CN115198271A - 一种高热匹配性热障涂层及其制备方法与应用 - Google Patents

一种高热匹配性热障涂层及其制备方法与应用 Download PDF

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CN115198271A
CN115198271A CN202210830197.6A CN202210830197A CN115198271A CN 115198271 A CN115198271 A CN 115198271A CN 202210830197 A CN202210830197 A CN 202210830197A CN 115198271 A CN115198271 A CN 115198271A
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coating
tgo
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尹斌
邓春明
谭僖
毛杰
张小锋
邓畅光
刘敏
周克崧
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Abstract

本发明涉及高温防护涂层技术领域，具体为一种高热匹配性热障涂层及其制备方法。热障涂层服役条件下主要包括：PtAl涂层(底层)，TGO氧化膜(中间层)和YSZ陶瓷层(面层)；本发明通过复合电镀在PtAl涂层中引入Zr‑Y元素，在热障涂层服役过程，在Zr、Y协同作用下在TGO氧化膜晶界析出Y2O3稳定ZrO2，从而提高TGO氧化膜与YSZ和PtAl涂层的热匹配性；同时TGO氧化膜析出的Y2O3稳定ZrO2阻碍Al元素的外氧化，延缓了PtAl涂层相变，提高了TGO氧化膜与PtAl涂层的粘附性。如此，全方位增加TGO与YSZ、TGO与PtAl涂层的匹配性，从而显著提高热障涂层的服役性能。

