CN117403171A - Preparation method of thermal barrier coating with long service life and high interface bonding strength - Google Patents
Preparation method of thermal barrier coating with long service life and high interface bonding strength Download PDFInfo
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- CN117403171A CN117403171A CN202311258335.9A CN202311258335A CN117403171A CN 117403171 A CN117403171 A CN 117403171A CN 202311258335 A CN202311258335 A CN 202311258335A CN 117403171 A CN117403171 A CN 117403171A
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- 239000012720 thermal barrier coating Substances 0.000 title claims abstract description 31
- 238000002360 preparation method Methods 0.000 title abstract description 10
- 239000011159 matrix material Substances 0.000 claims abstract description 73
- 238000005507 spraying Methods 0.000 claims abstract description 71
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 63
- 239000000956 alloy Substances 0.000 claims abstract description 63
- 239000000843 powder Substances 0.000 claims abstract description 50
- 239000000919 ceramic Substances 0.000 claims abstract description 34
- 238000000034 method Methods 0.000 claims abstract description 24
- 239000002184 metal Substances 0.000 claims abstract description 22
- 238000010285 flame spraying Methods 0.000 claims abstract description 13
- 239000002245 particle Substances 0.000 claims abstract description 11
- 238000007750 plasma spraying Methods 0.000 claims abstract description 10
- 230000003746 surface roughness Effects 0.000 claims abstract description 10
- 239000000758 substrate Substances 0.000 claims description 31
- 239000007921 spray Substances 0.000 claims description 27
- 229910000601 superalloy Inorganic materials 0.000 claims description 24
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 14
- ATUOYWHBWRKTHZ-UHFFFAOYSA-N Propane Chemical compound CCC ATUOYWHBWRKTHZ-UHFFFAOYSA-N 0.000 claims description 14
- 238000001816 cooling Methods 0.000 claims description 12
- 238000005488 sandblasting Methods 0.000 claims description 12
- 238000010438 heat treatment Methods 0.000 claims description 10
- 238000010926 purge Methods 0.000 claims description 8
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 claims description 7
- 239000001257 hydrogen Substances 0.000 claims description 7
- 229910052739 hydrogen Inorganic materials 0.000 claims description 7
- 229910052757 nitrogen Inorganic materials 0.000 claims description 7
- 239000001294 propane Substances 0.000 claims description 7
- 229910001233 yttria-stabilized zirconia Inorganic materials 0.000 claims description 7
- 238000012544 monitoring process Methods 0.000 claims description 4
- 238000001931 thermography Methods 0.000 claims description 4
- 238000007664 blowing Methods 0.000 claims description 2
- 239000010410 layer Substances 0.000 abstract description 64
- 238000005516 engineering process Methods 0.000 abstract description 9
- 230000008569 process Effects 0.000 abstract description 5
- 230000003647 oxidation Effects 0.000 abstract description 3
- 238000007254 oxidation reaction Methods 0.000 abstract description 3
- 239000002344 surface layer Substances 0.000 abstract description 3
- 238000012360 testing method Methods 0.000 description 4
- 238000000576 coating method Methods 0.000 description 2
- 230000004075 alteration Effects 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000005524 ceramic coating Methods 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 238000004372 laser cladding Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- 238000004901 spalling Methods 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- 238000012876 topography Methods 0.000 description 1
Classifications
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- 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
-
- 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
- C23C4/073—Metallic material containing MCrAl or MCrAlY alloys, where M is nickel, cobalt or iron, with or without non-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
- 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
Abstract
The embodiment of the invention discloses a preparation method of a thermal barrier coating with long service life and high interface bonding strength, which comprises the following steps: step 1: preheating a high-temperature alloy matrix to enable the surface temperature of the high-temperature alloy matrix to reach a preset temperature, and spraying metal bonding layer powder onto the surface of the high-temperature alloy matrix by adopting a supersonic flame spraying method to form a metal bonding layer; step 2: and spraying ceramic powder onto the surface of the metal bonding layer by an atmospheric plasma spraying method to deposit and form a ceramic layer. According to the invention, the bonding layer is prepared by adopting a supersonic flame spraying technology, and the preparation of the bonding layer with high density and high surface roughness can be realized simultaneously by selecting proper spraying powder particle size and controlling the temperature of the matrix, so that the oxidation resistance of the thermal barrier coating can be ensured, the interface bonding strength of the interface bonding layer and the ceramic surface layer can be improved, and the one-step forming of the thermal barrier coating with long service life and high interface bonding strength is realized. The invention has the advantages of simple process flow and low cost.
