CN110512166B - Marine corrosion resistant abradable material, coating and preparation method thereof - Google Patents
Marine corrosion resistant abradable material, coating and preparation method thereof Download PDFInfo
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- CN110512166B CN110512166B CN201910962275.6A CN201910962275A CN110512166B CN 110512166 B CN110512166 B CN 110512166B CN 201910962275 A CN201910962275 A CN 201910962275A CN 110512166 B CN110512166 B CN 110512166B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C26/00—Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C9/00—Alloys based on copper
- C22C9/01—Alloys based on copper with aluminium as the next major constituent
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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
- C23C24/00—Coating starting from inorganic powder
- C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
- C23C24/082—Coating starting from inorganic powder by application of heat or pressure and heat without intermediate formation of a liquid in the layer
- C23C24/085—Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides
- C23C24/087—Coating with metal alloys or metal elements only
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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
- C23C4/06—Metallic material
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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
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C26/00—Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes
- C22C2026/007—Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes with additional metal compounds being nitrides
Abstract
The invention discloses a marine corrosion resistant abradable material, a coating and a preparation method thereof, and belongs to the technical field of gas turbines. The coating is prepared by adopting single-phase CuAl with excellent corrosion resistance and abradability as an abradable surface layer framework component, adopting insulated polyester or boron nitride and the like as an abradable component, adopting CuAl which has the chemical components completely consistent with those of the abradable surface layer framework component as a bottom layer material and adopting a thermal spraying method, so that the problems of non-corrosion resistance of the traditional abradable coating framework component, galvanic corrosion generated between the components and between the surface layer and the bottom layer due to potential difference, and coating corrosion caused by easy penetration of corrosive media into a coating/matrix interface and the like are solved, and the coating has wide application in marine gas turbines, aero-engines, ground gas turbines and the like in service in marine environments.
Description
Technical Field
The invention relates to a structural design and a preparation method of an abradable seal coating for sealing an aircraft engine gas path, and belongs to the technical field of gas turbines.
Background
The abradable seal coating is coated on the surface of the stator part of the gas turbine, and can be actively abraded when being abraded with the rotor part under the high-temperature and high-speed working condition, so that the minimum gap between the rotor and the stator can be controlled through interference fit of the rotor and the stator, the rotor part is protected from being abraded, and the abradable seal coating has important significance for reducing the oil consumption of the gas turbine, improving the efficiency and operating safety. The abradable seal coating is easy to be invaded by corrosive media such as salt fog and the like in a marine environment due to the characteristics of multiple holes, multiple components and multiple layers, galvanic corrosion between different components and different layers occurs, the problems of performance degradation, falling and block falling of the coating and the like are caused, and the safety and efficiency of the operation of a gas turbine are seriously influenced.
The abradable coating typically consists of an abradable face layer and a bonding primer layer. The abradable surface layer material is composed of a skeleton component for providing the strength of the abradable surface layer material and an abradable component for providing the abradability of the abradable surface layer material, wherein the skeleton component is generally metal such as Al, AlSi, CuAl, NiCr and the like, the abradable component is generally a non-metal material with low shear strength such as graphite, boron nitride, polyphenyl ester and the like, and in addition, a large number of holes are formed in the abradable surface layer in most cases; the bonding bottom layer material mainly comprises nickel aluminum, molybdenum, MCrAlY and the like. In a corrosive medium environment, the metal framework can be corroded; when the coating contains conductive components such as graphite, galvanic corrosion can occur between the metal framework component and the graphite abradable component; interlayer corrosion can occur due to the potential difference between the abradable face material and the underlying material. In corrosive environments, when the abradable coating is corroded and damaged, corrosive media penetrate into the coating/substrate interface, galvanic corrosion between the coating and the substrate can occur, resulting in the coating falling off as a whole.
