CN114853494A - Composite ceramic powder with self-repairing capability and preparation method and application thereof - Google Patents
Composite ceramic powder with self-repairing capability and preparation method and application thereof Download PDFInfo
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Abstract
The invention provides composite ceramic powder with self-repairing capability, which comprises ytterbium disilicate and silicon carbide whiskers with the molar content of 5-50 percent, and the preparation method comprises the steps of adding deionized water into the ytterbium disilicate powder and the silicon carbide whiskers with a certain size, carrying out ball milling and mixing to obtain mixed slurry, drying and screening the mixed slurry, preparing the slurry with the deionized water and a polyvinyl alcohol adhesive before granulation, and carrying out centrifugal spray granulation to obtain sprayable powder with the particle size of 30-60 mu m. According to the invention, the silicon carbide crystal whiskers generate a bridging crack effect through two-step chemical reaction, and the environment barrier coating prepared by plasma spraying of the powder can obviously observe the recovery of ytterbium disilicate content and the high retention of strength under a water oxygen test through high-temperature heat treatment, so that the self-repairing of the coating is realized, and the service life of the environment barrier coating in a high-temperature water oxygen corrosion environment is favorably prolonged; the preparation method has the advantages of simple preparation process, low equipment requirement and strong operability.
Description
Technical Field
The invention relates to the technical field of ceramic matrix composite surface environmental barrier coatings, in particular to composite ceramic powder with self-repairing capability and a preparation method and application thereof.
Technical Field
The advanced aircraft engine is a recognized great national weight machine, and along with the increasingly intense competition of all countries in the world in the field of the aircraft industry, the development of the aircraft engine and components thereof towards larger thrust-weight ratio, higher energy conversion efficiency, more energy conservation and environmental protection and longer service life is a necessary trend. Based on the requirements, the inlet temperature of the gas turbine must be continuously increased, and the temperature resistance of the hot-end component of the engine must also be continuously increased. Through years of development, the service temperature of the traditional alloy part is continuously improved but approaches the limit by using a high-temperature alloy technology, a cooling technology, a thermal barrier coating technology and the like. Under the circumstances, silicon-based ceramics and the composite material thereof are considered to be ideal materials for preparing hot end parts of next generation aircraft engines, typically silicon carbide ceramic matrix composite materials, by replacing alloys due to the advantages of low density, good mechanical properties, excellent high-temperature stability, good oxidation resistance and the like.
The biggest problem of the silicon carbide ceramic material is that the high-temperature gas environment is a complex environment with water vapor and oxidizing gas coupled, and the silicon carbide can be corroded by water and oxygen to generate volatile Si (OH) x Resulting in rapid material loss and dramatic performance degradation. Environmental barrier coating technology is an effective solution to this problem. By coating the surface of the ceramic matrix composite materialA protective coating with a barrier effect is prepared, so that physical barrier to corrosive media can be realized, and the composite material is protected.
For the above reasons, materials used as environmental barrier coatings need to have good water-oxygen corrosion resistance and, more importantly, must have a coefficient of thermal expansion matched to the base material in order to prevent the occurrence of thermal cycle cracking. After several generations of development, rare earth silicates have become a new generation of environmental barrier coating (surface layer) material which is currently attracting much attention, wherein the material is represented by ytterbium disilicate Yb 2 Si 2 O 7 Has the advantages of good phase stability, thermal expansion coefficient similar to that of the silicon carbide ceramic matrix composite material, and the like.
