CN109648931A - 多层热阻隔件 - Google Patents
多层热阻隔件 Download PDFInfo
- Publication number
- CN109648931A CN109648931A CN201811136857.0A CN201811136857A CN109648931A CN 109648931 A CN109648931 A CN 109648931A CN 201811136857 A CN201811136857 A CN 201811136857A CN 109648931 A CN109648931 A CN 109648931A
- Authority
- CN
- China
- Prior art keywords
- insulation layer
- thermal insulation
- sealant
- hollow micro
- layer
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 230000004888 barrier function Effects 0.000 title claims abstract description 77
- 238000009413 insulation Methods 0.000 claims abstract description 103
- 239000000565 sealant Substances 0.000 claims abstract description 65
- 238000002485 combustion reaction Methods 0.000 claims abstract description 22
- 229910010293 ceramic material Inorganic materials 0.000 claims abstract description 15
- 239000000758 substrate Substances 0.000 claims description 27
- 239000000463 material Substances 0.000 claims description 19
- 238000000034 method Methods 0.000 claims description 13
- 239000000919 ceramic Substances 0.000 claims description 5
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 claims description 4
- 229910001928 zirconium oxide Inorganic materials 0.000 claims description 4
- 229910052581 Si3N4 Inorganic materials 0.000 claims description 3
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 3
- MYXYKQJHZKYWNS-UHFFFAOYSA-N barium neodymium Chemical compound [Ba][Nd] MYXYKQJHZKYWNS-UHFFFAOYSA-N 0.000 claims description 3
- 239000005350 fused silica glass Substances 0.000 claims description 3
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 claims description 3
- 229910002077 partially stabilized zirconia Inorganic materials 0.000 claims description 2
- 239000010410 layer Substances 0.000 abstract description 155
- 239000012790 adhesive layer Substances 0.000 abstract description 37
- 239000007789 gas Substances 0.000 abstract description 17
- 238000007789 sealing Methods 0.000 abstract description 8
- 239000012212 insulator Substances 0.000 abstract description 5
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 27
- 229910052751 metal Inorganic materials 0.000 description 26
- 239000002184 metal Substances 0.000 description 26
- 239000011248 coating agent Substances 0.000 description 19
- 238000000576 coating method Methods 0.000 description 19
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 17
- 238000002844 melting Methods 0.000 description 14
- 230000008018 melting Effects 0.000 description 14
- 230000007704 transition Effects 0.000 description 13
- 238000005245 sintering Methods 0.000 description 12
- 229910052759 nickel Inorganic materials 0.000 description 11
- 229910052742 iron Inorganic materials 0.000 description 8
