CN106191752A - A kind of thermal barrier coating melt surface deposit protective coating and preparation method thereof - Google Patents
A kind of thermal barrier coating melt surface deposit protective coating and preparation method thereof Download PDFInfo
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Abstract
A kind of thermal barrier coating melt surface deposit protective coating and preparation method thereof, described thermal barrier coating includes at least one tack coat and at least one ceramic layer, described tack coat is coated in described high temperature alloy matrix surface, described ceramic layer coats is in described tie layer surface, the described ceramic layer contacted with described tack coat is for based on yittrium oxide PSZ material layer, described surface ceramii layer is also coated with protective coating, described protective coating uses alumina base dusty spray, uses Supersonic Plasma Spraying technique to prepare.The preparation method of this protective coating, including alumina base dusty spray drying and processing, clamping workpiece also adjusts parameter, the spray gun utilizing Supersonic Plasma Spraying equipment produces plasma flame flow and uniformly preheats described thermal barrier coating surface, open powder feeding, at alumina base dusty spray 1-3 described in described thermal barrier coating surface spraying all over to form described protective coating.
Description
Technical field
The present invention relates to a kind of thermal barrier coating melt surface deposit protective coating and preparation method thereof, particularly
A kind of high energy, high speed Supersonic Plasma Spraying technique is utilized to prepare fine and close, thin alumina base protective coating
Thermal barrier coating melt surface deposit protective coating and preparation method thereof.
Background technology
Thermal barrier coating (Thermal Barrier Coating, TBC) is the resistance to height utilizing ceramic material excellent
Warm, heat insulation, corrosion resistance, by a kind of high temperature knot compound mutually to pottery and metallic matrix in the way of coating
Structure material surface guard technology, generally by the ceramic topcoats of lower thermal conductivity and has with metallic matrix, ceramic topcoats
It is made up of the metal bonding coating of good coefficient of thermal expansion matching.The use of thermal barrier coating can significantly improve aviation
Engine high-temperature hot-end component operating temperature, improves hot-end component service life, thus improves gas turbine and send out
The motivation thermal efficiency.
Since 20 century 70s, oxidation zirconio thermal barrier coating (Thermal Barrier Coatings,
TBCs) it is applied successfully to protect aero-engine and turbine blade of gas turbine, combustor and other height
Temperature parts, 6～8wt%Y2O3-ZrO2(being referred to as 8YSZ yittrium oxide PSZ) material has
There is the most excellent characteristic, as big in high tenacity, high intensity, good thermal shock resistance, thermal coefficient of expansion,
Anticorrosive etc., there is important using value in fields such as a lot of Aeronautics and Astronautics.8YSZ is up to now
Heat barrier coat material the most classical, obtains in terms of aero-engine and gas turbine and widely applies.
Along with aero-engine thrust-weight ratio and thermal efficiency of gas turbine improve constantly, its turbine inlet temperature is the most continuous
Improving, before advanced aero-turbine, temperature is higher than 1500 DEG C, and currently advanced Gas Turbine
Front temperature is also above 1400 DEG C.List of references 1David R C, Matthias O, Nitin P P.
Thermal-barrier coatings for more efficient gas-turbine engines[J].
MRS Bulletin, 2012,37 (10): 891-898 and list of references 2Carlos G L, John W H,
Marie-Hélène Vidal-Sétif,Curtis A J.Environmental degradation of
thermal barrier coatings by molten deposits[J].MRS Bulletin,2012,
Describing melted CMAS deposit in 37 (10): 932-941 is that following higher efficiency gas turbine starts
The key problem that must take into during machine thermal barrier coating service.CMAS basic ingredient be dust in air,
The impurity such as Na, Ca, S, P, the K in the melted complex of mineral and volcanic ash etc. and fuel oil, it has relatively
Low melting point (1230-1250 DEG C), during thermal barrier coating service, meeting fusion sediment is to thermal barrier coating surface,
Simultaneously can be along ceramic coating cosmetic bug (hole and micro-crack, column crystal gap etc.), even more microcosmic
Grain boundary sites penetrates into coat inside, be deposited on coating surface CMAS deposit can increase coat inside heat should
Power, penetrates into coat inside CMAS and ceramic coating can be caused to accelerate sintering and the closing of pores, coating heat insulation
Effect and mechanical performance can substantially decay；SiO in CMAS simultaneously2The Y in 8YSZ can be dissolved2O3, cause it
High-temperature stability reduces, and phase transformation unstability is occurred to early；Simultaneously because Ca in CMAS2+It is diffused into YSZ crystal grain
In the middle of, 8YSZ can be caused to accelerate sintering, CaO can replace Y simultaneously2O3As ZrO2Stabilizer, this meeting
Causing the 8YSZ material too early phase transformation unstability with excellent high temperature stability, above CMAS is to 8YSZ thermal boundary
The impact of coating can cause coating premature failure, coating service life to significantly reduce.
CMAS smelt deposits is the most progressively paid attention to by domestic and international scientific research personnel, how to delay or to solve
CMAS smelt deposits is following efficiently boat on impact and the too early Damage and Failure in thermal barrier coating service life-span
The key problem that empty electromotor and gas turbine must be examined.At present both at home and abroad noble metal protective coating,
The aspects such as thermal barrier coating top layer laser melting coating densification, heat barrier coat material doping vario-property have carried out exploration
Journal of Sex Research.
In order to be effectively improved the thermal cycle of thermal barrier coating under CMAS smelt deposits and high temperature combustion environment
In the life-span, utilize optimization design and the optimum preparation condition of protective coating layer micro structure, a kind of low cost of proposition,
High efficiency and effectively delay the CMAS safeguard structure to thermal barrier coating failure effect, is current high-performance gas
The key technical problem that turbogenerator hot-end component protective coating is urgently to be resolved hurrily.
