CN117107311A - 一种Pt改性的叶片叶尖防护涂层及其制备方法 - Google Patents
一种Pt改性的叶片叶尖防护涂层及其制备方法 Download PDFInfo
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- 239000011253 protective coating Substances 0.000 title claims abstract description 62
- 238000002360 preparation method Methods 0.000 title claims abstract description 16
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims abstract description 93
- 229910052759 nickel Inorganic materials 0.000 claims abstract description 46
- 238000009713 electroplating Methods 0.000 claims abstract description 42
- 238000000034 method Methods 0.000 claims abstract description 36
- 238000000576 coating method Methods 0.000 claims abstract description 35
- 239000011248 coating agent Substances 0.000 claims abstract description 33
- 239000002245 particle Substances 0.000 claims abstract description 33
- 239000000758 substrate Substances 0.000 claims abstract description 33
- 238000005269 aluminizing Methods 0.000 claims abstract description 20
- 229910000951 Aluminide Inorganic materials 0.000 claims abstract description 13
- 239000002131 composite material Substances 0.000 claims abstract description 12
- 238000000151 deposition Methods 0.000 claims abstract description 11
- 238000007733 ion plating Methods 0.000 claims abstract description 10
- 238000000137 annealing Methods 0.000 claims abstract description 5
- 229910000601 superalloy Inorganic materials 0.000 claims abstract description 5
- 239000010410 layer Substances 0.000 claims description 69
- 238000007747 plating Methods 0.000 claims description 38
- 239000000243 solution Substances 0.000 claims description 16
- 239000011159 matrix material Substances 0.000 claims description 13
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 claims description 12
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 claims description 12
- 239000008367 deionised water Substances 0.000 claims description 9
- 229910021641 deionized water Inorganic materials 0.000 claims description 9
- 238000010438 heat treatment Methods 0.000 claims description 9
- 239000010935 stainless steel Substances 0.000 claims description 9
