CN115637402A - Method for preparing high-temperature abradable seal coating with hierarchical holes or gradient Kong Nai based on electrostatic field auxiliary term conversion - Google Patents
Method for preparing high-temperature abradable seal coating with hierarchical holes or gradient Kong Nai based on electrostatic field auxiliary term conversion Download PDFInfo
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Abstract
A method for preparing a high-temperature abradable seal coating with a hierarchical hole or gradient Kong Nai based on electrostatic field auxiliary term conversion relates to the field of seal coatings, in particular to a method for preparing a high-temperature abradable seal coating with a hierarchical hole or gradient hole. The invention solves the problem of how to improve the thermal shock resistance and the abradability of the sealing coating by regulating and controlling the pore structure in the coating. The method comprises the following steps: 1. pretreating a base material; 2. preparing a bonding layer; 3. preparing the abradable seal coating. According to the invention, the pore structure in the coating is adjusted by adding the short-acting filling material and doping the electrostatic field auxiliary item to convert the porous ceramic feed, micro-nano hierarchical pores or gradient pores are formed by one or more times of preparation, the pore structure is controllable, wherein the micro-pores can improve the strain tolerance of the coating and improve the thermal shock resistance of the sealed coating, the nano-pores distributed in a dispersing manner are beneficial to reducing the thermal conductivity and improving the abradability of the coating, the service temperature of the ceramic framework of the sealed coating is high, and the coating is simple and efficient to prepare.
Description
Technical Field
The invention relates to the field of sealing coatings, in particular to a preparation method for preparing a Kong Nai high-temperature abradable sealing coating with a multi-level hole or gradient based on electrostatic field auxiliary item conversion.
Background
With the aggravation of energy crisis, the improvement of engine efficiency and the reduction of oil consumption become one of the research hotspots of the current aero-engine. Research shows that blade tip clearance has important influence on the efficiency of a compressor and a turbine, the power of an engine and the oil consumption rate. Due to the influences of factors such as thermal expansion difference of materials of a rotor and a casing of the engine, blade extension effect, part machining error, assembly tolerance, displacement and deformation caused by vibration of parts and the like, the clearance between the rotor and the stator of the engine is too small, scraping abrasion of the rotor and the stator and damage of the casing and the blades are caused, and even serious faults of the engine can occur in severe cases. In order to improve the efficiency of the engine and protect the blades and the casing from being scratched and damaged, an abradable sealing coating is introduced in the design and development of the air path seal of the aeroengine, and the minimum air path gap is maintained so as to improve the performance of the engine.
The content and distribution of pores in the sealed coating have very important influence on the thermal shock resistance and the abradability of the coating. The published patent (CN 109554657A) adopts plasma spraying with a double powder feeding structure to prepare a NiCrAlY/zirconia and abradable seal mixed surface layer with a gradual change structure, so that the coating has the performances of titanium fire resistance and abradability, but the service temperature of the coating is lower (about 450 ℃) and the problem that the coating is easy to lose efficacy due to thermal stress in the service process is ignored, and the thermal shock resistance of the coating is not considered. The published patent (CN 114645236A) adopts a plasma evaporation deposition technology to prepare a sealing coating of a pure ceramic material, wherein the coating comprises framework columnar crystals and particles filled in gaps of the columnar crystals, longitudinal pores among the columnar crystals enable the coating to have better thermal shock resistance, and fine nano pores are filled among the particles in the gaps of the columnar crystals, so that the abradable sealing coating of a composite structure has good abradability. But the plasma evaporation deposition technology is not popular enough, the spraying preparation cost is high, and the regulation range of the prepared coating pore is not controllable.
Disclosure of Invention
The invention solves the problem of how to improve the thermal shock resistance and the abradability of the sealing coating by regulating and controlling the pore structure in the coating, and provides a method for preparing the sealing coating with hierarchical pores or gradient Kong Nai high-temperature abradable based on the conversion of an electrostatic field auxiliary term, wherein the service temperature of the coating can reach 1150 ℃.
A method for preparing a Kong Nai high-temperature abradable seal coating with multi-level holes or gradients based on electrostatic field auxiliary term conversion is specifically completed according to the following steps:
1. pretreatment of the substrate:
removing impurities and oil stains on the surface of the base material, and performing sand blasting treatment on the surface of the base material to obtain a pretreated base material;
2. preparing a bonding layer:
spraying the bonding layer powder on the surface of the pretreated base material to obtain the base material with the bonding layer on the surface;
the bonding layer powder is NiCoCrAlY;
3. preparing an abradable seal coating:
spraying the abradable seal coating powder on the surface of a substrate with a bonding layer on the surface once or for multiple times to obtain the substrate with the abradable seal coating on the surface, namely completing the preparation of the high-temperature abradable seal coating with multi-level holes or gradient holes, which has controllable pore space, large strain tolerance, high thermal shock resistance and low thermal conductivity;
the abradable seal coating powder in the third step is prepared from spray granulation dense ceramic feed, porous ceramic feed, fugitive filling material feed and ceramic powder layer-by-layer coating lubricating material feed, wherein the mass fraction of the spray granulation dense ceramic feed is 30% -70%, the mass fraction of the porous ceramic feed is 30% -70%, the mass fraction of the ceramic powder layer-by-layer coating lubricating material feed is 4% -10%, and the mass fraction of the fugitive filling material feed is 4% -10%.