Summary of the invention
The technical problem to be solved is to thermal barrier coating premature failure for CMAS smelt deposits
Impact, it is provided that a kind of thermal barrier coating melt surface deposit protective coating and preparation method thereof, prepare one
Plant high-compactness, uniform, thin alumina base thin layer protective coating, to delay the infiltration rate of CMAS,
Reduce the CMAS impact on coating premature failure, improve thermal barrier coating under high-temperature fuel gas and CMAS coupling condition
Thermal cycle life.
To achieve these goals, the invention provides a kind of thermal barrier coating melt surface deposit protection to be coated with
Layer, this thermal barrier coating is attached to high temperature alloy matrix surface, and wherein, described thermal barrier coating includes that at least one glues
Knot layer and at least one ceramic layer, described tack coat is coated in described high temperature alloy matrix surface, described ceramic layer
Being coated in described tie layer surface, the described ceramic layer contacted with described tack coat is for steady based on yittrium oxide part
Determining zirconia material layer, described surface ceramii layer is also coated with protective coating, and described protective coating uses oxidation
Aluminum base dusty spray, uses Supersonic Plasma Spraying technique to prepare.
Above-mentioned thermal barrier coating melt surface deposit protective coating, wherein, described protective coating average thickness
For 5-15 μm, the porosity of described protective coating is less than 5%.
Above-mentioned thermal barrier coating melt surface deposit protective coating, wherein, described alumina base dusty spray
In comprise the rare earth oxide Re of 0-10mol.%2O3, to form ReAlO in described protective coating3Or
Re3Al5O12。
Above-mentioned thermal barrier coating melt surface deposit protective coating, wherein, described rare earth oxide Re2O3
For Gd2O3、Y2O3、Sm2O3、Nd2O3Or La2O3In one or more.
Above-mentioned thermal barrier coating melt surface deposit protective coating, wherein, described alumina base dusty spray
Particle size range be 45 μm-75 μm, 15 μm-45 μm or 5 μm-25 μm.
In order to above-mentioned target is better achieved, present invention also offers a kind of thermal barrier coating melt surface deposit
The preparation method of protective coating, wherein, this thermal barrier coating is attached to high temperature alloy matrix surface, described thermal boundary
Coating includes at least one tack coat and at least one ceramic layer, and described tack coat is coated in described high temperature alloy matrix
Surface, described ceramic layer coats at described tie layer surface, the described ceramic layer contacted with described tack coat is
Based on yittrium oxide PSZ material layer, described surface ceramii layer is also coated with protective coating, described
The preparation of protective coating comprises the steps:
S100, alumina base dusty spray drying and processing, be 45 μm-75 μm, 15 μm-45 by particle size range
The alumina base dusty spray of μm or 5 μm-25 μm carries out oven drying at low temperature process, described oxygen in an oven
Change aluminum base dusty spray and should have good mobility；
S200, clamping workpiece also adjust parameter, are installed in frock by the workpiece preparing described thermal barrier coating,
Open Supersonic Plasma Spraying equipment and adjusting process parameter be as follows:
Voltage: 150-160V；
Electric current: 400-450A；
Main gas: 80-90L/min；
Secondary gas: 9-10L/min；
Carrier gas flux: 6-8L/min；
Powder sending quantity: 8-20g/min；
Spray gun flutter rate: 300-1000mm/s；
S300, utilize Supersonic Plasma Spraying equipment spray gun produce plasma flame flow uniformly preheat described heat
Barrier coating surface, preheating temperature is 200-500 DEG C；
S400, unlatching powder feeding, at alumina base dusty spray 1-3 described in described thermal barrier coating surface spraying
All over to form described protective coating.
The preparation method of above-mentioned thermal barrier coating melt surface deposit protective coating, wherein, described protection is coated with
Layer average thickness is 5-15 μm, and the porosity of described protective coating is less than 5%.
The preparation method of above-mentioned thermal barrier coating melt surface deposit protective coating, wherein, described aluminium oxide
Base dusty spray comprises the rare earth oxide Re of 0-10mol.%2O3, to be formed in described protective coating
ReAlO3Or Re3Al5O12。
The preparation method of above-mentioned thermal barrier coating melt surface deposit protective coating, wherein, described rare earth oxygen
Compound Re2O3For Gd2O3、Y2O3、Sm2O3、Nd2O3Or La2O3In one or more.
The preparation method of above-mentioned thermal barrier coating melt surface deposit protective coating, wherein, described step
After S400, also include:
S500, post processing, be processed by shot blasting described protective coating to reduce described protective coating further
Surface roughness.
The method have technical effect that:
The present invention utilizes high energy, on thermal barrier coating surface, preparation causes the Supersonic Plasma Spraying technique of high speed
Close, thin alumina base protective coating, by system fading margin spray power, powder sending quantity, spray gun flutter rate
Deng, improve and coating layer touch smelt deposits CMAS (CaO-MgO-Al2O3-SiO2) fusing point, reduce be coated with
Layer surface roughness, reduces CMAS and adheres to have higher-density prevention fusion sediment with protective coating self
Thing penetrates into, and then delays the CMAS smelt deposits infiltration reagentia to coating under hot environment, at CMAS
Smelt deposits and high-temperature fuel gas act on down jointly, significantly improve the thermal cycle life of thermal barrier coating.In nothing
Under CMAS smelt deposits simulated conditions, on coating thermal cycle life substantially without impact.There is preparation technology
Simply, different size parts thermal barrier coating surfacecti proteon demand, working (machining) efficiency high are met.
