CN115852294A - Thermal barrier coating containing surface cracks based on stress regulation and control and preparation method thereof - Google Patents
Thermal barrier coating containing surface cracks based on stress regulation and control and preparation method thereof Download PDFInfo
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Abstract
The invention discloses a thermal barrier coating containing surface cracks based on stress regulation, which is prepared by regulating and controlling the peak spraying stress in the preparation process of an APS coating, wherein longitudinal surface cracks penetrating through the thickness direction are periodically distributed in a ceramic layer of the thermal barrier coating, and the coating among the surface cracks is a compact low-porosity coating; the invention also discloses a preparation method of the thermal barrier coating containing the surface cracks, which comprises the following steps: 1. installing and debugging a spraying stress measuring device; 2. setting spraying parameters; 3. preheating a substrate; 4. spraying and measuring peak stress; 5. preparing a thermal barrier coating containing surface cracks. According to the invention, by regulating and controlling the peak spraying stress in the preparation process of the APS coating, surface cracks which are periodically distributed and penetrate through the thickness direction are introduced into the ceramic layer of the thermal barrier coating, so that the thermal barrier coating has the advantages of high temperature resistance limit, high strain tolerance limit and long service life; the method realizes the regulation and control of the thermal barrier coating structure based on the stress regulation and control method, and has simple process and convenient regulation and control.
Description
Technical Field
The invention belongs to the technical field of thermal barrier coating preparation, and particularly relates to a thermal barrier coating containing surface cracks based on stress regulation and control and a preparation method thereof.
Background
As the heart of modern industry, the difficulty of designing and manufacturing of the gas turbine is very high, the gas turbine intensively reflects the industrial level of a country, and is also known as the 'mingzhu' of equipment manufacturing industry. The working efficiency of the gas turbine determines the performance of the gas turbine, and the working efficiency is directly related to the working temperature, so that the working efficiency is directly limited by the high temperature resistance and the service life of the hot-end component. Thermal Barrier Coatings (TBCs) technology is one of core technologies for hot end component Thermal protection, and the application of a Thermal Barrier coating with the thickness of 250 μm can reduce the surface temperature of a blade from 10K to 170K, which is equivalent to 30 years of efforts of human beings in improving high-temperature alloy. In addition, the thermal barrier coating structure has strong designability, and the thermal insulation limit still has huge temperature rise potential, so the thermal barrier coating structure is considered to be one of the most key means for solving the heat resistance problem of the hot-end component of the heavy-duty gas turbine.
At present, the most widely used thermal barrier coating system is a classic three-layer structure, comprising four material components, namely a ceramic layer, a bonding layer, a superalloy substrate, and a thermally grown oxide with alumina as a main component formed between the ceramic layer and the bonding layer during service. The thermal barrier coating widely applied to the heavy-duty gas turbine is prepared by an Atmospheric Plasma Spraying (APS) method, the APS thermal barrier coating shows a typical laminated stacked structure, gaps and cavities among the flaky structures enable the whole coating to show a loose and porous macroscopic characteristic, and therefore the ceramic layer has lower thermal conductivity and certain toughness, the process is simple, the cost is low, and the thermal barrier coating becomes the first choice of a thermal protection system of a high-temperature component of the gas turbine. However, the thermal barrier coating of the heavy-duty gas turbine has the disadvantages of large difference of material properties and dimensions of each layer, complex interface between each layer, many initial microcracks and pore defects of the coating, and unusually severe service environment (high temperature, high pressure, impact, thermal gradient, etc.), which causes the coating to be prone to cracking and debonding in the service environment, thereby causing spalling failure. Controllable surface cracks are introduced into the thermal barrier coating by regulating and controlling the APS process, so that the strain tolerance of the coating can be improved, the service life of the coating with the same thickness can be prolonged, and the coating thickness and the heat insulation effect can be increased on the premise of keeping the service life not to be reduced. The design idea of the coating not only considers the requirements of strong heat insulation and long service life, but also has low cost and high efficiency.
