CN113564512A - Method for preparing whisker toughened plasma spraying ceramic matrix sealing coating - Google Patents

Method for preparing whisker toughened plasma spraying ceramic matrix sealing coating Download PDF

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CN113564512A
CN113564512A CN202110836641.0A CN202110836641A CN113564512A CN 113564512 A CN113564512 A CN 113564512A CN 202110836641 A CN202110836641 A CN 202110836641A CN 113564512 A CN113564512 A CN 113564512A
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whisker
powder
ceramic
preparing
ysz
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CN113564512B (en
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程涛涛
王志平
韩志勇
王仕成
邢思佳
肖玉汗
朱妍
王梦婷
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Civil Aviation University of China
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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
    • C23C4/12—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
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00—Aeronautics or air transport
    • Y02T50/60—Efficient propulsion technologies, e.g. for aircraft

Abstract

A method for preparing a whisker toughened plasma spraying ceramic-based sealing coating. The method comprises the steps of preparing a whisker-containing raw material, preparing whisker-containing agglomerated powder, plasma spraying a metal bonding layer, plasma spraying a whisker toughening layer, plasma spraying a ceramic surface layer and the like. The invention has the advantages that: the technological process is simple, the operation is easy, the whisker toughening technology in the ceramic sintering process is introduced into the plasma spraying process, and the toughening of the interface of the ceramic coating and the metal bonding layer can be realized only by one preparation technology of the plasma spraying. The cost is low, the raw material of the whisker toughening layer can be obtained only by adding a small amount of Si C whisker components into the raw material of the ceramic coating, the mass ratio of the Si C whisker to the YSZ ceramic is less than 1/10, and the thickness ratio of the Si C whisker toughening layer to the ceramic surface layer is less than 1/10. The thermal cycle performance of the coating is improved by an interface whisker toughening method on the basis of not changing the microtexture and the performance of the ceramic surface layer and not influencing the abradability of the ceramic surface layer.

Description

Method for preparing whisker toughened plasma spraying ceramic matrix sealing coating
Technical Field
The invention belongs to the technical field of interface design and optimization of plasma spraying coatings, and particularly relates to a method for preparing a whisker toughened plasma spraying ceramic-based sealing coating.
Background
The reduction of clearance between rotor and the stator in the aeroengine gas circuit system of obturating has important meaning to promoting engine work efficiency, reduction oil consumption, along with the continuous improvement of gas temperature in the turbine, the plasma spraying ceramic base of having higher heat-resisting temperature (more than 1000 ℃) seals tight coating and is one of the key technology of current advanced engine. The ceramic-based sealing coating is generally a multilayer system comprising a nickel-based high-temperature alloy substrate, a metal bonding layer (BC layer), a thermal growth oxide layer (TGO layer) and a ceramic surface layer (TC layer), and the complex system structure and the severe service environment can cause the failure of the coating in the use process, including salt solution electrochemistry and thermal corrosion in the marine atmospheric environment, mechanical erosion of inclusions in high-speed airflow, thermal aging caused by high-temperature gas oxidation, cracking and peeling caused by thermal cycle and the like, wherein the most significant influence is premature peeling failure of the ceramic surface layer in the thermal cycle process, and the peeling of the ceramic surface layer can directly cause the loss of the sealing function of the coating, so that the ceramic-based sealing coating becomes a problem to be solved in the application process.
Scientific researchers at home and abroad have achieved some achievements in optimizing the thermal cycle performance of the thermal spraying ceramic surface layer. Early researchers can prepare a cylindrical ceramic surface layer by using an electron beam physical vapor deposition (EB-PVD) method, and TGO growth stress and thermal mismatch stress in a thermal cycle process can be effectively released through numerous longitudinal micro-cracks among columns, so that the ceramic surface layer prepared by the EB-PVD method has good thermal cycle performance, but the EB-PVD method is high in cost and extremely low in coating deposition efficiency, and is not suitable for coating preparation and commercial application of large parts. The suspension plasma spraying technology (SPS), the plasma physical vapor deposition technology (PS-PVD) and the like which are proposed in the last 10 years can be used for preparing coatings with similar 'columnar' structures, and the thermal cycle performance of a ceramic surface layer is improved to different degrees, but the methods have high requirements on raw materials, and meanwhile, the equipment is expensive, the process is complex, and the cost control is not very advantageous. In recent years, a method for releasing residual stress by using longitudinal cracks is proposed, the longitudinal cracks vertical to a coating are generated on a ceramic surface layer by using a surface concentrated heating mode, the stress concentration at the interface of the ceramic surface layer and TGO can be relieved by the longitudinal cracks, the TGO growth stress and the thermal mismatch stress are released, and the thermal cycle life of the coating is prolonged. The method has simple process and low cost, but the longitudinal cracks are generated by a surface concentrated heating mode, the density is not high, the distribution is not uniform, the effect of improving the thermal cycle performance of the coating is limited, and therefore, the application is greatly limited.
