CN116770210A - High-heat-insulation long-service-life thermal barrier coating containing vertical crack structure and preparation method thereof - Google Patents
High-heat-insulation long-service-life thermal barrier coating containing vertical crack structure and preparation method thereof Download PDFInfo
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- CN116770210A CN116770210A CN202310737873.XA CN202310737873A CN116770210A CN 116770210 A CN116770210 A CN 116770210A CN 202310737873 A CN202310737873 A CN 202310737873A CN 116770210 A CN116770210 A CN 116770210A
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- 239000012720 thermal barrier coating Substances 0.000 title claims abstract description 58
- 238000009413 insulation Methods 0.000 title claims abstract description 36
- 238000002360 preparation method Methods 0.000 title abstract description 19
- 229910002080 8 mol% Y2O3 fully stabilized ZrO2 Inorganic materials 0.000 claims description 78
- 239000000843 powder Substances 0.000 claims description 54
- 239000000919 ceramic Substances 0.000 claims description 50
- 238000005507 spraying Methods 0.000 claims description 49
- 239000007921 spray Substances 0.000 claims description 44
- 238000005516 engineering process Methods 0.000 claims description 42
- 238000007750 plasma spraying Methods 0.000 claims description 35
- 238000000034 method Methods 0.000 claims description 26
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims description 24
- 239000000758 substrate Substances 0.000 claims description 19
- 229910052735 hafnium Inorganic materials 0.000 claims description 14
- 239000000463 material Substances 0.000 claims description 14
- 239000011159 matrix material Substances 0.000 claims description 14
- 238000005488 sandblasting Methods 0.000 claims description 13
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 claims description 12
- VBJZVLUMGGDVMO-UHFFFAOYSA-N hafnium atom Chemical compound [Hf] VBJZVLUMGGDVMO-UHFFFAOYSA-N 0.000 claims description 12
- 229910052761 rare earth metal Inorganic materials 0.000 claims description 12
- 150000002910 rare earth metals Chemical class 0.000 claims description 12
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 10
- 239000002086 nanomaterial Substances 0.000 claims description 10
- 238000010285 flame spraying Methods 0.000 claims description 8
- 229910001092 metal group alloy Inorganic materials 0.000 claims description 8
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 6
- 239000003350 kerosene Substances 0.000 claims description 6
- 239000011858 nanopowder Substances 0.000 claims description 6
- 239000001301 oxygen Substances 0.000 claims description 6
- 229910052760 oxygen Inorganic materials 0.000 claims description 6
- 239000002245 particle Substances 0.000 claims description 5
- RKTYLMNFRDHKIL-UHFFFAOYSA-N copper;5,10,15,20-tetraphenylporphyrin-22,24-diide Chemical compound [Cu+2].C1=CC(C(=C2C=CC([N-]2)=C(C=2C=CC=CC=2)C=2C=CC(N=2)=C(C=2C=CC=CC=2)C2=CC=C3[N-]2)C=2C=CC=CC=2)=NC1=C3C1=CC=CC=C1 RKTYLMNFRDHKIL-UHFFFAOYSA-N 0.000 claims description 4
- 239000000203 mixture Substances 0.000 claims description 4
- 229910001404 rare earth metal oxide Inorganic materials 0.000 claims description 4
- 238000005406 washing Methods 0.000 claims description 4
- RUDFQVOCFDJEEF-UHFFFAOYSA-N yttrium(III) oxide Inorganic materials [O-2].[O-2].[O-2].[Y+3].[Y+3] RUDFQVOCFDJEEF-UHFFFAOYSA-N 0.000 claims description 3
- 229910003266 NiCo Inorganic materials 0.000 claims description 2
- 229910052804 chromium Inorganic materials 0.000 claims description 2
- 229910001938 gadolinium oxide Inorganic materials 0.000 claims description 2
- 229940075613 gadolinium oxide Drugs 0.000 claims description 2
- CMIHHWBVHJVIGI-UHFFFAOYSA-N gadolinium(iii) oxide Chemical compound [O-2].[O-2].[O-2].[Gd+3].[Gd+3] CMIHHWBVHJVIGI-UHFFFAOYSA-N 0.000 claims description 2
- 238000005469 granulation Methods 0.000 claims description 2
- 230000003179 granulation Effects 0.000 claims description 2
- 229910052751 metal Inorganic materials 0.000 claims description 2
- 239000002184 metal Substances 0.000 claims description 2
- 229910002077 partially stabilized zirconia Inorganic materials 0.000 claims description 2
- 229910052727 yttrium Inorganic materials 0.000 claims description 2
- 241000968352 Scandia <hydrozoan> Species 0.000 claims 1
- 230000004888 barrier function Effects 0.000 claims 1
- 239000002103 nanocoating Substances 0.000 claims 1
- HJGMWXTVGKLUAQ-UHFFFAOYSA-N oxygen(2-);scandium(3+) Chemical compound [O-2].[O-2].[O-2].[Sc+3].[Sc+3] HJGMWXTVGKLUAQ-UHFFFAOYSA-N 0.000 claims 1
- -1 ytterbia Chemical compound 0.000 claims 1
- 238000000576 coating method Methods 0.000 abstract description 38
- 239000011248 coating agent Substances 0.000 abstract description 35
- 230000000052 comparative effect Effects 0.000 description 19
- 238000007749 high velocity oxygen fuel spraying Methods 0.000 description 12
- 239000007789 gas Substances 0.000 description 11
- 239000000956 alloy Substances 0.000 description 10
- 229910045601 alloy Inorganic materials 0.000 description 9
- PXHVJJICTQNCMI-UHFFFAOYSA-N nickel Substances [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 9
- 238000004140 cleaning Methods 0.000 description 8
- 238000007788 roughening Methods 0.000 description 8
- 238000001816 cooling Methods 0.000 description 5
- 238000005328 electron beam physical vapour deposition Methods 0.000 description 5
- 235000019441 ethanol Nutrition 0.000 description 5
- 230000035939 shock Effects 0.000 description 5
- 229910052593 corundum Inorganic materials 0.000 description 4
- 239000010431 corundum Substances 0.000 description 4
- 229910052759 nickel Inorganic materials 0.000 description 4
- 230000010355 oscillation Effects 0.000 description 4
- 239000004576 sand Substances 0.000 description 4
- 229910000601 superalloy Inorganic materials 0.000 description 4
- 238000002474 experimental method Methods 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- 229910001233 yttria-stabilized zirconia Inorganic materials 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 2
