CN109865645A - The method for forming porous thermal barrier coating - Google Patents
The method for forming porous thermal barrier coating Download PDFInfo
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- CN109865645A CN109865645A CN201811464772.5A CN201811464772A CN109865645A CN 109865645 A CN109865645 A CN 109865645A CN 201811464772 A CN201811464772 A CN 201811464772A CN 109865645 A CN109865645 A CN 109865645A
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- barrier coating
- thermal barrier
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- gas
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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
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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
- C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
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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
- C23C4/04—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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- 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
- C23C4/18—After-treatment
Abstract
The invention discloses a kind of methods for controlling the porosity parameter of porous thermal barrier coating.This method includes being arranged in raw material on substrate to form porous thermal barrier coating.Raw material includes that gas forms additive and thermal barrier coating material.Deposition step further includes the amount that gas by controlling raw material feed rate, in raw material forms additive, and temperature of raw material arranged on substrate or combinations thereof controls the porosity parameter of porous thermal barrier coating.
Description
Technical field
The disclosure mainly on be related to the method to form porous thermal barrier coating.More specifically, this disclosure relates to control more
The porosity parameter of hole thermal barrier coating.
Background technique
Thermal barrier coating is generally used for working or being exposed in the product of high temperature under high temperature.For example, aeroturbine and
Land turbine may include the one or more components protected by thermal barrier coating.Examples of materials for thermal barrier coating includes
Rare earth-stabilized zirconia material, such as yttrium stable zirconium oxide (YSZ).Rare earth-stabilized zirconia material is being evaluated as dense sintering body
When the thermal conductivity with about 2.2W/m-K.It is partly due to its high temperature capabilities, low heat conductivity and relatively easy to deposit, YSZ quilt
The thermal barrier coating material being widely used as in gas turbine.In recent years, have increasing need for being further improved thermal barrier properties to subtract
Total weight, thickness and the quantity of the small material for being used to form thermal barrier coating.
Also it can reduce the thermal conductivity of thermal barrier coating by increasing the porosity of coating.Conventionally, it is suitable to can be used
Deposition technique for example forms thermodynamic barrier by air plasma spray (APS) or by electro beam physics vapour deposition (EPVD)
Coating.Can usually have around being characterized in that by the thermal barrier coating of APS process deposits is the irregular of on-uniform porosity porosity
Increase crystal grain micro-structure.It can produce the resistance to strain grain structure of column, energy by the thermal barrier coating of EBPVD process deposits
It is enough to expand and shrink in the case where the stress for not causing to lead to spallation.However, EBPVD technique may more be provided than APS technique
This intensive.Therefore, it is necessary to the improved porosity that can control thermal barrier coating, thus control thermal barrier coating thermal conductivity
Coating process.
Summary of the invention
One embodiment of the disclosure is related to one kind and forms porous thermodynamic barrier by the way that raw material to be arranged on substrate
The method of coating.The raw material includes that gas forms additive and thermal barrier coating material.Deposition step also comprises logical
Cross control raw material feed rate, the gas in raw material forms the amount of additive, the raw material of arrangement on substrate
Temperature or combinations thereof control the porosity parameter of porous thermal barrier coating.
Another embodiment of the present disclosure is related to a kind of by using air plasma spraying process to arrange raw material on substrate
Material is come the method that forms porous thermal barrier coating.The raw material includes that gas forms additive and thermal barrier coating material
Material.Deposition step also comprises more to control by using the temperature of the raw material arranged on auxiliary thermal source control substrate
The porosity parameter of hole thermal barrier coating.
Another embodiment of the present disclosure is related to a kind of method for forming the porous thermal barrier coating including alternation porosity.Institute
The method of stating includes being arranged in raw material to form porous thermal barrier coating on substrate, wherein the raw material includes gas
Form additive and thermal barrier coating material.It is described arrangement include by control raw material in gas formed additive amount,
Temperature of arranged raw material on substrate or combinations thereof is controlled using auxiliary thermal source to form the alternation in thermal barrier coating
Porosity.
Specifically, technical scheme 1 is related to a kind of method for forming porous thermal barrier coating, comprising: on substrate
Raw material is arranged to form the porous thermal barrier coating, wherein the raw material includes that gas forms additive and heat shielding
Barrier coating material, and wherein the arrangement includes the gas by controlling raw material feed rate, in the raw material
Body forms temperature of raw material arranged on substrate described in the amount of additive or combinations thereof to control the porous thermodynamic barrier
The porosity parameter of coating.
Technical scheme 2 is related to method according to technical solution 1, which is characterized in that the control is described more
The porosity parameter of hole thermal barrier coating includes that the institute for the raw material arranged on the substrate is controlled using auxiliary thermal source
State temperature.
Technical scheme 3 is related to the method according to technical solution 2, which is characterized in that by cloth on the substrate
The raw material set is heated to be greater than the temperature for the temperature that the substrate is resistant to.
Technical scheme 4 is related to method according to technical solution 3, which is characterized in that by cloth on the substrate
The raw material set is heated to the temperature in about 1000 DEG C to about 1500 DEG C of range.
Technical scheme 5 is related to method according to technical solution 1, which is characterized in that the control is described more
The porosity parameter of hole thermal barrier coating includes that the gas in the raw material is formed to the amount of additive
Control is in the range of about 0.1wt% to about 10wt%.
Technical scheme 6 is related to method according to technical solution 1, which is characterized in that the control is described more
The porosity parameter of hole thermal barrier coating includes controlling the raw material feed rate in about 2.5gm/min to about
In the range of 100gm/min.