- 229910001220 stainless steel Inorganic materials 0.000 claims description 9
- 239000000126 substance Substances 0.000 claims description 9
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 9
- 238000005238 degreasing Methods 0.000 claims description 8
- 239000012790 adhesive layer Substances 0.000 claims description 7
- 229910045601 alloy Inorganic materials 0.000 claims description 7
- 239000000956 alloy Substances 0.000 claims description 7
- 239000003795 chemical substances by application Substances 0.000 claims description 7
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 claims description 6
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 6
- 229910015372 FeAl Inorganic materials 0.000 claims description 6
- 239000007864 aqueous solution Substances 0.000 claims description 6
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- 238000007789 sealing Methods 0.000 claims description 6
- 230000003213 activating effect Effects 0.000 claims description 5
- 238000004140 cleaning Methods 0.000 claims description 5
- 238000004519 manufacturing process Methods 0.000 claims description 5
- 229920000642 polymer Polymers 0.000 claims description 4
- 229910016569 AlF 3 Inorganic materials 0.000 claims description 3
- 238000001035 drying Methods 0.000 claims description 3
- 235000019441 ethanol Nutrition 0.000 claims description 3
- 238000011049 filling Methods 0.000 claims description 3
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- 239000013077 target material Substances 0.000 claims description 3
- 238000004506 ultrasonic cleaning Methods 0.000 claims description 3
- 238000005406 washing Methods 0.000 claims description 3
- 238000001816 cooling Methods 0.000 claims description 2
- 238000005498 polishing Methods 0.000 claims description 2
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- 230000003647 oxidation Effects 0.000 abstract description 22
- 238000007254 oxidation reaction Methods 0.000 abstract description 22
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- 238000012986 modification Methods 0.000 abstract description 2
- 230000004048 modification Effects 0.000 abstract description 2
