CN115584463B - Fused salt corrosion resistant thermal barrier coating and preparation method thereof - Google Patents
Fused salt corrosion resistant thermal barrier coating and preparation method thereof Download PDFInfo
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- CN115584463B CN115584463B CN202210873244.5A CN202210873244A CN115584463B CN 115584463 B CN115584463 B CN 115584463B CN 202210873244 A CN202210873244 A CN 202210873244A CN 115584463 B CN115584463 B CN 115584463B
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- 150000003839 salts Chemical class 0.000 title claims abstract description 87
- 230000007797 corrosion Effects 0.000 title claims abstract description 79
- 238000005260 corrosion Methods 0.000 title claims abstract description 79
- 239000012720 thermal barrier coating Substances 0.000 title claims abstract description 54
- 238000002360 preparation method Methods 0.000 title abstract description 8
- 238000004942 thermal barrier coating method Methods 0.000 title description 2
- 239000002131 composite material Substances 0.000 claims abstract description 45
- 239000000919 ceramic Substances 0.000 claims abstract description 41
- 239000000843 powder Substances 0.000 claims abstract description 33
- 239000002667 nucleating agent Substances 0.000 claims abstract description 17
- 238000005507 spraying Methods 0.000 claims abstract description 17
- 239000011248 coating agent Substances 0.000 claims abstract description 14
- 238000000576 coating method Methods 0.000 claims abstract description 14
- 229910052661 anorthite Inorganic materials 0.000 claims abstract description 9
- GWWPLLOVYSCJIO-UHFFFAOYSA-N dialuminum;calcium;disilicate Chemical compound [Al+3].[Al+3].[Ca+2].[O-][Si]([O-])([O-])[O-].[O-][Si]([O-])([O-])[O-] GWWPLLOVYSCJIO-UHFFFAOYSA-N 0.000 claims abstract description 9
- 229910004298 SiO 2 Inorganic materials 0.000 claims abstract description 8
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims abstract description 6
- 239000010410 layer Substances 0.000 claims description 112
- 238000009413 insulation Methods 0.000 claims description 23
- 238000000034 method Methods 0.000 claims description 15
- 238000007750 plasma spraying Methods 0.000 claims description 12
- 238000002156 mixing Methods 0.000 claims description 8
- 230000004888 barrier function Effects 0.000 claims description 7
- 230000008595 infiltration Effects 0.000 claims description 7
- 238000001764 infiltration Methods 0.000 claims description 7
- 239000000463 material Substances 0.000 claims description 7
- 239000002344 surface layer Substances 0.000 claims description 6
- 238000010290 vacuum plasma spraying Methods 0.000 claims description 6
- 239000002245 particle Substances 0.000 claims description 5
- 238000005240 physical vapour deposition Methods 0.000 claims description 4
- 230000000903 blocking effect Effects 0.000 claims description 3
- 229910010293 ceramic material Inorganic materials 0.000 claims description 3
- 238000010288 cold spraying Methods 0.000 claims description 2
- 238000010285 flame spraying Methods 0.000 claims description 2
- 229910052761 rare earth metal Inorganic materials 0.000 claims description 2
- 150000002910 rare earth metals Chemical class 0.000 claims description 2
- 239000007921 spray Substances 0.000 claims description 2
- 239000012790 adhesive layer Substances 0.000 claims 1
- 238000006243 chemical reaction Methods 0.000 abstract description 4
- 239000011812 mixed powder Substances 0.000 abstract description 4
- 239000007788 liquid Substances 0.000 abstract description 2
- 230000000149 penetrating effect Effects 0.000 abstract 1
- 230000035515 penetration Effects 0.000 description 17
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 8
- 230000000052 comparative effect Effects 0.000 description 7
- 239000007789 gas Substances 0.000 description 5
- 229910052786 argon Inorganic materials 0.000 description 4
- 239000011575 calcium Substances 0.000 description 4
- 238000005524 ceramic coating Methods 0.000 description 4
- 239000000725 suspension Substances 0.000 description 4
- 239000011229 interlayer Substances 0.000 description 3
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000012159 carrier gas Substances 0.000 description 2
- 238000000151 deposition Methods 0.000 description 2
- 230000009977 dual effect Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000001307 helium Substances 0.000 description 2
- 229910052734 helium Inorganic materials 0.000 description 2
- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium atom Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- -1 microcracks Substances 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 239000011164 primary particle Substances 0.000 description 2
- 239000011734 sodium Substances 0.000 description 2
- 230000007704 transition Effects 0.000 description 2
- 238000005303 weighing Methods 0.000 description 2
- 229910001233 yttria-stabilized zirconia Inorganic materials 0.000 description 2
- 229910002080 8 mol% Y2O3 fully stabilized ZrO2 Inorganic materials 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- 229910019501 NaVO3 Inorganic materials 0.000 description 1
