CN113564512B - Method for preparing whisker toughened plasma sprayed ceramic-based seal coating - Google Patents

Method for preparing whisker toughened plasma sprayed ceramic-based seal coating Download PDF

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CN113564512B
CN113564512B CN202110836641.0A CN202110836641A CN113564512B CN 113564512 B CN113564512 B CN 113564512B CN 202110836641 A CN202110836641 A CN 202110836641A CN 113564512 B CN113564512 B CN 113564512B
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whisker
ceramic
powder
layer
ysz
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CN113564512A (en
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程涛涛
王志平
韩志勇
王仕成
邢思佳
肖玉汗
朱妍
王梦婷
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Civil Aviation University of China
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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
    • 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
    • C23C4/073—Metallic material containing MCrAl or MCrAlY alloys, where M is nickel, cobalt or iron, with or without non-metal elements
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00—Aeronautics or air transport
    • Y02T50/60—Efficient propulsion technologies, e.g. for aircraft

Abstract

A method for preparing whisker toughened plasma sprayed ceramic-based seal coating. The preparation method comprises the steps of preparation of whisker-containing raw materials, preparation of whisker-containing agglomerated powder, plasma spraying of a metal bonding layer, plasma spraying of a whisker toughening layer, plasma spraying of a ceramic surface layer and the like. The invention has the advantages that: the process flow is simple, the operation is easy, the whisker toughening technology in the ceramic sintering process is introduced into the plasma spraying process, and the toughening at the interface of the ceramic coating and the metal bonding layer can be realized by only one preparation technology of plasma spraying. The cost is low, the raw material of the whisker toughening layer can be obtained by only adding a small amount of Si C whisker component into the raw material of the ceramic coating, the mass ratio of Si C whisker to YSZ ceramic is less than 1/10, and the thickness ratio of the Si C whisker toughening layer to the ceramic surface layer is less than 1/10. The microscopic texture and performance of the ceramic surface layer are not changed, and the thermal cycle performance of the coating is improved by an interface whisker toughening method on the basis of not affecting the abradability of the ceramic surface layer.

Description

Method for preparing whisker toughened plasma sprayed ceramic-based seal coating
Technical Field
The invention belongs to the technical field of interface design and optimization of plasma spraying coatings, and particularly relates to a method for preparing a whisker toughened plasma spraying ceramic-based seal coating.
Background
The reduction of the clearance between the rotor and the stator in the aeroengine gas circuit sealing system has important significance for improving the working efficiency of the engine and reducing the oil consumption, and along with the continuous improvement of the gas temperature in the turbine, the plasma spraying ceramic-based sealing coating with higher heat-resistant temperature (more than 1000 ℃) is one of the key technologies of the current advanced engine. Ceramic-based seal coatings are generally multi-layer systems comprising a nickel-based superalloy substrate, a metal bond coat (BC layer), a thermally grown oxide layer (TGO layer) and a ceramic face layer (TC layer), and such complex architectures and severe service environments can lead to failure of such coatings during use, including electrochemical and thermal corrosion of salt solutions in marine atmospheric environments, mechanical erosion of inclusions in high-velocity gas streams, thermal aging caused by high-temperature gas oxidation, cracking and spalling caused by thermal cycling, etc., wherein the most significant impact is premature spalling failure of the ceramic face layer during thermal cycling, as spalling of the ceramic face layer can directly lead to loss of seal function of the coating, which becomes a problem to be solved in the application of ceramic-based seal coatings.