Technical scheme 7 is related to method according to technical solution 1, which is characterized in that the gas formation adds
Adding agent includes graphite, carbide, oxycarbide, nitride or combinations thereof.
Technical scheme 8 is related to method according to technical solution 1, which is characterized in that the gas formation adds
Adding agent includes elemental carbon.
Technical scheme 9 is related to method according to technical solution 1, which is characterized in that the thermal barrier coating
Material includes yttria-stabilized zirconia.
Technical scheme 10 is related to method according to technical solution 1, which is characterized in that uses air plasma
Spraying process arranges the raw material on the substrate.
Technical scheme 11 is related to method according to technical solution 1, which is characterized in that the porosity parameter
Including average cell size, average pore amount, pore size distribution, hole micro-structure or combinations thereof.
Technical scheme 12 is related to method according to technical solution 1, which is characterized in that the porous thermodynamic barrier
Coating includes multiple holes, so that at least some of the multiple hole hole is in crystal grain.
Technical scheme 13 is related to method according to technical solution 1, which is characterized in that the control is described more
The porosity parameter of hole thermal barrier coating includes by the average cell size control in multiple holes in the porous thermal barrier coating
It makes in about 0.1 micron to about 25 microns of range.
Technical scheme 14 is related to method according to technical solution 1, which is characterized in that the control is described more
The porosity parameter of hole thermal barrier coating includes by the average pore amount control in multiple holes in the porous thermal barrier coating
It makes in the range of about 5 volume % to about 10 volume %.
Technical scheme 15 is related to method according to technical solution 1, which is characterized in that the control heat
The porosity parameter of barrier coatings further includes the alternation porosity to be formed across the thickness of the thermal barrier coating.
Technical scheme 16 is related to a kind of method for forming porous thermal barrier coating, comprising: sky is used on substrate
Gas plasma spray coating process arranges raw material to form the porous thermal barrier coating, wherein the raw material includes gas
Additive and thermal barrier coating material are formed, and wherein the arrangement includes controlling cloth on the substrate by using auxiliary thermal source
The temperature for the raw material set controls the porosity parameter of the porous thermal barrier coating.
Technical scheme 17 is related to the method according to technical solution 16, which is characterized in that will be on the substrate
The raw material of arrangement is heated to the temperature in about 1000 DEG C to about 1500 DEG C of range.
Technical scheme 18 is related to the method according to technical solution 16, which is characterized in that the gas is formed
Additive includes elemental carbon.
Technical scheme 19 is related to the method according to technical solution 16, which is characterized in that the thermodynamic barrier applies
Layer material includes yttria-stabilized zirconia.
Technical scheme 20 is related to a kind of method for forming the porous thermal barrier coating including alternation porosity, described
Method includes: that raw material is arranged on substrate to form the porous thermal barrier coating, wherein the raw material includes gas
Body forms additive and thermal barrier coating material, and wherein the arrangement includes applying in the following manner to form the thermodynamic barrier
The alternation porosity of layer: the amount that the gas in the raw material forms additive is controlled, auxiliary thermal source control is used
The temperature for the raw material arranged on the substrate is made, or combinations thereof.
Detailed description of the invention
When the reading of reference attached drawing is described in detail below, it will more fully understand these and other features of the invention, side
Face and advantage, wherein throughout the drawings, similar character indicates similar portion, in the accompanying drawings:
Fig. 1 shows the method according to an embodiment of the present disclosure for forming porous thermal barrier coating；
Fig. 2 shows the methods according to an embodiment of the present disclosure for forming porous thermal barrier coating.
Fig. 3 shows the method according to an embodiment of the present disclosure for forming porous thermal barrier coating.
Fig. 4 shows the sectional view of the schematic diagram of porous thermal barrier coating according to an embodiment of the present disclosure；
Fig. 5 shows another sectional view of the schematic diagram of porous thermal barrier coating according to an embodiment of the present disclosure；And
Fig. 6 shows scanning electron microscope (SEM) micro- photograph of porous thermal barrier coating according to an embodiment of the present disclosure
Piece.
Specific embodiment
As used approximate term can be used for modifying any quantitative table in entire disclosure and claims herein
Show, the quantificational expression can be changed in a manner of admissible in the case where not causing its relevant basic function to change.Therefore,
Specified exact value is not limited to for example, by the value that terms such as " about " are modified.In some cases, approximate term can correspond to use
In the precision of the instrument of measurement described value.Herein and in entire disclosure and claims, scope limitation can combine and/
Or exchange, unless in addition context or term indicate, otherwise such range determines to include all subranges wherein contained.
In following description and claims, unless context in addition clearly stipulate that otherwise singular " one ",
"one", " described " include plural referents.As used herein, unless context is in addition clearly stipulate that otherwise term "or"
Exclusive meaning is had no, and refers to that there are the components mentioned by least one, and the group including mentioned component wherein may be present
The example of conjunction.
As used herein, term "available" and " can be " indicate the possibility occurrence in one group of situation；Specified attribute, spy
Property or function possess；And/or by expressing one or more in ability associated with the verb of identification, technical ability or possibility
It is a to assert another verb.Therefore, the use instruction modified term of "available" and " can be " is obvious appropriate, capable or suitable
In indicated technical ability, function or purposes, while in view of modified term may sometimes inappropriate, Bu Nenghuo in some cases
It is improper.
As used herein, term " coating " refers to is arranged at least one of bottom surface in a manner of continuously or discontinuously
Material on point.In addition, term " coating " may not mean that the thickness of institute's material arranged is uniform, and institute's material arranged can have uniformly
Or variable thickness.Term " coating " can refer to signal layer coating material or can refer to laminated coating material.In the multiple layer, coating material
Material may be the same or different.
