CN115747795A - Thermal barrier coating bonding layer with long service life and preparation method thereof - Google Patents
Thermal barrier coating bonding layer with long service life and preparation method thereof Download PDFInfo
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- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
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Abstract
The invention discloses a thermal barrier coating bonding layer with long service life and a preparation method thereof. According to the invention, the distribution form of the rare earth element in the bonding layer is regulated and controlled by a short-pulse-width, low-energy and multiple-irradiation high-current pulse electron beam technology, so that the rare earth element forms rare earth enriched nano dispersed particles, and the bonding layer in which the rare earth element is uniformly distributed in the form of the enriched nano particles is obtained, thereby overcoming the defect that the oxidation resistance is unfavorable due to uneven distribution or easy agglomeration in the form of oxides of the rare earth element in the bonding layer, and having important significance for improving the high-temperature oxidation resistance of the thermal barrier coating.
Description
Technical Field
The invention belongs to the technical field of surface modification, and particularly relates to a thermal barrier coating bonding layer with a long service life and a preparation method thereof.
Background
Thermal Barrier Coating (TBC) is widely used in aircraft engines and gas turbines due to its high Thermal insulation and oxidation resistance. Conventional TBCs are dual layer structures consisting of a top ceramic layer + a bottom MCrAlY (M is Ni, co or Ni + Co) bond coat. Under high temperature environment, a Thermal Growth Oxide (TGO) layer is formed at the MCrAlY interface, which is a key factor influencing the thermodynamic performance and durability of the TBC. The ideal TGO is composed of continuous, dense and slowly growing alpha-Al 2 O 3 A structure having a shielding ability against element diffusion, good adhesion, and less volume change at the time of transition. But in a severe service environment, al in an ideal state 2 O 3 It is difficult to stabilize growth, and as oxidation time continues and thermal stress continues to build up, stress build-up within the oxide film can cause changes in the form and composition of the TGO, and can gradually crack, flake, and ultimately lead to failure of the coating.
Currently, the hot spraying technology for preparing the bonding layer is most widely applied to aeroengines. The thermal spraying technology mainly comprises low-pressure plasma spraying (LPPS) and high-velocity oxygen gas (HVOF), bonding layers prepared by the two technologies have high compactness and good high-temperature oxidation resistance, but the surfaces of the bonding layers prepared by the two technologies have high surface roughness, and the components of the prepared bonding layers cannot be completely uniformly distributed.
In order to further improve the high-temperature oxidation resistance of the bonding layer, researchers begin to develop six-element and seven-element bonding layers, namely, the bonding layers are mainly added with trace rare earth active elements. In the bonding layer, rare earth elements are very important, wherein the rare earth elements represented by Y can improve the adhesion of TGO and reduce the growth rate of TGO, thereby improving the high-temperature oxidation resistance and the hot corrosion resistance of the bonding layer. In addition, ta, si, hf and other elements are often added to promote Al 2 O 3 Nucleation rate and improved adhesion. But for the bonding layer, the distribution of the doped rare earth elements is not controllable, and if the rare earth elements are added excessively, a segregation phenomenon can be generated; and because the rare earth elements have strong oxygen affinity, the rare earth elements mostly exist in the form of oxides, if the service temperature is too high or the heat preservation time is too long, the oxides are easy to further form complex oxides, once the oxides are aggregated, the rare earth element effect is lost, the oxide film is caused to grow rapidly, and the deterioration effect on the bonding layer is realized.
Application publication No. CN108396278A discloses a long-life MCrAlY coating, a preparation method and application thereof in hot end parts, wherein the long-life MCrAlY coating is prepared by adopting a diffusion Y-infiltration technology, and Y in the coating is a high-stability intermetallic compound M 5 Y is present in the form of M 5 Y realizes the stable supply of Y in the coating, avoids the rapid oxidation of Y, further improves the thermal stability of the coating and prolongs the service life of the coating. Although the existing form of the original coating Y element is changed, the distribution of the Y element is not uniform and is not controllable in microstructure.
