CN111998789A - Thermal barrier coating spraying quality assessment and control method - Google Patents
Thermal barrier coating spraying quality assessment and control method Download PDFInfo
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- CN111998789A CN111998789A CN202010658058.0A CN202010658058A CN111998789A CN 111998789 A CN111998789 A CN 111998789A CN 202010658058 A CN202010658058 A CN 202010658058A CN 111998789 A CN111998789 A CN 111998789A
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/24—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
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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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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
Abstract
The invention discloses a thermal barrier coating spraying quality evaluation and control method, which adopts a laser profiler and a thermal barrier coating ceramic thermal insulation layer sprayed repeatedly, the preparation of a coating quality confirmation test piece is carried out before the spraying of a workpiece, the laser profiler is utilized to scan the full view of two-dimensional morphology, the data derivation → the extraction of three-section morphology characteristic curve → Gaussian fitting analysis → the extraction of Gaussian peak characteristic parameter → the comparison of high-quality coating standard parameter → the evaluation of the process stability and the coating quality flow, and the rapid and effective method for evaluating the coating quality can be carried out aiming at different process characteristic coatings, and can further determine the parameters of A, FWHM, A/FWHM, the X c of the transverse coordinate value corresponding to the Gaussian peak and the like through a large number of standard process tests and coating performance verification, thereby further enhancing the quality control and the process stability evaluation of the coating.
Description
Technical Field
The invention relates to the field of thermal barrier coating spraying, in particular to a thermal barrier coating spraying quality evaluation and control method.
Background
The thermal barrier coating is one of three key manufacturing technologies of the turbine blade of the modern gas turbine engine, and is an indispensable key technical means for improving the durability, the use temperature and the service means of the turbine blade, and the quality stability and the service reliability of the thermal barrier coating seriously affect the service safety of the turbine blade, even affect the power safety and the energy supply safety guarantee of aeroengine flight or ship power, power for power generation and the like. At present, the thermal barrier coating manufacturing technology of the turbine blade is still mainly based on the thermal spraying technology, wherein the atmospheric plasma spraying technology is the key core technology for preparing the ceramic thermal insulation layer. The atmospheric plasma spraying technology utilizes turbulent plasma to heat and melt powder so as to deposit a coating, has more process stability influence factors, and how to find a processing process quality control method which is rapid, simple and convenient and has low cost becomes a technical problem to be overcome by technical personnel in the field.
In the Atmospheric Plasma Spraying (APS) process, more than 60 process parameters are involved to influence the stability of the process and the quality of a coating, and the process comprises working environment parameters (temperature, humidity, dust concentration and the like), plasma power output parameters (current (I), output waveform and the like), plasma gas parameters (pressure (Pg), flow (Lg), combination and the like), plasma spraying power (P), plasma spraying powder delivery parameters (carrier gas flow (Lp), carrier gas pressure (Pp), carrier gas type, powder delivery amount (RPF), powder delivery angle, powder delivery distance, spray gun walking parameters (swing speed, stepping, walking direction and the like), substrate pretreatment parameters (sand blasting and cleaning states), preheating and temperature control parameters (temperature), plasma generator ablation state parameters, powder characteristics (morphology, microstructure, particle size distribution, fluidity, and the like, Loose packing density, etc.), the above parameters have great influence on plasma characteristics (enthalpy value, speed, temperature field, heat and mass transfer characteristics, etc.) in the spraying process, and finally all factors are coupled in the interaction relationship (particle temperature, speed, melting state, distribution, etc.) of plasma and powder, and the microstructure characteristics and performance of the coating are finally determined by combining the surface characteristics of the substrate. Under the condition of multi-coupling and multi-parameter, the coating preparation process range can be optimized through a simple orthogonal test, but the optimal process range can be determined by a large amount of data, but the plasma characteristics and the coating quality are changed due to the characteristics of the plasma, including attenuation loss of the cathode and the anode of a plasma generator along with use, parameter deviation, hardware structure or matching relation change and the like.
