冷喷涂制备MCrAlY涂层的研究进展
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摘要
综述了冷喷涂MCrAlY涂层的制备工艺、喷涂过程中微观组织演变、热生长氧化物(TGO)的组成、分布和预处理等对冷喷涂MCrAlY涂层的耐高温氧化性能的影响以及涂层的耐热腐蚀性能,并和其他热喷涂工艺制备的MCrAlY涂层进行了对比。指出了冷喷涂MCrAlY涂层在制备和性能方面的不足之处,并对其未来的发展进行了展望。
The preparation technology of cold-sprayed MCrAlY coatings,the microstructure evolution during spray process,the composition and distribution of thermal growing oxides,the effect of pretreatment on the high temperature oxidation behavior of MCrAlY coatings,and the hot corrosion resistance of MCrAlY coatings are reviewed in comparison with other thermal-sprayed bond coatings.Some problems of cold-sprayed MCrAlY coatings in preparation process and performance are pointed out,and the development in future is put forward.
The preparation technology of cold-sprayed MCrAlY coatings,the microstructure evolution during spray process,the composition and distribution of thermal growing oxides,the effect of pretreatment on the high temperature oxidation behavior of MCrAlY coatings,and the hot corrosion resistance of MCrAlY coatings are reviewed in comparison with other thermal-sprayed bond coatings.Some problems of cold-sprayed MCrAlY coatings in preparation process and performance are pointed out,and the development in future is put forward.
引文
[1]EVANS A G,MUMM D R,HUTCHINSON J W,et al.Mechanisms controlling the durability of thermal barrier coatings[J].Progress in Materials Science,2001,46(5):505-553.
[2]WRIGHT P K,EVANS A G.Mechanisms governing the performance of thermal barrier coatings[J].Current Opinion in Solid State and Materials Science,1999,4(3):255-265.
[3]BRINDLEY W J.Thermal barrier coatings[J].Journal of Thermal Spray Technology,1996,5(4):379-380.
[4]STRANGMAN T,RAYBOULD D,JAMEEL A,et al.Damage mechanisms,life prediction,and development of EB-PVD thermal barrier coatings for turbine airfoils[J].Surface and Coatings Technology,2007,202(4):658-664.
[5]ZHANG Q,LI C J,LI Y,et al.Thermal failure of nanostructured thermal barrier coatings with coldsprayed nanostructured NiCrAlY bond coat[J].Journal of Thermal Spray Technology,2008,17(5/6):838-845.
[6]AHMANIEMI S,VUORISTO P,MNTYLT,et al.Thermal cycling resistance of modified thick thermal barrier coatings[J].Surface and Coatings Technology,2005,190(2):378-387.
[7]BOSE S,MASI-MARCIN D J.Thermal barrier coating experience in gas turbine engines at Pratt&Whitney[J].Journal of Thermal Spray Technology,1997,6(1):99-104.
[8]LEVI C G.Emerging materials and processes for thermal barrier systems[J].Current Opinion in Solid State and Materials Science,2004,8(1):77-91.
[9]HSUEH C H,FULLER E R.Analytical modeling of oxide thickness effects on residual stresses in thermal barrier coatings[J].Scripta Materialia,2000,42(8):781-787.
[10]TANG F,SCHOENUNG J M.Local accumulation of thermally grown oxide in plasma-sprayed thermal barrier coatings with rough top-coat/bond-coat interfaces[J].Scripta Materialia,2005,52(9):905-909.
[11]RABIEI A,EVANS A G.Failure mechanisms associated with the thermally grown oxide in plasmasprayed thermal barrier coatings[J].Acta Materialia,2000,48(15):3963-3976.
[12]SCHLICHTING K W,PADTURE N P,JORDAN E H,et al.Failure modes in plasma-sprayed thermal barrier coatings[J].Materials Science and Engineering:A,2003,342(1):120-130.
[13]ZHANG Q,LI C J,LI C X,et al.Study of oxidation behavior of nanostructured NiCrAlY bond coatings deposited by cold spraying[J].Surface and Coatings Technology,2008,202(14):3378-3384.
[14]MATSUMOTO M,HAYAKAWA K,KITAOKA S,et al.The effect of preoxidationatmosphere on oxidation behavior and thermal cycle life of thermal barrier coatings[J].Materials Science and Engineering:A,2006,441(1):119-125.
[15]TEIXEIRA V,ANDRITSCHKY M,FISCHER W,et al.Effects of deposition temperature and thermal cycling on residual stress state in zirconia-based thermal barrier coatings[J].Surface and Coatings Technology,1999,120:103-111.