Description

一种高热匹配性热障涂层及其制备方法与应用
技术领域
本发明涉及高温防护涂层技术领域，具体而言，涉及一种高热匹配性热障涂层及其制备方法与应用。
背景技术
镍基高温合金由于其优异的高温力学性能被广泛应用于航空发动机和燃气轮机涡轮叶片，但是随着涡轮进口温度的不断提高(甚至高于1700℃)，镍基高温合金基体承温能力有限(Ni的熔点为1450℃)，必须在基体表面添加热障涂层以提高涡轮叶片的服役可靠性。
传统的热障涂层分为陶瓷层和金属粘结层。其中陶瓷层主要由YSZ(Y2O3-ZrO2)组成，主要功能为隔热，以提高基体的承温能力。金属粘结层一方面作为陶瓷层和高温合金基体的过渡层，另一方面产生致密的氧化膜，以提高高温合金基体的抗高温氧化和抗热腐蚀性能。常见的金属粘结层为MCrAlY涂层和PtAl涂层。
在热障涂层服役过程中，环境中的氧气通过陶瓷层进入与粘结层发生反应，在粘接层和陶瓷层之间形成氧化膜即TGO，氧化膜主要为致密的Al2O3。一方面，由于YSZ(Y2O3-ZrO2)陶瓷层与TGO氧化膜(Al2O3)热膨胀系数相差较大，服役过程中YSZ/TGO界面容易产生应力集中，产生裂纹；另一方面，服役过程PtAl涂层由于Al元素消耗发生相变，产生体积膨胀，加上TGO与PtAl涂层的热膨胀系数相差较大，变形不同步，从而导致TGO与PtAl涂层粘结不牢靠，容易在界面位置开裂。由此可见，TGO氧化膜与YSZ、PtAl涂层的匹配性不足，是整个热障涂层提前失效的关键原因。国内外研究表明，TGO氧化膜的性能是决定涡轮叶片热障涂层服役寿命最关键的因素之一。因此，亟需提高TGO与YSZ、TGO与PtAl涂层的热匹配性，进而提高热障涂层服役可靠性及服役寿命。
发明内容
本发明的目的在于提供一种高热匹配性热障涂层及其制备方法，以提高热障涂层YSZ陶瓷层与TGO氧化膜热匹配性，同时提高TGO氧化膜与PtAl涂层的热匹配性并增加其粘附性，从而提高热障涂层的服役可靠性及服役寿命。
本发明的技术方案是：
本发明提出的一种高热匹配性热障涂层，由以下涂层结构组成：含Zr和Y元素的PtAl涂层和YSZ陶瓷层；其中含Zr和Y元素的PtAl涂层作为底层，YSZ陶瓷层作为面层。
一种高热匹配性热障涂层的制备方法，包括以下步骤：
(1)将Zr粉和Y粉混后进行高能球磨，形成Zr-Y合金粉末；
(2)在高温合金基体上进行复合电镀：以铂网为阳极，电镀液为磷酸氢根四氨合铂，并加入Zr-Y合金粉，电镀得到Zr-Y掺杂Pt复合层；
(3)将电镀后的样品真空退火：先将步骤(2)所得Zr-Y掺杂Pt复合层在低温度下保温以去除电镀应力，然后在高温下保温，扩散降低样品表面铂的浓度，避免后续形成PtAl2脆性相；
(4)气相渗铝：将步骤(3)所得真空退火后的样品进行高温气相渗铝，获得含有Zr-Y的PtAl涂层；
(5)陶瓷隔热层制备：在步骤(4)PtAl涂层上制备YSZ陶瓷层(Y2O3-ZrO2)。
优选地，步骤(1)所述Zr粉和Y粉的总量中Y粉的含量为4～12wt％。
优选地，步骤(2)所述高温合金基体包括多晶高温合金、单晶高温合金。
优选地，步骤(2)所述电镀液中磷酸氢根四氨合铂的浓度为2g/L～10g/L，Zr-Y合金粉末浓度为0.5g/L～20g/L；粉末粒径≤3μm，电镀时的电流密度为0.5A/dm2～6A/dm2，获得的复合层厚度为2～10μm。
优选地，步骤(3)所述低温为420～620℃，保温时间为1～6h；所述高温为1010～1080℃，保温时间为2～7h。
更优选地，步骤(3)所述真空退火在气压小于2×10-3Pa的环境中进行，退火步骤具体为先升高至420～620℃保温1～6h，以去除电镀应力，随后继续加热至1010～1080℃保温2～7h，以稀释表面Pt浓度。升温速率小于10℃/min，
优选地，步骤(4)所述渗铝温度为1050～1100℃，优选为1070℃，渗铝时间为2～8h；
优选地，步骤(4)获得的PtAl涂层中，主要包含β-NiAl相，或含少量PtAl2相和Ni3Al相，其中Zr-Y和Pt主要固溶在β相中。
优选地，步骤(5)所述YSZ陶瓷层通过大气等离子喷涂方法、等离子喷涂-物理气相沉积方法或电子束-物理气相沉积方法制备。
一种高热匹配性热障涂层通过上述方法制备得到。
所述高热匹配性热障涂层的制备方法在提高TGO与YSZ、TGO与PtAl涂层的匹配性中的应用。
本发明提出的一种高热匹配性热障涂层在服役条件下主要包括：PtAl涂层，TGO氧化膜和YSZ陶瓷层；其中PtAl涂层作为底层，TGO氧化膜作为中间层，YSZ陶瓷层作为面层。
本发明的设计思想是：
