WO2020215699A1 - 一种抗低熔点氧化物腐蚀的稀土钽酸盐陶瓷及其制备方法 - Google Patents

一种抗低熔点氧化物腐蚀的稀土钽酸盐陶瓷及其制备方法 Download PDF

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WO2020215699A1
WO2020215699A1 PCT/CN2019/118483 CN2019118483W WO2020215699A1 WO 2020215699 A1 WO2020215699 A1 WO 2020215699A1 CN 2019118483 W CN2019118483 W CN 2019118483W WO 2020215699 A1 WO2020215699 A1 WO 2020215699A1
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powder
rare earth
corrosion
ceramic
melting point
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French (fr)
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冯晶
种晓宇
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昆明理工大学
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Priority to JP2021562912A priority Critical patent/JP7412019B2/ja
Priority to US17/418,214 priority patent/US20220144705A1/en
Priority to EP19926187.6A priority patent/EP3892601A4/en
Publication of WO2020215699A1 publication Critical patent/WO2020215699A1/zh

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Definitions

  • the invention relates to the technical field of thermal barrier coatings, in particular to rare earth tantalate ceramics resistant to corrosion by low melting point oxides and a preparation method thereof.
  • Thermal barrier coatings are mainly used in the aero-engine industry, mainly to insulate heat, reduce the thermal mismatch between the coating and the alloy matrix, effectively resist particle impact, and protect the parts of the aero-engine in the high-temperature area. It requires good thermodynamics. Performance, such as low thermal conductivity, high thermal expansion coefficient, and high temperature stability.
  • the widely used thermal barrier coatings mainly include yttria stabilized zirconia (YSZ) and rare earth zirconates (RE 2 Zr 2 O 7 ), etc., but they all have certain shortcomings: YSZ has a low operating temperature ( ⁇ 1200°C). ), and the thermal conductivity is relatively high; while rare earth zirconates have the problem of low thermal expansion coefficient, which prompted researchers to find thermal barrier coatings that can replace the above-mentioned ceramic materials.
  • YSZ yttria stabilized zirconia
  • RE 2 Zr 2 O 7 rare earth zirconates
  • the current preparation methods of ceramic powder make the crystal structure of rare earth tantalate powder have certain microcracks and pores. Because aero-engines fly over in harsh environments, such as In the sky above volcanic rocks, a certain amount of sand, floating dust and fly ash will be sucked in from the inlet.
  • the chemical components of these silicate mineral particles are basically the same, mainly CaO, MgO, Al 2 O 3 , SiO 2 and a small amount of Ni and Fe oxides. Their melting points are about 1200 °C, collectively referred to as Calcium-Magnesium-Alumino-Silicate (CMAS).
  • CMAS Calcium-Magnesium-Alumino-Silicate
  • the inlet temperature of the engine turbine is usually above 1200°C, and at 1200°C, the CMAS particles will melt. Therefore, the CMAS particles are also called low-melting oxides.
  • the surface of the coating is deposited and "slowly" penetrates into the interior of the coating along the cracks in the coating.
  • the brittle glass phase produced during the cooling process reduces the strain tolerance of the coating, which causes the coating to delamination and crack, and finally fails. The problem.
  • the invention provides a rare earth tantalate ceramic resistant to corrosion by low melting point oxides and a preparation method thereof, so as to solve the problem that the existing thermal barrier coating is prone to cracking in harsh environments.
  • a rare earth tantalate ceramic resistant to corrosion by low melting point oxides The general chemical formula of the ceramic is RETaO 4 , the crystal structure of the ceramic is monoclinic, and the lattice space group is I2(5). The density of the ceramic is More than 98%.
  • a rare earth ytterbium tantalate ceramic resistant to corrosion by low melting point oxides The ceramic is sintered from Yb 2 O 3 powder and Ta 2 O 5 powder.
  • the general chemical formula of the ceramic is YbTaO 4 or Yb 3 TaO 7 .
  • the crystal structure is single-phase, and the density of the ceramic is greater than 97%.
  • the density of a rare earth tantalate ceramic resistant to corrosion by low melting point oxides is greater than 98%, that is, the content of cracks and pores in the rare earth tantalate is very small, making low melting point oxides (such as aeroengines) Calcium oxide, magnesium oxide, aluminum oxide, and silicon oxide in the working environment cannot effectively penetrate into the ceramics after melting at high temperatures, preventing the penetration of molten oxides and the reaction with ceramic materials.
  • the rare earth tantalate (RETaO 4 ) ceramic has a monoclinic crystal structure and no other impurity phases, so the length of the grain boundary is relatively uniform, that is, there is no too long or too short grain boundary. In this way, the size distribution of the crystal grains is also relatively uniform, and the microcracks between the crystal grains are correspondingly reduced, thereby improving the corrosion resistance of the rare earth tantalate against low melting point oxides.
  • the density of a rare earth ytterbium tantalate ceramic that is resistant to corrosion by low melting point oxides in this basic scheme is greater than 97%
  • the content of cracks and pores in the rare earth ytterbium tantalate is very small, so that low melting point oxides (such as calcium oxide, magnesium oxide, aluminum oxide and silicon oxide in the working environment of aero engines) cannot effectively penetrate into the ceramic after melting at high temperatures.
  • low melting point oxides such as calcium oxide, magnesium oxide, aluminum oxide and silicon oxide in the working environment of aero engines
  • the inside of it prevents the penetration of molten oxides and the reaction with ceramic materials.
  • the rare earth ytterbium tantalate (YbTaO 4 or Yb 3 TaO 7) ceramics has a single-phase crystal structure and no other impurity phases, so the length of the grain boundaries is relatively uniform, that is, no too long or too short The grain boundaries appear, so that the grain size distribution is relatively uniform, and the microcracks between the grains are correspondingly reduced, thereby improving the corrosion resistance of ytterbium tantalate to low melting point oxides.
  • RE is one element or several elements among Sm, Eu, Gd, Dy, Ho, and Er.
  • the radii of several rare earth ions in this scheme are relatively large, all in the range of 0.100 ⁇ 0.116nm. Therefore, when a variety of rare earth oxides are used to react with tantalum oxide, each rare earth element can replace each other in solid solution. The same elements all form a single-phase rare earth tantalate. Other rare earth elements, such as Sc element, have an ionic radius of 0.075nm, which is much smaller than other rare earth elements. Its oxide reacts with tantalum oxide to form a metastable monoclinic phase under high temperature reaction, and the ion difference between rare earth elements Giants cannot replace each other to form a solid solution. The crystal structure is different from that of other rare earth tantalates.
  • a method for preparing rare earth tantalate ceramics resistant to corrosion by low melting point oxides includes the following steps:
  • Step (1) Weigh RE 2 O 3 powder and Ta 2 O 5 powder with a molar ratio of RE:Ta of 1:1, add a solvent and mix, use a ball mill for ball milling, and obtain powder A after drying;
  • Step (2) drying the powder A obtained in step (1) and sieving for the first time to obtain powder B;
  • Step (3) Place the powder B obtained in step (2) in a mold for compaction, and pre-sinter after holding the pressure to form a block C, where the holding pressure is 200-300 MPa, and the holding time is 1-10 min ,
  • the pre-sintering temperature is 800 ⁇ 1200°C, and the pre-sintering time is 10 ⁇ 20h;
  • Step (4) After the block C in step (3) is cooled to room temperature, it is ground with a grinder, and then sieved a second time to obtain powder D;
  • Step (5) Sintering the powder D in step (4) to obtain a rare earth tantalate ceramic resistant to corrosion by low melting point oxides, wherein the sintering temperature is 1500-1800°C, and the pressure sintering time is 5-30 min.
  • step (1) to step (5) is used to prepare rare earth tantalate (RETaO 4 ) ceramic block with a density greater than 98%, which has fewer internal micro-cracks and low porosity, which can be used as a thermal barrier coating When the layer is used, it can resist the corrosion of low melting point CMAS oxide at high temperature.
  • RETaO 4 rare earth tantalate
  • step (1) is to mechanically mix RE 2 O 3 powder and Ta 2 O 5 powder uniformly, and the addition of solvent is to reduce the surface activity of RE 2 O 3 powder and Ta 2 O 5 powder, and reduce the adhesion between the powders. Accessibility.
  • step (2) is to remove the solvent in powder A, while sieving out the large particles of powder that may be bonded together in step (1) to ensure the compactness of the final sintered mass.
  • the purpose of maintaining the pressure of powder B in step (3) is to discharge the gas in powder B under pressure, thereby reducing the pores in the crystal structure of block C, and the purpose of pre-sintering is to consume part of the internal energy in the powder , Reduce the sintering activity of powder B, increase the reaction temperature of powder B, prevent it from reacting at a lower temperature to form the second phase, and also prevent it from generating impurities in the final high-temperature sintering. In addition, because the pre-sintering did not reach the reaction Temperature, so there is no chemical reaction at this time.
  • step (4) the block with reduced sintering activity in step (3) is ground and then further sieved to obtain powder D with a small particle size.
  • the purpose of this step is that the powder D with a small particle size plays a role in the reaction between rare earth oxide and tantalum oxide.
  • the rare earth oxide and tantalum oxide can simultaneously use multiple powders D as crystal nuclei for nucleation and growth.
