CN115029695B - Low-emissivity composite coating resistant to ultrahigh-temperature cyclic thermal shock and preparation method thereof - Google Patents
Low-emissivity composite coating resistant to ultrahigh-temperature cyclic thermal shock and preparation method thereof Download PDFInfo
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- CN115029695B CN115029695B CN202111682750.8A CN202111682750A CN115029695B CN 115029695 B CN115029695 B CN 115029695B CN 202111682750 A CN202111682750 A CN 202111682750A CN 115029695 B CN115029695 B CN 115029695B
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Abstract
The invention discloses a low-emissivity composite coating resistant to ultrahigh-temperature cyclic thermal shock and a preparation method thereof. The composite coating is composed of a bonding layer, a heat insulation and cooling layer, an anti-impact oxygen barrier layer and a low-radiation layer which are sequentially arranged from bottom to top. The preparation method of the composite coating comprises the steps of cleaning and drying the surface of the high-temperature alloy by using acetone or ethanol, roughening the clean surface by using white corundum under the pressure of 0.55-0.65Mpa, preparing the bonding layer, the heat insulation and cooling layer, the anti-impact oxygen barrier layer and the low-emissivity layer by using supersonic flame, atmospheric plasma, vacuum plasma and magnetron sputtering respectively, and finally forming a low-emissivity composite coating which is resistant to ultrahigh-temperature cyclic thermal shock on the surface of the high-temperature alloy. The thermal barrier coating prepared by the invention has the surface emissivity of 0.23-0.24 at 25 ℃ and 0.2-0.21 at 1400 ℃, and thermal shock examination is carried out for up to 4015 times at 1400 ℃, thus being a great leap in the thermal shock field of the prior coating technology.
Description
Technical Field
The invention belongs to the technical field of thermal barrier coatings, and particularly relates to a low-emissivity composite coating resistant to ultrahigh-temperature cyclic thermal shock and a preparation method thereof.
Background
The high-temperature alloy has high-temperature strength, good oxidation resistance and corrosion resistance, good comprehensive properties such as fatigue property and fracture toughness, and is widely applied to important fields such as aerospace, petrochemical industry and the like. Nickel-base superalloys are of particular importance throughout the superalloy arts and are widely used to manufacture the hottest end pieces of aircraft jet engines and various industrial gas turbines. Along with the continuous improvement of the thrust-weight ratio of an engine, the service condition of the high-temperature alloy is more rigorous, various degradation speeds of the material are accelerated in a high-temperature environment, unstable tissue, deformation and crack growth under the action of temperature and stress and oxidation corrosion of the surface of the material are easy to occur in the using process, the single crystal alloy material is developed to the fourth generation, the temperature bearing capacity is improved to 1140 ℃, the temperature bearing capacity is close to the use temperature limit of a metal material, and the requirement of an advanced aeroengine cannot be further met.
The thermal barrier coating is a coating system consisting of a metal bonding layer and a ceramic surface coating, the occurrence of the thermal barrier coating technology provides an effective protection means for a key hot-end component, and the adaptation of the yttrium oxide stabilized zirconia serving as an active thermal barrier coating material to a base body is rapidly reduced after the temperature is higher than a phase change point due to relatively high thermal conductivity and emissivity, low thermal expansion coefficient, high oxygen flux at high temperature and volume phase change at about 1200 ℃, so that vertical cracks penetrating through a surface layer rapidly appear, the contents of high-temperature air and other molten media are continuously improved, a TGO layer rapidly grows, and cannot be effectively attached to the alloy base body and provide a proper cooling gradient, the increasingly severe service environment requirements cannot be met, and the rapid development of hypersonic aircrafts and high-performance large aircrafts is limited.
The GSZ/YSZ composite thermal barrier coating is prepared by Liu, and other people in Beijing aviation material research institute by an electron beam physical vapor deposition method, is compact and uniform, has good high-temperature thermal adaptation and thermal shock service life, but is complex in operation, low in deposition efficiency and large in technical difficulty; van wei Wei et al at the university of northand-Central utilize a high-energy supersonic plasma spraying system to prepare Sc on GH4169 high-temperature alloy 2 O 3 YSZ thermal barrier coating, the coating has a nano-unmelted particle/layered structure 'dual-mode' structure, which can improve the thermal stress tolerance of the coating, but the surface emissivity is relatively high, the heat insulation effect is limited, and the cycle life is not high. Therefore, how to improve the superhigh temperature and thermal shock resistance of the high-temperature alloy again on the basis of the application bottleneck of the high-temperature alloy is a technical problem to be solved in the field.
Disclosure of Invention
A first object of the invention is to provide a low-emissivity composite coating that is resistant to thermal shock due to ultra-high temperature cycling,
the second purpose of the invention is to provide a preparation method of the low-emissivity composite coating which can resist superhigh temperature cycle thermal shock.
