CN114182191A - Thermal barrier coating and preparation method thereof - Google Patents
Thermal barrier coating and preparation method thereof Download PDFInfo
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- CN114182191A CN114182191A CN202111498240.5A CN202111498240A CN114182191A CN 114182191 A CN114182191 A CN 114182191A CN 202111498240 A CN202111498240 A CN 202111498240A CN 114182191 A CN114182191 A CN 114182191A
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- 239000012720 thermal barrier coating Substances 0.000 title claims abstract description 29
- 238000002360 preparation method Methods 0.000 title abstract description 11
- 238000004942 thermal barrier coating method Methods 0.000 title description 2
- 239000002245 particle Substances 0.000 claims abstract description 41
- 229910052751 metal Inorganic materials 0.000 claims abstract description 33
- 239000002184 metal Substances 0.000 claims abstract description 33
- 229910044991 metal oxide Inorganic materials 0.000 claims abstract description 33
- 150000004706 metal oxides Chemical class 0.000 claims abstract description 33
- 238000010438 heat treatment Methods 0.000 claims abstract description 29
- 239000000758 substrate Substances 0.000 claims abstract description 14
- 229910052741 iridium Inorganic materials 0.000 claims abstract description 7
- 229910052702 rhenium Inorganic materials 0.000 claims abstract description 7
- 238000005507 spraying Methods 0.000 claims description 25
- 239000000919 ceramic Substances 0.000 claims description 19
- 230000003647 oxidation Effects 0.000 claims description 13
- 238000007254 oxidation reaction Methods 0.000 claims description 13
- 238000000034 method Methods 0.000 claims description 10
- 239000000843 powder Substances 0.000 claims description 9
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims description 8
- 230000008569 process Effects 0.000 claims description 8
- PXHVJJICTQNCMI-UHFFFAOYSA-N nickel Substances [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 7
- PNEYBMLMFCGWSK-UHFFFAOYSA-N Alumina Chemical compound [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 4
- 229910000428 cobalt oxide Inorganic materials 0.000 claims description 4
- IVMYJDGYRUAWML-UHFFFAOYSA-N cobalt(ii) oxide Chemical compound [Co]=O IVMYJDGYRUAWML-UHFFFAOYSA-N 0.000 claims description 4
- 229910000480 nickel oxide Inorganic materials 0.000 claims description 4
- GNRSAWUEBMWBQH-UHFFFAOYSA-N oxonickel Chemical compound [Ni]=O GNRSAWUEBMWBQH-UHFFFAOYSA-N 0.000 claims description 4
- 238000001816 cooling Methods 0.000 claims description 3
- 238000002347 injection Methods 0.000 claims description 3
- 239000007924 injection Substances 0.000 claims description 3
- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 claims description 3
- 229910052753 mercury Inorganic materials 0.000 claims description 3
- 238000004321 preservation Methods 0.000 claims description 3
- QDOXWKRWXJOMAK-UHFFFAOYSA-N dichromium trioxide Chemical compound O=[Cr]O[Cr]=O QDOXWKRWXJOMAK-UHFFFAOYSA-N 0.000 claims description 2
- 238000002844 melting Methods 0.000 abstract description 3
- 230000000977 initiatory effect Effects 0.000 abstract 1
- 229910052707 ruthenium Inorganic materials 0.000 abstract 1
- 239000010410 layer Substances 0.000 description 118
- 239000011159 matrix material Substances 0.000 description 22
- 239000012790 adhesive layer Substances 0.000 description 14
- 238000009792 diffusion process Methods 0.000 description 12
- 239000003963 antioxidant agent Substances 0.000 description 6
- 230000003078 antioxidant effect Effects 0.000 description 6
- 239000000203 mixture Substances 0.000 description 5
- 238000013461 design Methods 0.000 description 4
- 238000005488 sandblasting Methods 0.000 description 4
- 239000007921 spray Substances 0.000 description 4
- 238000005336 cracking Methods 0.000 description 3
- WGLPBDUCMAPZCE-UHFFFAOYSA-N Trioxochromium Chemical compound O=[Cr](=O)=O WGLPBDUCMAPZCE-UHFFFAOYSA-N 0.000 description 2
- 230000009471 action Effects 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 2
- 229910000423 chromium oxide Inorganic materials 0.000 description 2
- 238000004140 cleaning Methods 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 230000002401 inhibitory effect Effects 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- SIWVEOZUMHYXCS-UHFFFAOYSA-N oxo(oxoyttriooxy)yttrium Chemical compound O=[Y]O[Y]=O SIWVEOZUMHYXCS-UHFFFAOYSA-N 0.000 description 2
- 230000002028 premature Effects 0.000 description 2
- 230000035882 stress Effects 0.000 description 2
- 238000006467 substitution reaction Methods 0.000 description 2
