CN113088967A - Thermal barrier coating with SN/APS composite structure double-bonding layer and preparation method thereof - Google Patents
Thermal barrier coating with SN/APS composite structure double-bonding layer and preparation method thereof Download PDFInfo
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Abstract
The invention relates to the field of thermal barrier coatings, in particular to a thermal barrier coating with an SN/APS composite structure double-bonding layer and a preparation method thereof. The thermal barrier coating comprises a nanocrystalline bonding layer, a NiCrAlY bonding layer and a spraying ceramic layer, wherein the nanocrystalline bonding layer is prepared by adopting a magnetron sputtering technology, and the NiCrAlY bonding layer and the ceramic layer are prepared by adopting an APS technology. The preparation method of the thermal barrier coating combines the characteristics that the magnetic control nanocrystalline bonding layer and the high-temperature alloy substrate do not have mutual diffusion, and the physical compatibility of the sprayed NiCrAlY bonding layer and the sprayed ceramic layer is good, breaks through the structural design concept of the traditional thermal barrier coating, and effectively improves the diffusion resistance and thermal cycle spalling resistance of the thermal barrier coating with the double bonding layers in the composite structure.
Description
Technical Field
The invention relates to the field of thermal barrier coatings, in particular to a thermal barrier coating with an SN/APS composite structure double-bonding layer and a preparation method thereof.
Background
With the continuous progress and development of engine technology in China, the requirement on the service performance of high-temperature structural materials is higher and higher. At present, the main development directions of the engine are to increase the combustion temperature of the turbine, increase the thrust-weight ratio and improve the service efficiency of the turbine components in a harsh environment. Because the high-temperature protective coating has the unique advantage of improving the comprehensive service performance of materials, the high-temperature protective coating technology represented by Thermal Barrier Coatings (TBCs) technology has become one of the key technologies for advanced engine development.
The thermal barrier coating mainly has three structural forms of double layers, multiple layers and gradient, wherein the most widely used thermal barrier coating is a double-layer structure. The double-layer structure thermal barrier coating mainly comprises a surface ceramic layer and a bottom metal bonding layer. The bonding layer has the effect of improving the adhesion and compatibility of the ceramic layer and the metal substrate, and at the same time, protects the substrate from oxidation to a certain extent and extent.
Currently, MCrAlY (M stands for Ni or Co or Ni + Co) is widely selected as the bond coat material, and the preparation methods include Physical Vapor Deposition (PVD) and Plasma Spray (PS). Ni, Co, Ni + Co in alloy components are matrix elements of the coating, Cr mainly ensures the hot corrosion resistance of the coating, Al provides the oxidation resistance of the coating, and trace element Y (usually less than 1 percent by mass) can improve Al2O3The film layer is combined with the substrate, andthe thermal shock resistance of the coating can be improved. The MCrAlY coating has good oxidation resistance and hot corrosion resistance. However, because the MCrAlY bonding layer has a significant difference in element composition with single crystal superalloy for advanced engine blades, the tendency for interdiffusion of elements at the interface at high temperatures is greater. The interdiffusion results not only in changing the coating composition and accelerating the growth of Thermal Growth Oxide (TGO); and due to the diffusion of Al to the alloy matrix, a brittle topological Close-Packed phase (TCP) in the alloy is rapidly precipitated, so that the mechanical property of the blade is greatly reduced.
Compared with the MCrAlY coating, the magnetron Sputtering Nanocrystalline (Sputtering Nanocrystalline) has the following characteristics: 1) the component design is consistent with the component phase of the matrix, and the interdiffusion phenomenon can not occur after long-term service, and the high-temperature mechanical property of the alloy is not influenced; 2) excellent oxidation resistance, nano-scale grain size and numerous grain boundary diffusion paths promote the selective oxidation of Al element; 3) the oxide film has good adhesion, and the anti-stripping property of the oxide film is obviously improved. However, the surface of the magnetic control nanocrystalline coating is smooth, and the magnetic control nanocrystalline coating is poorly combined with a ceramic layer prepared by an atmospheric plasma spraying technology.