The first purpose of the invention is realized in such a way that the low-emissivity composite coating capable of resisting superhigh temperature cycle thermal shock is characterized in that the composite coating consists of a bonding layer, a heat insulation and cooling layer, an anti-impact oxygen barrier layer and a low-emissivity layer which are arranged in sequence from bottom to top;
the bonding layer is made of noble metal modified NiCoCrAlY powder, wherein the mass percent of the noble metal is 1-10%;
the heat insulation and cooling layer comprises one or more of 8YSZ, 7YSZ and 3 YSZ;
the component of the shock-resistant oxygen-resistant layer is Y x Gd 1-x TaO 4 Powder;
the low-radiation layer is made of platinum-based alloy powder;
the thickness of the bonding layer is 100-200 μm, the thickness of the heat insulation and cooling layer is 75-125 μm, and the thickness of the impact-resistant oxygen barrier layer is 150-250 μm; the thickness of the low-radiation layer is 10-50 mu m.
The second purpose of the invention is realized in such a way that the preparation method of the low-emissivity composite coating resistant to the superhigh-temperature cyclic thermal shock is realized, the method comprises the steps of cleaning and drying the surface of the high-temperature alloy by using acetone or ethanol, roughening the clean surface by using white corundum under the pressure of 0.55-0.65Mpa, then respectively preparing the bonding layer, the heat insulation and cooling layer, the anti-impact oxygen barrier layer and the low-emissivity layer by using supersonic flame, atmospheric plasma, vacuum plasma and magnetron sputtering, and finally forming a layer of the low-emissivity composite coating resistant to the superhigh-temperature cyclic thermal shock on the surface of the high-temperature alloy.
The beneficial effects of the invention are as follows:
1) Aiming at the problems of high surface radiance, small heat insulation gradient and poor thermal shock stability in the prior art, the invention provides a low-radiance composite coating resistant to ultrahigh-temperature cyclic thermal shock and a preparation method thereof, so that the service temperature of the surface of a high-temperature alloy is reduced in terms of radiance and heat insulation gradient, and the shock resistance of the high-temperature alloy is greatly optimized in terms of material intrinsic performance and coating structure design.
2) The invention endows the coating with different excellent performances by regulating and controlling the size, the quantity and the distribution range of the internal pores of different functional layers, wherein the impact resistant layer examines the direct contact of the environment with high-speed flame, and the impact abrasion and other stress actions are most obvious, so the invention achieves the purposes of reducing the porosity, lightly densifying the outer surface layer, increasing the structural strength by improving the power of spraying equipment, increasing the powder feeding amount and slightly reducing the spraying distance, and further combines with the higher fracture toughness of tantalate, thereby greatly improving the impact resistance of the system.
3) The NiCoCrAlY alloy is selected as the bonding layer because the NiCoCrAlY has the characteristics of high melting point and strong oxidation resistance, and a certain amount of rare noble metals (platinum, palladium, rhodium, ruthenium, iridium and osmium) with strong oxidation resistance are added to further improve the oxidation resistance of the bonding layer material, so that the generation of thermally generated oxides on the surface of the bonding layer is inhibited, and the thermal stress between layers in a coating system is reduced;
4) According to the invention, the YSZ ceramic is used as the heat insulation and cooling layer, because the zirconia has extremely low thermal conductivity and good high-temperature stability, and the characteristics of two-phase composition can relatively inhibit the growth of crystal grains, improve the anti-sintering performance of the material, improve the phase change point of the zirconia through mutual solid solution, ensure that the porosity in the coating is basically unchanged, and simultaneously, the coating is a porous structure, further reduces the thermal conductivity, thereby providing excellent heat insulation and cooling effects;
5) The invention uses tantalate Y x Gd 1-x TaO 4 The tantalate is used as a strong oxygen ion insulator to hinder the internal diffusion of active oxygen atoms in a material system at high temperature, so that the oxidation rate of the bonding layer is slowed down, and the service life of the thermal barrier coating material system is greatly prolonged; and secondly, the tantalate has extremely high-temperature fracture toughness due to the cooperative toughening of the ferroelasticity and the fibrous ferroelastic domain, and bears most of external stress caused by high-temperature circulating flame flow in a coating system, so that the stability of the system structure is ensured, and the thermal shock resistance of the coating is greatly improved.
6) The invention uses the refractory metal modified metal platinum as the low-radiation layer, because the radiation rate of the metal platinum is only 0.05-0.18, and the metal platinum layer also has good high-temperature oxidation resistance and chemical stability, and simultaneously, a certain amount of refractory metals such as tungsten, molybdenum, iridium and the like are added to further improve the high-temperature stability and corrosion resistance of the metal platinum layer, the integral temperature of the system is obviously reduced by preparing the refractory metals on the surface of the system through magnetron sputtering, and relatively mild service temperature is provided for the inside of the system under the same heat source condition.
7) The coating prepared by the invention has the advantages of 1-2.4W.K due to extremely low thermal conductivity -1 .m -1 (25-900 ℃) below RE 2 Si 2 O 7 And RE 2 SiO 5 Equal coating material, considerable bonding strength between layers (37-43 MPa), thermal expansion coefficient 11X 10 matched with high-temperature alloy matrix -6 K -1 (1200 ℃), high hardness (10 GPa), low modulus (120-180 GPa) and high fracture toughness (3.0 MPa.m) under the iron elastic phase transition toughening mechanism 1/2 ) High temperature phase stability, excellent chemical compatibility, high deposition rate. The low thermal conductivity, the porosity and the interface effect of each functional layer provide a thermal insulation gradient, the high hardness provides impact resistance, the high bonding strength and the high thermal expansion coefficient provide adaptability with a base body, the low modulus and the high toughness provide thermal stress tolerance, and all factors are integrated, so that the thermal shock performance of the coating is improved, and the thermal shock examination times are increased. The thermal barrier coating prepared by the invention is based on the excellent coating material, spraying technology and coating design scheme, and thermal shock examination is carried out for up to 4015 times at 1400 ℃, thus being a great leap in the thermal shock field of the existing coating technology.