- 238000005524 ceramic coating Methods 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 150000003839 salts Chemical class 0.000 description 2
- 238000005245 sintering Methods 0.000 description 2
- 238000005728 strengthening Methods 0.000 description 2
- 239000000725 suspension Substances 0.000 description 2
- 238000005253 cladding Methods 0.000 description 1
- 238000000151 deposition Methods 0.000 description 1
- 230000008021 deposition Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 238000004372 laser cladding Methods 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- SIWVEOZUMHYXCS-UHFFFAOYSA-N oxo(oxoyttriooxy)yttrium Chemical compound O=[Y]O[Y]=O SIWVEOZUMHYXCS-UHFFFAOYSA-N 0.000 description 1
- UZLYXNNZYFBAQO-UHFFFAOYSA-N oxygen(2-);ytterbium(3+) Chemical compound [O-2].[O-2].[O-2].[Yb+3].[Yb+3] UZLYXNNZYFBAQO-UHFFFAOYSA-N 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- HYXGAEYDKFCVMU-UHFFFAOYSA-N scandium oxide Chemical compound O=[Sc]O[Sc]=O HYXGAEYDKFCVMU-UHFFFAOYSA-N 0.000 description 1
- 238000004901 spalling Methods 0.000 description 1
- 238000005382 thermal cycling Methods 0.000 description 1
- 238000007751 thermal spraying Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 229910003454 ytterbium oxide Inorganic materials 0.000 description 1
- 229940075624 ytterbium oxide Drugs 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
- C23C4/08—Metallic material containing only metal elements
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
- C23C4/11—Oxides
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/129—Flame spraying
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/134—Plasma spraying
Abstract
The invention relates to the technical field of high-temperature coating protection, in particular to a high-heat-insulation long-service-life thermal barrier coating with a vertical crack structure and a preparation method thereof.
Description
Technical Field
The invention relates to the technical field of high-temperature coating protection, in particular to a high-heat-insulation long-service-life thermal barrier coating with a vertical crack structure and a preparation method thereof.
Background
The thermal barrier coating technology and the high temperature structural material and cooling technology are called three key core technologies of the hot end component of the advanced gas turbine engine. Even if the air film cooling technology is adopted, the working temperature of the surface of the hot end part is far higher than the temperature bearing capacity of the existing alloy material. In addition, the application of film cooling technology makes the processing of hot end components more complex, and the increase of cooling air flow also reduces the thermal efficiency. Thermal barrier coating technology is currently the most effective way to improve the high thrust to weight ratio and thermal efficiency of gas turbine engines. Currently Atmospheric Plasma Spraying (APS) and electron beam physical vapor deposition (EB-PVD) are the most commonly used techniques for preparing thermal barrier coatings. APS are widely used because of their high heat source temperature, simple operation, high spray efficiency, low thermal conductivity of the resulting coating, and the like. However, APS coatings also suffer from poor layer-to-layer bonding, low stress damage tolerance, poor thermal shock resistance, and the like. The EB-PVD coating has the advantages of high bonding strength, high stress damage tolerance, excellent impact resistance and long thermal cycle life. However, EB-PVD techniques also suffer from low deposition efficiency, high thermal conductivity of the coating, and poor thermal insulation.
In order to improve the heat insulation performance and the bonding strength of the coating and prolong the service life of the hot end component, various advanced thermal spraying technologies are continuously developed. The Chinese patent CN201910093357.1 adopts a mixed spraying technology and a water flow impact method to prepare the anti-sintering long-service-life thermal barrier coating with the double-layer columnar structure. The Chinese patent No. 202111414306.8 provides a preparation method of a dense thick thermal barrier coating, which adopts nano ceramic powder with single-peak granularity grading as a raw material, and prepares the ceramic thermal barrier coating with low porosity and high bonding strength through a high-energy plasma spraying process, so that the thermal shock resistance and the heat insulation performance of the coating are effectively improved, the service temperature of the coating is further improved, and the service life of the coating is prolonged. The invention CN202010438702.3 provides a high-performance thermal barrier coating for a heavy-duty gas turbine blade and a preparation method of a multi-process combination thereof, and particularly relates to a preparation method of a YSZ ceramic layer by adopting a laser cladding technology to prepare an MCrAlY bonding layer, a laser shock strengthening technology to regulate and control a MCrAlY cladding layer tissue structure and a stress state in a large area, a laser shock micro-modeling technology to selectively process micro-pit textures on the surface of the strengthening layer, and an atmospheric plasma spraying technology to prepare the thermal barrier coating. The thermal barrier coating has excellent interface bonding strength, high-temperature oxidation resistance and thermal shock resistance. Chinese patent No. CN202210068076.2 describes a technique for preparing DVC thermal barrier coating by high enthalpy atmospheric plasma spraying, the power of the plasma spray gun is selected to be 50-210kW, the speed of the spray gun movement is 500-1000mm/s, and the preheating temperature is selected to be between room temperature and 380 ℃. In particular, the thermal barrier coating with the vertical crack structure is prepared by high-energy plasma spraying, suspension plasma spraying, atmospheric plasma spraying and other technologies. The introduction of vertical cracks can significantly improve the stress damage tolerance and service life of the thermal barrier coating.