  • grinding and sieving are used in this step to make the particle size of powder D
  • the distribution is very uniform, the size distribution of the crystal nuclei formed by rare earth oxide and tantalum oxide is also relatively uniform, and there will be no too large or too small crystal grains formed during the whole reaction process, so that the final rare earth tantalate ceramic grains
  • the particle size distribution is uniform;
  • the powder in order to shorten the preparation time, the powder is usually sintered at high temperature directly after the powder is ground and mixed, so as to obtain the final required ceramic. This is why the crystal structure of the existing ceramic sintered at high temperature is used. The reason for the large number of microcracks and pores inside.
  • the rare earth tantalate ceramic powder or bulk material obtained in step (5) due to the low content of microcracks or pores in the crystal structure of the ceramic material, it is difficult for the molten oxide to enter the inside of the crystal of the ceramic material at high temperatures. It has good corrosion resistance to low melting point oxides.
  • the time of ball milling in the step (1) is 10-24 h, and the rotation speed of the ball mill is 300-600 r/min.
  • the RE 2 O 3 powder and Ta 2 O 5 powder can be fully mixed uniformly by adopting the ball milling speed and time in this solution.
  • the drying temperature is 60-100°C, and the drying time is 5-15h.
  • the mesh of the first sieving in the step (1) is 100-300 mesh
  • the mesh of the second sieving in the step (4) is 300-600.
  • the rotating speed of the grinder is 1000-2000 r/min, and the grinding time is 20-48 h.
  • the block C is ground using the grinding parameters in this solution, and the obtained powder D has a small particle size and a relatively uniform particle size distribution.
  • the purity of RE 2 O 3 powder and Ta 2 O 5 powder in the step (1) is not less than 99.9%.
  • the solvent in the step (1) is ethanol or distilled water.
  • ethanol and distilled water have better dispersibility for RE 2 O 3 powder and Ta 2 O 5 powder, so that RE 2 O 3 powder and Ta 2 O 5 powder can be more fully mixed.
  • the molar ratio of the RE 2 O 3 powder and Ta 2 O 5 powder to the solvent in the step (1) is (3:1) to (5:1).
  • a method for preparing rare earth ytterbium tantalate ceramics resistant to corrosion by low melting point oxides includes the following steps:
  • Step (1) Weigh Yb 2 O 3 powder and Ta 2 O 5 powder with a Yb:Ta molar ratio of 1:1 or 3:1, add a solvent to mix, and use a ball mill for ball milling to obtain powder A;
  • Step (2) dry the powder A obtained in step (1) and sieving for the first time to obtain powder B;
  • Step (3) Place the powder B obtained in step (2) in a mold for pre-sintering after compaction to form a block C, where the holding pressure is 100-200 MPa, and the holding time is 10-20 min.
  • the temperature is 1000 ⁇ 1200°C, and the pre-sintering time is 10 ⁇ 20h;
  • Step (4) After the block C in step (3) is cooled to room temperature, it is ground with a grinder, and then sieved a second time to obtain powder D;
  • Step (5) Sintering the powder D in step (4) to obtain a rare earth ytterbium tantalate ceramic resistant to corrosion by low melting point oxides, wherein the sintering temperature is 1700-1800°C and the sintering time is 5-10h.
  • step (1) to step (5) is used to prepare a ytterbium tantalate (YbTaO 4 or Yb 3 TaO 7 ) ceramic block with a density greater than 97%, which has fewer internal microcracks and low porosity.
  • YbTaO 4 or Yb 3 TaO 7 ytterbium tantalate
  • step (1) is to mechanically mix Yb 2 O 3 powder and Ta 2 O 5 powder uniformly, and the addition of solvent is to reduce the surface activity of Yb 2 O 3 powder and Ta 2 O 5 powder and reduce the adhesion between the powders. Accessibility.
  • step (2) is to remove the solvent in powder A, while sieving out the large particles of powder that may be bonded together in step (1) to ensure the compactness of the final sintered mass.
  • the purpose of maintaining the pressure of powder B in step (3) is to discharge the gas in powder B under pressure, thereby reducing the pores in the crystal structure of block C, and the purpose of pre-sintering is to consume part of the internal energy in the powder , Reduce the sintering activity of powder B, increase the reaction temperature of powder B, prevent it from reacting at a lower temperature to form the second phase, and also prevent it from generating impurities in the final high-temperature sintering. In addition, because the pre-sintering did not reach the reaction Temperature, so there is no chemical reaction at this time.
  • step (4) the block with reduced sintering activity in step (3) is ground and further sieved to obtain a powder D with a small particle size.
  • the purpose of this step is that the powder D with a small particle size plays a role in the reaction between ytterbium oxide and tantalum oxide. Helps nucleation. During the reaction of ytterbium oxide and tantalum oxide, multiple powders D can be used as crystal nuclei to nucleate and grow at the same time.
  • this step uses grinding and sieving, the particle size distribution of powder D is very
  • the size distribution of the crystal nuclei formed by ytterbium oxide and tantalum oxide is also relatively uniform, and there will be no too large or too small crystal grains formed during the whole reaction process, which makes the final rare earth tantalate ceramic crystal grain size
  • the distribution is uniform; it should be noted that when excessively large crystal grains are formed during the reaction (a larger crystal nucleus will produce such a situation), these large crystal grains will grow up quickly and squeeze smaller crystals.
  • the grain boundary energy between large and small crystal grains is too high, making the grain boundary prone to point defects (pores) or line defects (microcracks) leading to ceramic
  • the corrosion resistance of low melting point oxides is reduced.
  • the powder in order to shorten the preparation time, the powder is usually sintered at high temperature directly after the powder is ground and mixed, so as to obtain the final required ceramic. This is why the crystal structure of the existing ceramic sintered at high temperature is used. The reason for the large number of microcracks and pores inside.
  • Step (5) Sintering to obtain a ytterbium tantalate ceramic with a density greater than 97%.
  • the crystal structure has fewer pores, uniform crystal grain size distribution, and very few internal microcracks. It is resistant to corrosion by low melting point oxides at high temperatures. The key is.
  • the time of ball milling in the step (1) is 10-24 h, and the rotation speed of the ball mill is 300-500 r/min.
  • the Yb 2 O 3 powder and Ta 2 O 5 powder can be fully mixed uniformly by adopting the ball milling speed and time in this solution.
  • the drying temperature is 50-200°C
  • the drying time is 8-24h.
  • the mesh of the first sieving in the step (1) is 100-300 mesh.
  • the mesh in the technical scheme is used for sieving, and the large-diameter powder particles in the powder A that are bonded together during the ball milling process are sieved to obtain powder A with a uniform powder particle size distribution.
  • the mesh of the second sieving in the step (4) is 300-600 mesh.
  • the rotating speed of the grinder is 1000-2000 r/min, and the grinding time is 20-48 h.
  • the block C is ground by using the grinding parameters in the solution, and the block C can be sufficiently ground, and the obtained powder D has a small particle size and a relatively uniform particle size distribution.
  • the purity of Yb 2 O 3 powder and Ta 2 O 5 powder in the step (1) is not less than 99.9%.
  • the solvent in the step (1) is ethanol or distilled water.
  • ethanol and distilled water have better dispersibility for Yb 2 O 3 powder and Ta 2 O 5 powder, so that Yb 2 O 3 powder and Ta 2 O 5 powder can be more fully mixed.
  • the molar ratio of the Yb 2 O 3 powder and Ta 2 O 5 powder to the solvent in the step (1) is (3:1) to (5:1).
  • Figure 1 is an XRD pattern of the rare earth tantalate (HoTaO 4 ) ceramic prepared in Example 5 of the present invention
  • Figure 2 is an SEM image of the rare earth tantalate (HoTaO 4 ) ceramic prepared in Example 5 of the present invention
  • FIG. 3 is a physical diagram of the rare earth tantalate (HoTaO 4 ) ceramic prepared in Example 5 of the present invention after the CMAS high temperature corrosion resistance test;
  • Example 4 is a physical diagram of the rare earth tantalate (ErTaO 4 ) ceramic prepared in Example 6 of the present invention after the CMAS high temperature corrosion resistance test;
  • Fig. 5 is an XRD pattern of the rare earth tantalate (RETaO 4 ) ceramics prepared in Examples 1 to 6 of the present invention after CMAS high temperature corrosion resistance test;
  • Example 6 is an XRD pattern of Ytterbium tantalate (YbTaO 4 ) ceramic prepared in Example 13 of the present invention
  • Example 7 is an SEM image of Ytterbium tantalate (YbTaO 4 ) ceramic prepared in Example 13 of the present invention.
  • FIG. 8 is a physical diagram of the anti-CMAS high temperature corrosion test of Ytterbium tantalate (YbTaO 4 ) ceramic prepared in Example 13 of the present invention at 1300° C. for 10 hours;
  • Fig. 9 is an XRD pattern of compatibility detection of Ytterbium tantalate (YbTaO 4 ) ceramic alumina prepared in Example 13 of the present invention.
  • a rare earth tantalate ceramic resistant to corrosion by low melting point oxides The general chemical formula of the ceramic is RETaO 4 , and RE is one or more elements of Sm, Eu, Gd, Dy, Ho, and Er.
  • RE is one or more elements of Sm, Eu, Gd, Dy, Ho, and Er.
  • the ceramic The crystal structure of is monoclinic, the lattice space group is I2(5), and the density of the ceramic is greater than 98%.