- 239000000446 fuel Substances 0.000 description 7
- 239000012720 thermal barrier coating Substances 0.000 description 7
- 238000009792 diffusion process Methods 0.000 description 6
- BVPWJMCABCPUQY-UHFFFAOYSA-N 4-amino-5-chloro-2-methoxy-N-[1-(phenylmethyl)-4-piperidinyl]benzamide Chemical compound COC1=CC(N)=C(Cl)C=C1C(=O)NC1CCN(CC=2C=CC=CC=2)CC1 BVPWJMCABCPUQY-UHFFFAOYSA-N 0.000 description 5
- 239000004411 aluminium Substances 0.000 description 5
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 5
- 229910052782 aluminium Inorganic materials 0.000 description 5
- 239000011521 glass Substances 0.000 description 5
- 239000007769 metal material Substances 0.000 description 5
- 238000007493 shaping process Methods 0.000 description 5
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 4
- 230000008901 benefit Effects 0.000 description 4
- 150000001875 compounds Chemical class 0.000 description 4
- 229910052802 copper Inorganic materials 0.000 description 4
- 239000010949 copper Substances 0.000 description 4
- 238000010438 heat treatment Methods 0.000 description 4
- 238000007747 plating Methods 0.000 description 4
- 229920000642 polymer Polymers 0.000 description 4
- 229910000990 Ni alloy Inorganic materials 0.000 description 3
- TVZPLCNGKSPOJA-UHFFFAOYSA-N copper zinc Chemical compound [Cu].[Zn] TVZPLCNGKSPOJA-UHFFFAOYSA-N 0.000 description 3
- 238000013461 design Methods 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 239000005439 thermosphere Substances 0.000 description 3
- 229910001369 Brass Inorganic materials 0.000 description 2
- 208000025599 Heat Stress disease Diseases 0.000 description 2
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 2
- 239000010951 brass Substances 0.000 description 2
- 239000003054 catalyst Substances 0.000 description 2
- 230000006835 compression Effects 0.000 description 2
- 238000007906 compression Methods 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 238000007772 electroless plating Methods 0.000 description 2
- 238000010285 flame spraying Methods 0.000 description 2
- 239000012530 fluid Substances 0.000 description 2
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 2
- 239000010931 gold Substances 0.000 description 2
- 229910052737 gold Inorganic materials 0.000 description 2
- 238000002347 injection Methods 0.000 description 2
- 239000007924 injection Substances 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 238000005096 rolling process Methods 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 238000012546 transfer Methods 0.000 description 2
- 238000007740 vapor deposition Methods 0.000 description 2
- 229910052725 zinc Inorganic materials 0.000 description 2
- 239000011701 zinc Substances 0.000 description 2