As used herein, unless specifically indicated otherwise, otherwise term " on being arranged in ... " refers to and is arranged to directly with one another
Contact or layer or coating by having intervening layer and mediate contact therebetween.
One embodiment of the disclosure is related to a kind of method for forming porous thermal barrier coating.The method includes by raw material
Material is arranged on substrate to form porous thermal barrier coating, wherein the raw material includes that gas forms additive and heat shielding
Barrier coating material.Deposition step includes forming additive by the gas in control raw material feed rate, raw material
Amount, the temperature of raw material arranged on substrate or combinations thereof control the porosity parameter of porous thermal barrier coating.
Fig. 1 shows the method 10 according to some embodiments of the present disclosure.Method 10 is included in step 11 and provides substrate 110,
Raw material 121 is arranged on substrate 110 to form arranged raw material 120, and in step 13 in base in step 12
Porous thermal barrier coating 130 is formed on material 110.
It is ease of explanation although note that in Fig. 1, substrate 110 is shown with face profile, substrate 110 can have
The combination of any suitable geometry or profile, such as complex geometric shapes, non-planar profile or both.As made herein
Being referred to, term " complex geometric shapes " can not easily or consistently can recognize or reproducible shape, for example, be not square,
Round or rectangle.In some embodiments, substrate 110 can be one that turbogenerator etc. is exposed to the component of hot environment
Point.In some embodiments, turbogenerator can be aircraft engine.Alternatively, turbogenerator, which can be, is used in industry
The engine of any other type in.The non-limiting example of such turbogenerator includes land used in power plant
Turbogenerator used in turbogenerator used in upper turbogenerator, marine vessel or oil rig.Propeller for turboprop
The non-limiting example of machine component includes the turbine airfoils such as blade and wheel blade, turbine protecting cover, turbine nozzle, turbine bucket
(bucket), the combustor components such as liner and deflector, hot baffle, the booster hardware of gas-turbine unit and fields
Technical staff known to other similar turbine parts.
Substrate 110 may include ceramic matrix composite or metal superalloy.The non-limiting reality of suitable metal superalloy
Example includes iron-based supperalloy, cobalt-base superalloy, nickel based super alloy or combinations thereof.
Substrate 110 can be the pre-constructed unit of turbogenerator, or can be manufactured before deposition step.In some realities
It applies in example, the step 11 for providing substrate may include one or more preliminary steps, such as cleaning, polishing, arrangement adhesive coatings etc.
Deng.In some embodiments, in step 11, substrate 110 can be coated with adhesive coatings (not shown).Adhesive coatings can be by metal
Oxidation-resistant material is formed, and protects bottom substrate 110 and porous thermal barrier coating 130 is enable more firmly to adhere to substrate
110.The suitable material of adhesive coatings includes M1CrAlY alloy powder, wherein M1Indicate metal, such as iron, nickel, platinum or cobalt.It is other
The non-limiting example of suitable bonding coating material includes metal aluminide, such as nickel aluminide, platinum aluminide or combinations thereof.
As previously mentioned, in step 12, by the arrangement of raw material 121 on substrate 110 to form arranged raw material material
Material 120.As used herein, term " raw material " refers to form the mixing of the homogeneity of two or more materials of single phase
Object or finger-type at two or more materials of more than one phase heterogeneous mixture.Raw material 121 can be in solid shape
Formula, liquid form or semi-solid form.In certain embodiments, raw material 121 is in powder type.
As it was earlier mentioned, raw material 121 includes that gas forms additive and thermal barrier coating material.In some embodiments
In, raw material 121 includes the homogenous mixts that gas forms additive and thermal barrier coating material.In certain embodiments,
Gas forms additive and is dissolved into thermal barrier coating material in advance to form raw material 121.Without being bound by any theory
In the case where, it is believed that by the way that gas formation additive is incorporated to raw material material when manufacturing raw material 121 (such as raw material powder)
In material 121, the porosity parameter of porous thermal barrier coating 130 can control.For example, additive is formed by control gas to exist
One or more of amount, size or distribution in raw material 121.
As used herein, term " gas formation additive " refer to can be oxidized at high temperature it is non-reacted insoluble
The material of (with thermal barrier coating material) gas, the gas are coated by thermal barrier coating material, and hole is consequently formed.Suitable gas
The example that body forms additive includes but is not limited to graphite, carbide, oxycarbide, nitride or combinations thereof.In certain implementations
In example, it includes elemental carbon that gas, which forms additive,.As described in detail later, during or after deposition step, gas formation adds
Add dosage form at gas, such as carbon monoxide, carbon dioxide, nitrous oxide or any suitable gas, this depends on gas used
The composition of body formation additive.Insoluble gas is coated in thermal barrier coating during arrangement or rear deposition step, thus shape
Pore-forming.In some embodiments, being largely coated in thermal barrier coating material in formed gas.As used herein art
Language " a large amount of in gas " refers at least 90 volume % of formed gas.This and the fugitive material shape for being used to form porous coating
In contrast with, coating material undergoes high temperature so that fugitive material decomposes or oxidation, and gained gas is discharged from coating, thus
Generate hole.
As used herein, term " thermal barrier coating " refer to including can reduce the bottom substrate for going to product hot-fluid,
Namely form the coating of the material of thermodynamic barrier.Composition of the porous thermal barrier coating in terms of the type of thermal barrier coating material and amount
It may depend on one or more factors, the desired heat of composition, thermal barrier coating including neighbouring bonding coating layer (if present) is swollen
Swollen coefficient (CTE) characteristic and the desired thermal barrier properties of thermal barrier coating.