Under the background, researchers and engineers at home and abroad utilize means and measures such as establishment of coating process parameters, coating performance and microstructure association rules, online particle temperature/speed monitoring, online performance (thickness, residual stress, mechanical performance and the like), improvement of automatic control level of equipment and parameter negative feedback control (for example, the net energy stable control is realized by adopting a computer-aided control technology), and disclosure of deposition process mechanisms (sputtering formation and coating formation) to guide process regulation and control; although the above-mentioned partial technologies have already been commercialized, there are the following technical problems: firstly, closed-loop control of online real-time negative feedback is not really realized, namely a fully-coupled regulation and control mechanism based on microstructure characteristics, performance and parameters; secondly, each technology can only feed back local problems, and the quality characteristics of the coating and the consistency of the processing process cannot be comprehensively and directly evaluated; and the hardware cost is high, and the requirement on the technical level of operators is high.
On the basis of the problems, the plasma and the spraying raw material powder which are two most key links in the atmospheric plasma spraying process and the coupling relation of the plasma and the spraying raw material powder are further intensively solved, a plasma-powder-coating forming process quality evaluation method is established, the stability diagnosis of the field real-time process and the consistency evaluation of the coating quality are carried out, and a simplified model, a simplified flow and a simplified method are developed, so that the method is one of the technical problems which must be overcome in the field at present. In the process of atmospheric plasma spraying, no matter which powder conveying mode and powder feeding nozzle are adopted, the spraying process requires that most of powder can be conveyed into a plasma high-temperature area, so that a coating with target performance is obtained, and when single-pass linear spraying is carried out in a reciprocating mode, the appearance characteristics that the middle area is protruded, the coating thickness is thick, and the edge is thin are formed. The two-dimensional morphology features are related to interaction relations between hardware and parameter-related plasmas and powder, such as various coating microstructures and performance-related features of powder distribution, melting effect, lamella thickness and the like in the plasmas, mutual management features are established by reasonably evaluating the technological process and coating quality of the two-dimensional morphology features, a coating quality control method under the condition of controlling the curing process by adopting the yield of the two-dimensional morphology physical features is explored, and no related report exists at present.
Disclosure of Invention
In order to solve the problems, the invention establishes a flow and a method for evaluating the process stability and the coating quality by adopting the two-dimensional shape of the atmospheric plasma spraying ceramic thermal insulation layer based on the current industry background technical requirements and the urgent requirements of the atmospheric plasma spraying thermal barrier coating on the process stability control and coating quality control technology and method, the process and the method can establish the relationship between the coating performance and the two-dimensional morphology of the coating under the conditions of fixed powder, a spray gun and a standard production process by accumulating data of a certain sample quantity, extract characteristic parameters of the two-dimensional morphology, and the control range is provided, the stability of the process and the quality of the target coating are evaluated before the workpiece coating is manufactured or in the decay period of the cathode and anode characteristics, the aim of controlling the process stability is achieved, the problems of process hardware or a yield system are fed back quickly, and the consistency of the product quality is guaranteed.
The invention aims to improve the stability and quality consistency of the atmospheric plasma spraying process, and rapidly evaluates and judges the stability of a coating preparation process system (hardware, parameter and other software) on a production site through the analysis of the reciprocating spraying two-dimensional morphology characteristics of a coating and the data processing of the physical yield of the morphology characteristics, and evaluates whether the coating quality meets a preset target or the performance of delivery quality requirements under standard or cured process parameters.