- 230000002035 prolonged effect Effects 0.000 abstract description 2
- 229910000943 NiAl Inorganic materials 0.000 description 8
- NPXOKRUENSOPAO-UHFFFAOYSA-N Raney nickel Chemical compound [Al].[Ni] NPXOKRUENSOPAO-UHFFFAOYSA-N 0.000 description 8
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- 238000007790 scraping Methods 0.000 description 5
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- 125000004122 cyclic group Chemical group 0.000 description 1
- 238000013461 design Methods 0.000 description 1
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- 230000002401 inhibitory effect Effects 0.000 description 1
- 230000000977 initiatory effect Effects 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 229910052697 platinum Inorganic materials 0.000 description 1
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- 239000002356 single layer Substances 0.000 description 1
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- 229910052727 yttrium Inorganic materials 0.000 description 1
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- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
- C25D5/10—Electroplating with more than one layer of the same or of different metals
- C25D5/12—Electroplating with more than one layer of the same or of different metals at least one layer being of nickel or chromium
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- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C19/00—Alloys based on nickel or cobalt
- C22C19/007—Alloys based on nickel or cobalt with a light metal (alkali metal Li, Na, K, Rb, Cs; earth alkali metal Be, Mg, Ca, Sr, Ba, Al Ga, Ge, Ti) or B, Si, Zr, Hf, Sc, Y, lanthanides, actinides, as the next major constituent
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Abstract
本发明涉及在金属材料表面沉积防护涂层技术领域,具体涉及一种Pt改性的叶片叶尖防护涂层及其制备方法。采用电镀与气相渗铝相结合的工艺,在镍基高温合金基体上制备出Pt改性的叶片叶尖防护涂层。首先在基体上电弧离子镀一层NiCrAlYSi粘结层;其次在粘结层表面通过复合电镀的方式固定硬质颗粒;随后在复合电镀层表面电镀一层纯Pt镀层并对其进行真空退火处理;最后采用高温低活度气相渗铝工艺得到Pt改性的叶片叶尖防护涂层,该涂层由NiCrAlYSi粘结层内层和镶嵌有cBN硬质颗粒的Pt改性的铝化物外层构成。本发明采用电镀的方法引入Pt元素进行改性,工艺简单,成本低,Pt改性的叶片叶尖防护涂层具有更好的高温抗氧化性,从而延长叶片叶尖防护涂层的使用寿命。
Description
技术领域