The researches adopt a certain technology or method to optimize the microscopic form of the ceramic coating, and the thermal cycle cracking resistance of the ceramic surface layer is improved by releasing the growing stress of the TGO layer which is continuously increased in the thermal cycle process and the thermal mismatch stress at the interface of the ceramic surface layer/TGO, however, the method still faces the problems of high preparation cost, low production efficiency, large technical difficulty, poor effect and the like.
Disclosure of Invention
In order to solve the problems, the invention aims to provide a method for preparing a whisker toughened plasma spraying ceramic-based sealing coating.
In order to achieve the aim, the method for preparing the whisker toughened plasma spraying ceramic-based sealing coating comprises the following steps which are carried out in sequence:
1) crushing and uniformly mixing a YSZ ceramic-based raw material consisting of absolute ethyl alcohol, YSZ powder, polyphenyl ester powder, sodium hexametaphosphate, PEG and PVA by using a ball mill to obtain YSZ ceramic-based raw material powder; wherein the dosage ratio of the absolute ethyl alcohol, the YSZ powder, the polyphenyl ester powder, the sodium hexametaphosphate, the PEG and the PVA is 200-300 ml, 80-120 g, 20-25 g, 3-5 g and 3-5 g;
2) preparing YSZ ceramic-based agglomerated powder from YSZ ceramic-based raw material powder by using a spray granulator;
3) crushing a whisker raw material consisting of absolute ethyl alcohol, SiC whisker, YSZ powder, polyphenyl ester powder, sodium hexametaphosphate, PEG and PVA by using a ball mill and uniformly mixing to obtain whisker raw material powder; wherein the dosage ratio of the absolute ethyl alcohol, the SiC crystal whisker, the YSZ powder, the polyphenyl ester powder, the sodium hexametaphosphate, the PEG and the PVA is 200-300 ml, 6-8 g, 80-120 g, 20-25 g, 3-5 g and 3-5 g;
4) preparing the whisker raw material powder into ceramic matrix agglomerated powder containing whiskers by using a spray granulator;
5) spraying NiCoCrAlY metal bonding layer powder on a nickel-based alloy matrix by using a plasma spray gun to prepare a metal bonding layer;
6) spraying the ceramic matrix agglomerated powder containing the whiskers on a metal bonding layer by using a plasma spray gun to prepare a whisker toughening layer;
7) and spraying the YSZ ceramic-based agglomerated powder on the whisker toughening layer by using a plasma spray gun to prepare the ceramic surface layer.
In the step 1) and the step 3), the rotating speed of the ball mill is 600-800 r/min, and ZrO is added2The grinding balls are 300-500 g, and the ball milling time is 10-12 h.
In the step 2) and the step 4), the inlet temperature of the spray granulator is 180-220 ℃, the outlet temperature is 100-120 ℃, the atomization rotating speed is 6000-6500 r/min, the solid content of the slurry is 50-60%, and the flow rate of the peristaltic pump is 30-35 mm/min.
In the step 5), the voltage of the plasma spray gun is 40-41V, the current is 780-800A, the powder feeding speed is 30-35 g/min, the spraying distance is 100-120 mm, and the thickness of the metal bonding layer is 100-150 μm.
In the step 6), the voltage of the plasma spray gun is 37-38V, the current is 750-760A, the powder feeding speed is 30-35 g/min, the spraying distance is 100-120 mm, and the thickness of the whisker toughening layer is 40-50 μm.
In the step 7), the voltage of the plasma spray gun is 41-42V, the current is 830-840A, the powder feeding speed is 30-35 g/min, the spraying distance is 80-90 mm, and the thickness of the ceramic surface layer is 500-600 mu m.