At present, no public report of a thermal barrier coating with a SN/APS composite structure and a double-bonding-layer is found, wherein the design concept is different from that of the existing thermal barrier coating structure.
Disclosure of Invention
The invention aims to provide a preparation method of a thermal barrier coating which has no mutual diffusion between a bonding layer and a substrate and has better combination with a ceramic layer by adopting a nanocrystalline coating prepared by magnetron sputtering and a NiCrAlY coating prepared by an atmospheric plasma spraying technology as a composite structure double-bonding layer.
The technical scheme of the invention is as follows:
a thermal barrier coating with SN/APS composite structure double bonding layers comprises an alloy substrate, a nanocrystalline bonding layer, a NiCrAlY bonding layer and a ceramic layer.
Further, the thickness of the nanocrystalline bonding layer is 30-36 μm, and the thickness of the NiCrAlY bonding layer is as follows: the thickness of the nanocrystalline bonding layer is approximately equal to 1:2, the total thickness of the bonding layer is 40-60 mu m, and the thickness of the ceramic layer is 170-210 mu m.
A preparation method of a thermal barrier coating with SN/APS composite structure double bonding layers is characterized in that a nanocrystalline bonding layer is prepared by adopting a magnetron sputtering technology, a NiCrAlY bonding layer is prepared by adopting an APS technology, and a ceramic layer is also prepared by adopting the APS technology, and specifically comprises the following steps:
step (1): pretreating a high-temperature alloy matrix;
step (2): preparing a nanocrystalline bonding layer on the high-temperature alloy substrate treated in the step (1) by adopting a magnetron sputtering technology, adjusting magnetron sputtering process parameters, and sputtering a nanocrystalline coating;
and (3): preparing a NiCrAlY bonding layer on the nanocrystalline bonding layer treated in the step (2) by adopting an atmospheric plasma spraying technology, adjusting plasma spraying process parameters, and spraying a NiCrAlY coating;
and (4): and (4) preparing a ceramic layer on the NiCrAlY bonding layer treated in the step (3) by adopting an atmospheric plasma spraying technology, adjusting spraying process parameters, and spraying the ceramic layer.
Further, the preparation method of the thermal barrier coating with the SN/APS composite structure double-bonding layer comprises the steps that in the step (1), the pretreatment process comprises polishing of a high-temperature alloy substrate, sand blasting treatment and finally ultrasonic cleaning of a mixed solution of absolute ethyl alcohol and acetone according to the ratio of 3: 1; wherein, the sand blasting medium adopted in the sand blasting process is 100-200 meshes of white corundum, the sand blasting pressure is 0.2-0.6 MPa, and the sand blasting distance is 60-100 mm.
Further, in the above preparation method of the thermal barrier coating with the SN/APS composite structure double-bond coat, the magnetron sputtering process parameters are adjusted in the step (2) as follows: vacuum degree P<6×10-3Pa, power 2000W, argon gas 0.10Pa, substrate temperature 200-250 ℃, deposition time 10-12 hours; the components of the nanocrystalline coating are consistent with those of the high-temperature alloy matrix.
Further, in the above preparation method of the thermal barrier coating having the SN/APS composite structure dual-bond coat, the plasma spraying process parameters in step (3) are adjusted as follows: the current is 400-600A, the voltage is 50-70V, the spraying distance is 70-100 mm, and the moving speed of the spray gun is 50-300 mm/s; the components of the NiCrAlY coating are Cr: 23-29 wt%, Al: 7-13 wt%, Y: 0-1 wt%, and the balance of Ni;
further, in the above preparation method of the thermal barrier coating having the SN/APS composite structure dual-bond coat, the plasma spraying process parameters adjusted in the step (4) are as follows: the current is 500-700A, the voltage is 60-80V, the spraying distance is 70-100 mm, and the moving speed of the spray gun is 50-300 mm/s; the ceramic layer is 8 YSZ.
