CN112962050A - Method for improving high temperature resistance and corrosion resistance of thermal barrier coating - Google Patents

Method for improving high temperature resistance and corrosion resistance of thermal barrier coating Download PDF

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Publication number
CN112962050A
CN112962050A CN202110248189.6A CN202110248189A CN112962050A CN 112962050 A CN112962050 A CN 112962050A CN 202110248189 A CN202110248189 A CN 202110248189A CN 112962050 A CN112962050 A CN 112962050A
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thermal barrier
barrier coating
coating
layer
corrosion resistance
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杨灵芳
黄智�
张荣珅
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Hunan University
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Hunan University
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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
    • 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
    • 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
    • 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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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)

Abstract

A method for improving the high temperature resistance and corrosion resistance of a thermal barrier coating belongs to the technical field of surface treatment and modification of thermal barrier coatings. The treatment method comprises the steps of firstly utilizing the yttria-stabilized zirconia thermal barrier coating remelted by the fiber laser, and then adopting flame sintering to realize the sealing of the top of the ceramic layer, thereby improving the high-temperature oxidation resistance and the corrosion resistance of the coating. The process conditions are as follows: the laser power is 150-. The advantages are that: the laser remelting enables a remelted layer of the thermal barrier coating to become compact, the filling and sintering of the oxide effectively supplements cracks of the laser remelted layer, and the two processes are combined to enable the surface of the top thermal barrier coating to be compact without penetrating cracks, effectively prevent oxygen from diffusing, reduce the growth of a thermal oxidation layer, and accordingly enable the high-temperature oxidation resistance and the corrosion resistance of the thermal barrier coating to be obviously improved.

