CN108411242B - Thermal barrier coating with particle erosion resistant surface layer and preparation method thereof - Google Patents
Thermal barrier coating with particle erosion resistant surface layer and preparation method thereof Download PDFInfo
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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
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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
- C23C4/04—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
Abstract
The thermal barrier coating is a ceramic layer which is arranged on a substrate by adopting a plasma spraying-physical vapor deposition process and is in a feather-like structure, the upper end of the ceramic layer is a high-cohesion surface layer, the part of the ceramic layer, which is positioned below the high-cohesion surface layer, is in interface-free connection with the high-cohesion surface layer, and the high-cohesion surface layer has the same material components, phases and macroscopic feather-like structures as the ceramic layer below the surface layer. The invention has simple process, low cost and high bonding strength of the coating, and the prepared thermal barrier coating with the surface layer with high cohesive strength can greatly improve the particle erosion resistance of the thermal barrier coating and has long service life.
Description
Technical Field
The invention belongs to the technical field of thermal barrier coatings, and relates to a thermal barrier coating with a particle erosion resistant surface layer and a preparation method thereof.
Background
Thermal Barrier Coatings (TBCs) are surface protection technologies which utilize the excellent high temperature resistance, corrosion resistance and low heat conduction performance of ceramic materials to compound the ceramic and a metal substrate in a coating mode, improve the service temperature and high temperature oxidation resistance of a hot end component, prolong the service life of the hot end component and improve the efficiency of an engine. The prior thermal barrier coating structure mainly comprises a lamellar structure and a columnar crystal structure, wherein the lamellar structure is mainly used for a part with lower temperature or static temperature, the coating and a base body are mechanically combined, the bonding strength is general, meanwhile, the strain tolerance of the lamellar structure is low, and the coating is easy to peel off prematurely under thermal shock. The latter has gaps among columnar crystals, so that the stress tolerance of the coating is high, and the thermal cycle life is long. But the vertical gaps between the columnar crystals become channels for hot and corrosive media, and the coating has low heat insulation and corrosion resistance.
The plasma spraying-physical vapor deposition (PS-PVD) technology is a novel vapor deposition coating method developed on the basis of low-pressure plasma spraying. The prepared thermal barrier coating structure is mainly a feather-like structure similar to columnar crystals. Researches find that the feather-shaped structure thermal barrier coating has better comprehensive performance, and the heat insulation performance of the feather-shaped structure thermal barrier coating is obviously higher than that of a columnar crystal structure and is close to that of a lamellar structure; the thermal cycle life is significantly longer than that of a lamellar structure and is close to that of a columnar crystal coating. However, it is worth noting that the low erosion resistance of the thermal barrier coating with feather structure prepared by PS-PVD is a short plate which is not negligible and needs to be improved.
The erosion failure refers to the phenomenon that under the repeated action of airflow with hard particles, a ceramic layer in an action area becomes dense, so that the thickness becomes thin, cracks are formed, and even a coating is peeled off. The hard particle sources mainly comprise two types, namely carbon particles formed in the combustion process or particles formed by erosion of the inner wall of a combustion chamber of an engine, turbine blades and the like; another is from foreign objects that are inhaled, such as sand, dust, salt, metal dust, etc. In the service process of an engine, hard particles deviate from a gas flow passage due to inertia force to impact the surface of a coating to form scouring, and the coating is easy to peel off, so that the failure is caused. The PS-PVD feather-like structure ceramic layer, when impacted and pressed by foreign particles, produces a shear band 450 to the surface in the ceramic layer, from which cracks are induced and grow, on the one hand, laterally and on the other hand, extending to the interface between the ceramic layer and the bonding layer. Meanwhile, thermal stress/energy generated by factors such as thermal expansion mismatching and phase change sintering in the coating can be released through the cracks, so that the cracks are rapidly increased and grown, and finally feather-like crystals are broken and fail.