However, the current techniques for preparing coatings containing vertical cracks, such as high energy plasma spraying, suspension plasma spraying, etc., are costly; in addition, the existing technology for preparing the coating with the vertical cracks mostly adopts a high-power plasma spraying technology and melting, crushing and spraying powder, and meanwhile, the substrate is required to be heated to more than 700 ℃ to obtain the thermal barrier coating with the vertical cracks. More importantly, the coatings currently prepared containing vertical cracks are mostly denser and vertical cracks in the coating up to the tie layer lead to poor resistance to molten salt corrosion and thermal insulation of the coating.
In view of the above drawbacks, the present inventors have finally achieved the present invention through long-time studies and practices.
Disclosure of Invention
The invention aims to solve the problems that the existing technology for preparing the coating with vertical cracks mostly adopts a high-power plasma spraying technology, melts, breaks and sprays powder, and simultaneously needs to heat a substrate to more than 700 ℃ to obtain the thermal barrier coating with vertical cracks, the coating is mostly compact, and the vertical cracks in the coating until a bonding layer lead to the corrosion resistance of molten salt and poor thermal insulation performance of the coating, and provides the thermal barrier coating with high thermal insulation and long service life and a preparation method thereof.
In order to achieve the aim, the invention discloses a high-heat-insulation long-service-life thermal barrier coating with a vertical crack structure, which sequentially comprises a metal alloy matrix, a bonding layer, an 8YSZ micro-nano structure heat insulation layer and a rare earth doped zirconia/hafnium ceramic layer with a vertical crack structure from bottom to top.
The bonding layer comprises a first bonding layer and a second bonding layer, the thickness of the first bonding layer is 80-100 mu m, the thickness of the second bonding layer is 30-60 mu m, the thickness of the 8YSZ micro-nano structure coating is 180-250 mu m, and the thickness of the rare earth doped zirconia/hafnium ceramic layer containing a vertical crack structure is 300-1300 mu m.
The bonding layer is MCrAlYSiHf, M is Ni or NiCo, and comprises the following components in percentage by mass: 61.9 to 74 percent of Ni+Co,20 to 25 percent of Cr,5 to 10 percent of Al,0.4 to 1.5 percent of Y,0.3 to 0.8 percent of Si and 0.3 to 0.8 percent of Hf.
The 8YSZ used for the 8YSZ micro-nano structural heat insulating layer is 8wt.% of yttria partially stabilized zirconia, the original powder is 20-40nm 8YSZ nano powder, and the 8YSZ nano powder is prepared from tetragonal phase t-ZrO 2 And monoclinic m- -ZrO 2 Composition of the tetragonal phase t-ZrO 2 The mass percentage of the monoclinic m-ZrO is more than 97 percent 2 The mass percentage of (2) is less than 3%.
The rare earth oxide in the rare earth doped zirconia/hafnium ceramic layer containing the vertical crack structure is any two or more of yttrium oxide, scandium oxide, ytterbium oxide and gadolinium oxide, and the total rare earth oxide accounts for less than 12 percent by mass;
the invention also discloses a preparation method of the high-heat-insulation long-service-life thermal barrier coating containing the vertical crack structure, which comprises the following steps:
s1, carrying out sand blasting coarsening pretreatment on a metal alloy matrix after washing the metal alloy matrix by adopting alcohol and acetone, carrying out ultrasonic washing on the metal alloy matrix after sand blasting coarsening,
s2, preparing a first bonding layer on the roughened surface of the metal matrix by adopting a supersonic flame spraying technology,
s3, preparing a second bonding layer on the first bonding layer by adopting an atmospheric plasma spraying technology;
s4, preheating the sample with the bonding layer obtained in the step S3 to 200-500 ℃;
s5, sequentially preparing an 8YSZ micro-nano structure heat insulation layer and a rare earth doped zirconia/hafnium ceramic layer with a vertical crack structure on the surface of the bonding layer by adopting an atmospheric plasma spraying technology.
The technological parameters of the supersonic flame spraying technology in the step S2 are as follows: the oxygen flow is 50-55L/min, the kerosene flow is 28-32L/min, the spraying distance is 330-380 mm, the powder feeding rate is 50-80 g/min, the gun barrel is 4-6 inches, the moving speed of the spray gun is 750-850 mm/s, and the step distance is 2-4 mm.
The technological parameters of the atmospheric plasma spraying technology in the step S3 are as follows: the spraying current is 400-500A, the spraying power is 28-34 kW, the powder feeding rate is 25-40 g/min, the spraying distance is 100-140 mm, the main air flow Ar is 40-55L/min, the H2 air flow is 4-8L/min, the moving speed of the spray gun is 750-850 mm/s, and the step distance is 2-4 mm.
