摘要
悬浮液等离子喷涂(SPS)解决了纳米尺度粉末输送困难的问题,在热喷涂领域得到了快速发展。介绍了悬浮液等离子喷涂的原理和特点,综述了不同工艺条件对热障涂层结构的影响:降低弧电压的波动可以提高SPS工艺的可控性;降低喷枪功率、降低悬浮液浓度、增大喷涂距离,可实现涂层由垂直裂纹结构向柱状晶结构的演变;降低表面粗糙度可提高柱状晶的均匀性;溶剂为乙醇、溶质粒度分布合理的悬浮液更容易获得柱状晶结构。总结了SPS制备热障涂层产生垂直裂纹结构和类柱状晶结构的机理,认为在相同表面粗糙度下,熔滴尺寸和切向速度是影响涂层结构的关键。SPS-8YSZ涂层的隔热性能和热循环性能较好,具有良好的应用前景。
Suspension plasma spray(SPS) technology develops quickly in the field of thermal spray due to solving the difficulty of transporting nano-powders. The processing principles and characteristics of SPS were introduced and the effects of different processing parameters on the structure of SPS thermal barrier coatings were summarized. Decreasing the fluctuation of arc voltage could enhance the controllability of SPS processing, and lowering down the power of plasma torch and concentration of suspension and increasing spray distance could all achieve the evolvement of dense vertical crack structure to column-like structure. The homogeneity of columns could be enhanced by lowering down the surface roughness. Suspension with reasonable distribution of solute and ethanol as solvent was more likely to obtain a column-like structure. The deposition mechanism of SPS dense vertical crack coatings and column-like structure coatings was concluded. When the surface roughness is kept the same, size and tangential velocity of molten droplets are the key factors that impact the microstructure of coatings, while surface roughness influences column-like structure the most. SPS-8 YSZ coating has a relatively good thermal insulation property and thermal cycling lifetime as well as a promising application.
引文
[1]MAUER G,GUIGNARD A,VA?EN R,et al.Process diagnostics in suspension plasma spraying[J].Surface&coatings technology,2010,204(4):961-966.
[2]TANG Z,KIM H,YAROSLAVSKI I,et al.Novel thermal barrier coatings produced by axial suspension plasma spray[C]//International thermal spray 2011.Hamburg:ASM International,2011:593-597.
[3]ZHOU Z H,DONOGHUE J,CURRY N,et al.A comparative study on the performance of suspension plasma sprayed thermal barrier coatings with different bond coat systems[J].Surface&coatings technology,2015,275(8):276-282.
[4]CURRY N,TANG Z L,MARKOCSAN N,et al.Influence of bond coat surface roughness on the structure of axial suspension plasma spray thermal barrier coatingsthermal and lifetime performance[J].Surface&coatings technology,2015,268(25):15-23.
[5]GANVIR A,CALINAS R F,MARKOCSAN N,et al.Experimental visualization of microstructure evolution during suspension plasma spraying of thermal barrier coatings[J].Journal of the European Ceramic Society,2018,365:894.
[6]MEILLOT E,DAMIANI D,VINCENT S,et al.Analysis by modeling of plasma flow interactions with liquid injection[J].Surface and coatings technology,2013,220(4):149-156.
[7]CARUYER C,VINCENT S,MEILLOT E,et al.Modeling the first instant of the interaction between a liquid and a plasma jet with a compressible approach[J].Surface&coatings technology,2010,205(4):974-979.
[8]MARCHAND C,VARDELLE A,MARIAUX G,et al.Modelling of the plasma spray process with liquid feedstock injection[J].Surface&coatings technology,2008,202(6):4458-4464.
[9]SOYSAL D,ANSAR A.A new approach to understand liquid injection into atmospheric plasma jets[J].Surface&coatings technology,2013,220(4):187-190.
[10]DAMIANI D,TARLET D,MEILLOT E.A particle-tracking-velocimetry(PTV)investigation of liquid injection in a dc plasma jet[J].Journal of thermal spray technology,2013,23(3):340-353.
[11]PATEYRON B,CALVE N,PAW?OWSKI L.Influence of water and ethanol on transport properties of the jets used in suspension plasma spraying[J].Surface&coatings technology,2013,220(15):257-260.
[12]TOMA F L,BERTRAND G,KLEIN D,et al.Development of photocatalytic active Ti O2 surfaces by thermal spraying of nanopowders[J].Journal of nanomaterials,2014,2008(1):58.
[13]DARUT G,VALETTE S,MONTAVON G,et al.Comparison of Al2O3 and Al2O3-Ti O2 coatings manufactured by aqueous and alcoholic suspension plasma spraying[C]//International thermal spray 2010.Singapore:ASM international,2010:212-217.