The principle of the invention is as follows:
according to the invention, the pore structure in the coating is adjusted by adding a short-acting filling material and doping an electrostatic field auxiliary item to convert the porous ceramic feed, micro-nano hierarchical holes or gradient holes are formed in one-step preparation, the pore structure is controllable, the micro-holes can improve the strain tolerance of the coating, the thermal shock resistance of the sealed coating is improved, the nano-holes distributed in a dispersing manner are beneficial to reducing the thermal conductivity and improving the abradability of the coating, the service temperature of the components of the ceramic framework of the sealed coating is high, the coating is simple to prepare and efficient, and the method has a very important significance for promoting the development of the aviation industry in China.
The invention has the advantages that:
1. according to the invention, the content, the pore diameter and the relative proportion of micro-nano hierarchical pores in the coating or the design of gradient pores by doping step by step can be effectively regulated and controlled by regulating and controlling the content of the short-acting filling material feed and the porous ceramic feed, so that the abradability of the coating is improved, and the thermal shock resistance of the coating is also improved;
2. the high-temperature abradable seal coating with the multistage holes prepared by the invention adopts a reciprocating type friction and wear testing machine to test the high-temperature friction coefficient at 1150 ℃, the friction coefficient of the composite coating in the testing time is about 0.5-0.6, the friction coefficient in the early stage of the testing stage is 0.55-0.6, and the friction coefficient in the later stage of the testing is slightly reduced to 0.5, which shows that the high-temperature abradable composite coating designed and prepared by the invention has good high-temperature abradability.
Drawings
FIG. 1 is a schematic structural view of a high temperature abradable seal coating with multistage holes as described in example 1;
FIG. 2 is a schematic structural view of the high temperature abradable seal coating with gradient holes described in example 2;
FIG. 3 is a micro-topography of a porous ceramic feedstock prepared using electrostatic field assisted term conversion in step three (3) of example 1;
FIG. 4 is a micro-topography of the high temperature abradable seal coating with multi-level holes prepared in step three of example 1, where (a) is a cross-sectional topography and (b) is a surface topography;
FIG. 5 shows the preparation of NiCrAlY/LaCrO in step three of example 1 3 -h-BN abradable seal layer high temperature coefficient of friction at 1150 ℃ tested using a reciprocating friction wear tester.
Detailed Description
The following examples further illustrate the present invention but are not to be construed as limiting the invention. Modifications and substitutions to methods, procedures, or conditions of the invention may be made without departing from the spirit of the invention.
The first embodiment is as follows: the embodiment of the invention relates to a method for preparing a Kong Nai high-temperature abradable seal coating with a multi-level hole or gradient based on electrostatic field auxiliary item conversion, which is specifically completed according to the following steps:
1. pretreatment of the substrate:
removing impurities and oil stains on the surface of the base material, and performing sand blasting treatment on the surface of the base material to obtain a pretreated base material;
2. preparing a bonding layer:
spraying the bonding layer powder on the surface of the pretreated base material to obtain the base material with the bonding layer on the surface;
the bonding layer powder is NiCoCrAlY;
3. preparing an abradable seal coating:
spraying the abradable seal coating powder on the surface of a substrate with a bonding layer on the surface once or for multiple times to obtain the substrate with the abradable seal coating on the surface, namely completing the preparation of the high-temperature abradable seal coating with multi-level holes or gradient holes, which has controllable pore space, large strain tolerance, high thermal shock resistance and low thermal conductivity;
the abradable seal coating powder in the third step is prepared from spray granulation dense ceramic feed, porous ceramic feed, fugitive filling material feed and ceramic powder layer-by-layer coating lubricating material feed, wherein the mass fraction of the spray granulation dense ceramic feed is 30% -70%, the mass fraction of the porous ceramic feed is 30% -70%, the mass fraction of the ceramic powder layer-by-layer coating lubricating material feed is 4% -10%, and the mass fraction of the fugitive filling material feed is 4% -10%.
The second embodiment is as follows: the present embodiment differs from the present embodiment in that: the base material in the first step is high-temperature alloy; the high-temperature alloy is stainless steel, nickel-based alloy or cobalt-based alloy; polishing the base material by using sand paper in the first step, removing oil stains on the surface by using absolute ethyl alcohol, and performing sand blasting treatment on the base material by using 60# corundum sand under the pressure of 0.3-0.4 MPa to obtain the pretreated base material. Other steps are the same as in the first embodiment.