- 230000003746 surface roughness Effects 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 230000003213 activating effect Effects 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 239000002390 adhesive tape Substances 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 229910052593 corundum Inorganic materials 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000006355 external stress Effects 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 230000006698 induction Effects 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- DYIZHKNUQPHNJY-UHFFFAOYSA-N oxorhenium Chemical compound [Re]=O DYIZHKNUQPHNJY-UHFFFAOYSA-N 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 229910003449 rhenium oxide Inorganic materials 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 230000001629 suppression Effects 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
- 238000004506 ultrasonic cleaning Methods 0.000 description 1
- 229910001845 yogo sapphire Inorganic materials 0.000 description 1
- RUDFQVOCFDJEEF-UHFFFAOYSA-N yttrium(III) oxide Inorganic materials [O-2].[O-2].[O-2].[Y+3].[Y+3] RUDFQVOCFDJEEF-UHFFFAOYSA-N 0.000 description 1
- 229910001928 zirconium oxide Inorganic materials 0.000 description 1
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Classifications
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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
- 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
- C23C4/11—Oxides
-
- 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
- C23C4/129—Flame spraying
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Coating By Spraying Or Casting (AREA)
- Other Surface Treatments For Metallic Materials (AREA)
Abstract
The invention provides a thermal barrier coating, wherein a bonding layer comprises a first bonding layer and a second bonding layer which are separated from a metal substrate from near to far, and the first bonding layer comprises MCrAlY particles and metal oxide particles; the total amount of the metal oxide particles in the first bonding layer is more than 15% by area percentage; the second bonding layer comprises 95.5-99.2% of MCrAlY and 0.8-4.5% of high-melting-point element by mass percentage; the high-melting point element is one or more of Re, Ru, Ta, Dy, Hf and Ir. The invention also provides a preparation method of the thermal barrier coating. The invention has the advantages that: the metal oxide particles are introduced into the first bonding layer, the longitudinal expansion of cracks in the bonding layer is inhibited, and the heat treatment step of the second bonding layer is removed, so that high-melting-point elements such as Re, Ru and Ir are distributed in the bonding layer more uniformly, the growth rate of TGO is inhibited, and the initiation of cracks caused by TGO is inhibited.
Description
Technical Field
The invention relates to the technical field of thermal barrier coatings, in particular to a thermal barrier coating and a preparation method thereof.
Background
The development of the industries such as aerospace, energy and power and the like puts higher and higher requirements on an aero-engine and a gas turbine, and particularly, along with the continuous increase of the design temperature before the turbine, the development of the industries such as aerospace, energy and power and the like brings great challenges to the heat insulation performance of a turbine blade coating and the long-term service stability of the blade. The most widely used Thermal Barrier Coatings (TBC) today consist of a top layer of partially yttria doped zirconia (PYSZ) and a bond coat of MCrAlY (M stands for Co and/or Ni elements).
After actual service, the surface of the turbine blade can generate local cracks, and the cracks can continuously expand inwards after being formed, so that the safe operation of the unit is influenced. The external reason of the crack generation is mainly the local fatigue of the blade in the service process, and the internal reason is that the bonding layer coated on the surface of the blade matrix has poor toughness and is easy to crack, and is mainly attributed to the following aspects: 1) cracks originate from a thermal growth oxide layer (hereinafter referred to as TGO) on the surface of the bonding layer, and are easy to crack under the action of internal stress and external high-low cycle fatigue after reaching a certain thickness to form crack sources; 2) due to poor toughness of the bonding layer, cracks can quickly expand to the interface of the metal matrix and the bonding layer under the action of external stress after being formed; 3) because the difference between the components of the bonding layer and the metal matrix is usually large, high-temperature interdiffusion can occur in the service process, an interdiffusion layer is formed between the surface of the metal matrix and the bottom of the bonding layer, brittle sheet-shaped tissues are easily generated in the interdiffusion layer, the toughness is reduced, and partial cracks diffused to the interface of the interdiffusion layer and the bonding layer can be promoted to expand into the metal matrix.
