CN116254496B - Preparation method of thermal barrier coating - Google Patents
Preparation method of thermal barrier coating Download PDFInfo
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- CN116254496B CN116254496B CN202211102359.0A CN202211102359A CN116254496B CN 116254496 B CN116254496 B CN 116254496B CN 202211102359 A CN202211102359 A CN 202211102359A CN 116254496 B CN116254496 B CN 116254496B
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- 239000012720 thermal barrier coating Substances 0.000 title claims abstract description 38
- 238000002360 preparation method Methods 0.000 title claims abstract description 30
- 229910052751 metal Inorganic materials 0.000 claims abstract description 89
- 239000002184 metal Substances 0.000 claims abstract description 89
- 238000010438 heat treatment Methods 0.000 claims abstract description 43
- 238000000576 coating method Methods 0.000 claims abstract description 28
- 239000011248 coating agent Substances 0.000 claims abstract description 26
- 239000000919 ceramic Substances 0.000 claims abstract description 23
- 238000009413 insulation Methods 0.000 claims abstract description 15
- 238000004519 manufacturing process Methods 0.000 claims abstract description 9
- 238000007749 high velocity oxygen fuel spraying Methods 0.000 claims abstract 2
- 238000000034 method Methods 0.000 claims description 60
- 239000007921 spray Substances 0.000 claims description 47
- 238000005488 sandblasting Methods 0.000 claims description 21
- 229910052593 corundum Inorganic materials 0.000 claims description 9
- 239000010431 corundum Substances 0.000 claims description 9
- 239000004576 sand Substances 0.000 claims description 6
- 230000001681 protective effect Effects 0.000 claims description 4
- 238000005422 blasting Methods 0.000 claims description 2
- 239000010410 layer Substances 0.000 description 94
- 230000008569 process Effects 0.000 description 30
- 210000002381 plasma Anatomy 0.000 description 27
- 238000005516 engineering process Methods 0.000 description 15
- 239000007789 gas Substances 0.000 description 12
- 230000003647 oxidation Effects 0.000 description 10
- 238000007254 oxidation reaction Methods 0.000 description 10
- 230000033001 locomotion Effects 0.000 description 9
- 230000003746 surface roughness Effects 0.000 description 9
- 230000009471 action Effects 0.000 description 7
- 238000005507 spraying Methods 0.000 description 6
- 238000009792 diffusion process Methods 0.000 description 5
- 239000011159 matrix material Substances 0.000 description 5
- 239000002245 particle Substances 0.000 description 5
- 239000000843 powder Substances 0.000 description 5
- ATUOYWHBWRKTHZ-UHFFFAOYSA-N Propane Chemical compound CCC ATUOYWHBWRKTHZ-UHFFFAOYSA-N 0.000 description 4
- 229910045601 alloy Inorganic materials 0.000 description 4
- 239000000956 alloy Substances 0.000 description 4
- 238000000151 deposition Methods 0.000 description 4
- 238000005328 electron beam physical vapour deposition Methods 0.000 description 4
- 238000010285 flame spraying Methods 0.000 description 4
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 4
- 238000010290 vacuum plasma spraying Methods 0.000 description 4
- 229910000951 Aluminide Inorganic materials 0.000 description 3
- 239000013078 crystal Substances 0.000 description 3
- 230000007547 defect Effects 0.000 description 3
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- 238000007669 thermal treatment Methods 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 2
- 230000015556 catabolic process Effects 0.000 description 2
- 238000005229 chemical vapour deposition Methods 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
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- 238000010168 coupling process Methods 0.000 description 2
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- 238000000280 densification Methods 0.000 description 2
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- 238000000265 homogenisation Methods 0.000 description 2
- 238000009776 industrial production Methods 0.000 description 2
- 239000003350 kerosene Substances 0.000 description 2
- 239000003345 natural gas Substances 0.000 description 2
- 238000013021 overheating Methods 0.000 description 2
- 238000007750 plasma spraying Methods 0.000 description 2
- 238000007747 plating Methods 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 239000001294 propane Substances 0.000 description 2
- 229910052596 spinel Inorganic materials 0.000 description 2
- 239000011029 spinel Substances 0.000 description 2
- 108091028732 Concatemer Proteins 0.000 description 1
- MYMOFIZGZYHOMD-UHFFFAOYSA-N Dioxygen Chemical compound O=O MYMOFIZGZYHOMD-UHFFFAOYSA-N 0.000 description 1
