CN112575296A - 一种涡轮叶片高温防护涂层及其制备方法 - Google Patents

一种涡轮叶片高温防护涂层及其制备方法 Download PDF

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CN112575296A
CN112575296A CN202011258186.2A CN202011258186A CN112575296A CN 112575296 A CN112575296 A CN 112575296A CN 202011258186 A CN202011258186 A CN 202011258186A CN 112575296 A CN112575296 A CN 112575296A
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程玉贤
王红丽
孙得雨
李想
袁福河
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AECC Shenyang Liming Aero Engine Co Ltd
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    • 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
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    • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
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Abstract

本发明属于防护涂层技术领域，具体涉及一种涡轮叶片高温防护涂层及其制备方法。本发明的技术方案如下：一种涡轮叶片高温防护涂层，包括内腔渗铝涂层和外表面MCrAlY渗铝涂层，其中M＝Ni、Co或Ni+Co。本发明提供的涡轮叶片高温防护涂层及其制备方法，叶片内腔气相渗铝处理后气膜孔易清理,不堵塞,不烧结，渗层100％覆盖，厚度和成分最大变化不超过20％；叶片外表面形成了β相涂层，在有效提高了MCrAlY涂层中的Al含量同时对涂层力学性能无影响。

Description

一种涡轮叶片高温防护涂层及其制备方法
技术领域
本发明属于防护涂层技术领域，具体涉及一种涡轮叶片高温防护涂层及其制备方法。
背景技术
涡轮叶片被誉为“皇冠上的明珠”，其服役环境恶劣，需同时具有良好的抗热冲击、耐高温腐蚀、抗高热交变和复杂应力性能。为了提高涡轮叶片的承温能力，涡轮叶片内腔采用复杂冷却通道以实现气膜冷却，同时其外表面施加防护涂层。随着涡轮前燃气温度的升高，先进航空发动机涡轮叶片内腔温度已高达900～950℃，同时气冷叶片壁厚薄，几何形状复杂，内腔氧化/热腐蚀与裂纹的产生是不可预见的，严重影响了叶片的服役寿命和可靠性。在叶片内腔表面施加防护涂层,降低叶片基体合金的氧化腐蚀速率,是延长空心气冷叶片服役寿命的有效和可行途径。目前采用的固体粉末法和料浆注入法不能彻底解决内腔渗层不均匀、气膜孔堵塞、渗后清理难等问题，严重影响了叶片气膜孔内渗层质量。
涡轮叶片外表面一般采用铝化物扩散涂层和MCrAlY(M＝Ni,Co或Ni+Co)包覆涂层。铝化物涂层主要由抗氧化性能良好的β相组成，但其成分不容易按照要求控制，涂层对基体合金的机械性能影响很大。MCrAlY(M＝Ni,Co或Ni+Co)涂层具有成分和厚度可按要求控制，使之兼顾耐蚀性与机械性能，满足不同使用工况特点，因而作为涡轮叶片外表面高温防护涂层材料或热障涂层的粘结底层材料得到了广泛的研究和应用。典型MCrAlY涂层中Al含量在8-15wt.％之间，Cr含量在15-22wt.％之间，涂层组织主要由γ和γ′相组成，其内部有部分β-NiAl或β-CoAl以弥散相形式存在。涂层中Al的作用是在高温下形成Al2O3保护膜，Cr的添加可以改善涂层的热腐蚀性能并因其"第三元素效应”降低发生Al2O3膜选择性氧化所需临界Al含量。活性元素Y可以促进Al2O3膜的形核和生长，还能利用“钉扎效应”改善氧化膜粘附性，提高涂层的抗氧化能力，但是过多的Y的加入会导致严重的晶界偏析，涂层的高温和力学性能反而会下降，因此其加入量一般≤1wt.％。
高温防护涂层主要依靠其表面形成一层连续致密的Al2O3/Cr2O3膜对基体提供保护，涂层中的Al、Cr等元素含量对MCrAlY涂层的服役寿命非常重要。Lee等人的研究结果表明，涂层的使用寿命主要取决于涂层厚度、涂层中β-NiAl的含量以及涂层的氧化速率。提高涂层中Al、Cr元素含量可以提高MCrAlY涂层的高温氧化和热腐蚀寿命，但涂层中的Al和Cr含量提高到一定程度时，涂层的脆性急剧增加，服役过程中形成的裂纹扩展至零件基体，影响叶片服役寿命和可靠性。此外，直接制备高铝涂层存在靶材可加工性降低问题。
发明内容
本发明提供一种涡轮叶片高温防护涂层及其制备方法，叶片内腔气相渗铝处理后气膜孔易清理,不堵塞,不烧结，渗层100％覆盖，厚度和成分最大变化不超过20％；叶片外表面形成了β相涂层，在有效提高了MCrAlY涂层中的Al含量同时对涂层力学性能无影响。
本发明的技术方案如下：
一种涡轮叶片高温防护涂层，包括内腔渗铝涂层和外表面MCrAlY渗铝涂层，其中M＝Ni、Co或Ni+Co。
上述涡轮叶片高温防护涂层的制备方法，包括如下步骤：1)对涡轮叶片内腔进行磨粒流处理，去除内腔表面的残渣；2)对涡轮叶片外表面进行湿吹砂处理，活化零件表面；3)涡轮叶片外表面采用真空电弧镀工艺制备MCrAlY底层；4)涡轮叶片内腔和涡轮叶片外表面的MCrAlY底层上采用化学气相沉积工艺制备渗铝层。
本发明的有益效果为：本发明采用真空电弧镀MCrAlY涂层后进行渗铝处理，使MCrAlY涂层相组成由γ/γ′相变成β相，该涂层在氧化过程中能形成连续致密的Al2O3氧化膜，具有良好的抗氧化腐蚀性能。本发明对叶片内腔进行渗铝处理，提升内腔抗高温氧化腐蚀能力，气相渗铝处理后气膜孔易清理,不堵塞,不烧结，渗层100％覆盖，厚度和成分最大变化不超过20％。本发明针对内腔残留物影响渗铝层结合力问题，采用磨粒流对内腔进行光整处理。
附图说明
图1为涡轮叶片NiCrAlY涂层XRD相分析结果；
图2为涡轮叶片NiCrAlY渗铝后涂层XRD相分析结果；
图3为高温合金基体、NiCrAlY涂层和NiCrAlY渗铝涂层试样宏观形貌；
图4为高温合金基体、NiCrAlY涂层和NiCrAlY渗铝涂层试样在1050℃恒温氧化300小时的氧化动力学曲线图；
图5为涡轮叶片涂敷NiCrAlY涂层并渗铝后叶身涂层截面照片；
图6为涡轮叶片涂敷NiCrAlY涂层并渗铝后气膜孔内涂层截面照片。
具体实施方式
一种涡轮叶片高温防护涂层的制备方法，包括如下步骤：
1)采用磨粒流对涡轮叶片内腔进行处理。
2)对叶片表面进行湿吹砂处理，并进行超声波清洗、丙酮溶液浸洗、烘干。湿吹砂工艺参数为：白刚玉砂粒度为180目，刚玉砂含量20％，风压0.15MPa，吹砂距离为180mm。
3)叶片表面采用真空电弧镀涂覆30μm NiCrAlY底层。离子清理工艺参数为：偏压电压U＝500V～700V，电弧电流I＝70±2A，占空比D＝25～45％。沉积工艺参数为：偏压电压U＝200V～275V，电弧电流I＝70±2A，占空比D＝10～30％。
4)对上述NiCrAlY底层及叶片内腔进行化学气相渗铝处理。
如图1所示，NiCrAlY底层主要由γ/γ′相组成；如图2所示，NiCrAlY底层化学气相渗铝后涂层主要由β相组成；如图4所示，渗铝显著提高NiCrAlY的抗氧化性能，促进了连续致密Al2O3氧化膜的形成；如图5、6所示，叶片内、外表面涂层厚度均匀。