The invention has the beneficial effects that:
(1) the SN/APS composite structure bonding layer effectively solves two problems that the existing NiCrAlY coating is easy to generate element mutual diffusion at the interface of a service and a high-temperature alloy substrate at high temperature and the magnetic control nanocrystalline and a sprayed ceramic layer are poor in combination, and improves the service life of the thermal barrier coating;
(2) the preparation method of the thermal barrier coating combines the characteristics that the magnetic control nanocrystalline bonding layer and the high-temperature alloy substrate do not have mutual diffusion, and the physical compatibility of the sprayed NiCrAlY bonding layer and the sprayed ceramic layer is good, breaks through the structural design concept of the traditional thermal barrier coating, and effectively improves the diffusion resistance and thermal cycle spalling resistance of the thermal barrier coating with the double bonding layers in the composite structure.
(3) The thermal barrier coating is suitable for various high-temperature alloy workpieces, is not limited by factors such as high-temperature alloy components and workpiece shapes, and can be applied to protection of hot end components such as turbine blades of aero-engines.
Drawings
FIG. 1(a) is a schematic structural view of a dual-bond-layer thermal barrier coating of an SN/APS composite structure of the present invention;
FIG. 1(b) is a schematic structural view of a thermal barrier coating of a conventional NiCrAlY bonding layer;
FIG. 2 is a microstructure of a dual bond layer thermal barrier coating of an SN/APS composite structure of the present invention;
FIG. 3 is a partially enlarged view of the microstructure of a dual bond layer thermal barrier coating of the SN/APS composite structure of the present invention.
Detailed Description
In order to explain the present invention in more detail, the present invention is further explained with reference to the attached drawings and the embodiments, and the content of the present invention is not limited to the content referred to in the embodiments.
A thermal barrier coating with SN/APS composite structure double bonding layers comprises an alloy substrate, a nanocrystalline bonding layer, a NiCrAlY bonding layer and a ceramic layer.
The thickness of the nanocrystalline bonding layer is 30-36 mu m, and the thickness of the NiCrAlY bonding layer is as follows: the thickness of the nanocrystalline bonding layer is approximately equal to 1:2, the total thickness of the bonding layer is 40-60 mu m, and the thickness of the ceramic layer is 170-210 mu m.
Example 1:
a SN/APS composite structure double-bonding-layer thermal barrier coating is marked as SN/APS-1, wherein the preparation steps are as follows:
step (1): pretreating a high-temperature alloy matrix:
the high-temperature alloy substrate is sequentially polished by using No. 240 and No. 400 SiC sand paper, then sand blasting is carried out, a sand blasting medium is 200-mesh white corundum in the sand blasting process, the sand blasting pressure is 0.5MPa, the sand blasting distance is 80mm, and finally, the high-temperature alloy substrate is ultrasonically cleaned by using a mixed solution of anhydrous ethanol and acetone in a ratio of 3: 1.
Step (2): preparing a nanocrystalline bonding layer by a magnetron sputtering technology:
the treated high-temperature alloy substrate is arranged in a special tool, the nanocrystalline bonding layer deposition is carried out in a vacuum chamber of a magnetron sputtering device, the components of the magnetron nanocrystalline coating are consistent with those of the high-temperature alloy substrate, and the magnetron sputtering technological parameters are as follows: vacuum degree P<6×10-3Pa, power 2000W, argon gas 0.10Pa, substrate temperature 220 ℃, deposition time 11 hours.
