新型高温/超高温热障涂层及制备技术研究进展
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摘要
简单介绍了先进航空发动机高温/超高温热障涂层(TBCs)的研究背景、意义和现状;简述了近年来国际上在新一代超高温TBCs方面的研究进展。重点介绍了近年来北京航空航天大学在新型高温/超高温TBCs方面的研究成果,包括新型超高温、高隔热陶瓷隔热层材料,1 150℃以上新型抗高温氧化金属粘结层材料,以及电子束物理气相沉积(EB-PVD)、等离子体激活EB-PVD(PA EB-PVD)和等离子物理气相沉积(PS-PVD)等新型制备工艺。最后对TBCs在未来高性能航空发动机上的应用及发展趋势进行了展望。
The research background,significance and current status of high/ultra-high temperature thermal barrier coatings(TBCs)for aero-engine applications are briefly highlighted.The recent research progress in new generation TBCs for ultrahigh temperature applications is reviewed.Emphasis is laid on the recent research achievements of Beihang University which involves new ceramic topcoat materials with superior-high temperature capabilities and thermal barrier performances,novel metallic bond coat materials with good oxidation resistance at temperatures above 1 150°C,new processing technologies of TBCs including electron beam physical vapor deposition(EB-PVD),plasma activated EB-PVD(PA EB-PVD)and plasma spray physical vapor deposition(PS-PVD).Eventually,the prospective trends of TBCs for advanced aero-engine applications are forecast.
The research background,significance and current status of high/ultra-high temperature thermal barrier coatings(TBCs)for aero-engine applications are briefly highlighted.The recent research progress in new generation TBCs for ultrahigh temperature applications is reviewed.Emphasis is laid on the recent research achievements of Beihang University which involves new ceramic topcoat materials with superior-high temperature capabilities and thermal barrier performances,novel metallic bond coat materials with good oxidation resistance at temperatures above 1 150°C,new processing technologies of TBCs including electron beam physical vapor deposition(EB-PVD),plasma activated EB-PVD(PA EB-PVD)and plasma spray physical vapor deposition(PS-PVD).Eventually,the prospective trends of TBCs for advanced aero-engine applications are forecast.
引文
[1]Goward G W.Progress in coatings for gas turbine airfoils[J].Surface&Coatings Technology,1998,108(1/2/3):73-79.
[2]Milller R A.Thermal barrier coatings for aircraft engines:history and directions[J].Journal of Thermal Spray Technology,1997,6(1):35-42.
[3]Rebollo N R,Fabrichnay O,Levi C G.Phase stability of Y+Gd co-doped zirconia[J].Zeitschrift Fur Metallkunde,2003,94(3):163-170.
[4]Rahaman M N,Gross J R,Dutton R E,et al.Phase stability,sintering,and thermal conductivity of plasmasprayed ZrO2-Gd2O3 compositions for potential thermal barrier coating applications[J].Acta Materialia,2006,54(6):1615-1621.
[5]Leoni M,Jones R,Scardi P.Phase stability of scandia-yttria-stabilized zirconia TBCs[J].Surface&Coatings Technology,1998,108-109:107-113.
[6]Friedrich C,Gadow R,Schirmer T.Lanthanum hexaaluminate—a new material for atmospheric plasma spraying of advanced thermal barrier coatings[J].Journal of Thermal Spray Technology,2001,10(4):592-859.
[7]Bansal N P,Zhu D M.Thermal properties of oxides with magnetoplumbite structure for advanced thermal barrier coatings[J].Surface&Coatings Technology,2008,202(12):2698-2703.
[8]Lehmann H,Pitzer D,Pracht G,et al.Thermal conductivity and thermal expansion coefficients of the lanthanum rare-earth-element zirconate system[J].Journal of the American Ceramic Society,2003,86(8):1338-1344.
[9]Duderstadt E C,Bangalore A N.Thermal barrier coating system with intermetallic overlay bond coat:U.S.Patent,5238752[P].1993-08-24.
[10]Schnitt-Thoms K G,Hertter M.Improved oxide resistance of thermal barrier coatings[J].Surface&Coatings Technology,1999,120-121:84-88.
[11]Felten E J,Pettit F S.Use of platinum and rhodium to improve oxide adherence on Ni-8Cr-6Al Alloys[J].Oxidation of Metals,1976,10(1):189-233.
[12]Pint B A,Treska M,Hobbst L W.The effect of various oxide dispersions on the phase composition and morphology of A12O3 scales grown onβ-NiAl[J].Oxidation of Metals,1997,47(1-2):1-20.