Drawings
FIG. 1 is a schematic diagram of a composite coating system of example 1, wherein 1 is a superalloy substrate, 2 is a bonding layer, 3 is a heat and temperature reduction layer, 4 is an impact resistant and oxygen resistant layer, and 5 is a low emissivity layer;
FIG. 2 is a cross-sectional microscopic view of the composite coating of example 1;
FIG. 3 is a drawing of the composite coating of example 1 taken from 3130 thermal shock cycle experiments at 1400 ℃;
FIG. 4 is a coating change real shot image and a microscopic structure image of the composite coating of example 1 at the examination temperature of 2100 ℃ and 3130 ℃ respectively, wherein, the image A and the image a are a real shot image and a cross-section microscopic image at the examination temperature of 2100 ℃ respectively; the graph B and the graph B are respectively an actual shooting graph and a section microscopic graph at 3130 ℃ assessment temperature;
FIG. 5 shows the 0.4-1.1 μm emissivity of the impact resistant composite coating at 25 ℃;
FIG. 6 shows the 0.4-1.1 μm emissivity of the impact-resistant composite coating at 1400 ℃.
Detailed Description
The invention is described in further detail below with reference to the drawings and examples, but the invention is not limited in any way and any variations or modifications based on the teaching of the invention are within the scope of the invention.
The low-emissivity composite coating resistant to superhigh temperature cyclic thermal shock is characterized by consisting of a bonding layer, a heat insulation and cooling layer, an impact-resistant oxygen barrier layer and a low-emissivity layer which are sequentially arranged from bottom to top;
wherein, the bonding layer is formed by noble metal modified NiCoCrAlY powder, wherein the mass percent of the noble metal is 1-10%;
the heat insulation and cooling layer comprises one or more of 8YSZ, 7YSZ and 3 YSZ;
the shock-resistant oxygen-barrier layer is composed of Y x Gd 1-x TaO 4 A powder;
the low-radiation layer is composed of platinum-based alloy powder;
the thickness of the bonding layer is 100-200 μm, the thickness of the heat insulation and cooling layer is 75-125 μm, and the thickness of the impact-resistant oxygen barrier layer is 150-250 μm; the thickness of the low-radiation layer is 10-50 mu m.
The precious metal modified NiCoCrAlY powder consists of the following elements in percentage by mass: ni46.37%, cr25.95%, co21.54%, al5.63%, Y0.51%, and the balance of noble metal, wherein the particle size is 45-106 μm; the porosity of the bonding layer is not more than 3%.
The noble metal is one or more of platinum, palladium, rhodium, hafnium, ruthenium, iridium or osmium.
The porosity of the heat insulation and temperature reduction layer is controlled to be 10-15%.
The porosity of the anti-impact oxygen barrier layer is 5-10%; the non-gradient coating of the impact-resistant oxygen-blocking layer has no segregation and uniform coating components, all the components are uniformly distributed in the coating, and the specific content of each component does not change along with the thickness of the impact-resistant oxygen-blocking layer.
Said Y is x Gd 1-x TaO 4 The powder X has a value of 0.2 to 0.8.
The platinum-based alloy powder is added with one or more of iridium, rhodium, molybdenum and cobalt in a mass fraction of 0.1-5%.
