CN113560601B - Method for integrally forming high-temperature alloy and thermal barrier coating and alloy material with thermal barrier coating - Google Patents

Abstract

The invention provides a method for integrally forming a high-temperature alloy and a thermal barrier coating and an alloy material with the thermal barrier coating, and belongs to the technical field of additive manufacturing. According to the invention, the transition layer is arranged between the high-temperature alloy and the thermal barrier coating, and the high-temperature alloy and the thermal barrier coating in the transition layer are compounded by adopting a laser melting forming technology, so that metallurgical bonding can be formed between the high-temperature alloy and the thermal barrier coating, and the bonding strength of the thermal barrier coating and the high-temperature alloy is improved; the content of the high-temperature alloy powder and the content of the thermal barrier coating powder are set in a gradient manner in the preparation process of the transition layer, so that the bonding strength of the thermal barrier coating and the high-temperature alloy is further improved; meanwhile, the selective laser melting forming technology is adopted to realize the integrated forming of the high-temperature alloy and the thermal barrier coating, and the bonding strength of the thermal barrier coating and the high-temperature alloy is further improved.

Description

Method for integrally forming high-temperature alloy and thermal barrier coating and alloy material with thermal barrier coating

Technical Field

The invention belongs to the technical field of additive manufacturing, and particularly relates to a method for integrally forming a high-temperature alloy and a thermal barrier coating and an alloy material with the thermal barrier coating.

Background

Aeroengines and gas turbines are widely used in the fields of aerospace, marine power, oil field gas transportation and exploitation, and the like, as highly complex and precise thermal machinery. With the rapid development of modern industrial processes, the working environments of aircraft engines and gas turbines become more and more severe, and the interior of the machine is in the environment of high temperature, high pressure and high thermal load for a long time, which puts high requirements on the service life and reliability of hot end parts in the machine. At present, in practical application, the service requirements are mainly met by the following schemes: the hot end of the engine is made of high-temperature alloy, and a thermal barrier coating is prepared on the surface of the high-temperature alloy.

At present, the preparation method of the alloy material with the thermal barrier coating mainly comprises the steps of preparing the high-temperature alloy by adopting the traditional forging processing or additive manufacturing technology, and then sequentially depositing a metal bonding layer and a surface ceramic layer on the surface of the high-temperature alloy by adopting a plasma spraying mode. The whole process is complicated, the bonding strength of the thermal barrier coating and the high-temperature alloy is low, and the thermal barrier coating is easy to fall off in the using process.

Therefore, how to improve the bonding strength between the superalloy and the thermal barrier coating becomes a difficult problem to be solved urgently.

Disclosure of Invention

The invention aims to provide a method for integrally molding a high-temperature alloy and a thermal barrier coating and an alloy material with the thermal barrier coating. The alloy material with the thermal barrier coating prepared by the method provided by the invention has excellent bonding strength.

In order to achieve the above object, the present invention provides the following technical solutions:

the invention provides a method for integrally forming a high-temperature alloy and a thermal barrier coating, which comprises the following steps of:

preparing a high-temperature alloy, a transition layer and a thermal barrier coating on a substrate in sequence by adopting a selective laser melting forming technology;

the preparation method of the transition layer comprises the following steps: laying transition layer powder and carrying out laser melting forming on the high-temperature alloy layer by layer to obtain a transition layer;

the transition layer powder comprises high-temperature alloy powder and thermal barrier coating powder; along the direction from the high-temperature alloy to the thermal barrier coating, the content of the high-temperature alloy powder in each layer of transition layer powder is reduced layer by layer, and the content of the thermal barrier coating powder is increased layer by layer.

Preferably, the superalloy powder comprises a nickel-based superalloy powder, an iron-based superalloy powder, or a cobalt-based superalloy powder.

Preferably, the chemical composition of the iron-based superalloy powder comprises, in mass percent: 15.0-26.0% of Cr15.0-50.0% of Ni, 0.90-7.0% of Mo, less than or equal to 3.0% of A1, less than or equal to 3.50% of Ti, less than or equal to 0.25-5.50% of Nb0.12%, less than or equal to 1.0% of Si, less than or equal to 2.0% of Mn, less than or equal to 0.025% of P, less than or equal to 0.030% of S, less than or equal to 0.5% of Cu, less than or equal to 10.0% of W, 0.10-1.50% of V, less than or equal to 0.015% of B, less than or equal to 0.050% of Ce and the balance of Fe.

Preferably, the particle size of the high-temperature alloy powder is 15-70 μm.

Preferably, the thermal barrier coating powder comprises YSZ, mullite, CeO ₂ Mixed powder of YSZ and Al ₂ O ₃ Mixed powder of YSZ and Yb ₂ O ₃ Stabilized ZrO ₂ 、Er ₂ O ₃ Stabilized ZrO ₂ 、Dy ₂ O ₃ Stabilized ZrO ₂ 、HfO ₂ -Y ₂ O ₃ 、La ₂ Zr ₂ O ₇ Or MMeAl ₁₁ O ₁₉ (ii) a The MMeAl ₁₁ O ₁₉ M in the formula (I) is La or Nd, and Me is alkaline earth metal.

Preferably, the particle size of the thermal barrier coating powder is 100-200 μm.

Preferably, the process parameters of the laser fusion forming of each layer of the transition layer powder independently include: the laser power is 200-500W, the scanning speed is 400-2000 mm/s, and the scanning distance is 0.06-0.12 mm.

Preferably, the laying of each layer of transition layer powder comprises: and simultaneously feeding the high-temperature alloy powder and the thermal barrier coating powder to an area to be melted by laser.

Preferably, the total thickness of the transition layer is 0.2-0.5 mm.

The invention also provides the alloy material with the thermal barrier coating prepared by the method of the technical scheme, which comprises a transition layer and the thermal barrier coating which are sequentially arranged on the high-temperature alloy;

the transition layer comprises a superalloy and thermal barrier coating particles; the particles of the thermal barrier coating in the transition layer are distributed in an increasing gradient along the direction from the high-temperature alloy to the thermal barrier coating;

the high-temperature alloy and the transition layer as well as the transition layer and the thermal barrier coating are in metallurgical bonding.