- 229910000943 NiAl Inorganic materials 0.000 description 1
- NPXOKRUENSOPAO-UHFFFAOYSA-N Raney nickel Chemical compound [Al].[Ni] NPXOKRUENSOPAO-UHFFFAOYSA-N 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
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- 238000005137 deposition process Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 229910001882 dioxygen Inorganic materials 0.000 description 1
- 238000004070 electrodeposition Methods 0.000 description 1
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- 239000000295 fuel oil Substances 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 125000004435 hydrogen atom Chemical class [H]* 0.000 description 1
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- 239000002344 surface layer Substances 0.000 description 1
- 238000010301 surface-oxidation reaction Methods 0.000 description 1
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Classifications
-
- 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
-
- 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
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/02—Pretreatment of the material to be coated
- C23C14/024—Deposition of sublayers, e.g. to promote adhesion of the coating
- C23C14/025—Metallic sublayers
-
- 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
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/02—Pretreatment of the material to be coated
- C23C14/028—Physical treatment to alter the texture of the substrate surface, e.g. grinding, polishing
-
- 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
- C23C4/18—After-treatment
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
- F01D5/288—Protective coatings for blades
-
- 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
The application provides a preparation method of a thermal barrier coating, relates to the technical field of preparation processes of thermal protection coatings, and is designed for solving the problem that a high-performance thermal barrier coating is difficult to manufacture at low cost in the prior art. The preparation method of the thermal barrier coating sequentially comprises the steps of adopting HVOF to prepare a metal bonding layer on the surface of the blade; performing heat treatment on the metal bonding layer by adopting PS-PVD equipment; and preparing the ceramic thermal insulation coating. The preparation method of the thermal barrier coating provided by the application can reduce the production cost and improve the product performance.
Description
Technical Field
The application relates to the technical field of preparation processes of thermal protection coatings, in particular to a preparation method of a thermal barrier coating.
Background
The technology of thermal protection coating of turbine blade is one of the key technologies essential for advanced aeroengines, and along with the continuous elevation of the temperature before turbine and the development and change of high-temperature structural materials, the application of thermal barrier coating (Thermal barrier coatings, TBCs) on the surface of high-temperature alloy structural materials becomes necessary. The thermal barrier coating mainly comprises two parts, namely a metal bonding layer and a ceramic thermal insulation layer, and can be composed of two layers or multiple layers, wherein the metal bonding layer is mainly MCrAlY (M is Ni and/or Co) and aluminide at present, wherein the aluminide is mainly NiAl and NiPtAl, the aluminide coating is mainly prepared by electrodeposition, gas phase permeation or Chemical Vapor Deposition (CVD) and other technologies, and the MCrAlY bonding layer is mainly prepared by supersonic flame spraying (HVOF), atmospheric Plasma Spraying (APS), vacuum Plasma Spraying (VPS), vacuum ARC plating (ARC-PVD), electron beam physical vapor deposition (EB-PVD) and other technologies; the preparation technology of the first-generation MCrAlY coating mainly takes an APS technology as a main part, and as factors such as the matching property of a metal bonding layer and a ceramic heat-insulating coating, the influence of bonding layer oxidation on the service life of the thermal barrier coating and the like are gradually focused, the high-performance metal bonding layer technology with high cost and low efficiency such as VPS and the like is gradually developed as a main part. With the continuous improvement of manufacturing economy, economic affordability and the like of high-performance power systems, low-cost HVOF technology is developed to replace high-cost technology in the fields of aviation, heavy-duty gas turbines and the like, and the high-cost HVOF technology is applied.