[13]Pint B A.The oxidation behavior of oxide-dispersedβ-NiAl:I.short-term performance at 1 200℃[J].Oxidation of Metals,1998,49(5-6):531-559.
[14]Haynes J A,Pint B A,More K L,et al.Influence of sulfur,platinum,and hafnium on the oxidation behavior of CVD NiAl bond coatings[J].Oxidation of Metals,2002,58(5-6):513-544.
[15]Hara M,Matsuda Y,Fukumoto M,et al.Formation of Ni-aluminide coating containing Hf by molten-salt electrodeposition and cyclic-oxidation resistance[J].Oxidation of Metals,2008,70:295-306.
[16]Barrett C A.Effect of 0.1at.%zirconium on the cyclic oxidation resistance ofβ-NiAl[J].Oxidation of Metals,1988,30(5-6):361-390.
[17]Hamadi S,Bacos M P,Poulain M,et al.Oxidation resistance of a Zr-doped NiAl coating thermochemically deposited on a nickel-based superalloy[J].Surface&Coatings Technology,2009,204:756-760.
[18]Jedlinski J,Mrowec S.The influence of implanted yttrium on the oxidation behaviour ofβ-NiAl[J].Materials Science and Engineering,1987,87:281-287.
[19]Mrowec S,Jedlinski J,Gil A.The influence of certain reactive elements on the oxidation behaviour of chromia-and alumina-forming alloys[J].Materials Science and Engineering:A,1989,120:169-173.
[20]Zhang G Y,Zhang H,Guo J T.Effects of Dy on cyclic oxidation resistance of NiAl alloy[J].Surface and Coatings Technology,2006,201:2270-2275.
[21]Wang F H,Lou H.Hot corrosion of yttrium-modified aluminide coatings[J].Materials Science and Engineering:A,1989,121:387-393.
[22]Wang W,Yu P,Wang F H.The effect of yttrium addition on the isothermal oxidation behavior of sputtered K38nanocrystalline coating at 1 273Kin air[J].Surface&Coatings Technology,2007,201:7425-7431.
[23]Cao X Q,Vaβen R,Tietz F,et al.New double-ceramiclayer thermal barrier coatings based on zirconia-rare earth composite oxides[J].Journal of the European Ceramic Society,2006,26:247-251.
[24]Chen X L,Zhang Y F,Zhong X H,et al.Thermal cycling behaviors of the plasma sprayed thermal barrier coatings of hexaluminates with magnetoplumbite structure[J].Journal of the European Ceramic Society,2010,30(7):1649-1657.
[25]Cao X Q,Vassen R,Jungen W,et al.Thermal stability of lanthanum zirconate plasma-sprayed coating[J].Journal of the American Ceramic Society,2001,4(9):2086-2090.
[26]Wu R F,Pan W,Ren X R,et al.An extremely low thermal conduction ceramic:RE9.33(SiO4)6O2silicate oxyapatite[J].Acta Materialia,2012,60(15):5536-5544.
[27]Xu Q,Pan W,Wang J D,et al.Preparation and thermophysical properties of Dy2Zr2O7ceramic for thermal barrier coatings[J].Materials Letters,2005,59(22):2804-2807.
[28]Xu Q,Pan W,Wang J D,et al.Rare-earth zirconate ceramics with fluorite structure for thermal barrier coatings[J].Journal of the American Ceramic Society,2006,89(1):340-342.
[29]Lu X Y,Zhu R Z,He Y D.Reactive-element effect of electrodeposited Y2O3oxide films on the oxidation of Fe-25Cr and Fe-25Cr-10Al alloys[J].Oxidation of Metals,1995,43(3/4):353-362.
[30]Li Z,Gao W,Li S,et al.Oxidation behavior of a Ti3AlNb alloy with surface thin oxide films[J].Oxidation of Metals,2001,56(5/6):495-516.
[31]Ji X J,Gong S K,Xu H B,et al.Influence of rare earth elements additions in YSZ ceramic coatings of thermal barrier coatings on lattice distortion[J].Acta Aeronautica et Astronautic Sinica,2007,28(1):196-200.(in Chinese)冀晓鹃,宫声凯,徐惠彬,等.添加稀土元素对热障涂层YSZ陶瓷层晶格畸变的影响[J].航空学报,2007,28(1):196-200.
[32]Zhang H J.Preparation and thermal cycling properties study of the multicomponent rare earth oxides doped zirconia thermal barrier coatings[D].Beijing:Beihang University,2009.(in Chinese)张红菊.多元稀土氧化物掺杂二氧化锆基热障涂层的制备及热循环性能研究[D].北京:北京航空航天大学,2009.