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- 229910017518 Cu Zn Inorganic materials 0.000 description 1
- 229910017752 Cu-Zn Inorganic materials 0.000 description 1
- 229910017943 Cu—Zn Inorganic materials 0.000 description 1
- 229910001021 Ferroalloy Inorganic materials 0.000 description 1
- 229910001297 Zn alloy Inorganic materials 0.000 description 1
- 238000004026 adhesive bonding Methods 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 238000005219 brazing Methods 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 230000008021 deposition Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 239000011888 foil Substances 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
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- 239000000155 melt Substances 0.000 description 1
- 230000008450 motivation Effects 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 230000029058 respiratory gaseous exchange Effects 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 238000013517 stratification Methods 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
- 238000009736 wetting Methods 0.000 description 1
Classifications
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- B22F1/17—Metallic particles coated with metal
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Abstract
一种多层热阻隔件,其可施加于内燃机内部件的表面。多层热阻隔件提供对于燃烧气体进行密封的低导热性和低热容量的隔热件。多层热阻隔件包括彼此粘结的两个、三个或更多个层,例如,第一(粘结)层、第二(隔热)层以及第三(密封)层。隔热层设置在粘结层和密封层之间。粘结层粘结于该部件。隔热层包括中空微结构,这些中空微结构可烧结在一起,以形成提供低效导热性和低效热容量的隔热件。密封层可由陶瓷材料形成,且隔热层可包括变形的微结构,其具有相较高度更大的宽度。
Description
技术领域
本发明总地涉及多层热阻隔件,该多层热阻隔件可称为热阻隔件涂层(TBC),用以保护经受高温气体的部件。
背景技术
内燃机包括多个气缸、多个活塞、至少一个进气端口以及至少一个排气端口。气缸各自包括限定燃烧室的表面。内燃机的一个或多个表面可涂覆有热阻隔件涂层或多层热阻隔件,以改进内燃机的热传递特征。
发明内容
可称为复合热阻隔件涂层(TBC)的多层热阻隔件可施加于内燃机内一个或多个部件的表面。多层热阻隔件粘结于发动机的部件,以提供对于燃烧气体进行密封的低导热性和低热容量的隔热件。
多层热阻隔件可包括彼此粘结的两个、三个或更多个层,例如,第一(粘结)层、第二(隔热)层以及第三(密封)层。隔热层设置在粘结层和密封层之间。粘结层粘结于部件并且粘结于隔热层。
隔热层可包括中空微结构,这些中空微结构烧结在一起,以形成提供低效导热性和低效热容量的隔热件。在一些形式中,中空微结构变形为扁平形状,以增大接触面积,并且由此增大各个微结构之间的粘结。使得中空微结构变形还会在隔热层上产生光滑表面,从而导致与相邻层的增大接触。
密封层是薄膜,该薄膜构造成抵抗存在于发动机内的高温。密封层可渗透气体,并且呈现光滑表面。在一些形式中,密封层可基本上由陶瓷构成。在一些形式中,密封层可由中空微结构的压缩顶部层形成。
多层热阻隔件具有低导热性以减小热传递损失和低热容量,以使得多层热阻隔件的表面温度追踪燃烧室中的气体温度。因此,多层热阻隔件允许部件的表面温度能随着气体温度摆动。这减小热传递损失,且不会影响发动机的呼吸能力并且不会增大爆震趋势。此外,减小进入发动机的气缸的冷却空气的加热。附加地,排气温度升高,从而致使催化剂起燃时间更快且改进催化剂活性。
在可与这里描述的其他形式组合或者分开的一个形式中,提供一种多层热阻隔件,该多层热阻隔件至少包括隔热层和密封层。隔热层包括粘结在一起的多个中空微结构,且密封层粘结于隔热层。密封层是不可渗透的,且构造成对于隔热层进行密封。密封层可包括陶瓷材料或金属。
在可与这里描述的其他形式组合或者分开的一个形式中,提供一种多层热阻隔件,该多层热阻隔件也至少包括隔热层和密封层。隔热层包括多个变形的中空微结构。每个变形的中空微结构均具有大于其高度的宽度。多个变形的中空微结构粘结在一起。密封层粘结于隔热层,且密封层是不可渗透的,且构造成对于隔热层进行密封。
在可与这里描述的其他形式组合或者分开的又一形式中,提供一种形成用在内燃机的部件上的热阻隔件的方法。该方法包括提供多个中空微结构,各个中空微结构均具有在约10微米至约50微米的范围内的直径以产生隔热层。该方法进一步包括将力施加于隔热层,直到每个微结构均变形成具有宽度和高度的扁平中空微结构为止,该宽度大于高度。