The invention provides a method for integrally forming a high-temperature alloy and a thermal barrier coating, which comprises the following steps: preparing a high-temperature alloy, a transition layer and a thermal barrier coating on a substrate in sequence by adopting a selective laser melting forming technology; the preparation method of the transition layer comprises the following steps: laying transition layer powder and carrying out laser melting forming on the high-temperature alloy layer by layer to obtain a transition layer; the transition layer powder comprises high-temperature alloy powder and thermal barrier coating powder; along the direction from the high-temperature alloy to the thermal barrier coating, the content of the high-temperature alloy powder in each layer of transition layer powder is reduced layer by layer, and the content of the thermal barrier coating powder is increased layer by layer. According to the invention, the transition layer is arranged between the high-temperature alloy and the thermal barrier coating, and the high-temperature alloy and the thermal barrier coating in the transition layer are compounded by adopting a laser melting forming technology, so that metallurgical bonding can be formed between the high-temperature alloy and the thermal barrier coating, and the bonding strength of the thermal barrier coating and the high-temperature alloy is improved; the content of the high-temperature alloy powder and the content of the thermal barrier coating powder are set in a gradient manner in the preparation process of the transition layer, so that the bonding strength of the thermal barrier coating and the high-temperature alloy is further improved; meanwhile, the selective laser melting forming technology is adopted to realize the integrated forming of the high-temperature alloy and the thermal barrier coating, and the bonding strength of the thermal barrier coating and the high-temperature alloy is further improved. Experimental results show that the interlaminar shear strength of the alloy material with the thermal barrier coating prepared by the method is 92.6-94.7 MPa.

Drawings

FIG. 1 is a schematic structural diagram and a corresponding microstructure diagram of an alloy material with a thermal barrier coating provided by the present invention;

FIG. 2 shows the shear strength of the alloy materials with thermal barrier coatings prepared in examples 1-3.

Detailed Description

The invention provides a method for integrally forming a high-temperature alloy and a thermal barrier coating, which comprises the following steps:

preparing a high-temperature alloy, a transition layer and a thermal barrier coating on a substrate in sequence by adopting a selective laser melting forming technology;

the preparation method of the transition layer comprises the following steps: laying transition layer powder and carrying out laser melting forming on the high-temperature alloy layer by layer to obtain a transition layer;

the transition layer powder comprises high-temperature alloy powder and thermal barrier coating powder; along the direction from the high-temperature alloy to the thermal barrier coating, the content of the high-temperature alloy powder in each layer of transition layer powder is reduced layer by layer, and the content of the thermal barrier coating powder is increased layer by layer.

The invention adopts the selective laser melting forming technology to prepare the high-temperature alloy, the transition layer and the thermal barrier coating on the substrate in sequence.

In the present invention, the selective laser melting forming technique is preferably performed in a protective atmosphere; the protective atmosphere is preferably argon, nitrogen or carbon dioxide; the purity of the protective atmosphere is preferably more than or equal to 99.99%. The invention can perform 3D printing in protective atmosphere, and can prevent the raw materials from generating oxidation reaction with oxygen in the air.

The invention adopts the selective laser melting forming technology to prepare the high-temperature alloy on the substrate.

In the present invention, the preparation method of the superalloy preferably comprises the following steps:

(1) establishing a three-dimensional model of the high-temperature alloy, converting the three-dimensional model into data which can be cut, and introducing the data into selective laser melting equipment to obtain multilayer section data;

(2) according to the first layer of section data in the multilayer section data obtained in the step (1), laying a high-temperature alloy powder layer required by the first layer of section data on the substrate, and then performing laser scanning on the cross section of the high-temperature alloy powder layer to obtain a first solid layer;

(3) and (3) according to the Nth layer of section data in the multilayer section data obtained in the step (1), sequentially and repeatedly paving and scanning the laser on the surface of the first solid layer obtained in the step (2) to prepare the Nth solid layer, so as to obtain the high-temperature alloy.

The invention preferably establishes a three-dimensional model of the high-temperature alloy, converts the three-dimensional model into separable data and introduces the separable data into selective laser melting equipment to obtain multilayer section data. The invention has no special limitation on the operation of establishing a three-dimensional model of the high-temperature alloy, converting the three-dimensional model into separable data and introducing the separable data into selective laser melting equipment to obtain multilayer section data, and the operation known by the technicians in the field is adopted.

After the multilayer section data is obtained, preferably, according to the first layer of section data in the multilayer section data, a superalloy powder layer required by the first layer of section data is laid on the substrate, and then the cross section of the superalloy powder layer is subjected to laser scanning to obtain a first solid layer.

In the present invention, the superalloy powder preferably comprises a nickel-based superalloy powder, an iron-based superalloy powder, or a cobalt-based superalloy powder; the particle size of the high-temperature alloy powder is preferably 15-70 mu m. In the present invention, when the particle size of the superalloy powder does not satisfy the above requirements, the superalloy powder is preferably mechanically pulverized. The mechanical pulverization operation is not particularly limited in the present invention, and pulverization operations known to those skilled in the art may be employed.