Description

Method for improving high temperature resistance and corrosion resistance of thermal barrier coating
Technical Field
The invention relates to a method for improving the high temperature resistance and corrosion resistance of a thermal barrier coating, namely a surface treatment method for remelting the surface of the thermal barrier coating by adopting laser and sealing cracks by using an oxide, thereby improving the high temperature resistance and corrosion resistance of the thermal barrier coating, and belongs to the technical field of surface treatment and modification of the thermal barrier coating.
Background
With the development of aerospace technology, the service temperature of the internal parts of the engine is higher and higher, the requirements on the high temperature resistance and the corrosion resistance of the internal parts of the engine are higher and higher, and the prior art adopts the preparation of a thermal barrier coating with high-temperature oxidation resistance and thermal insulation performance on the surface of metal. The thermal barrier coating comprises a metal substrate, a bonding layer and a ceramic layer. The main preparation technologies of the current coating include plasma spraying and supersonic flame spraying, the coatings obtained by the technologies are mainly layered and stacked, more pores exist, and in the long-time use process, the growth of bonding layer oxides can be caused when oxygen enters and reaches the interface of the ceramic layer and the bonding layer, so that the ceramic layer falls and fails.
Laser remelting is used as a modification technology of a thermal barrier coating, and a high-energy heat source is used for rapidly moving so as to enable a material to be rapidly solidified after being melted. The thermal barrier coating after laser remelting has a tightly-packed vertical columnar structure on the surface layer, which has good effect on improving the layered packing and porous structure of the spray coating and prolonging the thermal oxidation resistance life of the coating.
However, laser remelting is used as hot working, and the ceramic layer subjected to laser remelting has obvious network cracks due to the characteristics of rapid cooling and rapid heating and large ceramic brittleness, wherein the cracks can penetrate through the whole ceramic layer even in depth, and can increase the thermal shock resistance of the coating, and meanwhile, direct channels are provided for oxygen entering the coating, so that the coating is subjected to interface cracking and even falls off to fail. Therefore, in order to improve the high-temperature oxidation resistance of the remelting coating, the surface of the ceramic coating needs to be subjected to crack control and repair treatment.
Disclosure of Invention
In order to overcome the above-mentioned disadvantages of the prior art, the present invention provides a method for improving the high temperature and corrosion resistance of a thermal barrier coating, thereby improving the high temperature oxidation resistance of a remelted coating.
In order to achieve the purpose, the technical scheme adopted by the invention comprises the following steps:
a method for improving the high temperature resistance and corrosion resistance of a thermal barrier coating comprises the following steps of firstly remelting the surface layer of a yttria-stabilized zirconia thermal barrier coating by using fiber laser, and then sealing the top of a ceramic layer by adopting flame sintering:
firstly, after a metal substrate is polished, cleaned and subjected to sand blasting treatment, a metal bonding layer is deposited on the metal substrate by using a plasma spraying method, and then a zirconia ceramic layer with stable yttria is continuously deposited on the bonding layer to finish the preparation of a thermal barrier coating;
and secondly, the process setting range of the optical fiber laser device is as follows: the laser power is 150-;
dispersing metal oxide into the solution to prepare oxide dispersion liquid, wherein the dispersion mode adopts an ultrasonic wave or a high-energy ball mill, the oxide is alumina, zirconia or silica, the solution is polyvinyl alcohol aqueous solution with the mass fraction of 40-70%, and the mass fraction of the oxide is 1-20%;
fourthly, coating the prepared metal dispersion liquid on the surface of the ceramic layer subjected to laser remelting in a dipping or brushing mode, drying at constant temperature, coating and drying again, and circulating the process for 3-5 times until the gap is filled;
fifthly, burning the surface for 2-5min by using oxyacetylene flame;
sixthly, cooling the treated sample, preparing for detection and analysis, and detecting the effects of crack sealing, high temperature resistance and corrosion resistance improvement.
The advantages of the present disclosure are as follows:
the interaction between the laser beam and the surface of the material is a rapid heating and rapid cooling process, the surface of the material can be instantly heated to be molten in a certain depth, and the formed great temperature gradient can enable the surface layer to be rapidly cooled by means of heat conduction to the matrix, so that the cooling speed is also fast, the surface coating material is subjected to surface remelting, and the performance of the material is improved. However, the rapid heating and cooling process inevitably causes some vertical large cracks in the remelted layer. The coating can fill the large cracks, the flame burning is much lower than the energy of the laser beam, and the oxide sintering can be realized without forming the cracks.
Firstly, the dispersed metal oxide permeates into cracks of the remelting coating in a dipping or brushing mode, and a sealing film is formed on the surface of the remelting coating; and then burning the surface layer by adopting an oxyacetylene flame sintering mode to form a compact antioxidant film. The process is suitable for various metal base materials with high and low melting points. The added oxide powder has lower thermal expansion coefficient and low thermal heat dissipation coefficient, and has better heat preservation effect and oxidation resistance.
Drawings
FIG. 1 is a cross-sectional view of a thermal barrier coating after laser remelting, which sequentially shows a metal substrate, a spray coating and a remelted layer from top to bottom, and shows that the remelted layer has more longitudinal cracks after laser remelting.
FIG. 2 is a surface topography of a thermal barrier coating after laser remelting, which shows that the surface of the thermal barrier coating has more cracks after laser remelting.
FIG. 3 is a surface topography of the coating after laser remelting after sealing treatment, showing that the surface becomes smooth after sealing treatment, the cracks in FIG. 2 are filled, and surface sealing is achieved.
FIG. 4 is a cross-sectional view of the laser-remelted coating after the sealing treatment, showing that after the sealing treatment, a thin ceramic layer is formed on the surface of the remelted layer to seal the open end of the longitudinal crack.
FIG. 5 is a high temperature oxidation resistance chart of the laser remelting test piece and the sealing treated test piece, which shows that the high temperature oxidation resistance of the test piece after sealing treatment is significantly improved.
FIG. 6 is a graph showing the corrosion resistance of the laser remelting coupon and the sealing treated coupon, showing that the coupons after sealing treatment have a reduced corrosion resistance tendency and a reduced corrosion rate.
Detailed Description