The method for preparing the whisker toughened plasma spraying ceramic matrix sealing coating provided by the invention has the following advantages:
(1) the technological process is simple, the operation is easy, the whisker toughening technology in the ceramic sintering process is introduced into the plasma spraying process, and the toughening of the interface between the ceramic coating and the metal bonding layer can be realized only by one preparation technology of the plasma spraying.
(2) The cost is low, the raw material of the whisker toughening layer can be obtained by only adding a small amount of SiC whisker components into the raw material of the ceramic coating, the mass ratio of the SiC whisker to the YSZ powder is less than 1/10, and the thickness ratio of the SiC whisker toughening layer to the ceramic surface layer is less than 1/10.
(3) The thermal cycle performance of the coating is improved by an interface whisker toughening method on the basis of not changing the microtexture and the performance of the ceramic surface layer and not influencing the abradability of the ceramic surface layer.
Drawings
FIG. 1 is a metallographic photograph of a cross section of a high-temperature seal coating containing a whisker toughening layer. Wherein the magnification of (a) and (b) is 50 and 10000 respectively.
FIG. 2 is a microscopic morphology of the SiC whisker containing ceramic agglomerated powder prepared by a spray granulation technique. Wherein the magnification of (a), (b) and (c) is 500, 2000 and 5000 respectively.
FIG. 3 is a microscopic morphology of a whisker toughening layer prepared by plasma spray technique in the present invention. Wherein the magnification of (a) and (b) is 500 and 2000 respectively.
And (b) in the figure 4, scanning electron microscope photos of whisker bridging and whisker pulling-out at the fracture after thermal cycle failure of the ceramic base sealing coating containing the whisker toughening layer are respectively shown.
Detailed Description
The following detailed description of embodiments of the invention is intended to be illustrative, and not to be construed as limiting the invention.
Example 1:
the method for preparing the whisker toughened plasma sprayed ceramic-based sealing coating provided by the embodiment comprises the following steps in sequence:
1) 200ml of absolute ethyl alcohol, 80g of YSZ (yttria stabilized zirconia) powder, 20g of polyphenyl ester powder and sodium hexametaphosphate (Na)6O18P6) Crushing and uniformly mixing YSZ ceramic-based raw materials consisting of 3g, PEG3g and PVA3g by using a ball mill to obtain YSZ ceramic-based raw material powder; the rotating speed of the ball mill is 600r/min, ZrO2The grinding ball is 300g, and the ball milling time is 10 h.
2) Preparing the YSZ ceramic-based raw material powder into YSZ ceramic-based agglomerated powder by using a spray granulator; the inlet temperature of the spray granulator is 180 ℃, the outlet temperature is 100 ℃, the atomization rotating speed is 6000r/min, the solid content of the slurry is 50%, and the flow rate of the peristaltic pump is 30 mm/min.
3) 200ml of absolute ethyl alcohol, 6g of SiC whisker, 80g of YSZ powder, 20g of polyphenyl ester powder and sodium hexametaphosphate (Na)6O18P6)3g, crushing a whisker raw material consisting of PEG3g and PVA3g by using a ball mill, and uniformly mixing to obtain whisker raw material powder; the rotating speed of the ball mill is 600r/min, ZrO2The grinding ball is 300g, and the ball milling time is 10 h.
4) Preparing the whisker raw material powder into ceramic matrix agglomerated powder containing whiskers by using a spray granulator; the inlet temperature of the spray granulator is 180 ℃, the outlet temperature is 100 ℃, the atomization rotating speed is 6000r/min, the solid content of the slurry is 50%, and the flow rate of the peristaltic pump is 30 mm/min.
5) Spraying NiCoCrAlY metal bonding layer powder (with the mark of CO110) on a nickel-based alloy substrate by using a plasma spray gun to prepare a metal bonding layer; the voltage of the plasma spray gun is 40V, the current is 780A, the powder feeding rate is 30g/min, the spraying distance is 100mm, and the thickness of the metal bonding layer is 100 mu m.
