CN111996492A - 一种氧化锆掺杂铌酸钆非晶高温陶瓷涂层的制备方法 - Google Patents
一种氧化锆掺杂铌酸钆非晶高温陶瓷涂层的制备方法 Download PDFInfo
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- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 title claims abstract description 20
- 229910001928 zirconium oxide Inorganic materials 0.000 title claims abstract description 20
- 238000002360 preparation method Methods 0.000 title claims abstract description 14
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- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims abstract description 22
- 238000000034 method Methods 0.000 claims abstract description 18
- CMIHHWBVHJVIGI-UHFFFAOYSA-N gadolinium(III) oxide Inorganic materials [O-2].[O-2].[O-2].[Gd+3].[Gd+3] CMIHHWBVHJVIGI-UHFFFAOYSA-N 0.000 claims abstract description 7
- ZKATWMILCYLAPD-UHFFFAOYSA-N niobium pentoxide Inorganic materials O=[Nb](=O)O[Nb](=O)=O ZKATWMILCYLAPD-UHFFFAOYSA-N 0.000 claims abstract description 7
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- FFQALBCXGPYQGT-UHFFFAOYSA-N 2,4-difluoro-5-(trifluoromethyl)aniline Chemical compound NC1=CC(C(F)(F)F)=C(F)C=C1F FFQALBCXGPYQGT-UHFFFAOYSA-N 0.000 description 1
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- FZLIPJUXYLNCLC-UHFFFAOYSA-N lanthanum atom Chemical compound [La] FZLIPJUXYLNCLC-UHFFFAOYSA-N 0.000 description 1
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- LEHFSLREWWMLPU-UHFFFAOYSA-B zirconium(4+);tetraphosphate Chemical compound [Zr+4].[Zr+4].[Zr+4].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O LEHFSLREWWMLPU-UHFFFAOYSA-B 0.000 description 1
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 description 1