Particularly, the thermal barrier coating melt surface deposit protective coating of the present invention is used to have following prominent excellent
Point:
1) alumina base protective coating thin, fine and close self has good high-temperature stability, will not be right
Heat-barrier coating ceramic layer composition and characteristic produce and significantly affect, the protective coating of average thickness 5-15 μm simultaneously
To thermal barrier coating thermal mismatching stress influence less, can give full play to dissimilar thermal barrier coating has possessed
Good thermal cycle life advantage；
2) protective coating has relatively low porosity (< 5%), can effectively delay CMAS smelt deposits
Infiltration；Meanwhile, the protective coating of low porosity, can reduce Coating Surface Roughness, reduce high-temperature fusion
The attachment of deposit CMAS；
3) thermal barrier coating of protective coating is prepared, under CMAS coupling condition, to feature thermal barrier coating and system
After standby protective coating, coating has carried out thermal cycle life test, and result of the test shows to prepare protective coating coating
At 1200 DEG C thermal cycle life relatively do not prepare protective coating coating improve 1.5 times-4 times (utilize document 3
Proposed in thermal cycle experiment method: He Qing, Wu Peng, Qu Yi, Wang Ruijun, Wang Weiping. Yi Zhongxin
Thermal barrier coating thermal cycle experiment method [J] under type CMAS coupling condition. material engineering, 2014,12:
92-98)；
4) coating thermal cycle conditions in the Thermal cycle oxidation not coupling CMAS and stove of protective coating is prepared
Under, thermal cycle life in cyclic oxidation life-span of thermal barrier coating and stove is coated with without impact, mainly thermal boundary substantially
Layer surface alumina oxide base protective coating be thermal barrier coating provide obstruction oxygen particle high temperature penetrate, reduce thermal boundary
Tie layer surface oxidation rate in coating；Thin layer protective coating is to thermal barrier coating thermal mismatching stress influence simultaneously
Less；
5) described protective coating and preparation method thereof have the advantage that is not limit thermal barrier coating self
Characteristic, has wide range of application, and relative vacuum plated film prepares noble metal protective coating and laser melting coating
The techniques such as surface densification process, have that preparation cost is low, can to prepare large-scale part surface heat barrier coating anti-
Protect coating, preparation efficiency advantages of higher.
Describe the present invention below in conjunction with the drawings and specific embodiments, but not as to the present invention's
Limit.
Accompanying drawing explanation
Figure 1A is that one embodiment of the invention prepares protective coating post plasma spraying thermal barrier coating Cross Section Morphology
Figure；
Figure 1B is one embodiment of the invention Thermal Barrier Coating Layers Prepared By Plasma Spraying ceramic layer and surface protection coating local
Shape appearance figure；
Fig. 2 A, 2B prepare protective coating in respectively one embodiment of the invention Thermal Barrier Coating Layers Prepared By Plasma Spraying surface
Forward and backward surface roughness test result；
Fig. 3 is not for preparing protective coating plasma spraying coating under CMAS coated conditions 1250 DEG C, 2h
Coating cross sections pattern after high-temperature heat treatment；
Fig. 4 is that one embodiment of the invention prepares after protective coating under CMAS coated conditions 1250 DEG C, 2h
Coating cross sections pattern after high-temperature heat treatment；
Fig. 5 is that (left side is anti-for not preparing for coating relative thermal cycling life test result under CMAS coupling condition
Protecting coating data, the right is for preparing data after protective coating)；
Fig. 6 be prepared by Fig. 4 protective coating thermal barrier coating thermal cycle lost efficacy after Cross Section Morphology；
Fig. 7 for prepare under conditions of coupling without CMAS before and after protective coating the thermal barrier coating cyclic oxidation life-span with
Stove interior-heat cycling life test result.
Wherein, reference
10 high temperature alloy matrixes
20 thermal barrier coatings
21 tack coats
22 ceramic layers
30 protective coatings
Detailed description of the invention
Structural principle and operation principle to the present invention are described in detail below in conjunction with the accompanying drawings:
Seeing Figure 1A-2B, Figure 1A is that one embodiment of the invention prepares protective coating post plasma spraying thermal boundary
Coating cross sections shape appearance figure, wherein thermal barrier coating is made up of matrix, metal bonding coating and ceramic layer, wherein glues
Knot layer and ceramic layer are at least one layer, and its ceramic layer can be one or more layers, wherein contacts with metal bonding coating
One layer should be yittrium oxide PSZ, contact ceramic layer, Ying Gao with alumina base protective coating
Temperature is lower and between protective coating without mutual chemical reaction, Figure 1A is for using Supersonic Plasma Spraying preparation gold
Belong to tack coat and air plasma spraying prepares ceramic topcoats, then use Supersonic Plasma Spraying technique system
The Cross Section Morphology of standby alumina base protective coating.Figure 1B is that one embodiment of the invention plasma spraying thermal boundary is coated with
Layer ceramic layer and surface protection coating local shape appearance figure, for the pattern after this protective coating partial enlargement, figure
It is forward and backward that 2A, 2B prepare protective coating in respectively one embodiment of the invention Thermal Barrier Coating Layers Prepared By Plasma Spraying surface
Surface roughness test result.The thermal barrier coating melt surface deposit protective coating of the present invention, this thermal boundary is coated with
Layer is attached to high temperature alloy matrix surface, and described thermal barrier coating includes at least one tack coat and at least one pottery
Layer, described tack coat is coated in described high temperature alloy matrix surface, and described ceramic layer coats is at described tack coat
Surface, the described ceramic layer contacted with described tack coat is based on yittrium oxide PSZ material layer,
Described surface ceramii layer is also coated with protective coating, and described protective coating uses alumina base dusty spray, makes
Prepare by Supersonic Plasma Spraying technique.Heat-barrier coating ceramic layer preparation technology be usually plasma spraying and
Electro beam physics vapour deposition, in plasma spraying coating, the defect such as micro-crack, hole and electron-beam are regulated the flow of vital energy
Between deposition column Jingjing, gap all can cause the infiltration of CMAS smelt deposits under the conditions of high-temperature service mutually,
The present invention in order to delay low melting point CMAS smelt deposits, be prepared for as shown in FIG. 1A and 1B fine and close,
Thin alumina base protective coating.