The third concrete implementation mode: the difference between this embodiment and the first or second embodiment is: spraying the bonding layer powder on the surface of the pretreated base material by adopting atmospheric plasma spraying; the technological parameters of the atmospheric plasma spraying are as follows: the current is 550A-600A, the power is 42 kW-45 kW, the flow rate of argon is 32 slpm-45 slpm, the flow rate of hydrogen is 9 slpm-12 slpm, the flow rate of carrier gas is 3 slpm-4 slpm, the rotation speed of a powder feeding disc is 30 rpm-40 slpm, and the spray distance is 80 mm-130 mm; the thickness of the bonding layer in the second step is 25-100 μm. The other steps are the same as those in the first or second embodiment.
The fourth concrete implementation mode: the difference between this embodiment and one of the first to third embodiments is as follows: spraying the abradable seal coating powder on the surface of the base material with the bonding layer by adopting atmospheric plasma spraying in the third step; the process parameters of the atmospheric plasma spraying are as follows: the current is 500A-550A, the power is 35 kW-45 kW, the flow rate of argon is 32 slpm-40 slpm, the flow rate of hydrogen is 9 slpm-12 slpm, the flow rate of carrier gas is 3 slpm-4 slpm, the rotation speed of a powder feeding disc is 30 rpm-40 rpm, and the spray distance is 100 mm-130 mm; the preparation method of the short-acting filling material feed in the third step comprises the following steps: putting the short-acting filling material into a sealed tank, adding zirconia balls and a solvent, and continuously performing ball milling to obtain uniformly mixed slurry; and introducing the slurry into spray granulation equipment, wherein the spray granulation parameters are as follows: the air inlet temperature is 180-220 ℃, the air outlet temperature is 100-120 ℃, the current is 25-50A, and the obtained powder feed size is 30-100 mu m; the solvent is deionized water or absolute ethyl alcohol; the short-acting filling material is one or more of polystyrene, polyethylene, polyester, nylon and latex; the thickness of the abradable seal coating layer in the third step is 50-500 μm. The other steps are the same as those in the first to third embodiments.
The fifth concrete implementation mode: the difference between this embodiment and the first to the fourth embodiments is: the preparation method of the spray granulation dense ceramic feed in the third step comprises the following steps: putting the ceramic powder into a sealed tank, adding zirconia balls and a solvent, and continuously performing ball milling to obtain uniformly mixed slurry; and (3) introducing the slurry into spray granulation equipment, wherein the spray granulation parameters are as follows: the air inlet temperature is 180-220 ℃, the air outlet temperature is 100-120 ℃, and the current is 25-50A, so that the obtained powder feed size is 30-100 mu m; the solvent is deionized water or absolute ethyl alcohol. The other steps are the same as those in the first to fourth embodiments.
The sixth specific implementation mode is as follows: the difference between this embodiment and one of the first to fifth embodiments is: the method for preparing the porous ceramic feed by converting the electrostatic field auxiliary item in the third step comprises the following steps: dissolving ceramic powder and polyether sulfone in a mass ratio of 3:1 in polyvinylpyrrolidone, and mechanically stirring for 10 hours in a water bath kettle at 60 ℃ to obtain uniform slurry; dispersing the uniform slurry into fine and uniform microspheres under the action of an electrostatic field; the voltage of the electrostatic field is 20-30 kV; immersing the microspheres in water, wherein the polyether sulfone shrinks and solidifies when meeting water, and the polyvinylpyrrolidone dissolves when meeting water, so that the microspheres keep better sphericity and form uniform radioactive finger-shaped pores in the microspheres; the height of the electrostatic field from the water surface is 10-20 cm, and the feeding speed of the slurry is 0.08-0.2 mm/s. The other steps are the same as those in the first to fifth embodiments.