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Abstract
本发明涉及热障涂层技术领域，具体公开了一种氧化锆掺杂铌酸钆非晶高温陶瓷涂层的制备方法，将ZrO2、Gd2O3和Nb2O5混合后的粉末进行高温烧结得到烧结体，氧化锆掺杂铌酸的化学计量比为x mol％ZrO2+Gd3NbO7；将烧结体粉碎成2～3mm的块体；采用EB‑PVD法将块体沉积到合金基体上，得到厚度为200～300μm的非晶陶瓷涂层，工艺参数为：舱室气压不高于3×10‑6Torr；沉积速率不低于10nm/min；样品台旋转速率不低于45r/min。本专利中沉积在合金基体上的非晶陶瓷涂层有着极低的热导率，这样能够对合金基体在高温环境下起到很好的隔热的效果，提高合金基体使用的环境温度。
Description
技术领域
本发明涉及热障涂层技术领域，特别涉及一种氧化锆掺杂铌酸钆非晶高温陶瓷涂层的制备方法。
背景技术
热障涂层在航空发动机上的广泛应用，其在现有的技术基础上很大程度上降低了高温燃气对发动机合金叶片的冲击和腐蚀，并降低了发动机叶片的表面温度，增加了发动机的服役年限。从以往研究的高温陶瓷材料来看，比较适用于高温热障涂层的陶瓷材料主要有氧化钇/氧化铈稳定的氧化锆、氧化锆/氧化铝、锆酸镧、锆酸锶、磷酸锆、硅酸锆、钛酸锆、莫来石、稀土氧化物陶瓷等，其中氧化钇稳定的氧化锆(YSZ)整体性能为最好，是目前广泛应用的陶瓷热障涂层。
但由于热障涂层陶瓷材料(YSZ)仅能稳定工作于其熔点温度以下的环境中，当工作温度超过其熔点温度时，YSZ陶瓷材料将会发生相变，热膨胀系数与基体材料变得不相匹配，由于热失配导致了高温陶瓷材料裂纹的形成，最终将导致热障涂层陶瓷材料脱落失效，已经难以满足热能发动机前燃气进口温度不断提高的要求。
稀土铌/钽酸盐陶瓷(RENb/TaO4)凭借着高的熔点，低热导率(1.38～1.94W·m-1·K-1)，高热膨胀系数(11×10-6K-1，1200℃)和铁弹韧性等优异的热物理性能和力学性能，被认为是最具潜力的新一代热障涂层材料。铁弹增韧机制赋予稀土铌/钽酸盐陶瓷优异的高温断裂韧性，这是其他潜在热障涂层材料所不具备的独特优势，而目前研究了掺杂元素锆对稀土钽/铌酸盐的影响，发现其热导率有下降的趋势；因此要如何最大化的体现出锆掺杂稀土钽/铌酸盐陶瓷涂层对合金基体的保护作用依旧是当前研究的重点。
发明内容
本发明提供了一种氧化锆掺杂铌酸钆非晶高温陶瓷涂层的制备方法，以得到热导率更低，符合高温环境使用需求的陶瓷涂层材料。
为了达到上述目的，本发明的技术方案为：
一种氧化锆掺杂铌酸钆非晶高温陶瓷涂层的制备方法，包括以下步骤：
步骤1：将ZrO2、Gd2O3和Nb2O5混合后的粉末进行高温烧结得到氧化锆掺杂铌酸钆烧结体，氧化锆掺杂铌酸的化学计量比为x mol％ZrO2+Gd3NbO7；
步骤2：将步骤1得到的烧结体粉碎成2～3mm的块体；
步骤3：采用EB-PVD法将步骤2得到的块体沉积到合金基体上，得到非晶陶瓷涂层，非晶陶瓷涂层的厚度为200～300μm；其中EB-PVD法的工艺参数为：舱室气压不高于3×10- 6Torr；沉积速率不低于10nm/min；样品台旋转速率不低于45r/min。
本技术方案的技术原理和效果在于：
1、本方案中沉积在合金基体上的非晶陶瓷涂层有着极低的热导率(＜1.2W·m-1·K-1)，这样能够对合金基体在高温环境下起到很好的隔热的效果，提高合金基体使用的环境温度。
2、本方案中氧化锆掺杂铌酸盐作为非晶陶瓷涂层，能够很好的阻碍热量由涂层表面向合金基体扩散，降低合金基体表面温度，提高合金基体的使用温度，原因在于，非晶陶瓷涂层其内部原子为无序排列，对声子形成了漫反射效应，使得非晶陶瓷涂层表面的热量被反射至四面八方，同时相比于传统有序排列的晶体态陶瓷涂层而言，尤其是氧化锆掺杂铌酸盐，非晶陶瓷涂层内部是不存在晶界或相界面的，也就说这样的结构能避免点缺陷、面缺陷等的引入，使得涂层的性能有很大的提升。
