CN108660407B - Thermal barrier coating with prefabricated microscopic longitudinal crack structure and preparation method thereof - Google Patents

Thermal barrier coating with prefabricated microscopic longitudinal crack structure and preparation method thereof Download PDF

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CN108660407B
CN108660407B CN201810224474.2A CN201810224474A CN108660407B CN 108660407 B CN108660407 B CN 108660407B CN 201810224474 A CN201810224474 A CN 201810224474A CN 108660407 B CN108660407 B CN 108660407B
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dry ice
spraying
thermal barrier
barrier coating
thermal
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CN108660407A (en
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董淑娟
曹学强
周鑫
蒋佳宁
邓龙辉
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Wuhan University of Technology WUT
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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
    • C23C4/12—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
    • 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
    • C23C4/11—Oxides

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  • Engineering & Computer Science (AREA)
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  • Chemical Kinetics & Catalysis (AREA)
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  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Coating By Spraying Or Casting (AREA)

Abstract

The invention discloses a prefabricated micro longitudinal beamA thermal barrier coating with a crack structure and a preparation method thereof. The ceramic heat-insulating layer of the thermal barrier coating contains implanted high-density microscopic longitudinal cracks, the preparation method is to prepare the ceramic heat-insulating layer by utilizing an atmospheric plasma spraying technology and coupling a dry ice particle spraying process, and the microscopic longitudinal cracks are implanted in the ceramic heat-insulating layer by online quenching of ceramic fused particles through the dry ice particle spraying process. Compared with the thermal barrier coating prepared by the traditional atmospheric plasma spraying and EB-PVD (Electron Beam-physical vapor deposition) method, the thermal barrier coating with the prefabricated microscopic longitudinal crack structure, which is designed and prepared by the invention, has the low thermal conductivity of the thermal barrier coating prepared by the traditional plasma spraying and the high strain tolerance of the thermal barrier coating prepared by the EB-PVD technology, and can insulate heat without reducing thermal shock and CMAS (CaO-MgO-Al) of the coating2O3‑SiO2) Stress generated by thermal stress mismatching is effectively released on the premise of corrosion resistance, so that the thermal cycle service life of the thermal barrier coating under the harsh working condition is prolonged.