From the reports at present, the research on APS thermal barrier coatings containing surface cracks is mostly limited to toughening mechanism verification, preparation process optimization experiments and basic performance tests. However, APS thermal barrier coatings containing surface cracks have not been widely used in industry to date. The main reason is that the spraying parameters related to surface crack formation (such as preheating temperature, coating single-pass thickness, spraying power, powder particle size, powder melting state, etc.) are numerous, the influence of the parameters on the stress distribution and evolution inside the coating in the preparation process is not clear, the optimization of the existing preparation process of the thermal barrier coating containing the surface crack APS is still mainly based on empirical trial and error spraying, and the mechanical support from empirical preparation to scientific preparation is lacked. Therefore, the patent provides a method for preparing the surface cracks of the APS thermal barrier coating based on stress regulation and control by taking the APS thermal barrier coating containing the surface cracks as an object.
Disclosure of Invention
The technical problem to be solved by the present invention is to provide a thermal barrier coating containing surface cracks based on stress control, aiming at the defects of the prior art. The thermal barrier coating containing the surface cracks introduces longitudinal surface cracks which are periodically distributed and penetrate through the thickness direction into the top layer of the surface ceramic layer of the thermal barrier coating by regulating and controlling the peak spraying stress in the preparation process of the APS coating, and simultaneously forms a compact low-porosity coating among the surface cracks, so that the thermal barrier coating containing the surface cracks has the advantages of high temperature resistance limit, high strain tolerance limit and long service life.
In order to solve the technical problems, the technical scheme adopted by the invention is as follows: the thermal barrier coating containing the surface cracks based on stress regulation is characterized by being prepared by regulating and controlling the peak spraying stress in the preparation process of an APS coating, the thermal barrier coating comprises a ceramic layer, a bonding layer and an alloy substrate layer from the surface to the inner, longitudinal surface cracks penetrating through the thickness direction are periodically distributed in the ceramic layer, and the coating among the surface cracks is a compact low-porosity coating.
The thermal barrier coating containing the surface cracks is prepared by regulating and controlling the peak spraying stress of the coating in the APS coating spraying process, the peak spraying stress in the coating is greatly improved in the stress regulating and controlling process, and then higher heat is input, so that the ceramic layer is melted more thoroughly, gaps and holes in the ceramic layer are filled, the coating between the longitudinal surface cracks is changed into a compact low-pore coating structure from a loose porous layered structure, and compared with the traditional layered APS coating, the thermal barrier coating containing the surface cracks has higher temperature resistance limit, larger strain tolerance and longer service life.
Different from the existing research for preparing the thermal barrier coating containing the surface cracks through accumulated spraying experience (the existing preparation method is obtained based on experience summary and has poor stability), the method establishes the mapping relation between the peak spraying stress and the coating microstructure by relating a simple and clear measurable mechanical parameter (coating spraying stress) of the thermal barrier coating with the surface crack characteristics of the thermal barrier coating through research, and further can determine the microstructure state of the coating according to the peak spraying stress to realize the regulation and control from a loose porous layered microstructure to a compact low-porosity and surface crack microstructure. When the method is used, the peak spraying stress level in the thermal barrier coating spraying process can be directly regulated and controlled, and the coating with the corresponding structure can be prepared.
The thermal barrier coating containing the surface cracks based on stress regulation is characterized In that the ceramic layer is made of zirconia YSZ with yttria partially stabilized, the bonding layer is made of NiCoCrAlY alloy, and the alloy matrix layer is made of In738 or In718 high-temperature alloy.
The thermal barrier coating containing the surface cracks based on stress regulation is characterized in that the thickness of the ceramic layer is 0.3 mm-1.0 mm. According to the invention, the thermal protection performance of the ceramic layer is effectively ensured by controlling the thickness of the ceramic layer, and the preparation of the longitudinal cracks in the ceramic layer is realized, so that the problems that the preparation of the longitudinal surface cracks is difficult and the density of the longitudinal surface cracks is too small due to too large thickness of the ceramic layer are avoided.