In order to improve the particle erosion resistance of the thermal barrier coating, a compact wear-resistant layer is prepared on the surface of the ceramic layer of the existing thermal barrier coating by adopting spraying, coating and laser surface treatment. For example, Wang et al used laser remelting to reduce the porosity of the ceramic layer surface and thereby increase the ceramic contentHardness of the surface of the porcelain layer (Effects of laser re-formation of microstructure and solid particles of ceramics of ZrO)2-7wt％Y2O3thermal barrier coating prepared by plasma spraying[J]8791-8799, ceramics International,2014,40 (6); zhang et Al use magnetron sputtering of aluminum metal followed by vacuum treatment to form a dense alumina layer to improve the resistance to particle erosion (J-erosion of Al-deposition on resistance of plated thermal barrier coating)]Transactions of non-ferrous Metals society of China 2015,25(8): 2587-; patent "a multilayer thermal barrier coating and a method for forming the same" (CN201410697118.4), and the like. The methods adopt different processes, but finally form a double-layer and multi-layer composite structure, and the outer layer is a compact layer to improve the scouring resistance. The compact outer layer and the compact inner layer of the composite structure are layered, and the two layers have obvious difference of organization structure, components and chemical phases and have obvious interlayer interfaces. The interlaminar interfaces can become weak links of the binding force, the thermal stability and the chemical stability of the coating, cracks are most easily generated on the interfaces when the coating is collided by particles, even the coatings are separated and fall off, the performance and the service life of the coating are influenced, meanwhile, the complicated multi-process and multi-flow preparation problem is brought, and the cost is greatly improved.
Disclosure of Invention
The invention aims to provide a thermal barrier coating with a particle erosion resistant surface layer and a preparation method thereof, wherein the thermal barrier coating has the advantages of simple process, low cost, high coating bonding strength and long service life.
The technical scheme of the invention is realized as follows:
a particle erosion resistant thermal barrier coating is characterized in that: the thermal barrier coating is composed of a feather-shaped ceramic layer main body and a high-cohesive-strength surface layer on the upper part of the main body, interface-free continuous transition is formed between the ceramic layer main body and the high-cohesive-strength surface layer, and the same material components, phases and macroscopic feather-shaped structures are maintained; the thickness of the high cohesive strength surface layer is 30-100 mu m, and the thickness ratio of the high cohesive strength surface layer to the ceramic layer main body is 1:9-1: 3.
The invention relates to a preparation method of a thermal barrier coating with a particle erosion resistant surface layer, which is characterized in that a ceramic layer main body and a high-cohesion surface layer are obtained by deposition in the early stage and the later stage of a spraying process respectively by adopting a plasma spraying-physical vapor deposition process and implementing an uninterrupted two-step method of dynamic adjustment. The method comprises the following specific steps:
1) cleaning the surface of the substrate and fixing the substrate on a workpiece moving table in a vacuum chamber;
2) closing the vacuum chamber, and vacuumizing until the pressure is less than or equal to 150 Pa;
3) feeding ceramic powder by adopting a plasma spraying-physical vapor deposition process under the conditions that the pressure of a vacuum chamber is less than or equal to 150Pa and the oxygen flow is 1-3L/min, evaporating the ceramic powder after the ceramic powder enters plasma flame flow, blowing the ceramic powder to a substrate by the plasma flame flow to carry out early deposition of a coating, and depositing the coating to 75-90% of the total thickness of the coating in the early stage;
4) and changing plasma gas and adjusting spraying parameters at the same time, and performing later deposition on the coating to obtain a surface layer with high cohesive strength, thereby completing the preparation of the ceramic layer with the feather-shaped structure.
Wherein the earlier deposition conditions comprise: the vacuum chamber pressure is less than or equal to 150Pa, the spraying current is 2500-2700A, the spraying power is 120-130 kW, the plasma working gas is Ar and He, the flow rate is Ar 25-45L/min and He 55-75L/min, the oxygen flow rate is 1-3L/min, the substrate temperature is 850-950 ℃, the powder feeding rate is 10-20 g/min, and the spraying distance is 850-1100 mm.
Wherein the post-deposition conditions comprise: the pressure of the vacuum chamber is less than or equal to 150Pa, the spraying current is 1900-2000A, the spraying power is 115-120 kW, and the plasma working gas is Ar, He or H2The flow rates are Ar 30-40L/min, He 55-65L/min and H25-10L/min, the temperature of the matrix is 900-950 ℃, the powder feeding rate is 5-10 g/min, and the spraying distance is 850-1100 mm.