本发明涉及在金属材料表面沉积防护涂层技术领域,具体涉及一种Pt改性的叶片叶尖防护涂层及其制备方法。
背景技术
航空发动机作为飞机飞行的动力机械,其结构高度复杂精密,技术集成度极高,因此其制造水平一直是衡量一个国家整体工业水平的标杆。航空发动机在工作时,进入发动机的空气由多级压气机压缩,然后在燃烧室中与燃油混合发生燃烧,最后高温高压的燃气以极高的速率通过涡轮叶片排出发动机。整个工作过程是在高温高压环境下实现,因此对整个发动机内部的密封性有着较高的要求,而发动机内部转子叶片与机匣间的间隙控制尤为重要。当涡轮叶片与机匣间的间隙过大时会导致循环效率降低,气流不稳;而间隙不足时则会限制冷却气流的流量,并导致叶尖与机匣摩擦,甚至造成叶片损伤,从而导致关键部件服役寿命下降。有研究表明涡轮部位的径向间隙每增加254μm,单位油耗将增加约0.1%,出口温度将降低1℃。因此,为了提高燃油效率并且降低油耗,先进航空发动机在设计制造过程中通常会在叶片叶尖和机匣之间引入气路密封系统,包括涂覆于叶片叶尖的密封材料和涂覆于机匣部件的可磨耗密封材料。
可磨耗密封材料在服役过程中会遭受转子叶片的刮削,从而将径向间隙减小到机械手段难以达到的水平。随着涡轮转子叶片叶尖与可磨耗密封材料刮削时间的增加,叶片叶尖会受到较大的磨损。由于高压涡轮叶片尖端裂纹的萌生与扩展是由循环热应力与腐蚀环境共同作用造成的,因此叶尖防护涂层应该具有高耐磨和抗氧化综合性能。对于在叶尖制备的单层防护涂层,如:铝化物涂层和MCrAlY涂层,虽然拥有良好的高温抗氧化和热腐蚀性能,但其抗刮削性能及抗摩擦磨损性能较差,因此目前各个国家在重点研究应用在涡轮叶片叶尖处的防护涂层。叶片叶尖防护涂层通常是将耐磨的硬质颗粒镶嵌在抗氧化性金属基体表面,从而实现叶片叶尖良好的刮削性和耐磨性。中国科学院金属研究所近年来发展了一种NiCrAlYSi+NiAl/cBN涂层,通过将cBN颗粒引入到铝化物涂层中从而制备出叶片叶尖防护涂层。研究发现该涂层有着良好的摩擦磨损性能,且在900℃下也有较好的抗氧化性能,但是其在高于900℃时抗氧化性能较差。
由此可见,叶片叶尖防护涂层虽然具有良好的摩擦磨损性能,但由于其抗氧化性元素含量不足或者硬质颗粒的引入导致其高温抗氧化性能较差,因此需要对其进行改性,从而提高防护涂层的高温抗氧化性能。而目前国内对此研究较少,尤其是针对800℃以上高温段的叶尖防护涂层。
发明内容
本发明的目的是提供一种Pt改性的叶片叶尖防护涂层及其制备方法,以解决目前航空发动机涡轮叶片叶尖防护涂层刮削性、摩擦磨损性能和高温抗氧化性能等不足的问题。本发明采用复合电镀的方法将Pt元素引入NiCrAlYSi+NiAl/cBN涂层中,其制备工艺简单,成本低;涂层中Pt元素含量可控,且分布均匀。
为了实现上述目的,本发明所采用的技术方案为:
一种Pt改性的叶片叶尖防护涂层的制备方法,该制备方法包括以下步骤:
(1)对镍基高温合金基体进行预处理
基体表面经800#砂纸打磨后进行湿喷砂处理,并用丙酮、酒精依次进行超声清洗;
(2)在预处理后的基体表面用电弧离子镀沉积NiCrAlYSi粘结层
按质量百分比计,所用NiCrAlYSi靶材成分为68.89Ni-18.11Cr-11.5Al-0.6Y-0.9Si,电弧离子镀沉积的工艺参数为:弧电压18~20V,弧电流60~100A,直流脉冲负偏压100~250V,占空比20~40%,沉积时间6~8h;
(3)在经步骤(2)制备的NiCrAlYSi粘结层表面预镀镍层
预镀镍过程为:将沉积有NiCrAlYSi粘结层的基体在体积分数20%的浓盐酸中活化30~60s,随后在瓦特液中电镀镍,基体作为阴极,纯镍板作为阳极,电流密度为1~3A/dm2,镀镍时间为2~4min;
(4)复合电镀cBN颗粒
电镀过程为:先将cBN颗粒均匀的分布在步骤(3)制备的预镀镍层表面,放入瓦特液中以0.5~1A/dm2的电流密度,复合电镀30min~1h固定cBN颗粒;然后取出基体并清理掉表面多余的颗粒;最后以0.5~2.0A/dm2的电流密度,电镀2.5~4h加固cBN颗粒;整个电镀过程中电镀槽的温度始终维持在40~50℃,阳极为纯镍板,阴极为基体;
(5)对经步骤(4)制备的基体表面进行镀Pt前预处理
首先对基体表面电化学除油,电化学除油溶液为NaOH水溶液,浓度为5~15g/L,基体作阴极,不锈钢板作阳极,电流密度为5~10A/dm2,时间为1~3min;电化学除油后用去离子水清洗,再将基体在体积分数20%的浓盐酸中活化1~3min;
(6)在经步骤(5)镀Pt前预处理后的基体表面预镀镍层,预镀镍层的方法和步骤(3)中所述方法相同;
(7)在经步骤(6)制备的预镀镍层表面电镀纯Pt层;
(8)将步骤(7)中所得的涂层进行退火处理
试样镀Pt后进行封管处理,在室温下置于马弗炉内,以3~10℃/min的速率升温到200~300℃保温1~3h,再以3~10℃/min的速率升温到500~700℃保温1~3h,最后以3~10℃/min的速率升温到1000~1100℃保温1~3h;
(9)化学气相渗铝