Based on the consideration of mechanical properties, the heat treatment process and the structure composition of the high-temperature alloy matrix cannot be changed at will, so in summary, the suppression of cracks on the surface of a metal matrix in service needs to be achieved from two aspects, one is to reduce stress concentration in design and avoid local premature cracking, and the other is to improve the design and preparation method of a bonding layer, and perform related design or improvement from the aspects of TGO generation speed, crack propagation in the bonding layer, crack propagation in the metal matrix and the like.
Disclosure of Invention
In view of the above problems, an object of the present invention is to provide a thermal barrier coating that can suppress crack propagation and has a long service life.
The invention provides a thermal barrier coating, which comprises a bonding layer and a ceramic layer sprayed on the outer surface of a metal substrate, wherein the bonding layer comprises a first bonding layer and a second bonding layer which are separated from the metal substrate from near to far, the first bonding layer comprises MCrAlY particles and metal oxide particles, and M in the MCrAlY represents Co and/or Ni elements; the total amount of the metal oxide particles in the first bonding layer is 15% or more in terms of area percentage; the second bonding layer comprises 95.5-99.2% of MCrAlY and 0.8-4.5% of high-melting-point elements in percentage by mass, wherein M represents Co and/or Ni elements; the high-melting-point element is one or more of Re, Ru, Ta, Dy, Hf and Ir.
Preferably, the ceramic layer is formed by spraying a part of yttrium oxide doped zirconium oxide powder.
Preferably, the thickness of the ceramic layer is 250-.
Preferably, the metal oxide particles comprise alpha-alumina, chromia, nickel oxide and cobalt oxide.
Preferably, the first adhesive layer has a thickness of 50 to 70% in the adhesive layer, and the second adhesive layer has a thickness of 30 to 50% in the adhesive layer.
Preferably, the total amount of metal oxide particles in the second bonding layer is 3% or less by area percentage.
The invention also provides a preparation method of the thermal barrier coating, which comprises the following steps:
s1, spraying a first bonding layer on the outer surface of the metal matrix, forming metal oxide particles among the MCrAlY particles by adjusting the powder oxidation degree in the spraying process, and ensuring that the area percentage of the metal oxide particles in the first bonding layer is more than 15% by controlling parameters;
s2, carrying out vacuum heat treatment on the first bonding layer;
s3, spraying a second bonding layer on the surface of the first bonding layer after the heat treatment is finished;
and S4, spraying a ceramic layer on the surface of the second bonding layer.
Preferably, in the S2, the vacuum heat treatment includes: and (3) performing vacuum heat treatment on the first bonding layer at a vacuum degree of not less than 0.3Pa (2-micron mercury injection), at a heat treatment temperature of 1080 +/-10 ℃, for a heat preservation time of 1h, at a heating rate of less than 10-25K/min and at a cooling rate of 20-40K/min.
The invention improves around inhibiting the generation and the propagation of cracks, and has the advantages that: 1, introducing metal oxide particles into the first bonding layer to inhibit longitudinal expansion of cracks in the bonding layer and interdiffusion of bonding layer components and a metal matrix, so that the growth speed of the interdiffusion layer is reduced, and the expansion of the cracks in the metal matrix is further inhibited; 2 removing the heat treatment step of the second bonding layer, so that high-melting-point elements such as Re, Ru, Ta, Dy, Hf and Ir are distributed in the bonding layer more uniformly, the growth rate of TGO is inhibited, and the origin of cracks initiated by the TGO is inhibited; 3, the existing bonding layer is changed into the combination of the first bonding layer and the second bonding layer, so that the adhesive can be applied to conventional spraying on the premise of not carrying out large process change, and the crack expansion is comprehensively inhibited, thereby inhibiting the cracking of the service parts.
Drawings
FIG. 1 is a schematic structural view of a thermal barrier coating of the present invention;
FIG. 2 is a schematic view of two distributions of refractory elements in a bond coat;
FIG. 3 is a flow diagram of a vacuum thermal diffusion process performed on a first bonding layer in one embodiment.