[16]GIL A,SHEMET V,VASSEN R,et al.Effect of surface condition on the oxidation behavior of MCrAlY coatings[J].Surface and Coatings Technology,2006,201(7):3824-3828.
[17]PANT B K,ARYA V,MANN B S.Development of low-oxide MCrAlY coatings for gas turbine applications[J].Journal of Thermal Spray Technology,2007,16(2):275-280.
[18]杜仲,王全胜,柳彦博,等.真空预氧化处理对热障涂层静态氧化行为的影响[J].航空材料学报,2015,35(5):27-31.
[19]LI Y,LI C J,YANG G J,et al.Thermal fatigue behavior of thermal barrier coatings with the MCrAlY bond coats by cold spraying and low-pressure plasma spraying[J].Surface and Coatings Technology,2010,205(7):2225-2233.
[20]HARDWICKE C U,LAU Y C.Advances in thermal spray coatings for gas turbines and energy generation:a review[J].Journal of Thermal Spray Technology,2013,22(5):564-576.
[21]张新格,邓畅光,邓春明,等.NiCrAlY涂层抗氧化性及氧化过程中的微观结构演变[J].航空材料学报,2015,35(5):21-26.
[22]ALKHIMOV A P,KOSAREV V F,PAPYRIN A N.A method of cold gas-dynamic spraying[J].Doklady Akademii Nauk SSSR,1990,315(5):1062-1065.
[23]PAPYRIN A.Cold spray technology[J].Advanced Materials&Processes,2001,159(9):49-51.
[24]周香林,张济山,巫湘坤,等.先进冷喷涂技术与应用[M].北京:机械工业出版社,2011:2-5.
[25]张文毓.冷喷涂技术应用现状与展望[J].全面腐蚀控制,2015(2):17-21.
[26]卢静,王光华,黄乐之,等.冷喷涂制备防腐涂层研究现状[J].表面技术,2016,45(9):88-94.
[27]李相波,王静,王佳,等.冷喷涂NiCoCrAlY涂层的微观性能研究[J].科技导报,2008,26(4):56-59.
[28]张强,杨冠军,李长久,等.冷喷涂纳米结构NiCrAlY涂层在氩气气氛中的氧化行为[J].中国表面工程,2008,21(6):5-9.
[29]张林伟,王鲁,王全胜,等.真空预氧化对冷喷涂NiCoCrAlY涂层氧化行为的影响[J].材料工程,2014(1):1-5.
[30]张林伟,王鲁,王全胜,等.真空预氧化对冷喷涂CoNiCrAIY涂层组织及热腐蚀性能的影响[J].材料工程,2013(4):12-16.
[31]张林伟,王鲁,王全胜,等.冷喷涂CoNiCrAlY涂层在Na2SO4熔盐中的热腐蚀行为[J].材料工程,2016,44(11):45-50.
[32]RICHER P,ZUNIGA A,YANDOUZI M,et al.CoNiCrAlY microstructural changes induced during cold gas dynamic spraying[J].Surface and Coatings Technology,2008,203(3):364-371.
[33]RICHER P,YANDOUZI M,BEAUVAIS L,et al.Oxidation behavior of CoNiCrAlY bond boats produced by plasma,hvof and cold gas dynamic spraying[J].Surface and Coatings Technology,2010,204(24):3962-3974.
[34]BORCHERS C,STOLTENHOFF T,HAHN M,et al.Strain-induced phase transformation of MCrAlY[J].Advanced Engineering Materials,2015,17(5):723-731.
[35]LEE K I,OGAWA K.Improved deposition efficiency of cold-sprayed CoNiCrAlY with pure Ni coatings and its high-temperature oxidation behavior after pretreatment in low oxygen partial pressure[J].Materials Transactions,2014,55(9):1434-1439.
[36]CHEN W R,WU X,MARPLE B R,et al.Pre-oxidation and TGO growth behavior of an air-plasmasprayed thermal barrier coating[J].Surface and Coatings Technology,2008,202(16):3787-3796.
[37]SHIBATA M,KURODA S,WANTANABE M,et al.Microstructure and oxidation of MCrAlY coatings produced by various thermal spray process[C]//Thermal Spray 2007:Building on 100 Years of Success.[S.l.]:[s.n.],2006:15-18.
