CN110629152A - Spraying method of thermal barrier coating with longitudinal cracks for combustion chamber - Google Patents
Spraying method of thermal barrier coating with longitudinal cracks for combustion chamber Download PDFInfo
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- CN110629152A CN110629152A CN201910954863.5A CN201910954863A CN110629152A CN 110629152 A CN110629152 A CN 110629152A CN 201910954863 A CN201910954863 A CN 201910954863A CN 110629152 A CN110629152 A CN 110629152A
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C19/00—Alloys based on nickel or cobalt
- C22C19/03—Alloys based on nickel or cobalt based on nickel
- C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
- C22C19/058—Alloys based on nickel or cobalt based on nickel with chromium without Mo and W
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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
- C23C4/06—Metallic material
- C23C4/073—Metallic material containing MCrAl or MCrAlY alloys, where M is nickel, cobalt or iron, with or without non-metal elements
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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
- C23C4/12—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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Abstract
The invention provides a spraying method of a thermal barrier coating with longitudinal cracks for a combustion chamber, which solves the problem that the thermal barrier coating for the combustion chamber in the prior art is caused by ZrO2The microstructure of the basal ceramic surface layer is a lamellar structure, ZrO2The surface layer of the base ceramic is thin, so that the heat cycle resistance is poor and the service life is short. It comprises the following steps: (1) spraying a NiCrAlY bonding layer on a region to be sprayed of the part; (2) after the NiCrAlY bonding layer is sprayed, preheating a region to be sprayed of the part by using a plasma spray gun to the temperature of 370-430 ℃; spraying ZrO by adopting a plasma spraying method after the part reaches the preheating temperature2A base ceramic facing; spraying during sprayingThe coating distance is 50mm-60 mm; (3) spray ZrO2And after the base ceramic surface layer is finished, putting the part into a vacuum furnace for heat treatment. The thermal barrier coating has the advantages of long service life and good heat insulation effect.
Description
Technical Field
The invention relates to the field of manufacturing and maintaining of aeroengines and ground gas turbines, in particular to a spraying method of a thermal barrier coating with a longitudinal crack for a combustion chamber.
Background
In order to increase the combustion temperature of aircraft engines and ground gas turbine combustors, it is necessary to spray a thermal barrier coating on the inside of the combustor, which is thermally insulating and resistant to hot corrosion. The thermal barrier coating mainly comprises two layers, namely a bonding layer and ZrO, wherein the bonding layer and the ZrO are respectively formed by NiCrAlY2Based on a ceramic top layer, and ZrO2The ceramic-based facing is critical to thermal insulation and hot corrosion resistance.
For civil aircraft engines or military aircraft engines with large bypass ratios, the service life of the engines is higher than that of other military aircraft engines with small bypass ratios, so that the service life of the thermal barrier coating used for the combustion chamber is higher. At present, the method mainly adopted for preparing the thermal barrier coating is a plasma spraying method. The thermal barrier coating for the combustion chamber is prepared by adopting the traditional plasma spraying method, because ZrO2The microstructure of the basal ceramic surface layer is a lamellar structure, ZrO2The base ceramic surface layer is thin, so that the heat cycle resistance is poor, the service life is greatly reduced, and the requirement of long service life is difficult to meet.
The applicant has found that the prior art has at least the following technical problems:
thermal barrier coating for combustion chambers in the prior art, due to ZrO2The microstructure of the basal ceramic surface layer is a lamellar structure, ZrO2The surface layer of the base ceramic is thin, so that the heat cycle resistance is poor and the service life is short.
Disclosure of Invention
The invention aims to provide a spraying method of a thermal barrier coating with longitudinal cracks for a combustion chamber, which aims to solve the problem that the thermal barrier coating for the combustion chamber in the prior art is ZrO2The microstructure of the basal ceramic surface layer is a lamellar structure, ZrO2The surface layer of the base ceramic is thin, so that the heat cycle resistance is poor and the service life is short. The technical effects that can be produced by the preferred technical scheme in the technical schemes provided by the invention are described in detail in the following.