The non-limiting example of suitable thermal barrier coating material includes zirconium oxide, pyrochlore or combinations thereof.In some realities
It applies in example, thermodynamic barrier material includes chemically stable zirconium oxide (such as metal oxide and zirconium oxide blend), such as
Yttria-stabilized zirconia, ceria stabilizing zirconia, stable calcium oxide zirconium oxide, scandium oxide-stabilizing zirconia, magnesia
Stabilizing zirconia, India's stabilizing zirconia, ytterbium oxide stabilizing zirconia, lanthana stabilizing zirconia, gadolinium oxide-stabilized zirconium oxide
And the mixture of such stabilizing zirconia.
In certain embodiments, thermal barrier coating material includes yttria-stabilized zirconia.Suitable stabilized with yttrium oxide oxygen
Change the yttrium oxide (combination weight based on yttrium oxide and zirconium oxide) that zirconium may include about 1wt% to about 20wt%, and more generally
Yttrium oxide of the about 3wt% to about 10wt%.Example yttria-stabilized zirconia thermal barrier coating include about 7wt% yttrium oxide and
The zirconium oxide of about 93wt%.Chemically stable zirconium oxide may also include dysprosia, erbium oxide, europium oxide, oxidation for these
One of second metal such as gadolinium, neodymia, praseodymium oxide, urania, hafnium oxide (such as group of the lanthanides or actinium series) oxide is a variety of
To further decrease the thermal conductivity of thermal barrier coating.
As used herein, term " porous thermal barrier coating " refers to the coating including multiple holes.As used herein
Term " the porosity parameter of porous thermal barrier coating " refers to the pore size in multiple holes in porous thermal barrier coating 130, hole ruler
One or more of very little distribution, the number in hole or hole micro-structure.Pore size is provided to the hole in porous thermal barrier coating 130
The instruction of intermediate value or average-size.Pore size distribution, which provides, deposits length, the width and thickness across porous thermal barrier coating 130
Pore size range quantitative description.Void content is the multiple hole total volume occupied by porous thermal barrier coating 130
In occupied percent by volume, and be also called " total porosity " of porous thermal barrier coating 130.By changing above-mentioned hole
One during degree parameter is multiple, it can control the total porosity in multiple holes in porous thermal barrier coating 130.Porous thermal barrier coating
The disclosure can be used in one or more of pore size, hole shape, the number in hole, pore size distribution or hole micro-structure in 130
Described in method controlled.
In some embodiments, the average cell size in multiple holes in porous thermal barrier coating 130 from about 0.1 micron to
In about 25 microns of range.In some embodiments, the average cell size in multiple holes in porous thermal barrier coating 130 is from about
0.25 micron to about 5 microns to range in.Multiple holes in porous thermal barrier coating 130 can be spy with any suitable shape
Sign.In certain embodiments, the shape in the hole in porous thermal barrier coating can be substantially spherical.In some embodiments, more
Spherical pore porosity in hole thermal barrier coating 130 can provide resistance to strain micro-structure, thus allow thermal barrier coating in gas turbine
More long duration is operated under operating condition.
Referring again to FIGS. 1, raw material 121 is arranged on substrate 110 using suitable equipment 115 in step 12.Raw material
Material 121 can be directly arranged in adhesive coatings (if present) or on substrate 110 by any one of various technologies, described
Various technologies include gas phase disposition, such as physical vapour deposition (PVD) (PVD), electro beam physics vapour deposition (EBPVD)；Plasma spray
It applies, such as air plasma spray (APS), suspending liquid plasma spraying (SPS) and vacuum plasma spray coating (VPS)；Other heat
Spray deposition, such as high-velocity oxy-fuel (HVOF) spraying, detonation or rod spraying (wire spray)；Chemical vapor deposition
(CVD), sol-gel method, or the combination of two or more being mentioned above in technology.
For arrange, deposit or in other ways formed porous thermal barrier coating 130 particular technique may depend on it is porous
One or more of the composition of thermal barrier coating 130, the thickness of porous thermal barrier coating 130 and wanted physical structure.At certain
In a little embodiments, using plasma spraying technology, specifically, APS technology, to arrange raw material 121.As previously noted
And it is raw material that it is co-deposited on substrate 110 or adhesive coatings (if present), which to form additive and thermal barrier coating material, for gas
Material 121.In some embodiments, co-deposition can by blending, mixing or in other ways by gas formed additive and
Thermal barrier coating combination of materials is together (such as powder) to provide the mixture being subsequently deposited on substrate/adhesive coatings
To realize.The blending or mixing that gas forms additive and thermal barrier coating material can provide raw material to depositing device
It realizes, or can be realized in depositing device 115 itself before 115 (such as APS rifles), form raw material wherein.Certain
In embodiment, before providing raw material 121 to depositing device 115, gas forms additive and is blended and dissolved in heat shielding
In barrier coating material.As used herein term " arranged raw material " refers to the raw material as deposited, that is, not yet
The raw material of additional step (such as heating) is undergone, or refers to and undergoes additional step (such as logical after deposition step
Cross auxiliary heating source for heating) raw material.As used herein term " arranged raw material " and " porous thermodynamic barrier painting
Layer " has difference, so that thermal barrier coating material is in partially or completely molten condition, and hole in " arranged raw material "
It may not be coated in coating yet.