  • the preparation method of the rare earth tantalate ceramics resistant to corrosion by low melting point oxides includes the following steps:
  • Step (1) Weigh RE 2 O 3 powder and Ta 2 O 5 powder with a molar ratio of RE:Ta of 1:1, add distilled water or ethanol solvent to mix, wherein RE 2 O 3 powder and Ta 2 O 5 powder The molar ratio to the solvent is (3:1) ⁇ (5:1).
  • the ball mill is used for ball milling, and powder A is obtained after drying.
  • the ball mill uses a frequency conversion planetary ball mill, the model is XQM, and the ball milling time is 10-24h.
  • the rotating speed of the ball mill is 300-600r/min, and the purity of the raw materials RE 2 O 3 powder and Ta 2 O 5 powder is not less than 99.9%.
  • Step (2) After drying the powder A obtained in step (1), it is sieved for the first time to obtain powder B, wherein the drying temperature is 60-100°C, the drying time is 5-15h, and the sieve for the first sieving Mesh 100 ⁇ 300 mesh.
  • Step (3) Place the powder B obtained in step (2) in a mold for compaction, and pre-sinter after holding the pressure to form a block C, where the holding pressure is 200-300 MPa, and the holding time is 1-10 min ,
  • the pre-sintering temperature is 800-1200°C
  • the pre-sintering time is 10-20h
  • the heating rate is 100°C/min.
  • Step (4) After the block C in step (3) is cooled to room temperature, it is ground with a grinder.
  • the grinder adopts a vertical laboratory sand mill, the model is WT0.3, and the grinding speed is 1000 ⁇ 2000r/ min, the grinding time is 20-48h, and then the second sieving is performed to obtain powder D.
  • the second sieving is 300-600 mesh.
  • Step (5) Sintering the powder D in step (4) to obtain the above-mentioned rare earth tantalate ceramic powder resistant to corrosion by low melting point oxides.
  • the sintering temperature is 1500-1800°C
  • the heating rate is 50°C/min
  • the sintering time It is 5-30 minutes, the powder material can be directly used for spraying to form a thermal barrier coating after granulation.
  • the bulk structure of the ceramic needs to be obtained, and the pressure treatment is carried out during the sintering in the above step (5), where the pressure is 40-100 MPa and the pressure time is 5-30 min.
  • a ceramic bulk material with the same composition and crystal structure as the powder is formed.
  • RETaO 4 ceramics with a density greater than 98% are obtained.
  • 12 sets of examples are selected for illustration.
  • Table 1 shows the specific parameters of Examples 1 to 6 of the present invention:
  • Table 2 shows the specific parameters of Examples 7-12 of the present invention:
  • Comparative Example 1 The difference from Example 1 is that the above steps (3) and (4) are not performed.
  • Comparative Example 2 The difference from Example 1 is that in step (5), the sintering temperature is 1100-1300°C, and the sintering time is 3-5h.
  • the ceramic blocks prepared in Examples 1 to 12 and Comparative Examples 1 to 2 were detected by scanning electron microscopy.
  • the SEM spectrum is shown in Figure 2.
  • the SEM spectrum in Figure 2 shows that the HoTaO4 ceramic sample has good crystallization, uniform crystal grain size, clear grain boundaries, and no second phase is seen within or between each crystal grain, which is consistent with the XRD results.
  • Figure 2 it is observed that there are very few cracks and pores in the rare earth tantalate (HoTaO 4 ) ceramic block, indicating that the ceramic does not generate excessive pressure and stress during the sintering process, and the density of 99.1% is obtained through testing.
  • the ceramic blocks obtained in Comparative Example 1 and Comparative Example 2 contained more pores, especially the ceramic block obtained in Comparative Example 1, in addition to more pores, also contained certain inclusions (not fully sintered RE 2 O 3 and Ta 2 O 5 powder), causing more microcracks in the crystal.
  • the Archimedes drainage method was used to measure the ceramic blocks prepared in Examples 1 to 12 and Comparative Examples 1 to 2. The measurement results are shown in Table 3. It can be seen that the ceramic blocks obtained in Examples 1 to 12 are The density is greater than 98%.
  • Table 3 shows the density measured in Examples 1-12 and Comparative Examples 1-2
  • Example 2 Example 3
  • Example 4 Example 5
  • Example 6 Example 7 Density (%) 99.2 99.14 99.25 99.15 99.1 98.2 98.9
  • Example 9 Example 10
  • Example 11 Comparative example 1 Comparative example 2 Density (%) 98.5 98.1 98.7 98.4 98.3 76.2 81.2
  • the CMAS powder prepared by the above method reduces the proportion of CMAS components in the front inlet of the engine turbine when the aero engine works in a harsh environment.
  • the above-mentioned CMAS powder was laid flat on the surface of the rare earth tantalate ceramic (RETaO 4 ) block prepared in Examples 1-12, where the amount of CMAS powder was 15 mg/cm 2 , and then sintered at a high temperature at a temperature of 1200 ⁇ 1500°C, the holding time is 5-20h.
  • RETaO 4 rare earth tantalate ceramic
  • Fig. 3 shows the CMAS high temperature corrosion resistance test of the rare earth tantalate (HoTaO 4 ) ceramic prepared in Example 5 after being sintered at 1300°C for 6 hours.
  • Fig. 4 is Example 6.
  • the obtained rare earth tantalate (ErTaO 4 ) ceramic anti-CMAS high temperature corrosion test is the physical picture after sintering at 1500 °C for 13 hours.
  • the pie-shaped piece in the above physical picture is the sintered ceramic block, and the surface is granular
  • the material is CMAS powder; at the same time, the rare earth tantalate (RETaO 4 ) block obtained in Examples 1 to 6 was subjected to XRD detection, and the XRD pattern is shown in FIG. 5.
  • the rare earth tantalate (RETaO 4 ) ceramics prepared in Examples 1 to 12 have very few microcracks and pores in the crystal structure, which makes their density high, above 98%, and has good resistance to low melting point oxides. Corrosion ability, when the temperature reaches 1200 ⁇ 1500°C, the rare earth tantalate (RETaO 4 ) ceramic block hardly reacts with CMAS powder, and its high temperature resistance to CMAS corrosion is much greater than that of YSZ.
  • the present invention is a rare earth ytterbium tantalate ceramic resistant to corrosion by low melting point oxides.
  • the general chemical formula of the ceramic is YbTaO 4 or Yb 3 TaO 7 , wherein the crystal structure of YbTaO 4 ceramics is monoclinic, and the lattice space group is I2 (5)
  • the crystal structure of Yb 3 TaO 7 ceramics is cubic phase, the lattice space group is Fm-3m, and the densities of the above two ceramics are both greater than 97%.
  • the preparation method of the rare earth tantalate ceramics resistant to corrosion by low melting point oxides includes the following steps:
  • Step (1) Weigh Yb 2 O 3 powder and Ta 2 O 5 powder with a Yb:Ta molar ratio of 1:1 or 3:1, add distilled water or ethanol solvent to mix, wherein Yb 2 O 3 powder and Ta The molar ratio of 2 O 5 powder to solvent is (3:1) ⁇ (5:1).
  • the ball mill is used for ball milling, and powder A is obtained after drying.
  • the ball mill adopts a frequency conversion planetary ball mill, the model is XQM, and the time of ball milling is 10-24h, the rotating speed of the ball mill is 300-500r/min, and the purity of the raw material Yb 2 O 3 powder and Ta 2 O 5 powder is not less than 99.9%.
  • Step (2) The powder obtained in step (1) is dried and sieved for the first time to obtain powder B, wherein the drying temperature is 50-200°C, the drying time is 8-24h, and the mesh size of the first sieving 100 ⁇ 300 mesh.
  • Step (3) Place the powder B obtained in step (2) in a mold for pre-sintering after compaction to form a block C, where the holding pressure is 100-200 MPa, and the holding time is 10-20 min.
  • the temperature is 1000 ⁇ 1200°C
  • the pre-sintering time is 10 ⁇ 20h
  • the heating rate is 100°C/min.
  • Step (4) After the block C in step (3) is cooled to room temperature, it is ground with a grinder.
  • the grinder adopts a vertical laboratory sand mill, the model is WT0.3, and the grinding speed is 1000 ⁇ 2000r/ min, the grinding time is 20-48h, and then the second sieving is performed to obtain powder D.
  • the second sieving is 300-600 mesh.
  • Step (5) Sintering the powder in step (4) to obtain the above-mentioned rare earth ytterbium tantalate ceramic powder with different stoichiometric ratios resistant to corrosion by low melting point oxides, wherein the sintering temperature is 1700 ⁇ 1800°C, and the heating rate is 50 °C/min, sintering time is 5-10h, the powder material can be directly used for spraying to form thermal barrier coating after granulation.
  • the bulk structure of the ceramics needs to be obtained, and the above step (5) is subjected to pressure treatment during sintering, wherein the pressure is 200-300MPa, and the pressure time is 20-30min.
  • a ytterbium tantalate ceramic (YbTaO 4 or Yb 3 TaO 7 ) with a density greater than 97% is obtained.
  • 6 groups of examples are selected for description.
  • Table 4 shows the specific parameters of Examples 13-18 of the present invention:
  • Comparative Example 3 The difference from Example 13 is that the above steps (3) and (4) are not performed.
  • Comparative Example 4 The difference from Example 13 is that the sintering temperature in step (5) is 1200-1400°C.