[38]LEE D B,KO J H,YI J H.Characterization of oxide scales formed on high-velocity oxyfuel-sprayed Ni-CoCr-Al-Y+ReTa coatings[J].Journal of Thermal Spray Technology,2005,14(3):315-320.
[39]ZHANG C,LIAO H L,LI W Y,et al.Characterization of YSZ solid oxide fuel cells electrolyte deposited by atmospheric plasma spraying and low pressure plasma spraying[J].Journal of Thermal Spray Technology,2006,15(4):598-603.
[40]ZHANG L W,NING X J,LU L,et al.Hot corrosion behavior of low-pressure cold-sprayed CoNiCrAlY coatings[J].Journal of Thermal Spray Technology,2016,25(3):587-594.
[41]SURYANARAYANA C.Mechanical alloying and milling[J].Progress in Materials Science,2001,46(1):1-184.
[42]SURYANARAYANA C.Mechanical alloying and milling[M].[S.n.]:CRC Press,2004,23-42.
[43]XI S Q,ZHOU J G,WANG X T.Research on temperature rise of powder during high energy ball milling[J].Powder Metallurgy,2013.
[44]DELOGU F.A Combined experimental and numerical approach to the kinetics of mechanically induced phase transformations[J].Acta Materialia,2008,56(4):905-912.
[45]李勇,张强,李长久,等.基于冷喷涂MCrAlY粘接层的热障涂层热循环失效的研究[C]//第七届全国表面工程学术会议.[出版地不详]:[出版者不详],2008:105-108.
[46]LI Y,LI C J,ZHANG Q,et al.Influence of TGO composition on the thermal shock lifetime of thermal barrier coatings with cold-sprayed MCrAlY bond coat[J].Journal of Thermal Spray Technology,2010,19(1/2):168-177.
[47]MATSUMOTO M,HAYAKAWA K,KITAOKA S,et al.The effect of preoxidation atmosphere on oxidation behavior and thermal cycle life of thermal barrier coatings[J].Materials Science and Engineering:A,2006,441(1):119-125.
[48]LI Y,LI C J,YANG G J,et al.Thermal fatigue behavior of thermal barrier coatings with the MCrAlY bond coats by cold spraying and low-pressure plasma spraying[J].Surface and Coatings Technology,2010,205(7):2225-2233.
[49]BONADEI A,MARROCCO T.Cold sprayed MCrAlY+X coating for gas turbine blades and vanes[J].Surface andCoatings Technology,2014,242:200-206.
[50]LI Y,LI C J,ZHANG Q,et al.Effect of chemical compositions and surface morphologies of MCrAlY coatingon its isothermal oxidation behavior[J].Journal of Thermal Spray Technology,2011,20(1/2):121-131.
[51]LEE K I,SATO K,OGAWA K.Mechanical properties and deposition mechanism of cold-sprayed CoNiCrAlY/YSZ cermet[J].Materials Transactions,2016,57(3):385-391.
[52]CIZEK J,MATEJKOVA M,KOURIL J,et al.Potential of new-generation electron beam technology in interface modification of cold and HVOF sprayed MCrAlY bond coats[J].Advances in Materials Science and Engineering,2016,2016:1-6.
[2]WRIGHT P K,EVANS A G.Mechanisms governing the performance of thermal barrier coatings[J].Current Opinion in Solid State and Materials Science,1999,4(3):255-265.
[3]BRINDLEY W J.Thermal barrier coatings[J].Journal of Thermal Spray Technology,1996,5(4):379-380.
[4]STRANGMAN T,RAYBOULD D,JAMEEL A,et al.Damage mechanisms,life prediction,and development of EB-PVD thermal barrier coatings for turbine airfoils[J].Surface and Coatings Technology,2007,202(4):658-664.
[5]ZHANG Q,LI C J,LI Y,et al.Thermal failure of nanostructured thermal barrier coatings with coldsprayed nanostructured NiCrAlY bond coat[J].Journal of Thermal Spray Technology,2008,17(5/6):838-845.
[6]AHMANIEMI S,VUORISTO P,MNTYLT,et al.Thermal cycling resistance of modified thick thermal barrier coatings[J].Surface and Coatings Technology,2005,190(2):378-387.
[7]BOSE S,MASI-MARCIN D J.Thermal barrier coating experience in gas turbine engines at Pratt&Whitney[J].Journal of Thermal Spray Technology,1997,6(1):99-104.
[8]LEVI C G.Emerging materials and processes for thermal barrier systems[J].Current Opinion in Solid State and Materials Science,2004,8(1):77-91.