The most prevalent technique for the preparation of environmental barrier coatings is thermal spray coating, typically plasma spray coating. Plasma spraying is a process of rapidly heating a coating material to a molten or semi-molten state and spraying it at a high speed onto a workpiece surface using a plasma arc as a heat source. In the process, because the instantaneous power is very high, the ytterbium disilicate has certain Si element loss to generate ytterbium monosilicate Yb 2 SiO 5 (ii) a In addition, there is also a loss of Si during long high-low temperature thermal cycles. This loss is accompanied by volume shrinkage, which can lead to voids and cracks in the coating. Furthermore, the thermal expansion coefficient of ytterbium monosilicate is 7.0 to 7.5 x 10 -6 K -1 ) Is significantly higher than that of silicon carbide (4.5-5.5 × 10) -6 K -1 ) And ytterbium disilicate (3.8-4.5X 10) -6 K -1 ) Therefore, the generation of ytterbium monosilicate further aggravates the thermal expansion mismatch, making the generation of thermal cycle cracks easier. The service life of the ytterbium disilicate environmental barrier coating is greatly shorter than expected due to the existence of the reasons, and the protection effect is greatly influenced.
Technical scheme
Aiming at the problems of the existing rare earth silicate environmental barrier coating material, the application provides composite ceramic powder with self-repairing capability and a preparation method thereof, and the realization method is that silicon carbide whiskers with certain content and size are introduced into ytterbium disilicate to form Yb 2 Si 2 O 7 -SiC w (wherein the subscript w is an English abbreviation denoting whiskers, i.e., whisker.) composite powder. On one hand, the crack bridging effect of the silicon carbide whisker can prevent the crack from expanding to a certain extent, and is beneficial to improving the strength and toughness of the coating; on the other hand, more importantly, the silicon oxide can be oxidized into vitreous silica in a long-term high-temperature application environment, and can play a role in filling and closing cracks generated by thermal cycling. The reaction process is as follows:
SiC(s)+O 2 (g)→SiO 2 (s)+CO 2 (g)
further, the silicon dioxide can react with ytterbium monosilicate to regenerate ytterbium disilicate, so that the cracks are filled, and the loss of substances is supplemented, wherein the reaction process is as follows:
Yb 2 SiO 5 (s)+SiO 2 (s)→Yb 2 Si 2 O 7 (s)
through the process, the cracks and the pores can be repaired in the true sense, and the loss of materials is supplemented, namely the structure and the function are recovered simultaneously, and not only the repaired type closed cracks are repaired, so that the service life of the environmental barrier coating is greatly prolonged.
Therefore, the technical scheme of the invention is as follows:
the invention firstly provides composite ceramic powder with self-repairing capability, which comprises raw material components of ytterbium disilicate and silicon carbide whiskers, wherein the molar content of the silicon carbide whiskers in a coating material is 5-50%; the diameter of the silicon carbide whisker is 20 nm-1000 nm, and the length of the silicon carbide whisker is 1 mu m-50 mu m.
Furthermore, the molar content of the silicon carbide whisker in the coating material is 10-40%; the diameter of the silicon carbide whisker is 100 nm-500 nm, and the length of the silicon carbide whisker is 5 mu m-30 mu m.
The invention also provides a preparation method of the composite ceramic powder with the self-repairing capability, which comprises the following steps:
s1, weighing and mixing the ytterbium disilicate powder and the silicon carbide whiskers according to a preset proportion to obtain mixed powder;
s2, dissolving the mixed powder in the S1 in deionized water, and performing ball milling to obtain mixed slurry;
s3, drying and sieving the mixed slurry in the S2 to obtain mixed powder;
s4, mixing the mixed powder in the S3 with deionized water and a polyvinyl alcohol adhesive, and uniformly mixing by using a stirrer to obtain slurry before granulation;
and S5, adding the slurry before granulation in the S4 into a centrifugal spray dryer, and drying to obtain the spraying powder with the particle size of 30-60 mu m.
Further, in step S2, the above step: the proportion of the mixed powder to deionized water and ball milling beads is 1 g: (0.5-2) g: (0.7-1.2) g; the ball milling beads are made of one or a combination of zirconia, alumina or silicon carbide; the ball milling tank is made of one of polyurethane, alumina or agate; the rotating speed during ball milling is 100-400 rpm, and the ball milling time is 1-12 h.