The invention relates to a preparation method of a low-emissivity composite coating resistant to superhigh temperature cyclic thermal shock, which comprises the steps of cleaning and drying the surface of a high-temperature alloy by using acetone or ethanol, roughening the clean surface by using white corundum under the pressure of 0.55-0.65Mpa, preparing a bonding layer, a heat insulation and cooling layer, an anti-impact oxygen-blocking layer and a low-emissivity layer by respectively using supersonic flame, atmospheric plasma, vacuum plasma and magnetron sputtering, and finally forming a low-emissivity composite coating resistant to superhigh temperature cyclic thermal shock on the surface of the high-temperature alloy; the technological parameters of the supersonic flame spraying are as follows: the maximum temperature of a workpiece is 350 +/-10 ℃, the gun speed of an x-axis spray gun is 450-700mm/s, the gun speed of a y-axis spray gun is 200-400mm/s, the gun distance of the spray gun is 330-340mm, the step distance of the spray gun is 3-10mm, the pressure of a combustion chamber is 70-95Pa, the powder feeding speed is 2-6rpm, the oxygen flow is 1500-1700scfh, the ratio range of oxygen to carrier gas is 60-75, the water inlet temperature range is 40-60 ℃, and the water return temperature range is less than or equal to 90 ℃;
the technological parameters of the atmospheric plasma spraying are as follows: the maximum temperature of a workpiece is 150 +/-10 ℃, the power of a spray gun is 30-40kW, the step pitch of the spray gun is 3-10mm, the current is 180-250A, the voltage ratio is 130-200/75-120, the gun pitch of the spray gun is 70-150mm, the xy gun speed is 520-980mm/s, the current is 100-330mm/s, the nitrogen flow is 50-70scfh, the hydrogen flow is 20-40scfh, the carrier gas flow is 20-35scfh, and the powder feeding speed is 5-10rpm;
the technological parameters of the high enthalpy plasma spraying are as follows: the maximum temperature is 150 +/-10 ℃, the power of a spray gun is 70-120kW, the current is 150-300A, the voltage ratio is 200-350/100-195, the distance of the spray gun is 70-130mm, the step pitch of the spray gun is 3-10mm, the moving speed of an x axis is 1000-1650mm/s, the moving speed of a y axis is 200-350mm/s,
the flow rate of argon gas is 150-200scfh, the flow rate of nitrogen is 50-100scfh, the flow rate of hydrogen is 20-50scfh, the flow rate of carrier gas is 20-50scfh, and the powder feeding speed is 5-10rpm;
the technological parameters of magnetron sputtering are as follows: vacuum degree of 1.0-3.0Pa, sputtering current of 110-130A, sputtering time of 60-300s, correction factor of 1.5, sample stage rotation speed of 5-10rpm, and water inlet and return temperature of less than or equal to 40 ℃.
The high-temperature alloy matrix is an iron-based, nickel-based, cobalt-based or high-chromium high-temperature alloy in GH series, inconel series, incoloy series, monel series, haugh series and Hayner series.
Example 1
(1) Selecting a phi 25.4mm high-temperature alloy HastelloyX bar, preparing an alloy test piece with the thickness of 6mm on a precision linear cutting machine, completely submerging a high-temperature alloy base material in an ethanol ultrasonic oscillator for 20min, preliminarily wiping and cleaning the surface of the high-temperature alloy by using absorbent cotton, placing the high-temperature alloy test piece in a vacuum drying oven at 80 ℃ for 3h, then roughening the clean surface by using white corundum under the air pressure of 0.55MPa, and cleaning scum on the surface by using blowing gas;
(2) Clamping a clean sand blasting state HastelloyX high-temperature alloy base material on a specific tool, controlling flame to preheat a test piece for 2 times by the clamping tool, keeping the preheating temperature below 350 ℃, preparing a NiCoCrAlYPd bonding layer with the thickness of 100 mu m on the surface of the high-temperature alloy HastelloyX by a supersonic flame spraying mode, and setting the parameters of the supersonic flame spraying: the speed of a spray gun on the x-axis and the y-axis is respectively 450mm/s and 300mm/s, the step distance of the spray gun is 5mm, the distance of the spray gun is 335mm, the pressure of a combustion chamber is 89.7Pa, the powder feeding speed is 4.5rpm, the flow rates of oxygen and carrier gas are respectively 1670scfh and 26scfh, and the water inlet temperature and the water return temperature are respectively 56.8 ℃ and 81 ℃;
(3) The HastelloyX high-temperature alloy is replaced on a plasma spraying tool in a short time, after preheating is carried out for 2 times at the temperature of not higher than 150 ℃, an 8YSZ-3YSZ heat-insulating and temperature-reducing layer with the thickness of 100 mu m and the porosity of 30 percent is prepared on the surface of the bonding layer in an air plasma spraying mode. When in atmospheric plasma spraying, the technological parameters are adjusted to 35kW of spray gun power, 200A of current, 135/110 of voltage ratio of a system spray gun, 85mm of distance of the spray gun, 5mm of step distance of the spray gun, 900mm/s and 250mm/s of movement speed of the spray gun on an x-axis and a y-axis, the flow rates of nitrogen, hydrogen and carrier gas are respectively 60scfh, 25scfh and 35scfh, and the powder feeding speed is 6rpm;
(4) When the spraying environment is stable, taking down HastelloyX high-temperature alloy, blowing and cleaning the surface, preparing the material with the thickness of 200 mu m, the porosity of 10 percent and the Y content on the surface of the heat-insulating and temperature-reducing layer by a high-enthalpy plasma spraying mode 0.8 Gd 0.2 TaO 4 An anti-impact oxygen barrier layer; first using Y 2 O 3 、Gd 2 O 3 And Ta 2 O 5 Preparing spherical Y from raw materials by a high-temperature solid-phase method 0.8 Gd 0.2 TaO 4 Preheating spherical powder for 2 times before spraying, wherein the highest temperature of a workpiece is 150 ℃, the process parameters are that the power of a spray gun is 80kW, the current is 380A, the voltage ratio of the spray gun of a system is 226/195, the distance of the spray gun is 155mm, the step pitch of the spray gun is 6.4mm, the moving speed of the spray gun on an x-axis and a y-axis is 1500mm/s and 300mm/s, the flow rates of argon, nitrogen, hydrogen and carrier gas are respectively 175scfh, 80scfh, 35scfh and 37scfh, and the powder feeding speed is 7rpm;
(5) The method comprises the steps of placing the HastelloyX high-temperature alloy with the anti-impact oxygen barrier layer on a rotating table, installing a platinum-based alloy target material, vacuumizing a deposition chamber, preparing a platinum-iridium alloy with the thickness of about 13nm on the surface of the anti-impact oxygen barrier layer in a plasma magnetron sputtering mode, wherein the process parameters of the plasma magnetron sputtering low-radiation layer are that the vacuum degree is 2.7Pa, the sputtering current is 120mA, the sputtering time is 200s, the correction factor is 1.9, the rotating speed of a sample table is 6rpm, the water inlet temperature is 20 ℃, and the water return temperature is 30 ℃.