渗铝的步骤为:将FeAl合金块(Fe-50wt.%Al)和AlF3·3H2O均匀混合放入干净的不锈钢坩埚中,FeAl合金块的成分为Al 50wt.%、Fe50 wt.%,将基体放入铺有渗铝剂的不锈钢坩埚中,并将基体悬挂于渗铝剂上方,准备完毕后装入化学气相渗炉内,关闭炉腔;使用机械泵将渗铝炉内的压强抽至100Pa以下后,充入Ar气至常压,该过程重复三次;随后开启加热,以5~20℃/min的升温速率升至1000~1100℃,保温3~6h,基体随炉冷却至100℃以下开炉取出;最后分别用去离子水、无水乙醇超声清洗并烘干,由此得到Pt改性的叶片叶尖防护涂层。
所述的Pt改性的叶片叶尖防护涂层的制备方法,步骤(2)中,用电弧离子镀法沉积的NiCrAlYSi粘结层的厚度保持在30~40μm。
所述的Pt改性的叶片叶尖防护涂层的制备方法,步骤(3)中,预镀镍层的厚度控制在1~5μm。
所述的Pt改性的叶片叶尖防护涂层的制备方法,步骤(4)中,cBN颗粒的粒径为50~150μm。
所述的Pt改性的叶片叶尖防护涂层的制备方法,步骤(7)中,电镀纯Pt层时,电镀液配方为:Na2HPO4浓度2~5g/L、[Pt(NH3)4]HPO4浓度5~10g/L,去离子水余量;电镀前用浓度为5~15g/L的NaOH水溶液调节镀液pH为9~11,基体作为阴极,纯Pt片作为阳极,电流密度为0.3~1mA/cm2,电镀液温度保持在80~100℃,电镀时间0.5~1.5h,电镀获得的纯Pt层厚度控制在1~5μm之间。
上述方法制备的Pt改性的叶片叶尖防护涂层,该涂层分为两个亚层,包括分布有cBN颗粒的Pt改性的铝化物外层和NiCrAlYSi粘结层内层。
所述的Pt改性的叶片叶尖防护涂层,Pt改性的铝化物外层为单一的β-(Ni,Pt)Al相,化学成分为:Pt 11~23wt.%,Al 17~24wt.%,Ni 58~66wt.%;NiCrAlYSi粘结层内层的成分为:Ni 78~85wt.%,Cr 6~13wt.%,Al 3~8wt.%,Y 0.5~1wt.%,Si 0.3~0.6wt.%,Pt0~0.05wt.%。
所述的Pt改性的叶片叶尖防护涂层,Pt改性的铝化物外层中基本不含PtAl2相,粘结层中基本不含Pt。
本发明的设计思想是:
虽然NiCrAlYSi+NiAl/cBN叶片叶尖防护涂层可以维持较好的密封性,但是其在900℃以上的抗氧化性较差。而研究发现将Pt元素引入涂层,不仅可以提高氧化膜与涂层的结合力,还可以促进单一α-Al2O3的形成,提高氧化膜的自愈合能力,同时还能抑制基体中难熔元素向涂层中的扩散,从而提高涂层的抗氧化性。通过电镀的方法制备纯Pt镀层,工艺简单,成本低,且对试样形状尺寸没有要求。所以,本发明采用电镀的工艺通过控制镀Pt层厚度来调控Pt元素在涂层中的含量。通过在cBN复合镀层表面引入镀Pt层,既可以使cBN颗粒保持较强的刮削性和耐磨性,同时还能保护叶片叶尖在较高温度下不被氧化,从而满足叶片叶尖防护涂层具有较高抗氧化性及良好密封性的双重目的。
本发明采用电镀与气相渗铝相结合的工艺,在镍基高温合金基体上制备出Pt改性的叶片叶尖防护涂层。首先在基体上电弧离子镀一层NiCrAlYSi粘结层;其次在粘结层表面通过复合电镀的方式固定cBN硬质颗粒得到Ni/cBN复合电镀层;随后在Ni/cBN表面电镀一层纯Pt镀层并对其进行真空退火处理;最后采用高温低活度气相渗铝工艺得到Pt改性的叶片叶尖防护涂层。Pt改性的叶片叶尖防护涂层由NiCrAlYSi粘结层内层和镶嵌有cBN硬质颗粒的Pt改性的铝化物外层构成。
本发明的优点及有益效果是:
1、本发明采用电镀的方法首次将Pt元素引入NiCrAlYSi+NiAl/cBN叶尖防护涂层中进行改性,且制备工艺简单,成本低。
2、本发明制备的Pt改性的叶片叶尖防护涂层中Pt元素含量可控,且分布均匀。
3、本发明制备的Pt改性的叶片叶尖防护涂层分为两个亚层,NiCrAlYSi粘结层内层和镶嵌有cBN硬质颗粒的Pt改性的铝化物外层,属于多层复合涂层。NiCrAlYSi粘结层中基本不含Pt;外层的cBN硬质颗粒可以起到良好的耐磨性,Pt改性的铝化物外层具有良好的高温抗氧化性。
附图说明
图1为Pt改性的叶片叶尖防护涂层的表面形貌。
图2为Pt改性的叶片叶尖防护涂层制备态表面XRD图谱分析。图中,横坐标2θ为衍射角(deg.),纵坐标Intensity为相对强度(a.u.)。
图3为Pt改性的叶片叶尖防护涂层的截面形貌。
图4为Pt改性的叶片叶尖防护涂层和普通NiCrAlYSi+NiAl/cBN叶尖防护涂层在900℃条件下的恒温氧化动力学曲线。图中,横坐标Oxidation time为氧化时间(h),纵坐标Mass gain为增重(mg/cm2)。
具体实施方式
以下结合附图及实施例详述本发明。显然,所描述的实施例仅仅是本发明的一个实施例,而不是全部实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的其他实施例,都属于本发明保护的范围。
实施例1