In order to achieve the purpose, the invention provides the following technical scheme:
the invention provides a spraying method of a thermal barrier coating with a longitudinal crack for a combustion chamber, which comprises the following steps:
(1) spraying a NiCrAlY bonding layer on a region to be sprayed of the part;
(2) spray ZrO2The base ceramic surface layer specifically comprises:
firstly, after spraying a NiCrAlY bonding layer, preheating a to-be-sprayed area of a part by using a plasma spray gun to the temperature of 370-430 ℃;
secondly, spraying ZrO by adopting a plasma spraying method after the part is preheated to 370-430 DEG C2A base ceramic facing; the spraying distance is 50-60 mm when spraying;
(3) spray ZrO2And after finishing the surface layer of the base ceramic, putting the part into a vacuum furnace for heat treatment.
Further, in the step (2),
firstly, after spraying a NiCrAlY bonding layer, preheating a to-be-sprayed area of a part by using a plasma spray gun to 380-420 ℃;
② after the parts are preheated to 380-420 ℃, spraying ZrO by adopting a plasma spraying method2A base ceramic facing; the spraying distance is 52mm-58mm when spraying.
Further, theIn the step (2), ZrO is sprayed2The base ceramic surface layer adopts ZrO2Based ceramic powder of said ZrO2The particle size of the base ceramic powder is 11 μm to 125. mu.m.
Further, the ZrO2The base ceramic powder comprises the following components in percentage by weight Y2O3 7%-9%，ZrO2The balance being.
Further, in the second step of the step (2), ZrO is sprayed2The spraying technological parameters of the base ceramic surface layer are as follows: the nitrogen flow is 38L/min-40L/min; the hydrogen flow is 7.5L/min-8.5L/min; the working current is 600A-700A; the working voltage is 78V-82V; the powder feeding amount is 23g/min-25 g/min.
Further, in the step (2), the ZrO2The thickness of the base ceramic surface layer is 0.9mm-1.0 mm.
Further, in the step (3), the heat treatment temperature is 1036-1064 ℃ and the time is 4.0-4.5 h.
Further, in the step (1), NiCrAlY powder is adopted for spraying the NiCrAlY bonding layer, and the particle size of the NiCrAlY powder is 53-106 μm;
the NiCrAlY powder comprises, by weight, 21.0-23.0% of chromium, 9.0-11.0% of aluminum, 0.5-1.5% of iridium, and the balance of nickel.
Further, in the step (1), a NiCrAlY bonding layer is sprayed by a plasma spraying method, and the thickness of the NiCrAlY bonding layer is 0.2mm-0.3 mm; the spraying process parameters of the NiCrAlY bonding layer are as follows: the nitrogen flow is 70L/min-72L/min, the hydrogen flow is 7L/min-8L/min, the working current is 500A-600A, the working voltage is 75V-80V, the spraying distance is 130mm-135mm, and the powder feeding amount is 45g/min-50 g/min.
Further, before spraying the NiCrAlY bonding layer, 46-mesh white corundum sand grains are adopted to roughen the surface of the area to be sprayed of the part.