Claims (2)

1.一种涡轮叶片高温防护涂层，其特征在于，包括内腔渗铝涂层和外表面MCrAlY渗铝涂层，其中M＝Ni、Co或Ni+Co。
2.如权利要求1所述的涡轮叶片高温防护涂层的制备方法，其特征在于，包括如下步骤：1)对涡轮叶片内腔进行磨粒流处理，去除内腔表面的残渣；2)对涡轮叶片外表面进行湿吹砂处理，活化零件表面；3)涡轮叶片外表面采用真空电弧镀工艺制备MCrAlY底层；4)涡轮叶片内腔和涡轮叶片外表面的MCrAlY底层上采用化学气相沉积工艺制备渗铝层。
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CN108048805A (zh) * 2017-12-08 2018-05-18 中国航发动力股份有限公司 一种涡轮叶片复合涂层及其制备方法
CN111570952A (zh) * 2020-05-09 2020-08-25 中国航发沈阳发动机研究所 一种气冷空心叶片气膜孔内壁尖角倒圆装置及方法

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0578860A (ja) * 1991-09-20 1993-03-30 Hitachi Ltd 合金被覆ガスタービン翼及びその製造方法
EP1380672A1 (en) * 2002-07-09 2004-01-14 Siemens Aktiengesellschaft Highly oxidation resistant component
EP1411148A1 (en) * 2002-10-15 2004-04-21 ALSTOM Technology Ltd Method of depositing a MCrALY-coating on an article and the coated article
US20060141283A1 (en) * 2004-12-29 2006-06-29 Honeywell International, Inc. Low cost inovative diffused MCrAIY coatings
CN101310971A (zh) * 2007-05-25 2008-11-26 中国科学院金属研究所 一种MCrAlY加复合梯度涂层及制备工艺
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