The technological parameters of the atmospheric plasma spraying in the step S5 are as follows: the spraying current is 500-650A, the spraying power is 36-40 kW, the powder feeding rate is 35-50 g/min, the spraying distance is 70-100 mm, the main air flow Ar is 40-50L/min, the moving speed of the spray gun is 250-350 mm/s, and the step distance is 2-4 mm.
The powder materials of the 8YSZ micro-nano structural heat insulation layer and the rare earth doped zirconia/hafnium ceramic layer with the vertical crack structure in the step S5 are primary nano agglomerated powder obtained through a spray granulation process, and then sintered for 4-6 hours at 900-1100 ℃, and screened to obtain the powder materials of the 8YSZ micro-nano structural heat insulation layer with the grain size within the range of 10-40 mu m and the powder materials of the rare earth doped zirconia/hafnium ceramic layer with the vertical crack structure.
Compared with the prior art, the invention has the beneficial effects that:
1. the invention adopts the common (conventional) atmospheric plasma spraying technology to prepare the thermal barrier coating system containing the heat insulation ceramic layer and the high stress damage tolerance ceramic layer, the preparation method is simple, the cost is low, the technology is controllable, and the prepared thermal barrier coating has the low heat conductivity coefficient of the common plasma spraying coating and the excellent thermal cycle performance of the electron beam physical vapor deposition coating;
2. the preheating temperature of the matrix in the preparation process is 200-500 ℃, which is far lower than the working temperature of the matrix alloy, and the mechanical properties of the matrix alloy are not affected in the spraying process;
3. the micro-nano structure heat insulation ceramic layer contains a certain amount of nano tissues, so that the toughness of the whole coating is improved, and the heat conductivity coefficient of the coating is reduced;
4. compared with a coating with a compact vertical crack structure (DVC), the ceramic layer with the vertical crack has certain porosity, is beneficial to enhancing the heat insulation performance and sintering resistance of the coating, and can also improve the thermal cycle life of a thermal barrier coating system.
Drawings
FIG. 1 is a schematic structural diagram of a high thermal insulation long life thermal barrier coating system containing a vertical crack structure;
FIG. 2 is a cross-sectional morphology of a thermal barrier coating of the 8YSZ micro-nano structure containing vertical cracks according to the invention;
FIG. 3 is a surface morphology of a NiCrAlYSiHf/8YSZ thermal barrier coating of vertical crack structure before and after 1000 thermal cycles at 1100 ℃;
FIG. 4 is a graph of thermal conductivity as a function of temperature for a ceramic coating of the present invention having a vertical crack structure GdYb-8 YSZ.
Detailed Description
The above and further technical features and advantages of the present invention are described in more detail below with reference to the accompanying drawings.
Example 1
NiCoCrAlYSiHf/8YSZ/Sc-8YSZ thermal barrier coating system
The specific composition (percentage mass fraction) of the bonding layer NiCoCrAlYSiHf in this example: 44Ni-20Co-24Cr-10Al-1Y-0.5Si-0.5Hf;
8YSZ and Sc-8YSZ (92.5 ZrO 2 -4.0Y 2 O 3 -3.5Sc 2 O 3 Wt.%) the original average particle size of the nanopowder material is about 30nm, the average particle size of 8YSZ and Sc-8YSZ nanopowder sintered spray powder is about 30 μm, the size of the spray powder is in the range of 10-40 μm;
the specific preparation steps of the NiCoCrAlYSiHf/8YSZ/Sc-8YSZ thermal barrier coating system in the embodiment are as follows:
a. cleaning a nickel-based superalloy substrate by alcohol and acetone, removing greasy dirt and the like on the surface, performing sand blasting roughening pretreatment by adopting 24-mesh brown corundum sand, and cleaning the substrate subjected to sand blasting roughening by adopting ultrasonic oscillation by taking absolute ethyl alcohol as a medium;
b. the method adopts a supersonic flame spraying technology (HVOF) to prepare a NiCoCrAlYSiHf bonding layer with the thickness of 100 mu m on the surface of a sand-blasted roughened substrate, and the specific technological parameters of the HVOF NiCoCrAlYSiHf bonding layer are as follows: the oxygen flow is 52L/min, the kerosene flow is 30L/min, the spraying distance is 350mm, the powder feeding rate is 60g/min, the gun barrel is 4 inches, the moving speed of the spray gun is 800mm/s, and the step distance is 3mm;
c. the specific process parameters of the NiCoCrAlYSiHf bonding layer with the thickness of 50 μm and APS NiCoCrAlYSiHf bonding layer are then prepared on the surface of the bonding layer containing HVOF NiCoCrAlYSiHf by adopting an atmospheric plasma spraying technology: the spraying current is 500A, the spraying power is 33kW, the powder feeding rate is 30g/min, the spraying distance is 120mm, the main air flow Ar gas is 45L/min, the moving speed of the spray gun is 800mm/s, and the step distance is 3mm;
d. finally, preparing an 8YSZ ceramic layer with the thickness of 180 mu m and an Sc-8YSZ ceramic layer with the thickness of 1100 mu m on the surface of an alloy sample with a NiCoCrAlYSiHf bonding layer preheated to 500 ℃ by adopting a conventional atmospheric plasma spraying technology, wherein the specific atmospheric plasma spraying technological parameters are as follows: the spraying current is 600A, the spraying power is 38kW, the powder feeding rate is 35g/min, the spraying distance is 80mm, the main air flow Ar gas is 45L/min, the moving speed of the spray gun is 300mm/s, and the step distance is 3mm.