Based on the technical scheme, the embodiment of the invention can at least produce the following technical effects:
(1) the invention provides a thermal barrier with longitudinal cracks for a combustion chamberThe spraying method of the coating, this method adopts plasma spray gun to preheat the spray area of the part to the temperature of 370 duC-430 duC before spraying ZrO2 base ceramic surface course, can form certain temperature gradient; the spraying distance is 50mm-60mm, which is beneficial to forming longitudinal cracks in the ZrO2 base ceramic surface layer; the length of the longitudinal crack is ZrO2The thickness of the base ceramic surface layer is 0.5-1.0 time, the crack density is 1/mm-5/mm, the included angle between the crack and the matrix is 45-90 degrees, the thermal shock resistance of the coating can be obviously improved, and the damaged ZrO can be improved2Longitudinal damage tolerance of the base ceramic facing, thereby extending the life of the coating;
(2) the invention provides a method for spraying a thermal barrier coating with longitudinal cracks for a combustion chamber, and ZrO prepared by the method2The thickness of the base ceramic surface layer coating can reach 0.9mm-1.0mm, the porosity is 5% -10%, the thermal conductivity is 1.3W/m.K-1.6W/m.K, and a good thermal insulation effect can be achieved;
(3) according to the spraying method of the thermal barrier coating with the longitudinal cracks for the combustion chamber, the service life of the thermal barrier coating prepared by the method can reach more than 16000 hours; the method can be widely applied to spraying and recoating the coating of the combustion chamber of the aircraft engine and the ground gas turbine with the characteristic of long service life.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.
FIG. 1 is a metallographic structure of a thermal barrier coating layer in example 1 of the present invention;
FIG. 2 is a metallographic representation of the metallographic structure of a thermal barrier coating layer according to example 2 of the invention;
FIG. 3 is a metallographic representation of the metallographic structure of a thermal barrier coating layer according to example 3 of the invention;
FIG. 4 is a metallographic representation of the metallographic structure of a thermal barrier coating layer according to example 4 of the invention;
FIG. 5 is a metallographic representation of the metallographic structure of a thermal barrier coating layer according to example 5 of the invention;
fig. 6 is a metallographic structure diagram of a thermal barrier coating layer in example 6 of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the technical solutions of the present invention will be described in detail below. It is to be understood that the described embodiments are merely exemplary of the invention, and not restrictive of the full scope of the invention. All other embodiments, which can be derived by a person skilled in the art from the examples given herein without any inventive step, are within the scope of the present invention.
Example 1:
after 18000 hours of operation, the heavy-duty gas turbine is overhauled to find that most coatings of the combustion chamber parts fall off, and a thermal barrier coating needs to be coated again. After the residual coating is removed, the coating recovery is carried out on the part by adopting the spraying method provided by the invention; the method comprises the following specific steps:
(1) carrying out texturing treatment on the surface of a region to be sprayed of the part by adopting 46-mesh white corundum sand grains;
(2) spraying a NiCrAlY bonding layer in a region to be sprayed of the part by adopting a plasma spraying method, wherein the thickness of the NiCrAlY bonding layer is 0.25 mm;
the NiCrAlY bonding layer is sprayed by NiCrAlY powder, and the particle size of the NiCrAlY powder is 53-106 mu m; the NiCrAlY powder comprises the following components, by weight, 22.0% of chromium, 9.9% of aluminum, 1.2% of iridium and the balance of nickel;
the spraying process parameters of the NiCrAlY bonding layer are that the nitrogen flow is 71L/min, the hydrogen flow is 7.5L/min, the working current is 560A, the working voltage is 78V, the spraying distance is 135mm, and the powder feeding amount is 48 g/min;
(3) spray ZrO2The base ceramic surface layer specifically comprises:
firstly, after spraying a NiCrAlY bonding layer, preheating a to-be-sprayed area of a part by using a plasma spray gun to the temperature of 390 ℃;
② after the parts are preheated to 3Spraying ZrO by adopting a plasma spraying method after 90 DEG C2A base ceramic facing; the spraying distance during spraying is 55 mm; ZrO (ZrO)2The thickness of the base ceramic surface layer is 0.95 mm;
spray ZrO2The base ceramic surface layer adopts ZrO2Based ceramic powder of said ZrO2The particle size of the base ceramic powder is 11-125 μm; the ZrO2The base ceramic powder comprises the following components in percentage by weight Y2O3 8%，ZrO292 percent;
spray ZrO2The spraying technological parameters of the base ceramic surface layer are as follows: the nitrogen flow is 39L/min; the hydrogen flow rate is 8.0L/min; the working current is 650A; the working voltage is 80V; the powder feeding amount is 24 g/min;
(4) spray ZrO2After finishing the surface layer of the base ceramic, putting the part into a vacuum furnace for heat treatment; the heat treatment temperature is 1055 ℃ and the time is 4.0 h.
