CN115354322A - 一种高孔隙热障涂层的制备方法 - Google Patents
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Abstract
一种高孔隙热障涂层的制备方法,涉及一种热障涂层的制备方法。为了解决现有方法制备的热障涂层的寿命短和隔热效果差的问题,提出一种高孔隙热障涂层的制备方法。方法:使用电镀基体表面制备中间连接层;制备等离子喷涂粉体,采用等离子喷涂工艺在中间连接层表面制备热障涂层;对热障涂层进行热处理。本发明将钠钙玻璃和改性SiN陶瓷微粉组成喷涂粉体形成核壳结构,引入的Fe2O3形成了孔隙网络,提高了热障涂层的热导率和表观弹性模量。硅油产生游离硅原子将缺陷处进行修复重连,使得SiN的晶体的结构完整性大幅度提高,本发明高温合金基体与热障涂层之间的界面结合力高,避免高温服役后热障涂层开裂剥落。
Description
技术领域
本发明涉及一种热障涂层的制备方法。
背景技术
汽轮机包括燃气轮机和航空发动机部等,燃气轮机和航空发动机部件多为具有高温强度、抗氧化腐蚀性能等的高温合金材料;一般的燃气轮机和航空发动机内部部件的环境温度约为1600℃左右,远超了镍基单晶高温合金等高温合金的工作极限。为了避免高温合金在高于自身承温极限的环境下失效,在高温合金上制备热障涂层是目前航空发动机和地面燃机必备的隔热防护措施之一;热障涂层使得高温合金部件的温度工作极限提高。
热障涂层的制备方法包括等离子喷涂法、电子束物理气相沉积法、超音速火焰喷涂、静电喷涂辅助气相沉积、激光熔覆法等,等离子喷涂是热障涂层的主要制备方法。等离子喷涂能够为常见的主要制备方法。公开号为CN114480999A的专利公开了一种超高温长寿命热障涂层材料及超高温长寿命热障涂层的制备方法,该专利中超高温长寿命热障涂层是由超高温长寿命热障涂层材料通过球磨得到纳米团聚体,将该纳米团聚体经大气等离子喷涂工艺喷涂在粘结层上形成陶瓷层制备而成。公开号为CN107815633A的专利公开了一种高性能热障涂层的制备方法,采用溶胶喷雾热解法合成工艺制备具有精细的纳米结构、组分均匀和纯四方相的4YSZ粉末,再依次经喷雾干燥造粒、筛分和大气等离子喷涂(APS)制备涂层。
虽然等离子喷涂法已经广为应用,但提高等离子喷涂热障涂层的服役寿命是当前亟需解决的难点问题。等离子喷涂的高温烧结使得涂层内的微孔隙大量愈合,涂层刚度提高,过于致密,因此高温服役后极易开裂,涂层的隔热效果降低,服役寿命缩短。
发明内容
本发明为了解决现有方法制备的热障涂层的寿命短和隔热效果差的问题,提出一种高孔隙热障涂层的制备方法。
本发明高孔隙热障涂层的制备方法按照以下步骤进行:
步骤一:对高温合金基体进行表面除杂处理;
步骤二:使用电镀在高温合金基体表面制备中间连接层;
所述中间连接层材质为Fe;
步骤三:制备等离子喷涂粉体
①、将聚硅氮烷置于保护气氛和250~257℃下保温0.4~0.5h得到SiCN,将粉碎得到SiCN微粉,并与Fe2O3微粉混合,然后进行高温热解,得到SiN陶瓷微粉;
所述Fe2O3的添加量为SiCN质量的5%;
所述高温热解工艺为:氮气气氛下,在1180~1190℃烧结1.5h;
②、将所得SiN陶瓷微粉和硅油混合,然后进行烧结和球磨,得到改性SiN陶瓷微粉;