In the aspect of optimizing the thermal cycle performance of the thermal spraying ceramic surface layer, domestic and foreign scientific researchers have achieved some results. Early researchers can prepare a ceramic surface layer with a columnar structure by using an electron beam physical vapor deposition (EB-PVD) method, and can effectively release TGO growth stress and thermal mismatch stress in a thermal cycle process through numerous longitudinal microcracks among columns, so that the ceramic surface layer prepared by the EB-PVD method has good thermal cycle performance, but the EB-PVD method has high cost and extremely low coating deposition efficiency, and is not suitable for coating preparation and commercial application of large-scale components. Suspension plasma spraying technology (SPS), plasma physical vapor deposition technology (PS-PVD) and the like proposed in the last 10 years can be used for preparing a coating with a similar columnar structure, so that the thermal cycle performance of a ceramic surface layer is improved to different degrees, but the methods have high requirements on raw materials, meanwhile, equipment is expensive, the process is complex, and the method has no great advantage in the aspect of cost control. In recent years, a method for releasing residual stress by utilizing longitudinal cracks is proposed, a surface concentrated heating mode is utilized to enable a ceramic surface layer to generate longitudinal cracks perpendicular to a coating, stress concentration at the interface between the ceramic surface layer and a TGO (thermal growth couple) can be relieved through the longitudinal cracks, TGO growth stress and thermal mismatch stress are released, and the thermal cycle life of the coating is prolonged. The method has simple process and low cost, but longitudinal cracks are generated by a surface concentrated heating mode, the density is not high, the distribution is uneven, and the effect of improving the thermal cycle performance of the coating is limited, so that the application is greatly limited.
The research adopts a certain technology or method to optimize the microscopic morphology of the ceramic coating, and improves the thermal cycle cracking resistance of the ceramic surface layer by releasing the growing stress of the TGO layer and the thermal mismatch stress at the ceramic surface layer/TGO interface, which are continuously increased in the thermal cycle process, however, the method still has the problems of high preparation cost, low production efficiency, large technical difficulty, poor effect and the like.
Disclosure of Invention
In order to solve the problems, the invention aims to provide a method for preparing a whisker toughened plasma sprayed ceramic matrix sealing coating.
In order to achieve the above purpose, the method for preparing the whisker toughened plasma sprayed ceramic matrix sealing coating provided by the invention comprises the following steps in sequence:
1) Crushing and uniformly mixing YSZ ceramic-based raw materials consisting of absolute ethyl alcohol, YSZ powder, polyphenyl ester powder, sodium hexametaphosphate, PEG and PVA by using a ball mill to obtain YSZ ceramic-based raw material powder; wherein the dosage ratio of the absolute ethyl alcohol to the YSZ powder to the polyphenyl ester powder to the sodium hexametaphosphate to the PEG to the PVA is 200-300 ml to 80-120 g to 20-25 g to 3-5 g;
2) Preparing YSZ ceramic-based raw material powder into YSZ ceramic-based agglomerated powder by using a spray granulator;
3) Crushing and uniformly mixing whisker raw materials consisting of absolute ethyl alcohol, siC whisker, YSZ powder, polyphenyl ester powder, sodium hexametaphosphate, PEG and PVA by using a ball mill to obtain whisker raw material powder; wherein the dosage ratio of the absolute ethyl alcohol, the SiC whisker, the YSZ powder, the polyphenyl ester powder, the sodium hexametaphosphate, the PEG and the PVA is 200-300 ml to 6-8 g to 80-120 g to 20-25 g to 3-5 g;
4) Preparing the whisker raw material powder into ceramic-based agglomerated powder containing whiskers by using a spray granulator;
5) Spraying NiCoCrAlY metal bonding layer powder on a nickel-based alloy matrix by using a plasma spray gun to prepare a metal bonding layer;
6) Spraying the ceramic-based agglomerated powder containing the whisker on the metal bonding layer by using a plasma spray gun to prepare a whisker toughening layer;
7) And spraying the YSZ ceramic-based agglomerated powder on the whisker toughening layer by using a plasma spray gun to prepare the ceramic surface layer.
In the step 1) and the step 3), the rotating speed of the ball mill is 600-800 r/min, and ZrO 2 The grinding ball is 300-500 g, and the ball milling time is 10-12 h.
In the step 2) and the step 4), the inlet temperature of the spray granulator is 180-220 ℃, the outlet temperature is 100-120 ℃, the atomization rotating speed is 6000-6500 r/min, the solid content of slurry is 50-60%, and the flow rate of a peristaltic pump is 30-35 mm/min.
In the step 5), the voltage of the plasma spray gun is 40-41V, the current is 780-800A, the powder feeding rate is 30-35 g/min, the spraying distance is 100-120 mm, and the thickness of the metal bonding layer is 100-150 mu m.
In the step 6), the voltage of the plasma spray gun is 37-38V, the current is 750-760A, the powder feeding rate is 30-35 g/min, the spraying distance is 100-120 mm, and the thickness of the whisker toughening layer is 40-50 mu m.