  • the ceramic blocks prepared in Examples 13-18 and Comparative Examples 3 to 4 were detected by scanning electron microscope. Take the ytterbium tantalate (YbTaO 4 ) ceramic block prepared in Example 13 as an example, and its SEM spectrum is shown in Figure 7. It can be seen from the SEM spectrum in Figure 7 that the ytterbium tantalate (YbTaO 4 ) ceramic sample has good crystallization, uniform crystal grain size, and clear grain boundaries. There is no second phase within or between each crystal grain. Consistent with XRD results. According to Fig.
  • the ceramic blocks obtained in Comparative Example 3 and Comparative Example 4 contained more pores.
  • the ceramic block obtained in Comparative Example 3 contained more pores and certain inclusions (not fully sintered). Y 2 O 3 and Ta 2 O 5 powder), causing more microcracks in the crystal.
  • the Archimedes drainage method was used to measure the ceramic blocks prepared in Examples 13-18 and Comparative Examples 3 to 4. The measurement results are shown in Table 2. The results are the results of the ceramic blocks obtained in Examples 13-18. The density is more than 97%.
  • Table 5 shows the density of ceramic blocks prepared in Examples 13 to 18 and Comparative Examples 3 to 4
  • the CMAS powder prepared by the above method reduces the proportion of CMAS components in the front inlet of the engine turbine when the aero engine works in a harsh environment.
  • the above CMAS powder was laid flat on the surface of the ytterbium tantalate ceramic block prepared in Examples 13-18, where the amount of CMAS powder was 35mg/cm2, and then high-temperature sintering was carried out.
  • the sintering temperature was 1200-1500°C, and the holding time was 5 ⁇ 20h.
  • Example 13 is the actual picture of the Ytterbium tantalate (YbTaO 4 ) ceramic made in Example 13 in the high temperature corrosion resistance test of CMAS at 1300 °C for 10 hours.
  • the above picture shows the pie shape After the sintered ceramic block, the particles on the surface are CMAS powder. It can be observed that there is still a large amount of CMAS powder on the surface of the ceramic sample, and the melting point of the CMAS powder is lower than 1200°C. ) After holding for several hours, it shows that the molten CMAS liquid does not react with the ceramic material and is difficult to penetrate into the ceramic material.
  • the ceramic material Since the ceramic material is used as a thermal barrier coating on the base material, it usually needs to be combined with the base material through an adhesive layer, and the adhesive layer usually contains Al 2 O 3 , now the tantalic acid obtained in Examples 13-18 Ytterbium ceramic block powder, after mixing with alumina powder, heat preservation at 1200 ⁇ 1500°C for 7h, and XRD detection of the ceramic after heat preservation.
  • YbTaO 4 ytterbium tantalate
  • the ytterbium tantalate (YbTaO 4 or Yb 3 TaO 7 ) ceramics prepared in Examples 13 to 18 have very few internal cracks and pores in the crystal structure, resulting in high density, which is above 97%, and has good resistance.
  • Low melting point oxide corrosion ability when the temperature reaches 1200 ⁇ 1500°C, the ytterbium tantalate ceramic block hardly reacts with the CMAS powder, and its high temperature resistance CMAS corrosion resistance is much greater than that of YSZ, and the powder is used as a thermal barrier coating When it does not react with alumina in the bonding layer, it has good alumina compatibility and high temperature chemical stability

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Abstract

一种抗低熔点氧化物腐蚀的稀土钽酸盐陶瓷，该陶瓷的化学通式为RETaO 4，制备方法为：取RE 2O 3粉末和Ta 2O 5粉末，加入溶剂混合，采用球磨机进行球磨，得到粉末A；将粉末A干燥后进行第一次过筛，得到粉末B；将粉末B放置在模具内压实后进行预烧结，形成块体C，待块体C冷却至室温后采用研磨机进行研磨，后进行第二次过筛，得到粉末D；将粉末D烧结得到稀土钽酸盐陶瓷。采用该技术方案得到的稀土钽酸盐陶瓷致密度高，耐低熔点氧化物腐蚀能力强。

Description