Wherein, described protective coating average thickness is preferably 5-15 μm, and the porosity of described protective coating is little
In 5%.Described alumina base dusty spray comprises the rare earth oxide Re of 0-10mol.%2O3, with institute
State formation ReAlO in protective coating3Or Re3Al5O12.Described rare earth oxide Re2O3For Gd2O3、Y2O3、Sm2O3、
Nd2O3Or La2O3In one or more, one or more rare earth oxides therein can be comprised.Rare earth oxygen
Compound (Re2O3) interpolation, can in alumina base coating formed ReAlO3Or Re3Al5O12, this chemical combination
Thing high-temperature thermodynamics is stable, and rare earth compound dissolves and enters in CMAS smelt deposits simultaneously, can be further
Improve CMAS fusing point, optimum effect is played in CMAS protection.The granularity model of described alumina base dusty spray
Enclose is 45 μm-75 μm, 15 μm-45 μm or 5 μm-25 μm.
The preparation method of the thermal barrier coating melt surface deposit protective coating of the present invention, wherein, this thermal boundary is coated with
Layer is attached to high temperature alloy matrix surface, and described thermal barrier coating includes at least one tack coat and at least one pottery
Layer, described tack coat is coated in described high temperature alloy matrix surface, and described ceramic layer coats is at described tack coat
Surface, the described ceramic layer contacted with described tack coat is based on yittrium oxide PSZ material layer,
Described surface ceramii layer is also coated with protective coating, and the preparation of described protective coating comprises the steps:
Step S100, alumina base dusty spray drying and processing, by particle size range be 45 μm-75 μm, 15
The alumina base dusty spray of μm-45 μm or 5 μm-25 μm carries out oven drying at low temperature process in an oven,
Described alumina base dusty spray should have good mobility；
Step S200, clamping workpiece also adjust parameter, are installed on by the workpiece preparing described thermal barrier coating
In frock, open Supersonic Plasma Spraying equipment and adjusting process parameter be as follows:
Voltage: 150-160V；
Electric current: 400-450A；
Main gas (argon): 80-90L/min；
Secondary gas (hydrogen): 9-10L/min；
Carrier gas flux: 6-8L/min；
Powder sending quantity: 8-20g/min；
Spray gun flutter rate: 300-1000mm/s；
Step S300, utilize Supersonic Plasma Spraying equipment spray gun produce plasma flame flow uniformly preheat
Described thermal barrier coating surface, preheating temperature is 200-500 DEG C, to thermal barrier coating surface preheating temperature requirement is
200-500 DEG C, it is to avoid too low preheating temperature can not form dense coating, when also avoiding temperature too high simultaneously,
Protective coating produces more horizontal stroke, longitudinal crack, thus coordinates spraying parameter, control and improve protection
Coating quality；
Step S400, unlatching powder feeding, at alumina base dusty spray described in described thermal barrier coating surface spraying
1-3 is all over to form described protective coating.
In the present embodiment, after described step S400, also include:
Step S500, post processing, be processed by shot blasting to reduce further described anti-to described protective coating
Protect the surface roughness of coating.
After completing above-mentioned steps, metallographic method and gray level method is utilized to test average thickness and the hole of protective coating respectively
Gap rate, protective coating average thickness is 5-15 μm, and porosity is less than 5%.Protective coating as shown in Figure 1B
THICKNESS CONTROL in the requirement of 5-15 μm, main consider alumina base protective coating and heat-barrier coating ceramic layer it
Between difference existing for hot physical property, mechanical performance, such as thermal coefficient of expansion, elastic modelling quantity, this difference can be at pottery
Enamel coating produces thermal mismatching stress, in order to reduce the impact on heat-barrier coating ceramic layer performance, in the present invention
Control protective coating thickness in the range of 5-15 μ m thick.
Using Supersonic Plasma Spraying technique to prepare dense coating, prepared protective coating porosity is less than
When 5%, can substantially slow down CMAS infiltration at high temperature, reduce the surface roughness of coating simultaneously.Fig. 2 A,
2B is for preparing Coating Surface Roughness test result before and after protective coating, before preparing protective coating, plasma
Spraying thermal barrier coating surface roughness Ra be 8.2 μm, Rz be 51.92 μm, after preparing protective coating,
Ra is reduced to 7.5 μm, and Rz is reduced to 44.65 μm；The reduction of Coating Surface Roughness can reduce cold
The adhesion of CMAS under hot alternation condition, is conducive to delaying the impact of CMAS smelt deposits.
Prepare before and after protective coating coating 1250 DEG C, under the conditions of 2h heat treatment, coat identical before heat treatment
Surface density CMAS (33%CaO+7.2%MgO+12.7%Al2O3+ 46.7%SiO2+ 0.4%Bal (wt.%)), enter
The simulation that under row high temperature, thermal barrier coating is affected by CMAS, does not prepares the thermal barrier coating of protective coating after heat treatment
Cross Section Morphology is not as it is shown on figure 3, prepare protective coating thermal barrier coating surface C MAS at high-temperature heat treatment process
In seriously penetrate into coat inside, CMAS smelt deposits enters inside ceramic layer simultaneously, is filled with pottery
The defects such as enamel coating inner pore and micro-crack；CMAS creates dissolution phenomena to part heat-barrier coating ceramic layer,
Portion ceramic layer occurs in that powdery feature.Fig. 4 is for cutting after preparing alumina base protective coating heat treatment
Face pattern, has no that CMAS substantially penetrates into after preparing protective coating, substantially occurs in CMAS deposit layer simultaneously
Strip wollastonite phase, illustrates in alumina base coating that aluminium oxide or rare earth oxide dissolve and enters CMAS
In, improve and contact CMAS layer fusing point with protective coating.