能可选地提供附加的特征,包括但不限于以下:密封层包括陶瓷材料;其中,陶瓷材料包括以下至少一种:氧化锆、部分稳定氧化锆、氮化硅、熔融氧化硅以及钛酸钡钕(BNT);其中,密封层基本上由陶瓷材料构成;进一步包括粘结层,该粘结层构造成粘结于金属基底;隔热层,该隔热层粘结于粘结层;其中,粘结层包括铜基材料、锌基材料以及包括铜和锌的合金的至少一种;其中,多个中空微结构的每个包括镍基材料和铁基材料的至少一种;其中,密封层的厚度并不大于5微米;其中,隔热层具有75和300微米之间的厚度;其中,多个微结构的每个微结构均具有不超过100μm的宽度;其中,隔热层具有至少90%或至少95%的孔隙率;每个中空微结构均是扁平的且具有宽度和高度;宽度大于高度;每个变形的中空微结构的大部分外部表面积均粘结于相邻的变形的中空微结构;每个变形的中空微结构均具有大体长方体形状。
可提供又一些附加的特征,包括但不限于以下:其中,施加力的步骤包括将经加热辊子滚动抵靠于多层热阻隔件,以使得多个中空微结构变形;其中,施加力的步骤包括利用冲压件和成形模具来压缩多个中空微结构,以使得多个中空微结构变形;其中,施加力的步骤包括向多个中空微结构施加真空力,以使得多个中空微结构变形;该方法进一步包括将隔热层设置到粘结层上;其中,粘结层施加于隔热层的与密封层相对地设置的一部分;将密封层设置到隔热层上;以及加热隔热层、粘结层以及密封层。
此外,可提供包括呈现表面的金属基底的部件,该部件具有粘结于该表面的多层热阻隔件的型式。此外,本发明设想一种内燃机,该内燃机包括这样的部件,该部件具有设置在其上或者粘结于其的任何型式多层热阻隔件,其中,该部件构造成经受燃烧气体。
当结合附图时,从用于执行本教示的最佳模式的以下详细描述中,本发明的上述特征和优点以及其他特征和优点会显而易见。
附图说明
图1是车辆的示意图,展示了单缸式内燃机的侧视图,该单缸式内燃机具有设置在多个部件上的根据本发明原理的多层热阻隔件;
图2是根据本发明原理的设置在图1所示部件上的多层热阻隔件的示意剖视侧视图;
图3是根据本发明原理的设置在图1所示部件上的多层热阻隔件的另一示例的示意剖视侧视图;
图4是根据本发明原理的设置在图1所示部件上的多层热阻隔件的又一示例的示意剖视侧视图;
图5A是说明根据本发明原理的形成多层热阻隔件的方法的一个示例的示意剖视侧视图;以及
图5B是说明根据本发明原理的形成多层热阻隔件的方法的另一示例的示意剖视侧视图。
具体实施方式
本领域普通技术人员会认识到的是,诸如“之上”、“之下”、“向上”、“向下”、“顶部”、“底部”等术语描述性地用于附图,且并不表示对由所附权利要求所限定的本发明范围有所限制。
参照附图,其中,类似的附图标记指代整个视图中的类似部件,图1示出示例车辆10的一部分。车辆10可包括发动机13,该发动机具有部件12。部件12具有施加于其的这里所公开类型的复合(多层)热阻隔件“涂层”14。多层热阻隔件14可称为复合热阻隔件涂层(TBC);其实际上是由多个层构成的工程化表面,这会在下文进行进一步详细地描述。
虽然图1所示的车辆10和发动机13是适合于这里公开的多层热阻隔件14的典型事例应用,但本文的设计并不局限于车辆和/或发动机的应用。固定或移动的机器或制造件(其中,其部件暴露于热量)可受益于本设计的使用。为了一致地说明,车辆10和发动机13之后会描述为示例系统,但不会将多层热阻隔件14使用限制为此种示例。
图1说明限定单个气缸26的发动机13。然而,本领域技术人员会认识到的是,本发明还可适用于具有多个气缸26的发动机13的部件12。每个气缸26均限定燃烧室30。发动机13构造成提供能量用于车辆10的推进。发动机13可包括但不限于柴油发动机或汽油发动机。
发动机13进一步包括进气组件36和排气歧管38,其各自与燃烧室30流体连通。发动机13包括往复活塞28,该往复活塞能在气缸26内可滑动地移动。
燃烧室30构造成用于燃烧空气/燃料混合物,以提供用于车辆10的推进的能量。空气可经由通过进气组件36进入发动机13的燃烧室30,其中,从进气歧管进入燃烧室30的空气流由至少一个进气阀32控制。燃料喷射到燃烧室30中,以与空气混合,或者引导通过进气阀32,该进气阀提供空气/燃料混合物。空气/燃料混合物在燃烧室30内点燃。空气/燃料混合物的燃烧产生废气,该废气离开燃烧室30并且抽吸进入排气歧管38。更确切地说,离开燃烧室30的空气流(排气流)由至少一个排气阀34控制。
参照图1和2,多层热阻隔件14可设置在发动机13的诸如活塞28、进气阀32、排气阀34、排气歧管38的内壁和/或燃烧圆顶39之类部件12的一个或多个的面或表面上。多层热阻隔件14粘结于部件12以形成隔热件,该隔热件构造成在发动机13的操作期间减小热传递损失、提高效率并且升高废气温度。多层热阻隔件14构造成提供低导热性和低热容量。这样,低导热性减小热传递损失,且低热容量意指多层热阻隔件14的表面在温度摆动期间追踪气体的温度,且使得进入气缸的冷却空气的加热最小。
参照图2,每个部件12包括呈现表面18的基底16,且多层热阻隔件14粘结于基底16的表面18。多层热阻隔件14可包括三个层,例如第一(粘结)层20、第二(隔热)层22以及第三(密封)层24。然而,取决于所提供的材料,应意识到的是,在一些实施例中,多层热阻隔件14可并不包括第一粘结层20,因为隔热层22的外部部分可构造成直接地粘结于基底16。例如,当隔热层22包括镍(Ni)且基底16包括铁(Fe)时,可无需第一层20。此外,如果期望的话,多层热阻隔件14可包括三个以上层。
隔热层22包括多个中空微结构40,这些中空微结构烧结在一起,以产生具有极高孔隙率的层。较佳地是,隔热层22的孔隙率是至少80%。更佳地是,隔热层22的孔隙率是至少95%。高孔隙率使得对应体积的空气和/或气体能容纳在其中,由此提供低效导热性和低效热容量的期望隔热特性。隔热层22的厚度T2在100微米(μm)和1毫米(mm)之间。更佳地是,隔热层22的厚度T2在100和500μm之间。甚至更佳地是,隔热层22的厚度T2在100和300μm之间。
隔热层22构造成承受至少80巴的压力。更佳地是,隔热层22构造成承受至少100巴的压力。甚至更佳地是,隔热层22构造成承受至少150巴的压力。附加地,关于温度,隔热层22构造成承受至少500摄氏度(℃)的表面温度。更佳地是,隔热层22构造成承受至少800℃的温度。甚至更佳地是,隔热层22构造成承受至少1100℃的温度。多层热阻隔件14的热容量可构造成确保基底16的表面18并不超过300℃.