6) Spraying the ceramic matrix agglomerated powder containing the whiskers on a metal bonding layer by using a plasma spray gun to prepare a whisker toughening layer; the voltage of the plasma spray gun is 37V, the current is 750A, the powder feeding speed is 30g/min, the spraying distance is 100mm, and the thickness of the whisker toughening layer is 40 μm.
7) Spraying the YSZ ceramic-based agglomerated powder on the whisker toughening layer by using a plasma spray gun to prepare a ceramic surface layer; the voltage of the plasma spray gun was 41V, the current was 830A, the powder feeding rate was 30g/min, the spraying distance was 80mm, and the thickness of the ceramic surface layer was 500. mu.m.
Example 2:
the method for preparing the whisker toughened plasma sprayed ceramic-based sealing coating provided by the embodiment comprises the following steps in sequence:
1) prepared from anhydrous ethanol 300ml, YSZ powder 120g, polyphenyl ester powder 25g, and sodium hexametaphosphate (Na)6O18P6) Crushing and uniformly mixing 5g of YSZ ceramic-based raw material consisting of PEG5g and PVA5g by using a ball mill to obtain YSZ ceramic-based raw material powder; the rotating speed of the ball mill is 800r/min, ZrO2The grinding ball is 500g, and the ball milling time is 12 h.
2) Preparing the YSZ ceramic-based raw material powder into YSZ ceramic-based agglomerated powder by using a spray granulator; the inlet temperature of the spray granulator is 220 ℃, the outlet temperature is 120 ℃, the atomization rotating speed is 6500r/min, the solid content of slurry is 60%, and the flow rate of a peristaltic pump is 35 mm/min.
3) Comprises anhydrous ethanol 300ml, SiC whisker 8g, YSZ powder 120g, polyphenyl ester powder 25g, and sodium hexametaphosphate (Na)6O18P6) Crushing and uniformly mixing 5g of whisker raw materials consisting of PEG5g and PVA5g by using a ball mill to obtain whisker raw material powder; the rotating speed of the ball mill is 800r/min, ZrO2The grinding ball is 500g, and the ball milling time is 12 h.
4) Preparing the whisker raw material powder into ceramic matrix agglomerated powder containing whiskers by using a spray granulator; the inlet temperature of the spray granulator is 220 ℃, the outlet temperature is 120 ℃, the atomization rotating speed is 6500r/min, the solid content of slurry is 60%, and the flow rate of a peristaltic pump is 35 mm/min.
5) Spraying NiCoCrAlY metal bonding layer powder (with the mark of CO110) on a nickel-based alloy substrate by using a plasma spray gun to prepare a metal bonding layer; the voltage of the plasma spray gun is 41V, the current is 800A, the powder feeding speed is 35g/min, the spraying distance is 120mm, and the thickness of the metal bonding layer is 150 μm.
6) Spraying the ceramic matrix agglomerated powder containing the whiskers on a metal bonding layer by using a plasma spray gun to prepare a whisker toughening layer; the voltage of the plasma spray gun is 38V, the current is 760A, the powder feeding speed is 35g/min, the spraying distance is 120mm, and the thickness of the whisker toughening layer is 50 μm.
7) Spraying the YSZ ceramic-based agglomerated powder on the whisker toughening layer by using a plasma spray gun to prepare a ceramic surface layer; the voltage of the plasma spray gun is 42V, the current is 840A, the powder feeding speed is 35g/min, the spraying distance is 90mm, and the thickness of the ceramic surface layer is 600 μm.
Example 3:
the method for preparing the whisker toughened plasma sprayed ceramic-based sealing coating provided by the embodiment comprises the following steps in sequence:
1) prepared from anhydrous ethanol 250ml, YSZ powder 100g, polyphenyl ester powder 22g, and sodium hexametaphosphate (Na)6O18P6) Crushing and uniformly mixing YSZ ceramic-based raw materials consisting of 4g, PEG4g and PVA4g by using a ball mill to obtain YSZ ceramic-based raw material powder; the rotating speed of the ball mill is 700r/min, ZrO2The grinding ball is 400g, and the ball milling time is 11 h.
2) Preparing the YSZ ceramic-based raw material powder into YSZ ceramic-based agglomerated powder by using a spray granulator; the inlet temperature of the spray granulator is 200 ℃, the outlet temperature is 110 ℃, the atomization rotating speed is 6300r/min, the solid content of slurry is 55%, and the flow rate of the peristaltic pump is 32 mm/min.