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
- 238000002441 X-ray diffraction Methods 0.000 description 1
- MCMNRKCIXSYSNV-UHFFFAOYSA-N ZrO2 Inorganic materials O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 229910000323 aluminium silicate Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- ZFXVRMSLJDYJCH-UHFFFAOYSA-N calcium magnesium Chemical compound [Mg].[Ca] ZFXVRMSLJDYJCH-UHFFFAOYSA-N 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000005238 degreasing Methods 0.000 description 1
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- 238000010586 diagram Methods 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000001747 exhibiting effect Effects 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 239000012466 permeate Substances 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
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- 239000013049 sediment Substances 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- 238000007873 sieving Methods 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- CMZUMMUJMWNLFH-UHFFFAOYSA-N sodium metavanadate Chemical compound [Na+].[O-][V](=O)=O CMZUMMUJMWNLFH-UHFFFAOYSA-N 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 238000001694 spray drying Methods 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 239000011593 sulfur Substances 0.000 description 1
- 229910052717 sulfur Inorganic materials 0.000 description 1
- 230000000930 thermomechanical effect Effects 0.000 description 1
- 230000008719 thickening Effects 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 description 1
Classifications
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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
- C23C4/04—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
- C23C4/11—Oxides
-
- 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
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
- C23C14/08—Oxides
-
- 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
- C23C24/00—Coating starting from inorganic powder
- C23C24/02—Coating starting from inorganic powder by application of pressure only
- C23C24/04—Impact or kinetic deposition of particles
-
- 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
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
- C23C28/32—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer
- C23C28/321—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer with at least one metal alloy layer
- C23C28/3215—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer with at least one metal alloy layer at least one MCrAlX layer
-
- 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
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
- C23C28/34—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates
- C23C28/345—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer
- C23C28/3455—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer with a refractory ceramic layer, e.g. refractory metal oxide, ZrO2, rare earth oxides or a thermal barrier system comprising at least one refractory oxide layer
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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
- C23C4/04—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
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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
- C23C4/129—Flame spraying
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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
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- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Inorganic Chemistry (AREA)
- Ceramic Engineering (AREA)
- Coating By Spraying Or Casting (AREA)
Abstract
The invention relates to a thermal barrier coating resisting molten salt corrosion and a preparation method thereof, wherein a CMAS and CMAS+NaVO 3 molten salt corrosion resisting layer is a composite ceramic layer formed by spraying composite oxide/YSZ mixed powder, the composite oxide powder contains Al 2O3 and one or more nucleating agents of SiO 2、TiO2, mgO and CaO, and the prepared composite ceramic layer contains 5-15 wt.% of composite oxide; when the coating is in service, the second phase Al 2O3 reacts with liquid molten salt rapidly to generate a high-melting-point anorthite plugging layer, the reaction process is accelerated by the introduced nucleating agent, the molten salt can be prevented from penetrating and corroding into the thermal barrier coating by a small amount of composite oxide, and the CMAS and CMAS+NaVO 3 corrosion resistance of the thermal barrier coating is remarkably improved.
Description
Technical Field
The invention belongs to the field of protection of thermal barrier coatings, and relates to a thermal barrier coating resistant to molten salt corrosion and a preparation method thereof.
Background
The information disclosed in the background of the invention is only for enhancement of understanding of the general background of the invention and is not necessarily to be taken as an admission or any form of suggestion that this information forms the prior art already known to a person of ordinary skill in the art.