Element number description:
1 metallic matrix
2 inter-diffusion layer
3 first adhesive layer
4 second adhesive layer
5 ceramic layer
Detailed Description
The following describes embodiments of the present invention in further detail with reference to the accompanying drawings. These embodiments are merely illustrative of the present invention and are not intended to limit the present invention.
As shown in fig. 1, the conventional thermal barrier coating mainly includes a bonding layer and a ceramic layer 5 sprayed on the outer surface of the metal substrate 1, the bonding layer can play a role in resisting oxidation corrosion and matching thermal expansion coefficient, and the bonding layer can generate high-temperature mutual diffusion in the high-temperature service process, so that a mutual diffusion layer 2 is formed between the surface of the metal substrate 1 and the bottom of the bonding layer. The thermal barrier coating is based on the conventional thermal barrier coating, and the bonding layer comprises a first bonding layer 3 and a second bonding layer 4 which are arranged at a distance from a metal substrate 1 from near to far.
The first bond coat 3 includes MCrAlY particles and metal oxide particles, M in MCrAlY represents Co and/or Ni element; the total amount of the metal oxide particles in the first bonding layer 3 is 15% by area or more. The second bonding layer 4 comprises 95.5-99.2% of MCrAlY and 0.8-4.5% of high-melting-point elements in percentage by mass, wherein M represents Co and/or Ni elements; the high-melting point element is one or more of Re, Ru, Ta, Dy, Hf and Ir. The total amount of the metal oxide particles in the second adhesive layer 4 is 3% or less in terms of area percentage.
In the first binder layer 3, the metal oxide particles are generally a mixture mainly of α -alumina and containing chromium oxide, nickel oxide, and cobalt oxide, and the specific composition differs depending on the composition of the MCrAlY powder selected. In a specific embodiment of the present invention, the metal oxide in the first bonding layer 3 has the following composition by mass percent: 25.39% of aluminum oxide, 19.78% of chromium oxide, 21.85% of cobalt oxide, 32.69% of nickel oxide, and the sum of rhenium oxide, yttrium oxide and other impurity oxides is 0.29%. The upper limit of the area percentage of the metal oxide particles takes the bonding strength of the bonding layer after heat treatment as an assessment standard, the single bonding strength is not lower than 40MPa, and the average value of 5 times of tests is not lower than 50 MPa.
Since Al in the bonding layer reacts with oxygen diffused from the ceramic layer 5 under a high temperature environment, a TGO layer having a main component of α -Al2O3 is formed between the bonding layer/ceramic layer 5 interface, which is effective as an oxidation resistant film to prevent oxidation of the metal substrate 1. But cracks also easily originate from the TGO and eventually propagate into the metal matrix 1. In order to solve the problem, the invention is provided with two bonding layers. The existence of the metal oxide particles can make the cracks extending into the first bonding layer 3 tend to transversely extend, so that the longitudinal extension of the cracks in the first bonding layer 3 and the induction effect of the cracks on the metal matrix 1 are inhibited, and the mutual diffusion of elements between the first bonding layer 3 and the metal matrix 1 is inhibited through the metal oxide particles with controllable total amount, so that the cracking tendency of the mutual diffusion layer 2 is reduced, and the loss of the antioxidant element Al in the first bonding layer 3 can be effectively slowed down. In the present invention, therefore, the area percentage of the metal oxide particles in the first bonding layer 3 is set to 15% or more. For the second bonding layer 4 adjacent to the ceramic layer 5, the addition of the high-melting-point elements Re, Ru, Ta, Dy, Hf, Ir, and the like can slow down the diffusion rate of the antioxidant element Al to avoid premature failure of the antioxidant film, but too many metal oxide particles can prevent the diffusion of the antioxidant element Al in the second bonding layer 4, so that the antioxidant film cannot be generated in time, and therefore, the area percentage of the metal oxide particles in the second bonding layer 4 is controlled to be less than 3% in the invention, and the stable existence of the antioxidant film is ensured.
In a specific implementation, the first adhesive layer 3 has a thickness of 50-70% in the adhesive layer, and the second adhesive layer 4 has a thickness of 30-50% in the adhesive layer. The ratio of the thicknesses of the first adhesive layer 3 and the second adhesive layer 4 in the adhesive layers can be adjusted by those skilled in the art according to actual needs. The ceramic layer 5 is formed by spraying part of yttria-doped zirconia (PYSZ) or other ceramic materials, and the spraying mode can be APS, EB-PVD and other common ceramic layer preparation modes. The thickness of the ceramic layer 5 is 250-550 μm.