And (3): preparing a NiCrAlY bonding layer by an atmospheric plasma spraying technology:
the sample of sputtering nanocrystalline tie coat is installed at special frock, carries out NiCrAlY coating spraying in atmosphere plasma spraying laboratory, and NiCrAlY coating component is Cr: 27 wt%, Al: 11 wt%, Y: 0.5 wt%, and the balance being Ni. The plasma spraying process parameters are as follows: the current 520A, the voltage 64V, the spraying distance 100mm and the moving speed of the spray gun 150 mm/s.
And (4): preparing a ceramic layer by an atmospheric plasma spraying technology:
and (3) mounting the sample of the SN/APS composite structure double-bonding layer in a special tool, and spraying a ceramic layer in an atmosphere plasma spraying laboratory, wherein the ceramic layer is 8 YSZ. The plasma spraying process parameters are as follows: current 590A, voltage 70V, spraying distance 100mm and spray gun moving speed 150 mm/s.
Example 2:
a SN/APS composite structure double-bonding-layer thermal barrier coating is marked as SN/APS-2, wherein the preparation steps are as follows:
step (1): pretreating a high-temperature alloy matrix:
the high-temperature alloy substrate is sequentially polished by using No. 240 and No. 400 SiC sand paper, then sand blasting is carried out, a sand blasting medium is 100-mesh white corundum in the sand blasting process, the sand blasting pressure is 0.5MPa, the sand blasting distance is 80mm, and finally, the high-temperature alloy substrate is ultrasonically cleaned by using a mixed solution of anhydrous ethanol and acetone in a ratio of 3: 1.
Step (2): preparing a nanocrystalline bonding layer by a magnetron sputtering technology:
the treated high-temperature alloy matrix is arranged in a special tool, the nanocrystalline bonding layer deposition is carried out in a vacuum chamber of a magnetron sputtering device, the components of the magnetron nanocrystalline coating are consistent with those of the high-temperature alloy matrix, and the magnetron sputtering technological parameters are as follows: vacuum degree P<6×10-3Pa, power 2000W, argon gas 0.10Pa, substrate temperature 220 ℃, deposition time 11 hours.
And (3): preparing a NiCrAlY bonding layer by an atmospheric plasma spraying technology:
the sample of sputtering nanocrystalline tie coat is installed at special frock, carries out NiCrAlY coating spraying in atmosphere plasma spraying laboratory, and NiCrAlY coating component is Cr: 27 wt%, Al: 11 wt%, Y: 0.5 wt%, and the balance being Ni. The plasma spraying process parameters are as follows: the current 520A, the voltage 64V, the spraying distance 100mm and the moving speed of the spray gun 150 mm/s.
And (4): preparing a ceramic layer by an atmospheric plasma spraying technology:
and (3) mounting the sample of the SN/APS composite structure double-bonding layer in a special tool, and spraying a ceramic layer in an atmosphere plasma spraying laboratory, wherein the ceramic layer is 8 YSZ. The plasma spraying process parameters are as follows: current 590A, voltage 70V, spraying distance 100mm and spray gun moving speed 150 mm/s.
Example 3:
a SN/APS composite structure double-bonding-layer thermal barrier coating is marked as SN/APS-3, wherein the preparation steps are as follows:
step (1): pretreating a high-temperature alloy matrix:
the high-temperature alloy matrix is sequentially polished by using No. 240 and No. 400 SiC sand paper, then sand blasting is carried out, a sand blasting medium is 80-mesh glass beads in the sand blasting process, the sand blasting pressure is 0.5MPa, the sand blasting distance is 80mm, and finally the high-temperature alloy matrix is ultrasonically cleaned by using a mixed solution of anhydrous ethanol and acetone according to the ratio of 3: 1.
Step (2): preparing a nanocrystalline bonding layer by a magnetron sputtering technology:
the treated high-temperature alloy matrix is arranged in a special tool, the nanocrystalline bonding layer deposition is carried out in a vacuum chamber of a magnetron sputtering device, the components of the magnetron nanocrystalline coating are consistent with those of the high-temperature alloy matrix, and the magnetron sputtering technological parameters are as follows: vacuum degree P<6×10-3Pa, power 2000W, argon gas 0.10Pa, substrate temperature 220 ℃, deposition time 11 hours.