In order to achieve the purpose, the invention adopts the following process method:
according to an aspect of an embodiment of the present invention, there is provided a method for evaluating the spraying quality of a thermal barrier coating, including:
s11: performing reciprocating linear spraying of a thermal barrier coating on a square sample, wherein the physical center of a spray gun is superposed with the center line of the square sample in the first direction in the spraying process, and the swing amplitudes of the distances from the physical center of the spray gun to the center of the square sample are the same;
s12: setting a reference surface by using a laser profiler, scanning to obtain a reciprocating spraying surface, establishing a coordinate system by using the center and the initial state of the substrate, and scanning to obtain the two-dimensional morphology of the coating in the first direction;
s13: deriving raw data of the two-dimensional topography;
s14: selecting characteristic data of a specific section position according to the length of the coating sprayed in the first direction, and deriving a data drawing graph;
s15: drawing the derived data, combining longitudinal coordinate values of the feature data of the specific section positions to obtain an average value corresponding to the transverse coordinate values, carrying out homogenization treatment on the data, and fitting the data after the homogenization treatment by adopting a Gaussian formula;
s16: extracting full width at half maximum FWHM, peak height A and Gaussian peak corresponding abscissa value Xc of the Gaussian characteristic peak, and calculating A/FWHM value;
s17: repeating the steps S11-S16 for multiple times to obtain a physical standard parameter of the two-dimensional topography feature of the high-quality coating, and comparing the parameters of the sampling parameter of the target sample with the standard parameter to obtain a deviation value of the sampling parameter of the target sample and whether the sampling parameter of the target sample is in the range of the standard parameter of the high-quality coating;
s18: and evaluating the coating quality according to the result of S17, and giving conclusions about process stability and quality evaluation.
Preferably, the first direction is a single direction or a direction crossing the longitudinal direction.
Preferably, the number of spraying passes is not less than 10 or the thickest position of the coating is not less than 0.3 mm.
Preferably, the specific cross-sectional positions include an 1/2 cross-sectional position, a 1/3 cross-sectional position, and a symmetrical 2/3 cross-sectional position of the square sample.
Preferably, the parameter comparison is performed by using programmed automatic verification software.
According to another aspect of an embodiment of the present invention, there is provided a method for controlling the spraying quality of a thermal barrier coating, including:
s10: under the conditions of standard process, fixed equipment and powder material, before formal processing production, according to the actual spraying parameters and pretreatment characteristics of the workpiece, the coating is sprayed for multiple times in the same reciprocating downward direction, and the performance conformity of the coating is evaluated by the evaluation method,
s19: if the sampling parameter of the target sample is within the standard parameter range, judging that the process is qualified, and if the coating quality of the target sample meets the requirement, spraying the workpiece; if not, the hardware and the parameters of the equipment are checked, the verification is carried out again, and the flow returns to S11 to restart until the parameters are qualified.
By adopting the technical scheme, the method has the advantages that,
the invention has the following beneficial effects:
1. the quality control method and the evaluation method have low cost and high efficiency, avoid the interference of an online monitoring or monitoring instrument on the spraying process and the working scene, and have no influence on the process layout;
2. the method adopts the prior art means, can obtain the two-dimensional shape physical parameter range of the coating quality and the stability control of the technological process through a small amount of coating performance sample data, and is suitable for the coating quality control in the large-scale industrial production process;
3. the method has short time consumption, the spraying times are few in the reciprocating spraying process of the atmospheric plasma spraying, parameters are obtained by scanning with a rapid laser profiler, the judgment of whether the stability of the technological process and the coating quality meet can be given out by manual processing in a short time (less than 30min) or automatic software processing (less than 5min), and whether the process can be carried out or continuous production is determined;
4. the method embodies physical parameters of an abstract process, has low requirements on field operators, and can quickly evaluate the process quality by the aid of a parameter range acquired by technicians, wherein the operators perform reciprocating spraying test piece preparation according to a process, scan the appearance according to an operation flow and adopt a mode of software automatic data processing or manual data processing according to a standard flow;
5. the method is flexible, can evaluate the process quality in the interval period of replacing main consumables, maintaining and recovering equipment and producing for a long time, avoids the complex process of installing and debugging equipment instruments on line, and can effectively control the parameter control, the quality control, the abnormal control of the process stability and the like in the implementation process of the special processing technology on the production site;
6. under the condition of standard production process, the method has the characteristic of high screening precision (more than 99.9%), can realize quick, direct and high-precision elimination for the conditions of abnormal process control and coating quality, and can greatly improve the stability and quality consistency of the coating process.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below. It should be apparent that the drawings in the following description are merely exemplary, and that other embodiments can be derived from the drawings provided by those of ordinary skill in the art without inventive effort.