Application publication No. CN102719782A discloses a treatment method for improving oxidation resistance of a bonding layer of a thermal barrier coating, which adopts a long pulse width of 50-200 mus and a pulse width of 8-18J/cm 2 The MCrAlY bonding layer is sprayed by irradiating plasma by a high-energy-density electron beam technology, so that the surface roughness of the coating is reduced, the pores and holes of the coating are reduced, and the oxidation resistance of the coating is effectively improved. However, the technology only reduces the surface roughness of the coating, forms a compact melting layer, has a certain effect on improving the oxidation resistance of the coating, but has a limited modification effect, and does not mention a fine grain effect and an element regulation effect because of larger pulse width and longer remelting time. For MCrAlY series bonding layers, the higher the service temperature is, the more serious the element diffusion is, and the defects that the rare earth elements are aggregated and form oxides to cause the reduction of the high-temperature oxidation resistance of the bonding layers still exist.
Disclosure of Invention
Based on the technical problems, the invention provides a thermal barrier coating bonding layer with long service life and a preparation method thereof, the distribution form of rare earth elements in the bonding layer is regulated and controlled by a high-current pulse electron beam technology with short pulse width, low energy and multiple times of irradiation, so that the rare earth elements form rare earth enriched nano-dispersed particles, and the bonding layer in which the rare earth elements are uniformly distributed in the form of enriched nano-particles is obtained, thereby overcoming the defect that the oxidation resistance is unfavorable because the rare earth elements in the bonding layer are unevenly distributed or are easily agglomerated in the form of oxides, and having important significance for improving the high-temperature oxidation resistance of the thermal barrier coating.
The invention provides a thermal barrier coating bonding layer with a long service life.
The rare earth elements in the bonding layer form Al-Y enriched nano particles, and the Al-Y enriched nano particles are uniformly distributed in the coating and can be used as Al 2 O 3 The nucleation sites effectively promote the rapid formation of the oxide film and anchor Al through the nano oxide pins which are dispersed and distributed 2 O 3 The method reduces oxide film wrinkles, slows down the growth rate of oxides, avoids local rapid oxidation of rare earth elements such as Y and the like, effectively improves the thermal stability of the bonding layer, and prolongs the high service life of the thermal barrier coating.
Preferably, in the MCrAlY or MCrAlYX bonding layer, M is one of Ni or Co, and X is at least one of Ta, si, hf, zr; preferably, X is Ta.
When X in the MCrAlYX bonding layer is Ta, not only can the 'active element effect' be exerted, but also Ta elements are uniformly distributed in a form of enriched nano particles, and the bonding layer with more excellent performance is obtained.
Preferably, the MCrAlY or MCrAlYX bond coat has a Y content of at least 0.8 wt.%.
Preferably, the enriched nanoparticles are Y-Al enriched nanoparticles.
The invention also provides a preparation method of the thermal barrier coating bonding layer with long service life, which comprises the following steps: after preparing the MCrAlY or MCrAlYX bonding layer on the surface of the matrix, the MCrAlY or MCrAlYX bonding layer is irradiated by adopting a pulsed electron beam process, so that the defect of uneven element distribution in the MCrAlY or MCrAlYX bonding layer is eliminated, the rare earth elements in the bonding layer are uniformly distributed in an enriched nanoparticle form, and the thermal barrier coating bonding layer with high service life is obtained.
In the invention, the MCrAlY or MCrAlYX bonding layer surface after the irradiation of the high-current pulse electron beam is remelted, so that the defects of surface roughness, microcracks and the like generated in the original bonding layer preparation process can be obviously eliminated, the surface roughness is reduced, the flattening is realized, the formation of the TGO with flatness and consistent thickness during the high-temperature oxidation period is facilitated, and the stress concentration area is eliminated; on a microscopic level, the remelting effect caused by the irradiation of the high-current pulse electron beams can cause the surface area to generate a modified state similar to quenching, and the rapid remelting and cooling processes (10) 7-9 K/s) initiates the massive formation of nano-crystals, and the accompanying stress also generates abundant micro-defects, which provides a channel for the selective diffusion of Al element in the oxidation stage; more importantly, the non-equilibrium solidification process initiated by electron beam irradiation in the remelting process can realize the regulation and control of the distribution and existence form of the rare earth elements, which is specifically represented as follows: after low-frequency electron beam irradiation modification, remelting and vaporization are generated on the surface of the bonding layer due to energy injection of electron beams, rare earth elements and aluminum elements in vaporized components are oxidized at a low vacuum degree due to high temperature and high activity, and are finally deposited on the surface of the coating again in the form of rare earth-aluminum oxide particles, and the content of the rare earth elements on the surface of the coating is remarkably improved by the redeposited particles; after modification by electron beam irradiation for a high number of times, re-deposited particles are repeatedly remelted and precipitated in the process of rapid cooling to form rare earth-enriched nano-dispersed particles densely distributed in the remelted layer, so that rare earth elements are uniformly diffused in depth; the obtained rare earth enriched nano-particle structure can effectively promote the rapid formation of compact TGO in the initial oxidation stage, and form rare earth oxide nails in the subsequent oxidation stage, thereby obviously improving the bonding force of TGO, reducing the growth rate of TGO, leading the obtained bonding layer to have excellent high-temperature oxidation resistance, and meeting the requirements of practical application of a thermal barrier coating of an aeroengine.