The thermal barrier coating containing the surface cracks based on stress regulation is characterized in that the surface cracks longitudinally penetrate along the thickness direction of the ceramic layer and are periodically distributed along the length direction of the ceramic layer, and the density of the surface cracks is not more than 2.2 strips/mm. In the research process, the invention discovers that when the density of the surface cracks along the length direction of the ceramic layer exceeds 2.2 strips/mm, the strength and the strain tolerance of the ceramic layer are reduced, so that the service performance of the ceramic layer is reduced on the contrary, the maximum power restriction of APS spraying equipment is comprehensively considered, the density of the surface cracks is limited not to exceed 2.2 strips/mm, and meanwhile, the regulation and control of the crack density are realized by regulating and controlling the peak spraying stress.
The thermal barrier coating containing the surface cracks based on stress regulation is characterized in that the regulation range of the peak spraying stress is 700MPa to 1200MPa. In the research process of the invention, the correlation exists between the peak spraying stress and the microstructure of the thermal barrier coating, as shown in fig. 1: when the peak spraying stress is less than 500MPa, the correspondingly prepared APS coating is of a traditional layered structure, such as the coatings marked as 1# to 3# in figure 1; when the peak spraying stress is 500MPa to 1200MPa, crack structures are formed in the correspondingly prepared APS coating, such as the coatings marked as 4# to 22# in the graph 1, wherein when the regulation range of the peak spraying stress is about more than 400MPa and not more than 700MPa, the essence of the correspondingly prepared APS coating is a transition state plane strain structure coating, such as the coatings marked as 4# to 8# in the graph 1, because the peak spraying stress is higher than the threshold value of the initiation of the macro cracks but does not reach the critical value of the generation of the macro surface cracks, the coating has a macro fracture line structure distributed along each direction, the service performance of the coating is more consistent with that of a traditional laminated structure, when the regulation range of the peak spraying stress is 700MPa to 1200MPa, the correspondingly prepared APS coating contains surface cracks, and the surface cracks penetrate longitudinally along the thickness direction of the ceramic layer and are distributed periodically along the length direction, and the density of the cracks is increased correspondingly with the increase of the peak spraying stress.
In addition, the invention also discloses a method for preparing the thermal barrier coating containing the surface cracks based on stress control, which is characterized by comprising the following steps:
step one, installing and debugging a spraying stress measuring device: selecting an F4 spray gun as an APS spray gun, placing a spray stress measuring device below the spray gun, adjusting the relative distance, and then debugging to an operable state;
step two, setting spraying parameters: setting the spraying distance of an F4 spray gun to be 80mm to 140mm, and the spraying power to be 32kW to 42kW;
step three, matrix preheating treatment: moving an F4 spray gun to scan and preheat an alloy matrix base plate with a bonding layer, and then performing scanning and preheating circulation for 0 to 10 times to enable the surface temperature of the base plate to reach 500 to 1500 ℃;
step four, spraying and peak stress measurement: scanning within 3s to 10s after preheating circulation is finished in the third step, moving an F4 spray gun to spray ceramic powder on the alloy matrix base plate with the bonding layer to form a ceramic layer, and starting a spraying stress measuring device to perform real-time spraying stress measurement on the ceramic layer;
step five, preparing a thermal barrier coating containing surface cracks: and C, adjusting and optimizing the spraying parameters including the spraying distance and the spraying power according to the peak spraying stress in the real-time spraying stress measurement result in the step four, and continuously spraying to prepare and form the thermal barrier coating containing the surface cracks.
The device for measuring the real-time spraying stress in the invention is a high-temperature heat-proof structure force and heat parameter measuring device disclosed in the patent application No. 202210832072.7, namely a high-temperature heat-proof structure force and heat parameter measuring device and method.
The preparation method of the thermal barrier coating containing the surface cracks based on stress regulation is realized by regulating and controlling parameters on the basis of the original atmospheric plasma spraying method (APS), and the peak spraying stress is regulated by regulating and controlling the spraying parameters including the spraying distance and the spraying power according to the relation between the peak spraying stress and the ceramic layer structure, so that the ceramic layer is prepared, the regulation and control of the thermal barrier coating structure are realized, and the process is simple.