本发明提供一种高热匹配性的热障涂层，通过复合电镀在PtAl涂层中引入Zr-Y元素，从而在热障涂层服役过程在TGO氧化膜(Al2O3)中引入Y2O3稳定ZrO2，由于Zr和Y的协同作用，生成的Y2O3稳定ZrO2热稳定性好且韧性高，并且其热膨胀系数较TGO氧化膜与PtAl涂层更接近。因此，一方面提高了TGO氧化膜与YSZ(Y2O3-ZrO2)的热匹配性，同时提高了TGO与PtAl涂层的热匹配性。另一方面，Y2O3稳定ZrO2分布于TGO晶界，阻碍PtAl涂层中Al元素外氧化，减少了PtAl涂层由于氧化相变引起体积膨胀，进一步提高了TGO与PtAl涂层的粘附性。因此，全方位增加TGO与YSZ、TGO与PtAl涂层的匹配性，从而提高热障涂层的服役寿命及服役可靠性。
本发明具有如下优点：
1.本发明将Y-Zr粉加入到PtAl涂层中，在涂层服役过程，由于Zr和Y的协同作用在TGO氧化膜中形成Y2O3稳定ZrO2，方法简单、含量可控；
2.本发明在TGO氧化膜生成了Y2O3稳定ZrO2较单一的ZrO2热稳定性、韧性更好，且其热膨胀系数与YSZ、PtAl涂层相近，因此提高了TGO与YSZ、TGO与PtAl涂层的热匹配性；
3.本发明形成的Y2O3稳定ZrO2较单一的ZrO2热稳定性好，其弥散分布于TGO晶界，阻碍了PtAl涂层中Al元素的外氧化，提高了TGO与PtAl涂层的粘附性。
附图说明
图1为本发明高热匹配性热障涂层与传统热障涂层对比示意图。
图2为实施例1热障涂层(ZrYPtAl-YSZ)的截面形貌。
图3为对比例1热障涂层(PtAl-YSZ)的截面形貌。
图4为对比例2热障涂层(ZrPtAl-YSZ)的截面形貌。
图5为热障涂层中PtAl涂层(a)、(Zr,Pt)Al涂层(b)、(Zr,Y,Pt)Al涂层(c)的能谱。
图6为实施例1和对比例1、2的热障涂层的热循环寿命对比(高温循环氧化增重曲线，温度为1100℃，循环周期为1h)。
具体实施方式
在具体实施过程中，本发明一种高热匹配性热障涂层及其制备方法，包括如下步骤：
(1)表面处理方法：对高温合金进行研磨后喷砂，并进行超声清洗去油；
(2)Zr粉和Y粉(Y含量为4～12wt％)进行高能球磨，形成Zr-Y合金粉末；
(3)在高温合金基体上进行复合电镀：以铂网为阳极，电镀液为磷酸氢根四氨合铂，并加入Zr-Y合金粉(粒径≤3μm)，电镀Zr-Y-Pt复合层厚度为2～10μm。
(4)将电镀后的样品真空退火：其中真空炉内的气压小于2×10-3Pa，升温速率小于10℃/min，先升高至420～620℃保温1～6h，以去除电镀应力，随后继续加热至1010～1080℃保温2～7h，以稀释表面Pt浓度；
(5)气相渗铝：将真空退火后的样品进行高温气相渗铝，渗剂为铁铝粉，活化剂为氯化铵，渗铝温度为1070℃，时间为2～8h，获得PtAl涂层，涂层主要包含β-NiAl相，或含少量PtAl2相和Ni3Al相，其中Pt、Zr和Y主要固溶在β相中，其中PtAl涂层厚度为30～90μm；
(6)陶瓷隔热层制备：在PtAl涂层上制备YSZ陶瓷层(Y2O3-ZrO2)，陶瓷层可经大气等离子喷涂方法、等离子喷涂-物理气相沉积方法或电子束-物理气相沉积方法制备。陶瓷层厚度为100～500μm。
下面，通过实例对本发明进一步详细说明。
实施例1：
(1)表面处理方法：用金刚石砂纸对高温合金研磨后及进行湿喷砂，湿喷砂后保证样品表面粗糙度在1～3Ra，随后放入酒精中超声清洗去除样品表面污油；
(2)Zr粉和Y粉(其中Y含量为8wt％)进行高能球磨，形成Zr-Y合金粉末；
(2)在高温合金基体上进行复合电镀：以铂网为阳极，电镀液为浓度为10g/L磷酸氢根四氨合铂，并加入Zr粉末和Y粉(粒径≤3μm)，Zr粉和Y粉浓度为10g/L，电流密度为1A/dm2，电镀Zr-Y-Pt复合层厚度为5μm。
(3)将电镀后的样品真空退火：其中真空炉内的气压小于2×10-3Pa，升温速率小于12℃/min，先升高至500℃保温2h，以去除电镀应力，随后继续加热至1060℃保温5h，以稀释表面Pt浓度；
(4)气相渗铝：将真空退火后的样品进行高温气相渗铝，渗剂为铁铝粉，活化剂为氯化铵，渗铝温度为1070℃，时间为6h，获得含Zr、Y的PtAl涂层，即(Zr,Y,Pt)Al涂层。涂层主要包含β-NiAl相，其中Pt、Zr和Y主要固溶在β相中；PtAl涂层厚度为50μm；
(5)陶瓷隔热层制备：在PtAl涂层上利用等离子喷涂物理气相沉积制备YSZ陶瓷层(7wt％Y2O3-ZrO2)，其中喷距700mm，喷涂真空度为0.8bar，喷涂600遍，陶瓷层厚度为190μm。
对比例1
本对比例提供的材料与实施例1基本相同，不同之处仅在于没有加入Zr粉和Y粉，粘结层为纯PtAl涂层。
对比例2
本对比例提供的材料与实施例1基本相同，不同之处仅在于仅加入Zr粉末(粒径≤3μm)进行复合电镀，粘结层为掺杂Zr的PtAl涂层，即(Zr,Pt)Al涂层。
表1为高温循环氧化500次后涂层的热膨胀系数(600～700℃测试)。
Figure BDA0003747906280000051
上述实施例为本发明较佳的实施方式，但本发明的实施方式并不受上述实施例的限制，其他的任何未背离本发明的精神实质与原理下所作的改变、修饰、替代、组合、简化，均应为等效的置换方式，都包含在本发明的保护范围之内。