[33]Ma W,Gong S K,Xu H B,et al.The thermal cycling behavior of lanthanum-cerium oxide thermal barrier coating prepared by EB-PVD[J].Surface&Coatings Technology,2006,200(16-17):5113-5118.
[34]Ma W,Gong S K,Xu H B,et al.On improving the phase stability and thermal expansion coefficients of lanthanum cerium oxide solid solutions[J].Scripta Materialia,2006,54(8):1505-1508.
[35]Ma W,Gong S K,Li H F,et al.Novel thermal barrier coatings based on La2Ce2O7/8YSZ double-ceramic-layer systems deposited by electron beam physical vapor deposition[J].Surface&Coatings Technology,2008,202(12):2704-2708.
[36]Guo L,Guo H B,Gong S K,et al.Improvement on the phase stability,mechanical properties and thermal insulation of Y2O3-stabilized ZrO2by Gd2O3and Yb2O3co-doping[J].Ceramics International,2013,39(8):9009-9015.
[37]Guo H B,Zhang T,Wang S X,et al.Effect of Dy on oxide scale adhesion of NiAl coatings at 1 200℃[J].Corrosion Science,2011,53:2228-2232.
[38]Li D Q,Guo H B,Wang D,et al.Cyclic oxidation ofβ-NiAl with various reactive element dopants at 1 200℃[J].Corrosion Science,2013,66:125-135.
[39]Zhang T,Guo H B,Gong S K,et al.Effects of Dy on the adherence of Al2O3/NiAl interface:a combined first-principles and experimental studies[J].Corrosion Science,2013,66:59-66.
[40]Guo H B,Gong S K,Xu H B.Progress in thermal barrier coatings for advanced aeroengines[J].Materials China,2009,29(9/10):18-26.(in Chinese)郭洪波,宫声凯,徐惠彬.先进航空发动机热障涂层技术研究进展[J].中国材料进展,2009,29(9/10):18-26.
[41]Guo H B,Vassen R,Stover D.Atmospheric plasma sprayed thick thermal barrier coatings with high segmentation crack density[J].Surface&Coatings Technology,2004,186(3):353-363.
[42]Xu H B,Guo H B,Liu F S,et al.Development of gradient thermal barrier coatings and their hot-fatigue behavior[J].Surface and Coatings Technology,2000,130(1):133-139.
[43]Muehlberger E,Meyer P.LPPS-thin film processes:overview of origin and future possibilities[C]//Thermal Spray,2009:737-740.
[44]Von Niessen K,Gindrat M.Vapor phase deposition using aplasma spray process[J].Journal of Engineering for Gas Turbines and Power,2011,133(6):133-141.
[45]Hospach A,Mauer G,Vaβen R,et al.Columnar-structured thermal barrier coatings(TBCs)by thin film lowpressure plasma spraying(LPPS-TF)[J].Journal of Thermal Spray Technology,2011,20(1-2):116-120.
[46]Mauer G,Hospach A,Vaβen R.Process development and coating characteristics of plasma spray-PVD[J].Surface&Coatings Technology,2013,220:219-224.
[47]Huang H,Eguchi K,Kambara M.Ultrafast thermal plasma physical vapor deposition of yttria-stabilized zirconia for novel thermal barrier coatings[J].Journal of Thermal Spray Technology,2006,15(4):83-91.
[2]Milller R A.Thermal barrier coatings for aircraft engines:history and directions[J].Journal of Thermal Spray Technology,1997,6(1):35-42.
[3]Rebollo N R,Fabrichnay O,Levi C G.Phase stability of Y+Gd co-doped zirconia[J].Zeitschrift Fur Metallkunde,2003,94(3):163-170.
[4]Rahaman M N,Gross J R,Dutton R E,et al.Phase stability,sintering,and thermal conductivity of plasmasprayed ZrO2-Gd2O3 compositions for potential thermal barrier coating applications[J].Acta Materialia,2006,54(6):1615-1621.
[5]Leoni M,Jones R,Scardi P.Phase stability of scandia-yttria-stabilized zirconia TBCs[J].Surface&Coatings Technology,1998,108-109:107-113.
[6]Friedrich C,Gadow R,Schirmer T.Lanthanum hexaaluminate—a new material for atmospheric plasma spraying of advanced thermal barrier coatings[J].Journal of Thermal Spray Technology,2001,10(4):592-859.