The invention also provides a preparation method of the thermal barrier coating, which comprises the following steps:
s1, spraying the first bonding layer 3 on the outer surface of the metal substrate 1, forming metal oxide particles among the MCrAlY particles by adjusting the powder oxidation degree in the spraying process, and ensuring that the area percentage of the metal oxide particles in the first bonding layer 3 is more than 15% by controlling parameters.
S2, carrying out vacuum heat treatment on the first bonding layer 3 to enable the interparticle interfaces in the first bonding layer 3 to disappear and to be homogenized, and elements at the interface of the first bonding layer 3 and the metal matrix 1 to be diffused, so that the thermal shock resistance of the thermal barrier coating is improved.
And S3, spraying a second bonding layer 4 on the surface of the first bonding layer 3 after the heat treatment is finished, and controlling parameters to ensure that the area percentage of the metal oxide particles in the second bonding layer 4 is less than 3%.
As shown in FIG. 2, before the spray coating of the bonding layer and the heat treatment of the bonding layer, these high melting point elements are in an unstable state and can be distributed relatively uniformly in the bonding layer, thereby reducing the diffusion rate of the oxidation resistant element Al in the bonding layer, reducing the growth rate of TGO, and improving the overall oxidation performance of the thermal barrier coating. However, after high-temperature heat treatment, these high-melting-point elements usually reach a steady state and agglomerate to form a phase rich in the high-melting-point elements, so that the total amount of the high-melting-point elements in other regions is reduced, the diffusion rate of elements such as Al is increased, and the oxidation resistance is reduced.
Therefore, in the preparation method of the thermal barrier coating, the second bonding layer 4 added with the high-melting-point element is not subjected to vacuum heat treatment, and the total amount of the metal oxide particles in the second bonding layer 4 is strictly controlled, so that the oxidation performance of the whole thermal barrier coating can meet the requirement.
And S4, spraying a ceramic layer 5 on the surface of the second bonding layer 4.
In conclusion, the bonding layer in the thermal barrier coating is divided into two parts, the first bonding layer 3 is arranged close to the metal substrate 1, an oxidation layer is introduced into the first bonding layer 3 and subjected to vacuum heat treatment, the oxidation layer can slow down the longitudinal propagation speed of cracks in the bonding layer, so that the cracks tend to deflect transversely, high-temperature diffusion between the bonding layer and the metal substrate can be inhibited, the surface interdiffusion of the metal substrate and the growth speed of the bonding layer 2 are reduced, the toughness reduction of the interdiffusion layer 2 is avoided, the crack diffusion is further inhibited, and the operability and the production cost are considered; the second bonding layer 4 is close to the ceramic layer 5, and the vacuum heat treatment step is removed in the preparation process of the second bonding layer 4 added with the high-melting-point element, so that the high-melting-point element is kept in unsteady state and uniformly distributed in the bonding layer, and the oxidation resistance of the bonding layer is further improved.
With reference to fig. 1, the following is a specific preparation example of the thermal barrier coating of the present invention:
step 1: cleaning, namely cleaning the surface of the metal matrix 1 to be sprayed, checking whether oil stains and the like exist on the surface of the metal matrix 1, and performing ultrasonic cleaning on the metal matrix 1;
step 2: shielding: shielding a non-spraying area of the metal matrix 1 through a tool or an adhesive tape, and visually detecting whether shielding leakage exists or not;
and step 3: sand blasting: carrying out sand blasting on the sprayed area of the shielded metal matrix 1, activating the surface, wherein 30-mesh silicon carbide sand is adopted for sand blasting, the pressure is 2bar, and the surface roughness reaches Ra of 5-6um after sand blasting;
and 4, step 4: spraying the first bonding layer 3: the first bonding layer 3 is sprayed by supersonic flame, the spraying thickness is between 50-70% of the total thickness of the bonding layer and is 100-140 microns (calculated according to the total thickness of 200 microns), the total amount of metal oxide particles in the first bonding layer 3 is controlled to be more than 15% by controlling parameters, such as 18%, the bonding strength is not lower than 40MPa at a time, and the average value of 5 times of tests is not lower than 50 MPa. The porosity is controlled within 2 percent.