Compared with the prior art, the invention has the following advantages:
1. according to the thermal barrier coating containing the surface cracks, the longitudinal surface cracks which are periodically distributed and penetrate through the thickness direction are introduced into the top layer of the surface ceramic layer of the thermal barrier coating by regulating and controlling the peak spraying stress in the preparation process of the APS coating, and meanwhile, compact low-porosity coatings are formed among the surface cracks, so that the thermal barrier coating containing the surface cracks has the advantages of high temperature resistance limit, high strain tolerance limit and long service life.
2. The width of the surface crack in the thermal barrier coating containing the surface crack based on stress regulation is smaller and is usually less than 10 mu m, compared with the conventional coating thickness of more than 300 mu m, the loss of heat through the surface crack as a heat transmission channel is less, so that the heat insulation performance of the thermal barrier coating is not obviously reduced, the heat insulation performance of the thermal barrier coating is ensured, and the service life of the thermal barrier coating is prolonged.
3. Compared with the method for preparing EB-PVD thermal barrier coating and the like, the method introduces surface cracks into APS coating, the thermal barrier coating containing the surface cracks based on stress regulation can effectively increase the coating thickness and the heat insulation effect, and is suitable for the high-temperature components of the gas turbine which are continuously in service in the high-temperature environment for a long time.
4. The invention develops a preparation method of the thermal barrier coating containing the surface cracks based on stress regulation and control through regulating and controlling parameters on the basis of the original APS technology, and directly measures and controls the parameters according to the real-time spraying stress so as to regulate the peak spraying stress, thereby realizing the regulation and control of the thermal barrier coating structure, and having simple process and convenient and fast regulation and control.
5. The method for measuring the spraying stress in real time in the preparation method of the thermal barrier coating containing the surface cracks is realized by the existing equipment, has low cost and high efficiency, does not need to adopt new equipment, has the advantages of simplicity, rapidness, easy operation, no secondary pollution, economy and environmental protection.
The technical solution of the present invention is further described in detail by the accompanying drawings and examples.
Drawings
FIG. 1 is a plot of peak spray stress of APS versus microstructure of a thermal barrier coating.
Fig. 2 is a schematic cross-sectional structure of a conventional layered thermal barrier coating.
FIG. 3 is a schematic cross-sectional structural view of the thermal barrier coating containing surface cracks based on stress control according to the present invention.
FIG. 4 is a cross-sectional profile of a thermal barrier coating containing surface cracks of example 1 of the present invention.
FIG. 5 is a graph of the real-time spray stress as a function of thickness for a thermal barrier coating containing surface cracks according to example 1 of the present invention.
FIG. 6 is a cross-sectional topographical view of a thermal barrier coating containing surface cracks according to comparative example 1 of the present invention.
Fig. 7 is a graph of real-time spray stress as a function of thickness for a thermal barrier coating containing surface cracks of comparative example 1 of the present invention.
FIG. 8 is a cross-sectional topographical view of the thermal barrier coating of comparative example 2 containing surface cracks in accordance with the present invention.
FIG. 9 is a graph of real-time spray stress as a function of thickness for a thermal barrier coating containing surface cracks of comparative example 2 of the present invention.
Detailed Description
Fig. 2 is a schematic cross-sectional structure diagram of a conventional layered thermal barrier coating, fig. 3 is a schematic cross-sectional structure diagram of a thermal barrier coating containing surface cracks based on stress control, and as can be seen from a comparison between fig. 2 and fig. 3, surface cracks which penetrate through the thickness direction and are periodically distributed along the length direction are periodically distributed in a ceramic layer of the thermal barrier coating containing surface cracks based on stress control, compared with the conventional layered thermal barrier coating, and the coating between the surface cracks is a dense low-porosity coating.
Example 1
The thermal barrier coating containing the surface cracks based on stress regulation and control is prepared by regulating and controlling the peak spraying stress in the preparation process of the APS coating, the thermal barrier coating comprises a ceramic layer, a bonding layer and an alloy substrate layer from the surface to the inner, the ceramic layer longitudinally penetrates along the thickness direction of the ceramic layer, the surface cracks are periodically distributed along the length direction of the ceramic layer, and the coating among the surface cracks is a compact low-porosity coating; the thickness of the ceramic layer is 1.0mm, and the regulation and control range of the peak spraying stress is 700MPa to 1200MPa; the ceramic layer is made of yttria partially stabilized zirconia YSZ, the bonding layer is made of NiCoCrAlY alloy, and the alloy matrix layer is made of In738 high-temperature alloy.