A method for improving the high temperature resistance and corrosion resistance of a thermal barrier coating comprises the following steps of firstly remelting the surface layer of a yttria-stabilized zirconia thermal barrier coating by using fiber laser, and then sealing the top of a ceramic layer by adopting flame sintering:
firstly, after a metal substrate is polished, cleaned and subjected to sand blasting treatment, a metal bonding layer is deposited on the metal substrate by using a plasma spraying method, and then a zirconia ceramic layer with stable yttria is continuously deposited on the bonding layer to finish the preparation of a thermal barrier coating;
and secondly, the process setting range of the optical fiber laser device is as follows: the laser power is 150-;
dispersing metal oxide into the solution to prepare oxide dispersion liquid, wherein the dispersion mode adopts an ultrasonic wave or a high-energy ball mill, the oxide is alumina, zirconia or silica, the solution is polyvinyl alcohol aqueous solution with the mass fraction of 40-70%, and the mass fraction of the oxide is 1-20%;
fourthly, coating the prepared metal dispersion liquid on the surface of the ceramic layer subjected to laser remelting in a dipping or brushing mode, drying at constant temperature, coating and drying again, and circulating the process for 3-5 times until the gap is filled;
fifthly, burning the surface for 2-5min by using oxyacetylene flame;
sixthly, cooling the treated sample, preparing for detection and analysis, and detecting the effects of crack sealing, high temperature resistance and corrosion resistance improvement.
The present invention is further described in detail below with reference to specific experimental procedures:
firstly, preparing a test sample wafer of a plasma spraying thermal barrier coating, wherein the model of gray cast iron is 250, and the size is 15mm multiplied by 5mm, and adopting thread fixingFixing on a substrate in a fixed mode, performing polishing, cleaning, sand blasting and other treatment, spraying an adhesive layer with the thickness of 0.1mm on the surface of a sample by using a plasma spraying method, wherein the material is NiCoCrAlY, and then spraying a ceramic layer with the thickness of 0.9mm, and the material is 6-8% of Y2O3ZrO of2。
A treatment method for improving the performance of a thermal barrier coating specifically comprises the following steps:
the first step is as follows: according to the technical requirements of fiber laser equipment, the process setting range is as follows: the laser power is 250W, the scanning speed is 1300m/s, the defocusing amount is 40cm, the lap joint rate is 40%, and the laser remelting is carried out on the surface layer of the thermal barrier coating, so that the thickness of the remelting layer reaches 200 mu m.
The second step is that: alumina powder with a size specification of 50nm was dispersed ultrasonically in a 50% strength aqueous polyvinyl alcohol solution until a stable dispersion was formed.
The third step: coating the prepared alumina dispersion liquid on the surface of the ceramic layer subjected to laser remelting in a brushing way, in order to enable alumina to better penetrate into cracks of a remelted layer, ultrasonically vibrating the coated test piece for 5-10min at the working frequency of 20Hz, drying at the constant temperature of 80 ℃ for 2h after vibration, taking out, cooling, coating and drying again, and circulating the process for 2-3 times until gaps are fully filled under a metallographic microscope.
The fourth step: and (3) burning the surface for 3min by using an outer flame of oxyacetylene flame, and cooling to detect the metallographic oxidation resistance of the test piece.
By way of example, a comparison study was conducted between a sealed test piece after laser remelting and an unsealed remelted test piece. XRD is used for testing the change condition of the phase structure of the sample before and after treatment; observing the change conditions of the surface and the section of the sample before and after treatment by using a metallographic microscope; the change in hardness of the test pieces before and after the treatment was measured by a microhardness tester. And a high temperature oxidation cycle test at 500 ℃ in air and a corrosion resistance test in brine were performed on the closed samples and the non-closed samples.
The results of both XRD tests showed that the phase structure of both samples was mainly tetragonal. Therefore, the phase structure of the surface of the test piece is not transformed after the closed burning treatment, so that the failure of the coating caused by the change of the volume of the coating due to the change of the phase structure does not exist.
And observing the test piece before and after sealing by using a metallographic microscope, wherein the unclosed laser remelting test piece has more cracks with different sizes on the surface, and the cracks are repaired and filled after sealing treatment, so that the surface is flat and smooth. From the section appearance, the unclosed sample section has more longitudinal cracks and transverse cracks, part of the cracks directly reach the bonding layer of the thermal barrier coating, a conveying channel is provided for oxygen to reach the bonding layer, the long-time use of the coating in a high-temperature environment is very difficult, and the opening of the cracks of the sample after being closed and burned is well closed, so that the oxygen is prevented from entering to a certain extent. FIG. 2 is a surface topography of a test piece without sealing treatment, and the surface of the thermal barrier coating has more cracks. Fig. 3 is a surface topography after the sealing treatment, showing that the surface becomes smooth and the cracks in fig. 2 are filled by the sealing treatment, thereby sealing the surface. FIG. 1 is a cross-sectional view of the coating without the sealing treatment, showing that the remelted layer has more longitudinal cracks. FIG. 4 is a cross-sectional profile of the coating after encapsulation, with a thin ceramic layer on the top of the remelted layer closing the open end of the longitudinal crack.
The microhardness of the test piece before and after sealing was measured by a microhardness meter. The test result shows that the average microhardness of the remelted test piece is 1400 HV300, the average microhardness of the sealed test piece is 1350 HV300, and the microhardness of the sealed test piece has no great change, which indicates that the mechanical property is stable.
And performing a high-temperature cyclic oxidation experiment at 500 ℃ on the test piece before and after sealing, and testing the high-temperature oxidation resistance of the test piece. As seen from FIG. 5, the remelted specimen had an average weight increase of 2.56 mg/cm2Average weight gain of the test piece after sealing is 2.37 mg/cm2And the reduction of the oxidation rate constant is found through dynamic curve fitting calculation, namely the oxidation rate is reduced after the sealing, which shows that the high-temperature oxidation resistance can be improved.
The corrosion resistance of the sealed test piece was tested. The corrosion resistance test was performed in 3.5g/L saline, and the polarization curve obtained by fitting the test results is shown in FIG. 6. It can be seen that the self-corrosion potential after the blocking treatment is more positive than that of the test piece without blocking treatment, indicating that the electrochemical activity of the blocked test piece is smaller and the corrosion tendency is smaller. The fitting calculation shows that the annual corrosion rate of the test piece is improved from 0.651 to 0.409 mm/a after the sealing treatment, which indicates that the corrosion resistance of the sealed test piece is obviously improved.