Description

Thermal barrier coating with prefabricated microscopic longitudinal crack structure and preparation method thereof
Technical Field
The invention belongs to the technical field of materials, and particularly relates to a thermal barrier coating with a prefabricated microscopic longitudinal crack structure and a preparation method thereof.
Background
With the development of aviation, aerospace, ship, electric power and automobile technologies, the research and development level of the aircraft engine and gas turbine engine technologies becomes a bottleneck restricting the continuous progress of modern industry. Currently, continuously increasing the operating temperature of metal hot end components is the key to developing high efficiency, long service life engines. Therefore, the use of Thermal Barrier Coatings (TBCs) with high temperature oxidation resistance and thermal insulation on the surface of metallic hot end components is the most effective and feasible technical approach to increase the operating temperature of aviation and gas turbine engines.
Thermal Barrier Coatings (TBCs) are coating systems that provide thermal insulation and protection against high temperature oxidation and corrosion. The working temperature of the engine can be improved by depositing a ceramic coating with a certain thickness and lower thermal conductivity on the surface of the metal substrate. TBCs, on the other hand, may improve service life and reliability of metal hot end components. Currently, most widely used TBC systems all employ a double layer structure: a surface ceramic layer (TC) for heat insulation and a metal bonding layer (BC) for improving the physical compatibility of the matrix and the ceramic layer. Currently, the most common methods for preparing thermal barrier coatings are Atmospheric Plasma Spray (APS) and electron beam physical vapor deposition (EB-PVD); among them, the coating prepared by APS has a typical layered structure and has better heat insulation performance, but TBCs are in service in a very severe thermodynamic load environment and usually suffer from thermal fatigue failure, resulting in premature cracking, peeling and the like of the coating; EB-PVD prepared thermal barrier coatings have columnar grain microstructures with better strain tolerance and longer service life than APS prepared coatings. However, such TBCs with macro columnar gaps or macro longitudinal crack structures tend to have high thermal conductivity and are prone to CMAS corrosion failure; and EB-PVD equipment is expensive, low in deposition efficiency, uncontrollable in coating thickness and complex in surface cleaning, and is not suitable for preparing workpieces with complex structures and coatings on large workpieces. APS has been widely used for preparing thermal barrier coatings on aircraft engine blades, tail nozzles, gas turbine combustion chamber walls, thrust enhancers, fuel nozzles, transition intake pipe segments, turbine stationary components, and the like, due to its low processing cost, high deposition efficiency, good repeatability, and relatively simple process.
In view of the advantages and disadvantages of respective structures of thermal barrier coatings prepared by APS and EB-PVD, the invention discloses a thermal barrier coating with a microscopic longitudinal crack structure design and a preparation method thereof; the thermal barrier coating with the structural design has a double-layer structure like the traditional thermal barrier coating: a metal bonding layer and a surface ceramic layer; the ceramic surface layer of the thermal barrier coating contains artificially-implanted microscopic longitudinal cracks, and the strain tolerance of the coating is improved on the premise of not remarkably reducing the thermal shock resistance and the heat insulation performance of the coating, so that the service life of the thermal barrier coating is prolonged.
Disclosure of Invention
In order to solve the technical problems in the background technology, the invention provides a thermal barrier coating with a microscopic longitudinal crack structure design and a preparation method thereof; by means of the design of the coating structure and the preparation method, micro longitudinal cracks are implanted into the surface ceramic layer, the strain tolerance of the coating is improved, the problems of over-cracking, peeling and the like in the service process of preparing the thermal barrier coating by the APS method are solved, and the service life of the thermal barrier coating is prolonged.
In order to achieve the purpose, the invention is realized by the following technical scheme:
a thermal barrier coating with a prefabricated micro longitudinal crack structure is provided with a ceramic thermal insulation layer, wherein the ceramic thermal insulation layer contains high-density micro longitudinal cracks, and the ratio of the micro longitudinal cracks in the micro cracks is more than 33%.
Preferably, the ceramic heat-insulating layer material comprises yttria partially stabilized zirconia (YSZ) with low thermal conductivity, Lanthanum Zirconate (LZ), ceric acid (LC) and magnalium acid (LMA).
Preferably, the longitudinal size of any microscopic longitudinal crack in the ceramic heat insulation layer does not exceed the total thickness of the ceramic heat insulation layer, and the microscopic longitudinal crack is a non-penetrating crack.
A preparation method of a thermal barrier coating with a prefabricated microscopic longitudinal crack structure comprises the following steps:
(1) pre-treating, namely performing pre-heating treatment on a substrate needing to deposit a thermal barrier coating or a substrate with a metal bonding layer by adopting an atmospheric plasma flame flow coupled dry ice particle spraying process, wherein the pre-heating temperature is 60-100 ℃;
(2) and (2) spraying, namely depositing thermal barrier coating ceramic material powder on the substrate or the metal bonding layer pretreated in the step (1) by coupling an atmospheric plasma spraying method with a dry ice particle spraying process to obtain the thermal barrier coating containing the high-proportion microscopic longitudinal cracks.
