热障涂层材料及其制备技术的研究进展
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摘要
热障涂层能够增加高温合金的工作温度和使用寿命,被广泛用于航空发动机高温端部件的表面防护领域。对国内外热障涂层材料及其制备技术进行了综述,指出其存在的主要问题,并提出激光-感应复合熔覆梯度功能热障涂层的新方法,即在感应预热基材的同时实现与激光热源的复合,形成激光-感应复合熔覆热源,结合涂层的梯度结构设计,在高效率下获得无裂纹、高性能的热障涂层。
To increase the operation temperature and service life of superalloy, thermal barrier coatings are widely employed in the surface protective field of high- temperature components of aircraft engine. In this paper, the research progress on materials and preparation techniques of thermal barrier coatings is reviewed. The main issues are analyzed and the method of the functionally graded thermal barrier coatings by laserinduction hybrid cladding(LIHC) is put forward. Namely, the substrate is preheated meanwhile laser cladding is carried out to form LIHC heat source, which is combined with the design of functionally graded structure. As a result, the crack-free and high-property thermal barrier coatings can be obtained under the condition of high efficiency.
To increase the operation temperature and service life of superalloy, thermal barrier coatings are widely employed in the surface protective field of high- temperature components of aircraft engine. In this paper, the research progress on materials and preparation techniques of thermal barrier coatings is reviewed. The main issues are analyzed and the method of the functionally graded thermal barrier coatings by laserinduction hybrid cladding(LIHC) is put forward. Namely, the substrate is preheated meanwhile laser cladding is carried out to form LIHC heat source, which is combined with the design of functionally graded structure. As a result, the crack-free and high-property thermal barrier coatings can be obtained under the condition of high efficiency.
引文
1 Yu Haitao,Mu Rende,Xie Min,et al..Evolution status and processing technologies of thermalbarrier coatings[J].Chinese Rare Earths,2010,31(5):83-87.于海涛,牟仁德,谢敏,等.热障涂层的研究现状及其制备技术[J].稀土,2010,31(5):83-87.
2 Zhou Hong,Li Fei,He Bo,et al..Research progresses in materials for thermal barrier coatings[J].Materials Review,2006,20(10):40-43.周洪,李飞,何博,等.热障涂层材料研究进展[J].材料导报,2006,20(10):40-43.
3 Li Jianbao,Zhou Yichun.New Materials Science and Application Technology[M].Beijing:Tsinghua University Press,2004.李建保,周益春.新材料科学及其实用技术[M].北京:清华大学出版社,2004.
4 R A Miller.Thermal barrier coatings for aircraft engines:history and directions[J].Thermal Spray Technology,1997,6(1):35-39.
5 Liu Fengling.The structure design of thermal barrier coating for21 century[J].Materials Pr`otection,2000,33(1):86-88.刘凤岭.面向21世纪的热障涂层结构设计[J].材料保护,2000,33(1):86-88.
6 Xu Huibin,Gong Shengkai,Liu Fushun.Recent development in materials design of thermalbarrier coatings for gas turbine[J].Acta Aeronautica et Astronautica Sinica,2000,21(1):7-12.徐惠彬,宫声凯,刘福顺.航空发动机热障涂层材料体系的研究[J].航空学报,2000,21(1):7-12.
7 M L Mendelson,T N Mckechnie,L B Spiegel.Graded thermal barriercoatings:evaluation[J].Ceramic Engineering and Science Proceedings,2008,15(4):555-562.
8 Wang Xuebing,Zhang Xinghong,Du Shanyi.Current status of graded thermal barrier coatings[J].China Surface Engineering,2004,17(3):5-12.王学兵,张幸红,杜善义.梯度热涂层的研究现状[J].中国表面工程,2004,17(3):5-12.
9 Liu Chunbo,Lin Feng,Jiang Xianliang.Current state and future development of thermal barrier coating[J].Chinese J Nonferrous Metals,2007,17(1):1-13.刘纯波,林锋,蒋显亮.热障涂层的研究现状与发展趋势[J].中国有色金属学报,2007,17(1):1-13.
10 Lin Feng,Jiang Xianliang.Research progress on plasma spraying[J].J Functional Materials,2003,34(3):254-257.林锋,蒋显亮.热障涂层的研究进展[J].功能材料,2003,34(3):254-257.
11 Deng Shijun.High Performance Ceramic Coating[M].Beijing:Chemical Industry Press,2003.邓世均.高性能陶瓷涂层[M].北京:化学工业出版社,2003.
12 X Q Cao,R Vassen,D Stoever.Ceramic materials for thermalbarrier coatings[J].J Eur Ceram Soc,2004,24(1):1-10.
13 Lu Anxian,Chang Ying,Cai Xiaomei.Investigation on plasma-sprayed ZrO2thermal barrier coating on nickel alloy substrate[J].J Central South University of Technology,2012,9(4):225-228.
