CN116029086A - Service life control method of powder embedded aluminized coating - Google Patents
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Abstract
A service life control method of a powder embedded aluminized coating belongs to the technical field of coating service life control and overcomes the defect that the service life control of the aluminized coating cannot be realized in the prior art. The service life control method of the powder embedded aluminized coating comprises the following steps: step 1, preparing an aluminized test piece with initial coating thicknesses H1 and H2; step 2, fitting to obtain total quantity S of two aluminized test pieces Al 0 1、S 0 2; step 3, performing a high-temperature steam oxidation experiment under the condition of T1; step 4, fitting to obtain diffusion coefficients D1 and eta 1 of the aluminized test piece with the initial thickness H1 of the coating under T1; and/or fittingObtaining a diffusion coefficient D2 and eta 2 of an aluminized test piece with the initial thickness H2 of the coating under T1; step 5, calculating to obtain values of a and b; step 6, substituting D1 or D2 into the formula (1), and calculating to obtain S 0 The method comprises the steps of carrying out a first treatment on the surface of the Step 7, calculating to obtain the initial thickness H0 of the aluminized coating required by the coating reaching the target service life at the temperature T1; and 8, preparing an aluminized test piece with the initial thickness of the coating being more than or equal to H0.
Description
Technical Field
The invention belongs to the technical field of coating life control, and particularly relates to a life control method of a powder embedded aluminized coating.
Background
The heating surface of the boiler (water-cooled wall, superheater, reheater and economizer, also called as four pipes of boiler) is a key component in the boiler for recovering energy of coal-fired flue gas, heating steam and realizing energy conversion. Among failure reasons of four pipes of the high-parameter power station boiler, flue gas corrosion caused by pulverized coal combustion outside the furnace tube and high-temperature steam oxidation corrosion inside the furnace tube play an important role, and are also one of essential reasons for causing boiler explosion and leakage accidents. The development of high steam parameters and high efficiency of the thermal power plant unit makes the service condition of the boiler tube more complex and harsh, and the service performance of the material used under higher requirements also needs to be further improved.
The surface modification technology is a technology for strengthening the surface of a part or a material by changing the chemical composition or the structure of the surface of the material or the workpiece, and can improve the high-temperature oxidation corrosion performance of the high-temperature alloy. Compared with the development of a higher-grade heating surface material, the surface modification technology can obviously improve the oxidation resistance and corrosion resistance of the boiler tube on the basis of not reducing the mechanical property of the alloy matrix, not only solves the oxidation/corrosion problem of the alloy of the boiler tube in service, but also provides technical support for the unit with higher parameters for the continuous service of the material in service.
The aluminum coating technology is an economic and effective way capable of obviously improving the high-temperature oxidation resistance of the matrix without changing the mechanical properties of the matrix, is widely applied in the aerospace field at present, and has excellent oxidation resistance after the key parts of the gas turbine use the aluminum coating, and can be operated for thousands of hours at the temperature of more than 900 ℃. The excellent protection of aluminide coatings results from the slow growth of oxide films, whereas the growth of alumina is temperature dependent, and when the temperature is reduced by 200 ℃, the growth of alumina can be reduced by several orders of magnitude, so that the application of aluminide coatings to lower temperature (< 700 ℃) utility boiler tubes will have a significantly prolonged service life. The low-temperature aluminizing has lower diffusion rate, can obtain thinner coating, and has no brittle phase precipitation, so that the steam oxidation performance can be obviously changed on the basis of not changing the structure and mechanical property of the matrix material.
The P92-Al coating has good oxidation resistance. This is mainly because the water vapor is selectively oxidized with Al element in the coating layer at the initial stage of oxidation to form a single-molecule oxide film, and then the film growth is realized by electrochemical reaction, and the growth speed is slow, and the Al element is not completely oxidized into Al 2 O 3 . In one aspect, al is formed 2 O 3 The film can reduce the diffusion coefficient; on the other hand, the incompletely oxidized aluminum-rich layer can also continue to generate Al for the alloy 2 O 3 The film provides a sufficient source of Al such that the P92-Al coating has excellent vapor oxidation resistance.