Deposition step 12 further include control 121 feed rate of raw material, the gas in raw material 121 forms additive
Amount or the arranged raw material 120 on substrate 110 temperature to form porous thermal barrier coating 130.By controlling these
One or more of parameter controls the porosity parameter (and therefore, total porosity) of porous thermal barrier coating 130.Not by
In the case where any theoretical limitation, it is believed that, may be in porous thermal barrier coating 130 in the case where this rate-determining steps is not present
It is middle to generate uncontrolled aspherical or random distribution porosity.
In some embodiments, added by the gas formation in control 121 feed rate of raw material and raw material 121
Add one or both of amount of agent to control the porosity parameter of porous thermal barrier coating 130.As used herein term
" feed rate " refers to the rate for depositing raw material 121 in substrate 110 using suitable depositing device 115.In embodiment,
Using APS process deposits raw material, term " feed rate " refers to the spray rate of raw material 121.?
In some embodiments, the amount by the way that the gas in raw material 121 to be formed to additive is controlled in about 0.1wt% to about 10wt%
Range in control the porosity parameter of porous thermal barrier coating 130.In some embodiments, by by raw material 121
In gas form the amount of additive and control and control porous thermal barrier coating 130 in the range of about 0.5wt% to about 5wt%
Porosity parameter.In some embodiments, as described in detail later, the gas in raw material 121 forms the amount of additive
It can change in the duration of deposition step, so that the gas that arranged raw material 120 includes alternation content forms addition
Thus agent forms alternation porosity in the porous thermal barrier coating 130 of gained.In such embodiments, " gas formation adds term
Add the amount of agent " refer to that the gas in raw material 121 forms average magnitude of the additive in the entire duration of deposition step.
In some embodiments, by controlling 121 feed rate of raw material in about 2.5gm/min to about 100gm/
The porosity parameter of porous thermal barrier coating 130 is controlled in the range of min.In some embodiments, by by raw material
121 feed rates control the hole that porous thermal barrier coating 130 is controlled in the range of about 20gm/min to about 50gm/min
Spend parameter.Valve or any other suitable method can be used to control feed rate.This be used to form porous thermal barrier coating
Method be contrasted, feed rate or amount that gas in raw material forms additive are not controlled in the method, this can
It can lead to uncontrolled and random porosity.
In some embodiments, porous heat is controlled by the temperature of the arranged raw material 120 on control substrate 110
The porosity parameter of barrier coatings 130.(such as preheating can be passed through by controlling the temperature of raw material 121 before the deposition
Raw material), the temperature of deposition (such as the spraying temperature in the case where being deposited using APS, or by during deposition
Use auxiliary thermal source) or deposit one or more of temperature of substrate 110 of raw material thereon to control on substrate 110
The temperature of arranged raw material 120.In certain embodiments, by pre-add hot substrate and by maintaining arranged raw material
Temperature combines to control the temperature of the arranged raw material 120 on substrate 110.
In some embodiments, the arranged raw material 120 on substrate 110 is heated to can tolerate greater than substrate 110
Temperature temperature.As used herein, term " the tolerable temperature of substrate " refers to that substrate may be opened when being more than this temperature
Begin the temperature for deforming, melting or changing form.In some embodiments, arranged raw material can be heated to be similar to turbine
The temperature of engine operating temperature.Raw material is deposited and is heated to may make boundary similar to the temperature of engine operating temperature
The coating stress in face reduces, and at this temperature, thus the potential service life for improving the thermal barrier coating in engine.One
In a little embodiments, the temperature that the arranged raw material 120 on substrate 110 is heated in about 1000 DEG C to about 1500 DEG C of range
Degree.In certain embodiments, the arranged raw material 120 on substrate 110 is heated to about 1150 DEG C to about 1300 DEG C ranges
In temperature.
The arranged raw material 120 of auxiliary heating source for heating can be used.Term " auxiliary thermal source " refers to except for arranging raw material
Heat source used except the capital equipment of material 121.For example, when using APS technical arrangement raw material, APS equipment
It may include main heating source that is different from auxiliary thermal source and separating.The suitable including but not limited to infrared source (IR) of auxiliary thermal source, etc.
Plasma source, inductor or combinations thereof.In some embodiments, auxiliary thermal source be with the plasma source for APS technique not
Same plasma source.In certain embodiments, auxiliary thermal source includes induction coil.
Another embodiment of the present disclosure is related to a kind of method for forming porous thermal barrier coating using auxiliary thermal source.The side
Method includes using air plasma spraying process arrangement raw material on substrate to form porous thermal barrier coating, wherein described
Raw material includes that gas forms additive and thermal barrier coating material, and wherein deposition step includes by using auxiliary thermal source
The temperature of the arranged raw material on substrate is controlled to control the porosity parameter of porous thermal barrier coating.
Fig. 2 shows methods 20 according to an embodiment of the present disclosure.Method 20 includes: to provide substrate 110 in step 14；?
Step 15, arrange raw material to form arranged raw material 120 on substrate 110 using APS equipment 115；And in step
Rapid 16, porous thermal barrier coating 130 is formed on substrate 110.The method also includes being controlled in step 15 using auxiliary thermal source 125
Make the temperature of arranged raw material.Describe the non-limiting example of suitable auxiliary thermal source previously herein.Furthermore it please infuse
Meaning, although the size and shape that may depend on substrate use one or more heat sources Fig. 2 shows single auxiliary thermal source 125
125.In addition, in the degree of approach of the configuration of auxiliary thermal source 125, the placement of auxiliary thermal source 125 and auxiliary thermal source 125 and substrate 110
One or more may depend on required degree of heat and change.