14 Pan Wei,Xiu Qiang,Wang Jingdong,et al..Rare Earth Zirconate High Temperature Thermal Barrier Coating Material and Preparation Method[P].Chinese Patent,CN1657573,2005-08-24.潘伟,徐强,王敬栋,等.稀土锆酸盐高温热障涂层材料及其制备方法[P].中国专利,CN1657573,2005-08-24.
15 R Vassen,X Cao,F Tietz,et al..Zirconates as newmaterials for thermal barrier coatings[J].J Am Ceram Soc,2000,83(8):2023-2028.
16 Liu Jianming,Chen Meiying,Ren Xianjing,et al..The effects of alloy elements on the MCrAlYcoatings[J].Thermal Spray Technology,2010,2(4):30-34.刘建明,陈美英,任先京,等.合金元素在MCrAlY涂层中的作用[J].热喷涂技术,2010,2(4):30-34.
17 Mu Rende,He Limin,Lu Feng,et al..Development in research on TBC deposition technologies[J].Materials for Mechanical Engineering,2007,31(5):1-4.牟仁德,何利民,陆峰,等.热障涂层制备技术研究进展[J].机械工程材料,2007,31(5):1-4.
18 Zhang Gang,Liang Yong.Progress and research of laser prepared thermal barrier coatings[J].J Shenyang Institute of Technology,2000,19(1):1-7.张罡,梁勇.激光制备陶瓷热障涂层的研究和发展[J].沈阳工业学院学报,2000,19(1):1-7.
19 Guo Hongbo,Gong Shengkai,Xu Huibin,et al..Development of EB-PVD gradient thermal barrier coatings and their thermal fatigue behavious[J].Acta Metallurgica Sinica,2000,36(7):703-706.郭洪波,宫声凯,徐惠彬,等.EB-PVD梯度热障涂层的制备及其热疲劳性能[J].金属学报,2000,36(7):703-706.
20 He Shimei,He Limin,Mu Rende,et al..Effect of incontinuous deposition on the cyclic oxidation behavior of EB-PVD TBCs[J].Rare Metal Materials and Engineering,2007,36(3):702-705.贺世美,何利民,牟仁德,等.EB-PVD非连续沉积对热障涂层热循环氧化性能的影响[J].稀有金属材料与工程,2007,36(3):702-705.
21 Yu Haitao,Song Xiwen,Mu Rende.Thermal cycle characteristics of YSZ TBCs deposited by EB-PVD[J].Aeroengine,2010,36(6):50-57.于海涛,宋希文,牟仁德.电子束物理气相沉积YSZ热障涂层热循环性能[J].航空发动机,2010,36(6):50-57.
22 E W Douglas,A M Robert,I E Jeff,et al..Tailored microstructure of EB-PVD 8YSZ thermal barrier coatingswith low thermal conductivity and high thermal reflectivity for turbine applications[J].Surf Coat Technol,2005,190(1):132-149.
23 Zhi Xiang,Zhao Jianfeng,Cai Jun.Effect of process parameters on forming quality of fusion zone in laser cladding[J].Laser&Optoelectronics Progress,2011,48(10):101403.智翔,赵剑峰,蔡军.激光熔覆修复工艺参数对熔合区成形质量的影响[J].激光与光电子学进展,2011,48(10):101403.
24 Zhu Gangxian,Zhang Anfeng,Li Dichen.Effect of process parameters on surface smoothness in laser cladding[J].Chinese J Lasers,2010,37(1):296-301.朱刚贤,张安峰,李涤尘.激光熔覆工艺参数对熔覆层表面平整度的影响[J].中国激光,2010,37(1):296-301.
25 Yuan Qinglong,Feng Xudong,Cao Jingjing,et al..Research on microstructure of Ni-based alloy coating by laser cladding[J].Chinese J Lasers,2010,37(8):2116-2120.袁庆龙,冯旭东,曹晶晶,等.激光熔覆镍基合金涂层微观组织研究[J].中国激光,2010,37(8):2116-2120.
26 M F Morks,N F Fahim,T Muster,et al..In-situ synthesis of functional silica nanoparticles for enhancement the corrosion resistance of TBCs[J].Surf Coat Technol,2013,225:106-111.
27 Y T Pei,J H Ouyang,T C Lei.Laser cladding of ZrO2-(Ni alloy)composite coating[J].Surf Coat Technol,1996,81(2-3):131-135.
28 K M Jasim,R D Rawlings,D R F West.Thermal barrier coatings produced by laser cladding[J].J Mater Sci,1990,25(12):4943-4948.
29 J H Ouyang,S Nowotny,A Richter,et al..Characterization of laser clad yttria partially-stabilized ZrO2ceramic layers on steel 16MnCr5[J].Surf Coat Technol,2001,137(1):12-20.
30 Wang Dongsheng,Tian Zongjun,Wang Jingwen,et al..A method of crack control in laser cladding process with changing power density distribution of laser beam[J].Chinese J Lasers,2011,38(1):0103004.王东生,田宗军,王泾文,等.一种通过改变激光功率密度分布控制熔覆层裂纹的方法[J].中国激光,2011,38(1):0103004.