Performing metallographic detection on the thermal barrier coating sprayed in the example 1, wherein the metallographic structure is shown in fig. 1, and the porosity of the thermal barrier coating is 5%; having longitudinal cracks of length ZrO2The thickness of the base ceramic surface layer is 0.5-1.0 time, the density of the longitudinal cracks is 1/mm-5/mm, the included angle between the longitudinal cracks and the part matrix is 45-90 degrees, and the use requirement is met.
The thermal conductivity of the thermal barrier coating was measured to be 1.3W/m.K.
After long-term test run and examination, the service life of the combustion chamber sprayed with the thermal barrier coating reaches 36000 hours, which is doubled compared with the original service life.
Example 2:
after a certain aeroderivative gas turbine is operated for 9000 hours, the overhaul finds that most coatings of combustion chamber parts fall off, and thermal barrier coatings need to be coated again. After the residual coating is removed, the coating recovery is carried out on the part by adopting the spraying method provided by the invention; the method comprises the following specific steps:
(1) carrying out texturing treatment on the surface of a region to be sprayed of the part by adopting 46-mesh white corundum sand grains;
(2) spraying a NiCrAlY bonding layer in a region to be sprayed of the part by adopting a plasma spraying method, wherein the thickness of the NiCrAlY bonding layer is 0.25 mm;
the NiCrAlY bonding layer is sprayed by NiCrAlY powder, and the particle size of the NiCrAlY powder is 53-106 mu m; the NiCrAlY powder comprises the following components, by weight, 22.5% of chromium, 9.8% of aluminum, 1.2% of iridium and the balance of nickel;
the spraying process parameters of the NiCrAlY bonding layer are that the nitrogen flow is 71L/min, the hydrogen flow is 7.5L/min, the working current is 560A, the working voltage is 78V, the spraying distance is 135mm, and the powder feeding amount is 48 g/min;
(3) spray ZrO2The base ceramic surface layer specifically comprises:
firstly, after spraying a NiCrAlY bonding layer, preheating a to-be-sprayed area of a part by using a plasma spray gun to the temperature of 425 ℃;
② spraying ZrO by plasma spraying method after the parts are preheated to 425 DEG C2A base ceramic facing; the spraying distance during spraying is 58 mm; ZrO (ZrO)2The thickness of the base ceramic surface layer is 0.95 mm;
spray ZrO2The base ceramic surface layer adopts ZrO2Based ceramic powder of said ZrO2The particle size of the base ceramic powder is 11-125 μm; the ZrO2The base ceramic powder comprises the following components in percentage by weight Y2O3 8%，ZrO292 percent;
spray ZrO2The spraying technological parameters of the base ceramic surface layer are as follows: the nitrogen flow is 39L/min; the hydrogen flow rate is 8.5L/min; the working current is 680A; the working voltage is 81V; the powder feeding amount is 23.8 g/min;
(4) spray ZrO2After finishing the surface layer of the base ceramic, putting the part into a vacuum furnace for heat treatment; the heat treatment temperature is 1050 ℃ and the time is 4.0 h.
Performing metallographic detection on the thermal barrier coating sprayed in the example 2, wherein the metallographic structure is shown in fig. 2, and the porosity of the thermal barrier coating is 5%; having longitudinal cracks of length ZrO2The thickness of the base ceramic surface layer is 0.5-1.0 time, the density of the longitudinal cracks is 1/mm-5/mm, the included angle between the longitudinal cracks and the part matrix is 45-90 degrees, and the use requirement is met。
The thermal conductivity of the thermal barrier coating was measured to be 1.5W/m.K.