The seventh embodiment: the difference between this embodiment and one of the first to sixth embodiments is: the ceramic powder layer-by-layer wrapped lubricating material feed is prepared by adopting a sol-gel, chemical coprecipitation, mechanochemical or physical wrapping method; the method for preparing the ceramic powder layer-by-layer wrapped lubricating material by using the chemical coprecipitation method comprises the following steps: heat-treating the spray-granulated lubricating material feed at 300 ℃ for 3h, placing the heat-treated feed in deionized water, preparing a lubricating material suspension by magnetic stirring and ultrasonic dispersion, wherein the solubility of the suspension is 0.015g/mL, then fully mixing the suspension with 0.033mol/L zirconium oxychloride precursor solution according to the volume ratio of 1:1, adding ammonia water to adjust the pH value to 3.6, and forming Zr (OH) on the surface of the lubricating material at the moment 4 Aging and filtering to clean the feed, drying at 110 deg.C for 24 hr, and heat treating at 500 deg.C for 3 hr to remove Zr (OH) from the surface of the lubricant 4 Conversion to ZrO 2 To obtain ZrO 2 Coating a lubricating material layer by layer; the preparation method of the layer-by-layer coated lubricating material by using a mechanochemical or physical coating method comprises the following steps: dissolving the lubricating material feed subjected to spray granulation in 200ml of tris-hydrochloric acid solution, stirring in a water bath at 30 ℃ for 10min, and mixing the lubricating material feed with the lubricating material feed in a mass ratio of 1:1 nano ZrO 2 Dissolving in 20g/L dopamine solution, adding 20ml ZrO 2 Titrating the dopamine mixed solution to a lubricating material and tris-hydrochloric acid mixed solution, stirring the titrated mixed solution in water bath at 30 ℃ for 24 hours, aging, filtering, cleaning the feed, and drying at room temperature to obtain ZrO 2 Coating a lubricating material layer by layer; the lubricating material is one or more of h-BN, fluoride, alkaline earth chromate, sulfate and molybdate; the fluoride is one or a mixture of more of barium fluoride, lanthanum fluoride, cerium fluoride and calcium fluoride; the alkaline earth chromate is one or a mixture of barium chromate and strontium chromate; the sulfate is one or a mixture of more of barium sulfate, calcium sulfate and strontium sulfate; the molybdate is one or a mixture of silver molybdate, copper molybdate and cesium molybdate. The other steps are the same as those in the first to sixth embodiments.
The specific implementation mode is eight: the difference between this embodiment and one of the first to seventh embodiments is: the ceramic powder is rare earth stabilized zirconia, rare earth stabilized hafnium oxide, rare earth chromate, rare earth cerate, rare earth tantalate or rare earth niobate; the rare earth stabilized zirconia and the rare earth stabilized hafnium oxide are one or a mixture of more of lanthanum oxide, cerium oxide, yttrium oxide, ytterbium oxide, dysprosium oxide, holmium oxide stabilized zirconia and hafnium oxide; the rare earth chromate is one or a mixture of more of chromic acid, cerium chromate, praseodymium chromate and neodymium chromate; the rare earth cerate is one or a mixture of more of dysprosium cerate, yttrium cerate and lanthanum cerate; the rare earth tantalate is one or a mixture of more of ytterbium tantalate, yttrium tantalate, erbium tantalate, gadolinium tantalate, lanthanum tantalate and lutetium tantalate; the rare earth niobate is one or a mixture of more of yttrium niobate, neodymium niobate, europium niobate, erbium niobate, holmium niobate and lanthanum niobate. The other steps are the same as those in the first to seventh embodiments.
The specific implementation method nine: the difference between this embodiment and the first to eighth embodiments is: in the third step, uniformly mixing spray granulation dense ceramic feed, porous ceramic feed, short-acting filling material feed and ceramic powder layer-by-layer coating lubricating material feed to obtain abradable seal coating powder; the short-acting filling material feed is pyrolyzed in the thermal spraying process or removed in the subsequent thermal treatment, the feed is sprayed to the surface of the base material in a molten or semi-molten state in the thermal spraying process, sputtering-shaped micropores are formed in the coating, the size of the pores is 5-20 mu m, and the content of the micropores is 10-20%; the porous ceramic feed melts the ceramic shell in the plasma flame flow and keeps the internal pore structure of the powder unchanged, and aggregated round or radial nano-pores with the size of 200 nm-800 nm and the content of 5-15 percent are formed in the coating; in the third step, the wearable sealing coating can contain micro-nano hierarchical holes through one-time preparation. The other steps are the same as those in the first to eighth embodiments.
The detailed implementation mode is ten: the difference between this embodiment and the first to ninth embodiments is: changing the mass ratio of the porous ceramic feed to the short-acting filling material feed in the third step, and spraying the abradable seal coating powder on the surface of the base material with the bonding layer for many times, so that the high-temperature abradable seal coating with gradient holes can be prepared; and in the third step, the mass ratio of the porous ceramic feed to the short-acting filling material feed is changed, and the powder feeding speed is changed for many times to spray the abradable seal coating powder on the surface of the base material with the bonding layer on the surface, so that the high-temperature abradable seal coating with the gradient holes can be prepared. The other steps are the same as those in the first to ninth embodiments.