一种抗低熔点氧化物腐蚀的稀土钽酸盐陶瓷及其制备方法 技术领域
本发明涉及热障涂层技术领域，特别涉及抗低熔点氧化物腐蚀的稀土钽酸盐陶瓷及其制备方法。
背景技术
热障涂层主要应用于航空发动机工业，主要起到隔热、降低涂层与合金基体间的热失配、有效抵抗粒子冲击从而保护航空发动机高温区域零部件的作用，要求其具有良好的热力学性能，例如低的热导率、高的热膨胀系数以及高温稳定性等。
目前广泛使用的热障涂层主要有氧化钇稳定氧化锆(YSZ)和稀土锆酸盐(RE 2Zr 2O 7)等，但均存在一定程度的不足：YSZ使用温度较低(≦1200℃)，且热导率相对较高；而稀土锆酸盐则存在热膨胀系数较低的问题，这就促使研究人员去寻找能够替代上述陶瓷材料的热障涂层，2007年哈佛大学Clarke教授课题组同加州大学圣巴巴拉分校的Levi教授等提出了钽酸钇(YTaO 4)铁弹体有望作为新型热障涂层材料，但关于稀土钽酸盐的研究主要集中在其晶体结构和发光性能等方面的理论计算；2016年Wang等人通过固相反应法制得了稀土钽酸盐块体材料，得出了热导率远小于YSZ材料的结论，研究人员的大量研究与实验结论为稀土钽酸盐在热障涂层上的应用提供了理论的基础。
目前的陶瓷粉体的制备方法(如水热法、固相反应法等)使得稀土钽酸盐粉体的晶体结构内存在一定的微裂纹和气孔，由于航空发动机在恶劣的环境中飞越时，如火山岩上空等，会从进气道吸入一定的沙粒、浮尘和飞灰。经测试，这些硅酸盐矿物颗粒的化学组分都基本相同，主要为CaO、MgO、Al 2O 3、SiO 2以及少量的Ni和Fe的氧化物，其熔点大约在1200℃左右，统称为钙镁铝硅酸盐(Calcium-Magnesium-Alumino-Silicate，CMAS)。随着航空工业的发展，发动机涡轮前进口温度通常在1200℃以上，而在1200℃时，CMAS颗粒就会发生融化，因此又将CMAS颗粒称作低熔点氧化物，CMAS颗粒融化后在热障涂层的表面沉积，并沿着涂层中的裂纹“缓慢”渗入到涂层的内部，冷却过程中产生的脆性玻璃相导致涂层应变容限降低，从而引发涂层分层开裂，最后失效的问题。
发明内容
本发明提供了一种抗低熔点氧化物腐蚀的稀土钽酸盐陶瓷及其制备方法，以解决现有的热障涂层在恶劣环境中容易产生开裂的问题。
为了达到上述目的，本发明的基础方案为：
一种抗低熔点氧化物腐蚀的稀土钽酸盐陶瓷，该陶瓷的化学通式为RETaO 4，该陶瓷的晶体结构为单斜相，晶格空间群为I2(5)，该陶瓷的致密度大于98％。
一种抗低熔点氧化物腐蚀的稀土钽酸镱陶瓷，该陶瓷由Yb 2O 3粉末和Ta 2O 5粉末烧结而成，该陶瓷的化学通式为YbTaO 4或Yb 3TaO 7，该陶瓷的晶体结构为单相，该陶瓷的致密度大于97％。
本基础方案的技术原理和效果在于：
1、本基础方案中一种抗低熔点氧化物腐蚀的稀土钽酸盐陶瓷的致密度大于98％，即稀土钽酸盐内的裂纹和气孔含量非常少，使得低熔点氧化物(如航空发动机工作环境中的氧化钙、氧化镁、氧化铝和氧化硅)在高温下融化后无法有效渗透进入到陶瓷的内部，阻止了熔融状态的氧化物的渗透及和陶瓷材料的反应。
2、本基础方案中稀土钽酸盐(RETaO 4)陶瓷由于晶体结构为单斜相，无其他杂相的存在，因此晶界的长度都较为均匀，即无过长或过短的晶界出现，这样晶粒的粒度分布也是较为均匀的，晶粒间的微裂纹相应的减少，从而提高该稀土钽酸盐的耐低熔点氧化物的腐蚀性能。
3、本基础方案中一种抗低熔点氧化物腐蚀的稀土钽酸镱陶瓷的致密度大于97％，
即稀土钽酸镱内的裂纹和气孔含量非常少，使得低熔点氧化物(如航空发动机工作环境中的氧化钙、氧化镁、氧化铝和氧化硅)在高温下融化后无法有效渗透进入到陶瓷的内部，阻止了熔融状态的氧化物的渗透及和陶瓷材料的反应。
4、本基础方案中稀土钽酸镱(YbTaO 4或Yb 3TaO 7)陶瓷由于晶体结构为单相，无其他杂相的存在，因此晶界的长度都较为均匀，即无过长或过短的晶界出现，这样晶粒的粒度分布也是较为均匀的，晶粒间的微裂纹相应的减少，从而提高钽酸镱的耐低熔点氧化物的腐蚀性能。
进一步，RE为Sm、Eu、Gd、Dy、Ho、Er中的一种元素或几种元素。
有益效果：本方案中的几种稀土离子半径较大，均在0.100～0.116nm范围内，因此采用多种稀土氧化物与氧化钽反应时，各稀土元素能够相互置换固溶，因而与采用一种元素相同均形成单相的稀土钽酸盐。而其他稀土元素，例如Sc元素，其离子半径为0.075nm，远远小于其余的稀土元素，其氧化物在高温反应下与氧化钽生成的是亚稳态单斜相，且稀土元素间离子差异巨大无法相互置换形成固溶体，该晶体结构与其余稀土钽酸盐晶体结构不同，因此，根据发明人的实验证明采用稀土元素间离子差异巨大的稀土氧化物与氧化钽会导致两相或多相的产生，对稀土钽酸盐的致密性有一定的不良影响。
进一步，一种抗低熔点氧化物腐蚀的稀土钽酸盐陶瓷的制备方法，包括以下步骤：
步骤(1)：称取RE:Ta的摩尔比为1:1的RE 2O 3粉末和Ta 2O 5粉末，加入溶剂混合，采用球磨机进行球磨，经干燥后得到粉末A；
步骤(2)：将步骤(1)得到的粉末A进行干燥后进行第一次过筛，得到粉末B；
步骤(3)：将步骤(2)得到的粉末B放置在模具内压实，并保压后进行预烧结，形成块体C，其中保压压力为200～300MPa，保压时间为1～10min，预烧结的温度为800～1200℃，预烧结时间为10～20h；
步骤(4)：待步骤(3)中的块体C冷却至室温后采用研磨机进行研磨，后进行第二次过筛，得到粉末D；
步骤(5)：将步骤(4)中的粉末D进行烧结得到一种抗低熔点氧化物腐蚀的稀土钽酸盐陶瓷，其中烧结温度为1500～1800℃，加压烧结时间为5～30min。
有益效果：采用步骤(1)～步骤(5)的工艺制备得到了致密度大于98％的稀土钽酸盐(RETaO 4)陶瓷块体，其内部微裂纹少，气孔率低，作为热障涂层使用时，其在高温下能够抵抗低熔点的CMAS氧化物的腐蚀。
步骤(1)的目的在于将RE 2O 3粉末和Ta 2O 5粉末机械混合均匀，同时溶剂的加入是为了降低RE 2O 3粉末和Ta 2O 5粉末的表面活性，降低粉末间的粘接性。
步骤(2)的目的在于，将粉末A中的溶剂去除，同时将步骤(1)中可能粘接在一起的大颗粒粉末筛分掉，保证最后烧结块体的致密性。
步骤(3)中对粉末B进行保压的目的在于，在压力作用下，粉末B中的气体排出，进而减少块体C晶体结构中的气孔，而预烧结的目的在于消耗粉末内一部分内能，降低粉 末B的烧结活性，提高粉末B的反应温度，防止其在较低温度下发生反应形成第二相，同时也防止其在最终的高温烧结中产生杂质，另外由于预烧结时未达到反应的温度，因此此时没有发生化学反应。
步骤(4)对步骤(3)中烧结活性降低的块体研磨后进一步筛分，得到粒度小的粉末D，这一步的目的在于，小粒度的粉末D在稀土氧化物与氧化钽反应中起到帮助形核的作用，稀土氧化物与氧化钽反应过程中能够同时以多个粉末D为晶核进行形核长大，同时由于本步骤采用研磨并过筛的方式，使得粉末D的粒径分布十分的均匀，稀土氧化物与氧化钽形成的晶核尺寸分布也较为均匀，整个反应过程中不会有过大或者过小的晶粒形成，这样使得最后得到的稀土钽酸盐陶瓷晶粒的粒径分布均匀；
需要注意的是，当反应过程中有过大的晶粒形成时(晶核较大就会产生这样的情况)，这些大晶粒会迅速的长大，挤压尺寸较小的晶粒，这样就使得最后形成的陶瓷晶体结构中，大晶粒与小晶粒之间的晶界能过高，使得晶界处容易出现点缺陷(气孔)或线缺陷(微裂纹)导致陶瓷的抗低熔点氧化物腐蚀的性能降低。
而现有技术中为了缩短制备的时间，通常在粉末研磨混合后就直接对粉末进行高温烧结处理，从而得到最终的所需的陶瓷，这也是为何现有的采用高温烧结出来的陶瓷中晶体结构内部含有大量微裂纹和气孔的原因所在。
步骤(5)得到的稀土钽酸盐陶瓷粉体或块体材料，由于该陶瓷材料的晶体结构中微裂纹或气孔含量少，高温下，熔融的氧化物难以进入到陶瓷材料的晶体内部，使其具备良好的耐低熔点氧化物的腐蚀性能。
进一步，所述步骤(1)中球磨的时间为10～24h，球磨机的转速为300～600r/min。
有益效果：采用本方案中的球磨转速和时间，能够将RE 2O 3粉末和Ta 2O 5粉末充分的混合均匀。
进一步，所述步骤(1)中干燥温度为60～100℃，干燥时间为5～15h。
有益效果：采用本方案中的干燥温度和时间，能够使得粉末中的溶剂充分挥发出去。
进一步，所述步骤(1)中的第一次过筛的筛目为100～300目，所述步骤(4)中第二次过筛的筛目为300～600目。
有益效果：采用本技术方案中的筛目进行过筛，使得最后得到的粉末D粒度小，且粒 度分布较为均匀，从而提高粉末的烧结的致密性。
进一步，所述步骤(4)中研磨机的转速为1000～2000r/min，研磨时间为20～48h。
有益效果：采用本方案中的研磨参数对块体C进行研磨，得到的粉末D粒径小，且粒度分布较为均匀。
进一步，所述步骤(1)中RE 2O 3粉末和Ta 2O 5粉末的纯度不低于99.9％。
有益效果：采用纯度较高的前驱粉体，降低引入的杂质元素含量，避免杂质元素的引入到晶体中形成微裂纹，降低了最后烧结块体的致密性。