Description
Technical Field
The invention relates to the field of thermal barrier coatings, in particular to a preparation method of a thermal barrier coating with long service life and high interface bonding strength.
Background
High interface roughness is critical to improving thermal barrier coating interface bonding and service life. At present, a method of a double-layer bonding layer is mainly adopted to realize the preparation of the high-interface roughness thermal barrier coating: a compact NiCoCrAlY layer sprayed by finer powder is adopted at one side close to the substrate, so that the purpose of providing sufficient Al element supply is to ensure that a continuous compact alumina film can be formed in the service process; the rough layer is obtained by spraying coarser powder on one side close to the ceramic layer, the density is slightly low, and the purpose is to form higher interface roughness and ensure good binding force with the ceramic layer. The method of the double-layer bonding layer needs to adopt spraying powder with different particle sizes and different spraying parameters, so that the process is complex and the preparation cost is high. In recent years, a laser cladding method of a bonding layer is also utilized to improve the interface roughness (CN 104451672B) of a thermal barrier coating, but a metal bonding layer is required to be prepared by pre-spraying on the surface of a high-temperature alloy substrate, but the bonding layer is easily damaged by high laser energy, so that the components and mechanical properties of the substrate are damaged, and industrial application cannot be realized.
Disclosure of Invention
The technical problem to be solved by the embodiment of the invention is to provide a preparation method of the thermal barrier coating with long service life and high interface bonding strength, so as to realize one-step forming of the thermal barrier coating with long service life and high interface bonding strength.
In order to solve the technical problems, the embodiment of the invention provides a preparation method of a thermal barrier coating with long service life and high interface bonding strength, which comprises the following steps:
step 1: preheating a high-temperature alloy matrix to enable the surface temperature of the high-temperature alloy matrix to reach a preset temperature, and spraying metal bonding layer powder onto the surface of the high-temperature alloy matrix by adopting a supersonic flame spraying method to form a metal bonding layer;
step 2: and spraying ceramic powder onto the surface of the metal bonding layer by an atmospheric plasma spraying method to deposit and form a ceramic layer.
Further, the metal bond layer powder particle size ranges from 25 μm to 40 μm.
In the step 1, when ultrasonic flame spraying is adopted, sand blasting is firstly carried out on the surface of the high-temperature alloy matrix; the preset temperature range is 500-800 ℃, the distance between the supersonic flame gun and the superalloy substrate is 220-250 mm, the moving speed range of the supersonic flame gun is 1500-1800 mm/s, the powder feeding rotating speed is 2 r/min, the propane pressure is 90-95 PSI, the air pressure is 95-100 PSI, the hydrogen pressure is 25-30 PSI, and the nitrogen pressure is 40-50 PSI.
Further, step 1 comprises the sub-steps of:
(1) Monitoring the surface temperature of the high-temperature alloy matrix in real time by using a thermal imaging non-contact thermometer, preheating the high-temperature alloy matrix by using supersonic flame, and feeding no powder;
(2) Blowing the back side of the high-temperature alloy matrix by adopting compressed air, and starting powder feeding and spraying when the surface temperature of the high-temperature alloy matrix reaches a preset temperature by controlling the flow rate of the compressed air on the back side of the high-temperature alloy matrix;
(3) The supersonic flame gun moving path finishes covering the surface of the high-temperature alloy matrix once and records the covering as once spraying; stopping spraying after each spraying, and measuring the thickness of the metal bonding layer after the substrate is cooled;
(4) Repeating the substeps (1) - (3), controlling the thickness of the final metal bonding layer to be 150-200 mu m, and controlling the surface roughness Ra of the metal bonding layer to be 15-25 mu m.
Further, in the substep (2), when compressed air is adopted for purging, the purging direction of the air gun is perpendicular to the plane of the superalloy substrate, the flow rate of the compressed air is 40-70L/min, the distance between the air gun and the superalloy substrate is 100-200 mm, the moving path of the air gun is controlled by using a manipulator, the temperature of the superalloy substrate is uniformly controlled, and the moving speed of the air gun is 1500-1800 mm/s.
