CN101748402B - Method of laser induction composite cladding gradient function thermal barrier coating - Google Patents
Method of laser induction composite cladding gradient function thermal barrier coating Download PDFInfo
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- CN101748402B CN101748402B CN200910186673XA CN200910186673A CN101748402B CN 101748402 B CN101748402 B CN 101748402B CN 200910186673X A CN200910186673X A CN 200910186673XA CN 200910186673 A CN200910186673 A CN 200910186673A CN 101748402 B CN101748402 B CN 101748402B
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Abstract
The invention discloses a method of a laser induction composite cladding gradient function thermal barrier coating, which is characterized in that the methods and steps are as follows: (1) the surface of base material is provided with processing of rust removing, oil removing, cleaning and sand spraying; (2) meanwhile, the inert protective gas is blown into an induction heating zone through utilizing a copper pipe, which prevents the high-temperature oxidation; (3) a focused laser beam and a powder nozzle of an automatic double-hopper powder feeder are located in the induction heating zone, and the composition of the laser heat source and the induction heating source can be realized; (4) a numerical control machine is moved 70-30% of the laser spot diameter along the vertical direction of the laser scanning speed; (5) the mass percentage content of a ceramic phase in the composite powder is led to be increased by 0-90 wt.%; (6) steps (2)-(5) are repeated until the required thickness of the coating is achieved; otherwise, the work is ended. The advantages of the invention are as follows: (1) the size, the shape and the part needing to process of the base material are not limited; (2) for the gradient function thermal barrier coating, the content of the ceramic phase in the coating presents change of gradient and is controllable along the thickness direction of the coating; (3) the whole gradient function thermal barrier coating has no air hole and crack; (4) the service life is greatly increased.
Description
Technical field
The present invention relates to a kind of method of laser induction composite cladding gradient function thermal barrier coating.
Background technology
Along with aero-gas turbine develops towards high flow capacity ratio, high thrust-weight ratio, high inlet temperature direction, inlet temperature improves constantly before the turbine, at present near 2000K.Be to improve the work-ing life of elevated temperature heat end pieces such as turbo outer shroud, blade, guarantee the gas turbine safe and stable operation, except that the composition that improves superalloy, preparation technology and blade design, using the protective thermal barrier coating is at present effective means.
At present, the technology at superalloy hot-end component surface preparation thermal barrier coating mainly contains plasma spraying (plasma spraying), electron beam-physical vapor deposition (EB-PVD), laser melting coating (laser cladding) etc.Wherein, the plasma spraying Thermal Barrier Coating Technologies has technical maturity, simple to operate and efficient advantages of higher, but the thermal barrier coating and the base material of preparation are mechanical bond, and its inside exists a large amount of pores and tiny crack, causes being prone to peel off in the coating process under arms.The thermal barrier coating of electron beam-physical gas phase deposition technology preparation has columnar crystal structure; Its working life increases substantially with respect to plasma sprayed coating, but this technological operation is complicated, sedimentation effect is low, technical difficulty is big, the bonding strength of coating and base material is not high yet.The thermal barrier coating of laser melting and coating technique preparation has dense structure, and thinning ratio is low, forms the high metallurgical binding of bonding strength with base material, excellent resistance to high temperature oxidation and thermal shock resistance.But the lower and cladding layer of laser melting coating efficient metallurgical imperfection such as is prone to crack and has greatly limited this Industrial Application of Technology scope.
In addition, thermal barrier coating adopts the bilayer structure of ceramic layer-tack coat simple in structure usually, makes each interface layer obvious, and different thermal expansivity is prone to produce thermal stresses at interlayer, causes coating degradation and inefficacy.The multilayered structure that adopts matrix metal layer, multilayer insulation layer and oxidation prevention layer and ceramic top layer to constitute; Though can obtain thicker coating of relative bilayer structure and better antioxidant property; But the thermal shock resistance to coating improves not quite, and complex process, and repeatability is relatively poor with safety.Therefore, along with improving constantly of thermal barrier coating application requiring, must develop gradient function thermal barrier coating with thermal stresses pooling feature.