FIG. 2 is a cross-sectional profile of the present example NiCoCrAlYSiHf/8YSZ/Sc-8YSZ thermal barrier coating system containing a vertical crack structure. As is evident from the graph, the Sc-8YSZ ceramic obtained in the example has obvious vertical cracks, and the density of the vertical cracks is 3 bars/mm; meanwhile, the thickness of the micro-nano structure heat insulation ceramic layer in the embodiment is about 180 mu m8YSZ, and the thick expectation of the Sc-8YSZ ceramic layer with the high stress damage tolerance of the vertical crack structure is about 1100 mu m; in this example, the porosity of the Sc-8YSZ ceramic layer with high stress damage tolerance for a vertical crack structure was calculated by IMage J to be about 8%.
The alloy substrate with the NiCoCrAlYSiHf/8YSZ/Sc-8YSZ thermal barrier coating system prepared in this example was subjected to thermal cycle performance testing at 1100 ℃: each thermal cycle was heated in a 1100 ℃ thermal cycle oven for 50 minutes, and then cooled to room temperature for 10 minutes, completing one air-cooled thermal cycle. Finally, the crucible is pushed into the tube furnace again, and the next thermal cycle is entered. And in the circulation process, when the area of the peeling area of the surface of the coating reaches more than 5% of the surface area of the sample, judging that the coating fails to stop the experiment, and recording the circulation times at the moment. In the embodiment, after 1000 times of thermal cycle at 1100 ℃, the thermal barrier coating is still intact, and the coating has no obvious peeling phenomenon.
Example 2
NiCrAlYSiHf/8YSZ/Yb-YSH thermal barrier coating system
The specific components (percentage mass fraction) of the bonding layer NiCrAlYSiHf in this example are: 67Ni-23Cr-8Al-1Y-0.5Si-0.5Hf;
8YSZ and Yb-YSH (88 HfO) 2 -4.0Y 2 O 3 -8Yb 2 O 3 Wt.%) the average particle size of the nano-agglomerate sintered spray powder is about 30 μm, the size of the spray powder is in the range of 10-40 μm;
the specific preparation steps of the NiCrAlYSiHf/8YSZ/Yb-YSH thermal barrier coating system in the embodiment are as follows:
a. cleaning a nickel-based superalloy substrate by alcohol and acetone, removing greasy dirt and the like on the surface, performing sand blasting roughening pretreatment by adopting 24-mesh brown corundum sand, and cleaning the substrate subjected to sand blasting roughening by adopting ultrasonic oscillation by taking absolute ethyl alcohol as a medium;
b. preparing an 80 mu m-thick NiCrAlYSiHf bonding layer on the surface of a sand-blasted roughened substrate by adopting a supersonic flame spraying (HVOF) technology, wherein the HVOF NiCrAlYSiHf bonding layer comprises the following specific technological parameters: the oxygen flow is 52L/min, the kerosene flow is 30L/min, the spraying distance is 380mm, the powder feeding rate is 50g/min, the gun barrel is 4 inches, the moving speed of the spray gun is 800mm/s, and the step distance is 3mm;
c. the specific process parameters of the NiCrAlYSiHf bonding layer with the thickness of 60 mu m and the APS NiCoCrAlYSiHf bonding layer are prepared on the surface of the NiCrAlYSiHf bonding layer containing HVOF by adopting an Atmospheric Plasma Spraying (APS) technology: the spraying current is 500A, the spraying power is 33kW, the powder feeding rate is 30g/min, the spraying distance is 120mm, the main air flow Ar gas is 45L/min, the H2 air flow is 5L/min, the moving speed of the spray gun is 800mm/s, and the step distance is 3mm;
d. finally, preparing an 8YSZ micro-nano structural ceramic layer with the thickness of 250 mu m and an Yb-YSH top ceramic layer with the thickness of 1100 mu m, which contains vertical cracks, on the surface of an alloy sample with a NiCrAlYSiHf bonding layer at the temperature of 450 ℃ by adopting a conventional atmospheric plasma spraying technology, wherein the specific atmospheric plasma spraying technological parameters are as follows: the spraying current is 600A, the spraying power is 38kW, the powder feeding rate is 40g/min, the spraying distance is 85mm, the main air flow Ar gas is 45L/min, the moving speed of the spray gun is 250mm/s, and the step distance is 3mm.
In this example, the vertical crack density was 3 bars/mm, and the porosity of the Yb-YSH ceramic layer with high stress damage tolerance for the vertical crack structure was calculated to be about 6% by IMage J.
The alloy substrate with the NiCrAlYSiHf/8YSZ/Yb-YSH thermal barrier coating system prepared in this example was subjected to thermal cycle performance testing at 1200 ℃: each thermal cycle was heated in a 1200 ℃ thermal cycle oven for 50 minutes, and then cooled to room temperature for 10 minutes, completing one air-cooled thermal cycle. Finally, the crucible is pushed into the tube furnace again, and the next thermal cycle is entered. And in the circulation process, when the area of the peeling area of the surface of the coating reaches more than 5% of the surface area of the sample, judging that the coating fails to stop the experiment, and recording the circulation times at the moment. FIG. 3 is the surface morphology of a thermal barrier coating of the present example containing a vertical crack structure NiCrAlYSiHf/8YSZ/Yb-YSH micro-nano structure after 1000 thermal cycles at 1200 ℃. As can be seen from the graph, the thermal barrier coating system of the embodiment NiCrAlYSiHf/8YSZ/Yb-YSH is still intact after 1000 times of thermal cycling at 1200 ℃, and the coating has no obvious flaking phenomenon.