In the step 7), the voltage of the plasma spray gun is 41-42V, the current is 830-840A, the powder feeding rate is 30-35 g/min, the spraying distance is 80-90 mm, and the thickness of the ceramic surface layer is 500-600 mu m.
The method for preparing the whisker toughened plasma sprayed ceramic-based seal coat has the following advantages:
(1) The process flow is simple, the operation is easy, the whisker toughening technology in the ceramic sintering process is introduced into the plasma spraying process, and the toughening at the interface of the ceramic coating and the metal bonding layer can be realized by only one preparation technology of plasma spraying.
(2) The cost is low, the raw material of the whisker toughening layer can be obtained by only adding a small amount of SiC whisker component into the raw material of the ceramic coating, the mass ratio of the SiC whisker to YSZ powder is less than 1/10, and the thickness ratio of the SiC whisker toughening layer to the ceramic surface layer is less than 1/10.
(3) The microscopic texture and performance of the ceramic surface layer are not changed, and the thermal cycle performance of the coating is improved by an interface whisker toughening method on the basis of not affecting the abradability of the ceramic surface layer.
Drawings
Fig. 1 is a metallographic photograph of a cross section of a high temperature seal coating of a whisker-containing toughening layer. Wherein the magnification of (a) and (b) is 50 and 10000 respectively.
FIG. 2 shows the microscopic morphology of SiC whisker-containing ceramic agglomerate powder prepared by spray granulation. Wherein the magnification of (a), (b) and (c) is 500, 2000 and 5000, respectively.
FIG. 3 is a microscopic morphology of a whisker toughening layer prepared by plasma spray technique in the present invention. Wherein the magnification of (a) and (b) is 500 and 2000 respectively.
And fig. 4 (a) and (b) are respectively scanning electron micrographs of whisker bridging and pulling out of whisker at a fracture after thermal cycle failure of the ceramic-based seal coating containing the whisker toughening layer.
Detailed Description
The following detailed description of embodiments of the invention is exemplary and intended to be illustrative of the invention and not to be construed as limiting the invention.
Example 1:
the method for preparing the whisker toughened plasma sprayed ceramic matrix sealing coating provided by the embodiment comprises the following steps in sequence:
1) 200ml of absolute ethanol, 80g of YSZ (yttria stabilized zirconia) powder, 20g of polyphenyl ester powder, and sodium hexametaphosphate (Na 6 O 18 P 6 ) 3g, PEG3g and PVA3g, crushing and uniformly mixing the YSZ ceramic-based raw materials by using a ball mill to obtain YSZ ceramic-based raw material powder; the rotation speed of the ball mill is 600r/min, and ZrO 2 The grinding ball is 300g, and the ball milling time is 10h.
2) Preparing the YSZ ceramic-based raw material powder into YSZ ceramic-based agglomerated powder by using a spray granulator; the inlet temperature of the spray granulator is 180 ℃, the outlet temperature is 100 ℃, the atomization rotating speed is 6000r/min, the solid content of slurry is 50%, and the flow rate of a peristaltic pump is 30mm/min.
3) 200ml of absolute ethyl alcohol, 6g of SiC whisker,80g of YSZ powder, 20g of polyphenyl ester powder, and sodium hexametaphosphate (Na 6 O 18 P 6 ) 3g, PEG3g and PVA3g, crushing the whisker raw materials by using a ball mill, and uniformly mixing to obtain whisker raw material powder; the rotation speed of the ball mill is 600r/min, and ZrO 2 The grinding ball is 300g, and the ball milling time is 10h.
4) Preparing the whisker raw material powder into ceramic-based agglomerated powder containing whiskers by using a spray granulator; the inlet temperature of the spray granulator is 180 ℃, the outlet temperature is 100 ℃, the atomization rotating speed is 6000r/min, the solid content of slurry is 50%, and the flow rate of a peristaltic pump is 30mm/min.
5) Spraying NiCoCrAlY metal bonding layer powder (with the mark of CO 110) on a nickel-based alloy matrix by using a plasma spray gun to prepare a metal bonding layer; the voltage of the plasma spray gun is 40V, the current is 780A, the powder feeding rate is 30g/min, the spraying distance is 100mm, and the thickness of the metal bonding layer is 100 mu m.