The structures, ratios, sizes, and the like shown in the present specification are only used for matching with the contents disclosed in the specification, so as to be understood and read by those skilled in the art, and are not used to limit the conditions that the present invention can be implemented, so that the present invention has no technical significance, and any structural modifications, changes in the ratio relationship, or adjustments of the sizes, without affecting the effects and the achievable by the present invention, should still fall within the range that the technical contents disclosed in the present invention can cover.
FIG. 1 is a schematic overall flow diagram of the present invention;
FIG. 2 is a schematic view of spray coating according to examples 1 and 2 of the present invention;
FIG. 3 is a graph comparing the bond strength of coatings with different characteristic parameters;
FIG. 4 is a graph comparing thermal shock resistance of coatings under different characteristic parameters;
FIG. 5 is a comparison graph of thermal cycle life of coatings under different characteristic parameters.
Where N represents a coating prepared using a new nozzle, L represents a coating prepared using an ablative nozzle, and M represents a coating prepared using a burnout nozzle.
Detailed Description
The present invention is described in terms of particular embodiments, other advantages and features of the invention will become apparent to those skilled in the art from the following disclosure, and it is to be understood that the described embodiments are merely exemplary of the invention and that it is not intended to limit the invention to the particular embodiments disclosed. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
In one aspect of the embodiments of the present invention, a thermal barrier coating spraying quality evaluation method is provided, which includes the following steps:
s11: according to a standard process, performing reciprocating linear spraying on the thermal barrier coating, adopting a single-direction spraying mode or a spraying mode with both depth and vertical direction, wherein the physical center of a spray gun is superposed with the center line of the square sample in the first direction in the spraying process, and the spraying times in all directions are not less than 10 times or the thickest position of the coating is not less than 0.3 mm; the swing amplitude of the distance from the center of the square sample is required to be the same in the spraying process.
S12: and setting a reference surface by using a laser profiler, scanning to obtain a reciprocating spraying surface, establishing a coordinate system by using the center and the initial state of the substrate, and scanning to obtain the two-dimensional morphology of the coating in a single direction or two directions.
S13: raw data of the two-dimensional topography are derived.
S14: according to the length of the sprayed coating in the direction, characteristic data of 1/2 positions (the center of a square sample), 1/3 and symmetrical 2/3 cross-section positions are selected, and a data drawing graph is derived.
S15: and drawing the derived data, combining three groups of data longitudinal coordinate values to obtain an average value, homogenizing the data, and fitting the obtained unique group of data by adopting a Gaussian formula.
S16: extracting full width at half maximum (FWHM), peak height (A) and coordinate value (Xc) corresponding to Gaussian peak, and calculating A/FWHM value.
S17: and repeating the steps S11-S16 for at least ten times to obtain the physical parameters of the two-dimensional morphology characteristics of the coating corresponding to the technological process meeting the quality requirement of the coating. And (4) comparing parameters by adopting programmed automatic verification software or manpower, and giving the deviation value and whether the deviation value is within the standard parameter range of the high-quality coating.
S18: and evaluating the coating quality according to the result of S17, and giving conclusions about process stability and quality evaluation.
By the evaluation method, the two-dimensional morphology physical parameter range for controlling the coating quality and the stability of the technological process can be obtained through a small amount of coating performance sample data, and the method is suitable for coating quality control in the large-scale industrial production process.
In another aspect of an embodiment of the present invention, a thermal barrier coating spraying quality control method is provided, as shown in fig. 1, the control method includes the following steps:
s10: and spraying for multiple times in the same downward direction according to the actual spraying parameters and the pretreatment characteristics of the workpiece before formal processing production under the conditions of standard processes, fixed equipment and powder materials, and evaluating the performance conformance of the coating.