Referring now to figure 1 with 2, in some embodiments, one of in the following manner or a variety of realize to being arranged
The heating of raw material 120: pre-add hot substrate 110 is simutaneously arranged and heats raw material 121；Or deposition step 12,15 it
Arranged raw material 120 is heated afterwards.In certain embodiments, by before deposition step 12,15 pre-add hot substrate 110 come
Realize the heating to arranged raw material 120.In some such examples, it can be used auxiliary thermal source 125 by 110 pre-add of substrate
Raw material 121 can be deposited on preheating substrate by heat to the first temperature.First temperature can be enough to melt thermodynamic barrier painting
The thermal barrier coating material melted is maintained molten state by layer material, but is lower than the tolerable temperature of substrate 110.?
In some embodiments, during deposition step 12,15, auxiliary thermal source 125 can be used that raw material is further heated to second
Temperature.Second temperature can be enough the oxidation for causing gas to form additive, thus be formed in the thermal barrier coating material of fusing
Gas, but it is greater than the tolerable temperature of substrate.For example, for Ni-based or cobalt-base superalloy, auxiliary thermal source can will be arranged
Raw material 120 is heated to the temperature of the fusing point greater than these superalloy, so that gas is formed.
The method may additionally include step 13,16, and cooling arranged raw material 120 is to form porous thermal barrier coating
130.In some embodiments, by using preheating substrate, gassiness body forms the raw material 121 of additive in a certain temperature
It is deposited such that gas forms additive oxidation and forms gas under degree.This gas can be in raw material still in molten state shape
At to make bubble formation hole.In some embodiments, the cooling rate of arranged raw material 120 coats this some holes
In arranged raw material 120.As previously mentioned, usable approach described herein controls the hole of these coating holes
Degree.In some embodiments, as described in detail later, auxiliary thermal source 125 can be also further controlled, so that can realize from auxiliary
The heating of heat source 125 in porous thermal barrier coating 130 to generate alternation porosity.
Another embodiment of the present disclosure is related to a kind of method for forming the porous thermal barrier coating including alternation porosity.Institute
The method of stating includes being arranged in raw material to form porous thermal barrier coating on substrate, wherein the raw material includes gas
Form additive and thermal barrier coating material.It is described arrangement include by control raw material in gas formed additive amount,
Temperature of arranged raw material on substrate or combinations thereof is controlled using auxiliary thermal source to form the alternation in thermal barrier coating
Porosity.
As used herein term " alternation porosity " refers to the thickness that porous thermal barrier coating 130 is crossed over by multiple holes
The variation of the percent by volume of occupied porous thermal barrier coating 130.For the specific region of porous thermal barrier coating 130,
The percent by volume that multiple holes occupy can be referred to as " porosity " of the specific region.In addition, term alternation porosity coverage holes
The discontinuous variation of porosity, consecutive variations of porosity or combinations thereof.For example, in some embodiments, the method can
It is included in formation alternation porosity in porous thermal barrier coating 130, so that porosity crosses over the thickness of porous thermal barrier coating 130
Continuously increase from the surface of region (or if it exists, adhesive coatings) to the porous thermal barrier coating 130 arranged close to substrate 110
Or reduce.In some other embodiments, raw material 121 can be arranged in substrate 110 in the form of discrete layer and (or if it exists, be glued
Close coating) on, so that there are the Spline smoothings of porosity (to increase or subtract for the different layers of porous thermal barrier coating 130 obtained by crossing over
It is small).In certain embodiments, the method includes forming porous thermal barrier coating 130, so that close to substrate 110 (if or depositing
In adhesive coatings) region and the surface of porous thermal barrier coating 130 can generally be free of porosity.Intermediate region can have
Possible discontinuous or continuous alternation porosity.In addition, the porosity in intermediate region may depend on porous thermal barrier coating
Wanted performance and increase or reduce.In the case where without being bound by any theory, it is believed that across the thickness of porous thermal barrier coating 130
The alternation porosity of degree may depend on final use application and provide wanted performance characteristics.For example, close by minimizing
Porosity in the layer/region on porous thermal barrier coating surface can enhance the anticorrosive or impact resistance of coating.It is some its
During it is applied, it may be necessary to which the porous surface of thermal barrier coating for example improves the sacrifice performance of coating.
Can by variation different zones/layer in hole number and different zones/layer in multiple holes average-size in
One of or both porous thermal barrier coating 130 in different zones/layer to change thermal barrier coating 130 porosity.?
In some embodiments, the amount of additive is formed by the gas in control raw material, is controlled on substrate using auxiliary thermal source
Temperature of arranged raw material or combinations thereof come formed across porous thermal barrier coating thickness alternation porosity.
Referring back to Fig. 1 and 2, in some embodiments, can for example be added by the gas formation in control raw material 121
Add the amount of agent to form the alternation porosity across the thickness of porous thermal barrier coating 130.Pass through gas in variation raw material 121
Body forms the amount of additive, can change the gas shape in arranged raw material 120 in the duration of deposition step 12,15
At the amount of additive.Therefore, the gas that alternation content is obtained in arranged raw material 120 forms additive.Arrange original
The gas of this alternation content in material material 120 forms additive can produce alternation porosity after oxidation.In some embodiments
In, it can be sunk by that will have a variety of chargings of variation gas formation additive level to provide depositing device 115 and control to enter
The charging of product equipment 115 is come the amount of the gas formation additive changed in raw material 121.
With continued reference to Fig. 2, in some other embodiments, it can for example pass through the temperature of the arranged raw material 120 of control
To form the alternation porosity across the thickness of porous thermal barrier coating 130.It in such embodiments, can be in deposition step 15
Auxiliary thermal source 125 is switched on or off depending on the wanted alternation of porosity during duration.For example, for its mid-term
It hopes layer/region of very small orifice porosity, auxiliary thermal source 125 can be cut off, thus minimize formation of the gas in those layers/region.