The following examples were used to demonstrate the beneficial effects of the present invention:
example 1: a preparation method for preparing a wearable sealing coating with multistage Kong Nai high temperature based on electrostatic field auxiliary term conversion is specifically completed according to the following steps:
1. pretreatment of the substrate:
removing impurities and oil stains on the surface of the base material, and performing sand blasting treatment on the surface of the base material to obtain a pretreated base material;
polishing the base material by using sand paper, removing oil stains on the surface by using absolute ethyl alcohol, and performing sand blasting treatment on the base material by using 60# corundum sand under the pressure of 0.3MPa to obtain a pretreated base material;
the base material in the first step is GH4061 high-temperature alloy;
2. preparing a bonding layer:
spraying the bonding layer powder on the surface of the pretreated base material by adopting an atmospheric plasma spraying method to obtain the base material with the bonding layer on the surface;
the bonding layer powder is NiCoCrAlY;
the process parameters of the atmospheric plasma spraying method are as follows: the current is 600A, the power is 45kW, the flow rate of argon is 45slpm, the flow rate of hydrogen is 9slpm, the flow rate of carrier gas is 3slpm, the rotation speed of a powder feeding disc is 30rpm, and the spray distance is 110mm;
3. preparing an abradable seal coating:
(1) preparing a short-acting filling material feed: putting the short-acting filling material into a sealed tank, adding zirconia balls and a solvent, and continuously performing ball milling to obtain uniformly mixed slurry; and introducing the slurry into spray granulation equipment, wherein the spray granulation parameters are as follows: the air inlet temperature is 180 ℃, the air outlet temperature is 110 ℃, and the current is 35A, so that the feeding size of the obtained powder is 30-100 mu m; the solvent is deionized water; the short-acting filling material is polyester;
(2) preparing a compact ceramic feed: mixing LaCrO 3 Putting the ceramic powder into a sealed tank, adding zirconia balls and a solvent, and continuously performing ball milling to obtain uniformly mixed slurry; and introducing the slurry into spray granulation equipment, wherein the spray granulation parameters are as follows: the air inlet temperature is 180 ℃, the air outlet temperature is 110 ℃, and the current is 35A, so that the feeding size of the obtained powder is 30-100 mu m; the solvent is deionized water;
(3) preparing porous ceramic feed by electrostatic field auxiliary item conversion: mixing LaCrO 3 Dissolving ceramic powder and polyether sulfone in a mass ratio of 3:1 in polyvinylpyrrolidone, and mechanically stirring for 10 hours in a 60 ℃ water bath to obtain uniform slurry; dispersing the uniform slurry into fine and uniform microspheres under the action of an electrostatic field; the voltage of the electrostatic field is 20kV; the height of the electrostatic field from the slurry is 15cm, and the feeding speed of the slurry is 0.2mm/s; immersing the microspheres in water, wherein the polyether sulfone shrinks and solidifies when meeting water, and the polyvinylpyrrolidone dissolves when meeting water, so that the microspheres keep better sphericity and form uniform radioactive finger-shaped pores in the microspheres;
(4) preparing ceramic powder and coating the lubricating material layer by layer for feeding: the preparation of the layer-by-layer wrapped lubricating material by using a chemical coprecipitation method comprises the following specific steps: carrying out heat treatment on a spray-granulated h-BN lubricating material feed at 300 ℃ for 3h, placing the heat-treated feed in deionized water, preparing a lubricating material suspension by magnetic stirring and ultrasonic dispersion, wherein the solubility of the suspension is 0.015g/mL, then fully mixing the suspension with 0.033mol/L zirconium oxychloride precursor solution according to a volume ratio of 1:1, adding ammonia water to adjust the pH value to reach 3.6, and forming Zr (OH) on the surface of the lubricating material at the moment 4 Aging, filtering, washing, drying at 110 deg.C for 24 hr, and heat treating at 500 deg.C for 3 hr to remove Zr (OH) from the surface of the lubricating material 4 Conversion to ZrO 2 To obtain ZrO 2 Coating the lubricating material layer by layer, namely coating the lubricating material feed layer by layer with ceramic powder;
(5) in the third step, uniformly mixing spray granulation dense ceramic feed, porous ceramic feed, short-acting filling material feed and ceramic powder layer-by-layer coating lubricating material feed to obtain abradable seal coating powder; wherein the mass fraction of the spray granulation compact ceramic feed in the abradable seal coating powder is 45%, the mass fraction of the porous ceramic feed is 45%, the mass fraction of the ceramic powder layer-by-layer wrapped lubricating material feed is 5%, and the mass fraction of the fugitive filling material feed is 5%;
(6) the abradable seal coating powder is sprayed on the surface of a base material with a bonding layer on the surface by an atmospheric plasma spraying method, heat preservation is carried out for 2 hours at 1000 ℃, the short-acting filling material feed is removed in the thermal spraying process, the feed is kept in a molten state in the spraying process and is sprayed on the surface of the base material, sputtering-shaped micron holes are formed in the coating, and the size of the holes is 5-20 microns; the porous ceramic feed melts the ceramic shell in the plasma flame flow and keeps the internal pore structure of the powder unchanged, and aggregated round or radial nano-pores with the size of 200 nm-800 nm are formed in the coating to obtain the powder with the surface containing NiCrAlY/LaCrO 3 h-BN abradable seal substrate, i.e., a process for preparing a high temperature abradable seal coating having multiple levels of Kong Nai based on electrostatic field assisted term conversion (as shown in FIG. 1);
the process parameters of the atmospheric plasma spraying method in the third step (6) are as follows: the current was 550A, the power was 45kW, the flow rate of argon was 40slpm, the flow rate of hydrogen was 9slpm, the flow rate of carrier gas was 3slpm, the rotation speed of the powder feeding plate was 30rpm, and the spray pitch was 110mm.