The invention is realized by a high-temperature oxidation resistance experiment and a thermal cycleThe experiment shows that the layer of rare earth enriched nano-dispersed particles regulated and controlled on the surface of the bonding layer by using pulsed electron beams can effectively promote the coating interface at the early stage of oxidation to quickly form a continuous and compact layer of Al 2 O 3 The protective film is uniformly distributed in the oxide film, the Y oxide pins with extremely small sizes are greatly improved in adhesion of the oxide film, and the high-temperature oxidation resistance and the heat corrosion resistance of the coating at 1100 ℃ and 1150 ℃ are improved by more than two times.
Preferably, the MCrAlY or MCrAlYX bonding layer is prepared on the surface of the matrix by adopting a low-pressure plasma spraying process.
The pulse electron beam technology is a self-quenching technology, can realize heating melting and even vaporization of a material surface layer, then quickly cool and solidify by relying on the self heat conduction of the material, and induce and form a series of physical and chemical processes, and because the temperature gradient induced by irradiation is extremely large, the processes belong to typical unstable processes, can induce and form a plurality of special metastable structures, but the modification effects of different bonding layers are greatly different: the surface of the bonding layer prepared by the atmospheric plasma spraying technology has too many pores and a lot of oxide inclusions, and in the irradiation process, because the internal gas overflows and the oxide is discharged, the surface polishing effect is difficult to realize, and Y-enriched nano-dispersed particles are difficult to induce the surface of the coating to form; the bonding layer prepared by the low-pressure plasma spraying technology is relatively compact, and the modification effect of the invention can be realized by reasonably controlling multiple processes in the irradiation process;
preferably, the MCrAlY or MCrAlYX bonding layer is irradiated multiple times using a short pulse width, low energy, multiple times pulsed electron beam process under vacuum.
Firstly, starting from the regulation of parameters of energy density and pulse width of a pulse electron beam, the energy density and the pulse width need to be controlled to be coordinated, if irradiation treatment is carried out by adopting higher energy density and long pulse width, the vaporization phenomenon on the surface of a bonding layer is aggravated, al element is consumed, and the solidification effect does not achieve the effect of uniformly separating out nano particles; secondly, starting with the regulation of the irradiation times of the pulsed electron beam, the method is important for the regulation of the rare earth enriched nano-dispersed particles: because the surface roughness of the bonding layer is relatively high, under low-frequency irradiation, the bonding layer in a relatively high convex area is firstly discharged and vaporized to form some vaporized particles to be deposited on the surface of the bonding layer again, but the surface of the bonding layer is not completely melted; with the increase of irradiation times, the bonding layer is continuously subjected to a melting-solidification accumulation process, the surface is continuously polished, some vaporized particles formed before are continuously melted into a liquid solution for redistribution, and Y element is low in solid solubility in a matrix, so that nano dispersed particles are easily separated out; however, once the irradiation frequency is too high, the surface layer vaporization phenomenon is aggravated again due to the action of heat accumulation on the surface of the coating, the surface of the bonding layer begins to have a fluctuated appearance, and the nano-dispersed particles gradually disappear.