1. Performing thermal shock assessment on the prepared coating, wherein the specific assessment conditions are as follows:
the assessment equipment comprises: engine thermal barrier coating thermal power coupling comprehensive test device jointly developed by two-machine thermal research of Kunming university of technology
And (4) assessment basis: according to the requirements of design departments, the method is carried out completely according to the commercial standard
Assessment parameters are as follows: examination time 1400 ℃ temperature rise time 20s
Temperature keeping time 60s and temperature reducing time 30s
Back purge on front quench on
Coating emissivity setting 0.2 background emissivity setting 0.8
Circulating cooling temperature: cooling to black iron state (lower than 300 deg.C)
Equipment parameters: x-axis moving speed: 80mm/s Z-axis moving speed: 40mm/s
X-axis ignition position: 10mm Z-axis ignition position: 130mm
Oxygen blowing time: 6s oxygen limit: 50l/min
Oxygen flow rate: gas ratio 18 l/min: 4:1
Coating emissivity setting 0.2 background emissivity setting 0.8
The technical parameters are that the heating temperature is 500-2700 ℃, the heating rate is increased to 1300 ℃ within 20s
Heat flux density of 40MW-200MW heat input power of 10-113KW
Gas velocity of 1200-2000 m/s particle velocity of 50-450 m/s
Gas pressure of 200-100 Psi and gas speed of 0.01-2 Mach
The test method comprises the following steps: and (3) performing a single-station continuous thermal shock test, clamping the sample HX-01 at the No. 1 station, heating the surface of the ceramic by adopting propylene oxide flame, cooling by adopting compressed air in the cooling process, and measuring the temperature of both surfaces by adopting an infrared thermometer.
The specific operation method comprises the following steps: the method comprises the steps of sweeping and cleaning the surface of a sprayed HastelloyX high-temperature alloy, fitting a specific tool groove and then fixedly mounting the sprayed HastelloyX high-temperature alloy on the premise of not touching the side edge of a coating, adjusting the relative position of a sample and a flame gun, opening a ventilation fan, sequentially starting a gas, oxygen, an air cooler, a water cooler and a thermodynamic coupling comprehensive testing device, debugging the gas pressure to 0.25Mpa through a gas pressure valve, debugging the oxygen pressure to 0.6Mpa, opening a control panel, setting the electronic ignition time to 6s, starting a station No. 1, setting the main control temperature to 1400 ℃, correcting the zero drift of a Y axis by 5mm, presetting check times for 5000 times, detecting a quenching device, confirming that an alarm system is in normal operation, starting a gun for ignition, shifting an electric arc to a safe ignition position, starting check, recording check data through the control panel, a fixed and handheld infrared thermometer and a stopwatch timer, and checking process sample parameters are shown in the following table 1.
TABLE 1 thermal shock test parameters of 1400 ℃ of the hastelloy low-emissivity composite coating prepared in example 1
And (3) testing results: as shown in fig. 4, the composite coating prepared by the invention cracks at 2100 times of circulating chamfer angle in 1400 ℃ thermal shock test, and partially falls off, but the coating of the evaluation surface is complete, the heat insulation performance is not influenced, the microstructure is complete and undamaged, the distribution is uniform, and the whole composite coating is in a relatively stable state, as shown in fig. 4A and fig. 4A; in 3130 times, the composite coating layer had fallen off, and according to the standard of the commercial design department, the area of the fall-off was 10%, the failure condition was reached, the thermal insulation performance was decreased, and the examination was stopped, and the microstructure had a more obvious coating damage at the juncture of the fall-off, as shown in fig. 4B and 4B. The thermal shock examination result fully shows that the composite coating prepared by the invention has excellent thermal shock resistance at the high temperature of 1400 ℃.
Y prepared in this example 0.8 Gd 0.2 TaO 4 The actual shot of 1400 ℃ thermal shock cycle experiment tooling of the/8 YSZ-3YSZ low-emissivity tantalate thermal barrier coating is shown in figure 3.
Y obtained in this example 0.8 Gd 0.2 TaO 4 The variation real-shot image and the microstructure of the 1400 ℃ thermal shock cycle test sample of the/8 YSZ-3YSZ low-emissivity tantalate thermal barrier coating are shown in figure 4.
2. Emissivity measurements were made on the coatings prepared in example 1
The test method comprises the following steps: and respectively measuring the radiance of the surface of the sprayed sample at room temperature and 1400 ℃ by using a reflection method and an energy method.