Further, in the step S2, the ratio of the mixed powder to deionized water to the ball milling beads is 1 g: (0.7-1.5) g: (0.8-1.0) g; the rotation speed of the ball milling is 250-300 rpm, and the ball milling time is 3-8 h.
Further, in the step S4, the ratio of the mixed powder, the deionized water, and the polyvinyl alcohol adhesive is (2-4) g: (6-8) g: 0.25 g.
Further, in step S4, the preparation method of the polyvinyl alcohol adhesive comprises: the mass ratio of polyvinyl alcohol powder to deionized water is 1 g: (18-20) g, heating and stirring at the stirring speed of 100-300 rpm, the heating temperature of 60-90 ℃, and the stirring time of 30-120 min.
The invention also provides an application method of the composite ceramic powder with the self-repairing capability, which is characterized in that the environmental barrier coating is prepared by a plasma spraying method.
The invention has the beneficial effects that:
the invention provides composite ceramic powder with self-repairing capability aiming at the problems of material loss and thermal cycle cracks of rare earth silicate environmental barrier coating materials represented by ytterbium disilicate under high-temperature thermal cycle, and the composite ceramic powder is prepared by introducing ytterbium disilicate into the ytterbium disilicateThe mode of the silicon carbide whisker is adopted, so that the cracks are inhibited and healed from the aspects of physics and chemistry, and the ytterbium monosilicate is converted into the ytterbium disilicate again, thereby compensating the material loss and recovering the material performance to the maximum extent. Moreover, such repairs are repeatable rather than disposable, and theoretically self-repairing will occur until the incoming silicon carbide is completely exhausted, which is very beneficial for the environmental barrier coating to be in service under long term high-low temperature thermal cycling conditions. Furthermore, Yb was produced by the above method 2 Si 2 O 7 -SiC w The composite material has the advantages of simple flow, strong operability, low requirements on equipment and environment, suitability for mass production and the like, the mechanical property of the coating is hopefully improved by introducing the silicon carbide whiskers, and the obtained powder can be directly used for preparing the coating by methods such as atmospheric plasma spraying and the like.
Drawings
These and/or other aspects and advantages of the present invention will become more apparent and more readily appreciated from the following detailed description of the embodiments of the invention, taken in conjunction with the accompanying drawings of which:
FIG. 1 is an X-ray diffraction (XRD) pattern of a self-repairing composite ceramic powder prepared in example 1 of the present invention after annealing and crystallization of a coating prepared by atmospheric plasma spraying;
FIG. 2 is an XRD (X-ray diffraction) pattern of a coating prepared by atmospheric plasma spraying of the self-repairing composite ceramic powder prepared in example 1 and subjected to heat treatment for 24 hours;
FIG. 3 is a graph showing the strength retention rate after water oxygen test of sprayed coatings of composite ceramic powders prepared in example 1 of the present invention and comparative example 1;
FIG. 4 is an XRD pattern of a non-self-healing composite ceramic powder spray coating of the present invention prepared in comparative example 1 after heat treatment.
Detailed Description
In order that those skilled in the art will better understand the present invention, the following detailed description of the invention is provided in conjunction with the accompanying drawings and the detailed description of the invention.
Example 1
The embodiment provides composite ceramic powder with self-repairing capability and a preparation method thereof, and the preparation method comprises the following steps:
s1, weighing and mixing ytterbium disilicate powder and silicon carbide whiskers according to the proportion that the content of the silicon carbide whiskers in a coating material is 20 mol%; wherein the average diameter of the silicon carbide crystal whisker is 300nm, and the average length is 10 μm;
s2, dissolving the mixed powder in the S1 into deionized water, and carrying out ball milling by using zirconia ball milling beads, wherein the ratio of the powder to the water to the beads is 1.0 g: 1.0 g: 0.8g to obtain mixed slurry;
s3, drying and sieving the mixed slurry in the S2 to obtain mixed powder;
s4, mixing the mixed powder in the S3 with deionized water and a polyvinyl alcohol adhesive (1:18, 60 ℃, stirring at 250rpm for 60min) according to the weight ratio of 3.5 g: 6.5 g: 0.25g of the mixture is mixed and evenly mixed by a stirrer to obtain slurry before granulation;
s5, adding the slurry before granulation in the step S4 into a centrifugal spray dryer to obtain powder for spraying, wherein the particle size of the powder is 30-45 microns.