[14]JOULIA A,BOLELLI G,GUALTIERI E,et al.comparing the deposition mechanisms in suspension plasma spray(SPS)and solution precursor plasma spray(SPPS)Deposition of yttria-stabilized zirconia(YSZ)[J].Journal of the European Ceramic Society,2014,34(15):3925-3940.
[15]LI D C,FENG J W,ZHAO H Y,et al.Microstructure formed by suspension plasma spraying:from YSZ splat to coating[J].Ceramics international,2017,43(10):7488-7496.
[16]PAWLOWSKI L.Suspension and solution thermal spray coatings[J].Surface&coatings technology,2009,203(19):2807-2829.
[17]ESPALLARGAS N.Future development of thermal spray coatings[M].Cambridge:Wood Head,2015:81-122.
[18]GUPTA M,MARKOCSAN N,LI X H,et al.Improving the lifetime of suspension plasma sprayed thermal barrier coatings[J].Surface&coatings technology,2017,332(12):550-559.
[19]FAUCHAIS P,VARDELLE M,GOUTIER S,et al.Key challenges and opportunities in suspension and solution plasma spraying[J].Plasma chemistry and plasma process,2015,35(3):511-525.
[20]SALAS R E,RAT V,COUDERT J F,et al.Influence of plasma instabilities in ceramic suspension plasma spraying[J].Journal of thermal spray technology,2007,16(5/6):857-865.
[21]CHEN D Y,JORDAN E H,GELL M.Microstructure of suspension plasma spray and air plasma spray Al2O3-ZrO2composite coatings[J].Journal of thermal spray technology,2009,18(3):421-426.
[22]WANG C H,WANG Y,FAN S,et al.Optimized functionally graded La2Zr2O7/8YSZ thermal barrier coatings fabricated by suspension plasma spraying[J].Journal of alloys and compounds,2015,649(37):1182-1190.
[23]DARUT G,AGEORGES H,DENOIRJEAN A,et al.Tribological performances of YSZ composite coatings manufactured by suspension plasma spraying[J].Surface&coatings technology,2013,217(2):172-180.
[24]GONG S,VANEVERY K,WANG H,et al.Microstructure and thermal properties of inflight rare-earth doped thermal barriers prepared by suspension plasma spray[J].Journal of the European Ceramic Society,2014,34(5):1243-1253.
[25]SCHLEGEL N,EBERT S,MAUER G,et al.Columnar-structured Mg-Al-spinel thermal barrier coatings(TBCs)by suspension plasma spraying(SPS)[J].Journal of thermal spray technology,2015,24(1/2):144-151.
[26]GUIGNARD A,MAUER G,VA?EN R,et al.Deposition and characteristics of submicrometer-structured thermal barrier coatings by suspension plasma spraying[J].Journal of thermal spray technology,2012,21(3/4):416-424.
[27]TARASI F,MEDRAJ M,DOLATABADI A,et al.Effective parameters in axial injection suspension plasma spray process of alumina-zirconia ceramics[J].Journal of thermal spray technology,2008,17(5/6):685-691.
[28]CHEN X L,OHNUKI T,KURODA S,et al.Columnar and DVC-Structured thermal barrier coatings deposited by suspension plasma spray:high-temperature stability and their corrosion resistance to the molten salt[J].Ceramics international,2016,42(15):16822-16832.
[29]CHEN X L,KURODA S,OHUNUKI T,et al.Effects of processing parameters on the deposition of yttria partially stabilized zirconia coating during suspension plasma spraying[J].Journal of america ceramic society,2016,99(11):3546-3555.
[30]CARPIO P,BLOCHET Q,PATEYRON B,et al.Correlation of thermal conductivity of suspension plasma sprayed yttria stabilized zirconia coatings with some microstructural effects[J].Materials letters,2013,107(3):370-373.
[31]CARPIO P,SALVADOR M D,BORRELL A,et al.Alumina-zirconia coatings obtained by suspension plasma spraying from highly concentrated aqueous suspensions[J].Surface&coatings technology,2016,307(12):713-719.
[32]CURRY N,EVERY K V,SNYDER T,et al.Performance testing of suspension plasma sprayed thermal barrier coatings produced with varied suspension parameters[J].Coatings,2015,5(7):338-356.
[33]RAMPON R,MARCHAND O,FILIATRE C,et al.Influence of suspension characteristics on coatings microstructure obtained by suspension plasma spraying[J].Surface&coating technology,2008,202(18):4337-4342.
