CN106458776A - 用于收缩顺从性的使用空心体的激光施釉 - Google Patents

用于收缩顺从性的使用空心体的激光施釉 Download PDF

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CN106458776A
CN106458776A CN201580023491.4A CN201580023491A CN106458776A CN 106458776 A CN106458776 A CN 106458776A CN 201580023491 A CN201580023491 A CN 201580023491A CN 106458776 A CN106458776 A CN 106458776A
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hollow body
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enamel
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杰拉尔德·J·布鲁克
艾哈迈德·卡迈勒
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Abstract

将空心体(18)并入到形成于基底(12)上的釉质材料层(10)中。利用能量束(22)加热粉状釉材料(16)和所述空心体以熔化所述釉材料而不熔化所述空心体，因为所述空心体具有相对更高的熔融温度。所述空心体提供了一定程度的机械顺从性，其防止所述釉质材料层在再凝固后开裂。在另一些实施方案中，在基底(32、52)上形成材料熔池(38、56)并且迫使空心球(40、54)进入紧邻移动束之后的所述熔融材料中。

Description

用于收缩顺从性的使用空心体的激光施釉
技术领域
本发明一般涉及材料技术领域，并且更特别地涉及用于在材料的表面施釉的方法。
背景技术
自古代起，施釉就已经用于在陶瓷物品上形成光滑的装饰性纹理。生陶瓷物品在送入窖中烧制之前通常涂覆干的或者含水的釉混合物。釉混合物可包含玻璃形成剂(例如二氧化硅)、用于降低二氧化硅的熔融温度的助熔剂(例如钠、钙或钾金属氧化物)和用于防止釉从局部流失的硬化剂(例如氧化铝)。
最近，激光能量已经被用作对超级合金燃气涡轮发动机部件上的陶瓷热障涂层材料施釉以保护涂层不被污染物氧化、腐蚀和熔渗的热源。然而，在激光熔化期间产生的极度局部热瞬态可造成釉质表面的开裂。美国专利5576069描述了一种两步法来修复这样的开裂，其涉及施加氧化锆粉末薄层，然后在预热基底的同时进行二次激光再熔化步骤，以使热梯度最小化。
附图说明
通过考虑附图的以下描述解释了本发明，附图示出了：
图1示出了利用结合有空心体的釉质材料的施釉方法。
图2示出了其中将空心体引入熔融基底材料中的施釉方法。
图3示出了利用釉质材料和熔化后引入空心体的施釉方法。
发明内容
本发明人已发现，激光施釉开裂问题的现有技术解决方案不令人满意，因为这样的两步法和专门的热处理增加了时间和成本。因此，本发明人已开发了一种新的施釉方法和施釉的产品，其克服了釉质表面开裂的问题。不像现有技术当前所做的那样修复开裂并且限制修复期间的热瞬态，本发明人首先避免开裂的产生。这不是通过采用特定的热处理限制热应力来实现的，而是通过调节出现的热应力实现的。这是通过将小的空心体引入釉熔体中实现的。空心体提供了一定程度的机械顺从性来以适应釉凝固期间的收缩应力，因此防止开裂。
图1示出了本发明的一个实施方案，其中将釉质材料层10沉积在基底12上。基底12可以是任何从接受釉中获益的材料，并且可包括金属合金、陶瓷材料和陶瓷基体复合材料(例如用于燃气涡轮发动机的热气通路部件)。在图1中，基底12可以是沉积在超级合金燃气涡轮发动机部件上的陶瓷热障涂层材料。在该实施方案中，通过使放置在基底12的表面20上的包含粉状釉材料16和空心体18的材料层14熔化并再凝固来形成釉质材料层10。粉状釉材料16可包含具体应用所需要的玻璃形成组分、助熔组分和硬化组分。能量束22(例如离子束或激光束)横过表面20以形成材料熔池24，其如图中箭头的方向所示的横过表面20而前进。
有利地，空心体18不被束22熔化，例如通过由熔融温度比粉状釉材料16更高的材料形成。在束22后面，使熔融材料在空心体18周围凝固以产生釉质表面26。在凝固过程期间空心体18的挠曲适应收缩应力，因此防止开裂。本文中所述的“不熔化”的条件包括空心体18的表面的一些部分偶然熔化，只要物体18维持它们的空心几何结构以提供所述的程度的机械顺从性即可。
空心体18可以是纳米、微米或毫米尺寸，更小的物体通常用于更薄釉质层10。在一个实施方案中，空心体18可以是直径为1.5微米至5微米的空心二氧化硅球，其可从一家微粒公司Microspheres-Nanospheres购得(http：//Microspheres-Nanospheres.com)。可使用其他氧化物材料制成空心体18，如SiO2、TiO2、Al2O3或ZrO2。可使用球以外的空心形状，例如已被开发用于锂离子电池构造的立方二氧化硅颗粒。
图2示出了本发明的一个实施方案，其中在基底32上形成釉质材料层30。在该实施方案中，不使用粉状釉质材料，而是能量束34横过基底32的表面36以形成沿着图中箭头的方向移动的基底材料熔池38。紧邻能量束34之后并且其中熔融基底材料38还未凝固的区域中，迫使多个空心体40进入基底材料熔池38中。然后使熔融材料38在空心体40周围凝固以形成柔顺性的釉质材料层30。在该实施方案中，空心体40没有直接暴露于能量束34的热量，并且因此可以(但是非强制性的)由比图1的实施方案中使用的材料具有更低熔融温度的材料形成空心体40。在一个实施方案中，空心体40由与基底32相同的材料形成，并且尽管其在被引入基底材料熔池38中后可经历一些偶然的表面熔化，但是其充当局部散热器，引起熔融材料的凝固而不熔化物体40。通过这种方式，可向釉质材料层30中引入孔隙和机械顺从性，而不改变其化学组成。在另一个实施方案中，空心球40可由在很高温度(约3642℃)下升华的碳制成，这有利于将空心球40引入到熔融超级合金或MCrAlY基底材料38中。
图3示出了另一个实施方案，其中不含空心体的粉状釉材料50沉积到基底52上，将空心体54引入到紧邻移动能量束58之后的材料熔池56中，在凝固后将其并入釉材料层60中。
尽管在本文中已示出并描述了本发明的多个实施方案，但是显而易见的是这样的实施方案仅以示例的方式被提供。可进行大量的变型、修改和替代，而不脱离本文中的发明。因此，本发明旨在仅受所附权利要求的精神和范围的限制。