The high-velocity oxygen-fuel (HVOF) is a low-cost preparation technique in an atmospheric environment in which powder materials are melted and softened by means of oxygen-kerosene, oxygen-gas (natural gas, propane, hydrogen, etc.) as heat sources, and particles are impacted to a substrate at high speed to form a coating. The controllability of the HVOF preparation process is poor, and the method is mainly characterized in the aspects of atmosphere exchange of jet flow and atmospheric environment, instability of jet flow and the like, so that a metal bonding layer prepared by HVOF spraying exists: (1) the number of unmelted particles is large; (2) certain oxide inclusions exist between the particles and the layers; (3) porosity, particles and flattened inter-particle defects are numerous, resulting in the high temperature service process: (1) the cost is uneven and the microstructure is discontinuous, so that the surface oxidation rate is not continuously diffused by aluminum element to supply oxidation consumption, and a brittle spinel phase is locally and rapidly formed; (2) the interface is uneven, so that when the ceramic thermal insulation layer is suitable for vapor deposition processes, such as EB-PVD and PS-PVD, the influence of limit and oxidation formation TGO (Thermally Grown Oxide ) on the interface stress is obviously increased, and the service life of the coating is influenced; (3) the components and defects cause oxidation in the metal bonding layer in the service process, finally lead to degradation and degradation of mechanical property, thermophysical property and the like of the metal bonding layer, lead to increase of thermal mismatch among layers of the thermal barrier coating, and lead to easy premature peeling failure of the coating.
The Plasma physical vapor deposition technology (PS-PVD) is a new coating preparation technology developed on the basis of low-pressure Plasma Spraying technology (LPPS), has the advantages of APS and EB-PVD, adopts a high-power Plasma spray gun and ultra-low working air pressure, and can quickly gasify spray powder by the generated high-energy Plasma jet, thereby quickly accelerating to more than 2-3 times of sonic velocity, and realizing gas-liquid-solid multiphase composite deposition and quasi-columnar crystal composite structure coating preparation. In the spraying deposition process, the PS-PVD process can realize the effect of coiling plating (non-line-of-sight deposition) under the condition of high energy and high speed by means of plasma expansion flow (with the diameter of 200-400 mm and the length of 1.5-2 m) under the condition of ultralow pressure (5-200 Pa), so that the thickness uniformity of the turbine guide blade, particularly the concatemer guide blade, is greatly improved. In order to improve the efficiency of the preparation process, avoid adopting processes such as VPS, PVD and the like with lower efficiency and higher cost to prepare the metal bonding layer, researchers put forward to prepare the metal bonding layer by adopting an HVOF process, assist in carrying out vacuum diffusion treatment on the metal bonding layer at 900-1100 ℃, improve the component uniformity, microstructure uniformity and compactness of the metal bonding layer and reduce oxidation and interlayer linear defects, so as to improve the high-temperature oxidation resistance of the metal bonding layer and improve the suitability of the ceramic thermal insulation coating, but the vacuum heat treatment increases additional procedures, process cost and preparation period, explores and searches a rapid heat treatment method and a low-cost and high-efficiency metal bonding layer modification way, and is one of key problems to be solved urgently by the researchers at present.
Disclosure of Invention
The first object of the present application is to provide a method for preparing a thermal barrier coating, so as to solve the technical problem that it is difficult to manufacture a high-performance thermal barrier coating with low cost in the prior art.
The application provides a preparation method of a thermal barrier coating, which comprises the steps of adopting an HVOF process to prepare a metal bonding layer on the surface of a blade; performing heat treatment on the metal bonding layer by adopting PS-PVD equipment; and preparing the ceramic thermal insulation coating.
The preparation method of the thermal barrier coating has the beneficial effects that:
the method saves the vacuum heat treatment link, reduces the production cost, combines the heat treatment process equipment and the process of the metal bonding layer with the preparation process technology of the ceramic heat insulation layer, can reduce the porosity of the metal bonding layer, improve the compactness, reduce the surface roughness of the metal bonding layer and improve the high-temperature oxidation resistance of the metal bonding layer, and is suitable for industrial production.
In a preferred technical scheme, the heat treatment of the metal bonding layer by adopting PS-PVD equipment comprises the following steps: clamping the blade in a turntable of PS-PVD equipment, and closing a vacuum cabin door; starting a plasma spray gun, starting a spray gun manipulator and a rotary table under preset technological parameters, and preheating the blades; and after the preset preheating time period, closing the plasma spray gun, and taking out the blade.
In the preferred technical scheme, the preset preheating time for preheating the blade is 2-5 min.
In the preferred technical scheme, when the blade is preheated, he and/or Ar is used as protective gas, the flow rate of Ar is 30 slpm-60 slpm, the flow rate of He is 60 slpm-40 slpm, and the vacuum pressure of the PS-PVD equipment is 200Pa.
In a preferred technical scheme, when the blade is preheated, the current of the plasma spray gun is 2000A-2600A, and the spraying distance is 900 mm-1200 mm.