6) Spraying the ceramic-based agglomerated powder containing the whisker on the metal bonding layer by using a plasma spray gun to prepare a whisker toughening layer; the voltage of the plasma spray gun is 37V, the current is 750A, the powder feeding rate is 30g/min, the spraying distance is 100mm, and the thickness of the whisker toughening layer is 40 mu m.
7) Spraying the YSZ ceramic-based agglomerated powder on the whisker toughening layer by using a plasma spray gun to prepare a ceramic surface layer; the plasma spray gun had a voltage of 41V, a current of 830A, a powder feeding rate of 30g/min, a spray distance of 80mm, and a ceramic surface layer thickness of 500 μm.
Example 2:
the method for preparing the whisker toughened plasma sprayed ceramic matrix sealing coating provided by the embodiment comprises the following steps in sequence:
1) Is prepared from absolute ethanol 300ml, YSZ powder 120g, polyphenyl ester powder 25g, sodium hexametaphosphate (Na) 6 O 18 P 6 ) Crushing and uniformly mixing 5g of YSZ ceramic-based raw materials consisting of 5g of PEG (polyethylene glycol), 5g of PVA (polyvinyl acetate) and 5g of PVA by using a ball mill to obtain YSZ ceramic-based raw material powder; the rotation speed of the ball mill is 800r/min, and ZrO 2 The grinding ball is 500g, and the ball milling time is 12h.
2) Preparing the YSZ ceramic-based raw material powder into YSZ ceramic-based agglomerated powder by using a spray granulator; the inlet temperature of the spray granulator is 220 ℃, the outlet temperature is 120 ℃, the atomization rotating speed is 6500r/min, the solid content of slurry is 60%, and the flow rate of a peristaltic pump is 35mm/min.
3) Is prepared from absolute alcohol 300ml, siC whisker 8g, YSZ powder 120g, polyphenyl ester powder 25g, sodium hexametaphosphate (Na) 6 O 18 P 6 ) 5g, 5g of PEG and 5g of PVA are crushed by a ball mill and uniformly mixed to obtain whisker raw material powder; the rotation speed of the ball mill is 800r/min, and ZrO 2 The grinding ball is 500g, and the ball milling time is 12h.
4) Preparing the whisker raw material powder into ceramic-based agglomerated powder containing whiskers by using a spray granulator; the inlet temperature of the spray granulator is 220 ℃, the outlet temperature is 120 ℃, the atomization rotating speed is 6500r/min, the solid content of slurry is 60%, and the flow rate of a peristaltic pump is 35mm/min.
5) Spraying NiCoCrAlY metal bonding layer powder (with the mark of CO 110) on a nickel-based alloy matrix by using a plasma spray gun to prepare a metal bonding layer; the voltage of the plasma spray gun is 41V, the current is 800A, the powder feeding speed is 35g/min, the spraying distance is 120mm, and the thickness of the metal bonding layer is 150 mu m.
6) Spraying the ceramic-based agglomerated powder containing the whisker on the metal bonding layer by using a plasma spray gun to prepare a whisker toughening layer; the voltage of the plasma spray gun is 38V, the current is 760A, the powder feeding rate is 35g/min, the spraying distance is 120mm, and the thickness of the whisker toughening layer is 50 mu m.
7) Spraying the YSZ ceramic-based agglomerated powder on the whisker toughening layer by using a plasma spray gun to prepare a ceramic surface layer; the plasma spray gun has a voltage of 42V, a current of 840A, a powder feeding rate of 35g/min, a spraying distance of 90mm and a thickness of 600 mu m of the ceramic surface layer.
Example 3:
the method for preparing the whisker toughened plasma sprayed ceramic matrix sealing coating provided by the embodiment comprises the following steps in sequence:
1) Will be prepared from 250ml of absolute ethanol, YSZ powder 100g, polyphenyl ester powder 22g, sodium hexametaphosphate (Na) 6 O 18 P 6 ) Crushing and uniformly mixing YSZ ceramic-based raw materials consisting of 4g, PEG4g and PVA4g by using a ball mill to obtain YSZ ceramic-based raw material powder; the rotation speed of the ball mill is 700r/min, and ZrO 2 The grinding ball is 400g, and the ball milling time is 11h.