In the present invention, the chemical composition of the nickel-base superalloy powder preferably includes, in mass percent: 9.0 to 28.0% of Cr, less than or equal to 21.0% of W, 2.0 to 10.0% of Mo, 10.20 to 4.40% of A, 0.15 to 3.50% of Ti, less than or equal to 5.0% of Fe, less than or equal to 5.50% of Nb, less than or equal to 0.15% of C, less than or equal to 22.0% of Co, less than or equal to 0.75% of Si, less than or equal to 1.0% of Mn, less than or equal to 0.040% of P, less than or equal to 0.040% of S, less than or equal to 0.01% of Mg, less than or equal to 0.006% of B, less than or equal to 0.5% of Cu, less than or equal to 0.03% of Zr, less than or equal to 0.030% of Ce, less than or equal to 0.50% of V, less than or equal to 0.50% of the balance of Ni, further preferably 15.0 to 25.0% of Cr, 1 to 15.0% of W, 3.0.0 to 7.0% of Mo, 10.00% of A, 0.00% of Ti, 0.00 to 3.00% of Ti, 0 to 3.00%, 1.00% of Fe, less than or equal to 0.50% of Ti, less than or equal to 0.040% of Cu, more preferably, less than or equal to 0.5.5.5.5.5.5% of Cu, less than or equal to 0.040% of Cu, more preferably, less than or equal to 0.5.5.5% of Cu, less than or equal to 0.5% of Cu, less than or equal to 0.5.5% of Cu, less than or equal to 0.5.5.040% of Cu, less than or equal to 0.5.5%, more preferably, less than or equal to 0.5% of Cu, less than or equal to 0% of Cu, less than or equal to 0.5% of Cr, less than or equal to 0.5% of Cu, less than or equal to 0.5.5% of Cu, less than or equal to 0.5%, more preferably, less than or equal to 0% of Cu, less than or equal to 0.5% of Cu, less than or equal to 0, less than or equal to 0.5% of Cu, less than or equal to 0.5%, more preferably, less than or equal to 0.5% of Cu, less than or equal to 0, less than or equal to 0.5%, B, less than or equal to 0.5% of Cu, less than or equal to 0.0.0.0.040% of Cu, less than or equal to 0.0.5%, B, less than or equal to 0.0.0.0.0.0.0.0.0%, 1 to 0% of Mo, less than or equal to 0% of Cu, less than or equal to 0%, B, less than or equal to 0.0.0.5%, B, less than or equal to 0%, 1 to 0.0.0.5%, B, less than or equal to 0.0.5%, 1 to 0.0%, B, less than or equal to 0%, 1 to 0%, more preferably, less than or equal to 0% of Mo, less than or equal to 0.5%, 1 to, 11.50-3.00 percent of A, 1.0-2.5 percent of Ti, 1.5-2.5 percent of Fe, 2.5-4.0 percent of Nb, 0.1-0.12 percent of C, 5-10.0 percent of Co, 0.2-0.4 percent of Si, 0.2-0.4 percent of Mn, less than or equal to 0.040 percent of P, less than or equal to 0.040 percent of S, less than or equal to 0.01 percent of Mg, less than or equal to 0.5 percent of Cu, less than or equal to 0.03 percent of B, less than or equal to 0.20 percent of Zr, less than or equal to 0.030 percent of Ce, less than or equal to 0.50 percent of V and the balance of Ni. The invention can not only improve the service temperature of the high-temperature alloy, but also further increase the bonding strength of the high-temperature alloy and the thermal barrier coating by controlling the content of each component in the nickel-based high-temperature alloy powder.

In the present invention, the chemical composition of the iron-based superalloy powder preferably includes, in mass percent: 15.0 to 26.0 percent of Cr, 15.0 to 50.0 percent of Ni, 0.90 to 7.0 percent of Mo, less than or equal to 3.0 percent of A1, less than or equal to 3.50 percent of Ti, 0.25 to 5.50 percent of Nb, less than or equal to 0.12 percent of C, less than or equal to 1.0 percent of Si, less than or equal to 2.0 percent of Mn, less than or equal to 0.025 percent of P, less than or equal to 0.030 percent of S, less than or equal to 0.5 percent of Cu, less than or equal to 10.0 percent of W, 0.10 to 1.50 percent of V, less than or equal to 0.015 percent of B, less than or equal to 0.050 percent of Ce, the balance of Fe, further preferably Cr 17.0 to 23.0 percent, Ni 20.0 to 40.0 percent of Mo, 1.5 to 5.0 percent of A, less than or equal to 2.5, Ti 1.0 to 2.5, 1.5 to 2.5 percent of Ti, 1.50 to 4.50 percent of Nb, less than or equal to 0.12 percent of C, less than or equal to 0.0.0, less than or equal to 1.0 percent of Si, less than or equal to 1.5 percent of Mn, less than or equal to 1.5 percent of P, less than or equal to 0 to 0.5, less than or equal to 0.5 percent of Ti, less than or equal to 0, less than or equal to 0.5 percent of B, less than or equal to 0.2, less than 0.2.5, less than or equal to 0, less than or equal to 0.5, less than or equal to 0.0, less than or equal to 0.0.0.0 to 0 to 0.0, less than or equal to 0, less than or equal to 0.2, less than or equal to 0, less than or equal to 0.2, less than or equal to 0, less than 0, less than or equal to 0.2, less than 0, less than 0.015 percent of C, less than or equal to 0.5 percent of C, less than 0, 0.2, 0, less than or equal to 0, less than or equal to 0.2.2.2, 0.2, 0, 0.2, 0, 0.2, 0.5, 0.2, 0.5, 0.2, 0.5 percent of Mo, 0.2, 0, 0.2, 0, 0.2, 0, 0.2, 0, 0.2.015 percent of Mo, 0, 0.5, 0.2, 0.2.2, 0.2, 0, P is less than or equal to 0.025 percent, S is less than or equal to 0.030 percent, Cu is less than or equal to 0.5 percent, W is 3.0-5.0 percent, V is 0.50-1.0 percent, B is less than or equal to 0.015 percent, Ce is less than or equal to 0.050 percent, and the balance is Fe. The invention can not only improve the service temperature of the high-temperature alloy, but also further increase the bonding strength of the high-temperature alloy and the thermal barrier coating by controlling the content of each component in the iron-based high-temperature alloy powder.