Therefore, in the present invention, it is necessary to reasonably control the parameters of pulsed electron beam irradiation: researches show that the bonding layer is treated by low-energy, short-pulse-width and multi-time irradiation, the surface of the bonding layer has the most uniform Y-enriched nano-dispersed particles, and other rare earth elements are uniformly distributed in the coating substrate; rare earth-enriched nano-dispersed particles formed on the surface of the coating by induction under the action of pulsed electron beams can effectively improve the protective oxide film Al in the early oxidation stage 2 O 3 The nucleation rate promotes the rapid formation of the oxide film, and the stable growth of the surface of the coating after electron beam polishing is utilized, at the later stage of oxidation, the rare earth elements can form oxide nails with extremely small sizes, the adhesion of the oxide film is effectively pinned, the growth rate of the oxide film is reduced, so that the obtained bonding layer has excellent high-temperature oxidation resistance and thermal corrosion resistance, and the requirement of practical application of the thermal barrier coating of the aero-engine is met.
Preferably, the pulse width is 1-3 mus, the electron beam energy is 20-30keV, and the energy density is 3-10J/cm 2 The irradiation times are 5-40 times.
Preferably, the pulse width is 1.5 μ s, the electron beam energy is 27keV, and the energy density is 5-8J/cm 2 The irradiation times are 20-30 times.
The invention provides a thermal barrier coating bonding layer with long service life and a preparation method thereof, which particularly utilizes a low-pressure plasma process to prepare an MCrAlY or MCrAlYX bonding layer on the surface of a substrate, and then utilizes a short-pulse-width and low-energy pulse electron beam technology to carry out multiple irradiation treatment on the MCrAlY or MCrAlYX bonding layer, so that the surface roughness defect of the bonding layer is eliminated, a polished surface is formed, surface crystal grains are refined, the phenomenon of uneven distribution of elements in the bonding coating is eliminated, and rare earth elements are controlled to be uniformly distributed in the form of nano particles. The rare earth element enriched nano-dispersed particles formed in the bonding layer are uniformly distributed, so that the nucleation rate of the protective oxide film can be greatly increased, the adhesion of the protective oxide film can be effectively improved, and the high-temperature oxidation resistance and the hot corrosion resistance of the coating can be improved by more than two times.
Aiming at the defects of the high-temperature protective coating in the prior art, the invention uses a high-current pulse electron beam irradiation process to regulate and control the distribution form of rare earth elements in the MCrAlY or MCrAlYX bonding layer from a modification process, improves the service performance of the thermal barrier coating, not only eliminates the surface defects of the bonding layer, but also effectively regulates and controls the distribution form of the additive elements near the surface layer of the bonding layer, particularly can obtain Y-element-enriched nano-dispersed particles, and has very important significance for improving the high-temperature oxidation resistance of the bonding layer.
Drawings
FIG. 1 is a graphical representation of a pristine NiCrAlY bond coat as described in examples 1-2 of the present invention;
FIG. 2 is a TEM morphology and active element Y distribution plot of a pristine NiCrAlY bond coat as described in examples 1-2 of the present invention;
FIG. 3 is a 5J/cm drawing of example 2 of the present invention 2 The electron beam energy density irradiation modifies the TEM morphology of the NiCrAlY bonding layer and the distribution diagram of the active element Y;
FIG. 4 is a graph showing the morphology of the oxide film after the high temperature oxidation of the original NiCoCrAlYTa bonding layer in example 3 of the present invention;
FIG. 5 is a graph showing the appearance of the oxide film after the irradiation modification of the NiCoCrAlYTa bonding layer is oxidized at high temperature in example 3 of the present invention.
Detailed Description
The present invention will be described in detail with reference to specific examples, but these examples should be explicitly mentioned for illustration, but should not be construed as limiting the scope of the present invention.