2) Preparing the YSZ ceramic-based raw material powder into YSZ ceramic-based agglomerated powder by using a spray granulator; the inlet temperature of the spray granulator is 200 ℃, the outlet temperature is 110 ℃, the atomization rotating speed is 6300r/min, the solid content of slurry is 55%, and the flow rate of a peristaltic pump is 32mm/min.
3) Is prepared from absolute alcohol 250ml, siC whisker 7g, YSZ powder 100g, polyphenyl ester powder 22g, sodium hexametaphosphate (Na) 6 O 18 P 6 ) 4g, PEG4g and PVA4g, crushing the whisker raw materials by using a ball mill, and uniformly mixing to obtain whisker raw material powder; the rotation speed of the ball mill is 700r/min, and ZrO 2 The grinding ball is 400g, and the ball milling time is 11h.
4) Preparing the whisker raw material powder into ceramic-based agglomerated powder containing whiskers by using a spray granulator; the inlet temperature of the spray granulator is 200 ℃, the outlet temperature is 110 ℃, the atomization rotating speed is 6300r/min, the solid content of slurry is 55%, and the flow rate of a peristaltic pump is 32mm/min.
5) Spraying NiCoCrAlY metal bonding layer powder (with the mark of CO 110) on a nickel-based alloy matrix by using a plasma spray gun to prepare a metal bonding layer; the plasma spray gun has a voltage of 41V, a current of 790A, a powder feeding rate of 32g/min, a spraying distance of 110mm and a thickness of 130 mu m.
6) Spraying the ceramic-based agglomerated powder containing the whisker on the metal bonding layer by using a plasma spray gun to prepare a whisker toughening layer; the voltage of the plasma spray gun is 38V, the current is 755A, the powder feeding rate is 33g/min, the spraying distance is 110mm, and the thickness of the whisker toughening layer is 45 mu m.
7) Spraying the YSZ ceramic-based agglomerated powder on the whisker toughening layer by using a plasma spray gun to prepare a ceramic surface layer; the plasma spray gun has a voltage of 41V, a current of 835A, a powder feeding rate of 33g/min, a spraying distance of 85mm and a thickness of 550 μm of the ceramic surface layer.
In the thermal cycle test process of the ceramic-based high-temperature sealing coating, the part with the largest bearing stress in the coating system is the TGO/ceramic surface layer interface because of the thermal property parameter mismatch, and the TGO growth stress and the thermal property mismatch stress are continuously increased along with the increase of the test thermal cycle test times, so that the crack initiation, growth and peeling at the TGO/ceramic surface layer interface are finally caused. The whisker toughening technology is introduced into the plasma spraying process in the ceramic sintering process based on the whisker toughening mechanism and the agglomeration granulation technology, and the whisker toughening layer is utilized to strengthen stress concentration and easy-to-crack parts (TGO/ceramic surface layer interfaces) in the YSZ-based high-temperature sealing coating, so that the thermal cycle performance of the plasma spraying ceramic-based sealing coating is improved.
Fig. 1 is a metallographic photograph of a cross section of a high temperature seal coating of a whisker-containing toughening layer. In the whole, the high-temperature sealing coating of the whisker-containing toughening layer sequentially comprises 4 parts of a nickel-based alloy matrix, a metal bonding layer, the whisker toughening layer, a YSZ-based ceramic surface layer and the like, as shown in a figure (1 a). FIG. 1 (b) is an enlarged photograph of the whisker toughening layer of FIG. 1 (a).
Fig. 2 shows the microscopic morphology of the SiC whisker-containing agglomerated powder, and as can be seen from fig. 2, the SiC whisker-containing agglomerated powder is spherical, and the SiC whiskers are better dispersed on the agglomerated particles and are more uniformly distributed. The flowability and bulk density of the SiC whisker-containing agglomerated powder are 91.37s/50g and 0.927g/cm respectively 3 The plasma spraying requirements of the invention are satisfied.
Fig. 3 shows the surface microscopic morphology of the SiC whisker-containing toughening layer prepared by the plasma spray technique, and it can be seen from fig. 3 that the structural integrity of the SiC whiskers is still maintained in the coating and the distribution is relatively uniform.
Fig. 4 shows SEM detection results of a fracture at the substrate side after thermal cycle failure of the high-temperature seal coating layer containing the whisker toughening layer, and as can be found from fig. 4 (a) and (b), the thermal cycle fracture of the coating layer shows an obvious porous structure, and obvious phenomena of whisker bridging and whisker pulling occur.