Currently, the most widely used thermal barrier coatings are based on 8YSZ ceramic materials, which benefit from their superior combination of properties, including lower thermal conductivity, higher coefficient of thermal expansion, higher fracture toughness, and better phase stability. When the thermal barrier coating is in high-temperature service, the working environment is harsh, and the peeling failure mechanism of the coating is complex, including high-temperature phase transformation of the ceramic layer, high-temperature sintering of the ceramic layer, unstable thickening of the TGO layer and the like. In addition, long-term service of turbine engines in dusty, pozzolanic and hazy environments can lead to the continual accumulation of glassy deposits on the surface of thermal barrier coatings, the major components of which are CaO, mgO, al 2O3 and SiO 2, abbreviated as Calcium Magnesium Aluminosilicates (CMAS). CMAS melts in a high-temperature working environment of 1200 ℃ and above, and continuously permeates and erodes the inside of the ceramic layer along defect channels such as pores, microcracks, interlayer weak bonding interfaces and the like on the surface of the ceramic layer. The CMAS molten salt and the YSZ material generate thermo-chemical reaction (Y 2O3 high temperature desolventizing) and thermo-mechanical action (CMAS solidification filling coating pore and microcrack), so that the phase change of the YSZ ceramic layer t' -ZrO 2→m-ZrO2 is induced prematurely, the strain tolerance of the YSZ ceramic layer is reduced, the peeling failure of the coating is accelerated, and the service life of the thermal barrier coating is severely limited.
In addition, when the engine uses fuel containing vanadium, sulfur, sodium and other impurities (combustion exhaust gas contains SO 2、V2VO5) or works in a marine salt spray corrosion environment, the generated corrosive molten salt such as Na 2SO4、NaVO3 can be adsorbed on the surface of the thermal barrier coating. After the fused salts are compounded with CMAS sediments, the melting point and viscosity of the CMAS are further reduced, the infiltration corrosion speed and depth of the compounded fused salts are increased, the high-temperature stability of the thermal barrier coating is damaged, and the service performance of the engine is seriously weakened.
Disclosure of Invention
Aiming at the problems existing in the prior art, the invention provides the thermal barrier coating with CMAS and CMAS+NaVO 3 fused salt corrosion resistance and the preparation method thereof, and a small amount of second phase Al 2O3 and nucleating agent added into a ceramic layer are quickly reacted with high-temperature fused salt to generate a high-melting-point anorthite plugging layer, so that the penetration speed of CMAS and CMAS+NaVO 3 fused salt is effectively slowed down, the penetration depth of CMAS and CMAS+NaVO 3 fused salt is reduced, and the thermal stability of the thermal barrier coating in CMAS and CMAS+NaVO 3 fused salt environments is improved. The dosage of Al 2O3 can be reduced by adding the nucleating agent, so that the comprehensive performance of the thermal barrier coating is improved.
In order to achieve the above object, the technical scheme of the present invention is as follows:
In a first aspect of the invention, a thermal barrier coating resistant to molten salt corrosion is provided, comprising a bond coat and a molten salt corrosion resistant layer; the molten salt corrosion resistant layer is a composite ceramic layer with a layered structure, and is formed by mixing and depositing YSZ (6 wt.% to 8wt.% Y 2O3 stabilized ZrO 2) powder and composite oxide powder, wherein the composite oxide powder consists of Al 2O3 and a nucleating agent.
Further, in the molten salt corrosion resistant layer, the mass fraction of the composite oxide is 5% -15%, and the balance is YSZ.
Further, in the composite oxide powder, the mass percentage of Al 2O3 is 90wt.% to 97wt.%, and the balance is a nucleating agent. The primary particle size of Al 2O3 may be 30-60 μm; the primary particle size of the nucleating agent may be 5-15 μm.
Further, the nucleating agent is one or more of SiO 2、TiO2, mgO and CaO.
Further, the composite oxide powder has a particle size of 20 to 80 μm. Furthermore, the porosity of the molten salt corrosion resistant layer is not particularly limited and can be 5% -20%.
Furthermore, the bonding layer material can be selected from an MCrAlY material system, and the thickness of the bonding layer is 100-150 mu m.
In one implementation, the thermal barrier coating further comprises a first thermal barrier layer; the bonding layer, the first heat insulation layer and the molten salt corrosion resistance layer are sequentially stacked to form the thermal barrier coating.
Further, the first heat insulation layer is of a layered structure, and is made of YSZ, rare earth zirconate and other heat insulation ceramic materials.