Example 1
The embodiment provides a preparation method of a thermal barrier coating bonding layer with long service life, which comprises the following steps:
(1) Grinding and polishing the surface of the high-temperature alloy matrix, performing ultrasonic cleaning by using acetone and alcohol to remove oil stains, and performing sand blasting treatment on the high-temperature alloy matrix to obtain a pretreated high-temperature alloy matrix;
(2) Preparing an original NiCrAlY bonding layer on the surface of the pretreated high-temperature alloy substrate by adopting a low-pressure plasma spraying process, and selecting spraying parameters according to the preparation requirements of the bonding layer: the current is 1700A, the voltage is 55V, the power is 86kw, the powder feeding speed is 35g/min, and the spray distance is 500mm;
(3) Under the vacuum condition, the original NiCrAlY bonding layer is subjected to irradiation treatment by adopting a pulse electron beam process, and irradiation parameters are selected according to the irradiation modification requirement of the bonding layer: vacuum degree P is less than or equal to 5 multiplied by 10 -3 Pa, electron beam energy of 27KeV, pulse width of 1.5 μ s, and energy density of 5J/cm 2 And bombarding for 10, 20, 30 and 40 times to obtain irradiation modified NiCrAlY bonding layers with different times, namely the thermal barrier coating bonding layer with the long service life.
Observing the original NiCrAlY bonding layer by using a three-dimensional confocal microscope to obtain a morphology diagram of the original NiCrAlY bonding layer shown in figure 1 in the embodiment 1 of the invention; referring to FIG. 1, the surface roughness of the original NiCrAlY bonding layer is as high as 8 μm, while the surface roughness of the NiCrAlY bonding layer modified by irradiation for different times is greatly reduced, namely 3.5 μm (10 times), 2.0 μm (20 times), 1.3 μm (30 times) and 2.9 μm (40 times), respectively;
the original NiCrAlY bonding layer and the irradiation modified NiCrAlY bonding layer with different times are observed by a scanning electron beam microscope, so that the original NiCrAlY bonding layer is rough and uneven in surface and has more unmelted large particles, in the irradiation modified NiCrAlY bonding layer with different times, 10 times of irradiation modified bonding layer is not completely melted, 20 times and 30 times of irradiation modified bonding layer are completely melted, the polishing effect is good, obvious nano crystal grains can be observed on the surface, the surface of the irradiation modified bonding layer with 40 times of irradiation has fluctuated appearance, and more vaporized particles are deposited on the surface; the surface of the bonding layer is not completely melted under low-frequency irradiation, the surface of the bonding layer is continuously polished and leveled along with the increase of the irradiation frequency, but when the irradiation frequency is too high, the surface vaporization is aggravated, and the Al element damage phenomenon is caused.
The original NiCrAlY bonding layer and the surface melting layer of the irradiation modified NiCrAlY bonding layer with different times are analyzed in detail by using a transmission electron microscope, and the TEM morphology and the active element Y distribution diagram of the original NiCrAlY bonding layer in the embodiment 1 of the invention shown in figure 2 are obtained. As shown in FIG. 2, the distribution of elements within the original NiCrAlY bond coat is very uneven; in the irradiation modified NiCrAlY bonding layer for different times, nanoparticles in the irradiation modified bonding layer for 10 times are not obvious, nanoparticles can be formed in the irradiation modified bonding layer for 20 times and 30 times, the size of the nanoparticles is gradually reduced along with the increase of the irradiation times, and the number of the nanoparticles on the surface of the irradiation modified bonding layer for 40 times is reduced;
and then the original NiCrAlY bonding layer and the irradiation modified NiCrAlY bonding layer with different times are respectively subjected to 1150-DEG C high-temperature oxidation resistance performance test, and the result shows that in the initial oxidation stage, the surface of the original NiCrAlY bonding layer can form continuous Al 2 O 3 An oxide film is doped with a small amount of mixed oxide, and the wrinkle phenomenon of the oxide film is serious; the surface of the NiCrAlY bonding layer modified by irradiation for different times can form a continuous and compact Al layer 2 O 3 A protective film; in the later oxidation stage, the oxide film of the original NiCrAlY bonding layer is seriously peeled off, the internal oxidation is serious, and the coating fails; the surface oxide films of the irradiation modified NiCrAlY bonding layers at different times are continuously compact, wherein the content of mixed oxides in the oxide films of the irradiation modified bonding layers at 10 times is higher, a small amount of internal oxidation occurs locally, the oxide films of the irradiation modified bonding layers at 20 times and 30 times are the most compact, the internal oxidation and the oxide film peeling phenomenon are not seen, the thickness of the oxide film on the surface of the irradiation modified bonding layer at 30 times is the thinnest, and the small-area peeling occurs locally on the oxide film of the irradiation modified bonding layer at 40 times; in contrast, 30 irradiation modified tie layer oxidation resistanceOptimally, the oxidation resistance of the bonding layer is improved by more than 2 times.
