CN108004543A - 一种抗cmas腐蚀的热障涂层及其制备方法 - Google Patents

一种抗cmas腐蚀的热障涂层及其制备方法 Download PDF

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CN108004543A
CN108004543A CN201711241465.6A CN201711241465A CN108004543A CN 108004543 A CN108004543 A CN 108004543A CN 201711241465 A CN201711241465 A CN 201711241465A CN 108004543 A CN108004543 A CN 108004543A
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thermal barrier
barrier coating
preparation
cmas
coating
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王璐
程玉贤
宋佳
刘礼祥
赵忠兴
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AECC Shenyang Liming Aero Engine Co Ltd
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Abstract

为了解决在役热障涂层易遭受CMAS腐蚀失效等问题，本发明提供了一种新型抗CMAS腐蚀的热障涂层及其制备方法。其特征在于：所述热障涂层由MCrAlY粘结底层、YSZ陶瓷面层和贵金属Pt面层组成，其中M为Ni和/或Co。采用本发明所述新型热障涂层，可以有效防止CMAS的腐蚀，提高热障涂层的可靠性和服役寿命。

Description

一种抗CMAS腐蚀的热障涂层及其制备方法
技术领域
本发明属于热障涂层技术领域，特别提供一种用于高温合金热端部件表面抗环境沉积物(CMAS)腐蚀的热障涂层及其制备方法。
背景技术
热障涂层(Thermal Barrier Coatings，TBCs)是先进航空发动机高温热端部件的关键技术之一，它一般由抗氧化腐蚀性能良好的金属粘结底层(PtAl或MCrAlY，M＝Ni，Co或Ni+Co)和导热系数低的陶瓷面层(Y2O3部分稳定的ZrO2,YSZ)组成。它与高温合金材料技术、冷却技术并重，成为发展高性能航空发动机的关键技术之一。热障涂层在航空发动机上的使用，将使高温合金能够承受更高的服役温度，提高涡轮前燃气进口温度，同时也可使发动机寿命和可靠性大幅度提高，耗油量降低，动力性能显著改善。根据美国航空航天局(NASA)研究工作报道，采用热障涂层，发动机工作温度每提高14～15℃，发动机总推力可增加1～2％；同时，在极限条件下工作的高温合金表面温度每降低14℃，相当于提高工件使用寿命一倍。因此，从可靠性增长、发动机延寿以及其发展型的研制需求来看，热障涂层是先进航空发动机设计不可或缺的选择。
近年来研究发现，航空发动机热障涂层除了要经受高温、热疲劳和机械载荷等作用外，还遭受化学腐蚀、侵蚀和冲刷，其中，一种以CaO、MgO、Al2O3和SiO2等混合氧化物(CMAS)组成的沉积物对热障涂层的性能和服役寿命产生了巨大的影响。CMAS是由于大气中的灰尘、砂石、火山灰及飞机跑道磨屑等颗粒被吸入航空发动机高温燃气流道内(如燃烧室、涡轮叶片等零部件)，在发动机循环的峰值温度(如起飞或降落)时，这些物质形成玻璃态熔融沉积物。CMAS熔体与涂层材料润湿性能良好，它会沿陶瓷层的微裂纹、孔洞等逐渐渗入涂层内部，填充陶瓷层中的空隙，降低了陶瓷层的断裂韧性，并且诱发循环氧化过程中的裂纹萌生。尤其是对于电子束物理气相沉积制备的热障涂层，由于CMAS的渗入，破坏了热障涂层原有的柱状晶结构，降低了涂层的应变容限，从而导致涂层过早发生剥落，影响热障涂层的服役寿命和可靠性。
发明内容
为了解决在役热障涂层易遭受CMAS腐蚀失效等问题，本发明提供了一种新型抗CMAS腐蚀的热障涂层及其制备方法。采用本发明所述方法，可以有效防止CMAS的腐蚀，提高热障涂层的可靠性和服役寿命。
本发明技术方案如下：
一种抗CMAS腐蚀的热障涂层，其特征在于：所述热障涂层由MCrAlY粘结底层、YSZ陶瓷面层和贵金属Pt面层组成，其中M为Ni和/或Si。其中，MCrAlY粘结底层厚度为30～50微米，YSZ陶瓷面层为100～150微米，Pt面层为3～5微米
本发明还提供了所述抗CMAS腐蚀的热障涂层的制备方法，其特征在于，具体制备步骤如下：
步骤1)：对部件进行表面预处理；
步骤2)：采用真空电弧镀、等离子喷涂(APS)或超音速喷涂(HVOF)在部件表面制备抗氧化腐蚀性能良好的MCrAlY金属粘结底层；
步骤3)：对MCrAlY金属粘结底层进行真空扩散热处理和吹砂预处理；
步骤4)：在上述处理后的MCrAlY金属粘结底层表面采用APS或电子束物理气相沉积(EB-PVD)方法制备YSZ陶瓷面层；
步骤5)：采用油石对YSZ陶瓷面层进行抛光处理；