As can be seen from fig. 1: the abradable seal coating contains micro-nano multi-level holes, the sputtering-shaped micro-holes are formed by pyrolysis of short-acting filling material feed in a thermal spraying process, the size of the holes is 5-20 mu m, and the content of the holes is 10-20%; the round or radial shape is formed by melting a ceramic shell of a porous ceramic feed in a plasma flame flow to keep the internal pore structure of the powder, the size is 200 nm-800 nm, and the content is 5-15%.
Example 2: the present embodiment is different from embodiment 1 in that: and step three (6), after the mass ratio of the porous ceramic feed to the short-acting filling material feed is changed for many times, the abradable seal coating powder is sprayed on the surface of the base material with the bonding layer on the surface, and the base material with the abradable seal coating on the surface is obtained, namely, the preparation of the Kong Nai high-temperature abradable seal coating with the gradient based on electrostatic field auxiliary term conversion is completed (as shown in figure 2). The other steps and parameters were the same as in example 1.
As can be seen from fig. 2: the abradable seal coating contains gradient holes, the content of the first layer of pores sprayed on the surface of the substrate is low, the seal layer and the bonding layer are kept well bonded, the mass ratio of porous ceramic feeding to short-acting filling material feeding is increased step by step along with the increase of the thickness of the seal layer, the content of micro-nano holes is increased, and the seal layer has excellent thermal shock resistance and abradability.
FIG. 3 is a micro-topography of a porous ceramic feedstock prepared by electrostatic field assisted conversion in step three (3) of example 1;
as can be seen from fig. 3: the grain size of the porous ceramic feed prepared by the electrostatic field assisted conversion is 1-20 mu m; the feeding material has better sphericity, the core part of the feeding material is a circular hole which is irregularly distributed, the size of the hole is 100 nm-400 nm, the edge is a radioactive finger-shaped hole which is closely arranged, and the size of the hole is 200 nm-800 nm.
FIG. 4 is a microstructure of the high temperature abradable seal coating with multi-level holes prepared in step three of example 1, where (a) is a cross-sectional profile and (b) is a surface profile.
As can be seen from fig. 4: niCrAlY bondcoat thickness of about 60 μm, laCrO 3 The thickness of the/h-BN sealing layer is about 120 mu m, sputtering-shaped micropores with the size of 5 mu m-20 mu m are formed in the coating layer according to a surface topography picture, the content of the micropores is 17.7%, round aggregated nanopores with the size of 200 nm-800 nm are also formed in the coating layer, and the content of the nanopores is 12.2%.
NiCrAlY/LaCrO prepared in example 1 was tested at 1150 ℃ using a reciprocating frictional wear tester 3 The high temperature coefficient of friction of the h-BN abradable seal, as shown in FIG. 5;
FIG. 5 shows the preparation of NiCrAlY/LaCrO in step three of example 1 3 The high-temperature friction coefficient of the-h-BN abradable seal layer is tested by adopting a reciprocating type friction and wear testing machine at 1150 ℃, the friction coefficient of the composite coating is about 0.5-0.6 in the testing time, the friction coefficient is 0.55-0.6 in the early stage of the testing stage, and the friction coefficient is slightly reduced to 0.5 in the later stage of the testing, which shows that the high-temperature abradable composite coating designed and prepared by the invention has good abradability.
Claims (10)
1. A method for preparing a Kong Nai high-temperature abradable seal coating with multi-level holes or gradients based on electrostatic field auxiliary term conversion is characterized by comprising the following steps:
1. pretreatment of the base material:
removing impurities and oil stains on the surface of the base material, and performing sand blasting treatment on the surface of the base material to obtain a pretreated base material;
2. preparing a bonding layer:
spraying the bonding layer powder on the surface of the pretreated base material to obtain a base material with a bonding layer on the surface;
the bonding layer powder is NiCoCrAlY;
3. preparing an abradable seal coating:
spraying the abradable seal coating powder on the surface of a substrate with a bonding layer on the surface once or for multiple times to obtain the substrate with the abradable seal coating on the surface, namely completing the preparation of the high-temperature abradable seal coating with multi-level holes or gradient holes, which has controllable pore space, large strain tolerance, high thermal shock resistance and low thermal conductivity;
the abradable seal coating powder in the third step is prepared from spray granulation dense ceramic feed, porous ceramic feed, fugitive filling material feed and ceramic powder layer-by-layer coating lubricating material feed, wherein the mass fraction of the spray granulation dense ceramic feed is 30% -70%, the mass fraction of the porous ceramic feed is 30% -70%, the mass fraction of the ceramic powder layer-by-layer coating lubricating material feed is 4% -10%, and the mass fraction of the fugitive filling material feed is 4% -10%.