The preparation method of the thermal barrier coating containing the surface cracks based on stress regulation comprises the following steps:
step one, installing and debugging a spraying stress measuring device: selecting an F4 spray gun as an APS spray gun, placing a spray stress measuring device below the spray gun, adjusting the relative distance, and then debugging to an operable state;
step two, setting spraying parameters: setting the spraying distance of an F4 spray gun to be 80mm to 90mm, and setting the spraying power to be 40kW to 42kW;
step three, matrix preheating treatment: moving an F4 spray gun to perform scanning preheating on an alloy matrix base plate with a bonding layer, and performing scanning preheating circulation for 8 to 10 times to enable the surface temperature of the base plate to reach 800-1000 ℃;
step four, spraying and peak stress measurement: scanning within 3s to 5s after preheating circulation is finished in the third step, moving an F4 spray gun to spray ceramic powder on an alloy matrix base plate with a bonding layer to form a ceramic layer, starting a spraying stress measuring device at the same time, and measuring the spraying stress of the ceramic layer in real time, wherein the regulation range of the peak spraying stress in the real-time spraying stress measuring result is 700MPa to 1200MPa;
step five, preparing a thermal barrier coating containing surface cracks: adjusting and optimizing spraying parameters including spraying distance and spraying power according to the peak spraying stress in the real-time spraying stress measurement result in the fourth step to prepare and form the thermal barrier coating containing the surface cracks; the density of surface cracks in the thermal barrier coating containing the surface cracks is 1.8 strips/mm-2.2 strips/mm.
FIG. 4 is a cross-sectional view of the thermal barrier coating with surface cracks of the present embodiment, and it can be seen from FIG. 4 that the coating has a high density of surface cracks, and the coating between the surface cracks is relatively dense and has low porosity.
Fig. 5 is a graph of the real-time spray stress of the thermal barrier coating with surface cracks according to the variation with thickness in this embodiment, and it can be seen from fig. 5 that the thermal barrier coating with higher density and surface cracks in this embodiment has a large peak spray stress, and as the spray continues to be sprayed, i.e., the thickness increases, the surface cracks rapidly propagate, and the peak spray stress rapidly decreases.
The thickness of the ceramic layer in the embodiment can be other values than 1.0mm within the range of 0.3mm to 1.0mm.
Comparative example 1
The thermal barrier coating containing the surface cracks based on stress regulation and control is prepared by regulating and controlling the peak spraying stress in the APS coating preparation process, the thermal barrier coating comprises a ceramic layer, a bonding layer and an alloy substrate layer from the surface to the inner, surface cracks penetrating through the thickness direction are periodically distributed in the ceramic layer, and the coating among the surface cracks is a compact low-porosity coating; the thickness of the ceramic layer is 1.0mm, and the regulation and control range of the peak spraying stress is 500MPa to 700MPa; the ceramic layer is made of yttria partially stabilized zirconia YSZ, the bonding layer is made of NiCoCrAlY alloy, and the alloy matrix layer is made of In738 high-temperature alloy.
The preparation method of the thermal barrier coating containing the surface cracks based on stress regulation comprises the following steps:
step one, installing and debugging a spraying stress measuring device: selecting an F4 spray gun as an APS spray gun, placing a spray stress measuring device below the spray gun, adjusting the relative distance, and then debugging to an operable state;
step two, setting spraying parameters: setting the spraying distance of an F4 spray gun to be 90mm to 100mm, and setting the spraying power to be 36kW to 40kW;
step three, matrix preheating treatment: moving an F4 spray gun to perform scanning preheating on an alloy matrix base plate with a bonding layer, and then performing 4~6 times of scanning preheating circulation to enable the surface temperature of the base plate to reach 500-600 ℃;
step four, spraying and peak stress measurement: scanning within 3s to 5s after preheating circulation is finished in the third step, moving an F4 spray gun to spray ceramic powder on an alloy matrix base plate with a bonding layer to form a ceramic layer, starting a spraying stress measuring device at the same time, and measuring the spraying stress of the ceramic layer in real time, wherein the regulation range of the peak spraying stress in the real-time spraying stress measuring result is 500MPa to 700MPa;
step five, preparing the thermal barrier coating containing the surface cracks: adjusting and optimizing spraying parameters including spraying distance and spraying power according to the peak spraying stress in the real-time spraying stress measurement result in the fourth step to prepare and form the thermal barrier coating containing the surface cracks; the density of surface cracks in the thermal barrier coating containing the surface cracks is 1.0 to 1.4 strips/mm.