In a preferred technical scheme, when the blades are preheated, the rotating speed of the blades is 100-200 rpm, the swing amplitude of the plasma spray gun is consistent with the width of the blades, and the swing speed of the plasma spray gun is 30-80 mm/s.
In a preferred embodiment, the plasma torch is perpendicular to the surface of the blade, and the swing of the plasma torch is performed simultaneously with the rotation of the blade.
In the preferred technical scheme, the metal bonding layer is an MCrAlY metal bonding layer prepared on the surface of the hollow blade, and M is Ni and/or Co.
In a preferred technical scheme, after the blade is subjected to heat treatment and before the ceramic thermal insulation coating is prepared, the method further comprises the step of carrying out sand blasting on the metal bonding layer on the surface of the blade.
In a preferred technical scheme, in the sand blasting treatment of the metal bonding layer on the surface of the blade, white corundum sand with 100-400 meshes is adopted for dry sand blasting or wet sand blasting.
Drawings
In order to more clearly illustrate the technical solutions of embodiments or background art of the present application, the drawings that are needed in the description of the embodiments or background art will be briefly described below, and it is apparent that the drawings in the following description are only embodiments of the present application, and that other drawings can be obtained according to the provided drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic flow chart of a method for preparing a thermal barrier coating according to an embodiment of the present application;
FIG. 2 is a cross-sectional morphology of a heat treated metal bond coat in a method for preparing a thermal barrier coating according to an embodiment of the application;
FIG. 3 is a typical cross-sectional morphology of a metallic bond layer prepared by an HVOF process in a method for preparing a thermal barrier coating according to a second embodiment of the present application;
FIG. 4 is a cross-sectional morphology of a heat treated metal bond coat in a method for preparing a thermal barrier coating according to a second embodiment of the present application;
fig. 5 is a cross-sectional morphology of a heat-treated metal bonding layer in a preparation method of a thermal barrier coating according to a third embodiment of the present application.
Detailed Description
In order that the above objects, features and advantages of the application will be readily understood, a more particular description of the application will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It should be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the scope of the application.
FIG. 1 is a schematic flow chart of a method for preparing a thermal barrier coating according to an embodiment of the present application; as shown in FIG. 1, the preparation method of the thermal barrier coating provided by the embodiment of the application comprises the steps of adopting an HVOF process to prepare a metal bonding layer on the surface of a blade; performing heat treatment on the metal bonding layer by adopting PS-PVD equipment; and preparing the ceramic thermal insulation coating.
The blade in the present application may be a blade of a gas turbine engine, and more specifically may be a hollow blade.
Through a high-energy PS-PVD plasma and an instantaneous preheating mode, the mutual diffusion of the metal bonding layer and the blade alloy matrix is realized, and the bonding strength of the coating is improved; meanwhile, under the action of high heat flow, the oxide between the sheet layers further dispersedly strengthens the metal bonding layer, improves the performance of the metal bonding layer, and reduces the oxide content of the metal bonding layer (the oxide content is reduced to below 0.1 percent when evaluated by a metallographic method); the mutual diffusion of the metal bonding layer and the matrix can improve the uniformity of the internal components of the metal bonding layer due to the oxidation of the surface layer of the metal bonding layer in the PS-PVD heat treatment process.
After the rapid heat treatment of PS-PVD, due to the structural characteristics of the air cooling blade, after the high heat flow is input to the surface of the metal bonding layer, a temperature gradient is continuously formed between the surface of the metal bonding layer and the back surface of the thin-wall part of the matrix in the heating process, the temperature gradient causes the formation of a component gradient inside the metal bonding layer in the heat treatment, the oxidation resistance of the metal bonding layer can be improved due to the relatively continuous component gradient of the metal bonding layer, the growth rate of Thermally Grown Oxide (TGO) on the surface of the metal bonding layer in a thermal barrier coating system is further reduced, meanwhile, the generation of brittle spinel phase is reduced, and the service life of the thermal barrier coating system is prolonged.
In a word, this embodiment combines characteristics (major diameter and length, high energy, supersonic) of PS-PVD efflux and characteristics such as hollow blade profile complicacy, thin wall and cavity, designs and uses the quick thermal treatment of adopting PS-PVD efflux to the metal tie coat of hollow blade surface, and this method has saved the vacuum thermal treatment link, has reduced manufacturing cost, combines ceramic insulating layer preparation technology with metal tie coat thermal treatment process equipment and process simultaneously, can reduce metal tie coat porosity and improve the compactness, reduces metal tie coat surface roughness and improves metal tie coat's high temperature oxidation resistance, is suitable for industrial production.