Example 3
NiCrAlYSiHf/8YSZ/GdYb-8YSZ thermal barrier coating system
The specific components (percentage mass fraction) of the bonding layer NiCrAlYSiHf in this example are: 64Ni-24Cr-10Al-1Y-0.5Si-0.5Hf;89ZrO 2 -4.0Y 2 O 3 -3.5Yb 2 O 3 -3.5Gd 2 O 3 (wt.%) (GdYb-8 YSZ for short)
The average grain diameter of the 8YSZ and GdYb-8YSZ nanometer agglomerated and sintered spraying powder is about 30 mu m, and the sizes of the spraying powder are all in the range of 10-40 mu m (the 1# powder feeder is filled with the 8YSZ nanometer agglomerated and sintered spraying powder and the 2# powder feeder is filled with the GdYb-8YSZ nanometer agglomerated and sintered spraying powder);
the specific preparation steps of the NiCrAlYSiHf/8YSZ thermal barrier coating system in the embodiment are as follows:
a. cleaning a nickel-based superalloy substrate by alcohol and acetone, removing greasy dirt and the like on the surface, performing sand blasting roughening pretreatment by adopting 24-mesh brown corundum sand, and cleaning the substrate subjected to sand blasting roughening by adopting ultrasonic oscillation by taking absolute ethyl alcohol as a medium;
b. preparing a NiCrAlYSiHf bonding layer with the thickness of 100 mu m on the surface of a substrate roughened by sand blasting by adopting a supersonic flame spraying (HVOF) technology, wherein the specific technological parameters of the HVOF NiCrAlYSiHf bonding layer are as follows: the oxygen flow is 52L/min, the kerosene flow is 30L/min, the spraying distance is 350mm, the powder feeding rate is 60g/min, the gun barrel is 4 inches, the moving speed of the spray gun is 800mm/s, and the step distance is 3mm;
c. then, an atmospheric plasma spraying technology is adopted to prepare a NiCrAlYSiHf bonding layer with the thickness of 50 mu m on the surface of the NiCrAlYSiHf bonding layer containing HVOF, and specific technological parameters of the APS NiCrAlYSiHf bonding layer are as follows: the spraying current is 500A, the spraying power is 33kW, the powder feeding rate is 30g/min, the spraying distance is 120mm, the main air flow Ar gas is 45L/min, the moving speed of the spray gun is 800mm/s, and the step distance is 3mm;
d. firstly, opening a No. 1 powder feeder, preparing an 8YSZ micro-nano structural ceramic layer with the thickness of 200 mu m on the surface of an alloy sample with a NiCrAlYSiHf bonding layer preheated to 500 ℃ by adopting a conventional atmospheric plasma spraying technology, and then closing the No. 1 powder feeder, opening a No. 2 powder feeder to prepare a GdYb-8YSZ vertical crack coating with the thickness of 1300 mu m, wherein the specific atmospheric plasma spraying technological parameters are as follows: the spraying current is 600A, the spraying power is 38kW, the powder feeding rate is 35g/min, the spraying distance is 80mm, the main air flow Ar gas is 45L/min, the moving speed of the spray gun is 250mm/s, and the step distance is 3mm.
The GdYb-8YSZ ceramic obtained in the example has obvious vertical cracks, and the density of the vertical cracks is 4 strips/mm; meanwhile, it can be observed that the thickness of the 8YSZ micro-nano heat insulation ceramic layer in the embodiment is about 200 mu m, and the presupposition of the GdYb-8YSZ ceramic layer with high stress damage tolerance of the vertical crack structure is about 1300 mu m; in this example, the high stress damage tolerance GdYb-8YSZ ceramic layer of the vertical crack structure was calculated by IMage J to have a porosity of about 5%. The thermal conductivity of the 1300 μm thick GdYb-8YSZ ceramic layer obtained in this example is shown in FIG. 4 as a function of temperature. As can be seen from the graph, the thermal conductivity of the GdYb-8YSZ micro-nano structure ceramic layer is reduced along with the increase of the temperature at the room temperature to 800 ℃, and the thermal conductivity at the temperature of 800 ℃ is 1.1 W.m -1 ·K -1 。
Example 4
NiCoCrAlYSiHf/8YSZ/Sc-8YbSZ thermal barrier coating system
The specific composition (percentage mass fraction) of the bonding layer NiCoCrAlYSiHf in this example: 50Ni-18.8Co-22Cr-8Al-0.6Y-0.3Si-0.3Hf;
8YSZ and Sc-8YbSZ (92 ZrO 2 -4Yb 2 O 3 -4Sc 2 O 3 (wt.%) the average particle size of the nano-agglomerate sintered spray powder is about 30 μm, the size of the spray powder is in the range of 10-40 μm;
the specific preparation steps of the NiCoCrAlYSiHf/8YSZ/Sc-8YbSZ thermal barrier coating system in the embodiment are as follows:
a. cleaning a nickel-based superalloy substrate by alcohol and acetone, removing greasy dirt and the like on the surface, performing sand blasting roughening pretreatment by adopting 24-mesh brown corundum sand, and cleaning the substrate subjected to sand blasting roughening by adopting ultrasonic oscillation by taking absolute ethyl alcohol as a medium;
b. the method adopts a supersonic flame spraying technology (HVOF) to prepare a NiCoCrAlYSiHf bonding layer with the thickness of 100 mu m on the surface of a sand-blasted roughened substrate, and the specific technological parameters of the HVOF NiCoCrAlYSiHf bonding layer are as follows: the oxygen flow is 53L/min, the kerosene flow is 31L/min, the spraying distance is 350mm, the powder feeding rate is 50g/min, the gun barrel is 4 inches, the moving speed of the spray gun is 800mm/s, and the step distance is 3mm;
c. the specific process parameters of the NiCoCrAlYSiHf bonding layer with the thickness of 50 μm and APS NiCoCrAlYSiHf bonding layer are then prepared on the surface of the bonding layer containing HVOF NiCoCrAlYSiHf by adopting an atmospheric plasma spraying technology: the spraying current is 500A, the spraying power is 33kW, the powder feeding rate is 25g/min, the spraying distance is 110mm, the main air flow Ar gas is 45L/min, the moving speed of the spray gun is 800mm/s, and the step distance is 3mm;
d. finally, preparing an 8YSZ micro-nano structural ceramic layer with the thickness of 200 mu m and an Sc-8YbSZ ceramic top layer with the vertical crack structure with the thickness of 500 mu m on the surface of an alloy sample with a NiCoCrAlYSiHf bonding layer preheated to 300 ℃ by adopting a conventional atmospheric plasma spraying technology, wherein the specific atmospheric plasma spraying technological parameters are as follows: the spraying current is 600A, the spraying power is 40kW, the powder feeding rate is 30g/min, the spraying distance is 85mm, the main air flow Ar gas is 45L/min, the moving speed of the spray gun is 250mm/s, and the step distance is 3mm.