Fig. 6 is a cross-sectional morphology of the thermal barrier coating containing surface cracks of the comparative example, and it can be seen from fig. 6 that the coating contains surface cracks, but has a low crack density, and the coating between the surface cracks is relatively dense and has low porosity.
Fig. 7 is a graph of the real-time spray stress as a function of thickness for the thermal barrier coating with surface cracks in this comparative example, and it can be seen from fig. 7 that the thermal barrier coating with a lower density of surface cracks in this comparative example has a lower peak spray stress, and as the spray continues to spray, i.e., the thickness increases, the surface cracks propagate and the peak spray stress slowly decreases.
Comparative example 2
The thermal barrier coating of the comparative example was prepared by the APS method, and included a ceramic layer, a bond coat layer, and an alloy substrate layer from the top and bottom; the thickness of the ceramic layer is 1.0mm, and the regulation range of the peak spraying stress is 0 to 500MPa; the ceramic layer is made of yttria partially stabilized zirconia YSZ, the bonding layer is made of NiCoCrAlY alloy, and the alloy matrix layer is made of In738 high-temperature alloy.
The preparation method of the thermal barrier coating of the comparative example comprises the following steps:
step one, installing and debugging a spraying stress measuring device: selecting an F4 spray gun as an APS spray gun, placing a spray stress measuring device below the spray gun, adjusting the relative distance, and then debugging to an operable state;
step two, setting spraying parameters: setting the spraying distance of an F4 spray gun to be 80mm to 90mm, and the spraying power to be 40kW to 42kW;
step three, matrix preheating treatment: moving an F4 spray gun to perform scanning preheating on an alloy matrix base plate with a bonding layer, and then performing 1~2 times of scanning preheating circulation to enable the surface temperature of the base plate to reach 200-400 ℃;
step four, spraying and peak stress measurement: scanning within 3s to 5s after preheating circulation is finished in the third step, moving an F4 spray gun to spray ceramic powder on an alloy matrix base plate with a bonding layer to form a ceramic layer, starting a spraying stress measuring device at the same time, and measuring the spraying stress of the ceramic layer in real time, wherein the regulation range of the peak spraying stress in the real-time spraying stress measuring result is 0MPa to 500MPa;
step five, preparing the thermal barrier coating containing the surface cracks: adjusting and optimizing spraying parameters including spraying distance and spraying power according to the peak spraying stress in the real-time spraying stress measurement result in the fourth step to prepare and form the thermal barrier coating containing the surface cracks; the density of surface cracks in the thermal barrier coating containing the surface cracks is 0 strip/mm.
FIG. 8 is a cross-sectional morphology of the thermal barrier coating containing surface cracks of the comparative example, and it can be seen from FIG. 8 that the coating is a traditional layered structure, no surface cracks are generated, the coating is relatively loose and porous, and the porosity is high.
Fig. 9 is a graph of the real-time spray stress versus thickness of the thermal barrier coating with surface cracks in this comparative example, and it can be seen from fig. 9 that the thermal barrier coating with the conventional layered structure in this comparative example has very small peak spray stress, and the peak spray stress remains substantially unchanged as the spraying continues, i.e., the thickness increases, and thus surface cracks cannot be generated.