S11: according to a standard process, performing reciprocating linear spraying on the thermal barrier coating, adopting a single-direction spraying mode or a spraying mode with both depth and vertical direction, wherein the physical center of a spray gun is superposed with the center line of the square sample in the first direction in the spraying process, and the spraying times in all directions are not less than 10 times or the thickest position of the coating is not less than 0.3 mm; the swing amplitude of the distance from the center of the square sample is required to be the same in the spraying process.
S12: and setting a reference surface by using a laser profiler, scanning to obtain a reciprocating spraying surface, establishing a coordinate system by using the center and the initial state of the substrate, and scanning to obtain the two-dimensional morphology of the coating in a single direction or two directions.
S13: raw data of the two-dimensional topography are derived.
S14: according to the length of the sprayed coating in the direction, characteristic data of 1/2 positions (the center of a square sample), 1/3 and symmetrical 2/3 cross-section positions are selected, and a data drawing graph is derived.
S15: and drawing the derived data, combining three groups of data longitudinal coordinate values to obtain an average value, homogenizing the data, and fitting the obtained unique group of data by adopting a Gaussian formula.
S16: extracting full width at half maximum (FWHM), peak height (A) and coordinate value (Xc) corresponding to Gaussian peak, and calculating A/FWHM value.
S17: and repeating the steps S11-S16 for at least ten times to obtain the physical parameters of the two-dimensional morphology characteristics of the coating corresponding to the technological process meeting the quality requirement of the coating. And (4) comparing parameters by adopting programmed automatic verification software or manpower, and giving the deviation value and whether the deviation value is within the standard parameter range of the high-quality coating.
S18: and evaluating the coating quality according to the result of S17, and giving conclusions about process stability and quality evaluation.
S19: if the parameters are within the range, the technological process is judged to be qualified, the quality of the target coating meets the requirement, and the workpiece can be sprayed; if not, the hardware and the parameters of the equipment are checked, the verification is carried out again, and the flow returns to S11 to restart until the parameters are qualified.
In step S11, the spraying parameters, direction, shape and size of the sample can be modified according to actual requirements.
In step S14, the position of the selected feature data may be modified according to actual requirements.
Therefore, the quality control method has low cost and high efficiency, avoids the interference of an online monitoring or monitoring instrument on the spraying process and the working scene, and has no influence on the process layout. The two-dimensional shape physical parameter range for controlling the coating quality and the stability of the technological process can be obtained through a small amount of coating performance sample data, and the method is suitable for coating quality control in the large-scale industrial production process. And the spraying quality control consumes short time, the spraying times are few in the reciprocating spraying process of the atmospheric plasma spraying, parameters are obtained by scanning with a rapid laser profiler, and the judgment of whether the process stability and the coating quality are consistent can be given out by manual processing in a short time (less than 30min) or automatic software processing (less than 5min) so as to determine whether the process can be carried out or continuous production is carried out. The abstract process is subjected to physical parameter concretization, the requirement on field operators is low, the operators can prepare the reciprocating spraying test piece according to the process through the parameter range obtained by technicians, the appearance is scanned according to the operation process, and the process quality can be rapidly evaluated in a mode of software automatic data processing or manual data processing according to the standard process. The method is flexible, can evaluate the process quality in the interval period of replacing main consumables, maintaining and recovering equipment and producing for a long time, avoids the complex process of installing and debugging equipment instruments on line, and can effectively control the parameter control, the quality control, the abnormal control of process stability and the like in the implementation process of the special machining process on the production site. Under the condition of standard production process, the method has the characteristic of high screening precision (more than 99.9%), can realize quick, direct and high-precision elimination for the conditions of abnormal process control and coating quality, and can greatly improve the stability and quality consistency of the coating process.
The specific control method and process can be understood and explained based on the following two examples.