进一步，所述步骤(1)中的溶剂为乙醇或蒸馏水。
有益效果：乙醇与蒸馏水对RE 2O 3粉末和Ta 2O 5粉末是分散性较好，使得RE 2O 3粉末和Ta 2O 5粉末能够更加充分的混合。
进一步，所述步骤(1)中的RE 2O 3粉末和Ta 2O 5粉末与溶剂的摩尔比为(3:1)～(5:1)。
有益效果：发明人通过实验的验证，在RE 2O 3粉末和Ta 2O 5粉末与溶剂的比例在该范围下，得到的粉末A混合得最为充分。
进一步，一种抗低熔点氧化物腐蚀的稀土钽酸镱陶瓷的制备方法，包括以下步骤：
步骤(1)：称取Yb:Ta的摩尔比为1:1或3:1的Yb 2O 3粉末和Ta 2O 5粉末，加入溶剂混合，采用球磨机进行球磨，得到粉末A；
步骤(2)：将步骤(1)得到的粉末A干燥后进行第一次过筛，得到粉末B；
步骤(3)：将步骤(2)得到的粉末B放置在模具内压实后进行预烧结，形成块体C，其中保压压力为100～200MPa，保压时间为10～20min，预烧结的温度为1000～1200℃，预烧结时间为10～20h；
步骤(4)：待步骤(3)中的块体C冷却至室温后采用研磨机进行研磨，后进行第二次过筛，得到粉末D；
步骤(5)：将步骤(4)中的粉末D进行烧结得到一种抗低熔点氧化物腐蚀的稀土钽酸镱陶瓷，其中烧结温度为1700～1800℃，烧结时间为5～10h。
有益效果：采用步骤(1)～步骤(5)的工艺制备得到了致密度大于97％的钽酸镱(YbTaO 4或Yb 3TaO 7)陶瓷块体，其内部微裂纹少，孔隙率低，作为热障涂层使用时，其在高温下能够抵抗低熔点的CMAS氧化物的腐蚀。
步骤(1)的目的在于将Yb 2O 3粉末和Ta 2O 5粉末机械混合均匀，同时溶剂的加入是为了降低Yb 2O 3粉末和Ta 2O 5粉末的表面活性，降低粉末间的粘接性。
步骤(2)的目的在于，将粉末A中的溶剂去除，同时将步骤(1)中可能粘接在一起的大颗粒粉末筛分掉，保证最后烧结块体的致密性。
步骤(3)中对粉末B进行保压的目的在于，在压力作用下，粉末B中的气体排出，进而减少块体C晶体结构中的气孔，而预烧结的目的在于消耗粉末内一部分内能，降低粉末B的烧结活性，提高粉末B的反应温度，防止其在较低温度下发生反应形成第二相，同时也防止其在最终的高温烧结中产生杂质，另外由于预烧结时未达到反应的温度，因此此时没有发生化学反应。
步骤(4)对步骤(3)中烧结活性降低的块体研磨后进一步筛分，得到粒度小的粉末D，这一步的目的在于，小粒度的粉末D在氧化镱与氧化钽反应中起到帮助形核的作用，氧化镱与氧化钽反应过程中能够同时以多个粉末D为晶核进行形核长大，同时由于本步骤采用研磨并过筛的方式，使得粉末D的粒径分布十分的均匀，氧化镱与氧化钽形成的晶核尺寸分布也较为均匀，整个反应过程中不会有过大或者过小的晶粒形成，这样使得最后得到的稀土钽酸盐陶瓷晶粒的粒径分布均匀；需要注意的是，当反应过程中有过大的晶粒形成时(晶核较大就会产生这样的情况)，这些大晶粒会迅速的长大，挤压尺寸较小的晶粒，这样就使得最后形成的陶瓷晶体结构中，大晶粒与小晶粒之间的晶界能过高，使得晶界处容易出现点缺陷(气孔)或线缺陷(微裂纹)导致陶瓷的抗低熔点氧化物腐蚀的性能降低。而现有技术中为了缩短制备的时间，通常在粉末研磨混合后就直接对粉末进行高温烧结处理，从而得到最终的所需的陶瓷，这也是为何现有的采用高温烧结出来的陶瓷中晶体结构内部含有大量微裂纹和气孔的原因所在。
步骤(5)烧结得到致密度大于97％的钽酸镱陶瓷，其晶体结构内部的孔隙少，且晶粒大小分布均匀，内部的微裂纹极少，是其抵抗低熔点氧化物在高温下腐蚀的关键所在。
进一步，所述步骤(1)中球磨的时间为10～24h，球磨机的转速为300～500r/min。
有益效果：采用本方案中的球磨转速和时间，能够将Yb 2O 3粉末和Ta 2O 5粉末充分的混合均匀。
进一步，所述步骤(2)中干燥温度为50～200℃，干燥时间为8～24h。
有益效果：采用本方案中的干燥温度和时间，能够使得粉末中的溶剂充分挥发出去。
进一步，所述步骤(1)中的第一次过筛的筛目为100～300目。
有益效果：采用本技术方案中的筛目进行过筛，将粉末A中在球磨过程中粘接在一起的大粒径粉末颗粒进行筛除，得到粉末粒径分布均匀的粉末A。
进一步，所述步骤(4)中第二次过筛的筛目为300～600目。有益效果：采用本技术方案中的筛目进行过筛，将研磨过程中未完全研磨的大粒径粉末颗粒进行筛除，得到粉末粒径分布均匀的粉末D，进而提高烧结后块体的致密度。
进一步，所述步骤(4)中研磨机的转速为1000～2000r/min，研磨时间为20～48h。
有益效果：采用本方案中的研磨参数对块体C进行研磨，能够对块体C进行较为充分的研磨，得到的粉末D粒径小，且粒径分布较为均匀。
进一步，所述步骤(1)中Yb 2O 3粉末和Ta 2O 5粉末的纯度不低于99.9％。
有益效果：采用纯度较高的前驱粉体，降低引入的杂质元素含量，避免杂质元素的引入到晶体中形成微裂纹，降低了最后烧结块体的致密性。
进一步，所述步骤(1)中的溶剂为乙醇或蒸馏水。
有益效果：乙醇与蒸馏水对Yb 2O 3粉末和Ta 2O 5粉末是分散性较好，使得Yb 2O 3粉末和Ta 2O 5粉末能够更加充分的混合。
进一步，所述步骤(1)中的Yb 2O 3粉末和Ta 2O 5粉末与溶剂的摩尔比为(3:1)～(5:1)。
有益效果：发明人通过实验的验证，在Yb 2O 3粉末和Ta 2O 5粉末与溶剂的比例在该范围下，得到的粉末A混合得最为充分。
附图说明
图1为本发明实施例5制得的稀土钽酸盐(HoTaO 4)陶瓷的XRD图；
图2为本发明实施例5制得的稀土钽酸盐(HoTaO 4)陶瓷的SEM图；
图3为本发明实施例5制得的稀土钽酸盐(HoTaO 4)陶瓷抗CMAS高温腐蚀实验后实物图；
图4为本发明实施例6制得的稀土钽酸盐(ErTaO 4)陶瓷抗CMAS高温腐蚀实验后实物图；
图5为本发明实施例1～6制得的稀土钽酸盐(RETaO 4)陶瓷抗CMAS高温腐蚀实验 后XRD图；
图6为本发明实施例13制得的钽酸镱(YbTaO 4)陶瓷的XRD图；
图7为本发明实施例13制得的钽酸镱(YbTaO 4)陶瓷的SEM图；
图8为本发明实施例13制得的钽酸镱(YbTaO 4)陶瓷抗CMAS高温腐蚀实验在1300℃保温10h的实物图；
图9为本发明实施例13制得的钽酸镱(YbTaO 4)陶瓷氧化铝相容性检测的XRD图。
具体实施方式
下面通过具体实施方式进一步详细说明：
一种抗低熔点氧化物腐蚀的稀土钽酸盐陶瓷，该陶瓷的化学通式为RETaO 4，RE为Sm、Eu、Gd、Dy、Ho、Er中的一种元素或多种元素，该陶瓷的晶体结构为单斜相，晶格空间群为I2(5)，该陶瓷的致密度大于98％。
上述抗低熔点氧化物腐蚀的稀土钽酸盐陶瓷的制备方法，包括以下几个步骤：
步骤(1)：称取RE:Ta的摩尔比为1:1的RE 2O 3粉末和Ta 2O 5粉末，加入蒸馏水或乙醇溶剂进行混合，其中RE 2O 3粉末和Ta 2O 5粉末与溶剂的摩尔比为(3:1)～(5:1)，采用球磨机进行球磨，经干燥后得到粉末A；其中球磨机采用变频行星式球磨机，型号为XQM，球磨的时间为10～24h，球磨机的转速为300～600r/min，且原料RE 2O 3粉末和Ta 2O 5粉末的纯度不低于99.9％。
步骤(2)：将步骤(1)得到的粉末A干燥后进行第一次过筛，得到粉末B，其中干燥温度为60～100℃，干燥时间为5～15h，第一次过筛的筛目100～300目。
步骤(3)：将步骤(2)得到的粉末B放置在模具内压实，并保压后进行预烧结，形成块体C，其中保压压力为200～300MPa，保压时间为1～10min，预烧结的温度为800～1200℃，预烧结时间为10～20h，升温速率为100℃/min。
步骤(4)：待步骤(3)中的块体C冷却至室温后采用研磨机进行研磨，其中研磨机采用立式实验室砂磨机，型号为WT0.3，研磨转速为1000～2000r/min，研磨时间为20～48h，后进行第二次过筛，得到粉末D，第二次过筛的筛目300～600目。
步骤(5)：将步骤(4)中的粉末D烧结得到上述抗低熔点氧化物腐蚀的稀土钽酸盐陶瓷粉体，烧结温度为1500～1800℃，升温速率为50℃/min，烧结时间为5～30min，该 粉体材料能够在造粒后直接用于喷涂形成热障涂层。
当需要检测陶瓷的性能时，需要得到该陶瓷的块体结构，在上述步骤(5)烧结时进行加压处理，其中加压的压力为40～100MPa，加压的时间为5～30min，这样形成成分、晶体结构与粉体相同的陶瓷块体材料。
采用上述方法得到了致密度大于98％的RETaO 4陶瓷。为充分说明采用上述方法制备的RETaO 4陶瓷的致密性，现选用其中的12组实施例进行说明。
表1为本发明实施例1～6的具体参数：
Figure PCTCN2019118483-appb-000001
Figure PCTCN2019118483-appb-000002
表2为本发明实施例7～12的具体参数：
Figure PCTCN2019118483-appb-000003
Figure PCTCN2019118483-appb-000004