As shown in FIG. 1, the heat treatment of the metal bonding layer using a PS-PVD apparatus preferably includes: clamping the blade in a turntable of PS-PVD equipment, and closing the vacuum cabin door; starting a plasma spray gun, starting a spray gun manipulator and a rotary table under preset technological parameters, and preheating the blades; after the preset preheating time period, the plasma spray gun is closed, and the blade is taken out.
By performing heat treatment on the blade, on which the metal bonding layer has been prepared, in a vacuum state, and by using the swing of the torch robot and the rotation of the turntable, it is possible to make the plasma cover the entire area of the blade surface, improving the heat treatment effect. Specifically, the porosity of the metal bonding layer can be greatly reduced in the heat treatment process, the porosity of the conventional HVOF metal bonding layer is 0.5% -1%, and the porosity of the metal bonding layer can be reduced to below 0.25% in the heat treatment process.
Preferably, the preset preheating time for preheating the blade is 2-5 min.
The preheating time of the blade is controlled to be longer than the preheating time, so that the blade body can be prevented from being overheated. Considering the traditional vacuum heat treatment in the prior art, the total time of heating, cooling and heat preservation is required to reach 12 hours, the preheating method can save the investment of vacuum heat treatment equipment and the time of vacuum heat treatment, the time of preheating and the time of vacuum preparation and workpiece installation and disassembly are only equivalent to less than 1/20 of the total length of the original time, the production efficiency is greatly improved, and the production cost is reduced.
By utilizing the swing gesture, the rapid rotation of the blade and the coupling of the spraying deposition parameters and the pores, the overheating of the blade matrix is avoided, the good homogenization and densification diffusion heat treatment of the metal bonding layer can be realized,
preferably, when the blade is preheated, he and/or Ar is used as protective gas, the flow rate of Ar is 30 slpm-60 slpm, the flow rate of He is 60 slpm-40 slpm, and the vacuum pressure of PS-PVD equipment is 200Pa. The gas flow and the vacuum pressure are the gas flow and the vacuum pressure after the arc starting. As the flow rate of Ar increases, the flow rate of He may correspondingly decrease.
He and Ar are adopted as protective gases, and under the flow and vacuum pressure, proper amount of plasmas can be generated to carry out heat treatment on the metal bonding layer on the surface of the blade, and the quality of the thermal barrier coating system can be ensured not to be reduced due to the generation of new oxides in the heat treatment process.
Preferably, the current of the plasma torch is 2000A to 2600A and the spraying distance is 900mm to 1200mm when preheating the blade.
Preferably, when the blade is preheated, the rotation speed of the blade is 100rpm to 200rpm, the swing amplitude of the plasma torch is consistent with the width of the blade, and the swing speed of the plasma torch is 30mm/s to 80mm/s.
Compared with the rotating speed in the common ceramic thermal insulation coating preparation process, the rotating speed of the blade is increased by more than one time, the swinging speed of the plasma spray gun is relatively low, and the swing gesture, the rapid rotation of the blade and the spray deposition parameter coupling pore are utilized to prevent the overheating of the blade matrix, and simultaneously ensure that the metal bonding layer can realize good homogenization and densification diffusion heat treatment.
Preferably, the plasma torch is perpendicular to the surface of the blade, and the swing of the plasma torch is performed simultaneously with the rotation of the blade.
Preferably, the metal bonding layer is an MCrAlY metal bonding layer prepared on the surface of the hollow blade, and M is Ni and/or Co.
As shown in FIG. 1, it is preferable to further include sand blasting the metallic bond coat on the blade surface after the heat treatment of the blade and before the ceramic thermal barrier coating is prepared.
Specifically, the sand blasting treatment can comprise shot blasting, sand blasting and other modes, and the surface oxide film after the heat treatment is removed by adopting the mode, so that the surface roughness of the metal bonding layer is reduced, and finally, the performance of the thermal barrier coating system is improved. In addition, the rate of TGO (Thermally Grown Oxide ) growth can also be reduced while the tie coat is in service.