Disclosure of Invention
The invention aims to overcome the defect that a traditional abradable seal coating is easy to corrode due to the fact that the traditional abradable seal coating is porous, multi-component and multi-layer and is easy to corrode when being invaded by corrosive media such as salt fog and the like in a marine environment, and provides an abradable material with marine corrosion resistance, a coating and a preparation method of the abradable material. The specific technical scheme is as follows.
A marine corrosion resistant abradable material characterized by: the abradable material comprises bottom layer material powder A and surface layer material powder B, wherein the powder A is composed of Cu and Al, the weight ratio of Al is 0.1-7.4%, and the balance is Cu; the powder B consists of the powder A, polyester, hexagonal boron nitride and a binder, and comprises the following components in percentage by weight: 70-99.5% of powder A; 0.5 to 30 percent of polyester; 0-5% of hexagonal boron nitride; 0-10% of binder.
In order to solve the corrosion problem of the metal framework material of the abradable surface layer, an optimized CuAl alloy component design is provided. Pure Cu has good marine corrosion resistance and excellent plasticity, can be used for the metal framework component of the abradable coating, but needs to be added with Al to improve the oxidation resistance so as to meet the application requirement of high-temperature working conditions. The currently used CuAl component is Cu-9Al which has good oxidation resistance, but the alloy of the component is an alpha + beta double-phase structure, and the potential difference between the two phases can cause Al-removing corrosion and insufficient corrosion resistance. According to the invention, continuous exploration discovers that when the Al content is within the range of 0.1-7.4%, the CuAl is an alpha single-phase structure, no interphase corrosion exists, excellent corrosion resistance and abradability are maintained, the oxidation resistance is good, the Al content can be adjusted according to the working condition temperature in practical application, the higher the Al content is, the higher the available temperature is, and the highest application temperature within the designed component range can reach 650 ℃.
In order to solve the problem of interlayer corrosion between the abradable surface layer and the bonding bottom layer, the invention takes the optimized component CuAl with 0.1-7.4% of Al content as the bonding bottom layer material, and keeps the bottom layer material and the abradable surface layer metal framework material completely consistent in component, thereby completely avoiding the galvanic corrosion problem caused by interlayer potential difference and obviously enhancing the corrosion resistance of the coating.
In order to solve the problem of corrosion among the wearing surface layer components, the invention selects the design of using non-conductive wearing components such as polyester, boron nitride and the like, and completely avoids galvanic corrosion among the components.
Further, the polyester is one or more of polyethylene terephthalate, polyimide and polyphenyl ester.
A preparation method of a marine corrosion resistant abradable material is characterized in that powder A is prepared by adopting atomization, smelting and crushing, high-energy ball milling, mechanical alloying, mechanical mixing or agglomeration compounding methods, and powder B is prepared by adopting a method of mechanically mixing a plurality of raw materials or carrying out agglomeration compounding by using a binder.
A preparation method of an ocean corrosion resistant abradable coating is characterized in that powder A is subjected to cold spraying, supersonic flame spraying or low-pressure plasma spraying to prepare a bottom layer on the surface of a substrate; and (3) spraying the powder B on the bottom layer by adopting atmospheric plasma spraying, supersonic flame spraying or cold spraying to prepare a surface layer.
In order to prevent corrosive media from permeating the coating and permeating the coating/matrix interface, the invention adopts the processes of cold spraying or supersonic flame spraying and the like to prepare the compact bottom layer, thereby avoiding the problems of high porosity of the coating, easy permeation of the corrosive media and the like existing in the traditional atmosphere plasma spraying bottom layer. Because the melting point of CuAl is lower, the effect of preparing the compact bottom layer by adopting a cold spraying method is best, and the compact CuAl bottom layer can also be prepared by adopting an improved supersonic flame spray gun or the compact bottom layer is prepared by adopting low-pressure plasma with higher cost.
Further, the coating is subjected to heat treatment after the surface layer is prepared, and organic components are burnt off to obtain a porous structure, so that the abradability of the coating is improved, the residual stress is removed, and the bonding force of the coating is increased.