Further, the thickness of the first heat insulation layer is 100-200 mu m, the molten salt corrosion resistant layer is used for resisting CMAS and CMAS+NaVO 3 molten salt corrosion layers, and the preferable deposition thickness is 30-90 mu m; and the layer thickness ratio of the first heat insulation layer to the CMAS and CMAS+NaVO 3 fused salt corrosion resistant layer is 1.5-3, so that the heat barrier coating can be ensured to have better heat insulation performance and fracture toughness on the basis of exerting the CMAS and CMAS+NaVO 3 fused salt corrosion resistance of the composite oxide/YSZ composite ceramic layer.
In one implementation mode, in the thermal barrier coating for resisting CMAS and CMAS+NaVO 3 fused salt corrosion provided by the invention, a ceramic thermal insulation surface layer with a single-layer structure is directly formed above the bonding layer by using the composite oxide/YSZ mixed powder, the thickness is 100-300 mu m, the thermal conductivity is lower than 2.0W/(m.times.K), and the thermal barrier coating has a better thermal insulation effect.
In a second aspect of the invention, a method for preparing a thermal barrier coating resistant to molten salt corrosion is provided, comprising the steps of: and preparing the bonding layer and the molten salt corrosion resistant layer by spraying.
Further, the method also comprises preparing the first heat insulation layer by spraying.
Further, the bonding layer is prepared by spraying by any one method of low-pressure plasma spraying, vacuum plasma spraying, supersonic flame spraying and cold spraying.
Further, the first heat insulating layer is prepared by spraying by any one method of atmospheric plasma spraying, vacuum plasma spraying, supersonic plasma spraying and plasma physical vapor deposition.
Further, the molten salt corrosion resistant layer is prepared by spraying by any one method of atmospheric plasma spraying, vacuum plasma spraying, supersonic plasma spraying and plasma physical vapor deposition
In one embodiment, the bonding layer and the molten salt corrosion resistant layer are sprayed sequentially. Directly spraying a fused salt corrosion resistant layer on the bonding layer to form the heat insulation surface layer with the single ceramic structure of the layered structure.
In one embodiment, the bonding layer, the first heat-insulating layer with a layered structure and the molten salt corrosion resistant layer with a layered structure are sequentially prepared by spraying to form the ceramic heat-insulating surface layer with a double ceramic structure.
According to the thermal barrier coating provided by the invention, the optimized composite oxide addition amount can ensure that a sufficient amount of Al 2O3 uniformly contacts with CMAS and CMAS+NaVO 3 fused salt and reacts with liquid fused salt rapidly to generate a high-melting-point anorthite plugging layer, and the introduced nucleating agent accelerates the reaction process, so that the smaller addition amount of Al 2O3 can prevent the fused salt from invading into the thermal barrier coating, and the penetration speed and penetration depth of the fused salt are greatly reduced. The smaller amount of Al 2O3 added still enables the heat insulation surface layer to have lower heat conductivity, larger thermal expansion coefficient and higher strain tolerance. The YSZ layer of the first heat insulation layer has excellent comprehensive performance, good heat insulation performance, fracture toughness, thermal shock resistance, phase stability and thermal expansion coefficient which is closer to that of the bonding layer, and meets the long-service-life working requirement; although the first heat insulation layer and the composite oxide/YSZ composite ceramic layer are different in material system, the smaller addition amount of Al 2O3 enables the two layers of components to realize gradient transition, so that the thermal mismatch stress between the two layers can be relieved, and the interlayer bonding strength of the double ceramic layers is ensured. The thermal barrier coating for resisting CMAS and CMAS+NaVO 3 fused salt corrosion provided by the invention has the characteristics of low thermal conductivity, high fracture toughness and good high-temperature thermal stability on the whole, and can ensure the heat insulation performance and the strain tolerance of the thermal barrier coating on the basis of exerting the CMAS and CMAS+NaVO 3 fused salt corrosion resistance of the composite oxide/YSZ composite ceramic layer, thereby prolonging the service life of the thermal barrier coating. The CMAS and CMAS+NaVO 3 fused salt corrosion resistant thermal barrier coating provided by the invention takes low-cost industrialized YSZ powder as a raw material, the composite oxide powder is simple to prepare, the addition amount of Al 2O3 is small, the coating preparation flow is short, and the industrial application is expected to be realized rapidly.