In recent years; Can be under the high-level efficiency condition; Thermal stresses in the coating is reduced to minimum degree, thereby prepares laser induction composite coating technique (Zhou Shengfeng, the HuangYongjun of high performance flawless coating; Zeng Xiaoyan; Hu Qianwu.Microstructure characteristics of Ni-basedWC composite coatings by laser induction hybrid rapid cladding.Materials Scienceand Engineering:A, 2008,480 (1-2): 564-572) caused people's extensive interest.But, do not see bibliographical information about adopting the laser induction composite coating technique to prepare the high and flawless gradient function thermal barrier coating that have a thermal stresses pooling feature of ceramic phase content.
Summary of the invention
The object of the present invention is to provide a kind of method of laser induction composite cladding gradient function thermal barrier coating; Laser induction composite cladding gradient function thermal barrier coating has chemical ingredients, weave construction and mechanical property along coat-thickness direction continually varying characteristics in gradient; The thermal stresses of having avoided matrix and ceramic layer thermal expansivity not to match and having caused can increase substantially the thermal shock resistance and the work-ing life of coating.
The present invention realizes like this, it is characterized in that method steps is:
(1) at first with matrix metal MCrAlY (M=Ni, NiCo) zirconium white (ZrO of powdered alloy and ceramic phase ceria stabilized
2+ (6～8%) CeO
2) or boride, silicide and the intermetallic compound of casting WC and HMP, high firmness be respectively charged in two loading hoppers of twin-bucket automatic powder feeding device; Then with substrate surface eliminate rust, oil removing, cleaning and sandblasting; The powder feeding rate of two loading hoppers through accurate adjusting twin-bucket powder feeder, making ceramic phase quality percentage composition in composite powder (mixture of being made up of ceramic phase and matrix metal) is 0～90wt.%.
(2) distance between substrate surface and the load coil is controlled in 2～10mm; Feed electric current to load coil; And adjusting induction heating power; Making substrate surface is 300～1000 ℃ by the temperature of induction heating, utilizes copper pipe that the induction heating district is blown into inert protective gas simultaneously, prevents its high temperature oxidation;
(3) powder jet with focussed laser beam and twin-bucket automatic powder feeding device is positioned in the induction heating district, realizes the compound of laser thermal source and induction heating source; Utilize powder jet that composite powder is blown into laser induction composite and cover in the molten bath that thermal source forms, fusing takes place and spreads out on the surface of base material in composite powder in the molten bath, and after laser beam and induction heating source were removed, the melting layer cooling is solidification and crystallization formation coating also; Laser induction composite covers in the process, and the angle between powder jet and substrate surface normal direction is 30～70 °, and the vertical range of powder jet and base material is 10～15mm; Powder mass flow is 1～12kg/h; The laser beam spot diameter is 1～20mm, and laser power is 2～8kW, and induction heating power is 20～200kW; Laser scanning speed is 1～12m/min, and the thickness of single-layer coating is 0.1～2mm;
(4) after laser induction composite has covered together, move numerically-controlled machine along the vertical direction of laser scanning speed, its distance that moves is 70～30% of a laser spot diameter;
(5) after laser induction composite has covered one deck coating; Zero position when laser head, load coil and powder jet are turned back to a last coating laser induction composite and cover; And rise to the thickness distance of a last coating along the Z axle; Increase the powder feeding rate of ceramic phase simultaneously, make the quality percentage composition of ceramic phase in composite powder increase by 0～90wt.%;
(6) whether the thickness of detection coating reaches the thickness requirement of expection, if do not have, repeating step (2)-(5) reach desired thickness up to coating; Otherwise, end-of-job.
Ceramic phase of the present invention is embedded in the matrix metal, and is adjustable arbitrarily in 0～90wt.% scope along the coat-thickness direction.
According to the invention when carrying out step (3), laser beam adopts CO
2Laser, Nd:YAG laser or optical-fiber laser, the powder jet with twin-bucket automatic powder feeding device after the line focus is positioned in the induction heating district, realizes the compound of laser thermal source and induction heating source.
According to the invention when step (4), numerically-controlled machine is moved 70～30% of laser spot diameter along the vertical direction of laser scanning speed, thereby the overlapping rate of controlling between continuous two passages is 30～70%.