[9]HSUEH C H,FULLER E R.Analytical modeling of oxide thickness effects on residual stresses in thermal barrier coatings[J].Scripta Materialia,2000,42(8):781-787.
[10]TANG F,SCHOENUNG J M.Local accumulation of thermally grown oxide in plasma-sprayed thermal barrier coatings with rough top-coat/bond-coat interfaces[J].Scripta Materialia,2005,52(9):905-909.
[11]RABIEI A,EVANS A G.Failure mechanisms associated with the thermally grown oxide in plasmasprayed thermal barrier coatings[J].Acta Materialia,2000,48(15):3963-3976.
[12]SCHLICHTING K W,PADTURE N P,JORDAN E H,et al.Failure modes in plasma-sprayed thermal barrier coatings[J].Materials Science and Engineering:A,2003,342(1):120-130.
[13]ZHANG Q,LI C J,LI C X,et al.Study of oxidation behavior of nanostructured NiCrAlY bond coatings deposited by cold spraying[J].Surface and Coatings Technology,2008,202(14):3378-3384.
[14]MATSUMOTO M,HAYAKAWA K,KITAOKA S,et al.The effect of preoxidationatmosphere on oxidation behavior and thermal cycle life of thermal barrier coatings[J].Materials Science and Engineering:A,2006,441(1):119-125.
[15]TEIXEIRA V,ANDRITSCHKY M,FISCHER W,et al.Effects of deposition temperature and thermal cycling on residual stress state in zirconia-based thermal barrier coatings[J].Surface and Coatings Technology,1999,120:103-111.
[16]GIL A,SHEMET V,VASSEN R,et al.Effect of surface condition on the oxidation behavior of MCrAlY coatings[J].Surface and Coatings Technology,2006,201(7):3824-3828.
[17]PANT B K,ARYA V,MANN B S.Development of low-oxide MCrAlY coatings for gas turbine applications[J].Journal of Thermal Spray Technology,2007,16(2):275-280.
[18]杜仲,王全胜,柳彦博,等.真空预氧化处理对热障涂层静态氧化行为的影响[J].航空材料学报,2015,35(5):27-31.
[19]LI Y,LI C J,YANG G J,et al.Thermal fatigue behavior of thermal barrier coatings with the MCrAlY bond coats by cold spraying and low-pressure plasma spraying[J].Surface and Coatings Technology,2010,205(7):2225-2233.
[20]HARDWICKE C U,LAU Y C.Advances in thermal spray coatings for gas turbines and energy generation:a review[J].Journal of Thermal Spray Technology,2013,22(5):564-576.
[21]张新格,邓畅光,邓春明,等.NiCrAlY涂层抗氧化性及氧化过程中的微观结构演变[J].航空材料学报,2015,35(5):21-26.
[22]ALKHIMOV A P,KOSAREV V F,PAPYRIN A N.A method of cold gas-dynamic spraying[J].Doklady Akademii Nauk SSSR,1990,315(5):1062-1065.
[23]PAPYRIN A.Cold spray technology[J].Advanced Materials&Processes,2001,159(9):49-51.
[24]周香林,张济山,巫湘坤,等.先进冷喷涂技术与应用[M].北京:机械工业出版社,2011:2-5.
[25]张文毓.冷喷涂技术应用现状与展望[J].全面腐蚀控制,2015(2):17-21.
[26]卢静,王光华,黄乐之,等.冷喷涂制备防腐涂层研究现状[J].表面技术,2016,45(9):88-94.
[27]李相波,王静,王佳,等.冷喷涂NiCoCrAlY涂层的微观性能研究[J].科技导报,2008,26(4):56-59.
[28]张强,杨冠军,李长久,等.冷喷涂纳米结构NiCrAlY涂层在氩气气氛中的氧化行为[J].中国表面工程,2008,21(6):5-9.
[29]张林伟,王鲁,王全胜,等.真空预氧化对冷喷涂NiCoCrAlY涂层氧化行为的影响[J].材料工程,2014(1):1-5.
[30]张林伟,王鲁,王全胜,等.真空预氧化对冷喷涂CoNiCrAIY涂层组织及热腐蚀性能的影响[J].材料工程,2013(4):12-16.
[31]张林伟,王鲁,王全胜,等.冷喷涂CoNiCrAlY涂层在Na2SO4熔盐中的热腐蚀行为[J].材料工程,2016,44(11):45-50.
[32]RICHER P,ZUNIGA A,YANDOUZI M,et al.CoNiCrAlY microstructural changes induced during cold gas dynamic spraying[J].Surface and Coatings Technology,2008,203(3):364-371.