The beneficial effects of the invention are as follows:
(1) According to the invention, al 2O3 and a nucleating agent are added into YSZ powder, al 2O3 reacts with CMAS or CMAS+NaVO 3 fused salt rapidly to generate the anorthite plugging layer with high melting point, and the effect of resisting CMAS and CMAS+NaVO 3 fused salt corrosion can be effectively achieved. The addition of the nucleating agent accelerates the reaction process, so that a small amount of added Al 2O3 can prevent molten salt from invading into the thermal barrier coating, and the penetration speed and penetration depth of the molten salt are greatly reduced.
(2) The specific dosage range of the Al 2O3 and the nucleating agent ensures that the Al 2O3 can generate a sufficiently compact anorthite blocking layer to prevent molten salt from invading into the thermal barrier coating, and simultaneously ensures that the components of the first heat insulation layer and the molten salt corrosion resistant layer realize gradient transition, relieves the thermal mismatch stress between the two layers and ensures the interlayer bonding strength of the double ceramic layers. The amount of nucleating agent ensures that Al 2O3 generates anorthite blocking layers with sufficient thickness.
(3) The thicknesses of the first heat insulation layer and the molten salt corrosion resistance layer and the layer thickness ratio of the first heat insulation layer and the molten salt corrosion resistance layer ensure that the thermal barrier coating has better heat insulation performance and fracture toughness on the basis of exerting CMAS and CMAS+NaVO 3 molten salt corrosion resistance of the composite oxide/YSZ composite ceramic layer.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the invention.
FIG. 1 is a schematic diagram of a thermal barrier coating structure for resisting CMAS and CMAS+NaVO 3 molten salt corrosion provided by the invention; wherein, 1, a basal body; 2. a bonding layer; 3. a first insulating layer; 4. a molten salt corrosion resistant layer;
FIG. 2 is a photograph of the cross-sectional morphology and Ca element penetration of a single ceramic structure thermal barrier coating CMAS in example 1 after 5 hours of high temperature corrosion, wherein gray black layers in the coating are Al 2O3 -based composite oxides;
FIG. 3 is an XRD pattern for a single ceramic structure thermal barrier coating CMAS in example 1 after 5 hours of high temperature corrosion;
FIG. 4 is a photograph of the cross-sectional morphology and Ca element penetration of the single ceramic structure thermal barrier coating CMAS+NaVO 3 high Wen Fu in example 1 after 5 hours of corrosion, the coating surface rod being anorthite;
FIG. 5 is a photograph of a 13wt.% composite oxide/YSZ-YSZ dual ceramic thermal barrier coating of example 2.
Detailed Description
It should be noted that the following detailed description is illustrative and is intended to provide further explanation of the invention. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.
Comparative example 1
And (3) carrying out degreasing and sand blasting roughening pretreatment on the high-temperature alloy matrix. The method comprises the steps of preparing a NiCoCrAlY bonding layer with the thickness of 100-150 mu m on the surface of a high-temperature alloy substrate by adopting atmospheric plasma spraying, wherein the spraying current is 700-850A, the voltage is 30-40V, the main gas argon flow is 40-60 L.min -1, the auxiliary gas helium flow is 6-9 L.min -1, the carrier gas argon flow is 3-6 L.min -1, the powder feeding rate is 15-30 g.min -1, and the spraying distance is 100-140 mm. The YSZ ceramic layer with the thickness of 300 mu m is prepared on the surface of the bonding layer by adopting atmospheric plasma spraying, the spraying current is 700-850A, the voltage is 30-40V, the main gas argon flow is 40-60 L.min -1, the auxiliary gas helium flow is 6-9 L.min -1, the carrier gas argon flow is 3-6 L.min -1, the powder feeding rate is 15-30 g.min -1, and the spraying distance is 100-140 mm.
CMAS powder was prepared with a molar ratio of 45SiO 2-33CaO-13AlO1.5 -9MgO and mixed with alcohol to form CMAS suspension. The suspension was uniformly applied to the ceramic layer surface and dried for 30 minutes and carefully weighed to give a CMAS coating density of 35mg/cm 2. The coating was then subjected to high temperature corrosion at 1250 ℃ for 5 hours. The results show that the YSZ ceramic coating is completely damaged by CMAS molten salt infiltration, i.e. the infiltration depth reaches 300 μm.