2. The method for preparing the 5363 high-temperature abradable seal coating with the multi-level holes or the gradient Kong Nai based on electrostatic field assisted term conversion as claimed in claim 1, wherein the substrate in the first step is a high-temperature alloy; the high-temperature alloy is stainless steel, nickel-based alloy or cobalt-based alloy; polishing the base material by using sand paper in the first step, removing oil stains on the surface by using absolute ethyl alcohol, and performing sand blasting treatment on the base material by using 60# corundum sand under the pressure of 0.3-0.4 MPa to obtain the pretreated base material.
3. The method for preparing the Kong Nai high temperature abradable seal coating based on electrostatic field assisted term conversion as claimed in claim 1, wherein in step two, the bonding layer powder is sprayed on the surface of the pretreated substrate by atmospheric plasma spraying; the technological parameters of the atmospheric plasma spraying are as follows: the current is 550A-600A, the power is 42 kW-45 kW, the flow rate of argon is 32 slpm-45 slpm, the flow rate of hydrogen is 9 slpm-12 slpm, the flow rate of carrier gas is 3 slpm-4 slpm, the rotation speed of a powder feeding disc is 30 rpm-40 slpm, and the spray distance is 80 mm-130 mm; the thickness of the bonding layer in the second step is 25-100 μm.
4. The method for preparing the high-temperature abradable seal coating with the multi-level holes or the gradient Kong Nai based on the electrostatic field assisted term conversion as claimed in claim 1, wherein the method is characterized in that in the third step, the abradable seal coating powder is sprayed on the surface of the substrate with the adhesive layer on the surface by using atmospheric plasma spraying; the process parameters of the atmospheric plasma spraying are as follows: the current is 500A-550A, the power is 35 kW-45 kW, the flow rate of argon is 32 slpm-40 slpm, the flow rate of hydrogen is 9 slpm-12 slpm, the flow rate of carrier gas is 3 slpm-4 slpm, the rotation speed of a powder feeding disc is 30 rpm-40 rpm, and the spray distance is 100 mm-130 mm; the preparation method of the short-acting filling material feed in the third step comprises the following steps: putting the short-acting filling material into a sealed tank, adding zirconia balls and a solvent, and continuously performing ball milling to obtain uniformly mixed slurry; and (3) introducing the slurry into spray granulation equipment, wherein the spray granulation parameters are as follows: the air inlet temperature is 180-220 ℃, the air outlet temperature is 100-120 ℃, and the current is 25-50A, so that the obtained powder feed size is 30-100 mu m; the solvent is deionized water or absolute ethyl alcohol; the short-acting filling material is one or more of polystyrene, polyethylene, polyester, nylon and latex; the thickness of the abradable seal coating layer in the third step is 50-500 μm.
5. The method for preparing the high-temperature abradable seal coating with the multi-stage holes or the gradient Kong Nai based on the electrostatic field assisted term conversion as claimed in claim 1, wherein the spray granulation dense ceramic feed in the third step is prepared by the following steps: putting the ceramic powder into a sealed tank, adding zirconia balls and a solvent, and continuously performing ball milling to obtain uniformly mixed slurry; and (3) introducing the slurry into spray granulation equipment, wherein the spray granulation parameters are as follows: the air inlet temperature is 180-220 ℃, the air outlet temperature is 100-120 ℃, the current is 25-50A, and the obtained powder feed size is 30-100 mu m; the solvent is deionized water or absolute ethyl alcohol.
6. The method for preparing the high-temperature abradable seal coating with the multi-stage holes or the gradient Kong Nai based on the electrostatic field assisted term conversion as claimed in claim 1, wherein the method for preparing the porous ceramic feed by the electrostatic field assisted term conversion in the third step is as follows: dissolving ceramic powder and polyether sulfone in a mass ratio of 3:1 in polyvinylpyrrolidone, and mechanically stirring for 10 hours in a water bath kettle at 60 ℃ to obtain uniform slurry; dispersing the uniform slurry into fine and uniform microspheres under the action of an electrostatic field; the voltage of the electrostatic field is 20-30 kV; immersing the microspheres in water, wherein the polyether sulfone shrinks and solidifies when meeting water, and the polyvinylpyrrolidone dissolves when meeting water, so that the microspheres keep better sphericity and form uniform radioactive finger-shaped pores in the microspheres; the height of the electrostatic field from the water surface is 10-20 cm, and the feeding speed of the slurry is 0.08-0.2 mm/s.