Utilize above-mentioned document 3 " a kind of thermal barrier coating thermal cycle experiment method under novel C MAS coupling condition "
In novel C MAS coupling condition under thermal barrier coating thermal cycle life test method, under same test conditions
(coating surface 1200 DEG C, 900 DEG C of the matrix back side are incubated 5min, 1%CMAS conveying in insulating process)
To preparing protective coating and not preparing the existing Thermal Barrier Coating Layers Prepared By Plasma Spraying of protective coating and carry out life span comparison
Research, the relative thermal cycling life test result of coating as it is shown in figure 5, thermal barrier coating as shown in Figure 1A,
Relatively not preparing protective coating coating, coating relative thermal cycle life is improved to 5.35 by 1, increase rate
More than 4 times.Fig. 6 is to prepare heat under protective coating coating high-temp combustion gas and CMAS coupling condition in Fig. 5
Coating cross sections morphology analysis after circulation inefficacy, above protective coating, CMAS smelt deposits is not penetrated into pottery
Layer is internal, and CMAS is set in above protective coating simultaneously, owing to protective coating reduces Coating Surface Roughness
With there is good compactness, cause occurring in that between CMAS and protective coating transversal crack, illustrate protection be coated with
Layer can effectively hinder CMAS to penetrate into and attachment.
In order to verify described thermal barrier coating after preparing protective coating to coating high-temp performance impact, the most right
Coating thermal cycle life affect, respectively 1050 DEG C, insulation 55min, cooling 5min be one circulation bar
Under part and 1100 DEG C, insulation 5min, cooling 5min be to have carried out preparing protective coating under a cycling condition
The test of thermal cycle life, result of the test such as Fig. 7 in the most existing thermal barrier coating cyclic oxidation life-span and stove
Shown in, do not prepare protective coating existing thermal barrier coating cyclic oxidation 1500h and disbonding, preparation protection occur
After coating, there is not disbonding in 1500h；Do not prepare thermal cycle life in protective coating existing thermal barrier coating stove
Reaching 8100 times, preparing coating thermal cycle life after above-mentioned protective coating is 7700 times, prepared by explanation
Protective coating is under the conditions of average thickness 5-15 μm, porosity are less than 5%, and the protective coating of dense thin is to warm
In barrier coating ceramic layer, thermal mismatching application impact is less, under the conditions of the cold cycling coupled without CMAS,
On the cycle life of thermal barrier coating substantially without impact.
The specific implementation process of the present invention be exemplified below:
Embodiment 1
Protective coating is prepared on normal atmospheric Thermal Barrier Coating Layers Prepared By Plasma Spraying surface.
Step S100: by purity be 99.5%, particle size range be the melting breaking type alumina base of 5-25 μm
Powder carries out 100 DEG C, 2h drying and processing in an oven, containing 5mol%Gd in dusty spray2O3(Gadolinia .)；
Step S200: prepared by certain type gas turbine DZ40M alloy vane surface HVAF
NiCrAlY metal bonding coating, normal atmospheric plasma spraying prepare the workpiece dress of nanometer 8YSZ thermal barrier coating
Block to rotary tooling, open Supersonic Plasma Spraying equipment, and it is as follows to adjust device parameter:
Voltage: 150V；
Electric current: 420A；
Main gas (argon): 90L/min；
Secondary gas (hydrogen): 9L/min；
Carrier gas flux: 6.5L/min；
Powder sending quantity: 10g/min；
Spray gun flutter rate: 500mm/s.
Step S300: uniformly preheat described thermal barrier coating, preheating temperature is 200-300 DEG C；
Step S400: carrying out protective coating at described surface of the work and come and go spraying, spraying pass is 2 times.
Above-mentioned surface of the work thermal barrier coating is carried out dissection and analysis, the thickest by metallographic method test protective coating
Degree and hole, average thickness is 9.8 μm, and porosity is 2.2%.
Above-mentioned surface of the work thermal barrier coating is coated with density is 30mg/cm2CMAS, be higher than at 1250 DEG C
Carrying out heat treatment 2h and 5h under the conditions of CMAS fusing point, cooldown rate is 5 DEG C/min, and checking CMAS penetrates into
Situation, by visual inspection, is had no that CMAS substantially penetrates into, is analyzed by Cross Section Morphology, without CMAS after 2h
Penetrating into, after 5h, CMAS trace penetrates into.After 2h heat treatment, CMAS and protective coating contact site knot of tissue
Structure is different from other positions, has wollastonite to be changed into anorthite, and fusing point significantly improves.
Embodiment 2
Protective coating is prepared on normal atmospheric Thermal Barrier Coating Layers Prepared By Plasma Spraying surface.
Step S100: by purity be 99.9%, particle size range be the melting breaking type aluminium oxide of 45-75 μm
Based powders carries out 100 DEG C, 2h drying and processing in an oven, containing 1.5mol%Y in dusty spray2O3(oxidation
Gadolinium)；
Step S200: prepared by a size of φ 30 × 3mmK403 alloy sample surface HVAF
NiCoCrAlY metal bonding coating (thickness 0.1mm), normal atmospheric plasma spraying prepare nanometer 8YSZ
The sample of thermal barrier coating (thickness 0.3mm) is installed, and opens Supersonic Plasma Spraying equipment, and adjusts
Device parameter is as follows:
Voltage: 155V；
Electric current: 400A；
Main gas (argon): 80L/min；
Secondary gas (hydrogen): 9.5L/min；
Carrier gas flux: 7.5L/min；
Powder sending quantity: 20g/min；
Spray gun flutter rate: 1000mm/s.