In the present invention, the chemical composition of the cobalt-based superalloy powder preferably includes, in mass percent: 2.50 to 25.0% of Cr, 5.0 to 30.0% of Ni, less than or equal to 10.0% of Mo, less than or equal to 20.0% of W, less than or equal to 10.0% of A1, less than or equal to 5.0% of Ti, less than or equal to 5.50% of Nb, less than or equal to 0.20% of C, less than or equal to 30.0% of Fe, less than or equal to 0.50% of Si, less than or equal to 2.0% of Mn, less than or equal to 0.050% of S, less than or equal to 0.20% of La, less than or equal to 0.030% of B, less than or equal to 0.50% of Cu, the balance of cobalt, further preferably 5.50 to 20.0% of Cr, 10.0 to 25.0% of Ni, 1.0 to 8.0% of Mo, 1.0 to 15.0% of W, 11.0 to 8.0%, 1.0 to 4.0% of Ti, 1.0 to 4.50% of Nb, less than or equal to 0.20%, less than or equal to 0% of C, less than or equal to 0.20%, more preferably 0% of Cr, less than or equal to 1.0% of Cu, less than or equal to 0% of Cu, less than or equal to 0.0%, less than or equal to 0% of Cu, less than or equal to 0%, less than or equal to 0.0%, more preferably 0 to 0.0 to 0%, less than or equal to 0.0%, 0% of Mo, less than or equal to 0.030%, less than or equal to 0%, 0% of Mo, less than or equal to 0% of Cu, less than or equal to 0.0.0%, 0 to 0% of Mo, less than or equal to 0.0% of Mo, less than or equal to 0% of Cu, less than or equal to 0.0.0% of Mo, less than or equal to 0% of Cu, less than or equal to 0%, 0% of Cu, less than or equal to 0.0.0% of Cu, less than or equal to 0%, less than or equal to 0.0%, less than or equal to 0%, less than or equal to 0% of Mo, less than or equal to 0% of Cu, less than or equal to 0% of Mo, less than or equal to 0% of Cu, 0% of Mo, less than or equal to 0% of Mo, 0.0.0% of Mo, less than or equal to 0%, 0.030%, 0% of Mo, less than or equal to 0% of C, 0% of Mo, less than or equal to 0% of Mo, 0.0% of C, 0% of B, 0% of Mo, 0% of B, less than or equal to 0% of Mo, 0% of 0.0% of C, less than or equal to 0% of Mo, 0.0.0.0.0%, 0% of 0.0% of C, less than or equal to 0% of 0%, 0% of B, less than or equal to 0% of 0.0% of C, 0.0% of C, Less than or equal to 0.50 percent of Si, less than or equal to 2.0 percent of Mn, less than or equal to 0.050 percent of P, less than or equal to 0.030 percent of S, less than or equal to 0.20 percent of La, less than or equal to 0.030 percent of B, less than or equal to 0.50 percent of Cu and the balance of cobalt. According to the invention, the service temperature of the high-temperature alloy can be improved by controlling the content of each component in the cobalt-based high-temperature alloy powder, and the bonding strength of the high-temperature alloy and the thermal barrier coating can be further increased.

In the invention, the superalloy powder layer is preferably dried before being laid; the drying temperature is preferably 100-150 ℃; the drying time is preferably 1-24 h, and more preferably 10-20 h.

In the invention, the thickness of the high-temperature alloy powder layer is preferably 0.10-0.20 mm.

In the present invention, the process parameters of the laser scanning include: the laser power is preferably 200-500W, and more preferably 250-450W; the scanning speed is preferably 400-2000 mm/s, more preferably 500-1500 mm/s, and even more preferably 800-1200 mm/s; the scanning interval is preferably 0.06-0.12 mm, and more preferably 0.08-0.10 mm; the preheating temperature is preferably 25-500 ℃, more preferably 50-400 ℃, and more preferably 100-200 ℃. The invention can further improve the heat resistance of the high-temperature alloy by controlling the technological parameters of laser scanning.

After the first solid layer is obtained, according to the section data of the Nth layer in the multilayer section data, the Nth solid layer is prepared on the surface of the first solid layer by sequentially repeating paving and laser scanning, and the high-temperature alloy is obtained.

In the present invention, the operation of preparing the nth solid layer is preferably the same as the operation of preparing the first solid layer, and will not be described herein again.

The invention adopts the selective laser melting forming technology to prepare the transition layer on the high-temperature alloy.

In the present invention, the method for preparing the transition layer comprises: and (3) paving transition layer powder and carrying out laser melting forming on the high-temperature alloy layer by layer to obtain a transition layer. According to the invention, the transition layer is arranged between the high-temperature alloy and the thermal barrier coating, and the laser melting forming technology is adopted for preparation, so that metallurgical bonding can be formed between the high-temperature alloy and the thermal barrier coating, and the bonding strength of the thermal barrier coating and the high-temperature alloy is improved.

The present invention preferably grit-blastes the superalloy prior to application of the transition layer powder. The operation of the blasting process is not particularly limited in the present invention, and a blasting operation known to those skilled in the art may be used. The invention adopts sand blasting treatment to improve the surface roughness of the high-temperature alloy, thereby improving the bonding strength with the transition layer.

In the present invention, the method for preparing the transition layer preferably includes the steps of:

I. establishing a three-dimensional model of the transition layer, converting the three-dimensional model into separable data, and introducing the data into selective laser melting equipment to obtain multilayer section data;

II. According to the first layer of section data in the multilayer section data obtained in the step I, laying a transition layer powder layer required by the first layer of section data on the high-temperature alloy, and then carrying out laser scanning on the cross section of the transition layer powder layer to obtain a1 st solid layer;

and III, according to the nth layer of cross section data in the multilayer cross section data obtained in the step I, sequentially and repeatedly paving and scanning the laser on the surface of the 1 st solid layer obtained in the step II to prepare an nth solid layer, so as to obtain a transition layer.

The invention preferably establishes a three-dimensional model of the transition layer, converts the three-dimensional model into data which can be cut and leads the data into selective laser melting equipment to obtain multilayer section data. The operation of establishing the three-dimensional model of the transition layer, converting the three-dimensional model into the data which can be cut and guiding the data into the selective laser melting equipment to obtain the multilayer section data is not particularly limited and can be realized by adopting the operation known by the technical personnel in the field.

After obtaining the multilayer section data, the invention preferably lays a transition layer powder layer required by the first layer section data on the superalloy according to the first layer section data in the multilayer section data, and then performs laser scanning on the cross section of the transition layer powder layer to obtain the 1 st solid layer.

In the present invention, the transition layer powder includes a superalloy powder and a thermal barrier coating powder.

In the present invention, the particle size and chemical composition of the superalloy powder are preferably the same as those of the superalloy powder used for preparing the superalloy, and thus the detailed description thereof is omitted.