Further, the ceramic powder in step 2 is yttria stabilized zirconia, wherein Y 2 O 3 The mass content of (2) was 8%.
Further, in the step 2, when the atmospheric plasma spraying is carried out, the superalloy substrate is preheated, the temperature of the superalloy substrate is controlled to be 300-400 ℃, the distance between an atmospheric plasma spray gun and the superalloy substrate is 90-120 mm, the moving speed of the atmospheric plasma spray gun is 800-1000 mm/s, the powder feeding speed is 50-60 g/min, the powder feeding air flow is 0.5-1.0L/min, the voltage range is 180-200V, the spraying current range is 250-300A, the Ar air flow speed range is 30-60L/min, and H 2 The air flow rate is in the range of 5-20L/min.
Further, step 2 comprises the sub-steps of:
(a) Monitoring the surface temperature of the high-temperature alloy matrix in real time by using a thermal imaging non-contact thermometer, heating the high-temperature alloy matrix by using atmospheric plasma flame, purging the back side of the high-temperature alloy matrix by adopting compressed air, controlling the temperature by controlling the flow velocity of the compressed air at the back side of the high-temperature alloy matrix, and starting powder feeding spraying when the surface temperature of the high-temperature alloy matrix reaches 300-400 ℃; the surface of the metal bonding layer covering the superalloy substrate is recorded as one-time spraying after the moving path of the atmospheric plasma spray gun is completed; stopping spraying after each spraying, and measuring the thickness of the ceramic layer after cooling;
(b) Repeating the substep (a) to control the thickness of the final ceramic layer to be 200-300 mu m, and controlling the surface roughness Ra of the ceramic layer to be 15-25 mu m.
Further, when compressed air is adopted for purging in the substep (a), the air gun is perpendicular to the plane of the superalloy substrate, the distance between the air gun and the superalloy substrate is 100-150 mm, the moving path of the air gun is controlled by a manipulator, the temperature of the superalloy substrate is uniformly controlled, the moving speed of the air gun is 800-1000 mm/s, and the flow rate of the compressed air is 70-80L/min.
The beneficial effects of the invention are as follows: the invention utilizes the supersonic flame spraying technology, carries out compressed air cooling on the back side of a high-temperature alloy matrix, controls the surface temperature of the matrix by controlling the flow rate and the distance of gas, prepares a bonding layer with high density and high surface roughness by using finer spraying powder particle size, and prepares a ceramic coating by atmospheric plasma spraying. The high-density bonding layer can ensure the oxidation resistance of the thermal barrier coating, and meanwhile, the high surface roughness can improve the interface junction strength of the interface bonding layer and the ceramic surface layer, so that the one-step forming of the thermal barrier coating with long service life and high interface junction strength is realized; the invention has the characteristics of simple process flow and low cost, and can realize large-scale industrial application.
Drawings
FIG. 1 is a schematic cross-sectional view of a thermal barrier coating with long life and high interfacial bond strength in accordance with an embodiment of the present invention.
FIG. 2 is a surface topography of a thermal barrier coating with long life and high interfacial bond strength of an embodiment of the invention.
Detailed Description
It should be noted that, without conflict, the embodiments and features of the embodiments in the present application may be combined with each other, and the present invention will be further described in detail with reference to fig. 1, fig. 2, and a specific embodiment.
The metal bond layer powder of the present invention may be a metal bond layer powder commonly used in the art, preferably NiCoCrAlY. The preset temperature is preferably 700 ℃.
Example 1
(1) And carrying out sand blasting treatment on the high-temperature alloy matrix. After sand blasting, the high-temperature alloy matrix is preheated by utilizing supersonic flame spraying, the distance between a spray gun and the high-temperature alloy matrix is 230 mm, the particle size of sprayed powder is 25-40 mu m, the moving speed of the spray gun is 1500 mm/s, the powder feeding rotating speed is 2 r/min, the propane pressure is 92 PSI, the air pressure is 95 PSI, the hydrogen pressure is 25 PSI, and the nitrogen pressure is 45 PSI.