It is generally believed that the failure mechanism of aluminide coatings under high temperature conditions consists essentially of the following: a. the oxide film is peeled off, and Al element is diffused outwards to form new Al 2 O 3 A membrane; b. inter-diffusion with the substrate. When the P92-Al coating is steamed at 650 DEG CUnder oxidation, the surface is rapidly formed with a layer of protective Al 2 O 3 Film, although at a lower temperature, al 2 O 3 The film still had good adhesion and no peeling occurred during the test. This causes the degradation mechanism of the aluminide coating to manifest itself primarily as Al in-diffusion. In the current numerous aluminized coating preparation processes, the service life control of the aluminized coating cannot be realized. The research of the invention plays a crucial decisive role in the preparation process of the coating.
Disclosure of Invention
Therefore, the technical problem to be solved by the invention is to overcome the defect that the service life control of the aluminized coating cannot be realized in the prior art, thereby providing a service life control method of the powder embedded aluminized coating.
For this purpose, the invention provides the following technical scheme.
A method for controlling the lifetime of a powder embedded aluminized coating comprising the steps of:
step 1, preparing an aluminized test piece with initial coating thicknesses H1 and H2;
step 2, coating meets the following relation:
wherein x is the depth of a certain position in the coating from the surface of the coating, C is the mass percent content of aluminum at the position x in the coating, D is the diffusion coefficient, t is the oxidation time, S is the total amount of Al in the coating, and eta is the calibration displacement of the Gaussian distribution center;
respectively obtaining the mass percentages of aluminum at different x positions of the aluminized test pieces with the initial thicknesses H1 and H2 of the coating prepared in the step 1; substituting the data obtained in the step into formula (1), and fitting to obtain total amount S of two aluminized test pieces Al 0 1、S 0 2；
Step 3, performing a high-temperature steam oxidation experiment on the aluminized test pieces with the initial thicknesses H1 and H2 of the prepared coating at the temperature T1;
step 4, obtaining the mass percentages of aluminum at different x positions in the coating when the aluminized test piece is oxidized for time T at the temperature of T1 according to the step 3; substituting the data obtained in the step into a formula (1), and fitting to obtain diffusion coefficients D1 and eta 1 of an aluminized test piece with the initial thickness H1 of the coating under T1; and/or fitting to obtain diffusion coefficients D2 and eta 2 of the aluminized test piece with the initial thickness H2 of the coating under T1;
step 4, the total amount S of Al in the coating meets the following conditions:
s=ah+b type (2)
Wherein a and b are constants related to the aluminized coating;
h1 and S 0 1, H2, S 0 2 is substituted into the formula (2), and the values of a and b are obtained through calculation;
step 5, substituting D1 or D2 into the formula (1), taking C to form the critical content of alumina, taking eta to be the value corresponding to D1 or D2, taking x to be 0 and t to be the target life of the coating, and calculating to obtain S 0 ；
Step 6, S is 0 Substituting the initial thickness H0 of the aluminized coating required by the target service life of the coating at the temperature T1 is calculated and obtained in the step (2);
and 7, preparing an aluminized test piece with the initial thickness of the coating being more than or equal to H0.
Further, the step 1 includes:
s101, degreasing and derusting a test piece to be aluminized, burying the test piece to be aluminized into a powder tank with aluminized powder, and compacting;
s102, placing the compacted powder tank into a heat treatment furnace, and sintering in a protective gas atmosphere;
s103, cooling to room temperature along with the furnace to obtain an aluminized test piece.
Further, in S101, the aluminized powder includes FeAl powder and a penetration enhancer.
Further, the permeation promoter is NH 4 Cl。
Further, the mass ratio of iron to aluminum in the FeAl powder is 1:1.