And (3): preparing a NiCrAlY bonding layer by an atmospheric plasma spraying technology:
the sample of sputtering nanocrystalline tie coat is installed at special frock, carries out NiCrAlY coating spraying in atmosphere plasma spraying laboratory, and NiCrAlY coating component is Cr: 27 wt%, Al: 11 wt%, Y: 0.5 wt%, and the balance being Ni. The plasma spraying process parameters are as follows: the current 520A, the voltage 64V, the spraying distance 100mm and the moving speed of the spray gun 150 mm/s.
And (4): preparing a ceramic layer by an atmospheric plasma spraying technology:
and (3) mounting the sample of the SN/APS composite structure double-bonding layer in a special tool, and spraying a ceramic layer in an atmosphere plasma spraying laboratory, wherein the ceramic layer is 8 YSZ. The plasma spraying process parameters are as follows: current 590A, voltage 70V, spraying distance 100mm and spray gun moving speed 150 mm/s.
Comparative example:
the thermal barrier coating of the common NiCrAlY bonding layer comprises the following specific implementation steps:
step (1): pretreating a high-temperature alloy matrix:
the high-temperature alloy substrate is sequentially polished by using No. 240 and No. 400 SiC sand paper, then sand blasting is carried out, a sand blasting medium is 200-mesh white corundum in the sand blasting process, the sand blasting pressure is 0.5MPa, the sand blasting distance is 80mm, and finally, the high-temperature alloy substrate is ultrasonically cleaned by using a mixed solution of absolute ethyl alcohol and acetone, wherein the ratio of acetone to acetone is 3: 1.
And (3): preparing a NiCrAlY bonding layer by an atmospheric plasma spraying technology:
the treated high-temperature alloy substrate is arranged in a special tool, and NiCrAlY coating spraying is carried out in an atmosphere plasma spraying laboratory, wherein the NiCrAlY coating comprises the following components: 27 wt%, Al: 11 wt%, Y: 0.5 wt%, and the balance being Ni. The plasma spraying process parameters are as follows: the current is 520A, the voltage is 64V, the spraying distance is 100mm, the moving speed of the spray gun is 150mm/s, and the thickness of the NiCrAlY bonding layer is 35-55 mu m.
And (4): preparing a ceramic layer by an atmospheric plasma spraying technology:
and (3) installing the sample of the NiCrAlY bonding layer in a special tool, and spraying a ceramic layer in an atmosphere plasma spraying laboratory, wherein the ceramic layer is 8 YSZ. The plasma spraying process parameters are as follows: the current 590A, the voltage 70V, the spraying distance 100mm, the moving speed of the spray gun 150mm/s and the thickness of the ceramic layer 170-210 μm.
The microstructure of the composite structure double-bonding-layer thermal barrier coating in the embodiment 1 is shown in fig. 2, fig. 3 is a partial enlargement of fig. 2, and the interfaces of the high-temperature alloy substrate/magnetic control nanocrystalline, magnetic control nanocrystalline/NiCrAlY and NiCrAlY/ceramic layer are well combined.
The thermal barrier coatings of examples 1-3 and comparative examples were tested for cyclic oxidation performance, incubated at 1100 deg.C for 60min, air cooled for 10min, and the cycle test was repeated. After 100 cycles, no significant spallation of the thermal barrier coatings obtained in examples 1-3 and comparative example above occurred. By introducing the sprayed NiCrAlY coating between the magnetic control nanocrystalline coating and the sprayed ceramic layer, the physical compatibility between the magnetic control nanocrystalline coating and the sprayed ceramic layer is effectively improved, and the service life of the nanocrystalline bonding layer thermal barrier coating is prolonged.