The corrosion-resistant abradable coating prepared by the invention can burn off organic components in the abradable surface layer through coating heat treatment to obtain the porous surface layer, so as to improve the abradability of the coating, and simultaneously, the release of the residual stress of the coating and the improvement of the binding force between the coatings are facilitated. The heat treatment temperature and time are determined experimentally based on the decomposition temperature and content of organic components in the abradable face layer, and typically the heat treatment temperature is not higher than 450 ℃.
The invention adopts insulated polyester or hexagonal boron nitride and the like as abradable components, adopts CuAl which is completely consistent with the chemical components of the abradable surface layer framework components as a bottom layer material, and prepares the coating by a thermal spraying method, thereby overcoming the problems that the traditional abradable coating framework components are not corrosion-resistant, galvanic corrosion is generated among the components and between the surface layer and the bottom layer due to potential difference, and the coating corrosion is caused by corrosive medium easily permeating into the coating/matrix interface, and the like, and having wide application prospect in marine gas turbines, aero-engines, ground gas turbines and the like in service in marine environment.
Detailed Description
Example 1
The method comprises the following steps: preparing CuAl alloy powder by adopting a vacuum atomization process, wherein the Al content is 0.1-7.4%;
step two: mixing the CuAl alloy powder prepared in the step one with polyphenyl ester powder according to the weight ratio of 9: 1, mechanically mixing to obtain abradable surface layer powder;
step three: carrying out surface cleaning and sand blasting coarsening on a matrix to be coated, screening CuAl powder prepared in the first step of being 400 meshes below, and preparing a CuAl bottom layer by adopting an Impact cold spraying gun, wherein the cold spraying parameters are as follows: the spraying distance is 20mm, the nitrogen pressure is 40bar, the powder feeding speed is 30g/min, the gas temperature is 450 ℃, and the coating thickness is 0.1-0.2 mm.
Step four: and (3) on the cold spraying CuAl bottom layer, adopting the wearable surface layer powder prepared in the second atmospheric plasma spraying step, wherein the spraying parameters are as follows: the current is 400A, the voltage is 70V, the powder feeding speed is 40g/min, the spraying distance is 120mm, and the thickness of the coating is 1.5-2 mm, so that the corrosion-resistant abradable coating is obtained.
Example 2
The method comprises the following steps: preparing CuAl alloy powder by adopting a vacuum atomization process, wherein the Al content is 0.1-7.4%;
step two: mixing the CuAl alloy powder prepared in the step one with polyphenyl ester powder according to the weight ratio of 9: 1, mechanically mixing, heating polyvinyl alcohol binder accounting for 3 percent of the total material weight in the mixture for agglomeration and granulation to obtain abradable surface layer powder;
step three: carrying out surface cleaning and sand blasting coarsening on a matrix to be coated, screening CuAl powder prepared in the first step of being 400 meshes below, and preparing a CuAl bottom layer by adopting an Impact cold spraying gun, wherein the cold spraying parameters are as follows: the spraying distance is 20mm, the nitrogen pressure is 40bar, the powder feeding speed is 30g/min, the gas temperature is 450 ℃, and the coating thickness is 0.1-0.2 mm.
Step four: and (3) on the cold spraying CuAl bottom layer, adopting the wearable surface layer powder prepared in the second atmospheric plasma spraying step, wherein the spraying parameters are as follows: the current is 410A, the voltage is 72V, the powder feeding speed is 45g/min, the spraying distance is 130mm, and the thickness of the coating is 1.5-2 mm.
Step five: and (3) placing the prepared coating in an atmospheric resistance furnace, and keeping the temperature at 450 ℃ for 5h to burn out the polyphenyl ester and the organic binder in the coating to obtain the corrosion-resistant abradable coating.