Preferably, in the sand blasting treatment of the metal bonding layer on the surface of the blade, white corundum sand of 100-400 meshes is adopted for dry sand blasting or wet sand blasting.
Embodiment one:
in the embodiment, the blade is a twin guide blade with a gas film hole, the metal bonding layer is made of NiCrAlY metal powder, a HVOF process is adopted to spray a coating on the surface of the hollow blade, the thickness is 30-100 mu m, and a PS-PVD process is adopted to carry out heat treatment on the metal bonding layer on the surface of the blade:
step one: coarsening treatment and preparation of a metal bonding layer:
adopting 60-mesh white corundum to coarsen the surface of the twin hollow blade under the condition of 0.3 MPa; preparing a metal bonding layer with the thickness of 30-100 mu m on the surface of the blade by adopting an oxygen-fuel gas (propane) supersonic flame spraying system.
Step two: clamping the blade, and setting motion parameters:
the method comprises the steps of clamping a blade on a rotary table of PS-PVD equipment, setting the rotation speed of the rotary table to be 200rpm through a manipulator demonstrator, setting the distance from the front end of a spray gun clamped by the manipulator to the blade to be 1200mm, enabling the swinging speed of the manipulator to be 80mm/s, and enabling the widest width of the blade facing the spray gun under any rotation angle to be the swinging width of the spray gun, namely, enabling the spray gun to swing left and right in a starting and stopping position of the physical center of the spray gun; the posture of the spray gun is vertical to the hollow blade; the swing track of the spray gun is at the center line position in the vertical direction of the blade.
Step three: opening equipment, setting technological parameters, and thermally treating a metal bonding layer of the blade:
starting PS-PVD equipment, and starting an arc of a plasma spray gun under 3500Pa, wherein the arc starting current is 800A, and the Ar flow is 80slpm during arc starting; the procedure runs according to the set parameters after the arc starting, specifically, the vacuum pressure is 200Pa, the Ar flow is 30slpm, the He flow is 60slpm, the spray gun current is 2600A during heat treatment, the parameters are controlled to reach the set values, a mechanical arm movement button is started, the mechanical arm performs actions according to the preset movement parameters in the second step, and the preset preheating time is 2min.
Step four: stopping the heat treatment and taking out the blade:
and after the preheating time is up, closing the plasma spray gun, when the surface temperature of the blade is lower than 600 ℃, closing the mechanical arm and the rotary table to move, backfilling Ar until the pressure in the vacuum chamber is 3500Pa, respectively filling Ar and air until the pressure in the vacuum chamber is atmospheric pressure, and taking out the hollow blade.
Step five: sand blasting:
selecting 400-mesh white corundum sand grains, and carrying out dry sand blasting treatment on the thermally treated blade under the condition of 0.2 MPa.
Step six: preparing a ceramic heat insulation layer according to the requirement:
and spraying and depositing a ceramic thermal insulation coating according to a ceramic thermal insulation layer preparation process and a PS-PVD process.
The surface roughness of the NiCrAlY bonding layer sprayed by the HVOF process is Ra:5.6 μm; porosity is 0.67%; the oxide content was 0.92%. The cross-sectional morphology of the heat-treated metal bonding layer by the process of example one is shown in fig. 2, and the surface roughness of the heat-treated NiCrAlY bonding layer is Ra:4.73 μm, roughness after sandblasting is Ra:3.2 μm; the porosity of the coating was 0.12% and the cross-sectional oxide content was 0.09%.
Embodiment two:
in the embodiment, the blade is a single-linked single-crystal alloy guide blade with a gas film hole, the metal bonding layer is NiCoCrAlY metal powder, a HVOF process is adopted to spray a coating on the surface of the hollow blade, the thickness is 40-80 mu m, and a PS-PVD process is adopted to carry out heat treatment on the metal bonding layer on the surface of the blade:
step one: coarsening treatment and preparation of a metal bonding layer:
adopting 60-mesh white corundum to coarsen the surface of the twin hollow blade under the condition of 0.2 MPa; specifically, an oxygen-fuel oil (aviation kerosene) supersonic flame spraying system is adopted to prepare a metal bonding layer with the thickness of 40-80 mu m on the surface of the blade.