3) 250ml of absolute ethyl alcohol, 7g of SiC whisker, 100g of YSZ powder, 22g of polyphenyl ester powder and sodium hexametaphosphate (Na)6O18P6)4g of whisker raw material consisting of PEG4g and PVA4g is crushed by a ball mill and uniformly mixed to obtain whisker raw material powder; the rotating speed of the ball mill is 700r/min, ZrO2The grinding ball is 400g, and the ball milling time is 11 h.
4) Preparing the whisker raw material powder into ceramic matrix agglomerated powder containing whiskers by using a spray granulator; the inlet temperature of the spray granulator is 200 ℃, the outlet temperature is 110 ℃, the atomization rotating speed is 6300r/min, the solid content of slurry is 55%, and the flow rate of the peristaltic pump is 32 mm/min.
5) Spraying NiCoCrAlY metal bonding layer powder (with the mark of CO110) on a nickel-based alloy substrate by using a plasma spray gun to prepare a metal bonding layer; the voltage of the plasma spray gun is 41V, the current is 790A, the powder feeding rate is 32g/min, the spraying distance is 110mm, and the thickness of the metal bonding layer is 130 μm.
6) Spraying the ceramic matrix agglomerated powder containing the whiskers on a metal bonding layer by using a plasma spray gun to prepare a whisker toughening layer; the voltage of the plasma spray gun is 38V, the current is 755A, the powder feeding speed is 33g/min, the spraying distance is 110mm, and the thickness of the whisker toughening layer is 45 μm.
7) Spraying the YSZ ceramic-based agglomerated powder on the whisker toughening layer by using a plasma spray gun to prepare a ceramic surface layer; the voltage of the plasma spray gun is 41V, the current is 835A, the powder feeding speed is 33g/min, the spraying distance is 85mm, and the thickness of the ceramic surface layer is 550 mu m.
In the thermal cycle test process of the ceramic-based high-temperature sealing coating, due to thermal physical property parameter mismatch, the part with the largest stress bearing capacity in a coating system is the TGO/ceramic surface layer interface, with the increase of the test thermal cycle test times, the TGO growth stress and the thermal physical property mismatch stress are also continuously increased, and finally, cracks at the TGO/ceramic surface layer interface are initiated, grown and peeled off. Based on a whisker toughening mechanism and an agglomeration granulation technology, the whisker toughening technology in the ceramic sintering process is introduced into the plasma spraying process, and the whisker toughening layer is utilized to strengthen stress concentration and easy cracking parts (TGO/ceramic surface layer interface) in the YSZ-based high-temperature sealing coating, so that the thermal cycle performance of the plasma spraying ceramic-based sealing coating is improved.
FIG. 1 is a metallographic photograph of a cross section of a high-temperature seal coating containing a whisker toughening layer. In the whole, the high-temperature seal coating containing the whisker toughening layer sequentially comprises 4 parts, such as a nickel-based alloy matrix, a metal bonding layer, the whisker toughening layer, a YSZ-based ceramic surface layer and the like, as shown in a figure (1 a). Fig. 1(b) is an enlarged photograph of the whisker toughening layer of fig. 1 (a).
FIG. 2 shows the microscopic morphology of the SiC whisker-containing agglomerated powder, and it can be seen from FIG. 2 that the SiC whisker-containing agglomerated powder is spherical, and the SiC whiskers have good dispersibility on the agglomerated particles and are distributed relatively uniformly. The flowability and the apparent density of the SiC whisker-containing agglomerated powder are 91.37s/50g and 0.927g/cm respectively3The requirements of the plasma spraying of the invention are met.
Fig. 3 is a surface microscopic morphology of a toughened layer containing SiC whiskers prepared by plasma spray technique, and it can be seen from fig. 3 that the structural integrity of the SiC whiskers is still retained in the coating and is distributed relatively uniformly.
FIG. 4 is SEM detection results of substrate side fracture after thermal cycle failure of a high-temperature seal coating containing a whisker toughening layer, and it can be found from FIGS. 4(a) and (b) that the thermal cycle fracture of the coating has an obvious porous structure, and obvious phenomena of whisker bridging and whisker pulling-out occur.