The ceramic-based sealing coating with the whisker-containing toughening layer has better thermal cycle life mainly because the whisker-containing toughening layer has better crack extension resistance, because the porous structure of the whisker-containing toughening layer, the whisker 'bridging' effect and the whisker 'pulling-out' effect consume a large amount of energy in the thermal cycle process, and the driving force of crack growth is reduced, so that the crack extension resistance of the whisker-containing toughening layer is improved, and finally the thermal cycle life of the coating is improved.

Claims (6)

1. A method for preparing whisker toughened plasma sprayed ceramic-based seal coating is characterized by comprising the following steps: the method comprises the following steps in sequence:
1) Crushing and uniformly mixing YSZ ceramic-based raw materials consisting of absolute ethyl alcohol, YSZ powder, polyphenyl ester powder, sodium hexametaphosphate, PEG and PVA by using a ball mill to obtain YSZ ceramic-based raw material powder; wherein the dosage ratio of the absolute ethyl alcohol to the YSZ powder to the polyphenyl ester powder to the sodium hexametaphosphate to the PEG to the PVA is 200-300 ml to 80-120 g to 20-25 g to 3-5 g;
2) Preparing YSZ ceramic-based raw material powder into YSZ ceramic-based agglomerated powder by using a spray granulator;
3) Crushing and uniformly mixing whisker raw materials consisting of absolute ethyl alcohol, siC whisker, YSZ powder, polyphenyl ester powder, sodium hexametaphosphate, PEG and PVA by using a ball mill to obtain whisker raw material powder; wherein the dosage ratio of the absolute ethyl alcohol, the SiC whisker, the YSZ powder, the polyphenyl ester powder, the sodium hexametaphosphate, the PEG and the PVA is 200-300 ml to 6-8 g to 80-120 g to 20-25 g to 3-5 g;
4) Preparing the whisker raw material powder into ceramic-based agglomerated powder containing whiskers by using a spray granulator;
5) Spraying NiCoCrAlY metal bonding layer powder on a nickel-based alloy matrix by using a plasma spray gun to prepare a metal bonding layer;
6) Spraying the ceramic-based agglomerated powder containing the whisker on the metal bonding layer by using a plasma spray gun to prepare a whisker toughening layer;
7) And spraying the YSZ ceramic-based agglomerated powder on the whisker toughening layer by using a plasma spray gun to prepare the ceramic surface layer.
2. The method for preparing the whisker toughened plasma sprayed ceramic matrix sealing coating according to claim 1, wherein the method comprises the steps of: in the step 1) and the step 3), the rotating speed of the ball mill is 600-800 r/min, and ZrO 2 The grinding ball is 300-500 g, and the ball milling time is 10-12 h.
3. The method for preparing the whisker toughened plasma sprayed ceramic matrix sealing coating according to claim 1, wherein the method comprises the steps of: in the step 2) and the step 4), the inlet temperature of the spray granulator is 180-220 ℃, the outlet temperature is 100-120 ℃, the atomization rotating speed is 6000-6500 r/min, the solid content of slurry is 50-60%, and the flow rate of a peristaltic pump is 30-35 mm/min.
4. The method for preparing the whisker toughened plasma sprayed ceramic matrix sealing coating according to claim 1, wherein the method comprises the steps of: in the step 5), the voltage of the plasma spray gun is 40-41V, the current is 780-800A, the powder feeding rate is 30-35 g/min, the spraying distance is 100-120 mm, and the thickness of the metal bonding layer is 100-150 mu m.
5. The method for preparing the whisker toughened plasma sprayed ceramic matrix sealing coating according to claim 1, wherein the method comprises the steps of: in the step 6), the voltage of the plasma spray gun is 37-38V, the current is 750-760A, the powder feeding rate is 30-35 g/min, the spraying distance is 100-120 mm, and the thickness of the whisker toughening layer is 40-50 mu m.
6. The method for preparing the whisker toughened plasma sprayed ceramic matrix sealing coating according to claim 1, wherein the method comprises the steps of: in the step 7), the voltage of the plasma spray gun is 41-42V, the current is 830-840A, the powder feeding rate is 30-35 g/min, the spraying distance is 80-90 mm, and the thickness of the ceramic surface layer is 500-600 mu m.
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