Example 1: cleaning a matrix alloy by using acetone, carrying out sand blasting treatment on a matrix by using an XP-5 suction type sand blasting machine, wherein the abrasive is 24-mesh white corundum sand, the sand blasting pressure is 0.4MPa, the sand blasting distance is 50-100mm, the sand blasting angle is 50-90 degrees, a DZ-HL5000 supersonic speed spraying system is used for preparing a bonding layer, the thickness is 10-30 mu m, the bonding layer is made of NiCoCrAlY powder, and the process parameter is that the oxygen flow is 20-60 m3The flow rate of kerosene is 10-50L/h, the powder feeding rate is 40-80 g/min, the spraying distance is 300-400 mm, and after the preparation of the bonding layer is finished, the adhesive layer is sprayed on the surface of the substratePreparing a ceramic layer by using a DH-80 plasma spraying system, wherein ceramic layer powder is 7YSZ, the technological parameters are current of 60-80A, voltage of 550-650V, powder feeding speed of 20-60 g/min and spraying distance of 50-100mm, the spraying track is as shown in figure 2, reciprocating spraying is carried out for 40 times along the Y direction, and the moving distance of a spray gun is Y0Plus or minus 30mm, the center of the spray gun needs to coincide with the center line in the process, and the temperature in the spraying process is required to be lower than 400 ℃.
Using a laser profiler to perform morphology scanning on the surface of a substrate to obtain coating profile data, extracting Y +/-15 mm position coating profile coordinate data from the derived data, fitting by using a Gaussian function, and obtaining profile curve characteristic parameters of the coating in the Y direction: the full width at half maximum (FWHM), peak height (A), Gaussian peak correspond to the abscissa value (Xc), and the A/FWHM value is calculated.
Repeating the steps for 10 times to obtain ten groups of characteristic parameters, and analyzing and concluding the monitoring range of the characteristic parameters by combining the microstructure and the performance characteristics of the coating: when Xc: -3 to 0mm, A: 0.2-0.35 mm, FWHM: 11-20 mm, A/FWHM: 0.01-0.032, the equipment state is normal, and the coating performance meets the use requirement.
According to the characteristic parameters obtained by statistical analysis, the coating spraying process is monitored, and characteristic parameters, microstructures and performances of a coating Y-direction two-dimensional profile curve are respectively analyzed for a coating N1 prepared by a new nozzle, a coating L1 prepared by an ablation nozzle and a coating M1 prepared by a burning loss nozzle, wherein only the nozzle states of a comparative example L1 and a comparative example M1 are respectively the ablation state and the burning loss state, and the substrate pretreatment, the bonding layer preparation and the ceramic layer preparation process are the same as those of the example N1. The coating topography data is obtained by using a laser profilometer, a Gaussian function is adopted to perform curve fitting on the coating profile, and the topographical feature parameter of the coating of the embodiment N1 is Xc: -0.47mm, a: 0.29mm, FWHM: 16.44mm, A/FWHM: 0.018, comparative example L1 coating has the morphological feature parameters Xc: -0.78mm, a: 0.27mm, FWHM: 17.79mm, A/FWHM: 0.015, comparative example M1 coating had topographical parameters Xc: 2.93mm, A: 0.44mm, FWHM: 7.78mm, A/FWHM: 0.057. the porosity of the coating of example N1 was 12%, the porosity of the unmelted particles was 2, the porosity of the coating of comparative example L1 was 11.3%, the porosity of the unmelted particles was 3, the porosity of the coating of comparative example M1 was 16%, the porosity of the unmelted particles was 9; keeping the temperature at 1100 ℃ for 5-10 min, wherein under the water quenching condition, the average thermal shock life of the M1 coating is 63 times, the average thermal shock life of the L1 coating is 290 times, and the average thermal shock life of the N1 coating is 275 times; under the thermal cycle conditions of 1100 ℃, heat preservation for 55min and cooling for 5min, the average thermal cycle life of the M1 coating is 400h, the average thermal cycle life of the L1 coating is 700h, and the average thermal cycle life of the N1 coating is 750 h; the bond strength of the coating was tested at a tensile rate of 1mm/min, with a bond strength of 29.11MPa for the M1 coating, 36.4MPa for the L1 coating, and 35.9MPa for the N1 coating.
