不同粘结层材料的PS-PVD热障涂层热震性能
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摘要
为探索不同粘结层材料对等离子喷涂-物理气相沉积(PS-PVD) YSZ陶瓷层的热震性能的影响,采用PS-PVD工艺在DZ40M高温合金上制备了NiCoCrAlYTa和NiCrAlY两种不同的金属粘结层及YSZ陶瓷层,用SEM及XRD等方法表征两种粘结层表面沉积的YSZ陶瓷层的形貌结构、显微硬度及物相,研究了两种涂层的1100℃水淬热震性能及失效模式.结果表明:PS-PVD制备的NiCoCrAlYTa和NiCrAlY两种粘结层均非常致密,陶瓷层均为典型羽毛型柱状结构;NiCoCrAlYTa-7YSZ和NiCrAlY-7YSZ两种羽柱状陶瓷层的孔隙率分别为16.1%和16.5%,显微硬度HV_(0.025)分别为615.8和683.6;陶瓷层的形貌结构及孔隙率、硬度等基本性能,对粘结层成份差异不敏感.1100℃水淬试验结果表明,NiCrAlY-7YSZ涂层的抗热震性能优于NiCoCrAlYTa-7YSZ涂层.失效模式是涂层在频繁的低温-高温热循环中羽柱状陶瓷层内部裂纹萌生和扩展,以及表面花菜头先剥落形成点蚀坑.随着热震次数增加,更多的点蚀坑随机出现并扩大,进而相连后形成大面积剥落区.
In order to explore the influence of different bond coating materials on the thermal shock performance of YSZ ceramic coating prepared by plasma spray-physical vapor deposition(PS-PVD), two different NiCoCrAlYTa and NiCrAlY bond coatings and YSZ ceramic coating were prepared on DZ40 M superalloy by PS-PVD process.The bond coating and YSZ ceramic coating were characterized by SEM and XRD.The morphology, microhardness and phase of the YSZ ceramic coating deposited on the surface of the two bond coatings were characterized.The thermal shock performance at 1100 °C and failure mode was studied for the two coatings.The results show that the two bond coatings of NiCoCrAlYTa and NiCrAlY prepared by PS-PVD are very dense, and ceramic coatings are typical feather-like columnar structures.The porosity of NiCoCrAlYTa-7 YSZ and NiCrAlY-7 YSZceramic coatings are 16.1% and 16.5%, respectively.The microhardness HV_(0.025) is 615.8 and 683.6, respectively.The coating structure, porosity and hardness of YSZ ceramic are not sensitive to differences in bond-coating composition.The water quenching test at 1100 °C showed that the thermal shock resistance of NiCrAlY-7 YSZ coating was better than that of NiCoCrAlYTa-7 YSZ coating.The failure mode is that during the frequent low-temperature-high temperature thermal cycle, the cracks inside the feather-like columnar structure begin to be generated and expanded, and the surface of the cauliflower head is first peeled off to form pitting pits.As the number of thermal shocks increases, more pitting pits appear randomly and expand, and then connect to form a large-area spalling zone.
In order to explore the influence of different bond coating materials on the thermal shock performance of YSZ ceramic coating prepared by plasma spray-physical vapor deposition(PS-PVD), two different NiCoCrAlYTa and NiCrAlY bond coatings and YSZ ceramic coating were prepared on DZ40 M superalloy by PS-PVD process.The bond coating and YSZ ceramic coating were characterized by SEM and XRD.The morphology, microhardness and phase of the YSZ ceramic coating deposited on the surface of the two bond coatings were characterized.The thermal shock performance at 1100 °C and failure mode was studied for the two coatings.The results show that the two bond coatings of NiCoCrAlYTa and NiCrAlY prepared by PS-PVD are very dense, and ceramic coatings are typical feather-like columnar structures.The porosity of NiCoCrAlYTa-7 YSZ and NiCrAlY-7 YSZceramic coatings are 16.1% and 16.5%, respectively.The microhardness HV_(0.025) is 615.8 and 683.6, respectively.The coating structure, porosity and hardness of YSZ ceramic are not sensitive to differences in bond-coating composition.The water quenching test at 1100 °C showed that the thermal shock resistance of NiCrAlY-7 YSZ coating was better than that of NiCoCrAlYTa-7 YSZ coating.The failure mode is that during the frequent low-temperature-high temperature thermal cycle, the cracks inside the feather-like columnar structure begin to be generated and expanded, and the surface of the cauliflower head is first peeled off to form pitting pits.As the number of thermal shocks increases, more pitting pits appear randomly and expand, and then connect to form a large-area spalling zone.