The prepared CMAS powder and NaVO 3 powder are weighed and evenly mixed according to the mass ratio of 9:1. In order to ensure uniform mixing of the powder, a ball mill can be used for mixing the powder for 12-48 hours. The mixed powder was mixed with alcohol to form a cmas+navo 3 suspension. The suspension was uniformly applied to the ceramic layer surface and dried for 30 minutes and carefully weighed to give a cmas+navo 3 coating density of 35mg/cm 2. The coating was then subjected to high temperature corrosion at 1250 ℃ for 5 hours. The results show that the YSZ ceramic coating is completely damaged by the molten salt infiltration of CMAS+NaVO 3, namely the infiltration depth reaches 300 mu m.
Example 1
Respectively weighing Al 2O3 powder and SiO 2 powder, wherein the particle size of the Al 2O3 powder is about 40 mu m, the particle size of the SiO 2 powder is about 10 mu m, preparing composite oxide powder (sieving particle size is 30-60 mu m) by spray drying, wherein the mass fraction of Al 2O3 is 97%, and the process can be realized by using any mixing and granulating technology known at present; and respectively weighing the YSZ powder and the composite oxide powder, and mixing to obtain the composite ceramic powder with the composite oxide powder mass fraction of 13%. To ensure uniform mixing of the powder, a 24h ball mill is used for mixing the powder.
And (3) preparing a bonding layer and a 13wt.% composite oxide/YSZ composite ceramic coating with the thickness of 300 mu m according to the technological parameters of the comparative case by spraying, so as to form the single ceramic structure thermal barrier coating. CMAS and CMAS+NaVO 3 molten salt corrosion tests were performed according to the comparative cases. The results show that the 13wt.% composite oxide/YSZ composite ceramic layer has a CMAS corrosion penetration distance of about 20 μm and a cmas+navo 3 corrosion penetration distance of about 22 μm, exhibiting excellent resistance to CMAS and cmas+navo 3 molten salt corrosion.
Example 2
13Wt.% composite oxide/YSZ mixed powder and tie coat were prepared as in example 1. And (3) sequentially spraying a first heat-insulating YSZ layer with the thickness of 170 mu m and a 13wt.% composite oxide/YSZ ceramic layer with the thickness of 90 mu m on the surface of the bonding layer by adopting comparative case technological parameters to form a thermal barrier coating with a double ceramic structure (as shown in figure 5), further reducing the influence on the heat conductivity and the heat mismatch of the thermal barrier coating caused by adding Al 2O3, and ensuring the excellent heat insulation performance and fracture toughness of the thermal barrier coating on the basis of playing the roles of CMAS and CMAS+NaVO 3 molten salt corrosion of the composite oxide/YSZ composite ceramic layer. CMAS and CMAS+NaVO 3 molten salt corrosion tests were performed according to the comparative cases. The results show that 13wt.% of the composite oxide/YSZ-YSZ dual ceramic thermal barrier coating has a CMAS corrosion penetration distance of about 21 μm and a CMAS+NaVO 3 corrosion penetration distance of about 23 μm.
From fig. 2-4, it can be seen that the YSZ ceramic coating is completely damaged by molten salt infiltration of CMAS and cmas+navo 3, the Ca element in CMAS having diffused from the ceramic layer surface to the ceramic layer bottom surface. The addition of 13wt.% composite oxide promotes the formation of anorthite plugging layer at the molten salt-coating interface, effectively blocks the penetration of CMAS and CMAS+NaVO 3 molten salt, and the Ca element diffusion in CMAS is limited to the surface area of the ceramic layer.
Comparative example 2
The specific preparation method is basically the same as that of embodiment 1, except that: no SiO 2 powder was added. CMAS and CMAS+NaVO 3 molten salt corrosion tests were performed. The results showed that the CMAS corrosion penetration distance was about 58 μm and the CMAS + NaVO 3 corrosion penetration distance was about 62 μm.