Spraying the powder on SiC by using atmospheric plasma f The thermal spraying coating contains a large amount of amorphous state, and an XRD pattern after annealing and crystallization is shown in figure 1. It can be seen that the presence of a considerable amount of ytterbium monosilicate in the environmental barrier coating at this point indicates that a loss of material has occurred during the coating preparation process, wherein a small amount of SiO is also present 2 And is the product of oxidation of silicon carbide during thermal spraying. After the coating is subjected to heat treatment in air at 1300 ℃, the XRD spectrum of the coating is shown in figure 2, according to the quantitative analysis of the phase refined by XRD, after annealing in air for 24 hours, the content of ytterbium monosilicate is reduced from 26 mol% to about 7 mol%, which shows that the silicon carbide crystal whisker has two steps of reaction to regenerate ytterbium disilicate, thereby supplementing the loss. The above samples were subjected to an oxidation test in a water-oxygen environment at 1300 c with a water vapor to oxygen ratio set to 1:1 for 20 hours as a cycle, the flexural strength of the composite material was measured and the strength retention rate (i.e., the ratio of the current strength to the initial strength) was calculated as shown in fig. 3, and it can be seen that the composite material retained about 94% of the strength after 200 hours of the test.
Comparative example 1
This comparative example was the same as example 1 except that the content of the silicon carbide whisker incorporated therein was 0.
The XRD pattern of the non-self-repairing environmental barrier coating obtained in the comparative example after heat treatment under the same conditions is shown in figure 4, and the content of ytterbium monosilicate is determined to be increased to about 28 mol% under the condition that silicon carbide whiskers are not introduced. After the oxidation test under the same condition, cracks appear on the surface of the coating after 80 hours, the coating fails, and as shown in figure 3, the strength retention after 200 hours is only about 32.5 percent
Example 2
This example provides a composite ceramic powder with self-healing capabilities and a method for making the same, as in example 1, except that the selected silicon carbide whiskers were present in an amount of 10 mol%.
After the environmental barrier coating prepared from the composite ceramic powder with the self-repairing capability obtained in the embodiment is subjected to heat treatment under the same condition, the content of ytterbium monosilicate is reduced to 7.4 mol%; after the same time oxidation test, the strength retention was 88.7%.
Example 3
This example provides a composite ceramic powder with self-healing capabilities and a method for making the same, as in example 1, except that the selected silicon carbide whiskers were 40 mol%.
After the environmental barrier coating prepared from the composite ceramic powder with the self-repairing capability obtained in the embodiment is subjected to heat treatment under the same condition, the content of ytterbium monosilicate is reduced to 7.8 mol%; after the same time oxidation test, the strength retention was 92.6%.
Example 4
This example provides a composite ceramic powder with self-healing capabilities and a method for making the same, as in example 1, except that the selected silicon carbide whiskers have an average length of 5 μm and an average diameter of 100 nm.
After the environmental barrier coating prepared from the composite ceramic powder with the self-repairing capability obtained in the embodiment is subjected to heat treatment under the same condition, the content of ytterbium monosilicate is reduced to 5.6 mol%; after the same time oxidation test, the strength retention was 87%.
Example 5
This example provides a composite ceramic powder having self-healing capabilities and a method for preparing the same as example 1, except that silicon carbide whiskers having an average length of 30 μm and an average diameter of 500nm were introduced.