Comparing the example 1 with the comparative example 1~2, it can be seen that there is a correlation between the peak spraying stress and the microstructure of the thermal barrier coating, compared with the APS coating with a cracked transition state plane strain structure prepared with the peak spraying stress ranging from 500mpa to 700mpa in the comparative example 1 and the APS coating with a traditional layered structure prepared with the peak spraying stress ranging from 0mpa to 500mpa in the comparative example 2, the invention introduces periodically distributed surface cracks penetrating through the thickness direction into the top layer of the surface ceramic layer of the thermal barrier coating by regulating the peak spraying stress ranging from 700mpa to 1200mpa in the preparation process of the APS coating, and forms a compact low-porosity coating among the surface cracks, which is beneficial to improving the temperature resistance limit, the strain tolerance and the service life of the thermal barrier coating containing the surface cracks.
The above description is only a preferred embodiment of the present invention, and is not intended to limit the present invention in any way. Any simple modification, change and equivalent changes of the above embodiments according to the technical essence of the invention are still within the protection scope of the technical solution of the invention.
Claims (6)
1. The thermal barrier coating containing the surface cracks based on stress regulation is characterized by being prepared by regulating and controlling the peak spraying stress in the preparation process of an APS coating, the thermal barrier coating comprises a ceramic layer, a bonding layer and an alloy substrate layer from the surface to the inner, longitudinal surface cracks penetrating through the thickness direction are periodically distributed in the ceramic layer, and the coating among the surface cracks is a compact low-porosity coating.
2. The thermal barrier coating containing the surface crack based on the stress control as claimed In claim 1, wherein the ceramic layer is made of yttria partially stabilized zirconia (YSZ), the bonding layer is made of NiCoCrAlY alloy, and the alloy matrix layer is made of In738 or In718 superalloy.
3. The thermal barrier coating containing the surface cracks based on the stress control as claimed in claim 1, wherein the surface cracks penetrate longitudinally along the thickness direction of the ceramic layer and are periodically distributed along the length direction of the ceramic layer, and the density of the surface cracks is not more than 2.2 strips/mm.
4. The thermal barrier coating containing the surface crack based on the stress control as claimed in claim 1, wherein the thickness of the ceramic layer is 0.3mm to 1.0mm.
5. The thermal barrier coating containing the surface cracks based on stress regulation and control as claimed in claim 1, wherein the regulation and control range of the peak spraying stress is from 700MPa to 1200MPa.
6. A method for preparing the thermal barrier coating containing surface cracks based on stress modulation according to any one of claims 1~5, comprising the steps of:
step one, installing and debugging a spraying stress measuring device: selecting an F4 spray gun as an APS spray gun, placing a spray stress measuring device below the spray gun, adjusting the relative distance, and then debugging to an operable state;
step two, setting spraying parameters: setting the spraying distance of an F4 spray gun to be 80mm to 140mm, and the spraying power to be 32kW to 42kW;
step three, matrix preheating treatment: moving an F4 spray gun to perform scanning preheating on an alloy matrix base plate with a bonding layer, and performing scanning preheating circulation for 0 to 10 times to enable the surface temperature of the base plate to reach 500-1500 ℃;
step four, spraying and peak stress measurement: scanning within 3s to 10s after preheating circulation is finished in the third step, moving an F4 spray gun to spray ceramic powder on an alloy matrix base plate with a bonding layer to form a ceramic layer, and simultaneously starting a spraying stress measuring device to carry out real-time spraying stress measurement on the ceramic layer;
step five, preparing the thermal barrier coating containing the surface cracks: and C, adjusting and optimizing the spraying parameters including the spraying distance and the spraying power according to the peak spraying stress in the real-time spraying stress measurement result in the step four, and continuously spraying to prepare and form the thermal barrier coating containing the surface cracks.
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| CN117072253A (en) * | 2023-10-16 | 2023-11-17 | 西安交通大学 | Thermal barrier coating for high-temperature blade of heavy-duty gas turbine and design, manufacture and evaluation methods thereof |
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| CN117072253B (en) * | 2023-10-16 | 2024-01-09 | 西安交通大学 | Thermal barrier coating for high-temperature blade of heavy-duty gas turbine and design, manufacture and evaluation methods thereof |
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| CN115852294B (en) | 2023-08-01 |
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