After long-term test run and examination, the service life of the combustion chamber sprayed with the thermal barrier coating reaches 18000 hours, which is doubled compared with the original service life.
Example 3:
the method for spraying the thermal barrier coating on the part of the combustion chamber of the aero-engine comprises the following specific steps:
(1) carrying out texturing treatment on the surface of a region to be sprayed of the part by adopting 46-mesh white corundum sand grains;
(2) spraying a NiCrAlY bonding layer in a region to be sprayed of the part by adopting a plasma spraying method, wherein the thickness of the NiCrAlY bonding layer is 0.2 mm;
the NiCrAlY bonding layer is sprayed by NiCrAlY powder, and the particle size of the NiCrAlY powder is 53-106 mu m; the NiCrAlY powder comprises, by weight, 21.0% of chromium, 11.0% of aluminum, 0.5% of iridium, and the balance of nickel;
the spraying process parameters of the NiCrAlY bonding layer are that the nitrogen flow is 70L/min, the hydrogen flow is 8.0L/min, the working current is 500A, the working voltage is 80V, the spraying distance is 130mm, and the powder feeding amount is 45 g/min;
(3) spray ZrO2The base ceramic surface layer specifically comprises:
firstly, after spraying a NiCrAlY bonding layer, preheating a to-be-sprayed area of a part by using a plasma spray gun to 430 ℃;
② spraying ZrO by plasma spraying method after the parts are preheated to 430 DEG C2A base ceramic facing; the spraying distance during spraying is 60 mm; ZrO (ZrO)2The thickness of the base ceramic surface layer is 1.0 mm;
spray ZrO2The base ceramic surface layer adopts ZrO2Based ceramic powder of said ZrO2The particle size of the base ceramic powder is 11-125 μm; the ZrO2The base ceramic powder comprises the following components in percentage by weight Y2O3 9%，ZrO2Is 91%;
spray ZrO2The spraying technological parameters of the base ceramic surface layer are as follows: the nitrogen flow is 40L/min; hydrogenThe air flow is 7.5L/min; the working current is 700A; the working voltage is 78V; the powder feeding amount is 25.0 g/min;
(4) spray ZrO2After finishing the surface layer of the base ceramic, putting the part into a vacuum furnace for heat treatment; the heat treatment was carried out at 1036 ℃ for 4.2 h.
Performing metallographic detection on the thermal barrier coating sprayed in the example 3, wherein the metallographic structure is shown in fig. 3, and the porosity of the thermal barrier coating is 10%; having longitudinal cracks of length ZrO2The thickness of the base ceramic surface layer is 0.5-1.0 time, the density of the longitudinal cracks is 1/mm-5/mm, the included angle between the longitudinal cracks and the part matrix is 45-90 degrees, and the use requirement is met.
The thermal conductivity of the thermal barrier coating was measured to be 1.6W/m.K.
After long-term trial and examination, the service life of the combustion chamber sprayed with the thermal barrier coating reaches 18000 hours, which is doubled compared with the prior art.