在一个示例中,中空微结构40可由中空聚合物、金属、玻璃和/或陶瓷中心45构成,其可以在形状上是球形或者可以球形开始。至少一个金属涂覆层44可设置在每个中空中心45的外表面上;在一些情形中,第一金属涂层可涂覆有第二金属涂层。金属涂覆层44可单独地或组合地包括镍(Ni)、铁等等。金属涂覆层44可经由电镀、火焰喷涂、涂抹、非电解镀、气相沉积等等设置在微结构40的外表面上。
应意识到的是,在金属涂覆微结构40的粘结或烧结期间,由聚合物、金属和玻璃构成的中空中心45所具有的熔融温度低于金属涂覆层44的熔融温度,且因此,中空中心45可熔融或以其他方式分解以变为金属涂覆层44自身的一部分,或者熔融且转换成中空微结构40内的材料块。然而,当中空中心45的熔融温度高于金属涂覆层44的材料的熔融温度时,例如当中空中心45由陶瓷材料形成时,中空中心45保持完整且并不分解或者变得被吸收。
在中空中心45由聚合物、金属和玻璃形成的情形中,中空中心45可根据中空中心45的材料特性和施加于微结构40的烧结温度熔融。因此,当中空中心45发生熔融时,内部金属涂覆层44A不再是“涂层”,而是变为微结构40的内壁46。
在微结构40是圆形的示例中,例如图2中所示,中空微结构40可借助示例具有在5和100μm之间、在20和100μm之间或者在20-40μm之间的直径D1。应意识到的是,微结构40无需具有相同的直径,因为直径的混合可构造成提供期望的开口孔隙率(例如,填充密度),从而为隔热层22提供期望大小的强度。
多个中空微结构40可在烧结温度下在压力下模制或烧结一定模制时间,直到粘结部形成在相邻中空微结构40的涂覆层44之间,以形成隔热层22。烧结温度可接近金属涂覆层44的熔融温度。然而,在中空中心45由陶瓷材料构成的情形中,烧结温度会并不低于金属涂覆中心45的熔融温度。
粘结层20构造成粘结于基底16的表面18并且粘结于隔热层22,以使得隔热层22附连于基底16。在一个非限制示例中,粘结层20构造成扩散到基底16的表面18中并且扩散到隔热层22中,以在它们之间形成粘结部。在一个非限制示例中,基底16包括铝,隔热层22包括镍涂覆微结构40,且粘结层20包括黄铜,即铜-锌(Cu-ZN)合金材料。确定Cu-Zn含量,以产生最佳粘结强度、最佳热膨胀特征、热处理工艺、抗疲劳性等等。铜和锌在铝、镍和铁中具有良好的固溶度,而铁和镍在铝中具有极低的固溶度。因此,具有铜和锌组合的粘结层20提供中间结构层,该中间结构层促进相邻铝基底16和相邻镍或铁隔热层22之间的扩散粘结。然而,应意识到的是,基底16、隔热层22以及粘结层20并不局限于铝、镍和黄铜,而是可包括其他材料。
粘结层20的一侧可设置在基底16的表面18上,以使得粘结层20设置在基底16和隔热层22之间。压缩力可在粘结温度下在至少最短施加时间内施加于隔热层22和基底16。粘结层20的材料的熔融温度低于基底16和隔热层22的材料的各个的熔融温度。在另一示例中,粘结层20的材料的熔融温度在基底16和隔热层22的材料的各个的熔融温度之间。此外,所需的粘结温度可低于基底16的材料和隔热层22的材料的熔融温度,但足够高以促进基底16的金属材料和粘结层20的金属之间以及粘结层20的金属材料和隔热层22的金属材料之间发生扩散粘结。
应意识到的是,在将粘结层20粘结于基底16的表面18之前,粘结层20可粘结于隔热层22的内表面。附加地,粘结层20并不局限于利用固态扩散粘结于基底16的表面18和/或隔热层22,因为也可使用其他粘合方法,例如通过润湿、铜焊及其组合来进行。
应意识到的是,可施加期望数量的粘结层20,以提供期望的特征,只要粘结层20粘结于隔热层22并且粘结于基底16即可。
密封层24设置在隔热层22之上,以使得隔热层22设置在密封层24和粘结层20之间。密封层24是高温薄膜。更确切地说,密封层24包括构造成承受至少1100℃的温度的材料。在一些形式中,密封层24可由诸如镍、铁、镍合金或任何其他期望金属之类的金属材料形成。在一些变型中,密封层24可包括陶瓷材料,和/或密封层24可基本上由陶瓷材料构成或者仅仅由陶瓷材料构成。当密封层24包含陶瓷材料时,陶瓷材料可包括氧化锆、部分稳定氧化锆、氮化硅、熔融氧化硅、钛酸钡钕(BNT)、任何其他期望陶瓷或者这些或其他陶瓷的组合。