Advantage of the present invention is: (1) laser induction composite covers the efficient height, can be to accurate location, the zone of needs processing, and needn't carry out integral body heating to base material, therefore to size, the shape of base material and need the position of processing unrestricted; (2) for gradient function thermal barrier coating, the content of ceramic phase in coating along the coat-thickness direction change in gradient, controlled, and can be in 0～90wt.% scope regulate arbitrarily; (3) gradient function thermal barrier coating and base material are the high metallurgical binding of bonding strength, and whole gradient function thermal barrier coating pore-free and crackle; (4) gradient function thermal barrier coating has excellent thermal shock resistance, improves 3～10 times with respect to the thermal shock resistance of plasma spraying identical component material, and service life increases substantially.
Description of drawings
Fig. 1 covers the device synoptic diagram of functionally gradient thermal barrier coating for laser induction composite of the present invention.
The load coil that Fig. 2 covers for laser induction composite of the present invention and the synoptic diagram of base material relative position.
Embodiment
Embodiment 1
At base material nickel base superalloy surface preparation NiCrAlY/ (ZrO
2+ (6～8%) CeO
2) gradient function thermal barrier coating, the thickness of this coating is 6mm, wherein zirconium white (the ZrO of ceramic phase ceria stabilized
2+ (6～8%) CeO
2) be embedded in the matrix metal NiCrAlY, and be any adjustable Gradient distribution in 0～90wt.% scope along the coat-thickness direction.
The implementation process of present embodiment does, like Fig. 1 and shown in Figure 2.
(1) selection of cladding material and preparation: matrix metal is the NiCrAlY powdered alloy; Its chemical ingredients is (mass percent) 50～70%Ni, 19～25%Cr, 6～8%Al, 0.08～1.5%Y; Its particle diameter is 45～90 μ m, and ceramic phase is the zirconium white (ZrO of ceria stabilized
2+ (6～8%) CeO
2), its particle diameter is 20～40 μ m, with the zirconium white (ZrO of NiCrAlY powdered alloy and ceria stabilized
2+ (6～8%) CeO
2) particle is respectively charged in two loading hoppers 7,7 ' of twin-bucket automatic powder feeding device 9, then with the surface of base material nickel base superalloy 14 eliminate rust, oil removing, cleaning and sandblasting.In addition, accurately regulate two loading hoppers 7 of twin-bucket powder feeder 9,7 ' powder feeding rate, make the zirconium white (ZrO of ceria stabilized
2+ (6～8%) CeO
2) quality percentage composition in composite powder 8 (mixture of being made up of the zirconium white and the NiCrAlY powdered alloy of ceria stabilized) is 0～90wt.%;
(2) surface of nickel base superalloy 14 and the distance that is equipped with between the load coil 10 of special-purpose magnetic conductor 16 are adjusted into 5mm; Feed electric current to load coil 10; And the induction heating power that utilizes computer 1 to regulate induction heating power 12; Making the surface of nickel base superalloy 14 is 800 ℃ by the temperature of load coil 10 heating; Utilize copper pipe 18 to be blown into nitrogen as protective gas simultaneously, prevent the high-temperature oxydation in eddy-current heating district 11 to eddy-current heating district 11;
(3) CO
2The laser beam that laser apparatus 2 sends is transferred to the focusing system 5 that is positioned at laser head 4 through light-conducting system 3 and focuses on the CO after the focusing
2The powder jet 6 of laser beam and twin-bucket automatic powder feeding device 9 is positioned in the induction heating district 11, realizes the compound of laser thermal source and induction heating source; Utilizing powder jet 6 that composite powder 8 is blown into laser induction composite covers in the molten bath 17 that thermal source forms; Fusing takes place and spreads out on the surface of nickel base superalloy 14 in composite powder 8 in molten bath 17; After laser beam and induction heating source were removed, melting layer cooling and solidification and crystallization formed coating 15;
Cover in the process at laser induction composite, the angle between the surface normal of powder jet 6 and nickel base superalloy 14 is 45 °, and powder jet 6 is 12mm with the vertical range on nickel base superalloy 14 surfaces; Powder mass flow is 6kg/h; The laser beam spot diameter is 5mm, and laser power is 8kW, and induction heating power is 80kW; Laser scanning speed is 3m/min, and the thickness of single-layer coating is 0.6mm.