Example 4:
the method for spraying the thermal barrier coating on the part of the combustion chamber of the aero-engine comprises the following specific steps:
(1) carrying out texturing treatment on the surface of a region to be sprayed of the part by adopting 46-mesh white corundum sand grains;
(2) spraying a NiCrAlY bonding layer in a region to be sprayed of the part by adopting a plasma spraying method, wherein the thickness of the NiCrAlY bonding layer is 0.3 mm;
the NiCrAlY bonding layer is sprayed by NiCrAlY powder, and the particle size of the NiCrAlY powder is 53-106 mu m; the NiCrAlY powder comprises, by weight, 23.0% of chromium, 9.0% of aluminum, 1.5% of iridium, and the balance of nickel;
the spraying process parameters of the NiCrAlY bonding layer are that the nitrogen flow is 72L/min, the hydrogen flow is 7.0L/min, the working current is 600A, the working voltage is 75V, the spraying distance is 130mm, and the powder feeding amount is 50 g/min;
(3) spray ZrO2The base ceramic surface layer specifically comprises:
firstly, after spraying a NiCrAlY bonding layer, preheating a to-be-sprayed area of a part by using a plasma spray gun to the temperature of 370 ℃;
② spraying ZrO by plasma spraying method after the part is preheated to 370 DEG C2A base ceramic facing; the spraying distance during spraying is 50 mm; ZrO (ZrO)2The thickness of the base ceramic surface layer is 0.9 mm;
spray ZrO2The base ceramic surface layer adopts ZrO2Based ceramic powder of said ZrO2The particle size of the base ceramic powder is 11-125 μm; the ZrO2The base ceramic powder comprises the following components in percentage by weight Y2O3 7%，ZrO2Is 93%;
spray ZrO2The spraying technological parameters of the base ceramic surface layer are as follows: the nitrogen flow is 38L/min; the hydrogen flow rate is 8.0L/min; the working current is 600A; the working voltage is 82V; the powder feeding amount is 23.0 g/min;
(4) spray ZrO2After finishing the surface layer of the base ceramic, putting the part into a vacuum furnace for heat treatment; the heat treatment temperature is 1064 ℃ and the time is 4.5 h.
Performing metallographic detection on the thermal barrier coating sprayed in the example 4, wherein the metallographic structure is shown in fig. 4, and the porosity of the thermal barrier coating is 8%; having longitudinal cracks of length ZrO2The thickness of the base ceramic surface layer is 0.5-1.0 time, the density of the longitudinal cracks is 1/mm-5/mm, the included angle between the longitudinal cracks and the part matrix is 45-90 degrees, and the use requirement is met.
The thermal conductivity of the thermal barrier coating was measured to be 1.6W/m.K.
After long-term test run and examination, the service life of the combustion chamber sprayed with the thermal barrier coating reaches 18000 hours, which is doubled compared with the original service life.
Example 5:
the method for spraying the thermal barrier coating on the part of the ground gas turbine combustor comprises the following specific steps:
(1) carrying out texturing treatment on the surface of a region to be sprayed of the part by adopting 46-mesh white corundum sand grains;
(2) spraying a NiCrAlY bonding layer in a region to be sprayed of the part by adopting a plasma spraying method, wherein the thickness of the NiCrAlY bonding layer is 0.22 mm;
the NiCrAlY bonding layer is sprayed by NiCrAlY powder, and the particle size of the NiCrAlY powder is 53-106 mu m; the NiCrAlY powder comprises, by weight, 21.5% of chromium, 10.5% of aluminum, 0.7% of iridium, and the balance of nickel;
the spraying process parameters of the NiCrAlY bonding layer are that the nitrogen flow is 70.5L/min, the hydrogen flow is 7.7L/min, the working current is 520A, the working voltage is 79V, the spraying distance is 132 mm, and the powder feeding amount is 47 g/min;
(3) spray ZrO2The base ceramic surface layer specifically comprises:
firstly, after spraying a NiCrAlY bonding layer, preheating a to-be-sprayed area of a part by using a plasma spray gun to 380 ℃;
② spraying ZrO by plasma spraying method after the parts are preheated to 380 DEG C2A base ceramic facing; the spraying distance during spraying is 52 mm; ZrO (ZrO)2The thickness of the base ceramic surface layer is 0.92 mm;
spray ZrO2The base ceramic surface layer adopts ZrO2Based ceramic powder of said ZrO2The particle size of the base ceramic powder is 11-125 μm; the ZrO2The base ceramic powder comprises the following components in percentage by weight Y2O3 8.5%，ZrO291.5 percent;
spray ZrO2The spraying technological parameters of the base ceramic surface layer are as follows: the nitrogen flow is 39.5L/min; the hydrogen flow is 8.2L/min; the working current is 620A; the working voltage is 79V; the powder feeding amount is 24.5 g/min;
(4) spray ZrO2After finishing the surface layer of the base ceramic, putting the part into a vacuum furnace for heat treatment; the heat treatment was carried out at 1040 ℃ for 4.0 hours.