列举2组对比例与实施例1～12得到的稀土钽酸盐陶瓷进行对比实验：
对比例1：与实施例1的区别在于，未进行上述步骤(3)与步骤(4)的操作。
对比例2：与实施例1的区别在于，步骤(5)中烧结温度为1100～1300℃，烧结的时间为3～5h。
现对实施例1～12和对比例1～2得到的陶瓷块体进行检测：
1、XRD表征：
采用X射线衍射仪对实施例1～12和对比例1～2制得的陶瓷块体进行检测，以实施例5得到的稀土钽酸盐(HoTaO 4)陶瓷块体为例，XRD图谱如图1所示，图1中HoTaO4陶瓷试样的XRD测试结果中衍射峰与其标准PDF卡片#24-0478的标准峰一一对应，无第二相衍射峰的存在，说明所制备得到样为单相的HoTaO4陶瓷，其晶体结构为单斜相，其中α＝γ＝90°而β＝95.5°，密度为9.71g/cm3，晶格空间群为I2(5)，同时XRD检测表明，在稀土钽酸盐(HoTaO 4)陶瓷块体中无其他杂质出现。
2、SEM表征：
采用扫描电镜对实施例1～12和对比例1～2制得的陶瓷块体进行检测，以实施例5制备的稀土钽酸盐(HoTaO 4)陶瓷块体为例，SEM图谱如图2所示，图2中SEM图谱可以看出HoTaO4陶瓷试样结晶良好，晶粒大小均匀，晶界清晰，各个晶粒之内或者之间没有看到第二相的存在，这与XRD结果一致。根据图2观察稀土钽酸盐(HoTaO 4)陶瓷块体中裂纹及气孔都非常少，说明陶瓷在烧结过程中没有产生过大的压力和应力，且通过检测得到致密度达99.1％。
而对比例1与对比例2得到的陶瓷块体中含有较多的气孔，尤其是对比例1制得的陶瓷块体内，除了较多的气孔外，还含有一定的夹杂物(未完全烧结的RE 2O 3和Ta 2O 5粉末)，使得晶体内部出现较多的微裂纹。
3、致密度检测：
采用阿基米德排水法对实施例1～12和对比例1～2制得的陶瓷块体进行测量，测量结果如表3所示，可以看出实施例1～12得到的陶瓷块体的致密度均大于98％以上。
表3为实施例1～12和对比例1～2测得的致密度
  实施例1 实施例2 实施例3 实施例4 实施例5 实施例6 实施例7
致密度(％) 99.2 99.14 99.25 99.15 99.1 98.2 98.9
  实施例8 实施例9 实施例10 实施例11 实施例12 对比例1 对比例2
致密度(％) 98.5 98.1 98.7 98.4 98.3 76.2 81.2
3、抗高温CMAS腐蚀实验：
3.1 CMAS制备
将氧化铝(Al 2O 3)、氧化镁(MgO)、氧化钙(CaO)和氧化硅(SiO 2)按照摩尔比为15：19：22：44进行混合后，加入蒸馏水在研磨机中进行研磨、混料得到均匀细小的粉末，其中研磨机转速为1000r/min，研磨时间为20h；将研磨后的粉末进行在100℃下干燥10h，在1000℃下预烧5h，得到块体，再将块体进行研磨过300目筛处理后，得到均匀的CMAS粉末。
采用上述方法制备的CMAS粉末还原了航空发动机在恶劣环境下工作时，发动机涡轮前进口中的CMAS成分比例。
3.2腐蚀实验
将上述CMAS粉末平铺在实施例1～12制备的稀土钽酸盐陶瓷(RETaO 4)块体的表面，其中CMAS粉末的量为15mg/cm 2，然后进行高温烧结，烧结的温度为1200～1500℃，保温时间为5～20h。
以实施例1～6为例，如图3为实施例5制得的稀土钽酸盐(HoTaO 4)陶瓷抗CMAS高温腐蚀实验在1300℃下烧结6h后的实物图，图4为实施例6制得的稀土钽酸盐(ErTaO 4)陶瓷抗CMAS高温腐蚀实验在1500℃下烧结13h后的实物图，上述实物图中呈饼状的是烧结后的陶瓷块体，而其表面的颗粒状物则为CMAS粉末；同时对实施例1～6得到的稀土钽酸盐(RETaO 4)块体进行XRD检测，XRD图谱如图5所示。
结合图3～图5可知，各陶瓷试样的表面仍然存在大量的CMAS粉末，而CMAS粉末的熔点低于1200℃，在高温(大于1200℃)下保温数小时后说明CMAS熔融液体并未与陶瓷材料反应，且难以渗透到陶瓷材料中，仅在实施例8得到的稀土钽酸盐(ErTaO 4)陶瓷检测到微量的MgO存在，说明CMAS在此温度下难以与稀土钽酸盐陶瓷材料反应，证 明了陶瓷材料优异的抗CMAS腐蚀特性。通常情况下其他不耐CMAS腐蚀的陶瓷材料例如YSZ在高温下保持数小时后，CMAS熔融液体与YSZ反应并渗透进入陶瓷内部，表面无CMAS粉末残留。
综上，本实施例1～12制备的稀土钽酸盐(RETaO 4)陶瓷晶体结构内微裂纹和气孔非常少，使得其致密度高，均在98％以上，具有良好的耐低熔点氧化物腐蚀的能力，当温度达1200～1500℃，稀土钽酸盐(RETaO 4)陶瓷块体与CMAS粉末几乎不发生反应，其抗高温CMAS腐蚀性能远大于YSZ。
本发明一种抗低熔点氧化物腐蚀的稀土钽酸镱陶瓷，该陶瓷的化学通式为YbTaO 4或Yb 3TaO 7，其中YbTaO 4陶瓷的晶体结构为单斜相，晶格空间群为I2(5)，Yb 3TaO 7陶瓷的晶体结构为立方相，晶格空间群为Fm-3m，上述两种陶瓷的致密度均大于97％。
上述抗低熔点氧化物腐蚀的稀土钽酸盐陶瓷的制备方法，包括以下几个步骤：
步骤(1)：称取Yb:Ta的摩尔比为1:1或3:1的Yb 2O 3粉末和Ta 2O 5粉末，加入蒸馏水或乙醇溶剂进行混合，其中Yb 2O 3粉末和Ta 2O 5粉末与溶剂的摩尔比为(3:1)～(5:1)，采用球磨机进行球磨，经干燥后得到粉末A；其中球磨机采用变频行星式球磨机，型号为XQM，球磨的时间为10～24h，球磨机的转速为300～500r/min，且原料Yb 2O 3粉末和Ta 2O 5粉末的纯度不低于99.9％。
步骤(2)：将步骤(1)得到的粉末干燥后进行第一次过筛，得到粉末B，其中干燥温度为50～200℃，干燥时间为8～24h，第一次过筛的筛目100～300目。
步骤(3)：将步骤(2)得到的粉末B放置在模具内压实后进行预烧结，形成块体C，其中保压压力为100～200MPa，保压时间为10～20min，预烧结的温度为1000～1200℃，预烧结时间为10～20h，升温速率为100℃/min。
步骤(4)：待步骤(3)中的块体C冷却至室温后采用研磨机进行研磨，其中研磨机采用立式实验室砂磨机，型号为WT0.3，研磨转速为1000～2000r/min，研磨时间为20～48h，后进行第二次过筛，得到粉末D，第二次过筛的筛目300～600目。
步骤(5)：将步骤(4)中的粉末进行烧结得到上述抗低熔点氧化物腐蚀的不同化学计量比的稀土钽酸镱陶瓷粉体，其中烧结温度为1700～1800℃，升温速率为50℃/min，烧结时间为5～10h，该粉体材料能够在造粒后直接用于喷涂形成热障涂层。
当需要检测陶瓷的性能时，需要得到该陶瓷的块体结构，将上述步骤(5)烧结时进行加压处理，其中加压压力为200～300MPa，加压时间为20～30min，
采用上述方法得到了致密度大于97％的钽酸镱陶瓷(YbTaO 4或Yb 3TaO 7)。为充分说明采用上述方法制备的钽酸镱陶瓷的致密性，现选用其中的6组实施例进行说明。
表4为本发明实施例13～18的具体参数：
Figure PCTCN2019118483-appb-000005
列举2组对比例与实施例13～18得到的钽酸镱陶瓷进行对比实验：
对比例3：与实施例13的区别在于，未进行上述步骤(3)与步骤(4)的操作。
对比例4：与实施例13的区别在于，步骤(5)中烧结温度为1200～1400℃。
现对实施例13～18和对比例3～4得到的陶瓷块体进行检测：
1、XRD表征：
采用X射线衍射仪对实施例13～18和对比例3～4制得的陶瓷块体进行检测，以实施例13得到的钽酸镱(YbTaO 4)陶瓷块体为例，其XRD图谱如图6所示，钽酸镱(YbTaO 4)陶瓷块体的衍射峰与其标准PDF卡片#24-1010的标准峰一一对应，无第二相衍射峰的存在，说明所制备得到样为单相的钽酸镱(YbTaO 4)陶瓷，其晶体结构为单斜相，其中α＝γ＝90°而β＝95.7°，晶格空间群为I2(5)，同时XRD检测表明，在钽酸镱(YbTaO 4)陶瓷块体中无其他杂质出现。
2、SEM表征：
采用扫描电镜对实施例13～18和对比例3～4制得的陶瓷块体进行检测，以实施例13制备的钽酸镱(YbTaO 4)陶瓷块体为例，其SEM图谱如图7所示，图7中SEM图谱可以看出钽酸镱(YbTaO 4)陶瓷试样结晶良好，晶粒大小均匀，晶界清晰，各个晶粒之内或者之间没有看到第二相的存在，这与XRD结果一致。根据图7观察钽酸镱(YbTaO 4)陶瓷块体中裂纹及气孔都非常少，说明陶瓷在烧结过程中没有产生过大的压力和应力，且通过检测得到致密度达98.1％。
而对比例3与对比例4得到的陶瓷块体中含有较多的气孔，尤其是对比例3制得的陶瓷块体内，除了较多的气孔外，还含有一定的夹杂物(未完全烧结的Y 2O 3和Ta 2O 5粉末)，使得晶体内部出现较多的微裂纹。
3、致密度检测：
采用阿基米德排水法对实施例13～18和对比例3～4制得的陶瓷块体进行测量，测量结果如表2所示，其结果为实施例13～18得到的陶瓷块体的致密度均大于97％以上。