Step S300: uniformly preheat above-mentioned thermal barrier coating, preheating temperature is 300-400 DEG C；
Step S400: carrying out protective coating at above-mentioned surface of the work and come and go spraying, spraying pass is 1 time.
Above-mentioned surface of the work thermal barrier coating is carried out dissection and analysis, the thickest by metallographic method test protective coating
Degree and hole, average coating thickness is 9.9 μm, and porosity is 4.9%.In the test preparation of this sample surfaces
Coating Surface Roughness before and after protective coating, before preparation, Ra is 8.81 μm, and after preparation, coating surface is coarse
Degree is 6.92 μm.Under above-mentioned identical thermal cycle conditions, protective coating is not prepared in test and preparation protection is coated with
The thermal cycle life of layer coating, under CMAS coupling condition, does not prepares the circulation of protective coating coating relative thermal
Life-span is 0.8, and after preparing protective coating, its relative thermal cycle life is 4.2, improves more than 4 times.
Embodiment 3
Protective coating is prepared on Supersonic Plasma Spraying thermal barrier coating surface.
Step S100: by purity be 99.9%, particle size range be the reunion slug type aluminium oxide of 15-45 μm
Based powders carries out 100 DEG C, 2h drying and processing in an oven, containing 10mol%Sm in dusty spray2O3；
Step S200: will prepare at IC10 single crystal alloy specimen surface HVAF
The fine and close 8YSZ thermal barrier coating (hole of NiCoCrAlYHfSi metal bonding coating, Supersonic Plasma Spraying preparation
Gap rate is 5%) sample be installed, and open Supersonic Plasma Spraying equipment, and adjust device parameter such as
Under:
Voltage: 160V；
Electric current: 430A；
Main gas (argon): 90L/min；
Secondary gas (hydrogen): 10L/min；
Carrier gas flux: 8L/min；
Powder sending quantity: 8.5g/min；
Spray gun flutter rate: 300mm/s.
Step S300: uniformly preheat above-mentioned thermal barrier coating, preheating temperature is 400-500 DEG C；
Step S400: carrying out protective coating at above-mentioned surface of the work and come and go spraying, spraying pass is 1 time.
Above-mentioned surface of the work thermal barrier coating is carried out dissection and analysis, the thickest by metallographic method test protective coating
Degree and hole, average coating thickness is 8.9 μm, and porosity is 2.8%.In the test preparation of this sample surfaces
Coating Surface Roughness before and after protective coating, before preparation, Ra is 6.8 μm, Coating Surface Roughness after preparation
It is 5.71 μm.Under identical thermal cycle conditions described above, protective coating is not prepared in test and preparation is anti-
Protect the thermal cycle life of coating coating, under CMAS coupling condition, do not prepare protective coating coating relative thermal
Cycle life is 1.5, and after preparing protective coating, its relative thermal cycle life is 4.1, improve 1.5 times with
On.
Embodiment 4
Protective coating is prepared on Electron Beam-Physical Vapor Deposited Thermal Barrier Coatings surface.
Step S100: by purity be 99.9%, particle size range be the melting breaking type aluminium oxide of 45-75 μm
Based powders carries out 100 DEG C, 2h drying and processing in an oven, containing 3mol%Y in dusty spray2O3With
5mol%Gd2O3；
Step S200: NiCrAlYSi will be deposited at nickel base superalloy specimen surface multi-arc ion plating process
Metal bonding coating, electro beam physics vapour deposition are prepared the sample of 8YSZ thermal barrier coating and are installed, and open super
Velocity of sound plasma spraying equipment, and it is as follows to adjust device parameter:
Voltage: 155V；
Electric current: 450A；
Main gas (argon): 80L/min；
Secondary gas (hydrogen): 9L/min；
Carrier gas flux: 7L/min；
Powder sending quantity: 8.1g/min；
Spray gun flutter rate: 400mm/s.
Step S300: uniformly preheat above-mentioned thermal barrier coating, preheating temperature is 200-300 DEG C；
Step S400: carrying out protective coating at above-mentioned surface of the work and come and go spraying, spraying pass is 1 time.
Above-mentioned surface of the work thermal barrier coating is carried out dissection and analysis, the thickest by metallographic method test protective coating
Degree and hole, average coating thickness is 5.5 μm, and porosity is 4.3%.In the test preparation of this sample surfaces
Coating Surface Roughness before and after protective coating, before preparation, Ra is 3.1 μm, Coating Surface Roughness after preparation
It is 2.92 μm.Use fine sandpaper to carry out follow-up polishing on protective coating surface, polish rear protecting coating
Surface roughness is 1.85 μm.Under identical thermal cycle conditions described above, test is not prepared protection and is coated with
Layer and the thermal cycle life preparing protective coating coating, under CMAS coupling condition, do not prepare protective coating
Coating relative thermal cycle life is 7.5, and after preparing protective coating, its relative thermal cycle life is 25.2, carries
High more than 2 times.
Embodiment 5
Protective coating is prepared on double ceramic layer thermal barrier coating surfaces.