步骤6)：在抛光处理后的YSZ陶瓷面层表面采用磁控溅射或多弧离子镀方法制备贵金属Pt面层。
作为优选的技术方案：
步骤1)中，对部件进行表面预处理的过程为：对部件进行湿吹砂处理，然后进行超声波清洗、丙酮溶液浸洗、烘干；其中湿吹砂工艺参数为：白刚玉砂粒度为180～280目，刚玉砂含量20％～35％，风压0.15MPa～0.25MPa，吹砂距离为180mm～350mm。
步骤2)中，采用真空电弧镀在部件表面制备MCrAlY金属粘结底层的工艺参数为：工作压强＜5.32×10-2Pa，电弧电流700～750A，工件电压30～34V，涂敷时间110～130min，冷却2.0～2.5h后取出。
步骤3)中，对MCrAlY金属粘结底层在1000℃～1050℃温度下进行真空扩散热处理2～4小时，然后进行湿吹砂预处理。
步骤4)中，采用电子束物理气相沉积方法制备YSZ陶瓷面层的工艺参数为：主真空室压强不大于5×10-2Pa，电子枪电压为17～20KV，靶材加热电流为1.5A，工件转速为15r/min，工件加热温度为900～950℃。
步骤5)中，对YSZ陶瓷面层抛光处理至粗糙度为0.8～1.2μm。
步骤6)中，采用多弧离子镀方法制备贵金属Pt面层的工艺参数如下：本地真空度＜7×10-3Pa，试片温度200～300℃，放电气体为氩气，气体分压2～3×10-1Pa，靶电流30～50A，工作负电压50～300V，涂敷时间50～70min，冷却至室温后取出样品。
本发明所述热障涂层用于航空发动机高温合金热端部件表面防护，与现有技术相比，具有以下主要优点：
(1)、采用的贵金属Pt面层具有很低的腐蚀介质透过率，提高了整个涂层的抗氧化腐蚀性能；
(2)、制备的热障涂层与CMAS润湿性差，试验结果表明该涂层具有优异的抗CMAS腐蚀性能，有效地解决了在役热障涂层易遭受CMAS腐蚀的问题。
附图说明
图1为在役热障涂层服役后表面沉积的大量CMAS沉积物宏观形貌及界面形貌。
图2为涂敷CMAS热障涂层试样1250dC热处理4小时后的界面形貌。
图3为在役热障涂层和本发明所述新型热障涂层1250dC热处理4小时后对CMAS的润湿程度对比。
图4为涂敷本发明新型热障涂层试样1250℃热处理4小时后的界面形貌。
具体实施方式
实施例1
一种高温合金热端部件抗CMAS腐蚀的热障涂层，由NiCrAlYSi粘结底层、YSZ陶瓷面层和贵金属Pt面层组成，其具体制备步骤如下：
步骤1)：对部件进行表面预处理；
对高温合金合金试样进行湿吹砂处理，并进行超声波清洗、丙酮溶液浸洗、烘干。湿吹砂工艺参数为：白刚玉砂粒度为180～280目，刚玉砂含量20％～35％，风压0.15MPa～0.25MPa，吹砂距离为180mm～350mm。
步骤2)：采用真空电弧镀在部件表面制备NiCrAlYSi金属粘结底层；
将上述试样安装到夹具上并用高温合金丝进行紧固。
将试样安装到真空电弧镀设备内进行NiCrAlYSi涂层的沉积，具体工艺参数如下：工作压强＜5.32×10-2Pa，电弧电流700～750A，工件电压30～34V，涂敷时间110～130min，冷却2h后取出。
步骤3)：将沉积完NiCrAlYSi金属粘结底层的试样在1000℃～1050℃温度下真空扩散热处理2小时后进行湿吹砂处理；
步骤4)：在NiCrAlYSi金属粘结底层表面制备YSZ陶瓷面层；
将上述试样安装到夹具上并用高温合金丝进行紧固后装入EB-PVD设备进行YSZ陶瓷面层沉积。沉积YSZ面层工艺参数为：主真空室压强不大于5×10-2Pa，电子枪电压为17～20KV，靶材加热电流为1.5A，工件转速为15r/min，工件加热温度为900～950℃。
步骤5)：采用油石将YSZ陶瓷面层抛光至粗糙度为0.8～1.2μm；
步骤6)：制备贵金属Pt面层；
将上述试样安装到夹具上并用高温合金丝进行紧固后装入多弧离子镀设备进行贵金属Pt面层沉积。具体工艺参数如下：本地真空度＜7×10-3Pa，试样温度200～300℃，放电气体为氩气，气体分压2～3×10-1Pa，靶电流30～50A，工作负电压50～300V，涂敷时间50min，冷却至室温后取出样品。
图1为在役热障涂层服役后表面沉积的大量CMAS沉积物宏观形貌及界面形貌。
图2为涂敷CMAS热障涂层试样1250dC热处理4小时后的界面形貌，从图中可以看出CMAS中Si元素几乎渗透整个涂层深度，Al、Ca也发生少量渗入，Mg元素近乎没有发生渗入。沿着涂层内部垂直裂纹处CMAS渗入最快，并且发生富集。
图3为在役热障涂层和本发明所述新型热障涂层1250℃热处理4小时后对CMAS的润湿程度对比。从图中可以观察到，新型热障涂层对CMAS的润湿角仅为6.7°，而在役热障涂层对CMAS的润湿角为39.8°，这表明CMAS对新型热障涂层不浸润，不易粘结在热障涂层表面。
图4为涂敷本发明新型热障涂层试样1250℃热处理4小时后的界面形貌，从图中可以看出CMAS几乎完全未渗入热障涂层中。这表明新型热障涂层具有优异的抗CMAS腐蚀性能。
上述实施例只为说明本发明的技术构思及特点，其目的在于让熟悉此项技术的人士能够了解本发明的内容并据以实施，并不能以此限制本发明的保护范围。凡根据本发明精神实质所作的等效变化或修饰，都应涵盖在本发明的保护范围之内。