[33]RICHER P,YANDOUZI M,BEAUVAIS L,et al.Oxidation behavior of CoNiCrAlY bond boats produced by plasma,hvof and cold gas dynamic spraying[J].Surface and Coatings Technology,2010,204(24):3962-3974.
[34]BORCHERS C,STOLTENHOFF T,HAHN M,et al.Strain-induced phase transformation of MCrAlY[J].Advanced Engineering Materials,2015,17(5):723-731.
[35]LEE K I,OGAWA K.Improved deposition efficiency of cold-sprayed CoNiCrAlY with pure Ni coatings and its high-temperature oxidation behavior after pretreatment in low oxygen partial pressure[J].Materials Transactions,2014,55(9):1434-1439.
[36]CHEN W R,WU X,MARPLE B R,et al.Pre-oxidation and TGO growth behavior of an air-plasmasprayed thermal barrier coating[J].Surface and Coatings Technology,2008,202(16):3787-3796.
[37]SHIBATA M,KURODA S,WANTANABE M,et al.Microstructure and oxidation of MCrAlY coatings produced by various thermal spray process[C]//Thermal Spray 2007:Building on 100 Years of Success.[S.l.]:[s.n.],2006:15-18.
[38]LEE D B,KO J H,YI J H.Characterization of oxide scales formed on high-velocity oxyfuel-sprayed Ni-CoCr-Al-Y+ReTa coatings[J].Journal of Thermal Spray Technology,2005,14(3):315-320.
[39]ZHANG C,LIAO H L,LI W Y,et al.Characterization of YSZ solid oxide fuel cells electrolyte deposited by atmospheric plasma spraying and low pressure plasma spraying[J].Journal of Thermal Spray Technology,2006,15(4):598-603.
[40]ZHANG L W,NING X J,LU L,et al.Hot corrosion behavior of low-pressure cold-sprayed CoNiCrAlY coatings[J].Journal of Thermal Spray Technology,2016,25(3):587-594.
[41]SURYANARAYANA C.Mechanical alloying and milling[J].Progress in Materials Science,2001,46(1):1-184.
[42]SURYANARAYANA C.Mechanical alloying and milling[M].[S.n.]:CRC Press,2004,23-42.
[43]XI S Q,ZHOU J G,WANG X T.Research on temperature rise of powder during high energy ball milling[J].Powder Metallurgy,2013.
[44]DELOGU F.A Combined experimental and numerical approach to the kinetics of mechanically induced phase transformations[J].Acta Materialia,2008,56(4):905-912.
[45]李勇,张强,李长久,等.基于冷喷涂MCrAlY粘接层的热障涂层热循环失效的研究[C]//第七届全国表面工程学术会议.[出版地不详]:[出版者不详],2008:105-108.
[46]LI Y,LI C J,ZHANG Q,et al.Influence of TGO composition on the thermal shock lifetime of thermal barrier coatings with cold-sprayed MCrAlY bond coat[J].Journal of Thermal Spray Technology,2010,19(1/2):168-177.
[47]MATSUMOTO M,HAYAKAWA K,KITAOKA S,et al.The effect of preoxidation atmosphere on oxidation behavior and thermal cycle life of thermal barrier coatings[J].Materials Science and Engineering:A,2006,441(1):119-125.
[48]LI Y,LI C J,YANG G J,et al.Thermal fatigue behavior of thermal barrier coatings with the MCrAlY bond coats by cold spraying and low-pressure plasma spraying[J].Surface and Coatings Technology,2010,205(7):2225-2233.
[49]BONADEI A,MARROCCO T.Cold sprayed MCrAlY+X coating for gas turbine blades and vanes[J].Surface andCoatings Technology,2014,242:200-206.
[50]LI Y,LI C J,ZHANG Q,et al.Effect of chemical compositions and surface morphologies of MCrAlY coatingon its isothermal oxidation behavior[J].Journal of Thermal Spray Technology,2011,20(1/2):121-131.
[51]LEE K I,SATO K,OGAWA K.Mechanical properties and deposition mechanism of cold-sprayed CoNiCrAlY/YSZ cermet[J].Materials Transactions,2016,57(3):385-391.
[52]CIZEK J,MATEJKOVA M,KOURIL J,et al.Potential of new-generation electron beam technology in interface modification of cold and HVOF sprayed MCrAlY bond coats[J].Advances in Materials Science and Engineering,2016,2016:1-6.