Example 2: cleaning a matrix alloy by using acetone, carrying out sand blasting treatment on a matrix by using an XP-5 suction type sand blasting machine, wherein the abrasive is 24-mesh white corundum sand, the sand blasting pressure is 0.4MPa, the sand blasting distance is 50-100mm, the sand blasting angle is 50-90 degrees, a DZ-HL5000 supersonic speed spraying system is used for preparing a bonding layer, the thickness is 10-30 mu m, the bonding layer is NiCoCrAlY powder, a DH-80 plasma spraying system is used for preparing a ceramic layer, the ceramic layer is 7YSZ, and the technological parameters of supersonic speed flame spraying and plasma spraying are the same as those of the embodiment 1. The spraying trajectory is shown in FIG. 2, and the spraying is performed 40 times in a reciprocating manner along the X direction, and the moving distance of the spray gun is X0Plus or minus 30mm, the center of the spray gun needs to coincide with the center line in the process, and the temperature in the spraying process is required to be lower than 400 ℃.
Using a laser profiler to perform morphology scanning on the surface of a substrate to obtain coating profile data, extracting X +/-15 mm position coating profile coordinate data from the derived data, fitting by using a Gaussian function, and obtaining profile curve characteristic parameters of the coating in the X direction: the full width at half maximum (FWHM), peak height (A), Gaussian peak correspond to the abscissa value (Xc), and the A/FWHM value is calculated.
Repeating the steps for 10 times to obtain ten groups of characteristic parameters, and analyzing and concluding the monitoring range of the characteristic parameters by combining the microstructure and the performance characteristics of the coating: when Xc: 2.5-4 mm, A: 0.4-0.55 mm, FWHM: 7-11 mm, A/FWHM: 0.04-0.079, the equipment state is normal, and the coating performance meets the use requirement.
Monitoring the coating spraying process according to the characteristic parameters obtained by statistical analysis, and respectively analyzing the characteristic parameters, microstructures and performances of the coating X-direction two-dimensional profile curve of the new nozzle prepared coating N2, the ablation nozzle prepared coating L2 and the burning loss nozzle prepared coating M2, wherein only the nozzle states of comparative examples L2 and M2 are respectively ablation and burning loss states, and the substrate pretreatment, bonding layer preparation and ceramic layer preparation processes are the same as those in example 2. The coating topography data is obtained by using a laser profilometer, a Gaussian function is adopted to perform curve fitting on the coating profile, and the topographical feature parameter of the coating of the embodiment N2 is Xc: 2.93mm, A: 0.43mm, FWHM: 9.88mm, A/FWHM: 0.044, the coating of comparative example L1 has the topographical parameters Xc: 3.75mm, A: 0.48mm, FWHM: 9.88mm, A/FWHM: 0.049, comparative example M1, the coating having topographical parameters Xc: 2.07mm, A: 0.56mm, FWHM: 6.98mm, A/FWHM: 0.08. the porosity of the coating of example N1 was 11.4%, 2 unmelted particles, the porosity of the coating of comparative example L1 was 10.7%, 1 unmelted particles, the porosity of the coating of comparative example M1 was 15.1%, 6 unmelted particles; keeping the temperature at 1100 ℃ for 5-10 min, wherein under the water quenching condition, the average thermal shock life of the M1 coating is 47 times, the average thermal shock life of the L1 coating is 310 times, and the average thermal shock life of the N1 coating is 275 times; under the thermal cycle conditions of 1100 ℃, heat preservation for 55min and cooling for 5min, the average thermal cycle life of the M1 coating is 432h, the average thermal cycle life of the L1 coating is 689h, and the average thermal cycle life of the N1 coating is 728 h; the coating bonding strength was tested at a tensile rate of 1mm/min, with M1 coating bonding strength of 22.7MPa, L1 coating bonding strength of 37.64MPa, and N1 coating bonding strength of 34.73MPa, and the coating properties under different characteristic parameters can be seen in FIGS. 3-5.