密封层24构造成较薄,例如厚度T3不超过20μm。更佳地是,密封层24构造成具有不超过5μm的厚度T3。密封层24不可渗透燃烧气体,以使得密封件设置在密封层24和隔热层22之间。此种密封件防止来自燃烧气体的诸如未经燃烧碳氢化合物、烟雾、部分反应燃料、液体燃料之类的碎屑进入由中空微结构40限定的多孔结构。如果允许此种碎屑进入多孔结构,则设置在多孔结构中的空气会最终被碎屑移位,且会降低或消除隔热层22的隔热特性。
密封层24可构造成呈现光滑的外表面42。具有光滑的密封层24对于防止产生湍流空气流会是重要的,因为空气流动经过密封层24的外表面42。此外,具有带有光滑表面的密封层24防止增大的热传递系数。在一个非限制示例中,密封层24可经由电镀或气相沉积施加于隔热层22。在另一个非限制示例中,密封层24可在烧结隔热层22的情形下同时地施加于隔热层22。
密封层24构造成具有充分地弹性,以在暴露于燃烧气体、热疲劳或碎屑期间抵抗断裂或破裂。此外,密封层24构造成具有充分地弹性,以承受下方隔热层22的膨胀和/或收缩。
现参照图3,隔热层22可包括一个以上的层。更确切地说,隔热层22可包括微结构层22A和过渡层22B。如上所述,微结构层22A是包括粘结在一起的多个中空微结构40的层。过渡层22B借助示例可包括镍或铁。在一些示例中,过渡层22B的金属材料和用于微结构层22A的微结构40的涂层可以是相同的,以促进层22A、22B之间的粘结。这样,当将微结构层22A和过渡层22B加热至足以将微结构层22A烧结至过渡层22B的温度时,微结构层22A的周界上的微结构40粘结于过渡层22B。
借助示例,微结构层22A较佳地形成为具有在100μm和1mm之间、在100和500μm之间或者在100和300μm之间的厚度T2。微结构层22A构造成承受至少150巴的压力并且承受至少1100℃的表面温度。
过渡层22B在接触点46处粘结于各个微结构40的涂层44。过渡层22B提供用于微结构层22A的支承结构或支柱,由此赋予隔热层22强度和刚度。在足够的时间内将热量施加于过渡层和粘结层的情形下,在粘结层20和基底16之间并且在粘结层20和隔热层22的过渡层22B之间发生金属扩散。与并不使用过渡层22B相比,过渡层22B提供与粘结层20的更大表面积接触,用于促进较大面积的扩散粘结,且微结构层22A的微结构40直接地扩散粘结于粘结层20(如图2中所示)。
再次参照图3,密封层24也可包括一个以上的层。更确切地说,密封层24可包括第一阻隔层24A和第二阻隔层24B。第一阻隔层24A可设置在隔热层22上,且第二阻隔层22B可设置在第一阻隔层24A上,以使得第一阻隔层24A设置在第二阻隔层24B和隔热层22之间。第二阻隔层24B可构造成呈现光滑的外表面42。
第一阻隔层24A和第二阻隔层24B可彼此层叠,以提供期望的特性,例如超级耐高温性、抗腐蚀性。在一个非限制示例中,第二阻隔层24B提供抗腐蚀性和超级耐高温性,而第一阻隔层24A提供对于下方隔热层22的密封,以防止碎屑进入限定在下方隔热层22的微结构40之间的开放空间。可施加任何期望数量的密封层24。不考虑部件阻隔层的数量,密封层24的厚度T3较佳地不超过20μm,或者甚至更佳地不超过5μm。
例如上文参照图2中示出的密封层24所描述的那样,密封层24的第一阻隔层24A和第二阻隔层24B的每个均可由金属或陶瓷形成。
此外,粘结层、隔热层以及密封层20、22、24各自构造成具有兼容的热膨胀系数特征,以承受热疲劳。
现参照图4,说明并且总地以114指代在本发明精神和范围内的多层热阻隔件的另一变型。多层热阻隔件114可在所有方面类似于上文示出的多层热阻隔件14,除了这里相对于隔热层122进行描述以外。因此,多层热阻隔件114可选地具有粘结层120,该粘结层设置在基底16的表面18上,该粘结层可与上文在图2和3中描述的粘结层20类似或相同。类似地,多层热阻隔件114具有密封层124,该密封层可与上文参照图2和3示出和描述的密封层24相同或类似。