Further, the mass ratio of the FeAl powder to the permeation assisting agent is 99:1.
Further, in S102, the sintering condition is 640-780 ℃ sintering for 4-8 hours.
Further, the shielding gas is argon.
Further, the high-temperature steam oxidation experimental conditions in the step 2 are as follows: dynamic 100% saturated steam with pressure of 0.1-30 MPa and steam flow rate of 100-120ml/s.
Analyzing the original thickness of the aluminized coating and the diffusion depth of the aluminized coating under different oxidation time by adopting a Scanning Electron Microscope (SEM), and analyzing the components of the aluminized coating at different depth positions by adopting an energy spectrometer.
The technical scheme of the invention has the following advantages:
according to the life control method of the powder embedded aluminized coating, the thickness of the coating in the target life can be predicted, so that the preparation process of the coating is controlled, the prepared material meets the use requirement, and the problem that the whole system cannot normally operate due to the fact that the service life of a pipe system is insufficient after the use is avoided. Meanwhile, the aluminizing process can be perfected, the production waste is avoided, the production cost is reduced, and the production efficiency and the economic benefit of enterprises are improved.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings that are needed in the description of the embodiments or the prior art will be briefly described, and it is obvious that the drawings in the description below are some embodiments of the present invention, and other drawings can be obtained according to the drawings without inventive effort for a person skilled in the art.
FIG. 1 is a scanning electron micrograph of an aluminized test piece having a coating thickness of 5 μm obtained in example 1.
FIG. 2 is a scanning electron micrograph of an aluminized test piece having a coating thickness of 30 μm obtained in example 1.
Detailed Description
The following examples are provided for a better understanding of the present invention and are not limited to the preferred embodiments described herein, but are not intended to limit the scope of the invention, any product which is the same or similar to the present invention, whether in light of the present teachings or in combination with other prior art features, falls within the scope of the present invention.
The specific experimental procedures or conditions are not noted in the examples and may be followed by the operations or conditions of conventional experimental procedures described in the literature in this field. The reagents or apparatus used were conventional reagent products commercially available without the manufacturer's knowledge.
Example 1
A method for controlling the lifetime of a powder embedded aluminized coating comprising the steps of:
step 1, preparing an aluminized test piece:
s101, degreasing and derusting a test piece to be aluminized, embedding aluminized powder according to the configuration of 99wt% FeAl powder and 1wt% permeation assisting agent, layering the pretreated test piece into a stainless steel tank, and compacting.
S102, placing the embedded test piece to be aluminized in a heat treatment furnace at 750 ℃, and sintering for 4 hours in an argon atmosphere to prepare the aluminized test piece with the coating thickness H1 of 30 mu m.
And placing the embedded test piece to be aluminized in a heat treatment furnace at 640 ℃, and sintering for 6 hours in an argon atmosphere to prepare the aluminized test piece with the coating thickness H2 of 5 mu m.
S103, cooling to room temperature along with the furnace, and taking out the test piece to finish the preparation of the aluminized coating. As shown in fig. 1 and 2.
Step 2, coating meets the following relation:
wherein x is the depth of a certain position in the coating from the surface of the coating, C is the mass percent content of aluminum at the position x in the coating, D is the diffusion coefficient, t is the oxidation time, S is the total amount of Al in the coating, and eta is the calibration displacement of the Gaussian distribution center;
respectively obtaining the mass percentages of aluminum at different x positions of the aluminized test piece with the initial thicknesses H1 and H2 of the coating prepared in the step 1 before the oxidation test is carried out; substituting the data obtained in the step into the formula (1), and fitting to obtain H1,Total amount S of H2 aluminized test piece Al 0 1 is 1418.50138, S 0 2 is 243.23653;
and 3, performing a high-temperature steam oxidation experiment on the aluminized test piece at the temperature of 650 ℃, wherein the steam oxidation experiment is a dynamic 100% saturated steam experiment, the pressure is 0.1MPa, the steam flow rate is 100ml/s, and the steam side service environment of the boiler tube of the power plant is simulated.