Preferably, the coupling manner in step (1) includes: preheating an atmospheric plasma flame flow and then spraying dry ice particles; b, preheating by adopting atmospheric plasma flame flow after the dry ice particles are sprayed; the dry ice particle spraying pretreatment has a certain cleaning effect on the matrix, and the 'condensation' caused by supercooling can be avoided by coupling with the atmospheric plasma preheating treatment.
Preferably, the coupling manner in step (2) includes: a, performing atmospheric plasma spraying deposition and then performing dry ice particle spraying treatment; and b, spraying and depositing the dry ice particles by using atmospheric plasma after the dry ice particles are sprayed.
Preferably, the included angle between the dry ice particle spray gun and the plasma spray gun in the steps (1) and (2) is 15-45 degrees, the distance between the dry ice particle spray gun and the coating is 20-40 mm, and the dry ice spray flow is 20-60 kg/h.
Compared with the prior art, the invention has the following advantages:
the invention provides a preparation method of a thermal barrier coating with a prefabricated microscopic longitudinal crack structure, which is characterized in that a ceramic thermal insulation layer is prepared by coupling a dry ice particle spraying process in an atmospheric plasma spraying process to form the thermal barrier coating; micro longitudinal cracks are implanted in the ceramic layer by the quenching effect of the dry ice particles on the molten ceramic particles. The method is simple and convenient to operate, can be synchronously completed on line in the existing atmospheric plasma spraying process, can sublimate after the dry ice particles are sprayed, has no secondary pollution, and is economic and environment-friendly.
The thermal barrier coating designed by the microscopic longitudinal crack structure is different from the thermal barrier coating with the macroscopic longitudinal crack structure, contains the microscopic longitudinal cracks with high proportion, can effectively improve the strain tolerance of the coating by greatly increasing the microscopic longitudinal crack density of the thermal barrier coating, does not remarkably reduce the performances of thermal shock, thermal insulation, CMAS corrosion resistance and the like of the coating, effectively prolongs the service life of the thermal barrier coating in a severe service environment, enlarges the application range of the thermal barrier coating, and enables the thermal barrier coating provided by the invention to be safely and reliably applied in the fields of aerospace, ship power, automobile manufacturing and the like.
Drawings
FIG. 1 is a schematic structural design diagram of a thermal barrier coating with a prefabricated microscopic longitudinal crack according to the present invention, wherein 1 represents a ceramic layer; 2 represents a tie layer; 3 represents a substrate, wherein the left side image is a schematic diagram of a thermal barrier coating with a macroscopic longitudinal crack or columnar structure, and the right side image is a schematic diagram of a thermal barrier coating with a prefabricated microscopic longitudinal crack structure;
FIG. 2 is a cross-sectional view of an 8YSZ thermal barrier coating with a microscopic longitudinal crack structure prepared in example 1 of the present invention, wherein (a) is a low-power topography of the 8YSZ thermal barrier coating, and (b) is a high-power topography of the 8YSZ ceramic surface layer;
fig. 3 is a sectional morphology of an LMA-type thermal barrier coating with a microscopic longitudinal crack structure prepared in example 2 of the present invention, where (a) is a low-power morphology of the LMA thermal barrier coating, and (b) is a high-power morphology of the LMA ceramic surface layer.
Detailed Description
The present invention is further illustrated by the following specific examples, which are illustrative of the present invention and do not limit the scope of the present invention.
Example 1
(1) Preheating a sample with a CoNiCrAlY metal bonding layer by an atmospheric plasma spraying flame flow coupling dry ice particle spraying process, wherein the specific coupling mode is that the sample is preheated by the atmospheric plasma spraying flame flow after being pretreated by the dry ice particle spraying process; according to the requirements of atmospheric plasma spraying equipment, selecting plasma spraying voltage to be 65.0V, current to be 630A and plasma spraying distance to be 115 mm; according to the requirements of dry ice particle spraying equipment, selecting cylindrical dry ice particles with the diameter of 3mm and the length of 3-10mm, wherein the flow rate of the dry ice is 42kg/h, and the distance between a dry ice particle spraying gun and a coating is 25 mm; the included angle between the dry ice spray gun and the plasma spray gun is 30 degrees; the preheating temperature is 100 ℃;
(2) y with the mass fraction of 8 percent and the particle diameter of 15-58 mu m by coupling the atmospheric plasma spraying with the dry ice particle spraying process2O3Partially stabilized ZrO2(8YSZ) powder is deposited on the preheated sample to obtain an 8YSZ thermal barrier coating containing 50.51 percent of micro longitudinal cracks; according to the requirements of atmospheric plasma spraying equipment, selecting a spraying voltage of 65.0V, a current of 630A, a powder feeding gas of Ar, a flow of 3.0SLPM, a plasma spraying distance of 115mm and a total thickness of a ceramic layer of 600 microns; according to the requirements of dry ice particle spraying equipment, selecting cylindrical dry ice particles with the diameter of 3mm and the length of 3-10mm, wherein the flow rate of the dry ice is 42kg/h, and the spraying distance is 25 mm; the coupling mode is that the dry ice particle spraying process is adopted to pretreat the sample and then the atmosphere plasma spraying deposition coating is carried outAnd the included angle between the dry ice spray gun and the plasma spray gun is 30 degrees.
To compare the thermal cycle life of the 8YSZ type thermal barrier coating with a microscopic longitudinal crack structure prepared in example 1, comparative example 1 is given below, and an 8YSZ type thermal barrier coating is prepared by conventional atmospheric plasma spraying.
Comparative example 1