Example 3
The method comprises the following steps: preparing CuAl alloy powder by adopting a vacuum atomization process, wherein the Al content is 0.1-7.4%;
step two: mixing the CuAl alloy powder prepared in the step one with polyphenyl ester powder and hexagonal boron nitride powder according to the weight ratio of 8: 1: 1, mechanically mixing, heating polyvinyl alcohol binder accounting for 3 percent of the total material weight in the mixture for agglomeration and granulation to obtain abradable surface layer powder;
step three: carrying out surface cleaning and sand blasting coarsening on a matrix to be coated, screening CuAl powder prepared in the first step of being less than 500 meshes, and preparing a CuAl bottom layer by adopting an Impact cold spraying gun, wherein the cold spraying parameters are as follows: the spraying distance is 20mm, the nitrogen pressure is 40bar, the powder feeding speed is 30g/min, the gas temperature is 450 ℃, and the coating thickness is 0.1-0.2 mm.
Step four: and (3) on the cold spraying CuAl bottom layer, adopting the wearable surface layer powder prepared in the second atmospheric plasma spraying step, wherein the spraying parameters are as follows: the current is 400A, the voltage is 70V, the powder feeding speed is 40g/min, the spraying distance is 120mm, and the thickness of the coating is 1.5-3 mm.
Step five: and (3) placing the prepared coating in an atmospheric resistance furnace, and keeping the temperature at 450 ℃ for 5h to burn out the polyphenyl ester and the organic binder in the coating to obtain the corrosion-resistant abradable coating.
Example 4
The method comprises the following steps: preparing CuAl alloy powder by adopting an inert gas atomization process, wherein the Al content is 0.1-7.4%;
step two: mixing the CuAl alloy powder prepared in the step one with polyphenyl ester powder according to the weight ratio of 17: 3, mechanically mixing, heating polyvinylpyrrolidone binder accounting for 3 percent of the total weight of the materials in the mixture for agglomeration and granulation to obtain the abradable surface layer powder;
step three: carrying out surface cleaning and sand blasting coarsening on a matrix to be coated, screening CuAl powder prepared in the step I of-140 meshes to +325 meshes, and preparing a CuAl bottom layer by adopting an Impact cold spraying gun, wherein the cold spraying parameters are as follows: the spraying distance is 20mm, the nitrogen pressure is 35bar, the powder feeding speed is 30g/min, the gas temperature is 500 ℃, and the coating thickness is 0.1-0.2 mm.
Step four: and (3) on the cold spraying CuAl bottom layer, adopting the wearable surface layer powder prepared in the second atmospheric plasma spraying step, wherein the spraying parameters are as follows: the current is 420A, the voltage is 65V, the powder feeding speed is 35g/min, the spraying distance is 110mm, and the thickness of the coating is 1.5-3 mm.
Step five: and (3) placing the prepared coating in an atmospheric resistance furnace, and keeping the temperature at 450 ℃ for 5h to burn out the polyphenyl ester and the organic binder in the coating to obtain the corrosion-resistant abradable coating.
Example 5
The method comprises the following steps: preparing CuAl alloy powder by adopting a smelting and crushing process, wherein the Al content is 0.1-7.4%;
step two: mixing the CuAl alloy powder prepared in the step one with polyphenyl ester powder according to the weight ratio of 9: 1, mechanically mixing to obtain abradable surface layer powder;
step three: carrying out surface cleaning and sand blasting coarsening on a matrix to be coated, screening CuAl powder prepared in the first step of being 400 meshes below, and preparing a CuAl bottom layer by adopting an Impact cold spraying gun, wherein the cold spraying parameters are as follows: the spraying distance is 20mm, the nitrogen pressure is 40bar, the powder feeding speed is 30g/min, the gas temperature is 450 ℃, and the coating thickness is 0.1-0.2 mm.
Step four: and (3) on the cold spraying CuAl bottom layer, adopting the wearable surface layer powder prepared in the second atmospheric plasma spraying step, wherein the spraying parameters are as follows: the current is 400A, the voltage is 70V, the powder feeding speed is 40g/min, the spraying distance is 120mm, and the thickness of the coating is 1.5-2 mm, so that the corrosion-resistant abradable coating is obtained.