The ceramic base sealing coating containing the whisker toughening layer has better thermal cycle life mainly because the whisker toughening layer has better capability of resisting crack propagation, and because the porous structure of the whisker toughening layer, the whisker bridging effect and the whisker pulling-out effect consume a large amount of energy in the thermal cycle process and reduce the driving force of crack growth, thereby improving the capability of resisting crack propagation of the whisker toughening layer and finally improving the thermal cycle life of the coating.

Claims (6)

1. A method for preparing a whisker toughened plasma sprayed ceramic-based sealing coating is characterized by comprising the following steps: the method comprises the following steps which are carried out in sequence:
1) crushing and uniformly mixing a YSZ ceramic-based raw material consisting of absolute ethyl alcohol, YSZ powder, polyphenyl ester powder, sodium hexametaphosphate, PEG and PVA by using a ball mill to obtain YSZ ceramic-based raw material powder; wherein the dosage ratio of the absolute ethyl alcohol, the YSZ powder, the polyphenyl ester powder, the sodium hexametaphosphate, the PEG and the PVA is 200-300 ml, 80-120 g, 20-25 g, 3-5 g and 3-5 g;
2) preparing YSZ ceramic-based agglomerated powder from YSZ ceramic-based raw material powder by using a spray granulator;
3) crushing a whisker raw material consisting of absolute ethyl alcohol, SiC whisker, YSZ powder, polyphenyl ester powder, sodium hexametaphosphate, PEG and PVA by using a ball mill and uniformly mixing to obtain whisker raw material powder; wherein the dosage ratio of the absolute ethyl alcohol, the SiC crystal whisker, the YSZ powder, the polyphenyl ester powder, the sodium hexametaphosphate, the PEG and the PVA is 200-300 ml, 6-8 g, 80-120 g, 20-25 g, 3-5 g and 3-5 g;
4) preparing the whisker raw material powder into ceramic matrix agglomerated powder containing whiskers by using a spray granulator;
5) spraying NiCoCrAlY metal bonding layer powder on a nickel-based alloy matrix by using a plasma spray gun to prepare a metal bonding layer;
6) spraying the ceramic matrix agglomerated powder containing the whiskers on a metal bonding layer by using a plasma spray gun to prepare a whisker toughening layer;
7) and spraying the YSZ ceramic-based agglomerated powder on the whisker toughening layer by using a plasma spray gun to prepare the ceramic surface layer.
2. The method of preparing a whisker toughened plasma sprayed ceramic matrix seal coating according to claim 1, wherein: in the step 1) and the step 3), the rotating speed of the ball mill is 600-800 r/min, and ZrO is added2The grinding balls are 300-500 g, and the ball milling time is 10-12 h.
3. The method of preparing a whisker toughened plasma sprayed ceramic matrix seal coating according to claim 1, wherein: in the step 2) and the step 4), the inlet temperature of the spray granulator is 180-220 ℃, the outlet temperature is 100-120 ℃, the atomization rotating speed is 6000-6500 r/min, the solid content of the slurry is 50-60%, and the flow rate of the peristaltic pump is 30-35 mm/min.
4. The method of preparing a whisker toughened plasma sprayed ceramic matrix seal coating according to claim 1, wherein: in the step 5), the voltage of the plasma spray gun is 40-41V, the current is 780-800A, the powder feeding speed is 30-35 g/min, the spraying distance is 100-120 mm, and the thickness of the metal bonding layer is 100-150 μm.
5. The method of preparing a whisker toughened plasma sprayed ceramic matrix seal coating according to claim 1, wherein: in the step 6), the voltage of the plasma spray gun is 37-38V, the current is 750-760A, the powder feeding speed is 30-35 g/min, the spraying distance is 100-120 mm, and the thickness of the whisker toughening layer is 40-50 μm.
6. The method of preparing a whisker toughened plasma sprayed ceramic matrix seal coating according to claim 1, wherein: in the step 7), the voltage of the plasma spray gun is 41-42V, the current is 830-840A, the powder feeding speed is 30-35 g/min, the spraying distance is 80-90 mm, and the thickness of the ceramic surface layer is 500-600 mu m.
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CN114774830A (en) * 2022-06-20 2022-07-22 矿冶科技集团有限公司 Multifunctional coating, preparation method thereof and power equipment

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