Referring now to Fig. 3, the method 30 to form the porous thermal barrier coating 130 with alternation porosity is shown.Method 30 is wrapped
It includes: in step 31, providing substrate 110；In step 32, on substrate 110 by the arrangement of thermal barrier coating material 112；In step 33,
Raw material 121 is arranged on thermal barrier coating material 112 to form the arranged raw material of multilayer (120', 120 ")；?
Step 34, thermal barrier coating material 112 is arranged on arranged raw material 120 " outermost layer 120 ", and in step
35, porous thermal barrier coating 130 is formed on substrate 110.The method also includes being controlled in step 33 using auxiliary thermal source 125
The temperature of arranged raw material 120', 120 ".Describe the non-limiting example of suitable auxiliary thermal source previously herein.?
In some embodiments, auxiliary thermal source 125 can also be in step 32 and 34 for thermal barrier coating material 112 to be arranged in substrate
On 110.Although note that Fig. 3 shows the raw material (120', 120 ") of two layers of arrangement, total porosity demand is depended on, it can
There are the raw materials of multi-tier arrangement on thermal barrier coating material 112.
In some embodiments, the amount that the gas in arranged raw material 120' forms additive may differ from being arranged
Raw material 120 " in amount.As previously mentioned, can by variation raw material 121 in gas formed additive amount come
The gas changed in arranged raw material 120 forms the amount of additive.This gas forms the change of additive capacity in different layers
Change can cause the variation of each layer of total porosity, thus generate the porous thermal barrier coating 130 with alternation porosity.Cause
This, in such embodiments, porous thermal barrier coating 130 includes multiple layers (112,120', 120 "), so that each layer of hole
Degree is different.
In some embodiments, the temperature of arranged raw material 120' can be with arranged raw material 120 " temperature not
Together.As previously mentioned, the temperature of arranged raw material 120 can be changed by controlling auxiliary thermal source 125.In different layers
The variation of this temperature can cause the variation of each layer of total porosity, thus generate the porous thermodynamic barrier with alternation porosity
Coating 130.Therefore, in such embodiments, porous thermal barrier coating 130 includes multiple layers (112,120', 120 "), so that often
One layer of porosity is different.
Figure 4 and 5 are shown using the porous heat including multiple holes 132 formed according to the method for some embodiments of the present disclosure
The sectional view of the schematic diagram of barrier coatings 130.In some embodiments, the porosity parameter of porous thermal barrier coating 130 is controlled
Including the model by the average cell size control in multiple holes 132 in porous thermal barrier coating 130 at about 0.1 micron to about 25 microns
In enclosing.In some embodiments, the porosity parameter for controlling porous thermal barrier coating 130 includes by porous thermal barrier coating 130
In multiple holes 132 average cell size control in about 0.25 micron to about 5 microns of range.In some embodiments, it controls
The porosity parameter for making porous thermal barrier coating 130 includes by the average pore in multiple holes 132 in porous thermal barrier coating 130
Amount control is in the range of about 1 volume % to about 10 volume %.In some embodiments, porous thermal barrier coating 130 is controlled
Porosity parameter includes controlling the average pore amount in multiple holes 132 in porous thermal barrier coating 130 in about 5 volume % to about
In the range of 10 volume %.
In some embodiments, the porosity parameter for controlling porous thermal barrier coating 130 includes controlling porous thermodynamic barrier to apply
The hole micro-structure in multiple holes 132 in layer 130.In some embodiments, porous thermal barrier coating 130 includes multiple holes 132, is made
At least some of the multiple hole hole is obtained in crystal grain.As used herein term " in crystal grain " means that hole is present in crystal grain
It is internal.In some embodiments, porous thermal barrier coating 130 includes multiple holes 132, so that at least some of the multiple hole
Hole (is present between crystal grain) in intercrystalline, or exists at the grain boundary.In certain embodiments, more than 50% in the multiple hole
In crystal grain.In certain embodiments, in the multiple hole more than 80% in crystal grain.
Fig. 4 shows the schematic diagram of the micro-structure of the porous thermal barrier coating 130 formed according to some embodiments of the present disclosure.
The micro-structure of porous thermal barrier coating 130 as shown in Figure 4 is characterized by having the crystal grain 134 of multiple crystal boundaries 136.Micro- knot
Structure further includes being present in multiple holes 132 inside crystal grain 134 (crystal grain inner hole).
The another of micro-structure that Fig. 5 shows the porous thermal barrier coating 130 formed according to some embodiments of the present disclosure shows
It is intended to.The micro-structure of porous thermal barrier coating 130 as shown in Figure 5 is characterized by having the crystal grain of multiple crystal boundaries 136
134.Micro-structure further include be present at multiple holes 132 inside crystal grain 134 (crystal grain inner hole) and crystal boundary 136 or between it is multiple
Hole 138 (intercrystalline hole).
Fig. 6 shows the porous thermal barrier coating for being coated with the mixture of YSZ and elemental carbon by using APS technique and being formed
130 scanning electron microscopy (SEM) microphoto.The feature of the micro-structure of porous thermal barrier coating 130 as shown in Figure 6
It is the crystal grain 134 with multiple crystal boundaries 136.Micro-structure further includes being present in multiple generally spherical in shape holes inside crystal grain 134
132 (crystal grain inner holes).Hole 132 is generated by the carbonaceous gas coated.