Step S100: by purity be 99.5%, particle size range be the melting breaking type aluminium oxide of 45-75 μm
Powder carries out 100 DEG C, 2h drying and processing in an oven, without rare earth oxide in dusty spray；
Step S200: will nickel base superalloy specimen surface plasma spraying NiCrAlY metal bonding coating,
Plasma spraying prepares 8YSZ, La2Zr2O7The sample of double ceramic layer thermal barrier coatings is installed, and opens supersonic speed
Plasma spraying equipment, and it is as follows to adjust device parameter:
Voltage: 156V；
Electric current: 420A；
Main gas (argon): 85L/min；
Secondary gas (hydrogen): 8.5L/min；
Carrier gas flux: 6.5L/min；
Powder sending quantity: 8.5g/min；
Spray gun flutter rate: 800mm/s.
Step S300: uniformly preheat above-mentioned thermal barrier coating, preheating temperature is 200-300 DEG C；
Step S400: carrying out protective coating at above-mentioned surface of the work and come and go spraying, spraying pass is 3 times.
Above-mentioned surface of the work thermal barrier coating is carried out dissection and analysis, the thickest by metallographic method test protective coating
Degree and hole, average coating thickness is 14.5 μm, and porosity is 4.7%.In the test preparation of this sample surfaces
Coating Surface Roughness before and after protective coating, before preparation, Ra is 7.52 μm, and after preparation, coating surface is coarse
Degree is 6.97 μm.Under above-mentioned identical thermal cycle conditions, test and do not prepare protective coating and preparation protection
The thermal cycle life of coating coating, under CMAS coupling condition, does not prepares protective coating coating relative thermal and follows
The ring life-span is 2.5, and after preparing protective coating, its relative thermal cycle life is 7.8, improves more than 2 times.
Embodiment 6
Protective coating is prepared on double ceramic layer thermal barrier coating surfaces.
Step S100: by purity be 99.95%, particle size range be the reunion slug type aluminium oxide of 15-45 μm
Based powders carries out 100 DEG C, 2h drying and processing in an oven, containing 3mol%Nd in dusty spray2O3With
3mol%La2O3；
Step S200: will be at nickel base superalloy specimen surface Supersonic Plasma Spraying NiCoCrAlY gold
Belong to tack coat, plasma spraying prepares the double ceramic layer thermal barrier coating of 8YSZ, 18YSZ prefabricated vertical crack structure
Sample be installed, and open Supersonic Plasma Spraying equipment, and it be as follows to adjust device parameter:
Voltage: 160V；
Electric current: 420A；
Main gas (argon): 90L/min；
Secondary gas (hydrogen): 9L/min；
Carrier gas flux: 7L/min；
Powder sending quantity: 10g/min；
Spray gun flutter rate: 600mm/s.
Step S300: uniformly preheat above-mentioned thermal barrier coating, preheating temperature is 300-400 DEG C；
Step S400: carrying out protective coating at above-mentioned surface of the work and come and go spraying, spraying pass is 2 times.
Above-mentioned surface of the work thermal barrier coating is carried out dissection and analysis, the thickest by metallographic method test protective coating
Degree and hole, average coating thickness is 9.7 μm, and porosity is 3.62%.In the test preparation of this sample surfaces
Coating Surface Roughness before and after protective coating, before preparation, Ra is 6.97 μm, and after preparation, coating surface is coarse
Degree is 6.36 μm.Under above-mentioned identical thermal cycle conditions, protective coating is not prepared in test and preparation protection is coated with
The thermal cycle life of layer coating, under CMAS coupling condition, does not prepares the circulation of protective coating coating relative thermal
Life-span is 4.5, and after preparing protective coating, its relative thermal cycle life is 13.5, improves more than 1.5 times.
Above example is all for existing thermal barrier coating, and when not describing coating layer thickness, plasma spraying thermal boundary is coated with
Layer adhesive layer thickness is 0.08-0.10mm, and ceramic layer thickness is 0.23-0.27mm；Electron beam physical vapor
Deposition coating layer thickness is tack coat 0.04-0.06mm, and ceramic layer thickness is 0.10-0.12mm；Plasma spray
Being coated with double ceramic layer composite coating adhesive layer thickness is 0.08-0.10mm；Ceramic layer thickness is respectively
0.12-0.15mm.The present invention does not limit thermal barrier coating its thickness and coating structure, in different structure coating
Surface all can be implemented.
The present invention uses high energy, the Supersonic Plasma Spraying technique of high speed is coated with at the thermal boundary with different characteristic
Fine and close, very thin alumina base protective coating, system fading margin spray power, powder sending quantity, spray are prepared in layer surface
It is that porosity is less than 5%, average thickness is the dense oxide of 5 μm-15 μm that rifle flutter rate obtains thickness
Aluminum base thin layer protective coating, protective coating can reduce thermal barrier coating surface roughness simultaneously.This protective coating
Less to thermal barrier coating thermal mismatching stress influence, the high-temperature hot that can give full play to dissimilar thermal barrier coating is followed
Ring life-span advantage；Protective coating can effectively delay the high temperature of CMAS deposit to penetrate into, it is possible to decrease CMAS
Adhesion after deposit solidification, under high-temperature gradient, gas heating, CMAS coupling condition, preparation should
After protective coating, the thermal cycle life of thermal barrier coating can improve 1.5 times-4 times.Prepare this protection to be coated with simultaneously
After Ceng, stress influence thermally matched to thermal barrier coating is less, under the conditions of without the cold cycling of CMAS, to heat
The impact of barrier coating cycle life is little.The present invention has delayed the damage to thermal barrier coating of smelt deposits CMAS,
Dramatically increase the thermal cycle life of thermal barrier coating under high-temperature fuel gas and CMAS coupling, make the thermal barrier coating can
High temperature alloy matrix to be provided the protective action of longer time.