The above embodiments are merely illustrative of the technical concepts and features of the present invention, and the purpose of the embodiments is to enable those skilled in the art to understand the contents of the present invention and implement the present invention, and not to limit the protection scope of the present invention. Variations and modifications which do not depart from the spirit and substance of the invention are intended to be included within the scope of the appended claims.
Claims (7)
1. A thermal barrier coating with SN/APS composite structure double bonding layers is characterized by comprising an alloy substrate, a nanocrystalline bonding layer, a NiCrAlY bonding layer and a ceramic layer.
2. The thermal barrier coating with the SN/APS composite structure double-bonding layer as claimed in claim 1, wherein the thickness of the nanocrystalline bonding layer is 30-36 μm, and the thickness of the NiCrAlY bonding layer is as follows: the thickness of the nanocrystalline bonding layer is approximately equal to 1:2, the total thickness of the bonding layer is 40-60 mu m, and the thickness of the ceramic layer is 170-210 mu m.
3. The preparation method of the thermal barrier coating with the SN/APS composite structure double-bonding layer as claimed in claim 1, wherein the nanocrystalline bonding layer is prepared by magnetron sputtering technology, the NiCrAlY bonding layer is prepared by APS technology, and the ceramic layer is also prepared by APS technology, and the method specifically comprises the following steps:
step (1): pretreating a high-temperature alloy matrix;
step (2): preparing a nanocrystalline bonding layer on the high-temperature alloy substrate treated in the step (1) by adopting a magnetron sputtering technology, adjusting magnetron sputtering process parameters, and sputtering a nanocrystalline coating;
and (3): preparing a NiCrAlY bonding layer on the nanocrystalline bonding layer treated in the step (2) by adopting an atmospheric plasma spraying technology, adjusting plasma spraying process parameters, and spraying a NiCrAlY coating;
and (4): and (4) preparing a ceramic layer on the NiCrAlY bonding layer treated in the step (3) by adopting an atmospheric plasma spraying technology, adjusting spraying process parameters, and spraying the ceramic layer.
4. The preparation method of the thermal barrier coating with the SN/APS composite structure double-bonding layer according to the claim 3, wherein the pretreatment process in the step (1) comprises grinding the high-temperature alloy substrate, then carrying out sand blasting treatment, and finally carrying out ultrasonic cleaning by using a mixed solution of absolute ethyl alcohol and acetone according to the ratio of 3: 1; wherein, the sand blasting medium adopted in the sand blasting process is 100-200 meshes of white corundum, the sand blasting pressure is 0.2-0.6 MPa, and the sand blasting distance is 60-100 mm.
5. The method for preparing the thermal barrier coating with the SN/APS composite structure double-bonding layer according to the claim 3, wherein the magnetron sputtering process parameters are adjusted in the step (2) as follows: vacuum degree P<6×10-3Pa, power 2000W, argon gas 0.10Pa, substrate temperature 200-250 ℃, deposition time 10-12 hours; the components of the nanocrystalline coating are consistent with those of the high-temperature alloy matrix.
6. The method for preparing the thermal barrier coating with the SN/APS composite structure dual-bonding layer according to the claim 3, wherein the parameters of the plasma spraying process in the step (3) are adjusted as follows: the current is 400-600A, the voltage is 50-70V, the spraying distance is 70-100 mm, and the moving speed of the spray gun is 50-300 mm/s; the components of the NiCrAlY coating are Cr: 23-29 wt%, Al: 7-13 wt%, Y: 0 to 1 wt%, and the balance being Ni.
7. The method for preparing a thermal barrier coating with an SN/APS composite structure dual-bonding layer according to claim 3, wherein the plasma spraying process parameters in the step (4) are adjusted as follows: the current is 500-700A, the voltage is 60-80V, the spraying distance is 70-100 mm, and the moving speed of the spray gun is 50-300 mm/s; the ceramic layer is 8 YSZ.
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