And 4, obtaining the mass percentages of aluminum corresponding to different x positions of the aluminized test piece after oxidizing the aluminized test piece for 1000 hours at 650 ℃ according to the step 3.
Substituting the obtained data into the formula (1), and fitting to obtain diffusion coefficients D1, S1 and eta 1 of the aluminized test piece at the temperature of 650 ℃ of the H1 coating, wherein the diffusion coefficients D1, S1 and eta 1 are respectively as follows: 0.06332, 897.09465, 7.84419.
Step 5, the total amount S of Al in the coating meets the following conditions:
s=ah+b type (2)
Wherein a and b are constants related to the aluminized coating;
h1 and S 0 1, H2, S 0 2 is substituted into the formula (2), and the values of a and b are calculated to be 47.02 and 7.9 respectively;
step 6, substituting D1 into the formula (1), wherein C is 3% of the critical content of alumina, eta is a value corresponding to D1, x is 0, t is the target life 70000h of the coating, and S is obtained through calculation 0 713.2;
step 7, substituting S into the formula (2), and calculating to obtain the initial diffusion depth H0=15 mu m of the aluminized coating required by the target service life of the coating;
and 8, preparing an aluminized test piece with the coating thickness of 15 mu m.
Example 2
A method for controlling the lifetime of a powder embedded aluminized coating comprising the steps of:
step 1, preparing an aluminized test piece:
s101, degreasing and derusting a test piece to be aluminized, embedding aluminized powder according to the configuration of 99wt% FeAl powder and 1wt% permeation assisting agent, layering the pretreated test piece into a stainless steel tank, and compacting.
S102, placing the embedded test piece to be aluminized in a heat treatment furnace at 750 ℃, and sintering for 4 hours in an argon atmosphere to prepare the aluminized test piece with the coating thickness H1 of 30 mu m.
And placing the embedded test piece to be aluminized in a heat treatment furnace at 640 ℃, and sintering for 6 hours in an argon atmosphere to prepare the aluminized test piece with the coating thickness H2 of 5 mu m.
S103, cooling to room temperature along with the furnace, and taking out the test piece to finish the preparation of the aluminized coating. As shown in fig. 1 and 2.
Step 2, coating meets the following relation:
wherein x is the depth of a certain position in the coating from the surface of the coating, C is the mass percent content of aluminum at the position x in the coating, D is the diffusion coefficient, t is the oxidation time, S is the total amount of Al in the coating, and eta is the calibration displacement of the Gaussian distribution center;
respectively obtaining the mass percentages of aluminum at different x positions of the aluminized test piece with the initial thicknesses H1 and H2 of the coating prepared in the step 1 before the oxidation test is carried out; substituting the data obtained in the step into the formula (1), and fitting to obtain the total amount S of the Al of the H1 and H2 aluminized test piece 0 1 is 1418.50138, S 0 2 is 243.23653;
and 3, performing a high-temperature steam oxidation experiment on the aluminized test piece at the temperature of 650 ℃, wherein the steam oxidation experiment is a dynamic 100% saturated steam experiment, the pressure is 0.1MPa, the steam flow rate is 100ml/s, and the steam side service environment of the boiler tube of the power plant is simulated.
And 4, obtaining the mass percentages of aluminum corresponding to different x positions of the aluminized test piece after oxidizing the aluminized test piece for 1000 hours at 650 ℃ according to the step 3.
Substituting the obtained data into the formula (1), and fitting to obtain diffusion coefficients D1, S1 and eta 1 of the aluminized test piece at the temperature of 650 ℃ of the H1 coating, wherein the diffusion coefficients D1, S1 and eta 1 are respectively as follows: 0.06332, 897.09465, 7.84419.