Example 2
The embodiment provides a preparation method of a thermal barrier coating bonding layer with long service life, which comprises the following steps:
(1) Grinding and polishing the surface of the high-temperature alloy matrix, performing ultrasonic cleaning by using acetone and alcohol to remove oil stains, and performing sand blasting treatment on the high-temperature alloy matrix to obtain a pretreated high-temperature alloy matrix;
(2) Preparing an original NiCrAlY bonding layer on the surface of the pretreated high-temperature alloy substrate by adopting a low-pressure plasma spraying process, and selecting spraying parameters according to the preparation requirements of the bonding layer: the current is 1700A, the voltage is 55V, the power is 86kw, the powder feeding speed is 35g/min, and the spray distance is 500mm;
(3) Under the vacuum condition, adopting a pulse electron beam process to carry out irradiation treatment on the original NiCrAlY bonding layer, and selecting irradiation parameters according to the irradiation modification requirement of the bonding layer: vacuum degree P is less than or equal to 5 multiplied by 10 -3 Pa, electron beam energy of 27KeV, pulse width of 1.5 μ s, bombardment times of 24 times, and energy density of 3, 5, 8, and 10J/cm 2 Obtaining different electron beam energy density irradiation modified NiCrAlY bonding layers, namely the thermal barrier coating bonding layer with high service life;
observing the original NiCrAlY bonding layer by using a three-dimensional confocal microscope to obtain a morphology diagram of the original NiCrAlY bonding layer shown in figure 1 in the embodiment 2 of the invention; referring to FIG. 1, it can be seen that the surface roughness of the original NiCrAlY bonding layer is as high as 8 μm, while the surface roughness of the NiCrAlY bonding layer modified by electron beam irradiation with different energy densities is greatly reduced, and is respectively 2.4 μm (3J/cm) 2 )、2.0μm(5J/cm 2 )、1.6μm(8J/cm 2 )、2.8μm(10J/cm 2 )；
The original NiCrAlY bonding layer and the modified NiCrAlY bonding layer irradiated by electron beams with different energy densities are observed by adopting a scanning electron beam microscope, so that the original NiCrAlY bonding layer is rough and uneven in surface and has more unmelted large particles, and in the modified NiCrAlY bonding layer irradiated by the electron beams with different energy densities, the thickness of the modified NiCrAlY bonding layer is 3J/cm 2 The surface of the energy density electron beam irradiation modified bonding layer is not completely melted, 5J/cm 2 And 8J/cm 2 The surface of the energy density electron beam irradiation modified bonding layer is thoroughly melted and has good polishing effect, and obvious nano grains can be observed on the surface, 10J/cm 2 The surface of the modified bonding layer is completely melted by the irradiation of the energy density electron beam, but the surface layer has more vaporization deposition particles which fluctuate and are uneven; explanation of 3J/cm 2 The energy density is too low, the surface of the coating is not completely melted, and the melting rate is 10J/cm 2 The energy density is too high, and the surface of the bonding layer has obvious vaporization phenomenon;
the original NiCrAlY bonding layer and the surface melting layer of the modified NiCrAlY bonding layer irradiated by different electron beam energy densities are analyzed in detail by using a transmission electron microscope to obtain a TEM morphology and activity Y element distribution diagram of the original NiCrAlY bonding layer in the embodiment 2 of the invention shown in the figure 2 and a 5J/cm element distribution diagram of the original NiCrAlY bonding layer in the embodiment 2 of the invention shown in the figure 3 2 The electron beam energy density irradiation modifies the TEM appearance and the active element Y distribution diagram of the NiCrAlY bonding layer; referring to FIG. 2, the distribution of elements in the original NiCrAlY bond coat is very uneven, and no obvious Y-enriched particles are seen; referring to FIG. 3, it can be seen that in the modified NiCrAlY bonding layer by electron beam irradiation with different energy densities, 3J/cm 2 The nano particles in the energy density electron beam irradiation modified bonding layer are not obvious, 5J/cm 2 、8J/cm 2 And 10J/cm 2 The energy density electron beam irradiation modified bonding layer can form nano particles, and the size of the nano particles is gradually reduced along with the increase of energy, 10J/cm 2 The quantity of the nanoparticles on the surface of the modified bonding layer irradiated by the energy density electron beam is reduced;