1. The reflection method comprises the following specific steps:
moving the light source to a set position, turning on the light source, turning on the photoelectric detector, and recording the numerical value of the detector by the computer to obtain the reflection and scattering intensity IHI (lambda, theta i, phi i, T) of the material surface in a quarter spherical space;
and 6, calculating the reflectivity rho (lambda, theta i, phi i, T) = (IHI + IH 2)/Is of the material surface in the whole space, thereby calculating the radiance of the material surface.
2. The energy method comprises the following steps:
when the temperature reaches the required temperature, controlling a motor displacement platform by using a computer, moving a sample to be measured to a measuring position to enable the surface of the sample to be coincided with the axial section of the semi-parabolic reflector, ensuring that the focus of the semi-parabolic reflector is in a region to be measured of the sample, and recording the radiant energy value of the sample in each direction in a 1/4 space by using a photoelectric detector;
and 5, extracting and calculating the data recorded twice by the computer, and calculating the recorded sample radiation energy value and the medium-temperature blackbody radiation energy value to obtain the radiance of the sample.
As a result:
the test samples were sprayed and were not surface polished. The measurement results are shown in fig. 5 and 6. From the figure, it can be known that the emissivity of the coating surface is 0.231 at the ambient temperature of 25 ℃ at the wavelength of 0.4-1.1 μm; the emissivity is only 0.204 at the ambient temperature of 1400 ℃, and the measurement result is far lower than that of a common thermal barrier coating material, so that considerable thermal insulation protection is provided for an internal high-temperature alloy substrate.
3. The thermodynamic properties of the coating samples prepared in example 1 were measured, and the results are shown in table 2:
table 2 sample thermodynamic properties of the coating of example 1
Example 2
(1) Except that the high-temperature alloy is changed into GH536 series, the other steps are the same as the step 1 in the embodiment 1;
(2) Clamping a clean sandblast GH536 high-temperature alloy base material on a specific tool, controlling flame to preheat a test piece including the clamping tool for 2 times, keeping the preheating temperature below 360 ℃, and preparing a 120 mu m NiCoCrAlYPt bonding layer on the surface of the high-temperature alloy GH536 in a supersonic flame spraying manner; setting parameters of supersonic flame spraying: the gun speeds of the spray guns of the x-axis and the y-axis are respectively 600mm/s and 200mm/s, the step pitch of the spray guns is 3mm, the gun pitch of the spray guns is 330mm, the pressure of the combustion chamber is 70.5Pa, the powder feeding speed is 2rpm, the flow rates of oxygen and carrier gas are respectively 1523scfh and 20.3scfh, and the water inlet temperature and the water return temperature are respectively 40 ℃ and 87 ℃;
(3) Replacing GH536 high-temperature alloy on a plasma spraying tool in a short time, preheating for 2 times at the temperature of not higher than 140 ℃, and preparing an 8YSZ-7YSZ heat-insulating and temperature-reducing layer with the thickness of 75 mu m and the porosity of 25 percent on the surface of a bonding layer in an atmosphere plasma spraying manner; when in atmospheric plasma spraying, the technological parameters are that the power of a spray gun is 30kW, the current is 180A, the voltage ratio of a system spray gun is 130/200, the distance between the spray gun and the spray gun is 70mm, the step distance of the spray gun is 3mm, the moving speed of the spray gun on an x-axis and a y-axis is 520mm/s and 100mm/s, the flow rates of nitrogen, hydrogen and carrier gas are respectively 50scfh, 20scfh and 20scfh, and the powder feeding speed is 5rpm;
(4) When the spraying environment is stable, taking down the GH536 high-temperature alloy and blowingCleaning the surface, preparing a layer with thickness of 150 μm, porosity of 8%, and Y content on the surface of the heat-insulating and cooling layer by high enthalpy plasma spraying 0.4 Gd 0.6 TaO 4 An anti-impact oxygen barrier layer; first using Y 2 O 3 、Gd 2 O 3 And Ta 2 O 5 Preparing spherical Y from raw materials by a high-temperature solid-phase method 0.4 Gd 0.6 TaO 4 Preheating spherical powder for 2 times before spraying, wherein the maximum temperature of a workpiece is 140 ℃, the process parameters are 70kW of spray gun power, 150A of current, 210/120 of voltage ratio of a system spray gun, 70mm of spray gun distance, 3mm of spray gun step distance, 1000mm/s and 200mm/s of spray gun movement speed of an x-axis y-axis, 150scfh, 50scfh, 20scfh and 20scfh of flow rate of argon, nitrogen, hydrogen and carrier gas, and 5rpm of powder feeding speed;
(5) Placing the GH536 high-temperature alloy with the anti-impact oxygen barrier layer on a rotating table, installing a platinum-based alloy target material, vacuumizing a deposition chamber, preparing platinum-iridium alloy with the thickness of about 8nm on the surface of the anti-impact oxygen barrier layer in a plasma magnetron sputtering mode, wherein the process parameters of the plasma magnetron sputtering of the low-radiation layer are that the vacuum degree is 2.0Pa, the sputtering current is 112mA, the sputtering time is 60s, the correction factor is 1.1, the rotating speed of the sample table is 5rpm, the water inlet temperature is 21 ℃, and the water return temperature is 34 ℃.