[7]Bansal N P,Zhu D M.Thermal properties of oxides with magnetoplumbite structure for advanced thermal barrier coatings[J].Surface&Coatings Technology,2008,202(12):2698-2703.
[8]Lehmann H,Pitzer D,Pracht G,et al.Thermal conductivity and thermal expansion coefficients of the lanthanum rare-earth-element zirconate system[J].Journal of the American Ceramic Society,2003,86(8):1338-1344.
[9]Duderstadt E C,Bangalore A N.Thermal barrier coating system with intermetallic overlay bond coat:U.S.Patent,5238752[P].1993-08-24.
[10]Schnitt-Thoms K G,Hertter M.Improved oxide resistance of thermal barrier coatings[J].Surface&Coatings Technology,1999,120-121:84-88.
[11]Felten E J,Pettit F S.Use of platinum and rhodium to improve oxide adherence on Ni-8Cr-6Al Alloys[J].Oxidation of Metals,1976,10(1):189-233.
[12]Pint B A,Treska M,Hobbst L W.The effect of various oxide dispersions on the phase composition and morphology of A12O3 scales grown onβ-NiAl[J].Oxidation of Metals,1997,47(1-2):1-20.
[13]Pint B A.The oxidation behavior of oxide-dispersedβ-NiAl:I.short-term performance at 1 200℃[J].Oxidation of Metals,1998,49(5-6):531-559.
[14]Haynes J A,Pint B A,More K L,et al.Influence of sulfur,platinum,and hafnium on the oxidation behavior of CVD NiAl bond coatings[J].Oxidation of Metals,2002,58(5-6):513-544.
[15]Hara M,Matsuda Y,Fukumoto M,et al.Formation of Ni-aluminide coating containing Hf by molten-salt electrodeposition and cyclic-oxidation resistance[J].Oxidation of Metals,2008,70:295-306.
[16]Barrett C A.Effect of 0.1at.%zirconium on the cyclic oxidation resistance ofβ-NiAl[J].Oxidation of Metals,1988,30(5-6):361-390.
[17]Hamadi S,Bacos M P,Poulain M,et al.Oxidation resistance of a Zr-doped NiAl coating thermochemically deposited on a nickel-based superalloy[J].Surface&Coatings Technology,2009,204:756-760.
[18]Jedlinski J,Mrowec S.The influence of implanted yttrium on the oxidation behaviour ofβ-NiAl[J].Materials Science and Engineering,1987,87:281-287.
[19]Mrowec S,Jedlinski J,Gil A.The influence of certain reactive elements on the oxidation behaviour of chromia-and alumina-forming alloys[J].Materials Science and Engineering:A,1989,120:169-173.
[20]Zhang G Y,Zhang H,Guo J T.Effects of Dy on cyclic oxidation resistance of NiAl alloy[J].Surface and Coatings Technology,2006,201:2270-2275.
[21]Wang F H,Lou H.Hot corrosion of yttrium-modified aluminide coatings[J].Materials Science and Engineering:A,1989,121:387-393.
[22]Wang W,Yu P,Wang F H.The effect of yttrium addition on the isothermal oxidation behavior of sputtered K38nanocrystalline coating at 1 273Kin air[J].Surface&Coatings Technology,2007,201:7425-7431.
[23]Cao X Q,Vaβen R,Tietz F,et al.New double-ceramiclayer thermal barrier coatings based on zirconia-rare earth composite oxides[J].Journal of the European Ceramic Society,2006,26:247-251.
[24]Chen X L,Zhang Y F,Zhong X H,et al.Thermal cycling behaviors of the plasma sprayed thermal barrier coatings of hexaluminates with magnetoplumbite structure[J].Journal of the European Ceramic Society,2010,30(7):1649-1657.
[25]Cao X Q,Vassen R,Jungen W,et al.Thermal stability of lanthanum zirconate plasma-sprayed coating[J].Journal of the American Ceramic Society,2001,4(9):2086-2090.
[26]Wu R F,Pan W,Ren X R,et al.An extremely low thermal conduction ceramic:RE9.33(SiO4)6O2silicate oxyapatite[J].Acta Materialia,2012,60(15):5536-5544.
[27]Xu Q,Pan W,Wang J D,et al.Preparation and thermophysical properties of Dy2Zr2O7ceramic for thermal barrier coatings[J].Materials Letters,2005,59(22):2804-2807.
[28]Xu Q,Pan W,Wang J D,et al.Rare-earth zirconate ceramics with fluorite structure for thermal barrier coatings[J].Journal of the American Ceramic Society,2006,89(1):340-342.
