CN113106374A - 一种耐高温高热流冲刷的复合涂层及其制备方法 - Google Patents

一种耐高温高热流冲刷的复合涂层及其制备方法 Download PDF

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CN113106374A
CN113106374A CN202110297657.9A CN202110297657A CN113106374A CN 113106374 A CN113106374 A CN 113106374A CN 202110297657 A CN202110297657 A CN 202110297657A CN 113106374 A CN113106374 A CN 113106374A
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文波
倪立勇
曲栋
杨震晓
马康智
吴朝军
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Aerospace Research Institute of Materials and Processing Technology
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Abstract

本发明公开一种耐高温高热流冲刷复合涂层及其制备方法，属于表面工程技术领域；本发明设计复合涂层结构与成分，优化复合涂层制备工艺，精细调控复合涂层组织结构，成功解决了薄壁件高温高热流冲刷易穿孔、防护涂层易开裂的技术难题；本技术发明工艺简单易行，成本经济，实用性强，具有高温高热流防护需求的热端部件或产品的涂层制备，本发明的热端部件或产品件的材质为铝合金、钛合金等较低熔点的金属。

Description

一种耐高温高热流冲刷的复合涂层及其制备方法
技术领域
本发明涉及一种耐高温高热流冲刷的复合涂层及其制备方法，属于防护涂层技术领域。
背景技术
等离子喷涂是通过电弧放电将通入等离子喷枪内部的气体电离，形成高温等离子体(达到10000K)，随后将喷涂的粉末材料送入等离子体中加热熔化，熔融的粉末粒子经过喷枪加速后撞击到基体材料表面冷凝形成涂层的方法。等离子喷涂解决了难熔金属或陶瓷材料等高熔点材料的难以喷涂的技术难题，提高了涂层和基体的结合强度，降低了涂层的孔隙率，大幅度地提高了涂层的质量，广泛应用于航天、航空、冶金、石化等领域。
氧化锆(ZrO2)是目前航空航天广泛使用热障涂层材料，它具有良好的热学稳定性，熔点达到2700℃，在25℃到1200℃范围内，热导率和热膨胀系数分别约为2～3W/m·K和10～11×10-6K-1。此外，氧化锆还具有优异的综合力学性能，维氏硬度达到10GPa，弹性模量约220GPa。常温下ZrO2为单斜相(m)，超过1200℃时会向四方相(t)转变，超过2370℃时会向立方相(c)转变，在发生物相转变的同时，ZrO2材料自身会发生体积变化，影响ZrO2高温应用的寿命及可靠性，通过在ZrO2中引入Y2O3形成固溶体，通常为6％-8wt.％Y2O3，形成氧化钇部分稳定氧化锆(YSZ)，一定程度可以将ZrO2的高温相稳定至室温，但是当温度超过1200℃后降温的时候，t相仍然会通过马氏体相变向m相转变产生约3％-5％的体积膨胀，涂层开裂剥落风险大，这大大限制了YSZ涂层在高温环境下的使用寿命及可靠性。
航天热端部件产品具有超高热流(＞10MW/m2)、超高温度(＞1500℃)的服役特点，服役过程温度梯度极高导致涂层材料的失效风险成倍增加，这对目前使用的YSZ涂层提出了更高的要求，需要采用新的设计思路和技术手段解决当前的难点。
发明内容
本发明的目的在于解决航天高温高热流冲刷导致涂层剥落失效的问题，提出一种耐高温高热流冲刷的复合涂层及其制备方法，设计多层复合结构，实现涂层结构与功能的匹配；采用多种制备手段，解决功能涂层制备工艺问题；采用精细化控制喷涂工艺，解决热应力缓和层、热稳定隔热层成分与微结构不均匀的问题，实现高性能热应力缓和层、热稳定隔热层的制备；通过优化涂料配方及喷涂工艺，解决耐冲刷层烧蚀防护能力低，工艺适应性差的问题，实现耐冲刷层的制备。
本发明的技术方案主要包括以下步骤：
一种耐高温高热流冲刷的复合涂层，该复合涂层由内至外(由待喷涂的材料表面至最外层)包括热应力缓和层、热稳定隔热层和耐冲刷层；
其中，热应力缓和层的材料为Ni基合金材料，优选为NiCrAlY、NiCrY、Ni包Al合金中的一种；
热稳定隔热层的材料为纳米氧化钇部分稳定氧化锆(YSZ)；
耐冲刷层的材料为甲基嵌段硅橡胶、软木、玻璃纤维、硅烷偶联剂和汽油的混合料浆，甲基嵌段硅橡胶、软木、玻璃纤维、硅烷偶联剂、汽油的质量比100：10～30：10～30：5～10：10～50。
一种耐高温高热流冲刷的复合涂层的制备方法，该方法的步骤包括：