(2) The back side of the high-temperature alloy matrix is purged by compressed air, the flow rate of the compressed air is 65-70L/min, and the surface temperature is controlled at 500 ℃. The distance between the air gun and the high-temperature alloy matrix is 150 mm, and the moving speed of the air gun is 1500 mm/s.
(3) And stopping spraying when one spraying is finished, and restarting spraying when the surface temperature reaches 500 ℃ under the actions of flame heating and back air flow cooling. Repeating the above operation, and finally controlling the thickness of the metal bonding layer to be 150-200 mu m.
(4) And preparing a ceramic layer on the surface of the bonding layer by adopting an atmospheric plasma spraying technology. The ceramic layer is yttria-stabilized zirconia with a mass content of 8%. During spraying, the distance between a spray gun and a substrate is 90 mm, the moving speed of the spray gun is 800 mm/s, the powder feeding speed is 50 g/min, the powder feeding airflow is 0.5L/min, the voltage is 180V, the spraying current is 250A, the Ar airflow speed is 50L/min, and H 2 The air flow rate was 10L/min.
(5) The back side of the matrix is purged by compressed air with the flow rate of 70-80L/min and the surface temperature of 300-400 ℃. The distance between the air gun and the superalloy substrate is 100 mm, and the moving speed of the air gun is 800 mm/s.
(6) And stopping spraying when the spraying is finished once, and restarting spraying when the surface temperature reaches 300-400 ℃ under the actions of flame heating and back air flow cooling. Repeating the above operation, and finally controlling the thickness of the ceramic layer to be 200-300 μm.
Example 2
(1) And carrying out sand blasting treatment on the high-temperature alloy matrix. After sand blasting, the high-temperature alloy matrix is preheated by utilizing supersonic flame spraying, the distance between a spray gun and the high-temperature alloy matrix is 230 mm, the particle size of sprayed powder is 25-40 mu m, the moving speed of the spray gun is 1500 mm/s, the powder feeding rotating speed is 2 r/min, the propane pressure is 92 PSI, the air pressure is 95 PSI, the hydrogen pressure is 25 PSI, and the nitrogen pressure is 45 PSI.
(2) The back side of the high-temperature alloy matrix is purged by compressed air, the flow rate of the compressed air is 60-65L/min, and the surface temperature is controlled at 600 ℃. The distance between the air gun and the high-temperature alloy matrix is 150 mm, and the moving speed of the air gun is 1500 mm/s.
(3) And stopping spraying when one spraying is finished, and restarting spraying when the surface temperature reaches 600 ℃ under the actions of flame heating and back air flow cooling. Repeating the above operation, and finally controlling the thickness of the bonding layer to be 150-200 μm.
(4) And preparing a ceramic layer on the surface of the bonding layer by adopting an atmospheric plasma spraying technology. The ceramic layer is yttria-stabilized zirconia with a mass content of 8%. When spraying, the surface temperature is controlled to 300-400 ℃, and the back compressed air flow rate is controlled to 70-80L/min. The distance between the spray gun and the matrix is 90 mm, the moving speed of the spray gun is 800 mm/s, the powder feeding speed is 50 g/min, the powder feeding air flow is 0.5L/min, the voltage is 180V, the spraying current is 250A, the Ar air flow rate is 50L/min, and H 2 The air flow rate was 10L/min.
(5) The back side of the high-temperature alloy matrix is purged by compressed air, the flow rate of the compressed air is 70-80L/min, and the surface temperature is controlled at 300-400 ℃. The distance between the air gun and the superalloy substrate is 100 mm, and the moving speed of the air gun is 800 mm/s.
(6) After each spraying, stopping spraying, and restarting spraying when the surface temperature reaches 300-400 ℃ under the actions of flame heating and back air flow cooling. Repeating the above operation, and finally controlling the thickness of the ceramic layer to be 200-300 μm.
Example 3
(1) And carrying out sand blasting treatment on the high-temperature alloy matrix. After sand blasting, the high-temperature alloy matrix is preheated by utilizing supersonic flame spraying, the distance between a spray gun and the high-temperature alloy matrix is 230 mm, the particle size of sprayed powder is 25-40 mu m, the moving speed of the spray gun is 1500 mm/s, the powder feeding rotating speed is 2 r/min, the propane pressure is 92 PSI, the air pressure is 95 PSI, the hydrogen pressure is 25 PSI, and the nitrogen pressure is 45 PSI.