In the case where without being bound by any theory, it is believed that gas forms additive (such as elemental carbon) in raw material
In the presence of can be due to gas (such as carbon monoxide, carbon dioxide etc.) caused by gas forms additive decomposition at high temperature
Generate additional porosity.These gases may fall into because being insoluble in thermal barrier coating material and stay in thermal barrier coating material.
The gas of cladding can inhibit the roughening of the hole in micro-structure and redistribution to the pressure that thermodynamic barrier material around applies, so that heat shielding
Barrier coating keeps fine porosity, and the micro-structure of thermal barrier coating can be able to thermostabilization.Controlled porosity can further generate compared with
The porous thermal barrier coating of low heat conductivity.Therefore, in some such embodiments, porous thermal barrier coating can provide the heat of enhancing
Protection, because the temperature gradient across coating is higher for identical coating layer thickness.Alternatively, can for relatively thin thermal barrier coating with
And turbine engine components are designed for lower cooling air flow velocity under applicable circumstances.This may cause processing and material
The reduction of cost, and promoting member service life and engine efficiency.
Previous examples only have it is illustrative, only to some features in the illustration disclosure.Therefore, applicant is intended to not make institute
Attached claims are limited by the example selection to illustrate the feature of the disclosure.As used in detail in the claims,
Word " comprising " and its grammatical variants logically also directed to and including variation and different degree phrase, such as it is but unlimited
In "consisting essentially of ..." and " Consists of ".When necessary, range has been provided；Those ranges include all sub- models therebetween
It encloses.It is expected that the variation of these ranges itself will inspire the practitioner with the general technology in fields, and not yet dedicating to
In the case where the public, those variations should be construed to be covered by the appended claims when possible.It is also contemplated that Science and Technology
Progress will make it possible the equivalent and substitute that are not included by the inexactness of language now, and these variations are answered
It is also construed to be covered by the appended claims when possible.
Claims (10)
1. a kind of method for forming porous thermal barrier coating, comprising:
Raw material is arranged on substrate to form the porous thermal barrier coating, wherein the raw material includes that gas is formed
Additive and thermal barrier coating material, and wherein the arrangement includes by control raw material feed rate, the raw material material
The gas in material forms temperature of raw material arranged on substrate described in the amount of additive or combinations thereof to control
State the porosity parameter of porous thermal barrier coating.
2. the method according to claim 1, wherein the hole of the control porous thermal barrier coating
Spending parameter includes that the temperature for the raw material arranged on the substrate is controlled using auxiliary thermal source.
3. according to the method described in claim 2, it is characterized in that, the raw material arranged on the substrate is heated to be greater than
The temperature for the temperature that the substrate is resistant to.
4. according to the method described in claim 3, it is characterized in that, the raw material arranged on the substrate is heated to about
Temperature in 1000 DEG C to about 1500 DEG C of range.
5. the method according to claim 1, wherein the hole of the control porous thermal barrier coating
Degree parameter includes controlling the amount of the gas formation additive in the raw material in about 0.1wt% to about
In the range of 10wt%.
6. the method according to claim 1, wherein the hole of the control porous thermal barrier coating
Degree parameter includes controlling the raw material feed rate in the range of about 2.5gm/min to about 100gm/min.
7. the method according to claim 1, wherein it includes graphite, carbide, carbon that the gas, which forms additive,
Oxide, nitride or combinations thereof.
8. the method according to claim 1, wherein it includes elemental carbon that the gas, which forms additive,.
9. the method according to claim 1, wherein the thermal barrier coating material includes stabilized with yttrium oxide oxidation
Zirconium.
10. a kind of method for forming the porous thermal barrier coating including alternation porosity, which comprises arranged on substrate
Raw material to form the porous thermal barrier coating, wherein
The raw material includes that gas forms additive and thermal barrier coating material, and wherein the arrangement includes by following
Mode forms the alternation porosity of the thermal barrier coating: controlling the gas in the raw material and forms addition
The amount of agent controls the temperature for the raw material arranged on the substrate using auxiliary thermal source, or combinations thereof.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US15/830,062 | 2017-12-04 | ||
| US15/830,062 US20190169730A1 (en) | 2017-12-04 | 2017-12-04 | Methods of forming a porous thermal barrier coating |
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| Publication Number | Publication Date |
|---|---|
| CN109865645A true CN109865645A (en) | 2019-06-11 |
Family
ID=64572135
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201811464772.5A Pending CN109865645A (en) | 2017-12-04 | 2018-12-03 | The method for forming porous thermal barrier coating |
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| Country | Link |
|---|---|
| US (1) | US20190169730A1 (en) |
| EP (1) | EP3492622A1 (en) |
| JP (1) | JP2019099921A (en) |
| CN (1) | CN109865645A (en) |
| CA (1) | CA3024842C (en) |
Cited By (2)
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|---|---|---|---|---|
| CN112339264A (en) * | 2019-08-07 | 2021-02-09 | 中国科学院福建物质结构研究所 | Heat preservation and insulation part based on fused deposition molding and preparation method thereof |
| CN115073882A (en) * | 2021-03-15 | 2022-09-20 | 中国科学院福建物质结构研究所 | In-situ cured epoxy resin part and preparation method thereof |
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Also Published As
| Publication number | Publication date |
|---|---|
| JP2019099921A (en) | 2019-06-24 |
| CA3024842C (en) | 2021-05-18 |
| US20190169730A1 (en) | 2019-06-06 |
| CA3024842A1 (en) | 2019-06-04 |
| EP3492622A1 (en) | 2019-06-05 |
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Application publication date: 20190611 |