In the invention, the particle size of the thermal barrier coating powder is preferably 100-200 μm; the thermal barrier coating powder preferably comprises YSZ, mullite and CeO ₂ Mixed powder of YSZ and Al ₂ O ₃ Mixed powder of YSZ and Yb ₂ O ₃ Stabilized ZrO ₂ 、Er ₂ O ₃ Stabilized ZrO ₂ 、Dy ₂ O ₃ Stabilized ZrO ₂ 、HfO ₂ -Y ₂ O ₃ 、La ₂ Zr ₂ O ₇ Or MMeAl ₁₁ O ₁₉ (ii) a The MMeAl ₁₁ O ₁₉ M in (1) is preferably La or Nd, Me is preferably an alkaline earth metal; the alkaline earth metal preferably includes one of Mg, Mn, Ni, Cu, Co and Fe.

In the present invention, Y in YSZ ₂ O ₃ The mass content of (b) is preferably 6-20%, more preferably 10-14%; the CeO ₂ CeO in mixed powder with YSZ ₂ Is preferably not higher than 15%; the Al is ₂ O ₃ Al in mixed powder with YSZ ₂ O ₃ Is preferably not higher than 25%; yb of the above ₂ O ₃ Stabilized ZrO ₂ Medium Yb ₂ O ₃ The mass content of (A) is preferably 2-10%; the Er ₂ O ₃ Stabilized ZrO ₂ Middle Er ₂ O ₃ The mass content of (A) is preferably 2-10%; the Dy is ₂ O ₃ Stabilized ZrO ₂ Middle Dy ₂ O ₃ The mass content of (b) is preferably 2 to 10%. The sources of the raw materials of the thermal barrier coating powder are not particularly limited in the present invention, and commercially available products well known to those skilled in the art can be used.

In the present invention, the transition layer powder is preferably dried before laying; the drying temperature is preferably 100-150 ℃; the drying time is preferably 1-24 h, and more preferably 10-20 h.

In the invention, the thickness of the transition layer powder layer is preferably 0.10-0.20 mm.

In the present invention, the process parameters of the laser scanning are preferably the same as the process parameters of the preparation of the superalloy, and are not described herein again.

After the 1 st solid layer is obtained, the invention preferably prepares the nth solid layer on the surface of the 1 st solid layer by sequentially repeating paving and laser scanning according to the nth layer cross section data in the multilayer cross section data, so as to obtain the transition layer.

In the present invention, the other operations for preparing the nth solid layer are preferably the same as the operations for preparing the first solid layer, and are not described herein again.

In the invention, along the direction from the high-temperature alloy to the thermal barrier coating, the content of the high-temperature alloy powder in each layer of transition layer powder is reduced layer by layer, and the content of the thermal barrier coating powder is increased layer by layer. The invention further improves the bonding strength of the thermal barrier coating and the high-temperature alloy by carrying out gradient arrangement on the high-temperature alloy content and the thermal barrier coating content in the transition layer.

In the present invention, the laying of each layer of the transition layer powder preferably includes: and simultaneously feeding the high-temperature alloy powder and the thermal barrier coating powder to an area to be melted by laser.

In the invention, the total thickness of the transition layer is preferably 0.2-0.5 mm.

In the invention, when the transition layer is divided into 5 layers for printing, along the direction from the high-temperature alloy to the thermal barrier coating, the mass content ratio of the high-temperature alloy powder to the thermal barrier coating powder in each layer of the transition layer powder is preferably (0.9-0.8): (0.1-0.2), (0.7-0.6): (0.3-0.4), 0.5: 0.5, (0.3-0.4): (0.6-0.7) and (0.1-0.2): (0.9-0.8).

In the invention, when the transition layer is divided into 4 layers for printing, along the direction from the high-temperature alloy to the thermal barrier coating, the mass content ratio of the high-temperature alloy powder to the thermal barrier coating powder in each layer of transition layer powder is preferably (0.9-0.7): (0.1-0.3), (0.6-0.5): (0.5-0.4), (0.3-0.4): (0.6-0.7) and (0.1-0.2): (0.9-0.8).

In the invention, when the transition layer is divided into 3 layers for printing, along the direction from the high-temperature alloy to the thermal barrier coating, the mass content ratio of the high-temperature alloy powder to the thermal barrier coating powder in each layer of the transition layer powder is preferably (0.9-0.6): (0.1-0.4), (0.7-0.5): (0.5-0.3) and (0.1-0.2): (0.9-0.8).

In the invention, when the transition layer is divided into 2 layers for printing, along the direction from the high-temperature alloy to the thermal barrier coating, the mass content ratio of the high-temperature alloy powder to the thermal barrier coating powder in each layer of the transition layer powder is preferably (0.9-0.5): (0.1-0.5) and (0.1-0.4): (0.6-0.9).

In the invention, along the direction from the high-temperature alloy to the thermal barrier coating, when each layer of transition layer powder is laid, the powder feeding rate of the high-temperature alloy powder is reduced layer by layer, and the powder feeding rate of the thermal barrier coating powder is increased layer by layer. The invention controls the powder feeding rate of the high-temperature alloy powder and the thermal barrier coating powder and the proportion of the high-temperature alloy powder and the thermal barrier coating powder in each layer of transition layer powder.

After the preparation of the transition layer is finished, the invention adopts the selective laser melting forming technology to prepare the thermal barrier coating on the transition layer. The invention adopts the selective laser melting forming technology to prepare the thermal barrier coating, and can further improve the bonding strength of the thermal barrier coating and the transition layer.

In the present invention, the preparation method of the thermal barrier coating preferably comprises the following steps:

1) establishing a three-dimensional model of the thermal barrier coating, converting the three-dimensional model into separable data, and introducing the data into selective laser melting equipment to obtain multilayer section data;

2) according to the first layer of section data in the multilayer section data obtained in the step 1), laying a thermal barrier coating powder layer required by the first layer of section data on a transition layer, and then performing laser scanning on the cross section of the thermal barrier coating powder layer to obtain a solid layer 1;

3) according to the Nth layer of section data in the multilayer section data obtained in the step 1), sequentially and repeatedly paving and laser scanning the surface of the solid layer 1 obtained in the step 2) to prepare a solid layer N, and thus obtaining the thermal barrier coating.