Compared with the prior art, the invention has the following advantages:
(1) the feather-shaped structure thermal barrier coating prepared by plasma spraying-physical vapor deposition has better comprehensive performance, is a new technology for the key development of the thermal barrier coating of a future high-performance aeroengine, but has the defects of high response capacity limit, high thermal cycle life and the like of the coating due to the gaps among the feather-shaped structures and low particle erosion resistance. The invention adopts the surface layer with high cohesive strength as the anti-particle scouring surface, which can greatly improve the anti-particle scouring performance of the coating;
(2) the impact-resistant layer prepared by traditional improvement is layered with the interior, and the interlayer interface can become the weak link of the coating binding force, thermal stability and chemical stability, and cracks are most likely to be generated or even fall off. In the deposition process of the feather-shaped thermal barrier coating, the plasma parameters are directly adjusted and changed, namely the spraying process is uninterrupted, the deposition is continued to prepare the surface layer with high cohesive strength, the surface layer and the coating grown previously have no difference in material components and phases, the macroscopic feather-shaped structure is not changed, the deposition mechanism of the evaporated ceramic layer material is changed only through parameter adjustment, and the coating with non-layering components and structure, higher cohesive strength of the surface layer and better erosion resistance in performance is formed. The invention avoids the introduction of an interlayer interface which can become a weak link of coating combination and thermal/chemical stability, and the coating structure is simpler;
(3) the traditional particle scouring resistant improved process brings very complicated preparation problems, and has more production flows and long time. The invention directly changes plasma parameters in the operation of a spraying program, does not need to stop a spray gun, stop powder feeding, interrupt the program and the like, does not need to discharge a vacuum cavity and replace other processes, and has convenient adjustment, simple process flow and low cost.
The invention will be further described with reference to the accompanying drawings.
Drawings
FIG. 1 is a schematic structural view of a thermal barrier coating of the present invention.
FIG. 2 is a graph showing the erosion weight loss of the coated particles of example 1 of the present invention.
Detailed Description
Example 1:
the example used superalloy K417G as the substrate, with a total coating thickness of 300 μm and a high cohesive strength surface layer of 50 μm. The thermal barrier coating ceramic layer material adopts Yttria Stabilized Zirconia (YSZ) ceramic powder (agglomerated spherical powder, the grain diameter is-30 +1 μm, and the components are shown in the following table).
| Composition (I) | ZrO2 | Y2O3 | HfO2 | Binder | Impurities |
| Weight percent of | Balance of | 7.5 | <2.5 | 1 | <0.1 |
The preparation process comprises the following steps:
firstly, grinding and polishing the surface of a substrate, and ultrasonically cleaning the substrate by alcohol to keep the surface clean;
secondly, preparing a ceramic layer on the substrate, and the specific steps are as follows:
(1) fixing the substrate on a workpiece motion table in a vacuum chamber;
(2) closing the vacuum chamber, vacuumizing, keeping the dynamic pressure of the vacuum chamber equal to 150Pa, and introducing oxygen into the vacuum chamber for 2L/min;
(3) ceramic layer powder is fed, plasma flame flow containing the ceramic layer material sweeps the matrix to deposit the coating, and the temperature of the matrix is controlled to be 850-950 ℃. The pre-coating deposition allows the coating to grow to 83% of the total thickness;
the preparation conditions are as follows: the spraying current is 2500A, the power is 123kW, the plasma working gas is Ar and He, the flow rate is Ar 35L/min and He 60L/min, the matrix temperature is 880 +/-20 ℃, the powder feeding rate is 20g/min, and the spraying distance is 950 mm;
(4) after the later deposition of the coating, changing plasma gas and simultaneously adjusting spraying parameters, and continuously depositing to prepare a surface layer with high cohesive strength;
the preparation conditions are as follows: the spraying current is 2000A, the power is 118.5kW, and the plasma working gas is Ar, He and H2The flow rates are Ar 35L/min, He 60L/min and H210L/min, fluctuation of the temperature of the matrix at 900-950 ℃, powder feeding rate of 10g/min and spraying distance of 950 mm;
and thirdly, finishing the preparation.