进一步，所述步骤1中高温烧结的温度为1400～1600℃，烧结的时间为5～8h。
有益效果：该烧结温度下能够得到氧化锆掺杂铌酸钆烧结体。
进一步，所述步骤1中ZrO2、Gd2O3和Nb2O5粉末采用球磨的方式混合，球磨机的转速为500r/min～800r/min，球磨时间为90～280min。
有益效果：通过球磨的方式能够使得ZrO2、Gd2O3和Nb2O5粉末之间混合得更加均匀，便于后续的烧结。
进一步，球磨混合后进行过筛处理，筛目不低于325目。
有益效果：过筛处理能够减少大颗粒陶瓷粉末在烧结过程中导致成分不均匀的问题。
进一步，所述步骤2中，对步骤1得到的烧结体冷却至室温后，再次进行粉碎、球磨和过筛处理，对过筛后的粉末进行二次烧结。
有益效果：二次烧结能够使烧结体的致密度提高，使其成分更均匀，从而保证EB-PVD的蒸镀速率稳定，涂层成分更均匀。
进一步，所述二次烧结的温度为1200～1400℃，烧结的时间为4～6h。
有益效果：该温度范围下能够得到成分均匀的烧结体。
进一步，所述步骤3中合金基体在沉积非晶陶瓷涂层之前进行表面去油污和杂质处理。
有益效果：减少合金基体表面的杂质，能够提高其与陶瓷涂层之间的附着性。
进一步，所述步骤3中合金基体在沉积非晶陶瓷涂层之前进行喷砂处理，喷砂后合金基体的表面粗糙度为30～40μm。
有益效果：喷砂能够提高合金基体表面的强度，而粗糙度设置为30～40μm便于涂层与合金基体之间的粘接。
进一步，对所述步骤3得到的非晶陶瓷涂层进行抛光处理，使其表面粗糙度为4～5μm。
附图说明
图1为本发明实施例1与对比例1的热导率随温度的变化曲线图。
具体实施方式
下面通过具体实施方式进一步详细说明：
实施例1：
一种氧化锆掺杂铌酸钆非晶高温陶瓷涂层的制备方法，包括以下步骤：
步骤1：按照3mol％ZrO2+Gd3NbO7的化学计量比分别称取ZrO2、Gd2O3和Nb2O5粉末，采用球磨机混合均匀，其中球磨机的转速为500r/min，球磨时间为120min，将球磨后的粉末干燥处理后过325目筛，得到粒径均匀的粉末，后在1400℃下烧结8h，氧化锆掺杂铌酸钆烧结体。
步骤2：将步骤1得到的烧结体粉碎成2～3mm的块体。
步骤3：将步骤2得到的块体采用EB-PVD法沉积到合金基体上，得到氧化锆掺杂铌酸钆非晶陶瓷涂层，非晶陶瓷涂层的厚度为200μm；其中EB-PVD法的工艺参数为：舱室气压不高于3×10-6Torr；沉积速率不低于10nm/min；样品台旋转速率不低于45r/min。
其中合金基体采用镍基合金材料，其在沉积涂层之前利用浸泡法除去镍基合金基体表面的油污和杂质，再利用超声振荡进行处理，后用去离子水冲洗干净后烘干；再对镍基合金基体进行喷砂处理，喷砂后表面粗糙度为20～40μm。
完成后对步骤3得到的非晶陶瓷涂层进行抛光处理，使其表面粗糙度为4～5μm。
实施例2和实施例3：
实施例2与实施例1的区别仅在于，x＝6，即实施例2中氧化锆掺杂铌酸的化学计量比为6mol％ZrO2+Gd3NbO7。
实施例3与实施例1的区别在于，x＝9，即实施例3中氧化锆掺杂铌酸的化学计量比为9mol％ZrO2+Gd3NbO7。
实施例4：
与实施例1的区别在于，步骤1中烧结温度为1600℃，烧结的时间为4h。
实施例5：
与实施例1的区别在于，步骤1得到的烧结体冷却至室温后，再次进行粉碎、球磨和过筛处理，并对过筛后的粉末进行二次烧结，其中二次烧结的温度为1200℃，烧结的时间为6h。
实施例6：
与实施例5的区别在于，二次烧结的温度为1400℃，烧结的时间为4h。
实施例7：
与实施例1的区别在于，步骤3中沉积的非晶陶瓷涂层的厚度为300μm。
对比例1：