and then the original NiCrAlY bonding layer and the modified NiCrAlY bonding layer irradiated by electron beams with different energy densities are respectively subjected to 1150-DEG C high-temperature oxidation resistance test, and the result shows that in the initial oxidation stage, the surface of the original NiCrAlY bonding layer can form continuous Al 2 O 3 An oxide film is doped with a small amount of mixed oxide, and the wrinkle phenomenon of the oxide film is serious; the surfaces of the NiCrAlY bonding layers modified by electron beam irradiation with different energy densities can form a layer of continuous and compact Al 2 O 3 A protective film; oxygen gasIn the later period of the formation, the oxide film of the original NiCrAlY bonding layer is seriously peeled off, the internal oxidation is serious, and the coating fails; the surface oxide film of the NiCrAlY bonding layer modified by electron beam irradiation with different energy densities is still continuously compact, wherein the thickness of the oxide film is 3J/cm 2 The content of mixed oxide in the energy density electron beam irradiation modified bonding layer oxide film is higher, a small amount of internal oxidation appears locally, and the thickness is 5J/cm 2 And 8J/cm 2 The oxide film of the bonding layer modified by the irradiation of the energy density electron beam is the most compact, has no internal oxidation and oxide film peeling phenomenon, and is 10J/cm 2 The energy density electron beam irradiates the modified bonding layer oxide film to locally peel off in a small area; in contrast, 5J/cm 2 And 8J/cm 2 The energy density electron beam irradiation modified bonding layer has optimal oxidation resistance, and the oxidation resistance of the bonding layer is improved by more than 1.5 times.
Example 3
The embodiment provides a preparation method of a thermal barrier coating bonding layer with long service life, which comprises the following steps:
(1) Grinding and polishing the surface of the high-temperature alloy matrix, performing ultrasonic cleaning by using acetone and alcohol to remove oil stains, and performing sand blasting treatment on the high-temperature alloy matrix to obtain a pretreated high-temperature alloy matrix;
(2) Preparing an original NiCoCrAlYTa bonding layer on the surface of the pretreated high-temperature alloy substrate by adopting a low-pressure plasma spraying process, and selecting spraying parameters according to the preparation requirements of the bonding layer: the current is 1700A, the voltage is 55V, the power is 86kw, the powder feeding rate is 35g/min, and the spray distance is 500mm;
(3) Under the vacuum condition, adopting a pulse electron beam process to carry out irradiation treatment on the original NiCoCrAlYTa bonding layer, and selecting irradiation parameters according to the irradiation modification requirement of the bonding layer: vacuum degree P is less than or equal to 5 multiplied by 10 -3 Pa, electron beam energy of 27KeV, pulse width of 1.5 μ s, and energy density of 8J/cm 2 And bombarding for 30 times to obtain the irradiation modified NiCoCrAlYTa bonding layer, namely the thermal barrier coating bonding layer with the long service life.
Observing the original NiCoCrAlYTa bonding layer by using a three-dimensional confocal microscope, wherein the surface roughness of the original NiCoCrAlYTa bonding layer is as high as 7.8 mu m, and the surface roughness of the irradiation modified NiCoCrAlYTa bonding layer is greatly reduced and is only 1.28 mu m;
the original NiCoCrAlYTa bonding layer and the irradiation modified NiCoCrAlYTa bonding layer are observed by adopting a scanning electron beam microscope, so that the original NiCoCrAlYTa bonding layer is rough and uneven in surface and has more unmelted large particles, the surface of the irradiation modified NiCrAlYTa bonding layer is melted completely, the polishing effect is good, obvious nano crystal grains can be observed on the surface, and obvious vaporization is not seen; the interface of the original NiCoCrAlYTa bonding layer presents a layered structure, the Ta element aggregation phenomenon locally appears, the irradiation modified NiCrAlY bonding layer forms a melting layer with the thickness of about 10 mu m, and the element segregation phenomenon is not seen in the melting layer;
through the detailed analysis of the surface layer melting layers of the original NiCoCrAlYTa bonding layer and the irradiation modified NiCoCrAlYTa bonding layer by using a transmission electron microscope, the fact that the elements in the original NiCoCrAlYTa bonding layer are distributed very unevenly and form clustered substances locally, the irradiation modified NiCoCrAlYTa bonding layer forms Y-enriched nano-dispersed particles which are distributed evenly, and the distribution of Ta elements is also very even is known.