表5为实施例13～18和对比例3～4制得的陶瓷块体致密度
Figure PCTCN2019118483-appb-000006
4、抗高温CMAS腐蚀实验：
4.1 CMAS制备
将氧化铝(Al 2O 3)、氧化镁(MgO)、氧化钙(CaO)和氧化硅(SiO 2)按照摩尔比为15：19：22：44进行混合后，加入蒸馏水在研磨机中进行研磨、混料得到均匀细小的粉末，其中研磨机转速为1000～2000r/min，研磨时间为20～48h；将研磨后的粉末进行在100～200℃下干燥10～20h、预烧结后得到块体，其中预烧结的温度为1000～1400℃，保温时间为5～10h，再将块体进行研磨过300～600目筛，得到均匀的CMAS粉末。
采用上述方法制备的CMAS粉末还原了航空发动机在恶劣环境下工作时，发动机涡轮前进口中的CMAS成分比例。
4.2腐蚀实验
将上述CMAS粉末平铺在实施例13～18制备的钽酸镱陶瓷块体的表面，其中CMAS粉末的量为35mg/cm2，然进行高温烧结，烧结的温度为1200～1500℃，保温时间为5～20h。
以实施例13为例，如图8所示为实施例13制得的钽酸镱(YbTaO 4)陶瓷抗CMAS高温腐蚀实验在1300℃保温10h的实物图，上述实物图中呈饼状的是烧结后的陶瓷块体，而其表面的颗粒状物则为CMAS粉末，可观察到陶瓷试样的表面仍然存在大量的CMAS粉末，而CMAS粉末的熔点低于1200℃，在高温(大于1200℃)下保温数小时后说明CMAS熔融液体并未与陶瓷材料反应，且难以渗透到陶瓷材料中，说明CMAS在此温度下难以与稀土钽酸盐陶瓷材料反应，证明了陶瓷材料优异的抗CMAS腐蚀特性。通常情况下其他不耐CMAS腐蚀的陶瓷材料例如YSZ在高温下保持数小时后，CMAS熔融液体与YSZ反应并渗透进入陶瓷内部，表面无CMAS粉末残留。
5、氧化铝相容性
由于陶瓷材料在作为热障涂层作用在基体材料上时，通常需要通过粘接层与基体材料结合，而粘接层中通常含有Al 2O 3，现将实施例13～18得到的钽酸镱陶瓷块粉末，与氧化铝粉末混合后，在1200～1500℃下保温7h，将保温后的陶瓷进行XRD检测，以实施例13制得的钽酸镱(YbTaO 4)陶瓷为例，其XRD图谱如图9所示，结果表明氧化铝与钽酸镱并未反应而是分别以单相氧化铝和单相的钽酸镱存在，可证明钽酸镱在作为热障涂层使用时，不会与粘接层中的氧化铝发生反应，具有良好的氧化铝相容性和高温化学稳定性。
综上，本实施例13～18制备的钽酸镱(YbTaO 4或Yb 3TaO 7)陶瓷的晶体结构内裂纹和气 孔非常少，使得其致密度高，均在97％以上，具有良好的耐低熔点氧化物腐蚀的能力，当温度达1200～1500℃，钽酸镱陶瓷块体与CMAS粉末几乎不发生反应，其抗高温CMAS腐蚀性能远大于YSZ，同时其粉体作为热障涂层使用时，不会与粘接层中的氧化铝发生反应，具有良好的氧化铝相容性和高温化学稳定性
以上所述的仅是本发明的实施例，方案中公知的具体结构及特性等常识在此未作过多描述。应当指出，对于本领域的技术人员来说，在不脱离本发明结构的前提下，还可以作出若干变形和改进，这些也应该视为本发明的保护范围，这些都不会影响本发明实施的效果和专利的实用性。本申请要求的保护范围应当以其权利要求的内容为准，说明书中的具体实施方式等记载可以用于解释权利要求的内容。

Claims (20)

  1. 一种抗低熔点氧化物腐蚀的稀土钽酸盐陶瓷，其特征在于：该陶瓷的化学通式为RETaO 4，该陶瓷的晶体结构为单斜相，晶格空间群为I2(5)，该陶瓷的致密度大于98％。
  2. 根据权利要求1所述的一种抗低熔点氧化物腐蚀的稀土钽酸盐陶瓷，其特征在于：RE为Sm、Eu、Gd、Dy、Ho、Er中的一种元素或多种元素。
  3. 根据权利要求2所述的一种抗低熔点氧化物腐蚀的稀土钽酸盐陶瓷的制备方法，其特征在于：包括以下步骤：
    步骤(1)：称取RE:Ta的摩尔比为1:1的RE 2O 3粉末和Ta 2O 5粉末，加入溶剂混合，采用球磨机进行球磨，得到粉末A；
    步骤(2)：将步骤(1)得到的粉末A干燥后进行第一次过筛，得到粉末B；
    步骤(3)：将步骤(2)得到的粉末B放置在模具内压实，并保压后进行预烧结，形成块体C，其中保压压力为200～300MPa，保压时间为1～10min，预烧结的温度为800～1200℃，预烧结时间为10～20h；
    步骤(4)：待步骤(3)中的块体C冷却至室温后采用研磨机进行研磨，后进行第二次过筛，得到粉末D；
    步骤(5)：将步骤(4)中的粉末D进行烧结得到一种抗低熔点氧化物腐蚀的稀土钽酸盐陶瓷，其中烧结温度为1500～1800℃，加压烧结时间为5～30min。
  4. 根据权利要求3所述的一种抗低熔点氧化物腐蚀的稀土钽酸盐陶瓷的制备方法，其特征在于：所述步骤(1)中球磨的时间为10～24h，球磨机的转速为300～600r/min。
  5. 根据权利要求3所述的一种抗低熔点氧化物腐蚀的稀土钽酸盐陶瓷的制备方法，其特征在于：所述步骤(2)中干燥温度为60～100℃，干燥时间为5～15h。
  6. 根据权利要求3所述的一种抗低熔点氧化物腐蚀的稀土钽酸盐陶瓷的制备方法，其特征在于：所述步骤(2)中的第一次过筛的筛目为100～300目，所述步骤(4)中第二次过筛的筛目为300～600目。
  7. 根据权利要求3所述的一种抗低熔点氧化物腐蚀的稀土钽酸盐陶瓷的制备方法，其特征在于：所述步骤(4)中研磨机的转速为1000～2000r/min，研磨时间为20～48h。
  8. 根据权利要求7所述的一种抗低熔点氧化物腐蚀的稀土钽酸盐陶瓷的制备方法， 其特征在于：所述步骤(1)中RE 2O 3粉末和Ta 2O 5粉末的纯度不低于99.9％。
  9. 根据权利要求3所述的一种抗低熔点氧化物腐蚀的稀土钽酸盐陶瓷的制备方法，其特征在于：所述步骤(1)中的溶剂为乙醇或蒸馏水。
  10. 根据权利要求3所述的一种抗低熔点氧化物腐蚀的稀土钽酸盐陶瓷的制备方法，其特征在于：所述步骤(1)中的RE 2O 3粉末和Ta 2O 5粉末与溶剂的摩尔比为(3:1)～(5:1)。
  11. 一种抗低熔点氧化物腐蚀的稀土钽酸镱陶瓷，其特征在于：该陶瓷由Yb 2O 3粉末和Ta 2O 5粉末烧结而成，该陶瓷的化学通式为YbTaO 4或Yb 3TaO 7，该陶瓷的晶体结构为单相，该陶瓷的致密度大于97％。
  12. 根据权利要求11所述的一种抗低熔点氧化物腐蚀的稀土钽酸镱陶瓷的制备方法，其特征在于：包括以下步骤：
    步骤(1)：称取Yb:Ta的摩尔比为1:1或3:1的Yb 2O 3粉末和Ta 2O 5粉末，加入溶剂混合，采用球磨机进行球磨，得到粉末A；
    步骤(2)：将步骤(1)得到的粉末A干燥后进行第一次过筛，得到粉末B；
    步骤(3)：将步骤(2)得到的粉末B放置在模具内压实，并保压后进行预烧结，形成块体C，其中保压压力为100～200MPa，保压时间为10～20min，预烧结的温度为1000～1200℃，预烧结时间为10～20h；
    步骤(4)：待步骤(3)中的块体C冷却至室温后采用研磨机进行研磨，后进行第二次过筛，得到粉末D；
    步骤(5)：将步骤(4)中的粉末D进行烧结得到一种抗低熔点氧化物腐蚀的稀土钽酸镱陶瓷，其中烧结温度为1700～1800℃，烧结时间为5～10h。
  13. 根据权利要求12所述的一种抗低熔点氧化物腐蚀的稀土钽酸镱陶瓷的制备方法，其特征在于：所述步骤(1)中球磨的时间为10～24h，球磨机的转速为300～500r/min。
  14. 根据权利要求12所述的一种抗低熔点氧化物腐蚀的稀土钽酸镱陶瓷的制备方法，其特征在于：所述步骤(2)中干燥温度为50～200℃，干燥时间为8～24h。
  15. 根据权利要求12所述的一种抗低熔点氧化物腐蚀的稀土钽酸镱陶瓷的制备方法，其特征在于：所述步骤(2)中的第一次过筛的筛目为100～300目。
  16. 根据权利要求12所述的一种抗低熔点氧化物腐蚀的稀土钽酸镱陶瓷的制备方法， 其特征在于：所述步骤(4)中第二次过筛的筛目为300～600目。
  17. 根据权利要求12所述的一种抗低熔点氧化物腐蚀的稀土钽酸镱陶瓷的制备方法，其特征在于：所述步骤(4)中研磨机的转速为1000～2000r/min，研磨时间为20～48h。
  18. 根据权利要求12所述的一种抗低熔点氧化物腐蚀的稀土钽酸镱陶瓷的制备方法，其特征在于：所述步骤(1)中Yb 2O 3粉末和Ta 2O 5粉末的纯度不低于99.9％。
  19. 根据权利要求12所述的一种抗低熔点氧化物腐蚀的稀土钽酸镱陶瓷的制备方法，其特征在于：所述步骤(1)中的溶剂为乙醇或蒸馏水。
  20. 根据权利要求12～19任意一项所述的一种抗低熔点氧化物腐蚀的稀土钽酸镱陶瓷的制备方法，其特征在于：所述步骤(1)中的Yb 2O 3粉末和Ta 2O 5粉末与溶剂的摩尔比为(3:1)～(5:1)。
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