Claims (10)

1.一种抗CMAS腐蚀的热障涂层，其特征在于：所述热障涂层由MCrAlY粘结底层、YSZ陶瓷面层和贵金属Pt面层组成，其中M为Ni和/或Co。
2.按照权利要求1所述抗CMAS腐蚀的热障涂层，其特征在于：MCrAlY粘结底层厚度为30～50微米，YSZ陶瓷面层为100～150微米，Pt面层为3～5微米。
3.一种权利要求1所述抗CMAS腐蚀的热障涂层的制备方法，其特征在于，具体制备步骤如下：
步骤1)：对部件进行表面预处理；
步骤2)：采用真空电弧镀、等离子喷涂或超音速喷涂在部件表面制备MCrAlY金属粘结底层；
步骤3)：对MCrAlY金属粘结底层进行真空扩散热处理和吹砂预处理；
步骤4)：在上述处理后的MCrAlY金属粘结底层表面采用APS或电子束物理气相沉积方法制备YSZ陶瓷面层；
步骤5)：采用油石对YSZ陶瓷面层进行抛光处理；
步骤6)：在抛光处理后的YSZ陶瓷面层表面采用磁控溅射或多弧离子镀方法制备贵金属Pt面层。
4.按照权利要求3所述抗CMAS腐蚀的热障涂层的制备方法，其特征在于，步骤1)中对部件进行表面预处理的过程为：对部件进行湿吹砂处理，然后进行超声波清洗、丙酮溶液浸洗、烘干；其中湿吹砂工艺参数为：白刚玉砂粒度为180～280目，刚玉砂含量20％～35％，风压0.15MPa～0.25MPa，吹砂距离为180mm～350mm。
5.按照权利要求3所述抗CMAS腐蚀的热障涂层的制备方法，其特征在于：步骤2)中，采用真空电弧镀在部件表面制备MCrAlY金属粘结底层的工艺参数为：工作压强＜5.32×10- 2Pa，电弧电流700～750A，工件电压30～34V，涂敷时间110～130min，冷却2.0～2.5h后取出。
6.按照权利要求3所述抗CMAS腐蚀的热障涂层的制备方法，其特征在于：步骤3)中，对MCrAlY金属粘结底层在1000℃～1050℃温度下进行真空扩散热处理2～4小时，然后进行湿吹砂预处理。
7.按照权利要求3所述抗CMAS腐蚀的热障涂层的制备方法，其特征在于：步骤4)中，采用电子束物理气相沉积方法制备YSZ陶瓷面层的工艺参数为：主真空室压强不大于5×10- 2Pa，电子枪电压为17～20KV，靶材加热电流为1.5A，工件转速为15r/min，工件加热温度为900～950℃。
8.按照权利要求3所述抗CMAS腐蚀的热障涂层的制备方法，其特征在于：步骤5)中，对YSZ陶瓷面层抛光处理至粗糙度为0.8～1.2μm。
9.按照权利要求3所述抗CMAS腐蚀的热障涂层的制备方法，其特征在于，步骤6)中，采用多弧离子镀方法制备贵金属Pt面层的工艺参数如下：本地真空度＜7×10-3Pa，试片温度200～300℃，放电气体为氩气，气体分压2～3×10-1Pa，靶电流30～50A，工作负电压50～300V，涂敷时间50～70min，冷却至室温后取出样品。
10.一种权利要求1所述抗CMAS腐蚀的热障涂层的应用，其特征在于：所述热障涂层用于航空发动机高温合金热端部件表面防护。
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