本实施例中,基体采用K438镍基高温合金,其化学成分如下(质量百分数):15.7Cr-8Co-2.4W-1.5Mo-3.2Al-3Ti-1.5Ta-0.1C-0.6Nb-0.05Zr-0.005B-Bal.Ni。采用电火花线切割从合金基材上切割出厚度为2mm、直径为12mm的试样,并在试样距边缘1mm处加工一个直径为1.5mm的圆孔,以方便电镀等过程中悬挂试样。
Pt改性的叶片叶尖防护涂层的制备方法,包括如下步骤:
(1)对试样进行表面处理。试样表面使用800#砂纸打磨,然后进行湿喷砂处理,随后用丙酮、酒精依次进行超声清洗。
(2)在预处理后的基体试样表面用电弧离子镀沉积NiCrAlYSi粘结层。所用NiCrAlYSi靶材成分为68.89Ni-18.11Cr-11.5Al-0.6Y-0.9Si(wt.%),电弧离子镀沉积的工艺参数为:弧电压20V,弧电流90A,直流脉冲负偏压160V,占空比25%,沉积时间7h,使镀的粘结层厚度在30~40μm之间。
(3)预镀镍层。预镀镍过程为:将沉积有粘结层的试样在20%(体积分数)浓盐酸中活化60s,随后在瓦特液中电镀镍,基体试样作为阴极,纯镍板作为阳极,电流密度为2A/dm2,镀镍时间为3min,使镀镍层厚度在1~3μm之间。
(4)电镀cBN颗粒。电镀过程为:将粒径为100μm的cBN颗粒均匀的分布在试样表面,放入瓦特液中以0.6A/dm2的电流密度,复合电镀1h固定cBN颗粒,然后取出试样并清理掉表面多余的颗粒;最后以0.8A/dm2的电流密度,电镀3h加固cBN颗粒。整个电镀过程中电镀槽的温度维持在45℃,阳极为纯镍板,阴极为试样。
(5)镀Pt前预处理。首先对试样表面电化学除油,电化学除油溶液为NaOH水溶液,浓度为5g/L,试样作阴极,不锈钢板作阳极,电流密度为8A/dm2,时间为1min。去离子水清洗之后,再将试样在20%(体积分数)的浓盐酸中活化1min。
(6)预镀镍层。预镀镍过程为:在瓦特液中电镀镍,基体试样作为阴极,纯镍板作为阳极,电流密度为2A/dm2,镀镍时间为3min,使镀镍层厚度保持在1~3μm之间。
(7)电镀纯Pt层。电镀液配方为:Na2HPO4浓度4g/L、[Pt(NH3)4]HPO4浓度5g/L,去离子水余量;电镀前用浓度为5g/L的NaOH水溶液调节镀液pH为10.5,试样作为阴极,纯Pt片作为阳极,电流密度为0.4mA/cm2,电镀液温度保持在92℃,电镀时间30min,电镀获得的Pt层厚度为2μm。
(8)退火处理。试样镀Pt后进行封管处理,在室温下置于马弗炉内,以5℃/min的速率升温到260℃保温2h,再以5℃/min的速率升温到650℃保温2h,最后以5℃/min的速率升温到1050℃保温2h。
(9)化学气相渗铝。渗铝的步骤为:将FeAl合金块(Fe-50wt.%Al)和AlF3·3H2O均匀混合作为渗铝剂,放入干净的不锈钢坩埚中,FeAl合金块的成分为Al 50wt.%、Fe50wt.%,将试样放入铺有渗铝剂的不锈钢坩埚中,并将试样悬挂于渗铝剂上方,准备完毕后装入化学气相渗炉内,关闭炉腔;使用机械泵将渗铝炉内的压强抽至100Pa以下,然后充入Ar气至常压,该过程重复三次;随后开启加热,以10℃/min的升温速率升至1080℃,保温4.5h;实验结束后,试样随炉冷却至100℃以下方可开炉取样,最后分别用去离子水、无水乙醇超声清洗并烘干,由此得到Pt改性的叶片叶尖防护涂层。
在本实施例中,由图1涂层的表面SEM图可以看出,制备后的叶尖防护涂层中黑色的cBN均匀地镶嵌在涂层中,两者结合紧密。经过图2所示的XRD分析得出,X射线探测深度范围内涂层为单相β-(Ni,Pt)Al涂层,且涂层在试样表面分布紧密,无开裂和鼓包。
如图3所示,由制备的叶尖防护涂层的截面SEM图可以看出,涂层分为两个亚层,其中:层1为分布有cBN颗粒的β-(Ni,Pt)Al涂层外层,层2为NiCrAlYSi粘结层。β-(Ni,Pt)Al涂层中Pt元素平均含量为18.6wt.%,Al元素平均含量为19.6wt.%,其余为Ni元素,该涂层中几乎不含PtAl2相,由于粘结层中Cr的扩散在靠近层2处还含有1.4wt.%的Cr元素。从图3中还可以看出,cBN与涂层基体结合紧密无缝隙,β-(Ni,Pt)Al涂层致密没有孔洞。NiCrAlYSi粘结层中元素平均含量为:Ni 83wt.%,Cr 10.3wt.%,Al 5.7wt.%,Y 0.5wt.%,Si0.47wt.%,Pt 0.03wt.%,可以看到粘结层中基本没有Pt元素。
如图4所示,由Pt改性的NiCrAlYSi+NiAl/cBN叶尖防护涂层和普通的NiCrAlYSi+NiAl/cBN叶尖防护涂层900℃条件下的恒温氧化动力学曲线可以看出,由于Pt的引入,在氧化的200h过程中Pt改性的NiCrAlYSi+NiAl/cBN叶尖防护涂层的氧化增重明显小于普通的NiCrAlYSi+NiAl/cBN叶尖防护涂层。说明Pt的加入可以显著减小叶尖防护涂层的氧化速率,从而提高涂层的高温抗氧化性。