图4的多层热阻隔件114中的差别在于隔热层122,但隔热层122也与上文描述的隔热层22具有一些相似之处。类似于隔热层22,图4中的隔热层122包括多个中空微结构140,这些中空微结构烧结在一起,以产生具有极高孔隙率的层。
较佳地是,隔热层122的孔隙率是至少80%。更佳地是,隔热层122的孔隙率是至少90%。甚至更佳地是,隔热层122的孔隙率是至少95%。如上所述,高孔隙率使得对应体积的空气和/或气体能容纳在其中,由此提供低效导热性和低效热容量的期望隔热特性。
隔热层122的厚度T2'在约75微米(μm)和1毫米(mm)之间。更佳地是,隔热层122的厚度T2'在75和500μm之间。甚至更佳地是,隔热层122的厚度T2'在75和300μm之间。
隔热层122构造成承受至少80巴的压力。更佳地是,隔热层122构造成承受至少100巴的压力。甚至更佳地是,隔热层122构造成承受至少150巴的压力。附加地,关于温度,隔热层122构造成承受至少500摄氏度(℃)的表面温度。更佳地是,隔热层122构造成承受至少800℃的温度。甚至更佳地是,隔热层122构造成承受至少1100℃的温度。多层热阻隔件114的热容量可构造成确保基底16的表面18并不超过300℃.
类似于上文描述的中空微结构40,图4的中空微结构140可由中空聚合物、金属、玻璃和/或陶瓷中心145构成,其可在形状上以球形开始(但此种形状最终改变为例如图4中所示形状那样的形状)。在此种示例中,中空中心145涂覆有诸如镍或铁合金的金属。在一个非限制示例中,中空微结构140由诸如镍、镍合金化合物之类的金属构成。至少一个金属涂覆层144可设置在每个中心145的外表面上。金属涂覆层144可单独地或组合地包括镍(Ni)、铁等等。金属涂覆层144可经由电镀、火焰喷涂、涂抹、非电解镀、气相沉积等等设置在微结构140的外表面上。中空中心145可熔融或以其他方式分解以变为金属涂覆层144自身的一部分,或者熔融并且转换成中空微结构140内的材料块。多个中空微结构140可在烧结温度下在压力下模制或烧结一定模制时间,直到粘结部形成在相邻中空微结构140的涂覆层144之间为止。
微结构140可如上所述产生;然而,在烧结期间,中空微结构140(其可以基本上球形或卵形开始)可变形为如图4中所示的变形微结构140,其中,微结构140变得扁平并且具有比高度h更大的宽度w。如图4中所示,变形的微结构140可具有大体矩形横截面,且在变形之后是大体长方体形状的,变形的微结构可类似于扁平的卵形。应理解的是,虽然微结构140描述为在烧结工艺期间变形,但应意识到的是,微结构140可在产生多层热阻隔件114的工艺的其他部分期间变形。此外,如图3中所示和所描述地那样,过渡层22B可施加于微结构140。
借助示例,中空微结构140可具有在5和100μm之间、在20和100μm或者在20-40μm之间的宽度w。类似地,高度h可具有类似的尺寸,除了在微结构140已变形或压缩之后高度h小于宽度w以外。应意识到的是,微结构140的每个无需具有相同的宽度w或直径h,因为可提供高度h和宽度w的混合以产生期望的开口孔隙率(例如,填充密度),从而为隔热层122提供期望大小的强度。
微结构140的变形形状增大相邻微结构140之间的接触面积,由此增大各个相邻微结构140之间的粘结并且导致更佳的热传递。可减小或消除微结构140之间的间隙和空隙。因此,每个变形的中空微结构140的大部分外部表面积均粘结于相邻的变形的中空微结构140。使得微结构140变形还在隔热层122的顶部边缘180上和底部边缘182上产生更光滑的表面,以导致分别与密封层124并且与粘结层120产生更佳接触(增大的接触面积)。
现参照图5A,说明用于使得隔热层122的微结构140变形且压实的一种方案。在形成层120、122、124的每个并且将这些层附连在一起之后,经加热辊子设备184在密封层124上滚动,以将力施加于多层热阻隔件114并且使得微结构140变形,直到它们如图5A中左侧上所示那样扁平为止。辊子184可在将力施加于多层热阻隔件114之前选择性地加热或者布置在炉子中。