The invention preferably establishes a three-dimensional model of the thermal barrier coating, converts the three-dimensional model into separable data and introduces the separable data into selective laser melting equipment to obtain multilayer section data. The invention has no special limitation on the operation of establishing a three-dimensional model of the thermal barrier coating, converting the three-dimensional model into separable data and introducing the separable data into selective laser melting equipment to obtain multilayer section data, and the operation is known by the technical personnel in the field.

After obtaining the multilayer section data, the invention preferably lays the thermal barrier coating powder layer required by the first layer section data on the substrate according to the first layer section data in the multilayer section data, and then performs laser scanning on the cross section of the thermal barrier coating powder layer to obtain the solid layer 1.

In the present invention, the particle size and chemical composition of the thermal barrier coating powder are preferably the same as those of the thermal barrier coating powder used in the transition layer, and are not described herein again.

In the invention, before laying the thermal barrier coating powder layer, the thermal barrier coating powder is preferably dried; the drying temperature is preferably 100-150 ℃; the drying time is preferably 1-24 hours, and more preferably 10-20 hours.

In the invention, the thickness of the thermal barrier coating powder layer is preferably 0.10-0.20 mm.

In the present invention, the laser scanning parameters are preferably the same as the laser scanning parameters used for preparing the superalloy, and are not described herein again.

After the solid layer 1 is obtained, according to the Nth layer of section data in the multilayer section data, the solid layer N is prepared on the surface of the solid layer 1 by sequentially repeating paving and laser scanning, and the thermal barrier coating is obtained.

In the present invention, the operation of preparing the solid layer N is preferably the same as the operation of preparing the solid layer 1, and will not be described herein again.

According to the invention, the transition layer is arranged between the high-temperature alloy and the thermal barrier coating, and the high-temperature alloy and the thermal barrier coating in the transition layer are compounded by adopting a laser melting forming technology, so that metallurgical bonding can be formed between the high-temperature alloy and the thermal barrier coating, and the bonding strength of the thermal barrier coating and the high-temperature alloy is improved; the content of the high-temperature alloy powder and the content of the thermal barrier coating powder are set in a gradient manner in the preparation process of the transition layer, so that the bonding strength of the thermal barrier coating and the high-temperature alloy is further improved.

The preparation method provided by the invention can realize the integrated formation of the high-temperature alloy and the thermal barrier coating, and achieves the purposes of increasing the bonding strength, saving the cost and improving the efficiency.

The invention also provides the alloy material with the thermal barrier coating prepared by the method in the technical scheme, which comprises a transition layer and the thermal barrier coating which are sequentially arranged on the high-temperature alloy; the transition layer comprises a superalloy and thermal barrier coating particles; the particles of the thermal barrier coating in the transition layer are distributed in an increasing gradient along the direction from the high-temperature alloy to the thermal barrier coating; the high-temperature alloy and the transition layer as well as the transition layer and the thermal barrier coating are in metallurgical bonding.

The schematic structural diagram and the corresponding microstructure of the alloy material with the thermal barrier coating provided by the invention are shown in FIG. 1. As can be seen from fig. 1, the color of the transition layer gradually becomes lighter from bottom to top, which illustrates that the content of the high-temperature alloy and the content of the thermal barrier coating in the transition layer of the alloy material with the thermal barrier coating provided by the present invention are set in a gradient manner.

The alloy material with the thermal barrier coating provided by the invention has excellent interlayer bonding strength.

The technical solution of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. 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 embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

Example 1

Raw materials:

the nickel-based superalloy powder comprises the chemical components of, by mass, 19.2% of Cr, 3.1% of Mo, 10.34% of A, 0.89% of Ti, 0.35% of Mn, 0.32% of Si, 5.0% of Fe, 0.30% of Cu, 1.0% of Co, 5.25% of Nb, 0.003% of B, 0.01% of P and the balance of Ni, and the particle size is 15-70 mu m;

the thermal barrier coating powder is YSZ powder, wherein Y ₂ O ₃ The mass fraction of the particles is 14%, and the particle size is 100-200 mu m;

the preparation method of the alloy component with the thermal barrier coating comprises the following steps:

(1) establishing a three-dimensional model of an alloy component with a thermal barrier coating, converting the three-dimensional model into separable data, and introducing the data into selective laser melting equipment to obtain multilayer section data;

(2) according to the section data of the high-temperature alloy in the multilayer section data obtained in the step (1), repeatedly paving a nickel-based high-temperature alloy powder layer on the substrate and performing laser melting forming in sequence to obtain the high-temperature alloy; wherein the thickness of each nickel-based superalloy powder layer is 0.15 mm; the laser power is 400W, the scanning speed is 1200mm/s, the scanning interval is 0.08mm, and the preheating temperature is 200 ℃;

(3) performing sand blasting treatment on the high-temperature alloy obtained in the step (2), and performing laying of transition layer powder and laser melting forming layer by layer on the surface of the high-temperature alloy obtained in the step (2) according to the section data of the transition layer in the multilayer section data obtained in the step (1) to obtain a transition layer;

wherein the transition layer powder is nickel-based superalloy powder and YSZ powder; along the direction from the high-temperature alloy to the thermal barrier coating, the content of the nickel-based high-temperature alloy powder in each layer of transition layer powder is reduced layer by layer, and the content of the YSZ powder is increased layer by layer; the thickness of each transition layer is 0.15 mm; the laser power is 400W, the scanning speed is 1200mm/s, the scanning interval is 0.08mm, and the preheating temperature is 200 ℃;

the laying of each layer of transition layer powder is as follows: simultaneously feeding the nickel-based superalloy powder and the YSZ powder to a region to be subjected to laser melting; the total thickness of the transition layer is 0.45 mm; along the direction from the high-temperature alloy to the thermal barrier coating, the mass content ratio of the high-temperature alloy powder to the thermal barrier coating powder in each layer of the transition layer powder is 0.9: 0.1, 0.7: 0.3 and 0.1: 0.9;

(4) according to the cross section data of the thermal barrier coating in the multilayer cross section data obtained in the step (1), sequentially and repeatedly paving YSZ powder on the surface of the transition layer obtained in the step (3) and preparing the thermal barrier coating by laser scanning to obtain an alloy component with the thermal barrier coating;

wherein the thickness of each thermal barrier coating is 0.15 mm; the laser power is 400W, the scanning speed is 1200mm/s, the scanning interval is 0.08mm, and the preheating temperature is 200 ℃;

the preparation of the alloy component with the thermal barrier coating is carried out in a protective atmosphere of 99.99% high-purity argon.