Described protective coating is steady to CMAS smelt deposits protection predominantly alumina base protective coating high temperature
Qualitative, the compactness of protective coating and its special composition, make aluminium oxide, aluminic acid rare-earth salts or rare earth oxide
Can be partly dissolved entrance and contact in CMAS with protective coating, the alumina base protection slowly consuming sacrifice is coated with
Layer can change the wollastonite (CaSiO of low melting point3) it is anorthite (CaAl mutually2Si2O8), improve CMAS layer
Fusing point and high-temperature stability with coating layer touch position；The high-compactness of protective coating can reduce CMAS and melt
The infiltration of deposit；The relatively low surface roughness of protective coating can reduce the adhesion of CMAS layer；Described protection
Coating is to thermal barrier coating matrix, tack coat and ceramic layer microstructure, material and process of preparing, coating
Thickness does not do restriction further, can prepare this protective coating on dissimilar thermal barrier coating surface, but high temperature makes
With when under environment, alumina base protective coating is existed solid state reaction with contact thermal barrier coating, this system thermal boundary is coated with
Layer is not suitable for preparing described protective coating.
Certainly, the present invention also can have other various embodiments, without departing substantially from present invention spirit and the feelings of essence thereof
Under condition, those of ordinary skill in the art work as can make various corresponding change and deformation according to the present invention, but
These change accordingly and deform the protection domain that all should belong to appended claims of the invention.
Claims (10)
1. a thermal barrier coating melt surface deposit protective coating, this thermal barrier coating is attached to high temperature alloy
Matrix surface, it is characterised in that described thermal barrier coating includes at least one tack coat and at least one ceramic layer, institute
State tack coat and be coated in described high temperature alloy matrix surface, described ceramic layer coats in described tie layer surface,
The described ceramic layer contacted with described tack coat is based on yittrium oxide PSZ material layer, described pottery
Enamel coating surface is also coated with protective coating, and described protective coating uses alumina base dusty spray, uses Supersonic
Prepared by speed plasma spray coating process.
2. thermal barrier coating melt surface deposit protective coating as claimed in claim 1, it is characterised in that
Described protective coating average thickness is 5-15 μm, and the porosity of described protective coating is less than 5%.
3. thermal barrier coating melt surface deposit protective coating as claimed in claim 1 or 2, its feature
It is, described alumina base dusty spray comprises the rare earth oxide Re of 0-10mol%2O3, with described
Protective coating is formed ReAlO3Or Re3Al5O12。
4. thermal barrier coating melt surface deposit protective coating as claimed in claim 3, it is characterised in that
Described rare earth oxide Re2O3For Gd2O3、Y2O3、Sm2O3、Nd2O3Or La2O3In one or more.
5. the thermal barrier coating melt surface deposit protective coating as described in claim 1,2 or 4, it is special
Levy and be, the particle size range of described alumina base dusty spray be 45 μm-75 μm, 15 μm-45 μm or
5μm-25μm。
6. the preparation method of a thermal barrier coating melt surface deposit protective coating, it is characterised in that should
Thermal barrier coating is attached to high temperature alloy matrix surface, and described thermal barrier coating includes at least one tack coat and at least
Ceramic layer, described tack coat is coated in described high temperature alloy matrix surface, and described ceramic layer coats is described viscous
Knot layer surface, the described ceramic layer contacted with described tack coat is for based on yittrium oxide PSZ material
Layer, described surface ceramii layer is also coated with protective coating, and the preparation of described protective coating comprises the steps:
S100, alumina base dusty spray drying and processing, be 45 μm-75 μm, 15 μm-45 by particle size range
The alumina base dusty spray of μm or 5 μm-25 μm carries out oven drying at low temperature process, described oxygen in an oven
Change aluminum base dusty spray and should have good mobility；
S200, clamping workpiece also adjust parameter, are installed in frock by the workpiece preparing described thermal barrier coating,
Open Supersonic Plasma Spraying equipment and adjusting process parameter be as follows:
Voltage: 150-160V；
Electric current: 400-450A；
Main gas: 80-90L/min；
Secondary gas: 9-10L/min；
Carrier gas flux: 6-8L/min；
Powder sending quantity: 8-20g/min；
Spray gun flutter rate: 300-1000mm/s；
S300, utilize Supersonic Plasma Spraying equipment spray gun produce plasma flame flow uniformly preheat described heat
Barrier coating surface, preheating temperature is 200-500 DEG C；
S400, unlatching powder feeding, at alumina base dusty spray 1-3 described in described thermal barrier coating surface spraying
All over to form described protective coating.
7. the preparation method of thermal barrier coating melt surface deposit protective coating as claimed in claim 6,
It is characterized in that, described protective coating average thickness is 5-15 μm, and the porosity of described protective coating is less than
5%.
The preparation side of thermal barrier coating melt surface deposit protective coating the most as claimed in claims 6 or 7
Method, it is characterised in that comprise the rare earth oxide Re of 0-10mol% in described alumina base dusty spray2O3,
To form ReAlO in described protective coating3Or Re3Al5O12。
9. the preparation method of thermal barrier coating melt surface deposit protective coating as claimed in claim 8,
It is characterized in that, described rare earth oxide Re2O3For Gd2O3、Y2O3、Sm2O3、Nd2O3Or La2O3In one
Plant or multiple.
10. the system of the thermal barrier coating melt surface deposit protective coating as described in claim 6,7 or 9
Preparation Method, it is characterised in that after described step S400, also include:
S500, post processing, be processed by shot blasting described protective coating to reduce described protective coating further
Surface roughness.
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| CN108300959A (en) * | 2018-04-26 | 2018-07-20 | 东莞市华鑫激光科技有限公司 | A kind of preparation method for the insulative ceramic coatings being sprayed at metal surface |
| CN108838041A (en) * | 2018-06-13 | 2018-11-20 | 福建工程学院 | A kind of coating method of energy-saving heat preserving coating |
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