And 5: the vacuum heat treatment is shown in fig. 3: the vacuum degree of the heat treatment is 0.3Pa (2 micron mercury injection) or higher, the heat treatment temperature is 1080 ℃ +/-10 ℃, the heat preservation time is 1h, the heating rate is less than 10-25K/min, the cooling rate is 20-40K/min, and the first bonding layer 3 is subjected to vacuum heat treatment.
Step 6: spraying the second bonding layer 4: spraying the second bonding layer 4 by supersonic flame, wherein the spraying thickness is 30-50% of the total thickness of the bonding layer and is 60-100 micrometers (calculated according to the total thickness of 200 micrometers), the total amount of metal oxide particles is controlled within 3% by adjusting parameters, the porosity is controlled within 2%, and the surface roughness is Ra:9-14 um.
And 7: spraying a ceramic layer 5: a YSZ surface layer with the thickness of 250-.
The following materials and equipment were used in this example:
the metal matrix 1 adopts a Rene80 high-temperature alloy Ni60Cr14Co9.5Ti5Mo4W4Al3 sheet with the diameter of 25mm and the thickness of 5 mm.
Supersonic flame spray gun: JER KOAT spray gun.
YSZ plasma flame spray gun: f4 spray gun.
The first 3 and second 4 tie layers are each made from MCrAlY powder under the trade designation SICOAT 2464. Powder particle size range 22-45 microns, Re content wt%: 1 to 1.8 percent.
The YSZ material is preferably ZrO2 7Y2O3(Metro 234A), the powder particle diameter is 16-90 μm, the spraying thickness is 300 microns, and the porosity is 15%.
The above description is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, various modifications and substitutions can be made without departing from the technical principle of the present invention, and these modifications and substitutions should also be regarded as the protection scope of the present invention.
Claims (8)
1. A thermal barrier coating comprises a bonding layer and a ceramic layer (5) which are sprayed on the outer surface of a metal substrate (1), and is characterized in that the bonding layer comprises a first bonding layer (3) and a second bonding layer (4) which are separated from the metal substrate (1) from near to far,
the first bond coat (3) includes MCrAlY particles and metal oxide particles, wherein M in the MCrAlY represents Co and/or Ni elements; the total amount of the metal oxide particles in the first bonding layer (3) is 15% or more in terms of area percentage;
the second bonding layer (4) comprises 95.5-99.2% of MCrAlY and 0.8-4.5% of high-melting-point elements in percentage by mass, wherein M represents Co and/or Ni elements; the high-melting-point element is one or more of Re, Ru, Ta, Dy, Hf and Ir.
2. The thermal barrier coating according to claim 1, characterized in that the ceramic layer (5) is sprayed from a partially yttria-doped zirconia powder.
3. The thermal barrier coating according to claim 1 or 2, characterized in that the thickness of the ceramic layer (5) is 250-550 μm.
4. The thermal barrier coating of claim 1, wherein the metal oxide particles comprise alpha-alumina, chromia, nickel oxide, and cobalt oxide.
5. The thermal barrier coating according to claim 1, characterized in that the thickness of the first bonding layer (3) in the bonding layer is 50-70% and the thickness of the second bonding layer (4) in the bonding layer is 30-50%.
6. The thermal barrier coating according to claim 1, characterized in that the total amount of metal oxide particles in the second bond coat (4) is 3% or less in area percentage.
7. A method of preparing a thermal barrier coating as claimed in claim 1, comprising the steps of:
s1, spraying a first bonding layer (3) on the outer surface of the metal substrate (1), forming metal oxide particles among MCrAlY particles by adjusting the powder oxidation degree in the spraying process, and ensuring that the area percentage of the metal oxide particles in the first bonding layer (3) is more than 15% by controlling parameters;
s2, carrying out vacuum heat treatment on the first bonding layer (3);
s3, spraying a second bonding layer (4) on the surface of the first bonding layer (3) after the heat treatment is finished;
and S4, spraying a ceramic layer (5) on the surface of the second bonding layer (4).
8. The method according to claim 7, wherein in the S2, the vacuum heat treatment includes: the vacuum degree of the heat treatment is not less than 0.3Pa (2 micron mercury injection), the heat treatment temperature is 1080 +/-10 ℃, the heat preservation time is 1h, the heating rate is less than 10-25K/min, the cooling rate is 20-40K/min, and the vacuum heat treatment is carried out on the first bonding layer (3).
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