Step two: clamping the blade, and setting motion parameters:
the method comprises the steps of clamping a blade on a turntable of PS-PVD equipment, setting the rotating speed of the turntable to be 100rpm through a manipulator demonstrator, setting the distance from the front end of a spray gun clamped by the manipulator to the blade to be 900mm, wherein the swinging speed of the manipulator is 30mm/s, and the widest amplitude of the blade facing the spray gun under any rotating angle is the swinging amplitude of the spray gun, namely the left-right swinging start-stop position of the physical center of the spray gun; the posture of the spray gun is vertical to the hollow blade; the swing track of the spray gun is at the center line position in the vertical direction of the blade.
Step three: opening equipment, setting technological parameters, and thermally treating a metal bonding layer of the blade:
starting PS-PVD equipment, and starting an arc of a plasma spray gun under 3500Pa, wherein the arc starting current is 1000A, and the Ar flow is 100slpm during arc starting; the procedure runs according to the set parameters after the arc starting, specifically, the vacuum pressure is 200Pa, the Ar flow is 60slpm, the He flow is 40slpm, the spray gun current is 2000A during heat treatment, the parameters are controlled to reach the set values, a mechanical arm movement button is started, the mechanical arm performs actions according to the preset movement parameters in the second step, and the preset preheating time is 5min.
Step four: stopping the heat treatment and taking out the blade:
and after the preheating time is up, closing the plasma spray gun, when the surface temperature of the blade is lower than 400 ℃, closing the mechanical arm and the rotary table to move, backfilling Ar until the pressure in the vacuum chamber is 3500Pa, respectively filling Ar and air until the pressure in the vacuum chamber is atmospheric pressure, and taking out the hollow blade.
Step five: sand blasting:
selecting 100-mesh white corundum sand grains, and carrying out wet sand blasting treatment on the thermally treated blade under the condition of 0.1 MPa.
Step six: preparing a ceramic heat insulation layer according to the requirement:
according to the preparation process of the ceramic heat-insulating layer, the PS-PVD is sprayed to deposit the ceramic heat-insulating coating.
The cross-sectional morphology of the NiCoCrAlY bonding layer sprayed by the HVOF process is shown in figure 3, and the surface roughness is Ra:5.9 μm; porosity is 0.5%; the oxide content was 1.3%. The cross-sectional morphology of the metal bonding layer after the heat treatment step in the second embodiment is shown in fig. 4, and the surface roughness of the NiCoCrAlY bonding layer after the heat treatment is Ra:4.53 μm, roughness after sandblasting is Ra:3.0 μm; the porosity of the coating was 0.15% and the cross-sectional oxide content was 0.08%.
Embodiment III:
in the embodiment, the blade is a gas turbine single crystal alloy working blade with a gas film hole, the metal bonding layer is NiCrAlYSi metal powder, a HVOF process is adopted to spray a coating on the surface of the hollow blade, the thickness of the metal bonding layer is 100-150 mu m, and a PS-PVD process is adopted to carry out heat treatment on the metal bonding layer on the surface of the blade:
step one: coarsening treatment and preparation of a metal bonding layer:
coarsening the surface of the twin hollow blade by adopting 120-mesh white corundum under the condition of 0.3MPa, and preparing a metal bonding layer with the thickness of 100-150 mu m on the surface of the blade by adopting an oxygen-fuel gas (natural gas) supersonic flame spraying system.
Step two: clamping the blade, and setting motion parameters:
the method comprises the steps of clamping a blade on a turntable of PS-PVD equipment, setting the rotating speed of the turntable to be 120rpm through a manipulator demonstrator, setting the distance from the front end of a spray gun clamped by the manipulator to the blade to be 1000mm, setting the swinging speed of the manipulator to be 50mm/s, and setting the widest amplitude of the blade facing the spray gun under any rotating angle to be the swinging amplitude of the spray gun, namely the left-right swinging start-stop position of the physical center of the spray gun; the posture of the spray gun is vertical to the hollow blade; the swing track of the spray gun is at the center line position in the vertical direction of the blade.
Step three: opening equipment, setting technological parameters, and thermally treating a metal bonding layer of the blade:
starting PS-PVD equipment, and starting an arc of a plasma spray gun under 3500Pa, wherein the arc starting current is 1000A, and the Ar flow is 100slpm during arc starting; the procedure runs according to the set parameters after the arc is started, specifically, the vacuum pressure is 200Pa, the Ar flow is 40slpm, the He flow is 50slpm, the spray gun current is 2200A during heat treatment, the parameters are controlled to reach the set values, a mechanical arm movement button is started, the mechanical arm performs actions according to the preset movement parameters in the second step, and the preset preheating time is 2.5min.