Example 2

Raw materials:

the chemical components of the iron-based high-temperature alloy powder comprise, by mass, 15.6% of Cr, 21.0% of W, 1.30% of Mo, 10.31% of A, 2.19% of Ti, 0.06% of C, 0.66% of Si, 1.35% of Mn, 0.35% of V, 24.71% of Ni and the balance of Fe, and the particle size is 15-70 mu m;

the thermal barrier coating powder is CeO ₂ And YSZ, wherein CeO ₂ Is 10% by mass, Y in YSZ ₂ O ₃ The mass fraction of the composite is 14% of the total mass of YSZ, and the particle size is 100-200 mu m;

the preparation method of the alloy component with the thermal barrier coating comprises the following steps:

(1) establishing a three-dimensional model of an alloy component with a thermal barrier coating, converting the three-dimensional model into separable data, and introducing the data into selective laser melting equipment to obtain multilayer section data;

(2) according to the section data of the high-temperature alloy in the multilayer section data obtained in the step (1), sequentially and repeatedly paving an iron-based high-temperature alloy powder layer on the substrate and carrying out laser melting forming to obtain the high-temperature alloy; wherein the thickness of each iron-based superalloy powder layer is 0.1 mm; the laser power is 300W, the scanning speed is 800mm/s, the scanning interval is 0.10mm, and the preheating temperature is 25 ℃;

(3) performing sand blasting treatment on the high-temperature alloy obtained in the step (2), and paving transition layer powder and performing laser melting forming layer by layer on the surface of the high-temperature alloy obtained in the step (2) according to the cross section data of the transition layer in the multilayer cross section data obtained in the step (1) to obtain the transition layer;

wherein the transition layer powder is iron-based high-temperature alloy powder and thermal barrier coating powder; in the direction from the high-temperature alloy to the thermal barrier coating, the content of the iron-based high-temperature alloy powder in each layer of transition layer powder is reduced layer by layer, and the content of the thermal barrier coating powder is increased layer by layer; the thickness of each transition layer is 0.1 mm; the laser power is 300W, the scanning speed is 800mm/s, the scanning interval is 0.10mm, and the preheating temperature is 25 ℃;

the laying of each layer of transition layer powder is as follows: simultaneously feeding iron-based high-temperature alloy powder and thermal barrier coating powder to a region to be subjected to laser melting; the total thickness of the transition layer is 0.50 mm; along the direction from the high-temperature alloy to the thermal barrier coating, the mass content ratio of the high-temperature alloy powder to the thermal barrier coating powder in each layer of the transition layer powder is 0.9: 0.1, 0.7: 0.3, 0.5: 0.5, 0.3: 0.7 and 0.1: 0.9;

(4) according to the sectional data of the thermal barrier coating in the multilayer sectional data obtained in the step (1), sequentially and repeatedly paving thermal barrier coating powder on the surface of the transition layer obtained in the step (3) and preparing the thermal barrier coating by laser scanning to obtain an alloy component with the thermal barrier coating;

wherein the thickness of each thermal barrier coating is 0.1 mm; the laser power is 300W, the scanning speed is 800mm/s, the scanning interval is 0.10mm, and the preheating temperature is 25 ℃;

the preparation of the alloy component with the thermal barrier coating is carried out in a protective atmosphere of 99.99% high-purity argon.

Example 3

Raw materials:

the cobalt-based high-temperature alloy powder comprises, by mass, 19.42% of Cr, 15.0% of W, 2.0% of Mo, 10.23% of Ni, 1.32% of Mn, 0.11% of Si, 0.003% of P, 0.17% of Fe, 0.12% of C, 0.001% of S and the balance of Co, and the particle size of the cobalt-based high-temperature alloy powder is 15-70 μm;

the thermal barrier coating powder is YSZ powder, wherein Y ₂ O ₃ The mass fraction of the compound is 15 percent, and the particle size is 100 mu m-200;

the preparation method of the alloy component with the thermal barrier coating comprises the following steps:

(1) establishing a three-dimensional model of the alloy component with the thermal barrier coating, converting the three-dimensional model into separable data, and introducing the separable data into selective laser melting equipment to obtain multilayer section data;

(2) according to the section data of the high-temperature alloy in the multilayer section data obtained in the step (1), sequentially and repeatedly paving a cobalt-based high-temperature alloy powder layer on the substrate and carrying out laser melting forming to obtain the high-temperature alloy; wherein the thickness of each nickel-based superalloy powder layer is 0.1 mm; the laser power is 380W, the scanning speed is 1000mm/s, the scanning interval is 0.12mm, and the preheating temperature is 300 ℃;

(3) performing sand blasting treatment on the high-temperature alloy obtained in the step (2), and performing laying of transition layer powder and laser melting forming layer by layer on the surface of the high-temperature alloy obtained in the step (2) according to the section data of the transition layer in the multilayer section data obtained in the step (1) to obtain a transition layer;

wherein the transition layer powder is cobalt-based superalloy powder and YSZ powder; along the direction from the high-temperature alloy to the thermal barrier coating, the content of the cobalt-based high-temperature alloy powder in each layer of transition layer powder is reduced layer by layer, and the content of the YSZ powder is increased layer by layer; the thickness of each transition layer is 0.1 mm; the laser power is 380W, the scanning speed is 1000mm/s, the scanning interval is 0.12mm, and the preheating temperature is 300 ℃;

the laying of each layer of transition layer powder is as follows: simultaneously feeding the cobalt-based high-temperature alloy powder and the YSZ powder to a region to be subjected to laser melting; the total thickness of the transition layer is 0.40 mm; along the direction from the high-temperature alloy to the thermal barrier coating, the mass content ratio of the cobalt-based high-temperature alloy powder to the YSZ powder in each layer of transition layer powder is 0.8: 0.2, 0.6: 0.4, 0.4: 0.6 and 0.2: 0.8;

(4) according to the sectional data of the thermal barrier coating in the multilayer sectional data obtained in the step (1), sequentially and repeatedly paving YSZ powder and laser scanning on the surface of the transition layer obtained in the step (3) to prepare the thermal barrier coating, so as to obtain an alloy component with the thermal barrier coating;

wherein the thickness of each layer of thermal barrier coating is 0.1 mm; the laser power is 380W, the scanning speed is 1000mm/s, the scanning interval is 0.12mm, and the preheating temperature is 300 ℃;

the preparation of the alloy component with the thermal barrier coating is carried out in a protective atmosphere of 99.99% high-purity argon.