Step 5, the total amount S of Al in the coating meets the following conditions:
s=ah+b type (2)
Wherein a and b are constants related to the aluminized coating;
h1 and S 0 1, H2, S 0 2 is substituted into formula (2), and the values of a and b are calculated to be 47.02 and 7.9, respectively.
Step 6, substituting D1 into the formula (1), wherein C is 3% of the critical content of alumina, eta is a value corresponding to D1, x is 0, t is the target life 125000h of the coating, and S is obtained by calculation 0 948.3;
step 7, substituting S into the formula (2), and calculating to obtain the initial diffusion depth H0=20μm of the aluminized coating required by the target service life of the coating;
and 8, preparing an aluminized test piece with the coating thickness of 20 mu m.
Example 3
A method for controlling the lifetime of a powder embedded aluminized coating comprising the steps of:
step 1, preparing an aluminized test piece:
s101, degreasing and derusting a test piece to be aluminized, embedding aluminized powder according to the configuration of 99wt% FeAl powder and 1wt% permeation assisting agent, layering the pretreated test piece into a stainless steel tank, and compacting.
S102, placing the embedded test piece to be aluminized in a heat treatment furnace at 750 ℃, and sintering for 4 hours in an argon atmosphere to prepare the aluminized test piece with the coating thickness H1 of 30 mu m.
And placing the embedded test piece to be aluminized in a heat treatment furnace at 640 ℃, and sintering for 6 hours in an argon atmosphere to prepare the aluminized test piece with the coating thickness H2 of 5 mu m.
S103, cooling to room temperature along with the furnace, and taking out the test piece to finish the preparation of the aluminized coating. As shown in fig. 1 and 2.
Step 2, coating meets the following relation:
wherein x is the depth of a certain position in the coating from the surface of the coating, C is the mass percent content of aluminum at the position x in the coating, D is the diffusion coefficient, t is the oxidation time, S is the total amount of Al in the coating, and eta is the calibration displacement of the Gaussian distribution center;
respectively obtaining the mass percentages of aluminum at different x positions of the aluminized test piece with the initial thicknesses H1 and H2 of the coating prepared in the step 1 before the oxidation test is carried out; substituting the data obtained in the step into the formula (1), and fitting to obtain the total amount S of the Al of the H1 and H2 aluminized test piece 0 1 is 1418.50138, S 0 2 is 243.23653;
and 3, performing a high-temperature steam oxidation experiment on the aluminized test piece at the temperature of 650 ℃, wherein the steam oxidation experiment is a dynamic 100% saturated steam experiment, the pressure is 0.1MPa, the steam flow rate is 100ml/s, and the steam side service environment of the boiler tube of the power plant is simulated.
And 4, obtaining the mass percentages of aluminum corresponding to different x positions of the aluminized test piece after oxidizing the aluminized test piece for 1000 hours at 650 ℃ according to the step 3.
Substituting the obtained data into the formula (1), and fitting to obtain diffusion coefficients D1, S1 and eta 1 of the aluminized test piece at the temperature of 650 ℃ of the H1 coating, wherein the diffusion coefficients D1, S1 and eta 1 are respectively as follows: 0.06332, 897.09465, 7.84419.
Step 5, the total amount S of Al in the coating meets the following conditions:
s=ah+b type (2)
Wherein a and b are constants related to the aluminized coating;
h1 and S 0 1, H2, S 0 2 is substituted into formula (2), and the values of a and b are calculated to be 47.02 and 7.9, respectively.
Step 6, substituting D1 into the formula (1), wherein C is 3% of the critical content of alumina, eta is a value corresponding to D1, x is 0, t is the target life 497000h of the coating, and S is obtained through calculation 0 1888.7;
step 7, substituting S into the formula (2), and calculating to obtain the initial diffusion depth H0=40 mu m of the aluminized coating required by the target service life of the coating;
and 8, preparing an aluminized test piece with the coating thickness of 40 mu m.