Y with the grain diameter of 15-58 mu m and the mass fraction of 8%2O3Partially stabilized ZrO2(8YSZ) powder is used as spraying powder, and a traditional atmospheric plasma spraying method is adopted to deposit an 8YSZ surface ceramic layer on the surface of a sample with a CoNiCrAlY metal bonding layer, so that the preparation of the thermal barrier coating is completed; the resulting 8YSZ coating contained 21.92% microscopic longitudinal cracks; according to the requirements of atmospheric plasma spraying equipment, the spraying voltage is 65.0V, the current is 630A, the powder feeding gas is Ar, the flow rate is 3.0SLPM, the spraying distance is 115mm, and the thickness of the ceramic layer is 600 μm.
For the 8YSZ thermal barrier coatings prepared in the above example 1 and comparative example 1, an automatic high-temperature water quenching fatigue test furnace was used for thermal cycle life test under the following test conditions: taking out after 30min of heat preservation at 1150 ℃, cooling for 18min at room temperature, recording the process as one thermal cycle, and testing for 50 thermal cycles in total. After 50 thermal cycles, the 8YSZ thermal barrier coating with the prefabricated micro longitudinal crack structure prepared in example 1 only peeled off a small amount at the edge of the coating, while the 8YSZ thermal barrier coating prepared in comparative example 1 almost peeled off completely.
Example 2
(1) Preheating a sample with a NiCrAlY metal bonding layer by an atmosphere plasma spraying flame flow coupling dry ice particle spraying process, wherein the coupling mode is specifically that the sample is preheated by the atmosphere plasma spraying flame flow and then subjected to dry ice particle spraying pretreatment; according to the requirements of atmospheric plasma spraying equipment, the spraying voltage is selected to be 67.2V, the current is 617A, and the plasma spraying distance is 100 mm; according to the requirements of dry ice particle spraying equipment, selecting cylindrical dry ice particles with the diameter of 3mm and the length of 3-10mm, wherein the flow rate of the dry ice is 42kg/h, the spraying distance is 25mm, and the included angle between a dry ice spray gun and a plasma spray gun is 30 degrees; the preheating temperature was 60 ℃.
(2) Through the process of coupling atmospheric plasma spraying with dry ice particle spraying, LaMgAl with the particle size of 32-125 mu m is sprayed11O19(LMA) powder is deposited on the preheated sample to obtain an LMA thermal barrier coating containing 46.84% of micro longitudinal cracks; according to the requirements of atmospheric plasma spraying equipment, selecting a spraying voltage of 67.2V, a current of 617A, a powder feeding gas of Ar, a flow of 2.8NLPM, a powder feeding rate of 15g/min, a spraying distance of 100mm and a ceramic layer thickness of 150 μm; according to the requirements of dry ice particle spraying equipment, selecting cylindrical dry ice particles with the diameter of 3mm and the length of 3-10mm, wherein the flow rate of the dry ice is 42kg/h, and the spraying distance is 25 mm; the coupling mode is that after atmospheric plasma spraying deposition, dry ice particle spraying treatment is carried out, and the included angle between a dry ice spray gun and the plasma spray gun is 30 degrees.
To compare the thermal cycle life of the LMA-type thermal barrier coating having a microscopic longitudinal crack structure prepared in example 2, comparative example 2 is given below, where the LMA-type thermal barrier coating is prepared by conventional atmospheric plasma spraying.
Comparative example 2
Adopting LMA powder with the particle size of 32-125 mu m as spraying powder, and depositing an LMA surface ceramic layer on the surface of a sample with a NiCrAlY metal bonding layer by adopting traditional atmospheric plasma spraying to finish the preparation of a thermal barrier coating; the resulting LMA coating contained 33.97% microscopic longitudinal cracks; according to the requirements of atmospheric plasma spraying equipment, the spraying voltage is 67.2V, the current is 617A, the powder feeding gas is Ar, the flow rate is 2.8NLPM, the powder feeding rate is 15g/min, the spraying distance is 100mm, and the thickness of the ceramic layer is 150 μm.
For the LMA-type thermal barrier coatings prepared in example 2 and comparative example 2 above, a thermal cycle life test was performed using a high-temperature tube furnace under the following test conditions: and (3) keeping the temperature at 1100 ℃ for 34min, taking out, carrying out air cooling at room temperature for 2min, recording the process as a thermal cycle, and recording the thermal cycle times when the peeling area of the coating is about 10% as the thermal cycle life. The thermal cycle life of the LMA thermal barrier coating prepared in example 2 and having the prefabricated micro longitudinal crack structure is 34 times, while the thermal cycle life of the LMA thermal barrier coating prepared in comparative example 2 is 28 times.
In example 1 and comparative example 1 above, and example 2 and comparative example 2, thermal barrier coatings with a preformed microscopic longitudinal crack structure prepared using the atmospheric plasma spray coupled dry ice particle blasting process of the present invention have higher thermal cycle life.
Compared with the thermal barrier coating prepared by the traditional atmospheric plasma spraying and EB-PVD (Electron Beam-physical vapor deposition) method, the thermal barrier coating with the prefabricated microscopic longitudinal crack structure, which is designed and prepared by the invention, has the low thermal conductivity of the thermal barrier coating prepared by the traditional plasma spraying and the high strain tolerance of the thermal barrier coating prepared by the EB-PVD technology, and can insulate heat without reducing thermal shock and CMAS (CaO-MgO-Al) of the coating2O3-SiO2) Stress generated by thermal stress mismatching is effectively released on the premise of corrosion resistance, so that the thermal cycle service life of the thermal barrier coating under the harsh working condition is prolonged.
Finally, it should be noted that the above embodiments are only used for illustrating the technical solutions of the present invention and not for limiting the protection scope of the present invention, and although the present invention is described in detail with reference to the preferred embodiments, it should be understood by those skilled in the art that modifications or equivalent substitutions can be made on the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.