(4) after laser induction composite has covered together, move numerically-controlled machine 13 along the vertical direction of laser scanning speed, its distance that moves is 50% of a laser spot diameter, thus the overlapping rate of controlling between continuous two passages is 50%;
(5) after laser induction composite has covered one deck coating; Zero position when utilizing computingmachine 1 that laser head 4, load coil 10 and powder jet 6 are turned back to a last coating laser induction composite and cover; And along Z axle rising 0.6mm; Increase the zirconic powder feeding rate of ceramic phase ceria stabilized simultaneously, make the zirconium white (ZrO of ceria stabilized
2+ (6～8%) CeO
2Quality percentage composition in composite powder 8 increases 10wt.%;
(6) whether the thickness of detection coating reaches the thickness requirement of expection, if do not have, repeating step (2)-(5) reach desired thickness up to coating; Otherwise, end-of-job.
At base material nickel base superalloy surface preparation NiCoCrAlY/Ti
3Al gradient function thermal barrier coating, the thickness of this coating are 3mm, wherein ceramic phase Ti
3Al is embedded in the matrix metal NiCoCrAlY, and is any adjustable Gradient distribution in 0～90wt.% scope along the coat-thickness direction.
The implementation process of present embodiment does, like Fig. 1 and shown in Figure 2.
(1) selection of cladding material and preparation: matrix metal is the NiCoCrAlY powdered alloy, and its chemical ingredients is (weight percent) 40～60%Ni, 18～22%Co, 19～25%Cr, 6～8%Al, 0.08～1.5%Y, and its particle diameter is 45～90 μ m; Ceramic phase is intermetallic compound Ti
3Al particle, its particle diameter are 40～60 μ m, then with NiCoCrAlY powdered alloy and Ti
3The Al particle is respectively charged in two loading hoppers 7,7 ' of twin-bucket automatic powder feeding device 9; With the surface of nickel base superalloy 14 eliminate rust, oil removing, cleaning and sandblasting.In addition, accurately regulate two loading hoppers 7 of twin-bucket powder feeder 9,7 ' powder feeding rate, make Ti
3The Al particle at composite powder 8 (by Ti
3The mixture that Al particle and NiCoCrAlY powdered alloy are formed) the quality percentage composition in is 0～90wt.%;
(2) surface of nickel base superalloy 14 and the distance that is equipped with between the load coil 10 of special-purpose magnetizer 16 are adjusted in the 8mm; Feed electric current to load coil 10; And utilize computingmachine 1 to regulate the induction heating power of induction heating power 12; Making the surface of nickel base superalloy 14 is 930 ℃ by the temperature of load coil 10 heating, utilizes 18 pairs of induction heating districts 11 of copper pipe to be blown into N simultaneously
2As shielding gas, prevent the high temperature oxidation in induction heating district 11;
(3) laser beam that sends of Nd:YAG laser instrument 2 is transferred to focusing system 5 focusing that are positioned at laser head 4 through light-conducting system 3; The powder jet 6 of Nd:YAG laser beam after the focusing and twin-bucket automatic powder feeding device 9 is positioned in the eddy-current heating district 11, realizes the compound of laser thermal source and eddy-current heating source; Utilizing powder jet 6 that composite powder 8 is blown into laser induction composite covers in the molten bath 17 that thermal source forms; Fusing takes place and spreads out on the surface of nickel base superalloy 14 in composite powder 8 in molten bath 17; After laser beam and eddy-current heating source were removed, melting layer cooling and solidification and crystallization formed coating 15; Laser induction composite covers in the process; Angle between the surface normal of powder jet 6 and nickel base superalloy 14 is 37 °; Powder jet 6 is 10mm with the vertical range on nickel base superalloy 14 surfaces; Powder mass flow is 12kg/h; The laser beam spot diameter is 8mm, and laser power is 3kW, and induction heating power is 120kW; Laser scanning speed is 8m/min, and the thickness of signal layer coating is 0.5mm;
(4) after laser induction composite has covered together, move numerically-controlled machine 13 along the vertical direction of laser scanning speed, its distance that moves is 45% of a laser spot diameter, thus the overlapping rate of controlling between continuous two passages is 55%;
(5) after laser induction composite has covered one deck coating, the zero position when utilizing computingmachine 1 that laser head 4, load coil 10 and powder jet 6 are turned back to a last coating laser induction composite and cover, and, increase ceramic phase Ti simultaneously along Z axle rising 0.5mm
3The powder feeding rate of Al makes Ti
3The quality percentage composition of Al particle in composite powder 8 increases 18wt.%;
(6) whether the thickness of detection coating reaches the thickness requirement of expection, if do not have, repeating step (2)-(5) reach desired thickness up to coating; Otherwise, end-of-job.
