词语是描述性和说明性的词语,而不是限制性的词语。可以在不偏离本发明各方面范围和精神的前提下,在如同当前陈述及修改的随附权利要求书的范围内进行各种变化。尽管在本文中参考特定的方式、材料和实施方案描述本发明,但本发明并不旨在限于本文公开的特例;相反,本发明延伸至例如在随附权利要求的范围内的所有功能上等效的结构、方法和用途。
Claims (20)
1.施用热阻挡涂层到制品的方法,其包括将等离子体加热的粉末涂覆材料热喷雾到所述制品的表面上,以产生具有3.0g/cc-5.5g/cc的密度并且具有5个宏观裂纹/线性2.54cm-60个宏观裂纹/线性2.54cm的垂直裂纹密度的多孔分段热阻挡涂层。
2.根据权利要求1所述的方法,其中所述涂层具有5体积%至高达25体积%的孔隙度。
3.根据权利要求1所述的方法,其中所述涂覆材料包含用氧化镁、氧化铈、氧化钇、氧化镱、氧化镝、氧化钆、氧化铒、氧化钕、氧化镧和/或氧化锶中的一种或多种稳定的氧化锆。
4.根据权利要求3所述的方法,其中氧化铪代替至少部分的氧化锆。
5.根据权利要求1所述的方法,其包括在施加所述热阻挡涂层之前,在所述制品上施用至少一个抗氧化粘合涂层。
6.根据权利要求5所述的方法,其包括在施加所述热阻挡涂层之前,在所述粘合涂层的顶部施用致密的或分段的氧化钇稳定的氧化锆层。
7.根据权利要求5所述的方法,其包括在施加所述热阻挡涂层之前,在所述粘合涂层的顶部施用至少一个中间涂层。
8.根据权利要求5所述的方法,其包括在施加所述热阻挡涂层之前,在所述粘合涂层的顶部施用至少一个顶涂层。
9.根据权利要求7所述的方法,其包括施用至少一个多孔分段涂层作为所述中间涂层。
10.根据权利要求8所述的方法,其包括施用至少一个多孔分段涂层作为所述顶涂层。
11.用多孔分段热阻挡涂层涂覆的制品,其中所述涂层具有3.0g/cc-5.5g/cc的密度并且具有5个宏观裂纹/线性2.54cm-60个宏观裂纹/线性2.54cm的垂直裂纹密度。
12.根据权利要求11所述的制品,其中所述涂层具有5体积%至高达25体积%的孔隙度。
13.根据权利要求11所述的制品,其中所述涂层包含用氧化镁、氧化铈、氧化钇、氧化镱、氧化镝、氧化钆、氧化铒、氧化钕、氧化镧和/或氧化锶中的一种或多种稳定的氧化锆。
14.根据权利要求13所述的制品,其中氧化铪代替至少部分的氧化锆。
15.根据权利要求11所述的制品,其中所述涂层包含氧化钇稳定的氧化锆。
16.根据权利要求11所述的制品,其包括在所述制品和所述热阻挡涂层之间的至少一个抗氧化粘合涂层。
17.根据权利要求16所述的制品,其包括在所述粘合涂层的顶部,且在所述热阻挡涂层之下的致密的或分段的氧化钇稳定的氧化锆层。
18.根据权利要求16所述的制品,其包括在所述粘合涂层的顶部,且在所述热阻挡涂层之下的至少一个中间涂层。
19.根据权利要求18所述的制品,其包括在所述粘合涂层的顶部,且在所述热阻挡涂层之下的至少一个顶涂层。
20.根据权利要求19所述的制品,其含有至少一个多孔分段涂层作为所述中间涂层或所述顶涂层。
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