Comparative example 3
The specific preparation method is basically the same as that of the embodiment 2, except that: no SiO 2 powder was added. CMAS and CMAS+NaVO 3 molten salt corrosion tests were performed. The results showed that the CMAS corrosion penetration distance was about 61 μm and the CMAS + NaVO 3 corrosion penetration distance was about 64 μm.
The above description is only of the preferred embodiments of the present invention and is not intended to limit the present invention, but various modifications and variations can be made to the present invention by those skilled in the art. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (15)
1. The thermal barrier coating resistant to molten salt corrosion is characterized by comprising a bonding layer and a molten salt corrosion resistant layer; the molten salt corrosion resistant layer is a composite ceramic layer with a layered structure and is formed by mixing YSZ powder and composite oxide powder, wherein the composite oxide powder consists of Al 2O3 and a nucleating agent; in the molten salt corrosion resistant layer, the mass fraction of the composite oxide is 5% -15%, and the balance is YSZ;
In the composite oxide powder, the mass percentage of Al 2O3 is 90-97 wt%, and the balance is nucleating agent;
The initial grain diameter of Al 2O3 is 30-60 μm; the initial particle size of the nucleating agent is 5-15 mu m;
the addition of the composite oxide promotes the anorthite blocking layer to be generated at the fused salt-coating interface, and effectively blocks CMAS and CMAS+NaVO 3 fused salt infiltration.
2. The molten salt corrosion resistant thermal barrier coating of claim 1, wherein the nucleating agent is one or more of SiO 2、TiO2, mgO, caO.
3. The molten salt corrosion resistant thermal barrier coating of claim 1 wherein the molten salt corrosion resistant layer has a porosity of 5% to 20%.
4. The molten salt corrosion resistant thermal barrier coating of claim 1, wherein the bond coat material is an MCrAlY material system, and the bond coat thickness is 100-150 μm.
5. The molten salt corrosion resistant thermal barrier coating of claim 1, further comprising a first thermal barrier layer; the bonding layer, the first heat insulation layer and the molten salt corrosion resistance layer are sequentially stacked to form the thermal barrier coating.
6. The molten salt corrosion resistant thermal barrier coating of claim 5, wherein the first thermal barrier layer is a layered structure and the material is YSZ, rare earth zirconate, or other thermal barrier ceramic material.
7. The molten salt corrosion resistant thermal barrier coating of claim 6, wherein the first thermal barrier layer has a thickness of 100-200 μιη and the molten salt corrosion resistant layer has a deposited thickness of 30-90 μιη; and the layer thickness ratio of the first heat insulation layer to the CMAS and CMAS+NaVO 3 molten salt corrosion resistant layer is 1.5-3.
8. The molten salt corrosion resistant thermal barrier coating of claim 1, wherein in the thermal barrier coating, a molten salt corrosion resistant layer is formed directly above the bond line, the thickness of the molten salt corrosion resistant layer being 100-300 μm.
9. The method of preparing a molten salt corrosion resistant thermal barrier coating of any one of claims 1-8, comprising the steps of: and preparing the bonding layer and the molten salt corrosion resistant layer by spraying.
10. The method for preparing a thermal barrier coating resistant to molten salt corrosion of claim 9, wherein the bond coat is sprayed by any one of low pressure plasma spraying, vacuum plasma spraying, supersonic flame spraying, cold spraying.
11. The method for preparing a thermal barrier coating resistant to molten salt corrosion of claim 9, wherein the molten salt corrosion resistant layer is prepared by spraying by any one of atmospheric plasma spraying, vacuum plasma spraying, supersonic plasma spraying, and plasma physical vapor deposition.
12. The method of claim 9, wherein the method of preparing comprises preparing the first insulating layer by spraying.
13. The method of claim 12, wherein the first thermal barrier layer is applied by any one of atmospheric plasma spraying, vacuum plasma spraying, supersonic plasma spraying, and plasma physical vapor deposition.
14. The method of claim 9, wherein the bonding layer and the molten salt corrosion resistant layer are sequentially sprayed to form a single ceramic thermal insulation surface layer having a layered structure.
15. The method of claim 9, wherein the adhesive layer, the first insulating layer having a layered structure, and the molten salt corrosion resistant layer having a layered structure are sequentially spray-coated to form a ceramic insulating surface layer having a double ceramic structure.
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