Claims (1)

1. A thermal barrier coating with a prefabricated microscopic longitudinal crack structure is characterized by being prepared by the following method:
(1) preheating a sample with a NiCrAlY metal bonding layer by an atmosphere plasma spraying flame flow coupling dry ice particle spraying process, wherein the coupling mode is specifically that the sample is preheated by the atmosphere plasma spraying flame flow and then subjected to dry ice particle spraying pretreatment; according to the requirements of atmospheric plasma spraying equipment, the spraying voltage is selected to be 67.2V, the current is 617A, and the plasma spraying distance is 100 mm; according to the requirements of dry ice particle spraying equipment, selecting cylindrical dry ice particles with the diameter of 3mm and the length of 3-10mm, wherein the flow rate of the dry ice is 42kg/h, the spraying distance is 25mm, and the included angle between a dry ice spray gun and a plasma spray gun is 30 degrees; the preheating temperature is 60 ℃;
(2) through the process of coupling atmospheric plasma spraying with dry ice particle spraying, LaMgAl with the particle size of 32-125 mu m is sprayed11O19(LMA) powder is deposited on the preheated sample to obtain an LMA thermal barrier coating containing 46.84% of micro longitudinal cracks; according to the requirements of atmospheric plasma spraying equipment, selecting a spraying voltage of 67.2V, a current of 617A, a powder feeding gas of Ar, a flow of 2.8NLPM, a powder feeding rate of 15g/min, a spraying distance of 100mm and a ceramic layer thickness of 150 μm; according to the requirements of dry ice particle spraying equipment, selecting cylindrical dry ice particles with the diameter of 3mm and the length of 3-10mm, wherein the flow rate of the dry ice is 42kg/h, and the spraying distance is 25 mm; the coupling mode is that after atmospheric plasma spraying deposition, dry ice particle spraying treatment is carried out, and the included angle between a dry ice spray gun and the plasma spray gun is 30 degrees.
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