NiAl/NiCoCrAlY/8YSZ复合喷涂层的微观结构与性能研究
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摘要
目的提高金属/陶瓷隔热涂层体系在海洋环境下的耐腐蚀性能。方法利用冷喷涂方法制备NiAl复合打底层和Ni CoCrAlY粘结层,与等离子喷涂制备的8YSZ陶瓷层构成适用于海洋环境的多层结构耐蚀隔热涂层体系。利用FE-SEM分别观察喷涂态粘结层和陶瓷层的表面、横截面形貌,通过EDS分析涂层元素分布;利用XRD分析表征涂层的物相组成;借助万能材料试验机,采用拉伸法测试涂层结合强度;利用热循环试验和焰流冲刷试验测试涂层的耐高温性能。结果微观分析表明,冷喷涂制备的NiAl复合打底层和Ni CoCrAlY粘结层形貌致密,涂层材料未发生明显氧化,颗粒变形程度不一,粘结层与基体间的结合强度约为18.4 MPa,粘结层与8YSZ陶瓷层界面结合紧密。陶瓷层物相结构和成分稳定,涂层经12次热震循环和1000个周期的高温焰流冲击后,表面未出现开裂、起皮和脱落。结论采用冷喷涂法和等离子喷涂法联合制备的耐蚀隔热复合涂层体系具备良好的耐热性和耐腐蚀性。冷喷涂制备的金属涂层结构致密,孔隙率低,与陶瓷层结合良好,能够有效提高涂层体系在腐蚀性环境中的耐蚀性能。NiAl复合涂层可以缓解Ni CoCrAlY粘结层和铝合金基材间的热匹配问题,增强涂层的结合性能。
The work aims to improve the corrosion resistance of metal/ceramic thermal insulation coatings in marine environment. NiAl composite coating and NiCoCrAlY bonding layer were prepared by cold spraying and formed to a multi-layer structure corrosion resistant and heat insulating coating system suitable for marine environment with 8 YSZ ceramic coating prepared by plasma spraying. The surface and cross-section microstructure of bonding layer and ceramic layer were observed by field emission scanning electron microscopy(FE-SEM), and the elements distribution was analyzed by energy dispersive spectral(EDS). The phase compositions of coatings were characterized by X-ray diffraction(XRD). Bonding strength test was carried out by tensile test with universal material testing machine. Thermal cycle test and high temperature flame erosion test were used to investigate the high temperature resistance of the coating. Microscopic analysis showed that the morphology of NiAl composite coating and NiCoCrAlY bonding layer was compact, there was few obvious oxidation observed in the coating and the degree of particle deformation was different. Bonding strength between bonding layer and matrix was about 18.4 MPa. The interface of bonding layer and 8 YSZ ceramic layer was closely bonded. The components of the ceramic layer were stable. No cracking, peeling or shedding occurred on the coating surface after 12 thermal shock tests and 1000 cycles of high temperature flame erosion. The composite coating prepared by cold spray and plasma spray has excellent thermal resistance and corrosion resistance. The metal coating prepared by cold spray has compact structure, low porosity and good bonding with ceramic layer,which can effectively improve the corrosion resistance of the coating system in corrosive environment. NiAl composite coating can alleviate the thermal matching problem between NiCoCrAlY layer and aluminum alloy substrate, thus enhancing bonding performance of the coating.
The work aims to improve the corrosion resistance of metal/ceramic thermal insulation coatings in marine environment. NiAl composite coating and NiCoCrAlY bonding layer were prepared by cold spraying and formed to a multi-layer structure corrosion resistant and heat insulating coating system suitable for marine environment with 8 YSZ ceramic coating prepared by plasma spraying. The surface and cross-section microstructure of bonding layer and ceramic layer were observed by field emission scanning electron microscopy(FE-SEM), and the elements distribution was analyzed by energy dispersive spectral(EDS). The phase compositions of coatings were characterized by X-ray diffraction(XRD). Bonding strength test was carried out by tensile test with universal material testing machine. Thermal cycle test and high temperature flame erosion test were used to investigate the high temperature resistance of the coating. Microscopic analysis showed that the morphology of NiAl composite coating and NiCoCrAlY bonding layer was compact, there was few obvious oxidation observed in the coating and the degree of particle deformation was different. Bonding strength between bonding layer and matrix was about 18.4 MPa. The interface of bonding layer and 8 YSZ ceramic layer was closely bonded. The components of the ceramic layer were stable. No cracking, peeling or shedding occurred on the coating surface after 12 thermal shock tests and 1000 cycles of high temperature flame erosion. The composite coating prepared by cold spray and plasma spray has excellent thermal resistance and corrosion resistance. The metal coating prepared by cold spray has compact structure, low porosity and good bonding with ceramic layer,which can effectively improve the corrosion resistance of the coating system in corrosive environment. NiAl composite coating can alleviate the thermal matching problem between NiCoCrAlY layer and aluminum alloy substrate, thus enhancing bonding performance of the coating.
引文
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[2]齐忠原,巫瑞智,王国军,等.铝合金在船舶和海洋工程中的应用[J].轻合金加工技术,2016,44(1):12-18.QI Zhong-yuan,WU Rui-zhi,WANG Guo-jun,et al.Application of aluminum alloys in shipping and ocean engineering[J].Light alloy fabrication technology,2016,44(1):12-18.
[3]KUMAR D,PANDEY K N,DAS D K.Thermal cyclic resistance behavior of inconel 800 super alloy substrate with thermal barrier coatings by plasma spraying[J].Materials today:proceedings,2015,2(4-5):3156-3160.