与实施例1的区别在于，步骤3中采用APS法将粒径为20～30μm的球状YSZ粉末沉积在合金基体上，形成了原子序列有序排列的晶体态陶瓷涂层，陶瓷涂层的厚度为200mm。
对比例2：
与实施例1的区别在于，步骤3中采用APS法将粒径为20～30μm的球状的氧化锆掺杂铌酸钆(化学计量比为3mol％ZrO2+Gd3NbO7)粉末沉积在合金基体上，形成了原子序列有序排列的晶体态陶瓷涂层，陶瓷涂层的厚度为200mm。
选取实施例1～7和对比例1～2得到的试样进行热导率检测：
采用激光热导仪进行测试，在800K温度时，实施例1～7和对比例1～2的测试结果如下表2所示。
表2为实施例1～7和对比例1～2的热导率(W·m-1·K-1)
以实施例1和对比例1的检测结果为例，如图1所示，图1中为实施例1和对比例1得到的非晶陶瓷涂层的热导率随温度的变化示意图，可见实施例1得到的非晶陶瓷涂层其热导率要远低于通常使用的YSZ。
另外从上表2可以得出：沉积有非晶陶瓷涂层的合金有着极低的热导率(＜1.2W·m-1·K-1)，这样能够对合金基体在高温环境下起到很好的隔热的效果，提高合金基体使用的环境温度。
以上所述的仅是本发明的实施例，方案中公知的具体材料及特性等常识在此未作过多描述。应当指出，对于本领域的技术人员来说，在不脱离本发明的前提下，还可以作出若干变形和改进，这些也应该视为本发明的保护范围，这些都不会影响本发明实施的效果和专利的实用性。本申请要求的保护范围应当以其权利要求的内容为准，说明书中的具体实施方式等记载可以用于解释权利要求的内容。
Claims (9)
1.一种氧化锆掺杂铌酸钆非晶高温陶瓷涂层的制备方法，包括以下步骤：
步骤1：将ZrO2、Gd2O3和Nb2O5混合后的粉末进行高温烧结得到氧化锆掺杂铌酸钆烧结体，氧化锆掺杂铌酸的化学计量比为x mol％ZrO2+Gd3NbO7；
步骤2：将步骤1得到的烧结体粉碎成2～3mm的块体；
步骤3：采用EB-PVD法将步骤2得到的块体沉积到合金基体上，得到非晶陶瓷涂层，非晶陶瓷涂层的厚度为200～300μm；其中EB-PVD法的工艺参数为：舱室气压不高于3×10-6Torr；沉积速率不低于10nm/min；样品台旋转速率不低于45r/min。
2.根据权利要求1所述的一种氧化锆掺杂铌酸钆非晶高温陶瓷涂层的制备方法，其特征在于：所述步骤1中高温烧结的温度为1400～1600℃，烧结的时间为5～8h。
3.根据权利要求1所述的一种氧化锆掺杂铌酸钆非晶高温陶瓷涂层的制备方法，其特征在于：所述步骤1中ZrO2、Gd2O3和Nb2O5粉末采用球磨的方式混合，球磨机的转速为500r/min～800r/min，球磨时间为90～280min。
4.根据权利要求3所述的一种氧化锆掺杂铌酸钆非晶高温陶瓷涂层的制备方法，其特征在于：球磨混合后进行过筛处理，筛目不低于325目。
5.根据权利要求4所述的一种氧化锆掺杂铌酸钆非晶高温陶瓷涂层的制备方法，其特征在于：所述步骤2中，对步骤1得到的烧结体冷却至室温后，再次进行粉碎、球磨和过筛处理，对过筛后的粉末进行二次烧结。
6.根据权利要求5所述的一种氧化锆掺杂铌酸钆非晶高温陶瓷涂层的制备方法，其特征在于：所述二次烧结的温度为1200～1400℃，烧结的时间为4～6h。
7.根据权利要求1所述的一种氧化锆掺杂铌酸钆非晶高温陶瓷涂层的制备方法，其特征在于：所述步骤3中合金基体在沉积非晶陶瓷涂层之前进行表面去油污和杂质处理。
8.根据权利要求1所述的一种氧化锆掺杂铌酸钆非晶高温陶瓷涂层的制备方法，其特征在于：所述步骤3中合金基体在沉积非晶陶瓷涂层之前进行喷砂处理，喷砂后合金基体的表面粗糙度为30～40μm。
9.根据权利要求1所述的一种氧化锆掺杂铌酸钆非晶高温陶瓷涂层的制备方法，其特征在于：对所述步骤3得到的非晶陶瓷涂层进行抛光处理，使其表面粗糙度为4～5μm。
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