[34]SOKO?OWSKI P,NYLEN P,MUSALEK R,et al.The Microstructural studies of suspension plasma sprayed zirconia coatings with the use of high-energy plasma torches[J].Surface&coatings technology,2017,318(3):250-261.
[35]SOKO?OWSKI P,KOZERSKI S,PAW?OWSKI L,et al.The key process parameters influencing formation of columnar microstructure in suspension plasma sprayed zirconia coatings[J].Surface&coatings technology,2014,260(11):97-106.
[36]FAN W,BAI Y,LI J R,et al.Microstructural design and properties of supersonic suspension plasma sprayed thermal barrier coatings[J].Journal of alloys and compounds,2017,699(3):763-774.
[37]CARPIO P,BANNIER,SALVADOR M D,et al.Effect of particle size distribution of suspension feedstock on the microstructure and mechanical properties of suspension plasma spraying YSZ coatings[J].Surface&coatings technology,2015,268(4):293-297.
[38]BERNARD B,BIANCHI L,MALIéA,et al.Columnar suspension plasma sprayed coating microstructure control for thermal barrier coating application[J].Journal of the European Ceramic Society,2016,36(4):1081-1089.
[39]VANEVERY K,KRANE M J,TRICE R W,et al.Column formation in suspension plasma-sprayed coatings and resultant thermal properties[J].Journal of thermal spray technology,2011,20(4):817-828.
[40]?ATKA L,CATTINI A,PAW?OWSKI L,et al.Thermal diffusivity and conductivity of yttria stabilized zirconia coatings obtained by suspension plasma spraying[J].Surface&coatings technology,2012,208(6):87-91.
[41]MAHADE S,CURRY N,BJ?RKLUND S,et al.Thermal conductivity and thermal cyclic fatigue of multilayered Gd2Zr2O7/YSZ thermal barrier coatings processed by suspension plasma spray[J].Surface&coatings technology,2015,283(12):329-336.
[42]KA?NER H,STUKE A,VA?EN R,et al.Influence of microstructure on thermal and optical properties of suspension plasma sprayed(SPS)and atmospheric plasma sprayed(APS)coatings[C]//ITSC.New York:Bochum Research,2008.
[43]BERGHAUS J O,BOUARICHA S,LEGOUX J G,et al.Injection conditions and in-flight particle states in suspension plasma spraying of alumina and zirconia nano-ceramics[J].Journal of thermal spray technology,2005,8:543.
[44]GELL M,JORDAN E H,TEICHOLZ M,et al.Thermal barrier coatings made by the solution precursor plasma spray process[J].Journal of thermal spray technology,2008,17(1):124-135.
[45]ZHU C,WANG Y G,AN L N,et al.Microstructure and oxidation behavior of conventional and pseudo graded NiCrAlY/YSZ thermal barrier coatings produced by supersonic air plasma spraying process[J].Surface&coatings technology,2015,272(6):121-128.
[46]GUO H,KURODA S,MURAKAMI H.Microstructures and properties of plasma sprayed segmented thermal barrier coatings[J].Journal of the American Ceramic Society,2010,89(4):1432-1439.
[47]BERNARD B,QUET A,BIANCHI L,et al.Thermal insulation properties of YSZ coatings:Suspension plasma spraying(SPS)versus electron beam physical vapor deposition(EB-PVD)and atmospheric plasma spraying(APS)[J].Surface&coatings technology,2017,318(5):122-128.
[48]GANVIR A,JOSHI S,MARKOCSAN N,et al.Tailoring columnar microstructure of axial suspension plasma sprayed TBCs for superior thermal shock performance[J].Materials and design,2018,144(4):192-208.
[49]JAMES L,SMIAL E K.Improved oxidation life of segmented plasma sprayed 8YSZ thermal barrier coatings[J].Journal of thermal spray technology,2004,13(1):66-75.
[50]SOHN Y H,KIM J H,JORDAN E H,et al.Thermal cycling of EB-PVD/MCrAlY thermal barrier coatings:Microstructural development and spallation mechanisms[J].Surface&coatings technology,2001,146(9):70-78.
[51]SAITO S,AL E.Stress variation with thermal cycling in the thermally grown oxide of an EB-PVD thermal barrier coating[J].Surface&coatings technology,2004,179(2):286-296.
[52]BAUFELD B,SCHULZ U.Life time dependency on the pre-coating treatment of a thermal barrier coating under thermal cycling[J].Surface&coatings technology,2006,201(6):2667-2675.
[53]师俊东,何箐.热障涂层服役环境模拟实验方法[J].航空材料学报,2018,38(2):32-42.SHI Jun-dong,HE Qing.Service environment simulation test method of thermal barrier coatings[J].Journal of aeronautical materials,2018,38(2):32-42.