The invention can be used in large-scale standardized production process, can effectively evaluate the stability of the spraying process by using the interval time of consumable replacement, equipment maintenance and product replacement, avoids the complex on-line monitoring instrument installation and debugging process and destructive off-line detection means, can quickly and efficiently identify the process control abnormity and the coating quality abnormity, and effectively improves the process stability and the product quality consistency in the coating production process.
In conclusion, when the device is used, the stability monitoring of the spraying equipment and the coating can be effectively completed by utilizing the two-dimensional profile characteristic parameters according to the practical application requirements. The above examples are only for illustrating the present invention, and the material, size, shape, and spraying track, pass, moving distance of the spray gun, two-dimensional shape obtaining manner, etc. of the sample substrate can be changed, and those skilled in the art can make various corresponding changes and modifications according to the present invention without departing from the spirit and essence of the present invention, but these corresponding changes and modifications should not be excluded from the scope of the present invention.
Claims (6)
1. A method for evaluating the spraying quality of a thermal barrier coating is characterized by comprising the following steps:
s11: performing reciprocating linear spraying of a thermal barrier coating on a square sample, wherein the physical center of a spray gun is superposed with the center line of the square sample in the first direction in the spraying process, and the swing amplitudes of the distances from the physical center of the spray gun to the center of the square sample are the same;
s12: setting a reference surface by using a laser profiler, scanning to obtain a reciprocating spraying surface, establishing a coordinate system by using the center and the initial state of the substrate, and scanning to obtain the two-dimensional morphology of the coating in the first direction;
s13: deriving raw data of the two-dimensional topography;
s14: selecting characteristic data of a specific section position according to the length of the coating sprayed in the first direction, and deriving a data drawing graph;
s15: drawing the derived data, combining longitudinal coordinate values of the feature data of the specific section positions to obtain an average value corresponding to the transverse coordinate values, carrying out homogenization treatment on the data, and fitting the data after the homogenization treatment by adopting a Gaussian formula;
s16: extracting full width at half maximum FWHM, peak height A and Gaussian peak corresponding abscissa value Xc of the Gaussian characteristic peak, and calculating A/FWHM value;
s17: repeating the steps S11-S16 for multiple times to obtain a physical standard parameter of the two-dimensional topography feature of the high-quality coating, and comparing the parameters of the sampling parameter of the target sample with the standard parameter to obtain a deviation value of the sampling parameter of the target sample and whether the sampling parameter of the target sample is in the range of the standard parameter of the high-quality coating;
s18: and evaluating the coating quality according to the result of S17, and giving conclusions about process stability and quality evaluation.
2. The evaluation method according to claim 1,
the first direction is a single direction or a crosswise direction.
3. The evaluation method according to claim 1,
the number of spraying passes is not less than 10 or the thickest position of the coating is not less than 0.3 mm.
4. The evaluation method according to claim 1,
the particular cross-sectional positions include the 1/2 cross-sectional position, the 1/3 cross-sectional position, and the symmetric 2/3 cross-sectional position of the square sample.
5. The evaluation method according to claim 1,
the parameter comparison is carried out by adopting programmed automatic verification software.
6. A method for controlling the spraying quality of a thermal barrier coating is characterized by comprising the following steps:
s10: spraying for a plurality of times in the same reciprocating direction according to the actual spraying parameters of the workpiece and the pretreatment characteristics of the workpiece under standard process and fixed equipment, powder material conditions, before formal processing production, and evaluating the coating performance conformity by the evaluation method according to any one of claims 1 to 5,
s19: if the sampling parameter of the target sample is within the standard parameter range, judging that the process is qualified, and if the coating quality of the target sample meets the requirement, spraying the workpiece; if not, the hardware and the parameters of the equipment are checked, the verification is carried out again, and the flow returns to S11 to restart until the parameters are qualified.
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