(2) The back side of the high-temperature alloy matrix is purged by compressed air, the flow rate of the compressed air is 55-60L/min, and the surface temperature is controlled at 700 ℃. The distance between the air gun and the high-temperature alloy matrix is 200 mm, and the moving speed of the air gun is 1500 mm/s.
(3) And stopping spraying when one spraying is finished, and restarting spraying when the surface temperature reaches 700 ℃ under the actions of flame heating and back air flow cooling. Repeating the above operation, and finally controlling the thickness of the bonding layer to be 150-200 μm.
(4) And preparing a ceramic layer on the surface of the bonding layer by adopting an atmospheric plasma spraying technology. The ceramic layer is yttria-stabilized zirconia with a mass content of 8%. When spraying, the surface temperature is controlled to 300-400 ℃, and the back compressed air flow rate is controlled to 70-80L/min. The distance between the spray gun and the matrix is 90 mm, the moving speed of the spray gun is 800 mm/s, the powder feeding speed is 50 g/min, the powder feeding air flow is 0.5L/min, the voltage is 180V, the spraying current is 250A, the Ar air flow rate is 50L/min, and H 2 The air flow rate was 10L/min.
(5) The back side of the matrix is purged by compressed air with the flow rate of 70-80L/min and the surface temperature of 300-400 ℃. The distance between the air gun and the superalloy substrate is 100 mm, and the moving speed of the air gun is 800 mm/s.
(6) After each spraying, stopping spraying, and restarting spraying when the surface temperature reaches 300-400 ℃ under the actions of flame heating and back air flow cooling. Repeating the above operation, and finally controlling the thickness of the ceramic layer to be 200-300 μm.
Example 4
(1) And carrying out sand blasting treatment on the high-temperature alloy matrix. After sand blasting, the high-temperature alloy matrix is preheated by utilizing supersonic flame spraying, the distance between a spray gun and the high-temperature alloy matrix is 230 mm, the particle size of sprayed powder is 25-40 mu m, the moving speed of the spray gun is 1500 mm/s, the powder feeding rotating speed is 2 r/min, the propane pressure is 92 PSI, the air pressure is 95 PSI, the hydrogen pressure is 25 PSI, and the nitrogen pressure is 45 PSI.
(2) The back side of the high-temperature alloy matrix is purged by compressed air, the flow rate of the compressed air is 45-50L/min, and the surface temperature is controlled at 750 ℃. The distance between the air gun and the high-temperature alloy matrix is 200 mm, and the moving speed of the air gun is 1500 mm/s.
(3) And stopping spraying every time the spraying is finished, and restarting the spraying when the surface temperature reaches 750 ℃ under the actions of flame heating and back air flow cooling. Repeating the above operation, and finally controlling the thickness of the bonding layer to be 150-200 μm.
(4) And preparing a ceramic layer on the surface of the bonding layer by adopting an atmospheric plasma spraying technology. The ceramic layer is yttria-stabilized zirconia with a mass content of 8%. When spraying, the surface temperature is controlled to 300-400 ℃, and the back compressed air flow rate is controlled to 70-80L/min. The distance between the spray gun and the matrix is 90 mm, the moving speed of the spray gun is 800 mm/s, the powder feeding speed is 50 g/min, the powder feeding air flow is 0.5L/min, the voltage is 180V, the spraying current is 250A, the Ar air flow rate is 50L/min, and H 2 The air flow rate was 10L/min.
(5) The back side of the matrix is purged by compressed air with the flow rate of 70-80L/min and the surface temperature of 300-400 ℃. The distance between the air gun and the superalloy substrate is 100 mm, and the moving speed of the air gun is 800 mm/s.
(6) After each spraying, stopping spraying, and restarting spraying when the surface temperature reaches 300-400 ℃ under the actions of flame heating and back air flow cooling. Repeating the above operation, and finally controlling the thickness of the ceramic layer to be 200-300 μm.