Claims (5)
1. A marine corrosion resistant abradable material characterized by: the abradable material comprises bottom layer material powder A and surface layer material powder B, wherein the powder A is composed of Cu and Al, the weight ratio of Al is 0.1-7.4%, and the balance is Cu; the powder B consists of the powder A, polyester, hexagonal boron nitride and a binder, and comprises the following components in percentage by weight: 70-99.5% of powder A; 0.5 to 30 percent of polyester; 0-5% of hexagonal boron nitride; 0-10% of binder.
2. The marine corrosion resistant abradable material of claim 1, wherein the polyester is one or more of polyethylene terephthalate, polyimide, and polyphenylene ether.
3. The method for preparing the marine corrosion resistant abradable material of claim 1 or 2, wherein powder a is prepared by atomization, melting and crushing, high energy ball milling, mechanical alloying, mechanical mixing or agglomeration compounding, and powder B is prepared by mechanical mixing of several raw materials or agglomeration compounding by using a binder.
4. A preparation method of a marine corrosion resistant abradable coating is characterized in that the marine corrosion resistant abradable material of claim 1 or 2 is used for preparing a coating, and powder A is used for preparing a bottom layer on the surface of a substrate by adopting a cold spraying method, a supersonic flame spraying method or a low-pressure plasma spraying method; and (3) spraying the powder B on the bottom layer by adopting atmospheric plasma spraying, supersonic flame spraying or cold spraying to prepare a surface layer.
5. A method of manufacturing as claimed in claim 4, wherein the coating is heat treated after the preparation of the top layer.
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| CN112359309B (en) * | 2020-11-23 | 2023-04-07 | 中国航发沈阳黎明航空发动机有限责任公司 | Preparation method of anti-adhesion coating for aero-engine driving connecting rod |
| CN114054743B (en) * | 2021-12-17 | 2023-07-21 | 武汉苏泊尔炊具有限公司 | Corrosion-resistant material, method for producing the same, and corrosion-resistant coating formed therefrom |
| CN114774830B (en) * | 2022-06-20 | 2022-09-02 | 矿冶科技集团有限公司 | Multifunctional coating, preparation method thereof and power equipment |
| CN115608984B (en) * | 2022-12-14 | 2023-03-14 | 矿冶科技集团有限公司 | Preparation method of mechanical mixed coating powder and coating powder |
| CN117229665B (en) * | 2023-11-16 | 2024-02-23 | 北京航空航天大学 | Marine environment-resistant stealth material protection system based on interlayer potential difference control |
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| CN101403086A (en) * | 2008-11-21 | 2009-04-08 | 沈阳黎明航空发动机(集团)有限责任公司 | Method for renovating lubricant pump casing bush with plasma spraying Cu-Al coating |
| JP5689735B2 (en) * | 2010-07-29 | 2015-03-25 | 日本ピストンリング株式会社 | piston ring |
| CN103073940B (en) * | 2013-01-25 | 2015-05-20 | 北矿新材科技有限公司 | Preparation method of salt-spray-corrosion-resistant hard-surface coating material for thermal spraying |
| CN106471144B (en) * | 2014-06-30 | 2019-04-12 | 日立金属株式会社 | Copper alloy, cold rolled sheet and its manufacturing method |
| US20190120075A1 (en) * | 2015-05-11 | 2019-04-25 | United Technologies Corporation | Near net shape abradable seal manufacturing method |
| CN105441862A (en) * | 2015-11-11 | 2016-03-30 | 沈阳黎明航空发动机(集团)有限责任公司 | Size repairing technique for high-pressure zero-level stator inner ring |
| CN108203799B (en) * | 2016-12-08 | 2019-09-27 | 中国航发沈阳黎明航空发动机有限责任公司 | A kind of resistance to marine corrosion thermal spraying abradable seal coating and preparation method thereof |
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