第一步，将待涂覆的产品表面进行喷砂处理，喷砂处理后对待涂覆的产品进行预热，其中，喷砂原料选用棕刚玉砂，喷砂气体压力0.1～0.5MPa，砂粒尺寸选用16～64目，喷砂距离为150～300mm，喷砂角度为60°～90°，喷砂移动速度150～400mm/s；预热温度为100～200℃；
第二步，采用等离子喷涂在经过预热处理后的待喷涂产品表面喷涂热应力缓和层，工艺参数选用：电流400～600A，主气(Ar)流量80～150L/min，辅气(H2或者He)流量为1～20L/min，送粉载气选用氩气(Ar)，流量为1～15L/min，送粉量为15～50g/min，喷涂距离为70～180mm，喷涂角度为70°～90°，喷涂厚度为0.02～0.2mm；
第三步，采用等离子喷涂在热应力缓和层表面喷涂热稳定隔热层，工艺参数选用：电流500～900A，主气(Ar或者N2)流量90～140L/min，辅气(H2或者He)流量为1～30L/min，送粉载气选用氩气(Ar)，流量为1～15L/min，送粉量为15～50g/min，喷涂距离为90～150mm，喷涂角度为70°～90°，喷涂厚度为0.05～1mm；
第四步，采用空气喷涂在热稳定隔热层表面喷涂耐冲刷层，工艺参数选用：空气压力0.1～0.6MPa，喷涂距离100～300mm，喷涂角度为70°～90°，喷涂厚度为0.05～5mm；
第五步，喷涂结束后，25～90℃烘箱保温24～72h至耐冲刷层固化完全；
待喷涂的产品为具有高温高热流防护需求的热端部件或产品，材质为铝合金、钛合金等较低熔点金属材料。
有益效果
(1)采用本技术可有效提高产品的耐高温高热流冲刷性能，最高可抵抗20MW/m2热流冲刷，最高温度达到1800℃。
(2)采用本技术制备的涂层结合力高，热应力缓和层结合强度超过50MPa，热稳定隔热层(YSZ)结合强度超过30MPa，耐冲刷层(S27)结合强度1MPa，剪切强度超过2MPa；
(3)采用本技术制备的涂层工艺稳定性高、涂层均匀性好，可满足大面积部件或产品的连续喷涂生产要求；
(4)采用本技术制备的复合涂层，沉积效率高、周期短、制备成本低，有利于大规模工程化应用。
(5)本发明公开一种耐高温高热流冲刷的复合涂层及其制备方法，属于表面工程技术领域；本发明设计复合涂层结构与成分，优化复合涂层制备工艺，精细调控复合涂层组织结构，成功解决了薄壁件高温高热流冲刷易穿孔、防护涂层易开裂的技术难题；本技术发明工艺简单易行，成本经济，实用性强，适用于具有高温高热流防护需求的热端部件或产品的涂层制备，本发明的热端部件或产品件的材质为铝合金、钛合金等较低熔点的金属。
附图说明
图1为喷涂完YSZ涂层后的表面照片；
图2为喷涂完S27固化后涂层的表面照片；
图3为喷涂完S27固化后涂层样件的截面照片；
具体实施方式
下面通过实例对本发明作进一步详细说明。
实施例1
对直径100mm×100mm×3mm的薄壁铝合金工件进行喷涂复合涂层，步骤为：
第一步，配置耐冲刷涂料，甲基嵌段硅橡胶、软木、玻璃纤维、硅烷偶联剂以及汽油的混合料浆，其中质量比为100：10：10：5：50；
第二步，对直径100mm×100mm×3mm的薄壁铝合金工件的待喷涂表面进行喷砂粗化处理，原料选用棕刚玉砂，喷砂的气体压力0.4MPa，砂粒尺寸选用24目，喷砂距离为160mm，喷砂角度为90°，喷砂移动速度150mm/s；
第三步，将铝合金工件进行预热，预热温度控制到150℃；
第四步，采用等离子喷涂在经过预热处理后的产品表面喷涂Ni包Al热应力缓和层，工艺参数选用：电流450A，主气(Ar)流量80L/min，辅气(H2)流量为5L/min，送粉载气(Ar)流量为5L/min，送粉量为30g/min，喷涂距离为150mm，喷涂角度为90°，喷涂厚度为0.05mm；
第五步，采用等离子喷涂在热应力缓和层表面喷涂纳米氧化钇部分稳定氧化锆(YSZ)热稳定隔热层，工艺参数选用：电流650A，主气(Ar)流量100L/min，辅气(H2)流量为10L/min，送粉载气(Ar)流量为5L/min，送粉量为20g/min，喷涂距离为100mm，喷涂角度为90°，喷涂厚度为0.5mm。喷涂YSZ热稳定隔热层完毕后，涂层形貌如图1所示。
第六步，采用空气喷涂在热稳定隔热层表面喷涂耐冲刷层(S27)，工艺参数选用：空气压力0.4MPa，喷涂距离100mm，喷涂角度为90°，喷涂厚度为0.05mm。
第七步，喷涂完毕后，将产品置于静止25℃，72h固化。喷涂完毕后，涂层形貌如图2所示。
最终所制备的涂层截面如图3所示，从内到外(左至右)，依次为铝合金基体、Ni包铝热应力缓和层、YSZ热稳定隔热层以及S27耐冲刷层。涂层结合紧密，未出现剥落开裂的缺陷，结合强度达到32MPa。
采用本实例的技术方法可有效提高铝合金等金属的耐冲刷性能，经过15MW/m2风洞冲刷考核后，铝合金基体结构稳定，基体未出现烧蚀穿孔的现象。