Comparative example 1
(1) And carrying out sand blasting treatment on the high-temperature alloy matrix. After sand blasting, the high-temperature alloy matrix is preheated by utilizing supersonic flame spraying, the distance between a spray gun and the high-temperature alloy matrix is 230 mm, the particle size of sprayed powder is 25-40 mu m, the moving speed of the spray gun is 1500 mm/s, the powder feeding rotating speed is 2 r/min, the propane pressure is 92 PSI, the air pressure is 95 PSI, the hydrogen pressure is 25 PSI, and the nitrogen pressure is 45 PSI.
(2) The back side of the high-temperature alloy matrix is not purged by compressed air, the temperature of the matrix is not controlled, the spraying is continuously carried out for five times, and the spraying is stopped. Repeating the above operation, and finally controlling the thickness of the bonding layer to be 150-200 μm.
(3) And preparing a ceramic layer on the surface of the bonding layer by adopting an atmospheric plasma spraying technology. The ceramic layer is yttria-stabilized zirconia with a mass content of 8%. When spraying, the distance between the spray gun and the matrix is 90 mm, the moving speed of the spray gun is 800 mm/s, and the powder feeding rate is 50 g/min, powder feeding air flow of 0.5L/min, voltage of 180V, spraying current of 250A, ar air flow rate of 50L/min, H 2 The air flow rate was 10L/min.
(4) The back side of the high-temperature alloy matrix is not purged by compressed air, the temperature of the matrix is not controlled, the spraying is continuously carried out for five times, and the spraying is stopped. Repeating the above operation, and finally controlling the thickness of the ceramic layer to be 200-300 μm.
The coatings prepared in the present invention were subjected to performance testing and the results obtained are shown in table 1. As can be seen from the results of fig. 1, 2 and table 1, increasing the spray surface temperature can increase the surface roughness and increase the thermal cycle life. But when the temperature reaches 750 ℃, the surface roughness begins to decrease, meanwhile, the oxygen content of the bonding layer is obviously increased, and the thermal cycle life of the thermal barrier coating is reduced. The optimal spraying temperature should be controlled around 700 ℃ by combining the results.
TABLE 1
The coating cohesion of the present invention was tested according to the American Standard ASTM C633-2001 method for testing adhesion bond Strength of thermal spray coatings.
Thermal cycle life test of thermal barrier coatings was tested according to ISO 1418-2012 Metallic and other inorganic coatings-Test methods for measuring thermal cycle resistance and thermal shock resistance for thermal barrier coatings. Wherein the test condition is that the temperature is kept at 1100 ℃ for 50 minutes, then the air cooling is carried out for 10 minutes, and the cycle times when the spalling area of the thermal barrier coating exceeds 30 percent are the thermal cycle life of the thermal barrier coating.
According to the invention, the bonding layer is prepared by adopting a supersonic flame spraying technology, and the preparation of the bonding layer with high density and high surface roughness can be realized simultaneously by selecting proper spraying powder particle size and controlling the temperature of the matrix, so that the oxidation resistance of the thermal barrier coating can be ensured, the interface bonding strength of the interface bonding layer and the ceramic surface layer can be improved, and the one-step forming of the thermal barrier coating with long service life and high interface bonding strength is realized. Compared with the prior art, the technology provided by the invention has the advantages of simple process flow and low cost.
The technical scheme is completely and clearly described by the example, but the invention is not limited by the example. Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made therein without departing from the spirit and scope of the invention as defined by the appended claims and their equivalents.
Claims (9)
1. A method for preparing a thermal barrier coating having a long lifetime and a high interfacial bond strength, comprising:
step 1: preheating a high-temperature alloy matrix to enable the surface temperature of the high-temperature alloy matrix to reach a preset temperature, and spraying metal bonding layer powder onto the surface of the high-temperature alloy matrix by adopting a supersonic flame spraying method to form a metal bonding layer;
step 2: and spraying ceramic powder onto the surface of the metal bonding layer by an atmospheric plasma spraying method to deposit and form a ceramic layer.
2. The method of producing a thermal barrier coating having a long life and high interfacial bond strength as recited in claim 1 wherein the metallic bond coat powder has a particle size in the range of 25 μm to 40 μm.