所述烧结温度为500~620℃;所述烧结时间为1~5h;
所述硅油为聚苯基硅油,硅油和SiN陶瓷微粉的质量比为0.2:1;
③、钠钙玻璃研磨成微粉并与改性SiN陶瓷微粉混合,并进行烧结,烧结后球磨,得到喷涂粉体;
所述钠钙玻璃和改性SiN陶瓷微粉的体积比为(0.1~0.25):1
步骤四:采用等离子喷涂工艺在中间连接层表面制备厚度为300~500μm的热障涂层;
所述等离子喷涂工艺:喷涂电流400~500A,喷涂电压45~55V,送粉速率1~2.2g/min,氩气流量90~120SCFH,氢气流量10~20SCFH,送粉方向90°,喷涂距离400~500mm,喷涂速度20mm/s;
步骤五、对热障涂层进行热处理,即完成;
所述热障涂层的热处理工艺为:热处理温度为1000~1200℃,保温时间为10~15h,升温速率为10~15℃/min。
本发明原理及有益效果为:
本发明等离子喷涂后在镍基单晶高温合金基体表面形成热障涂层,钠钙玻璃和改性SiN陶瓷微粉组成的喷涂粉体中,钠钙玻璃的软化点低,在制备热障中涂层中起到粘接和分隔改性SiN陶瓷微粉颗粒的作用,在等离子喷涂过程中改性SiN陶瓷微粉堆叠形成网络结构,并且SiN陶瓷微粉包覆钠钙玻璃形成核壳结构;SiCN中Fe2O3是过量的,即是催化剂,也是造孔剂;在等离子喷涂过程中钠钙玻璃形成熔体,Fe2O3在高温下分解产生氧气逸入钠钙玻璃熔体形成气孔,同时过量的氧气也会向热障涂层外部流动,形成垂直于热流方向的纵向孔隙,气孔以及纵向孔隙形成了孔隙网络,提高了热障涂层的热导率和表观弹性模量。本发明中硅油在烧结后分解成短链硅氧烷,产生游离硅原子,在高温下硅扩散到SiN陶瓷内占据SiN的缺陷位点,将缺陷处进行修复重连,使得SiN的晶体的结构完整性大幅度提高。本发明采用的中间连接层材质为Fe,中间连接层用于高温合金基体与热障涂层之间的线胀性能的梯度过渡,保证接头的热稳定性。中间连接层材质中的Fe以及热障涂层中的Fe在高温下相互扩散并形成新的界面产物,提高了高温合金基体与热障涂层之间的界面结合力,避免高温服役后热障涂层开裂剥落。
附图说明
图1为实施例1制备的高孔隙热障涂层的显微照片;
具体实施方式
本发明技术方案不局限于以下所列举具体实施方式,还包括各具体实施方式间的任意合理组合。
具体实施方式一:本实施方式步骤一:对高温合金基体进行表面除杂处理;
步骤二:使用电镀在高温合金基体表面制备中间连接层;
所述中间连接层材质为Fe;
步骤三:制备等离子喷涂粉体
①、将聚硅氮烷置于保护气氛和250~257℃下保温0.4~0.5h得到SiCN,将粉碎得到SiCN微粉,并与Fe2O3微粉混合,然后进行高温热解,得到SiN陶瓷微粉;
所述Fe2O3的添加量为SiCN质量的5%;
所述高温热解工艺为:氮气气氛下,在1180~1190℃烧结1.5h;
②、将所得SiN陶瓷微粉和硅油混合,然后进行烧结和球磨,得到改性SiN陶瓷微粉;
所述烧结温度为500~620℃;所述烧结时间为1~5h;
所述硅油为聚苯基硅油,硅油和SiN陶瓷微粉的质量比为0.2:1;
③、钠钙玻璃研磨成微粉并与改性SiN陶瓷微粉混合,并进行烧结,烧结后球磨,得到喷涂粉体;
所述钠钙玻璃和改性SiN陶瓷微粉的体积比为(0.1~0.25):1
步骤四:采用等离子喷涂工艺在中间连接层表面制备厚度为300~500μm的热障涂层;