It is apparent that the above examples are given by way of illustration only and are not limiting of the embodiments. Other variations or modifications of the above teachings will be apparent to those of ordinary skill in the art. It is not necessary here nor is it exhaustive of all embodiments. And obvious variations or modifications thereof are contemplated as falling within the scope of the present invention.
Claims (9)
1. The service life control method of the powder embedded aluminized coating is characterized by comprising the following steps of:
step 1, preparing an aluminized test piece with initial coating thicknesses H1 and H2;
step 2, coating meets the following relation:
wherein x is the depth of a certain position in the coating from the surface of the coating, C is the mass percent content of aluminum at the position x in the coating, D is the diffusion coefficient, t is the oxidation time, S is the total amount of Al in the coating, and eta is the calibration displacement of the Gaussian distribution center;
respectively obtaining the mass percentages of aluminum at different x positions of the aluminized test pieces with the initial thicknesses H1 and H2 of the coating prepared in the step 1; substituting the data obtained in the step into formula (1), and fitting to obtain total amount S of two aluminized test pieces Al 0 1、S 0 2；
Step 3, performing a high-temperature steam oxidation experiment on the aluminized test pieces with the initial thicknesses H1 and H2 of the prepared coating at the temperature T1;
step 4, obtaining the mass percentages of aluminum at different x positions in the coating when the aluminized test piece is oxidized for time T at the temperature of T1 according to the step 3; substituting the data obtained in the step into a formula (1), and fitting to obtain diffusion coefficients D1 and eta 1 of an aluminized test piece with the initial thickness H1 of the coating under T1; and/or fitting to obtain diffusion coefficients D2 and eta 2 of the aluminized test piece with the initial thickness H2 of the coating under T1;
step 5, the total amount S of Al in the coating meets the following conditions:
s=ah+b type (2)
Wherein a and b are constants related to the aluminized coating;
h1 and S 0 1, H2, S 0 2 is substituted into the formula (2), and the values of a and b are obtained through calculation;
step 6, substituting D1 or D2 into the formula (1), taking C to form the critical content of alumina, taking eta to be the value corresponding to D1 or D2, taking x to be 0 and t to be the target life of the coating, and calculating to obtain S 0 ；
Step 7, S is 0 Substituting the initial thickness H0 of the aluminized coating required by the target service life of the coating at the temperature T1 is calculated and obtained in the step (2);
and 8, preparing an aluminized test piece with the initial thickness of the coating being more than or equal to H0.
2. The method for controlling the lifetime of a powder-embedded aluminized coating according to claim 1, characterized in that said step 1 comprises:
s101, degreasing and derusting a test piece to be aluminized, burying the test piece to be aluminized into a powder tank with aluminized powder, and compacting;
s102, placing the compacted powder tank into a heat treatment furnace, and sintering in a protective gas atmosphere;
s103, cooling to room temperature along with the furnace to obtain an aluminized test piece.
3. The method of controlling the lifetime of a powder embedded aluminized coating according to claim 2, characterized in that in S101 the aluminized powder comprises FeAl powder and a penetration aid.
4. A method for controlling the lifetime of a powder-embedded aluminized coating according to claim 3, characterized in that the permeation aid is NH 4 Cl。
5. A method for controlling the lifetime of a powder embedded aluminized coating according to claim 3, characterized in that the mass ratio of iron to aluminum in the FeAl powder is 1:1.
6. A method for controlling the lifetime of a low temperature powder embedded aluminized coating according to claim 3, characterized in that the mass ratio of FeAl powder to penetration enhancer is 99:1.
7. The method for controlling the lifetime of a low temperature powder embedded aluminized coating according to claim 2, characterized in that in S102, the sintering condition is 640-780 ℃ sintering for 4-8 hours.
8. The method of claim 2, wherein the shielding gas is argon.
9. The method according to claim 1, wherein the experimental conditions of high temperature steam oxidation in step 2 are: dynamic 100% saturated steam with pressure of 0.1-30 MPa and steam flow rate of 100-120ml/s.
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