The prepared coating is subjected to thermal shock examination, the specific examination conditions are the same as those of the example 1 except that the radiance is adjusted to 0.19, and the parameters of the test samples in the examination process are shown in table 3:
TABLE 3 thermal shock test parameters at 1400 ℃ for GH series alloy low-emissivity composite coatings prepared in example 2
| Number of examination | Time of temperature rise | Sample back temperature | Cooling temperature | Flow of gas | Emissivity of radiation |
| 100 | 21 | 940 | 244 | 32 | 0.19 |
| 300 | 21 | 948 | 230 | 32 | 0.19 |
| 600 | 20 | 951 | 243 | 32 | 0.19 |
| 900 | 19 | 956 | 247 | 32 | 0.19 |
| 1200 | 19 | 943 | 251 | 31 | 0.19 |
| 1500 | 19 | 960 | 255 | 31 | 0.19 |
| 1800 | 19 | 975 | 245 | 31 | 0.19 |
| 2100 | 16 | 996 | 264 | 31 | 0.19 |
| 2400 | 18 | 952 | 266 | 30 | 0.19 |
| 2700 | 17 | 980 | 261 | 30 | 0.19 |
| 3000 | 16 | 955 | 274 | 30 | 0.19 |
| 3300 | 17 | 968 | 286 | 30 | 0.20 |
| 3600 | 17 | 975 | 257 | 30 | 0.21 |
| 3900 | 17 | 980 | 264 | 30 | 0.22 |
| 4015 | 18 | 994 | 277 | 30 | 0.25 |
Example 2Y 0.4 Gd 0.6 TaO 4 Compared with the thermal shock cycle test of 1400 ℃ of the example 1, the thermal insulation gradient of the/8 YSZ-7YSZ low-emissivity tantalate thermal barrier coating sample is further enlarged to 400 ℃ after 1000 times of examination, and when the examination times are increased to 4015 times, the shock-resistant oxide layer is intact, and the integral failure area of the low-emissivity layer is less than five percent. The emissivity is detected, and the emissivity is 0.257 when the emissivity of the surface of the coating is 25 ℃ at the ambient temperature under the wavelength of 0.4-1.1 mu m; the emissivity is only 0.235 at an ambient temperature of 1400 ℃.
The results of the thermodynamic property measurements of the coating samples prepared in example 2 are shown in table 4:
table 4 example 2 sample thermodynamic properties of coatings
Comparative examples 1 to 4
Table 5 shows the YSZ monolayer, ni/Al-YPSZ gradient coating, la of the prior art 2 Zr 2 O 7 And thermal fatigue performance assessment parameters and data.
TABLE 5 thermal shock test parameters for coating structures of comparative examples 1-4
| Sample examples | Coating structure | Mode of preparation | Examination temperature C | Number of cycles |
| Comparative example 1 | YSZ monolayer | APS | 1320-1350 | 220-1100 |
| Comparative example 2 | YSZ monolayer | EB-PVD | 1100 | 500 |
| Comparative example 3 | Ni/Al-YPSZ gradient coating | APS | 760 | 17 |
| Comparative example 4 | La 2 Zr 2 O 7 Single layer | APS | 1200-1260 | 135-977 |
Comparing tables 1-4 and 5, it can be known that the thermal barrier coating prepared by the invention has thermal shock examination up to 4015 times at 1400 ℃ based on the excellent coating material, spraying technology and coating design scheme, and compared with the prior art, the cycle number is far higher than that of the comparative examples 1-4 under the condition that the examination temperature is higher than that of the comparative examples 1-4, so that the technical scheme of the invention is a great leap in the thermal shock field of the prior coating technology.
Comparative example 6
The YSZ monolayer, la of the prior art, was treated in the same manner as in example 1 2 Ce 2 O 7 、La 2 Zr 2 O 7 、
LaPO 4 And Y 3 Al 5 O 12 The coating is subjected to emissivity testing, and specific data are shown in table 6.
As can be seen from Table 6, the composite coating of the present invention possesses extremely low emissivity relative to conventional thermal barrier coatings
The thermal protection effect of the coating on the high-temperature alloy matrix is greatly improved.