所述等离子喷涂工艺:喷涂电流400~500A,喷涂电压45~55V,送粉速率1~2.2g/min,氩气流量90~120SCFH,氢气流量10~20SCFH,送粉方向90°,喷涂距离400~500mm,喷涂速度20mm/s;
步骤五、对热障涂层进行热处理,即完成;
所述热障涂层的热处理工艺为:热处理温度为1000~1200℃,保温时间为10~15h,升温速率为10~15℃/min。
本实施方式具备以下有益效果:
本实施方式等离子喷涂后在镍基单晶高温合金基体表面形成热障涂层,钠钙玻璃和改性SiN陶瓷微粉组成的喷涂粉体中,钠钙玻璃的软化点低,在制备热障中涂层中起到粘接和分隔改性SiN陶瓷微粉颗粒的作用,在等离子喷涂过程中改性SiN陶瓷微粉堆叠形成网络结构,并且SiN陶瓷微粉包覆钠钙玻璃形成核壳结构;SiCN中Fe2O3是过量的,即是催化剂,也是造孔剂;在等离子喷涂过程中钠钙玻璃形成熔体,Fe2O3在高温下分解产生氧气逸入钠钙玻璃熔体形成气孔,同时过量的氧气也会向热障涂层外部流动,形成垂直于热流方向的纵向孔隙,气孔以及纵向孔隙形成了孔隙网络,提高了热障涂层的热导率和表观弹性模量。本实施方式中硅油在烧结后分解成短链硅氧烷,产生游离硅原子,在高温下硅扩散到SiN陶瓷内占据SiN的缺陷位点,将缺陷处进行修复重连,使得SiN的晶体的结构完整性大幅度提高。本实施方式采用的中间连接层材质为Fe,中间连接层用于高温合金基体与热障涂层之间的线胀性能的梯度过渡,保证接头的热稳定性。中间连接层材质中的Fe以及热障涂层中的Fe在高温下相互扩散并形成新的界面产物,提高了高温合金基体与热障涂层之间的界面结合力,避免高温服役后热障涂层开裂剥落。
具体实施方式二:本实施方式与具体实施方式一不同的是:步骤一所述高温合金基体为镍基单晶高温合金。
具体实施方式三:本实施方式与具体实施方式一或二不同的是:步骤一所述表面除杂处理工艺为喷砂。
具体实施方式四:本实施方式与具体实施方式一至三之一不同的是:步骤二所述中间连接层厚度为1~50μm。
具体实施方式五:本实施方式与具体实施方式一至四之一不同的是:步骤三所述SiCN微粉的粒径为20~30μm。
具体实施方式六:本实施方式与具体实施方式一至五之一不同的是:步骤三所述Fe2O3微粉的粒径为20~30μm。
具体实施方式七:本实施方式与具体实施方式一至六之一不同的是:步骤三①所述的保护气氛为氮气、氦气或者氩气。
具体实施方式八:本实施方式与具体实施方式一至七之一不同的是:步骤三③所述喷涂粉体的的粒径为30~60μm。
具体实施方式九:本实施方式与具体实施方式一至八之一不同的是:步骤四所述等离子喷涂工艺:喷涂电流450A,喷涂电压50V,送粉速率2g/min,氩气流量90SCFH,氢气流量15SCFH,送粉方向90°,喷涂距离500mm,喷涂速度20mm/s。
具体实施方式十:本实施方式与具体实施方式一至九之一不同的是:步骤五所述热障涂层的热处理工艺为:热处理温度为1100℃,保温时间为12h,升温速率为12℃/min。
实施例1:
本实施例高孔隙热障涂层的制备方法按照以下步骤进行:
步骤一:对基体进行表面除杂处理;
所述基体为镍基单晶高温合金(DD403);
所述表面除杂处理工艺为喷砂;
步骤二:使用电镀在高温合金基体表面制备中间连接层;
所述中间连接层材质为Fe;
所述中间连接层厚度为5μm;