Claims (10)

1.一种高热匹配性热障涂层，其特征在于由以下涂层结构组成：含Zr和Y元素的PtAl涂层和YSZ陶瓷层；其中含Zr和Y元素的PtAl涂层作为底层，YSZ陶瓷层作为面层。
2.一种制备权利要求1所述高热匹配性热障涂层的方法，其特征在于包括以下步骤：
(1)将Zr粉和Y粉混后进行高能球磨，形成Zr-Y合金粉末；
(2)在高温合金基体上进行复合电镀：以铂网为阳极，电镀液为磷酸氢根四氨合铂，并加入Zr-Y合金粉，电镀得到Zr-Y掺杂Pt复合层；
(3)将电镀后的样品真空退火：先将步骤(2)所得Zr-Y掺杂Pt复合层在低温度下保温以去除电镀应力，然后在高温下保温，扩散降低样品表面铂的浓度；
(4)气相渗铝：将步骤(3)所得真空退火后的样品进行高温气相渗铝，获得含有Zr-Y的PtAl涂层；
(5)陶瓷隔热层制备：在步骤(4)PtAl涂层上制备YSZ陶瓷层。
3.根据权利要求2所述的方法，其特征在于：步骤(1)所述Zr粉和Y粉的总量中Y粉的含量为4～12wt％。
4.根据权利要求2所述的方法，其特征在于：步骤(2)所述电镀液中磷酸氢根四氨合铂的浓度为2g/L～10g/L，Zr-Y合金粉末浓度为0.5g/L～20g/L。
5.根据权利要求2所述的方法，其特征在于：步骤(2)电镀时的电流密度为0.5A/dm2～6A/dm2，获得的复合层厚度为2～10μm。
6.根据权利要求2所述的方法，其特征在于：步骤(3)所述低温为420～620℃，保温时间为1～6h；所述高温为1010～1080℃，保温时间为2～7h。
7.根据权利要求2所述的方法，其特征在于：步骤(3)退火步骤具体为先升高至420～620℃保温1～6h，以去除电镀应力，随后继续加热至1010～1080℃保温2～7h，以稀释表面Pt浓度。
8.根据权利要求2所述的方法，其特征在于：步骤(4)所述渗铝温度为1050～1100℃，渗铝时间为2～8h。
9.根据权利要求2所述的方法，其特征在于：步骤(4)获得的PtAl涂层中，主要包含β-NiAl相，或含PtAl2相和Ni3Al相，其中Zr-Y和Pt主要固溶在β相中；步骤(5)所述YSZ陶瓷层通过大气等离子喷涂方法、等离子喷涂-物理气相沉积方法或电子束-物理气相沉积方法制备。
10.权利要求2所述的方法在提高TGO与YSZ、TGO与PtAl涂层的匹配性中的应用。
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