After the environmental barrier coating prepared from the composite ceramic powder with the self-repairing capability obtained in the embodiment is subjected to heat treatment under the same condition, the content of ytterbium monosilicate is reduced to 9.4 mol%; after the same time oxidation test, the strength retention was 90.3%.
Although the present invention has been described with reference to the preferred embodiments, it is not intended to be limited thereto. Those skilled in the art can make many possible variations and modifications to the disclosed solution, or modify equivalent embodiments using the teachings disclosed above, without departing from the scope of the solution. Therefore, any simple modification, equivalent change and modification made to the above embodiments according to the technical spirit of the present invention should fall within the protection scope of the technical scheme of the present invention, unless the technical spirit of the present invention departs from the content of the technical scheme of the present invention.
Claims (8)
1. The composite ceramic powder with the self-repairing capability is characterized in that the raw material components of the composite ceramic powder comprise ytterbium disilicate and silicon carbide whiskers, and the molar content of the silicon carbide whiskers in a coating material is 5-50%; the diameter of the silicon carbide whisker is 20 nm-1000 nm, and the length of the silicon carbide whisker is 1 mu m-50 mu m.
2. The composite ceramic powder with the self-repairing capability of claim 1, wherein the molar content of the silicon carbide whiskers in the coating material is 10-40%; the diameter of the silicon carbide whisker is 100 nm-500 nm, and the length of the silicon carbide whisker is 5 mu m-30 mu m.
3. The method for preparing the composite ceramic powder with the self-repairing capability according to claim 1 or 2, characterized by comprising the following steps:
s1, weighing and mixing the ytterbium disilicate powder and the silicon carbide whiskers according to a preset proportion to obtain mixed powder;
s2, dissolving the mixed powder in the S1 in deionized water, and performing ball milling to obtain mixed slurry;
s3, drying and sieving the mixed slurry in the S2 to obtain mixed powder;
s4, mixing the mixed powder in the S3 with deionized water and a polyvinyl alcohol adhesive, and uniformly mixing by using a stirrer to obtain slurry before granulation;
and S5, adding the slurry obtained in the S4 before granulation into a centrifugal spray dryer, and drying to obtain composite ceramic powder with the particle size of 30-60 mu m.
4. The method for preparing a composite ceramic powder having self-repairing ability according to claim 3, wherein in step S2:
the proportion of the mixed powder to deionized water and ball milling beads is 1 g: (0.5-2) g: (0.7-1.2) g;
the ball milling beads are made of one or a combination of zirconia, alumina or silicon carbide;
the ball milling tank is made of one of polyurethane, alumina or agate;
the rotating speed during ball milling is 100-400 rpm, and the ball milling time is 1-12 h.
5. The method for producing a composite ceramic powder having self-repairing ability as claimed in claim 3 or 4, wherein in step S2,
the proportion of the mixed powder to deionized water and ball milling beads is 1 g: (0.7-1.5) g: (0.8-1.0) g;
the rotation speed of the ball milling is 250-300 rpm, and the ball milling time is 3-8 h.
6. The preparation method of the composite ceramic powder with the self-repairing capability of claim 3, wherein in the step S4, the ratio of the mixed powder, the deionized water and the polyvinyl alcohol adhesive is (2-4) g: (6-8) g: 0.25 g.
7. The method for preparing the composite ceramic powder with the self-repairing capability according to claim 3 or 6, wherein in the step S4, the polyvinyl alcohol adhesive is prepared by the following steps: the mass ratio of polyvinyl alcohol powder to deionized water is 1 g: (18-20) g, heating and stirring at the stirring speed of 100-300 rpm, the heating temperature of 60-90 ℃, and the stirring time of 30-120 min.
8. The use of the composite ceramic powder with self-healing capability according to claim 1 or 2, wherein the environmental barrier coating is prepared by a plasma spraying process.
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| CN115557511A (en) * | 2022-09-30 | 2023-01-03 | 哈尔滨工业大学 | High-purity nanostructured ytterbium disilicate powder and preparation method thereof |
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