Step four: stopping the heat treatment and taking out the blade:
and after the preheating time is up, closing the plasma spray gun, when the surface temperature of the blade is lower than 400 ℃, closing the mechanical arm and the rotary table to move, backfilling Ar until the pressure in the vacuum chamber is 3500Pa, respectively filling Ar and air until the pressure in the vacuum chamber is atmospheric pressure, and taking out the hollow blade.
Step five: sand blasting:
and selecting 300-mesh white corundum sand grains, and carrying out dry sand blasting treatment on the thermally treated blade under the condition of 0.1 MPa.
Step six: preparing a ceramic heat insulation layer according to the requirement:
according to the preparation process of the ceramic heat-insulating layer, the PS-PVD is sprayed to deposit the ceramic heat-insulating coating.
The cross-sectional morphology of the NiCrAlYSi bonding layer sprayed by the HVOF process is shown in figure 1, and the surface roughness is Ra:6.1 μm; porosity is 0.42%; the oxide content was 0.65%. The cross-sectional morphology of the metal bonding layer after heat treatment in example 3 is shown in fig. 5, and the surface roughness of the NiCrAlYSi bonding layer after heat treatment is Ra:4.95 μm, roughness after sandblasting is Ra:3.7 μm; the porosity of the coating was 0.12% and the cross-sectional oxide content was 0.099%.
Although the present application is disclosed above, the present application is not limited thereto. Various changes and modifications may be made by one skilled in the art without departing from the spirit and scope of the application, and the scope of the application should be assessed accordingly to that of the appended claims.
Finally, it is further noted that relational terms such as first and second, and the like are used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Moreover, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one … …" does not exclude the presence of other like elements in a process, method, article, or apparatus that comprises the element.
In the above embodiments, descriptions of orientations such as "up", "down", and the like are shown based on the drawings.
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the application.
Thus, the present application is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims (8)
1. The preparation method of the thermal barrier coating is characterized by comprising the steps of adopting HVOF to prepare a metal bonding layer on the surface of a blade; performing heat treatment on the metal bonding layer by adopting PS-PVD equipment; preparing a ceramic thermal insulation coating; the heat treatment of the metal bonding layer by using PS-PVD equipment comprises the following steps: clamping the blade in a turntable of PS-PVD equipment, and closing a vacuum cabin door; starting a plasma spray gun, starting a spray gun manipulator and a rotary table under preset technological parameters, and preheating the blades; after the preset preheating time period, closing the plasma spray gun, and taking out the blade;
and when the blade is preheated, adopting He and/or Ar as protective gas, wherein the flow rate of Ar is 30 slpm-60 slpm, the flow rate of He is 60 slpm-40 slpm, and the vacuum pressure of the PS-PVD equipment is 200Pa.
2. The method for preparing a thermal barrier coating according to claim 1, wherein the preset preheating time period for preheating the blade is 2-5 min.
3. The method for producing a thermal barrier coating according to claim 2, wherein the plasma torch has a current of 2000A to 2600A and a spray distance of 900mm to 1200mm when preheating the blade.
4. A method of producing a thermal barrier coating according to claim 1 or 3, characterized in that the rotational speed of the blade is 100 rpm-200 rpm, the swing amplitude of the plasma torch is identical to the width of the blade, and the swing speed of the plasma torch is 30 mm/s-80 mm/s when the blade is preheated.
5. The method of producing a thermal barrier coating according to claim 1, wherein the plasma torch is perpendicular to the surface of the blade, and the swinging of the plasma torch is performed simultaneously with the rotation of the blade.
6. The method for preparing the thermal barrier coating according to claim 1, wherein the metal bonding layer is an MCrAlY metal bonding layer prepared on the surface of the hollow blade, and M is Ni and/or Co.
7. The method of producing a thermal barrier coating according to any one of claims 1-6, further comprising sand blasting a metallic bond coat of the blade surface after heat treating the blade and before producing a ceramic thermal barrier coating.
8. The method of producing a thermal barrier coating according to claim 7, wherein, in the case of the blade
In the sand blasting treatment of the metal bonding layer on the surface, white corundum sand with 100-400 meshes is adopted,
dry or wet blasting is performed.
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