The alloy components with thermal barrier coatings prepared in examples 1 to 3 were subjected to performance tests, and the results are shown in fig. 2. As can be seen from FIG. 2, the interlaminar shear strengths of the alloy members with thermal barrier coatings prepared in examples 1 to 3 are 92.6MPa, 94.2MPa and 94.7MPa in sequence.

From the above examples, it can be seen that the alloy member with the thermal barrier coating prepared by the preparation method provided by the invention has excellent bonding strength.

The foregoing is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, various modifications and decorations can be made without departing from the principle of the present invention, and these modifications and decorations should also be regarded as the protection scope of the present invention.

Claims (8)

1. A method for integrally forming a high-temperature alloy and a thermal barrier coating comprises the following steps:

preparing a high-temperature alloy, a transition layer and a thermal barrier coating on a substrate in sequence by adopting a selective laser melting forming technology;

the preparation method of the transition layer comprises the following steps: laying transition layer powder and carrying out laser melting forming on the high-temperature alloy layer by layer to obtain a transition layer;

the transition layer powder comprises high-temperature alloy powder and thermal barrier coating powder; along the direction from the high-temperature alloy to the thermal barrier coating, the content of the high-temperature alloy powder in each layer of transition layer powder is reduced layer by layer, and the content of the thermal barrier coating powder is increased layer by layer;

the thermal barrier coating powder is YSZ, mullite or CeO ₂ Mixed powder of YSZ and Al ₂ O ₃ Mixed powder of YSZ and Yb ₂ O ₃ Stabilized ZrO ₂ 、Er ₂ O ₃ Stabilized ZrO ₂ 、Dy ₂ O ₃ Stabilized ZrO ₂ 、HfO ₂ -Y ₂ O ₃ 、La ₂ Zr ₂ O ₇ Or MMeAl ₁₁ O ₁₉ (ii) a The MMeAl ₁₁ O ₁₉ M in the formula (I) is La or Nd, and Me is alkaline earth metal;

the process parameters for laser fusion forming of each layer of transition layer powder independently include: the laser power is 200-500W, the scanning speed is 1000-2000 mm/s, and the scanning distance is 0.10-0.12 mm;

when the transition layer is divided into 5 layers for printing, the mass content ratio of the high-temperature alloy powder to the thermal barrier coating powder in each layer of the transition layer powder is (0.9-0.8): (0.1-0.2), (0.7-0.6): (0.3-0.4), 0.5: 0.5, (0.3-0.4): (0.6-0.7) and (0.1-0.2): (0.9-0.8);

when the transition layer is divided into 4 layers for printing, the mass content ratio of high-temperature alloy powder to thermal barrier coating powder in each layer of transition layer powder is (0.9-0.7): (0.1-0.3), (0.6-0.5): (0.5-0.4), (0.3-0.4): (0.6-0.7) and (0.1-0.2): (0.9-0.8);

when the transition layer is divided into 3 layers for printing, along the direction from the high-temperature alloy to the thermal barrier coating, the mass content ratio of the high-temperature alloy powder to the thermal barrier coating powder in each layer of transition layer powder is (0.9-0.6): (0.1-0.4), (0.7-0.5): (0.5-0.3) and (0.1-0.2): (0.9-0.8);

when the transition layer is divided into 2 layers for printing, the mass content ratio of high-temperature alloy powder to thermal barrier coating powder in each layer of transition layer powder is (0.9-0.5) in sequence along the direction from the high-temperature alloy to the thermal barrier coating: (0.1-0.5) and (0.1-0.4): (0.6-0.9).

2. The method of claim 1, wherein the superalloy powder comprises a nickel-based superalloy powder, an iron-based superalloy powder, or a cobalt-based superalloy powder.

3. The method of claim 2, wherein the chemical composition of the iron-based superalloy powder comprises, in mass percent: 15.0-26.0% of Cr, 15.0-50.0% of Ni0, 0.90-7.0% of Mo, less than or equal to 3.0% of A1, less than or equal to 3.50% of Ti, 0.25-5.50% of Nb, less than or equal to 0.12% of C, less than or equal to 1.0% of Si, less than or equal to 2.0% of Mn, less than or equal to 0.025% of P, less than or equal to 0.030% of S, less than or equal to 0.5% of Cu, less than or equal to 10.0% of W, 0.10-1.50% of V, less than or equal to 0.015% of B, less than or equal to 0.050% of Ce and the balance of Fe.

4. The method according to claim 1 or 2, wherein the particle size of the superalloy powder is 15-70 μm.

5. The method of claim 1, wherein the thermal barrier coating powder has a particle size of 100 to 200 μm.

6. The method of claim 1, wherein the laying of each layer of transition layer powder comprises: and simultaneously feeding the high-temperature alloy powder and the thermal barrier coating powder to an area to be melted by laser.

7. The method of claim 1, wherein the transition layer has a total thickness of 0.2 to 0.5 mm.

8. The alloy material with the thermal barrier coating prepared by the method of any one of claims 1 to 7, which comprises a transition layer and the thermal barrier coating which are sequentially arranged on the high-temperature alloy;

the transition layer comprises a superalloy and thermal barrier coating particles; the particles of the thermal barrier coating in the transition layer are distributed in an increasing gradient along the direction from the high-temperature alloy to the thermal barrier coating;

and metallurgical bonding is formed between the high-temperature alloy and the transition layer and between the transition layer and the thermal barrier coating.

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