3. The method for preparing a thermal barrier coating with long service life and high interface bonding strength according to claim 1, wherein in step 1, when ultrasonic flame spraying is adopted, sand blasting is firstly carried out on the surface of a superalloy substrate; the preset temperature range is 500-800 ℃, the distance between the supersonic flame gun and the superalloy substrate is 220-250 mm, the moving speed range of the supersonic flame gun is 1500-1800 mm/s, the powder feeding rotating speed is 2 r/min, the propane pressure is 90-95 PSI, the air pressure is 95-100 PSI, the hydrogen pressure is 25-30 PSI, and the nitrogen pressure is 40-50 PSI.
4. The method of preparing a thermal barrier coating having a long life and high interfacial bond strength as recited in claim 1, wherein step 1 comprises the sub-steps of:
(1) Monitoring the surface temperature of the high-temperature alloy matrix in real time by using a thermal imaging non-contact thermometer, preheating the high-temperature alloy matrix by using supersonic flame, and feeding no powder;
(2) Blowing the back side of the high-temperature alloy matrix by adopting compressed air, and starting powder feeding and spraying when the surface temperature of the high-temperature alloy matrix reaches a preset temperature by controlling the flow rate of the compressed air on the back side of the high-temperature alloy matrix;
(3) The supersonic flame gun moving path finishes covering the surface of the high-temperature alloy matrix once and records the covering as once spraying; stopping spraying after each spraying, and measuring the thickness of the metal bonding layer after the substrate is cooled;
(4) Repeating the substeps (1) - (3), controlling the thickness of the final metal bonding layer to be 150-200 mu m, and controlling the surface roughness Ra of the metal bonding layer to be 15-25 mu m.
5. The method of claim 4, wherein in the sub-step (2), when compressed air is used for purging, the purging direction of the air gun is perpendicular to the plane of the superalloy substrate, the flow rate of the compressed air is 40-70L/min, the distance between the air gun and the superalloy substrate is 100-200 mm, and a mechanical arm is used for controlling the moving path of the air gun, so that the temperature of the superalloy substrate is uniformly controlled, and the moving speed of the air gun is 1500-1800 mm/s.
6. The method of producing a thermal barrier coating having a long lifetime and high interfacial bond strength as defined in claim 1, wherein the ceramic powder in step 2 is yttria stabilized zirconia, wherein Y 2 O 3 The mass content of (2) was 8%.
7. The method for preparing a thermal barrier coating with long service life and high interfacial bond strength as recited in claim 1, wherein in step 2, the high temperature alloy substrate is preheated prior to the atmospheric plasma sprayingThe temperature of the high-temperature alloy matrix is controlled to be 300-400 ℃, the distance between an atmospheric plasma spray gun and the high-temperature alloy matrix is 90-120 mm, the moving speed of the atmospheric plasma spray gun is 800-1000 mm/s, the powder feeding speed is 50-60 g/min, the powder feeding air flow is 0.5-1.0L/min, the voltage range is 180-200V, the spraying current range is 250-300A, the Ar air flow speed range is 30-60L/min, and H 2 The air flow rate is in the range of 5-20L/min.
8. The method of preparing a thermal barrier coating having a long life and high interfacial bond strength of claim 7, wherein step 2 comprises the sub-steps of:
(a) Monitoring the surface temperature of the high-temperature alloy matrix in real time by using a thermal imaging non-contact thermometer, heating the high-temperature alloy matrix by using atmospheric plasma flame, purging the back side of the high-temperature alloy matrix by adopting compressed air, controlling the temperature by controlling the flow velocity of the compressed air at the back side of the high-temperature alloy matrix, and starting powder feeding spraying when the surface temperature of the high-temperature alloy matrix reaches 300-400 ℃; the surface of the metal bonding layer covering the superalloy substrate is recorded as one-time spraying after the moving path of the atmospheric plasma spray gun is completed; stopping spraying after each spraying, and measuring the thickness of the ceramic layer after cooling;
(b) Repeating the substep (a) to control the thickness of the final ceramic layer to be 200-300 mu m, and controlling the surface roughness Ra of the ceramic layer to be 15-25 mu m.
9. The method of claim 8, wherein the compressed air is used for purging in the substep (a), the air gun is perpendicular to the plane of the superalloy substrate, the distance between the air gun and the superalloy substrate is 100-150 mm, the movement path of the air gun is controlled by a manipulator, the temperature of the superalloy substrate is uniformly controlled, the movement speed of the air gun is 800-1000 mm/s, and the flow rate of the compressed air is 70-80L/min.
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