作为在将辊子184于层120、122、124上滚动之前组装这些层的替代方案,辊子184可在将密封层124设置在隔热层122上之前直接地施加于微结构140。换言之,密封层124可在滚动操作之前或之后设置在隔热层122上。密封层124可替代地由变形微结构140的可足够压缩或者甚至塌陷的顶部层形成,以由隔热层122自身的顶部边缘180形成密封层124。替代地,密封层124可作为箔添加,或者密封层124可镀覆或沉积到变形微结构140的层122上。
现参照图5B,说明用于产生变形微结构140的另一方案。多层热阻隔件114由成形模具186保持在烧结炉子188内部。烧结炉子188可由支承结构190保持。产生微结构140的变形的力通过将多层热阻隔件114(或至少隔热层122)压缩在冲压件192和成形模具186之间以使得中空微结构140变形而施加。利用冲压件192和成形模具186的此种压缩可在烧结工艺期间发生。成形模具186和/或冲压件192可选择性地加热或布置在炉子中。
在又一变型中,真空力可在烧结期间、之前或之后施加于中空微结构140,以使得中空微结构140变形。
在形成多层热阻隔件114的任何变型中,形成多层热阻隔件114的工艺可包括例如通过烧结来加热隔热层122、粘结层120以及密封层124。
应意识到的是,这里描述的多层热阻隔件14、114可施加于除了存在于内燃机内以外的部件。更确切地说,多层热阻隔件14、114可施加于太空飞船、火箭、注塑模具等等的部件。
具体实施方式和附图或视图是对本发明的支持和描述,但本发明的范围仅仅由权利要求所限定。虽然已详细地描述了用于执行所要求的本发明的一些示例,但存在用于实践限定在所附权利要求中的本发明的各种替代设计和示例。此外,附图中示出的示例或者本文描述中提及的各个示例的特征并非必须理解为彼此独立的示例。而是,在一个示例中描述的每个特征可与来自其他示例的一个或多个其他期望特征相组合,从而产生并未用词语或参照附图描述的其他示例。因此,这些其他示例落在所附权利要求的范围框架内。
Claims (10)
1.一种多层热阻隔件,包括:
隔热层,所述隔热层包括粘结在一起的多个中空微结构;以及
密封层,所述密封层粘结于所述隔热层,且所述密封层是不可渗透的,且构造成对于所述隔热层进行密封,所述密封层包括陶瓷材料。
2.根据前述权利要求中任一项所述的多层热阻隔件,其中,所述密封层基本上由所述陶瓷材料构成。
3.根据前述权利要求中任一项所述的多层热阻隔件,其中,每个中空微结构均是扁平的且具有宽度和高度,所述宽度大于所述高度。
4.一种多层热阻隔件,包括:
隔热层,所述隔热层包括多个变形的中空微结构,每个变形的中空微结构均具有宽度和高度,所述宽度大于所述高度,其中,所述多个变形的中空微结构粘结在一起;以及
密封层,所述密封层粘结于所述隔热层,且所述密封层是不可渗透的,且构造成对于所述隔热层进行密封。
5.根据权利要求4所述的多层热阻隔件,每个变形的中空微结构的大部分外表面积粘结于所述多个变形的中空微结构的相邻的变形的中空微结构。
6.根据权利要求4或权利要求5所述的多层热阻隔件,每个变形的中空微结构均具有大体长方体形状。
7.根据权利要求4、权利要求5或权利要求6所述的多层热阻隔件,所述密封层包括陶瓷材料。
8.根据前述权利要求中任一项所述的多层热阻隔件,其中,所述陶瓷材料包括以下至少一种:氧化锆、部分稳定氧化锆、氮化硅、熔融氧化硅以及钛酸钡钕(BNT)。
9.一种部件,所述部件包括呈现表面的金属基底,且前述权利要求中任一项所述的多层热阻隔件粘结于所述表面。
10.一种形成用在内燃机的部件上的热阻隔件的方法,所述方法包括:
提供多个中空微结构,各个中空微结构均具有在10微米至约50微米的范围内的直径以产生隔热层;以及
将力施加于所述隔热层,直到所述中空微结构的每个均变形成具有宽度和高度的扁平中空微结构为止,所述宽度大于所述高度。
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