Example 1 a thermal barrier coating ceramic layer with a particle erosion resistant surface layer without interlayer interfaces was prepared by vapor deposition of YSZ material on the substrate surface. The total thickness of the ceramic layer is 300 μm, wherein the thickness of the ion scour resistant surface layer is 50 +/-5 μm.
The particle erosion resistance effect of the coating is tested by adopting a particle erosion experiment, referring to GE E50TF121 particle erosion standard, the erosion angle is 20 degrees, the distance is 100mm, the particle size of the erosion particles is about 55 mu m, the pressure is 0.25MPa, the erosion time is 25s, and fig. 2 is a graph of the erosion weightlessness of the coating particles of the embodiment. This example demonstrates that the particle erosion resistant surface layer does exist and exerts a very good particle erosion resistance and that the coating has a substantially increased service life.
Example 2:
in this example, a directionally solidified superalloy DZ40M was used as the substrate, the total coating thickness was designed to be 350 μm, and the particle erosion resistant surface layer was designed to be 70 μm. The material of the thermal barrier coating ceramic layer is yttria-stabilized zirconia YSZ.
The preparation process comprises the following steps:
firstly, grinding and polishing the surface of a substrate, and ultrasonically cleaning the substrate by alcohol to keep the surface clean;
secondly, preparing a ceramic layer on the substrate, and the specific steps are as follows:
(1) fixing the substrate on a workpiece motion table in a vacuum chamber;
(2) closing the vacuum chamber, vacuumizing, keeping the dynamic pressure of the vacuum chamber equal to 150Pa, and introducing oxygen into the vacuum chamber for 1.5L/min;
(3) ceramic layer powder is fed, plasma flame flow containing the ceramic layer material purges a substrate for coating deposition, and the temperature of the substrate is controlled at 920 +/-30 ℃. The coating pre-deposition allows the coating to grow to 80% of the total thickness;
the preparation conditions are as follows: the spraying current is 2600A, the power is 127kW, the plasma working gas is Ar and He, the flow rate is Ar 30L/min and He 70L/min, the temperature of the matrix is 900 +/-30 ℃, the powder feeding rate is 20g/min, and the spraying distance is 1000 mm;
(4) after the later deposition of the coating, changing plasma gas and simultaneously adjusting spraying parameters, and continuously depositing to prepare a surface layer with high cohesive strength;
the preparation conditions are as follows: the spraying current is 1900A, the power is 112kW, and the plasma working gas is Ar, He and H2The flow rates are Ar 30L/min, He 65L/min and H2 5L/min, the temperature of the matrix is 870 +/-20 ℃, the powder feeding rate is 5g/min, and the spraying distance is 1000 mm;
and thirdly, finishing the preparation.
Example 2 a thermal barrier coating ceramic layer having a particle erosion resistant surface layer without an interlayer interface was prepared by vapor deposition of YSZ material on the substrate surface to a total thickness of 350 μm.
The particle erosion resistance effect of the coating is tested by adopting a particle erosion experiment, the standard of GE E50TF121 particle erosion is referred, the erosion angle is 20 degrees, the distance is 100mm, the particle size of the erosion particles is about 55 mu m, the pressure is 0.25MPa, and the erosion time is 25 s. The erosion depth per unit time was measured, where the erosion rate of the YSZ thermal barrier coating without the particle erosion resistant surface layer prepared by plasma spray-pvd was 6.35 μm/s on average, and 1.1 μm/s on average in this example, as shown in the table below. The thickness of the coating flushed in unit time is greatly reduced, which shows that the particle-flushing-resistant surface layer has a very good particle-flushing-resistant effect, and the particle-flushing-resistant capability of the coating is greatly improved.
While the present invention has been described by way of examples, and not by way of limitation, other variations of the disclosed embodiments, as would be readily apparent to one of skill in the art, are intended to be within the scope of the present invention, as defined by the claims.