[29]Lu X Y,Zhu R Z,He Y D.Reactive-element effect of electrodeposited Y2O3oxide films on the oxidation of Fe-25Cr and Fe-25Cr-10Al alloys[J].Oxidation of Metals,1995,43(3/4):353-362.
[30]Li Z,Gao W,Li S,et al.Oxidation behavior of a Ti3AlNb alloy with surface thin oxide films[J].Oxidation of Metals,2001,56(5/6):495-516.
[31]Ji X J,Gong S K,Xu H B,et al.Influence of rare earth elements additions in YSZ ceramic coatings of thermal barrier coatings on lattice distortion[J].Acta Aeronautica et Astronautic Sinica,2007,28(1):196-200.(in Chinese)冀晓鹃,宫声凯,徐惠彬,等.添加稀土元素对热障涂层YSZ陶瓷层晶格畸变的影响[J].航空学报,2007,28(1):196-200.
[32]Zhang H J.Preparation and thermal cycling properties study of the multicomponent rare earth oxides doped zirconia thermal barrier coatings[D].Beijing:Beihang University,2009.(in Chinese)张红菊.多元稀土氧化物掺杂二氧化锆基热障涂层的制备及热循环性能研究[D].北京:北京航空航天大学,2009.
[33]Ma W,Gong S K,Xu H B,et al.The thermal cycling behavior of lanthanum-cerium oxide thermal barrier coating prepared by EB-PVD[J].Surface&Coatings Technology,2006,200(16-17):5113-5118.
[34]Ma W,Gong S K,Xu H B,et al.On improving the phase stability and thermal expansion coefficients of lanthanum cerium oxide solid solutions[J].Scripta Materialia,2006,54(8):1505-1508.
[35]Ma W,Gong S K,Li H F,et al.Novel thermal barrier coatings based on La2Ce2O7/8YSZ double-ceramic-layer systems deposited by electron beam physical vapor deposition[J].Surface&Coatings Technology,2008,202(12):2704-2708.
[36]Guo L,Guo H B,Gong S K,et al.Improvement on the phase stability,mechanical properties and thermal insulation of Y2O3-stabilized ZrO2by Gd2O3and Yb2O3co-doping[J].Ceramics International,2013,39(8):9009-9015.
[37]Guo H B,Zhang T,Wang S X,et al.Effect of Dy on oxide scale adhesion of NiAl coatings at 1 200℃[J].Corrosion Science,2011,53:2228-2232.
[38]Li D Q,Guo H B,Wang D,et al.Cyclic oxidation ofβ-NiAl with various reactive element dopants at 1 200℃[J].Corrosion Science,2013,66:125-135.
[39]Zhang T,Guo H B,Gong S K,et al.Effects of Dy on the adherence of Al2O3/NiAl interface:a combined first-principles and experimental studies[J].Corrosion Science,2013,66:59-66.
[40]Guo H B,Gong S K,Xu H B.Progress in thermal barrier coatings for advanced aeroengines[J].Materials China,2009,29(9/10):18-26.(in Chinese)郭洪波,宫声凯,徐惠彬.先进航空发动机热障涂层技术研究进展[J].中国材料进展,2009,29(9/10):18-26.
[41]Guo H B,Vassen R,Stover D.Atmospheric plasma sprayed thick thermal barrier coatings with high segmentation crack density[J].Surface&Coatings Technology,2004,186(3):353-363.
[42]Xu H B,Guo H B,Liu F S,et al.Development of gradient thermal barrier coatings and their hot-fatigue behavior[J].Surface and Coatings Technology,2000,130(1):133-139.
[43]Muehlberger E,Meyer P.LPPS-thin film processes:overview of origin and future possibilities[C]//Thermal Spray,2009:737-740.
[44]Von Niessen K,Gindrat M.Vapor phase deposition using aplasma spray process[J].Journal of Engineering for Gas Turbines and Power,2011,133(6):133-141.
[45]Hospach A,Mauer G,Vaβen R,et al.Columnar-structured thermal barrier coatings(TBCs)by thin film lowpressure plasma spraying(LPPS-TF)[J].Journal of Thermal Spray Technology,2011,20(1-2):116-120.
[46]Mauer G,Hospach A,Vaβen R.Process development and coating characteristics of plasma spray-PVD[J].Surface&Coatings Technology,2013,220:219-224.
[47]Huang H,Eguchi K,Kambara M.Ultrafast thermal plasma physical vapor deposition of yttria-stabilized zirconia for novel thermal barrier coatings[J].Journal of Thermal Spray Technology,2006,15(4):83-91.