Performing metallographic detection on the thermal barrier coating sprayed in the example 5, wherein the metallographic structure is shown in fig. 5, and the porosity of the thermal barrier coating is 5%; having longitudinal cracks of length ZrO2The thickness of the base ceramic surface layer is 0.5-1.0 time, the density of the longitudinal cracks is 1/mm-5/mm, the included angle between the longitudinal cracks and the part matrix is 45-90 degrees, and the use requirement is met.
The thermal conductivity of the thermal barrier coating was measured to be 1.4W/m.K.
After long-term test run and examination, the service life of the combustion chamber sprayed with the thermal barrier coating reaches 30000 hours.
Example 6:
the method for spraying the thermal barrier coating on the part of the ground gas turbine combustor comprises the following specific steps:
(1) carrying out texturing treatment on the surface of a region to be sprayed of the part by adopting 46-mesh white corundum sand grains;
(2) spraying a NiCrAlY bonding layer in a region to be sprayed of the part by adopting a plasma spraying method, wherein the thickness of the NiCrAlY bonding layer is 0.28 mm;
the NiCrAlY bonding layer is sprayed by NiCrAlY powder, and the particle size of the NiCrAlY powder is 53-106 mu m; the NiCrAlY powder comprises the following components, by weight, 22.5% of chromium, 9.5% of aluminum, 1.3% of iridium and the balance of nickel;
the spraying process parameters of the NiCrAlY bonding layer are that the nitrogen flow is 71.5L/min, the hydrogen flow is 7.2L/min, the working current is 570A, the working voltage is 77V, the spraying distance is 134 mm, and the powder feeding amount is 49 g/min;
(3) spray ZrO2The base ceramic surface layer specifically comprises:
firstly, after spraying a NiCrAlY bonding layer, preheating a to-be-sprayed area of a part by using a plasma spray gun to the temperature of 420 ℃;
② spraying ZrO by plasma spraying method after the parts are preheated to 420 DEG C2A base ceramic facing; the spraying distance during spraying is 57 mm; ZrO (ZrO)2The thickness of the base ceramic surface layer is 0.98 mm;
spray ZrO2The base ceramic surface layer adopts ZrO2Based ceramic powder of said ZrO2The particle size of the base ceramic powder is 11-125 μm; the ZrO2The base ceramic powder comprises the following components in percentage by weight Y2O3 7.5%，ZrO292.5 percent;
spray ZrO2The spraying technological parameters of the base ceramic surface layer are as follows: the nitrogen flow rate is 38.5L/min; the hydrogen flow is 7.8L/min; the working current is 680A; the working voltage is 81V; the powder feeding amount is 23.5 g/min;
(4) spray ZrO2After finishing the surface layer of the base ceramic, putting the part into a vacuum furnace for heat treatment; the heat treatment was carried out at 1060 ℃ for 4.5 hours.
Performing metallographic detection on the thermal barrier coating sprayed in the example 1, wherein the metallographic structure is shown in fig. 6, and the porosity of the thermal barrier coating is 6%; having longitudinal cracks of length ZrO2The thickness of the base ceramic surface layer is 0.5-1.0 time, the density of the longitudinal cracks is 1/mm-5/mm, the included angle between the longitudinal cracks and the part matrix is 45-90 degrees, and the use requirement is met.
The thermal conductivity of the thermal barrier coating was measured to be 1.3W/m.K.
After long-term test run and examination, the service life of the combustion chamber sprayed with the thermal barrier coating reaches 36000 hours, which is doubled compared with the original service life.