The Sc-8YbSZ ceramic obtained in the embodiment has obvious vertical cracks, and the density of the vertical cracks is 1 strip/mm; in this example, the porosity of the 8YSZ ceramic layer, which was calculated by means of IMage J to be a high stress damage tolerance for a vertical crack structure, was about 9%.
Comparative example 1
Comparative example 1 and inventive example 1 both employed the same NiCoCrAlYSiHf/8YSZ/Sc-8YSZ thermal barrier coating system. The components of the bonding layer are the same as those of the preparation process; the 8YSZ and Sc-8YSZ ceramic layers are also prepared using the same spray powder materials and conventional atmospheric plasma spray techniques. In contrast, comparative example 1 had a spray gun moving rate of 600mm/s in the conventional plasma spraying, whereas example 1 of the present invention employed 300mm/s. In both comparative example 1 and inventive example 1, 180 μm thick 8YSZ ceramic layers and 1100 μm thick Sc-8YSZ ceramic layers were prepared, the coating cross section in the comparative example was found to have no vertical crack structure appearance. Likewise, the NiCoCrAlYSiHf/8YSZ/Sc-8YSZ thermal barrier coating system obtained in the comparative example had complete spalling failure of the thermal barrier coating at 352 thermal cycles in an air-cooled thermal cycle test at 1100 ℃.
Comparative example 2
Comparative example 2 employed a NiCrAlYSiHf/8YSZ thermal barrier coating system. The components of the bonding layer are the same as those of the preparation process;
the 8YSZ ceramic layers were also prepared using the same spray powder materials and conventional atmospheric plasma spray techniques.
In contrast, in comparative example 1, the substrate preheating temperature was 450℃and the movement rate of the torch was 600mm/s in the conventional plasma spraying, whereas in example 1 of the present invention, the movement rate of the torch was 300mm/s as well, and the movement rate of the torch was significantly different. The ceramic layer was prepared in both comparative example 2 and inventive example 2 to a thickness of 1350 μm. Although the coating section in comparative example 2 was also found to have a vertical crack structure; however, after the thermal barrier coating system of NiCrAlYSiHf/8YSZ obtained in the comparative example was heat treated at 1250℃for 25 hours, a large amount of monoclinic phase m-ZrO was detected in the coating 2 When the phase exists and the air cooling thermal cycle experiment is carried out at 1200 ℃, larger cracks are found in the alloy matrix when the thermal cycle is carried out 86 times. In the case of the same ceramic layer thickness, the coating is still intact after heat treatment for 100h at 1250 ℃, the existence of the second phase is not detected, good high-temperature phase stability is still maintained, and more importantly, the thermal cycle life of the embodiment 2 of the invention at 1200 ℃ is still intact at 1000 times.
Comparative example 3
Comparative example 3 and inventive example 2 both employed the same NiCrAlYSiHf/8YSZ/Yb-YSH thermal barrier coating system. The components of the bonding layer are the same as those of the preparation process;
the 8YSZ ceramic layer and the Yb-YSH ceramic layer are prepared by adopting the same spray powder material and the conventional atmospheric plasma spray technology, and the preheating temperature of the matrix is 450 ℃;
except that the spray gun of comparative example 3 was moved at a rate of 450mm/s and the spray distance was 110mm. Whereas example 2 of the present invention employed a spray gun movement rate of 250mm/s as well, a spray distance of 85mm.
In both comparative example 3 and inventive example 2, a 250 μm thick 8YSZ micro-nano structured ceramic layer and a 1100 μm thick Yb-YSH top ceramic layer containing vertical cracks were prepared, no vertical cracks were found in the cross-sectional microstructure of the ceramic coating of comparative example 3. And the thermal barrier coating obtained in comparative example 3 had a thermal cycle life of only 32 cycles at 1200 ℃ and failed to completely spall off the ceramic layer. Analysis of the failure causes shows that: in the preparation of the coating of comparative example 3, the spray distance was 110mm, the spray powder material was running very low in the high temperature plasma flame flow rate, the surface temperature of the powder had been lowered by the time the droplet reached the substrate, and the spray gun movement rate was too high of 450mm/s, which did not exert a better heating effect on the powder material, and did not reach the critical conditions for forming a vertical crack structure.