7. The method for preparing the high-temperature abradable seal coating with the multi-level holes or the gradient Kong Nai based on the electrostatic field assisted term conversion as claimed in claim 1, wherein the ceramic powder layer-by-layer coating lubricating material feeding is sol-gelGlue, chemical coprecipitation, mechanochemical or physical coating; the method for preparing the ceramic powder layer-by-layer wrapped lubricating material by using the chemical coprecipitation method comprises the following steps: heat-treating the spray-granulated lubricating material feed at 300 ℃ for 3h, placing the heat-treated feed in deionized water, preparing a lubricating material suspension by magnetic stirring and ultrasonic dispersion, wherein the solubility of the suspension is 0.015g/mL, then fully mixing the suspension with 0.033mol/L zirconium oxychloride precursor solution according to the volume ratio of 1:1, adding ammonia water to adjust the pH value to 3.6, and forming Zr (OH) on the surface of the lubricating material at the moment 4 Aging, filtering, washing, drying at 110 deg.C for 24 hr, and heat treating at 500 deg.C for 3 hr to remove Zr (OH) from the surface of the lubricating material 4 Conversion to ZrO 2 To obtain ZrO 2 Coating a lubricating material layer by layer; the preparation method of the layer-by-layer wrapped lubricating material by using a mechanochemical or physical wrapping method comprises the following specific steps: dissolving the lubricating material feed subjected to spray granulation in 200ml of tris-hydrochloric acid solution, stirring in a water bath at 30 ℃ for 10min, and mixing the lubricating material feed with the lubricating material in a mass ratio of 1:1 nano ZrO 2 Dissolving in 20g/L dopamine solution, adding 20ml ZrO 2 Titrating the dopamine mixed solution to a lubricating material and tris-hydrochloric acid mixed solution, stirring the titrated mixed solution in water bath at 30 ℃ for 24 hours, aging, filtering, cleaning the feed, and drying at room temperature to obtain ZrO 2 Coating a lubricating material layer by layer; the lubricating material is one or more of h-BN, fluoride, alkaline earth chromate, sulfate and molybdate; the fluoride is one or a mixture of more of barium fluoride, lanthanum fluoride, cerium fluoride and calcium fluoride; the alkaline earth chromate is one or a mixture of barium chromate and strontium chromate; the sulfate is one or a mixture of more of barium sulfate, calcium sulfate and strontium sulfate; the molybdate is one or a mixture of silver molybdate, copper molybdate and cesium molybdate.
8. The method for preparing the Kong Nai high temperature abradable seal coating with multi-level holes or gradients based on electrostatic field assisted term conversion as claimed in claim 5 or 6, wherein the ceramic powder is rare earth stabilized zirconia, rare earth stabilized hafnium oxide, rare earth chromate, rare earth cerate, rare earth tantalate, rare earth niobate; the rare earth stabilized zirconia and the rare earth stabilized hafnium oxide are one or a mixture of more of lanthanum oxide, cerium oxide, yttrium oxide, ytterbium oxide, dysprosium oxide, holmium oxide stabilized zirconia and hafnium oxide; the rare earth chromate is one or a mixture of more of chromic acid, cerium chromate, praseodymium chromate and neodymium chromate; the rare earth cerate is one or a mixture of more of dysprosium cerate, yttrium cerate and lanthanum cerate; the rare earth tantalate is one or a mixture of more of ytterbium tantalate, yttrium tantalate, erbium tantalate, gadolinium tantalate, lanthanum tantalate and lutetium tantalate; the rare earth niobate is one or a mixture of more of yttrium niobate, neodymium niobate, europium niobate, erbium niobate, holmium niobate and lanthanum niobate.
9. The method for preparing the high-temperature abradable seal coating with the multi-level holes or the gradient Kong Nai based on the electrostatic field auxiliary term conversion as claimed in claim 1, wherein the spray granulation dense ceramic feed, the porous ceramic feed, the short-acting filling material feed and the ceramic powder layer-by-layer coating lubricating material feed are uniformly mixed in the third step to obtain abradable seal coating powder; the short-acting filling material feed is pyrolyzed in the thermal spraying process or removed in the subsequent thermal treatment, the feed is sprayed to the surface of the base material in a molten or semi-molten state in the thermal spraying process, sputtering-shaped micropores are formed in the coating, the size of the pores is 5-20 mu m, and the content of the micropores is 10-20%; the porous ceramic feed melts the ceramic shell in the plasma flame flow and keeps the internal pore structure of the powder unchanged, and aggregated round or radial nano-pores with the size of 200 nm-800 nm and the content of 5-15 percent are formed in the coating; in the third step, the wearable sealing coating can contain micro-nano hierarchical holes through one-step preparation.
10. The method for preparing the high-temperature abradable seal coating with the multistage holes or the gradient Kong Nai based on the electrostatic field auxiliary term conversion as claimed in claim 1, wherein the high-temperature abradable seal coating with the gradient holes can be prepared by changing the mass ratio of the porous ceramic feed to the fugitive filling material feed in the third step and spraying the abradable seal coating powder on the surface of the substrate with the bonding layer on the surface for multiple times; and in the third step, the mass ratio of the porous ceramic feed to the short-acting filling material feed is changed, and the powder feeding speed is changed for many times to spray the abradable seal coating powder on the surface of the base material with the bonding layer on the surface, so that the high-temperature abradable seal coating with the gradient holes can be prepared.
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