Claims (4)
1. the method for a laser induction composite cladding gradient function thermal barrier coating is characterized in that method steps is:
(1) at first boride, silicide and the intermetallic compound of the zirconium white of matrix metal MCrAlY powdered alloy and ceramic phase ceria stabilized or casting WC and HMP, high firmness is respectively charged in two loading hoppers of twin-bucket automatic powder feeding device; Wherein the M among the MCrAlY is Ni or NiCo; The quality percentage composition of cerium oxide is 6～8wt.% in the zirconium white of ceria stabilized; Then with substrate surface eliminate rust, oil removing, cleaning and sandblasting; The powder feeding rate of two loading hoppers through accurate adjusting twin-bucket powder feeder, making the quality percentage composition of ceramic phase in composite powder is 0～90wt.%;
(2) distance between substrate surface and the load coil is controlled in 2～10mm; Feed electric current to load coil; And adjusting induction heating power; Making substrate surface is 300～1000 ℃ by the temperature of induction heating, utilizes copper pipe that the induction heating district is blown into inert protective gas simultaneously, prevents its high temperature oxidation;
(3) powder jet with focussed laser beam and twin-bucket automatic powder feeding device is positioned in the induction heating district, realizes the compound of laser thermal source and induction heating source; Utilize powder jet that composite powder is blown into laser induction composite and cover in the molten bath that thermal source forms, fusing takes place and spreads out on the surface of base material in composite powder in the molten bath, and after laser beam and induction heating source were removed, the melting layer cooling is solidification and crystallization formation coating also; Laser induction composite covers in the process, and the angle between powder jet and substrate surface normal direction is 30～70 °, and the vertical range of powder jet and base material is 10～15mm; Powder mass flow is 1～12kg/h; The laser beam spot diameter is 1～20mm, and laser power is 2～8kW, and induction heating power is 20～200kW; Laser scanning speed is 1～12m/min, and the thickness of single-layer coating is 0.1～2mm;
(4) after laser induction composite has covered together, move numerically-controlled machine along the vertical direction of laser scanning speed, its distance that moves is 70～30% of a laser spot diameter;
(5) after laser induction composite has covered one deck coating; Zero position when laser head, load coil and powder jet are turned back to a last coating laser induction composite and cover; And rise to the thickness distance of a last coating along the Z axle; Increase the powder feeding rate of ceramic phase simultaneously, make the quality percentage composition of ceramic phase in composite powder increase by 0～90wt.%;
(6) whether the thickness of detection coating reaches the thickness requirement of expection, if do not have, repeating step (2)-(5) reach desired thickness up to coating; Otherwise, end-of-job.
2. the method for laser induction composite cladding gradient function thermal barrier coating according to claim 1 is characterized in that described ceramic phase is embedded in the matrix metal, and is adjustable arbitrarily in 0～90wt.% scope along the coat-thickness direction.
3. the method for laser induction composite cladding gradient function thermal barrier coating according to claim 1 is characterized in that when carrying out said step (3), and laser beam adopts CO
2Laser, Nd:YAG laser or optical-fiber laser, the powder jet with twin-bucket automatic powder feeding device after the line focus is positioned in the induction heating district, realizes the compound of laser thermal source and induction heating source.
4. the method for laser induction composite cladding gradient function thermal barrier coating according to claim 1; It is characterized in that when said step (4); Numerically-controlled machine is moved 70～30% of laser spot diameter along the vertical direction of laser scanning speed, thereby the overlapping rate of controlling between continuous two passages is 30～70%.
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