[4]梁明德,于继平,张鑫,等.高温热障涂层陶瓷层材料研究进展[J].热喷涂技术,2013(2):1-9.LIANG Ming-de,YU Ji-ping,ZHANG Xin,et al.Progress in ceramic materials for high temperature thermal barrier coatings[J].Thermal spray technology,2013(2):1-9.
[5]AZADI M,FARRAHI G H,WINTER G,et al.Experimental fatigue lifetime of coated and uncoated aluminum alloy under isothermal and thermo-mechanical loadings[J].Ceramics international,2013,39(8):9099-9107.
[6]郑军林,李亚楠.舰船高温防护涂层技术研究进展[J].材料开发与应用,2015(6):99-102.ZHENG Jun-lin,LI Ya-nan.Review on high temperature protective coating technology for ships[J].Development and application of materials,2015(6):99-102.
[7]张波,方志刚,李向阳,等.铝合金船舶的腐蚀防护技术现状与展望[J].中国材料进展,2014(7):414-417.ZHANG Bo,FANG Zhi-gang,LI Xiang-yang,et al.Status and prospect of corrosion protection technology about aluminum alloy ship[J].Materials China,2014(7):414-417.
[8]KLINKOV S V,KOSAREV V F,SOVA A A,et al.Calculation of particle parameters for cold spraying of metal-ceramic mixtures[J].Journal of thermal spray technology,2009,18(5):944-956.
[9]王存龙,杨森,马冰,等.冷喷涂技术及其在零件修复与功能涂层制备中的应用[J].焊接技术,2013(8):1-5.WANG Cun-long,YANG Sen,MA Bing,et al.Cold spray technology and its application in parts renewal and preparation of functional coating[J].Welding technology,2013(0):1-5.
[10]RICHER P,Zú?IGA A,YANDOUZI M,et al.CoNiCrAlY microstructural changes induced during cold gas dynamic spraying[J].Surface and coatings technology,2008,203(3):364-371.
[11]STOLTENHOFF T,KREYE H,RICHTER H J.An analysis of the cold spray process and its coatings[J].Journal of thermal spray technology,2002,11(4):542-550.
[12]CHEN C,XIE Y,VERDY C,et al.Numerical investigation of transient coating build-up and heat transfer in cold spray[J].Surface and coatings technology,2017,326:355-365.
[13]董彩常,王洪仁,黄国胜,等.冷喷涂铝涂层在海水中的腐蚀行为研究[J].腐蚀科学与防护技术,2010,22(2):90-93.DONG Cai-chang,WANG Hong-ren,HUANG Guo-sheng,et al.Corrosion behavior of cold-sprayed aluminum coating in seawater[J].Corrosion science and protection technology,2010,22(2):90-93.
[14]陈东,李忠盛,吴护林,等.冷喷涂纯铝涂层耐腐蚀性能研究[J].表面技术,2016,45(12):174-179.CHEN Dong,LI Zhong-sheng,WU Hu-lin,et al.Corrosion resistance of cold sprayed pure Al coating[J].Surface technology,2016,45(12):174-179.
[15]LAHIRI D,GILL P K,SCUDINO S,et al.Cold sprayed aluminum based glassy coating:synthesis,wear and corrosion properties[J].Surface and coatings technology,2013,232:33-40.
[16]LI C J,OHMORI A.Relationships between the microstructure and properties of thermally sprayed deposits[J].Journal of thermal spray technology,2002,11(3):365-374.
[17]王继东,王智慧.等离子喷涂CeO2-Y2O3稳定ZrO2陶瓷涂层耐高温铁水热震研究[J].中国表面工程,2010,23(3):10-13.WANG Ji-dong,WANG Zhi-hui.The thermal molten iron resistance performance of plasma sprayed ZrO2 stability of CeO2-Y2O3 ceramic coating[J].China surface engineering,2010,23(3):10-13.
[18]钱扬保,张伟刚.大气等离子喷涂ZrSiO4涂层的物相转变行为[J].硅酸盐学报,2008,36(8):1103-1108.QIAN Yang-bao,ZHANG Wei-gang.Phase-transformation behavior of plasma-sprayed ZrSiO4 coating materials[J].Journal of the Chinese ceramic society,2008,36(8):1103-1108.
[19]陈涛,惠宇,胥佳颖,等.纳米8YSZ粉的热处理对等离子喷涂涂层热震性能的影响[J].中国稀土学报,2016,34(2):189-198.CHEN Tao,HUI Yu,XU Jia-ying,et al.Effect of heat treatment of nano 8YSZ powder on thermal shock lifetime of plasma sprayed coating[J].Journal of the Chinese society of rare earths,2016,34(2):189-198.
[20]马东林,贺毅,王兰,等.等离子喷涂氧化铝涂层的热震性能及微观组织特征[J].热加工工艺,2011,40(4):102-105.MA Dong-lin,HE Yi,WANG Lan,et al.Thermal shock resistance and microstructure character of alumina coatings fabricated by plasma spraying[J].Hot working technology,2011,40(4):102-105.
[21]甄东霞,王铀,勾俊峰,等.稀土改性NiCoCrAlY层对YSZ和LZ/YSZ热障涂层高温性能的影响[J].热喷涂技术,2016,8(4):14-22.ZHEN Dong-xia,WANG You,GOU Jun-feng,et al.Effect of rare earth modified NiCoCrAlY coating on theproperties of YSZ and LZ/YSZ TBC by high temperature oxidation test[J].Thermal spray technology,2016,8(4):14-22.