Claims (19)

1.一种方法，包括：
引导能量束在基底上产生熔融材料层；
将多个空心体引入所述熔融材料层中；以及
使所述熔融材料在所述空心体周围凝固以产生釉质表面。
2.根据权利要求1所述的方法，还包括：
在所述基底的表面上沉积包含粉状材料和所述空心体的层；以及
引导所述能量束熔化所述粉状材料而不熔化所述空心体，以产生所述熔融材料层。
3.根据权利要求1所述的方法，还包括在所述能量束横过所述表面时将所述空心体引入所述能量束后面的所述熔融材料层中。
4.根据权利要求1所述的方法，还包括：
引导所述能量束熔化所述基底的表面层以产生所述熔融材料层；以及
在所述熔融材料凝固之前，将所述空心体引入所述熔融材料层中。
5.根据权利要求1所述的方法，还包括：
选择熔融温度高于玻璃形成材料的空心体；
在所述基底的表面上沉积所述玻璃形成材料和所述空心体；以及
将所述玻璃形成材料和所述空心体加热到高于所述玻璃形成材料的熔融温度但低于所述空心体的熔融温度的温度。
6.根据权利要求1所述的方法，其中所述基底包含陶瓷材料或金属合金，所述空心体包含碳。
7.根据权利要求1所述的方法，其中所述空心体包含空心球。
8.根据权利要求1所述的方法，其中所述能量束包括激光束。
9.根据权利要求1所述的方法，还包括：
使所述能量束横过所述基底的表面以产生基底材料熔池；
在所述熔融材料凝固之前，迫使空心体进入所述熔融基底材料层中，所述空心体形成为具有与所述基底相同的组成；以及
使所述熔融基底材料在所述空心体周围凝固而不熔化所述空心体。
10.根据权利要求1所述的方法，还包括：
在所述基底的表面上沉积包含粉状釉材料的层；
引导所述能量束熔化所述粉状材料以产生所述熔融材料层；以及
在所述能量束横过所述表面时将所述空心体引入所述能量束后面的所述熔融材料层中。
11.一种通过权利要求1所述的方法形成的产品，其包括：
基底；
设置在所述基底上的釉质材料层；以及
设置在所述釉质材料层中的多个空心体。
12.一种方法，包括：
使激光束横过表面的选定部分以产生熔融材料层；
将多个未熔空心球引入到所述熔融材料层中；以及
使所述熔融材料在所述空心球周围凝固以形成釉质材料层。
13.根据权利要求12所述的方法，还包括：
在所述表面上沉积包含粉状釉质材料和所述空心球的层；以及
使所述激光束横扫以熔化所述粉状釉质材料而不熔化所述空心球，以产生所述熔融材料层。
14.根据权利要求12所述的方法，还包括在所述激光束横过所述表面时将所述空心球引入所述激光束后面的所述熔融材料层中。
15.根据权利要求14所述的方法，其中所述空心球形成为具有与所述表面的组成相同的组成。
16.根据权利要求12所述的方法，还包括：
使所述激光束横过合金材料的表面以产生熔融合金材料层；以及
将多个空心碳球引入到所述熔融合金材料层中。
17.根据权利要求12所述的方法，还包括：
在超级合金燃气涡轮发动机部件的热障涂层的表面上沉积包含所述空心球的釉质材料；
使所述激光束横过所述热障涂层的所述表面的选定部分以产生熔融釉质材料层；
使所述熔融釉质材料层在所述空心球周围凝固，以釉化所述热障涂层材料的所述表面而不引起开裂。
18.一种通过权利要求17所述的方法形成的产品。
19.根据权利要求12所述的方法，还包括：
在所述表面上沉积不含空心球的釉质材料；
使所述激光束横过所述表面的选定部分以形成熔融釉质材料层；
在所述激光束横过所述表面时将所述空心球引入到所述激光束后面的所述熔融材料层中；以及
使所述熔融釉质材料层在所述空心球周围凝固。
CN201580023491.4A 2014-05-01 2015-04-13 用于收缩顺从性的使用空心体的激光施釉 Pending CN106458776A (zh)

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