引文
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[2] PADTURE N P,GELL M,JORDAN E H.Thermalbarrier coatings for gas-turbine engine applications [J].Science,2002,296(12):280-284.
[3] CLARKE D R,OECHSNER M,PADTURE N P.Thermal-barrier coatings for more efficient gas-turbine engines [J].MRS Bulletin,2012,37:891-898.
[4] ANDI M L,TUAN LG,GIULIANO G,et al.High-temperature vibration damping of thermal barrier coating materials[J].Surface and Coatings Technology,2007,202(4-7):693-697
[5] 郑蕾,郭洪波,郭磊,等.新一代超高温热障涂层研究[J].航空材料学报,2012,32 (6):14-24.
[6] 周益春,刘奇星,杨丽,等.热障涂层的破坏机理与寿命预测[J].固体力学学报,2010,31(5):504-531.
[7] VON N K,GINDRAT M.Plasma spray-PVD:a new thermal spray process to deposit out of the vapor phase[J].Journal of Thermal Spray Technology,2011,20(4):736-743.
[8] SAMPATH S,SCHULZ U,JARLIGO M O,et al.Processing science of advanced thermal-barrier systems [J],MRS Bulletin,2012,37:903-910.
[9] SHINOZAWA A,EGUCHI K,KAMBARA M,et al.Feather-like structured YSZ coatings at fast rates by plasma spray physical vapor deposition [J].Journal of Thermal Spray Technology,2010,19(1-2):190-197.
[10] MAUER G,HOSPACH A,VABEN R.Process development and coating characteristics of plasma spray-PVD [J].Surface and Coatings Technology,2013,220(1):219-224.
[11] GORAL M,KOTOWSKI S,NOWOTNIK A,et al.PS-PVD deposition of thermal barrier coatings [J].Surface and Coatings Technology,2013,237(1):51-55.
[12] MAO J,DENG Z Q,LIU M,et al.Regional characteristics of YSZ coating prepared by expanded Ar/He/H plasma jet at very low pressure[J],Surface and Coatings Technology,2017,328:240-247.
[13] DENG Z Q,MAO J,LIU M,et al.Regional characteristic of 7YSZ coatings prepared by PS-PVD technique [J].Rare Metals,doi:s12598-018-1041-y.
[14] MAO J,LIU M,DENG C G,et al.Preparation and distribution analysis of thermal barrier coatings deposited on multiple vanes by plasma spray-physical vapor deposition technology [J].Journal of Engineering Materials and Technology,2017,139(4):041003.
[15] 陈亚军,林晓娉,王志平,等.超音速火焰喷涂MCrAlY 粘结层对热障涂层热震性能的影响[J].材料热处理学报,2010,31 (11):155-160.
[16] 孙文改,王汉功,孙淑玲.锆酸镧热障涂层的热震性能研究[J].热加工工艺,2010,39(14):66-68.
[17] ZHU W,ZHANG Z B,YANG L,et al.Spallation of thermal barrier coatings with real thermally grown oxide morphology under thermal stress [J].Materials and Design,2018,146(15):180-193.
[18] RABIEI A,EVANS A G.Failure mechanisms associated with the thermally grown oxide in plasma-sprayed thermal coatings[J].Acta Materialia,2000,48(15):3963-3976
[19] SHEN Zaoyu,HE Limin,XU Zhenhua,et al.Rare earth oxides stabilized La2Zr2O7 TBCs:EB-PVD,thermal conductivity and thermal cycling life[J].Surface and Coatings Technology,2019,357(15):427-432.
[20] LIM L Y,MEGUID S A.Temperature dependent dynamic growth of thermally grown oxide in thermal barrier coatings[J].Materials and Design,2019,164(15):107543.