步骤三:制备等离子喷涂粉体
①、将聚硅氮烷置于保护气氛和250℃下保温0.5h得到SiCN,将粉碎得到SiCN微粉,并与Fe2O3微粉混合,然后进行高温热解,得到SiN陶瓷微粉;
所述Fe2O3的添加量为SiCN质量的5%;
所述SiCN微粉的粒径为25μm;
所述Fe2O3微粉的粒径为25μm;
所述高温热解工艺为:氮气气氛下,在1190℃烧结1.5h;
步骤三①所述的保护气氛为氮气、氦气或者氩气;
②、将所得SiN陶瓷微粉和硅油混合,然后进行烧结和球磨,得到改性SiN陶瓷微粉;
所述烧结温度为600℃;所述烧结时间为4h;
所述硅油为聚苯基硅油,硅油和SiN陶瓷微粉的质量比为0.2:1;
③、钠钙玻璃研磨成微粉并与改性SiN陶瓷微粉混合,并进行烧结,烧结后球磨,得到喷涂粉体;
所述喷涂粉体的的粒径为40μm;
所述钠钙玻璃和改性SiN陶瓷微粉的体积比为0.1:1
步骤四:采用等离子喷涂工艺在中间连接层表面制备厚度为400μm的热障涂层;
所述等离子喷涂工艺:喷涂电流450A,喷涂电压50V,送粉速率2g/min,氩气流量90SCFH,氢气流量15SCFH,送粉方向90°,喷涂距离500mm,喷涂速度20mm/s。
步骤五、对热障涂层进行热处理,即完成。
所述热障涂层的热处理工艺为:热处理温度为1100℃,保温时间为12h,升温速率为12℃/min。
图1为实施例1制备的高孔隙热障涂层的显微照片;图1能够看出热障涂层中含有含有纵向孔隙,孔隙丰富,形成了孔隙网络。根据《热喷涂涂层结合强度试验方法》(HB5476-91)测试,本实施例得到的热障涂层的界面结合强度达到95MPa。
实施例2:
本实施例高孔隙热障涂层的制备方法按照以下步骤进行:
步骤一:对基体进行表面除杂处理;
所述基体为镍基单晶高温合金(DD403);所述表面除杂处理工艺为喷砂;
步骤二:使用电镀在高温合金基体表面制备中间连接层;
所述中间连接层材质为Fe;所述中间连接层厚度为10μm;
步骤三:制备等离子喷涂粉体
①、将聚硅氮烷置于保护气氛和250℃下保温0.4h得到SiCN,将粉碎得到SiCN微粉,并与Fe2O3微粉混合,然后进行高温热解,得到SiN陶瓷微粉;
所述Fe2O3的添加量为SiCN质量的5%;
所述SiCN微粉的粒径为25μm;
所述Fe2O3微粉的粒径为25μm;
所述高温热解工艺为:氮气气氛下,在1180℃烧结1.5h;
步骤三①所述的保护气氛为氮气、氦气或者氩气;
②、将所得SiN陶瓷微粉和硅油混合,然后进行烧结和球磨,得到改性SiN陶瓷微粉;
所述烧结温度为550℃;所述烧结时间为4h;
所述硅油为聚苯基硅油,硅油和SiN陶瓷微粉的质量比为0.2:1;
③、钠钙玻璃研磨成微粉并与改性SiN陶瓷微粉混合,并进行烧结,烧结后球磨,得到喷涂粉体;
所述喷涂粉体的的粒径为40μm;
所述钠钙玻璃和改性SiN陶瓷微粉的体积比为0.1:1
步骤四:采用等离子喷涂工艺在中间连接层表面制备厚度为400μm的热障涂层;
所述等离子喷涂工艺:喷涂电流450A,喷涂电压50V,送粉速率2g/min,氩气流量90SCFH,氢气流量15SCFH,送粉方向90°,喷涂距离500mm,喷涂速度20mm/s。
步骤五、对热障涂层进行热处理,即完成。
所述热障涂层的热处理工艺为:热处理温度为1100℃,保温时间为12h,升温速率为12℃/min。