Then, the original NiCoCrAlYTa bonding layer and the irradiation modified NiCoCrAlYTa bonding layer are respectively subjected to high temperature oxidation resistance test to obtain a morphology diagram of an oxide film at the 1150 ℃ high temperature oxidation initial stage of the original NiCoCrAlYTa bonding layer in the embodiment 3 of the invention shown in FIG. 4 and a morphology diagram of an oxide film at the 1150 ℃ high temperature oxidation initial stage of the irradiation modified NiCoCrAlYTa bonding layer in the embodiment 3 of the invention shown in FIG. 5; referring to FIGS. 4 and 5, it is understood that continuous Al can be formed on the surface of the original NiCoCrAlYTa bonding layer at the initial stage of oxidation 2 O 3 The oxide film, but a large area of Ta segregation region (shown by the dotted frame and the arrow in FIG. 4) appears in the oxide film, and the wrinkle phenomenon of the oxide film is serious, and the surface of the irradiation modified NiCoCrAlYTa bonding layer can form a continuous and compact Al layer 2 O 3 The protective film (the position TGO shown by the arrow in figure 5 is relatively flat, the position of the virtual frame shows that only a trace amount of Ta is deviated), and the oxidation resistance of the irradiation modified NiCoCrAlYTa bonding layer is improved by more than 2 times.
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art should be considered to be within the technical scope of the present invention, and the technical solutions and the inventive concepts thereof according to the present invention should be equivalent or changed within the scope of the present invention.
Claims (9)
1. The thermal barrier coating bonding layer with the long service life is characterized in that the bonding layer is an MCrAlY or MCrAlYX bonding layer, and rare earth elements in the bonding layer are uniformly distributed in an enriched nanoparticle form.
2. The high service life thermal barrier coating bond coat as defined in claim 1, wherein in the MCrAlY or MCrAlYX bond coat, M is at least one of Ni or Co, and X is at least one of Ta, si, hf, zr; preferably, X is Ta.
3. The high life in service thermal barrier coating bond coat as claimed in claim 1 or 2, wherein the MCrAlY or MCrAlYX bond coat has a Y content of at least 0.8 wt.%.
4. The high life in service thermal barrier coating bond coat of any of claims 1-3, wherein the enriched nanoparticles are Y-Al enriched nanoparticles.
5. A method of forming a high service life thermal barrier coating bond coat as claimed in any of claims 1 to 4 comprising: after preparing the MCrAlY or MCrAlYX bonding layer on the surface of the matrix, the MCrAlY or MCrAlYX bonding layer is irradiated by adopting a pulsed electron beam process, so that the defect of uneven element distribution in the MCrAlY or MCrAlYX bonding layer is eliminated, the rare earth elements in the bonding layer are uniformly distributed in an enriched nanoparticle form, and the thermal barrier coating bonding layer with high service life is obtained.
6. The method for preparing a thermal barrier coating bonding layer with long service life according to claim 5, wherein a MCrAlY or MCrAlYX bonding layer is prepared on the surface of a substrate by a low-pressure plasma spraying process.
7. The method for preparing a high-service-life thermal barrier coating bonding layer according to claim 5 or 6, wherein the MCrAlY or MCrAlYX bonding layer is subjected to multiple irradiation treatments under a vacuum condition by using a short-pulse-width low-energy pulsed electron beam process.
8. The method of claim 7, wherein the pulse width is 1-3 μ s, the electron beam energy is 20-30keV, and the energy density is 3-10J/cm 2 The irradiation times are 5-40 times.
9. The method of claim 8, wherein the pulse width is 1.5 μ s, the electron beam energy is 27keV, and the energy density is 5-8J/cm 2 The irradiation times are 20-30 times.
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