Claims (2)
1. A particle erosion resistant thermal barrier coating characterized by: the thermal barrier coating is composed of a feather-shaped ceramic layer main body and a high-cohesive-strength surface layer on the upper part of the main body, interface-free continuous transition is formed between the ceramic layer main body and the high-cohesive-strength surface layer, and the same material components, phases and macroscopic feather-shaped structures are maintained; the thickness of the high cohesive strength surface layer is 30-100 microns, and the thickness ratio of the high cohesive strength surface layer to the ceramic layer main body is 1:9-1: 3; the ceramic layer main body and the high-cohesion-strength surface layer are obtained by respectively adopting different plasma spraying-physical vapor deposition conditions in the early stage and the later stage of the spraying process by adopting a plasma spraying-physical vapor deposition process and implementing a dynamically-adjusted uninterrupted two-step method; wherein the early deposition conditions comprise: the pressure of the vacuum chamber is less than or equal to 150Pa, the spraying current is 2500-2700A, the spraying power is 120-130 kW, the plasma working gas is Ar and He, the flow rate is Ar 25-45L/min and He 55-75L/min, the oxygen flow rate is 1-3L/min, the substrate temperature is 850-950 ℃, the powder feeding rate is 10-20 g/min, and the spraying distance is 850-1100 mm; rear endThe deposition conditions include: the pressure of the vacuum chamber is less than or equal to 150Pa, the spraying current is 1900-2000A, the spraying power is 115-120 kW, and the plasma working gas is Ar, He or H2The flow rates are Ar 30-40L/min, He 55-65L/min, and H25-10L/min, the temperature of the matrix is 900-950 ℃, the powder feeding rate is 5-10 g/min, and the spraying distance is 850-1100 mm.
2. The method of preparing a particle-erosion resistant thermal barrier coating of claim 1, wherein: the ceramic layer main body and the surface layer with high cohesive strength are both obtained by adopting a plasma spraying-physical vapor deposition process, implementing an uninterrupted two-step method of dynamic adjustment and respectively adopting different plasma spraying-physical vapor deposition conditions to deposit at the early stage and the later stage of the spraying process; wherein the content of the first and second substances,
the early deposition conditions include: the pressure of the vacuum chamber is less than or equal to 150Pa, the spraying current is 2500-2700A, the spraying power is 120-130 kW, the plasma working gas is Ar and He, the flow rate is Ar 25-45L/min and He 55-75L/min, the oxygen flow rate is 1-3L/min, the substrate temperature is 850-950 ℃, the powder feeding rate is 10-20 g/min, and the spraying distance is 850-1100 mm;
the post-deposition conditions include: the pressure of the vacuum chamber is less than or equal to 150Pa, the spraying current is 1900-2000A, the spraying power is 115-120 kW, and the plasma working gas is Ar, He or H2The flow rates are Ar 30-40L/min, He 55-65L/min, and H25-10L/min, the temperature of the matrix is 900-950 ℃, the powder feeding rate is 5-10 g/min, and the spraying distance is 850-1100 mm.
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| CN112111184B (en) * | 2020-07-31 | 2022-12-09 | 西安交通大学 | Anti-dust high-temperature adhesion coating alternately stacked in layered and column/tree shapes |
| CN112126889B (en) * | 2020-08-21 | 2021-10-01 | 中国地质大学（武汉） | Method for optimizing thermal barrier coating stability by constructing bionic structure through 3D printing |
| CN113151772A (en) * | 2021-03-31 | 2021-07-23 | 辽宁科技大学 | Novel high-temperature corrosion-resistant thermal barrier coating with double ceramic layer structure and preparation method thereof |
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| CA2760005A1 (en) * | 2010-12-21 | 2012-06-21 | Sulzer Metco Ag | Method for the manufacture of a thermal barrier coating structure |
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Address after: 510651 No. 363, Changxin Road, Guangzhou, Guangdong, Tianhe District Patentee after: Institute of new materials, Guangdong Academy of Sciences Address before: 510651 No. 363, Changxin Road, Guangzhou, Guangdong, Tianhe District Patentee before: GUANGDONG INSTITUTE OF NEW MATERIALS |