The foregoing description of the preferred embodiment of the invention is merely illustrative of the invention and is not intended to be limiting. It will be appreciated by persons skilled in the art that many variations, modifications, and even equivalents may be made thereto without departing from the spirit and scope of the invention as defined in the appended claims.
Claims (10)
1. A high-heat-insulation long-service-life thermal barrier coating containing a vertical crack structure is characterized by sequentially comprising a metal alloy substrate, a bonding layer, an 8YSZ micro-nano structure heat insulation layer and a rare earth doped zirconia/hafnium ceramic layer containing the vertical crack structure from bottom to top.
2. The high thermal insulation long life thermal barrier coating of claim 1, wherein said bond coat comprises a first bond coat and a second bond coat, said first bond coat having a thickness of 80 to 100 μm, said second bond coat having a thickness of 30 to 60 μm, said 8YSZ micro-nano structured coating having a thickness of 180 to 250 μm, said rare earth doped zirconia/hafnium ceramic layer having a vertical crack structure having a thickness of 300 to 1300 μm.
3. The high thermal insulation long life thermal barrier coating of claim 1, wherein the bond coat is MCrAlYSiHf, M is Ni or NiCo, comprising the following components in mass percent: 61.9 to 74 percent of Ni+Co,20 to 25 percent of Cr,5 to 10 percent of Al,0.4 to 1.5 percent of Y,0.3 to 0.8 percent of Si and 0.3 to 0.8 percent of Hf.
4. The high thermal insulation long life thermal barrier coating of claim 1, wherein the 8YSZ used in the 8YSZ micro-nano structured thermal barrier layer is 8wt.% yttria partially stabilized zirconia, the primary powder is 20-40nm 8YSZ nano powder, the 8YSZ nano powder is composed of tetragonal phase t-ZrO 2 And monoclinic m- -ZrO 2 Composition of the tetragonal phase t-ZrO 2 The mass percentage of the monoclinic m-ZrO is more than 97 percent 2 The mass percentage of (2) is less than 3%.
5. The high thermal insulation long life thermal barrier coating containing vertical crack structure according to claim 1, wherein the rare earth oxide in the rare earth doped zirconia/hafnium ceramic layer containing vertical crack structure is any one or more of yttria, scandia, ytterbia, gadolinium oxide, and the total rare earth oxide is less than 12% by mass.
6. A method of producing a high thermal insulation long life thermal barrier coating containing a vertical crack structure as claimed in any of claims 1 to 5, comprising the steps of:
s1, carrying out sand blasting coarsening pretreatment on a metal alloy matrix after washing the metal alloy matrix by adopting alcohol and acetone, carrying out ultrasonic washing on the metal alloy matrix after sand blasting coarsening,
s2, preparing a first bonding layer on the roughened surface of the metal matrix by adopting a supersonic flame spraying technology,
s3, preparing a second bonding layer on the first bonding layer by adopting an atmospheric plasma spraying technology;
s4, preheating the sample with the bonding layer obtained in the step S3 to 200-500 ℃;
s5, preparing an 8YSZ micro-nano structure heat insulation layer and a rare earth doped zirconia/hafnium ceramic layer with a vertical crack structure on the surface of the bonding layer by adopting an atmospheric plasma spraying technology.
7. The method for preparing the high thermal insulation long-life thermal barrier coating with the vertical crack structure according to claim 6, wherein the technological parameters of the supersonic flame spraying technology in the step S2 are as follows: the oxygen flow is 50-55L/min, the kerosene flow is 28-32L/min, the spraying distance is 330-380 mm, the powder feeding rate is 50-80 g/min, the gun barrel is 4-6 inches, the moving speed of the spray gun is 750-850 mm/s, and the step distance is 2-4 mm.
8. The method for preparing the high thermal insulation and long service life thermal barrier coating with the vertical crack structure according to claim 6, wherein the process parameters of the atmospheric plasma spraying technology in the step S3 are as follows: the spraying current is 400-500A, the spraying power is 28-34 kW, the powder feeding rate is 25-40 g/min, the spraying distance is 100-140 mm, the main air flow Ar is 40-55L/min, and H 2 The air flow is 4-8L/min, the moving speed of the spray gun is 750-850 mm/s, and the step distance is 2-4 mm.
9. The method for preparing the high thermal insulation and long service life thermal barrier coating with the vertical crack structure according to claim 6, wherein the process parameters of the atmospheric plasma spraying in the step S5 are as follows: the spraying current is 500-650A, the spraying power is 36-40 kW, the powder feeding rate is 35-50 g/min, the spraying distance is 70-100 mm, the main air flow Ar is 40-50L/min, the moving speed of the spray gun is 250-350 mm/s, and the step distance is 2-4 mm.
10. The method for preparing the high-thermal-insulation long-life thermal barrier coating with the vertical crack structure according to claim 6, wherein in the step S5, the 8YSZ micro-nano structural heat insulation layer and the rare earth doped zirconia/hafnium ceramic layer with the vertical crack structure are powder materials which are subjected to spray granulation to obtain primary nano agglomerated powder, then the primary nano agglomerated powder is sintered for 4-6 hours at 900-1100 ℃, and then the powder materials are screened to obtain the 8YSZ micro-nano structural heat insulation layer powder materials with the particle size in the range of 10-40 μm and the powder materials of the rare earth doped zirconia/hafnium ceramic layer with the vertical crack structure.
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