实施例结果表明,本发明Pt改性的叶片叶尖防护涂层具有更好的高温抗氧化性,从而延长叶片叶尖防护涂层的使用寿命,使航空发动机维持良好的密封性。
Claims (8)
1.一种Pt改性的叶片叶尖防护涂层的制备方法,其特征在于,该制备方法包括以下步骤:
(1)对镍基高温合金基体进行预处理
基体表面经800#砂纸打磨后进行湿喷砂处理,并用丙酮、酒精依次进行超声清洗;
(2)在预处理后的基体表面用电弧离子镀沉积NiCrAlYSi粘结层
按质量百分比计,所用NiCrAlYSi靶材成分为68.89Ni-18.11Cr-11.5Al-0.6Y-0.9Si,电弧离子镀沉积的工艺参数为:弧电压18~20V,弧电流60~100A,直流脉冲负偏压100~250V,占空比20~40%,沉积时间6~8h;
(3)在经步骤(2)制备的NiCrAlYSi粘结层表面预镀镍层
预镀镍过程为:将沉积有NiCrAlYSi粘结层的基体在体积分数20%的浓盐酸中活化30~60s,随后在瓦特液中电镀镍,基体作为阴极,纯镍板作为阳极,电流密度为1~3A/dm2,镀镍时间为2~4min;
(4)复合电镀cBN颗粒
电镀过程为:先将cBN颗粒均匀的分布在步骤(3)制备的预镀镍层表面,放入瓦特液中以0.5~1A/dm2的电流密度,复合电镀30min~1h固定cBN颗粒;然后取出基体并清理掉表面多余的颗粒;最后以0.5~2.0A/dm2的电流密度,电镀2.5~4h加固cBN颗粒;整个电镀过程中电镀槽的温度始终维持在40~50℃,阳极为纯镍板,阴极为基体;
(5)对经步骤(4)制备的基体表面进行镀Pt前预处理
首先对基体表面电化学除油,电化学除油溶液为NaOH水溶液,浓度为5~15g/L,基体作阴极,不锈钢板作阳极,电流密度为5~10A/dm2,时间为1~3min;电化学除油后用去离子水清洗,再将基体在体积分数20%的浓盐酸中活化1~3min;
(6)在经步骤(5)镀Pt前预处理后的基体表面预镀镍层,预镀镍层的方法和步骤(3)中所述方法相同;
(7)在经步骤(6)制备的预镀镍层表面电镀纯Pt层;
(8)将步骤(7)中所得的涂层进行退火处理
试样镀Pt后进行封管处理,在室温下置于马弗炉内,以3~10℃/min的速率升温到200~300℃保温1~3h,再以3~10℃/min的速率升温到500~700℃保温1~3h,最后以3~10℃/min的速率升温到1000~1100℃保温1~3h;
(9)化学气相渗铝
渗铝的步骤为:将FeAl合金块(Fe-50wt.%Al)和AlF3·3H2O均匀混合放入干净的不锈钢坩埚中,FeAl合金块的成分为Al 50wt.%、Fe50 wt.%,将基体放入铺有渗铝剂的不锈钢坩埚中,并将基体悬挂于渗铝剂上方,准备完毕后装入化学气相渗炉内,关闭炉腔;使用机械泵将渗铝炉内的压强抽至100Pa以下后,充入Ar气至常压,该过程重复三次;随后开启加热,以5~20℃/min的升温速率升至1000~1100℃,保温3~6h,基体随炉冷却至100℃以下开炉取出;最后分别用去离子水、无水乙醇超声清洗并烘干,由此得到Pt改性的叶片叶尖防护涂层。
2.根据权利要求1所述的Pt改性的叶片叶尖防护涂层的制备方法,其特征在于,步骤(2)中,用电弧离子镀法沉积的NiCrAlYSi粘结层的厚度保持在30~40μm。
3.根据权利要求1所述的Pt改性的叶片叶尖防护涂层的制备方法,其特征在于,步骤(3)中,预镀镍层的厚度控制在1~5μm。
4.根据权利要求1所述的Pt改性的叶片叶尖防护涂层的制备方法,其特征在于,步骤(4)中,cBN颗粒的粒径为50~150μm。
5.根据权利要求1所述的Pt改性的叶片叶尖防护涂层的制备方法,其特征在于,步骤(7)中,电镀纯Pt层时,电镀液配方为:Na2HPO4浓度2~5g/L、[Pt(NH3)4]HPO4浓度5~10g/L,去离子水余量;电镀前用浓度为5~15g/L的NaOH水溶液调节镀液pH为9~11,基体作为阴极,纯Pt片作为阳极,电流密度为0.3~1mA/cm2,电镀液温度保持在80~100℃,电镀时间0.5~1.5h,电镀获得的纯Pt层厚度控制在1~5μm之间。
6.一种权利要求1~5任一方法制备的Pt改性的叶片叶尖防护涂层,其特征在于,该涂层分为两个亚层,包括分布有cBN颗粒的Pt改性的铝化物外层和NiCrAlYSi粘结层内层。
7.根据权利要求6所述的Pt改性的叶片叶尖防护涂层,其特征在于,Pt改性的铝化物外层为单一的β-(Ni,Pt)Al相,化学成分为:Pt 11~23wt.%,Al 17~24wt.%,Ni58~66wt.%;NiCrAlYSi粘结层内层的成分为:Ni 78~85wt.%,Cr 6~13wt.%,Al 3~8wt.%,Y 0.5~1wt.%,Si 0.3~0.6wt.%,Pt0~0.05wt.%。
8.根据权利要求6所述的Pt改性的叶片叶尖防护涂层,其特征在于,Pt改性的铝化物外层中基本不含PtAl2相,粘结层中基本不含Pt。
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