Claims (1)

1. A method for improving the high temperature resistance and corrosion resistance of a thermal barrier coating is characterized by comprising the following steps: remelting the surface layer of the yttria-stabilized zirconia thermal barrier coating by using fiber laser, and then sealing the top of the ceramic layer by adopting flame sintering, wherein the method comprises the following specific steps:
firstly, after a metal substrate is polished, cleaned and subjected to sand blasting treatment, a metal bonding layer is deposited on the metal substrate by using a plasma spraying method, and then a zirconia ceramic layer with stable yttria is continuously deposited on the bonding layer to finish the preparation of a thermal barrier coating;
and secondly, the process setting range of the optical fiber laser device is as follows: the laser power is 150-;
dispersing metal oxide into the solution to prepare oxide dispersion liquid, wherein the dispersion mode adopts an ultrasonic wave or a high-energy ball mill, the oxide is alumina, zirconia or silica, the solution is polyvinyl alcohol aqueous solution with the mass fraction of 40-70%, and the mass fraction of the oxide is 1-20%;
fourthly, coating the prepared metal dispersion liquid on the surface of the ceramic layer subjected to laser remelting in a dipping or brushing mode, drying at constant temperature, coating and drying again, and circulating the process for 3-5 times until the gap is filled;
fifthly, burning the surface for 2-5min by using oxyacetylene flame;
sixthly, cooling the treated sample, preparing for detection and analysis, and detecting the effects of crack sealing, high temperature resistance and corrosion resistance improvement.
CN202110248189.6A 2021-03-07 2021-03-07 Method for improving high temperature resistance and corrosion resistance of thermal barrier coating Pending CN112962050A (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114686840A (en) * 2022-04-01 2022-07-01 北航（四川）西部国际创新港科技有限公司 anti-CMAS coating and preparation method thereof

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5576069A (en) * 1995-05-09 1996-11-19 Chen; Chun Laser remelting process for plasma-sprayed zirconia coating
US6756082B1 (en) * 1999-02-05 2004-06-29 Siemens Westinghouse Power Corporation Thermal barrier coating resistant to sintering
US20090110903A1 (en) * 2007-10-24 2009-04-30 General Electric Company Alumina-based protective coatings for thermal barrier coatings
CN101994078A (en) * 2010-12-11 2011-03-30 大连理工大学 Treatment method of improving oxidation resistance of thermal barrier coating
CN103911581A (en) * 2014-03-24 2014-07-09 燕山大学 Preparation method of zirconia thermal barrier coating based on roller
CN103993254A (en) * 2014-05-07 2014-08-20 江苏大学 Thermal barrier coating material with closed surface layer and preparation method thereof
CN107326319A (en) * 2017-06-28 2017-11-07 西安交通大学 A kind of laser remolten thermal barrier coating segmentation crack self-healing restorative procedure
US20170321559A1 (en) * 2016-05-09 2017-11-09 General Electric Company Thermal barrier system with bond coat barrier

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5576069A (en) * 1995-05-09 1996-11-19 Chen; Chun Laser remelting process for plasma-sprayed zirconia coating
US6756082B1 (en) * 1999-02-05 2004-06-29 Siemens Westinghouse Power Corporation Thermal barrier coating resistant to sintering
US20090110903A1 (en) * 2007-10-24 2009-04-30 General Electric Company Alumina-based protective coatings for thermal barrier coatings
CN101994078A (en) * 2010-12-11 2011-03-30 大连理工大学 Treatment method of improving oxidation resistance of thermal barrier coating
CN103911581A (en) * 2014-03-24 2014-07-09 燕山大学 Preparation method of zirconia thermal barrier coating based on roller
CN103993254A (en) * 2014-05-07 2014-08-20 江苏大学 Thermal barrier coating material with closed surface layer and preparation method thereof
US20170321559A1 (en) * 2016-05-09 2017-11-09 General Electric Company Thermal barrier system with bond coat barrier
CN107326319A (en) * 2017-06-28 2017-11-07 西安交通大学 A kind of laser remolten thermal barrier coating segmentation crack self-healing restorative procedure

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114686840A (en) * 2022-04-01 2022-07-01 北航（四川）西部国际创新港科技有限公司 anti-CMAS coating and preparation method thereof
CN114686840B (en) * 2022-04-01 2023-11-03 北航（四川）西部国际创新港科技有限公司 CMAS-resistant coating and preparation method thereof

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Application publication date: 20210615