The above description is only for the specific embodiments of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art can easily conceive of the changes or substitutions within the technical scope of the present invention, and all the changes or substitutions should be covered within the scope of the present invention.
Claims (10)
1. A method for spraying a thermal barrier coating with longitudinal cracks for a combustion chamber is characterized in that: the method comprises the following steps:
(1) spraying a NiCrAlY bonding layer on a region to be sprayed of the part;
(2) spray ZrO2The base ceramic surface layer specifically comprises:
firstly, after spraying a NiCrAlY bonding layer, preheating a to-be-sprayed area of a part by using a plasma spray gun to the temperature of 370-430 ℃;
secondly, spraying ZrO by adopting a plasma spraying method after the part is preheated to 370-430 DEG C2A base ceramic facing; the spraying distance is 50-60 mm when spraying;
(3) spray ZrO2And after the base ceramic surface layer is finished, putting the part into a vacuum furnace for heat treatment.
2. The method for spray coating a longitudinally cracked thermal barrier coating for a combustor as claimed in claim 1, wherein: in the step (2), the step (c),
firstly, after spraying a NiCrAlY bonding layer, preheating a to-be-sprayed area of a part by using a plasma spray gun to 380-420 ℃;
② after the parts are preheated to 380-420 ℃, spraying ZrO by adopting a plasma spraying method2A base ceramic facing; the spraying distance is 52mm-58mm when spraying.
3. The method for spray coating a longitudinally cracked thermal barrier coating for a combustor as claimed in claim 2, wherein: in the step (2), ZrO is sprayed2The base ceramic surface layer adopts ZrO2Based ceramic powder of said ZrO2The particle size of the base ceramic powder is 11 μm to 125. mu.m.
4. The method for spray coating a longitudinally cracked thermal barrier coating for a combustor as claimed in claim 3, wherein: the ZrO2The base ceramic powder comprises the following components in percentage by weight Y2O3 7%-9%，ZrO2The balance being.
5. The method for spray coating a longitudinally cracked thermal barrier coating for a combustor as claimed in claim 4, wherein: in the second step of the step (2), ZrO is sprayed2The spraying technological parameters of the base ceramic surface layer are as follows: the nitrogen flow is 38L/min-40L/min; the hydrogen flow is 7.5L/min-8.5L/min; the working current is 600A-700A; the working voltage is 78V-82V; the powder feeding amount is 23g/min-25 g/min.
6. The method for spray coating a longitudinally cracked thermal barrier coating for a combustor as claimed in claim 5, wherein: in the second step of the step (2), the ZrO2The thickness of the base ceramic surface layer is 0.9mm-1.0 mm.
7. The method for spray coating a longitudinally cracked thermal barrier coating for a combustor as claimed in claim 6, wherein: in the step (3), the heat treatment temperature is 1036-1064 ℃ and the time is 4.0-4.5 h.
8. Method for the spray coating of a longitudinally cracked thermal barrier coating for combustion chambers according to any one of claims 1 to 7, characterised in that: in the step (1), NiCrAlY powder is adopted for spraying the NiCrAlY bonding layer, and the particle size of the NiCrAlY powder is 53-106 μm;
the NiCrAlY powder comprises the following components in percentage by weight; 21.0 to 23.0 percent of chromium, 9.0 to 11.0 percent of aluminum, 0.5 to 1.5 percent of iridium and the balance of nickel.
9. The method for spray coating a longitudinally cracked thermal barrier coating for a combustor as claimed in claim 8, wherein: in the step (1), a NiCrAlY bonding layer is sprayed by a plasma spraying method, and the thickness of the NiCrAlY bonding layer is 0.2mm-0.3 mm.
10. The method for spray coating a longitudinally cracked thermal barrier coating for a combustor as claimed in claim 9, wherein: before spraying the NiCrAlY bonding layer, roughening the surface of the area to be sprayed of the part by using 46-mesh white corundum sand.
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Application publication date: 20191231 |