TABLE 6 emissivity of each coating structure of comparative example 6
| Coating surface material | State of coating | Color of coating | Emissivity at 1400 DEG C |
| YSZ | Spray coating state | White grey | 0.45 |
| YSZ | Heat treated state at 900 deg.C | White colour | 0.42 |
| YSZ | Polished state | White colour | 0.34 |
| La 2 Zr 2 O 7 | Spray coating state | Grey colour | 0.46 |
| LaPO 4 | Spray coating state | White colour | 0.40 |
| La 2 Ce 2 O 7 | Spray coating state | Yellow-white color | 0.50 |
| Y 3 Al 5 O 12 | As sprayed | Light yellow | 0.71 |
Claims (7)
1. The preparation method of the low-emissivity composite coating resistant to ultrahigh-temperature cyclic thermal shock is characterized in that the composite coating consists of a bonding layer, a heat insulation and cooling layer, an impact-resistant oxygen barrier layer and a low-emissivity layer which are sequentially arranged from bottom to top; the bonding layer is made of noble metal modified NiCoCrAlY powder, wherein the mass percent of the noble metal is 1-10%; the heat insulation and cooling layer comprises one or more of 8YSZ, 7YSZ and 3 YSZ; the component of the shock-resistant oxygen-barrier layer is Y x Gd 1-x TaO 4 Powder; the low-radiation layer is made of platinum-based alloy powder; the thickness of the bonding layer is 100-200 μm, the thickness of the heat insulation and cooling layer is 75-125 μm, and the thickness of the impact-resistant oxygen barrier layer is 150-250 μm; the thickness of the low-radiation layer is 10-50 mu m;
the preparation method comprises the following steps: cleaning and drying the surface of the high-temperature alloy by using acetone or ethanol, roughening the clean surface by using white corundum under the pressure of 0.55-0.65Mpa, and then preparing a bonding layer, a heat insulation and cooling layer, an anti-impact oxygen barrier layer and a low-emissivity layer by using supersonic flame, atmospheric plasma, vacuum plasma and magnetron sputtering respectively, and finally forming a low-emissivity composite coating layer which can resist ultrahigh-temperature cyclic thermal shock on the surface of the high-temperature alloy;
the technological parameters of the supersonic flame spraying are as follows: the maximum temperature of a workpiece is 350 +/-10 ℃, the gun speed of an x-axis spray gun is 450-700mm/s, the gun speed of a y-axis spray gun is 200-400mm/s, the gun distance of the spray gun is 330-340mm, the step distance of the spray gun is 3-10mm, the pressure of a combustion chamber is 70-95Pa, the powder feeding speed is 2-6rpm, the oxygen flow is 1500-1700scfh, the ratio range of oxygen to carrier gas is 60-75, the water inlet temperature range is 40-60 ℃, and the water return temperature range is less than or equal to 90 ℃;
the technological parameters of the atmospheric plasma spraying are as follows: the maximum temperature of a workpiece is 150 +/-10 ℃, the power of a spray gun is 30-40kW, the step pitch of the spray gun is 3-10mm, the current is 180-250A, the voltage ratio is 130-200/75-120, the gun pitch of the spray gun is 70-150mm, the xy gun speed is 520-980mm/s, the current is 100-330mm/s, the nitrogen flow is 50-70scfh, the hydrogen flow is 20-40scfh, the carrier gas flow is 20-35scfh, and the powder feeding speed is 5-10rpm;
the technological parameters of the high enthalpy plasma spraying are as follows: the maximum temperature is 150 +/-10 ℃, the power of a spray gun is 70-120kW, the current is 150-300A, the voltage ratio is 200-350/100-195, the distance between the spray gun and the spray gun is 70-130mm, the step distance between the spray gun is 3-10mm, the moving speed of an x axis is 1000-1650mm/s, the moving speed of a y axis is 200-350mm/s, the flow rate of argon is 150-200scfh, the flow rate of nitrogen is 50-100scfh, the flow rate of hydrogen is 20-50scfh, the flow rate of carrier gas is 20-50scfh, and the powder feeding speed is 5-10rpm;
the technological parameters of magnetron sputtering are as follows: the vacuum degree is 1.0-3.0Pa, the sputtering current is 110-130A, the sputtering time is 60-300s, the correction factor is 1.5, the rotating speed of the sample table is 5-10rpm, and the temperature of inlet return water is less than or equal to 40 ℃;
the thermal shock examination cycle times of the composite coating at 1400 ℃ reach 4015.
2. The method according to claim 1, characterized in that said NiCoCrAlY powder consists of the following elements in mass%: 46.37% of Ni, 25.95% of Cr, 21.54% of Co, 5.63% of Al and 0.51% of Y, and the grain diameter is 45-106 mu m; the porosity of the bonding layer is not more than 3%.
3. The method according to claim 1, wherein the noble metal is one or more of platinum, palladium, rhodium, hafnium, ruthenium, iridium, or osmium.
4. The method for preparing the heat insulation and temperature reduction layer according to claim 1, wherein the porosity of the heat insulation and temperature reduction layer is controlled to be 10-15%.
5. The preparation method of claim 1, wherein the porosity of the impact-resistant oxygen barrier layer is 5-10%, the components are uniformly distributed in the coating, and the specific content of each component does not change with the thickness of the impact-resistant oxygen barrier layer; y is x Gd 1-x TaO 4 The value of powder X is 0.2-0.8.
6. The method according to claim 1, wherein the platinum-based alloy powder is added with one or more of iridium, rhodium, molybdenum and cobalt metals in an amount of 0.1 to 5 mass%.
7. The method of claim 1, wherein the superalloy substrate is an iron-based, nickel-based, cobalt-based, or high chromium superalloy of the GH series, inconel series, incoloy series, monel series, hastelloy series, or hanna series.
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| CN1548578A (en) * | 2003-05-21 | 2004-11-24 | 中国科学院金属研究所 | Prepn of heat shock resisting heat barrier coating |
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| CN102127738A (en) * | 2010-11-25 | 2011-07-20 | 北京航空航天大学 | Multilayer thermal barrier coating and preparation method thereof |
| CN106536848A (en) * | 2014-07-30 | 2017-03-22 | 乐金华奥斯有限公司 | Low-emissivity coating and functional construction material for window/door comprising low-emissivity coating |
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