本实施例得到的热障涂层的界面结合强度达到92MPa。本实施例得到的热障涂层经历1000次火焰(1500℃)热冲击后试样表面仅有微小黑点,未见剥落和开裂。
Claims (10)
1.一种高孔隙热障涂层的制备方法,其特征在于:高孔隙热障涂层的制备方法按照以下步骤进行:
步骤一:对高温合金基体进行表面除杂处理;
步骤二:使用电镀在高温合金基体表面制备中间连接层;
所述中间连接层材质为Fe;
步骤三:制备等离子喷涂粉体
①、将聚硅氮烷置于保护气氛和250~257℃下保温0.4~0.5h得到SiCN,将粉碎得到SiCN微粉,并与Fe2O3微粉混合,然后进行高温热解,得到SiN陶瓷微粉;
所述Fe2O3的添加量为SiCN质量的5%;
所述高温热解工艺为:氮气气氛下,在1180~1190℃烧结1.5h;
②、将所得SiN陶瓷微粉和硅油混合,然后进行烧结和球磨,得到改性SiN陶瓷微粉;
所述烧结温度为500~620℃;所述烧结时间为1~5h;
所述硅油为聚苯基硅油,硅油和SiN陶瓷微粉的质量比为0.2:1;
③、钠钙玻璃研磨成微粉并与改性SiN陶瓷微粉混合,并进行烧结,烧结后球磨,得到喷涂粉体;
所述钠钙玻璃和改性SiN陶瓷微粉的体积比为(0.1~0.25):1
步骤四:采用等离子喷涂工艺在中间连接层表面制备厚度为300~500μm的热障涂层;
所述等离子喷涂工艺:喷涂电流400~500A,喷涂电压45~55V,送粉速率1~2.2g/min,氩气流量90~120SCFH,氢气流量10~20SCFH,送粉方向90°,喷涂距离400~500mm,喷涂速度20mm/s;
步骤五、对热障涂层进行热处理,即完成;
所述热障涂层的热处理工艺为:热处理温度为1000~1200℃,保温时间为10~15h,升温速率为10~15℃/min。
2.根据权利要求1所述的高孔隙热障涂层的制备方法,其特征在于:步骤一所述高温合金基体为镍基单晶高温合金。
3.根据权利要求1所述的高孔隙热障涂层的制备方法,其特征在于:步骤一所述表面除杂处理工艺为喷砂。
4.根据权利要求1所述的高孔隙热障涂层的制备方法,其特征在于:步骤二所述中间连接层厚度为1~50μm。
5.根据权利要求1所述的高孔隙热障涂层的制备方法,其特征在于:步骤三所述SiCN微粉的粒径为20~30μm。
6.根据权利要求1所述的高孔隙热障涂层的制备方法,其特征在于:步骤三所述Fe2O3微粉的粒径为20~30μm。
7.根据权利要求1所述的高孔隙热障涂层的制备方法,其特征在于:步骤三①所述的保护气氛为氮气、氦气或者氩气。
8.根据权利要求1所述的高孔隙热障涂层的制备方法,其特征在于:步骤三③所述喷涂粉体的的粒径为30~60μm。
9.根据权利要求1所述的高孔隙热障涂层的制备方法,其特征在于:步骤四所述等离子喷涂工艺:喷涂电流450A,喷涂电压50V,送粉速率2g/min,氩气流量90SCFH,氢气流量15SCFH,送粉方向90°,喷涂距离500mm,喷涂速度20mm/s。
10.根据权利要求1所述的高孔隙热障涂层的制备方法,其特征在于:步骤五所述热障涂层的热处理工艺为:热处理温度为1100℃,保温时间为12h,升温速率为12℃/min。
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