Claims (9)

1.一种耐高温高热流冲刷的复合涂层，其特征在于：该复合涂层由内至外依次包括热应力缓和层、热稳定隔热层和耐冲刷层；
其中，热应力缓和层的材料为Ni基合金材料；
热稳定隔热层的材料为纳米氧化钇部分稳定氧化锆；
耐冲刷层的材料为甲基嵌段硅橡胶、软木、玻璃纤维、硅烷偶联剂和汽油的混合料浆，甲基嵌段硅橡胶、软木、玻璃纤维、硅烷偶联剂、汽油的质量比为100：10～30：10～30：5～10：10～50。
2.根据权利要求1所述的一种耐高温高热流冲刷的复合涂层，其特征在于：热应力缓和层的材料为NiCrAlY、NiCrY、Ni包Al合金中的一种。
3.根据权利要求1所述的一种耐高温高热流冲刷的复合涂层，其特征在于：热稳定隔热层的材料为纳米氧化钇部分稳定氧化锆。
4.根据权利要求1所述的一种耐高温高热流冲刷的复合涂层，其特征在于：耐冲刷层的材料为甲基嵌段硅橡胶、软木、玻璃纤维、硅烷偶联剂和汽油的混合料浆，甲基嵌段硅橡胶、软木、玻璃纤维、硅烷偶联剂、汽油的质量比为100：10～30：10～30：5～10：10～50。
5.一种耐高温高热流冲刷的复合涂层的制备方法，其特征在于该方法的步骤包括：
第一步，将待涂覆的产品表面进行喷砂处理，喷砂处理后对待涂覆的产品进行预热，预热温度为100～200℃；
第二步，采用等离子喷涂在经过预热处理后的待喷涂产品表面喷涂热应力缓和层，工艺参数选用：电流400～600A，主气流量80～150L/min，辅气流量为1～20L/min，送粉载气选用Ar气，流量为1～15L/min，送粉量为15～50g/min，喷涂距离为70～180mm，喷涂角度为70°～90°，喷涂厚度为0.02～0.2mm；
第三步，采用等离子喷涂在热应力缓和层表面喷涂热稳定隔热层，工艺参数选用：电流500～900A，主气流量90～140L/min，辅气流量为1～30L/min，送粉载气选用Ar气，流量为1～15L/min，送粉量为15～50g/min，喷涂距离为90～150mm，喷涂角度为70°～90°，喷涂厚度为0.05～1mm；
第四步，采用空气喷涂在热稳定隔热层表面喷涂耐冲刷层，工艺参数选用：空气压力0.1～0.6MPa，喷涂距离100～300mm，喷涂角度为70°～90°，喷涂厚度为0.05～5mm；
第五步，喷涂结束后，25℃～90℃烘箱保温24～72h至耐冲刷层固化完全。
6.根据权利要求5所述的一种耐高温高热流冲刷的复合涂层的制备方法，其特征在于：第一步中，喷砂原料选用棕刚玉砂，喷砂气体压力0.1～0.5MPa，砂粒尺寸选用16～64目，喷砂距离为150～300mm，喷砂角度为60°～90°，喷砂移动速度150～400mm/s。
7.根据权利要求5所述的一种耐高温高热流冲刷的复合涂层的制备方法，其特征在于：第二步中，主气为Ar气，辅气为H2气或He气。
8.根据权利要求5所述的一种耐高温高热流冲刷的复合涂层的制备方法，其特征在于：第三步中，主气为Ar气或N2气，辅气为H2气或He气。
9.根据权利要求5所述的一种耐高温高热流冲刷的复合涂层的制备方法，其特征在于：涂层保护产品的材料为铝合金、钛合金等较低熔点金属材料。
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