31 Zhou Shengfeng,Du Nan,Zeng Xiaoyan.The Method of Functionally Graded Thermal Coating by Laser Induction Hybrid Rapid Cladding[P].Chinese Patent,CN101748402A,2010-06-23.周圣丰,杜楠,曾晓雁.激光感应复合熔覆梯度功能热障涂层的方法[P].中国专利,CN101748402A,2010-06-23.
32 Zhou Shengfeng,Dai Xiaoqin,Zhang Tianyou,et al..Functionally graded YSZ/NiCrAlY coating prepared by laser induction hybrid rapid cladding[J].Chinese J Lasers,2013,40(4):0403004.周圣丰,戴晓琴,张天佑,等.激光感应复合快速熔覆功能梯度YSZ/NiCrAlY涂层的研究[J].中国激光,2013,40(4):0403004.
2 Zhou Hong,Li Fei,He Bo,et al..Research progresses in materials for thermal barrier coatings[J].Materials Review,2006,20(10):40-43.周洪,李飞,何博,等.热障涂层材料研究进展[J].材料导报,2006,20(10):40-43.
3 Li Jianbao,Zhou Yichun.New Materials Science and Application Technology[M].Beijing:Tsinghua University Press,2004.李建保,周益春.新材料科学及其实用技术[M].北京:清华大学出版社,2004.
4 R A Miller.Thermal barrier coatings for aircraft engines:history and directions[J].Thermal Spray Technology,1997,6(1):35-39.
5 Liu Fengling.The structure design of thermal barrier coating for21 century[J].Materials Pr`otection,2000,33(1):86-88.刘凤岭.面向21世纪的热障涂层结构设计[J].材料保护,2000,33(1):86-88.
6 Xu Huibin,Gong Shengkai,Liu Fushun.Recent development in materials design of thermalbarrier coatings for gas turbine[J].Acta Aeronautica et Astronautica Sinica,2000,21(1):7-12.徐惠彬,宫声凯,刘福顺.航空发动机热障涂层材料体系的研究[J].航空学报,2000,21(1):7-12.
7 M L Mendelson,T N Mckechnie,L B Spiegel.Graded thermal barriercoatings:evaluation[J].Ceramic Engineering and Science Proceedings,2008,15(4):555-562.
8 Wang Xuebing,Zhang Xinghong,Du Shanyi.Current status of graded thermal barrier coatings[J].China Surface Engineering,2004,17(3):5-12.王学兵,张幸红,杜善义.梯度热涂层的研究现状[J].中国表面工程,2004,17(3):5-12.
9 Liu Chunbo,Lin Feng,Jiang Xianliang.Current state and future development of thermal barrier coating[J].Chinese J Nonferrous Metals,2007,17(1):1-13.刘纯波,林锋,蒋显亮.热障涂层的研究现状与发展趋势[J].中国有色金属学报,2007,17(1):1-13.
10 Lin Feng,Jiang Xianliang.Research progress on plasma spraying[J].J Functional Materials,2003,34(3):254-257.林锋,蒋显亮.热障涂层的研究进展[J].功能材料,2003,34(3):254-257.
11 Deng Shijun.High Performance Ceramic Coating[M].Beijing:Chemical Industry Press,2003.邓世均.高性能陶瓷涂层[M].北京:化学工业出版社,2003.
12 X Q Cao,R Vassen,D Stoever.Ceramic materials for thermalbarrier coatings[J].J Eur Ceram Soc,2004,24(1):1-10.
13 Lu Anxian,Chang Ying,Cai Xiaomei.Investigation on plasma-sprayed ZrO2thermal barrier coating on nickel alloy substrate[J].J Central South University of Technology,2012,9(4):225-228.
14 Pan Wei,Xiu Qiang,Wang Jingdong,et al..Rare Earth Zirconate High Temperature Thermal Barrier Coating Material and Preparation Method[P].Chinese Patent,CN1657573,2005-08-24.潘伟,徐强,王敬栋,等.稀土锆酸盐高温热障涂层材料及其制备方法[P].中国专利,CN1657573,2005-08-24.
15 R Vassen,X Cao,F Tietz,et al..Zirconates as newmaterials for thermal barrier coatings[J].J Am Ceram Soc,2000,83(8):2023-2028.
16 Liu Jianming,Chen Meiying,Ren Xianjing,et al..The effects of alloy elements on the MCrAlYcoatings[J].Thermal Spray Technology,2010,2(4):30-34.刘建明,陈美英,任先京,等.合金元素在MCrAlY涂层中的作用[J].热喷涂技术,2010,2(4):30-34.
17 Mu Rende,He Limin,Lu Feng,et al..Development in research on TBC deposition technologies[J].Materials for Mechanical Engineering,2007,31(5):1-4.牟仁德,何利民,陆峰,等.热障涂层制备技术研究进展[J].机械工程材料,2007,31(5):1-4.
18 Zhang Gang,Liang Yong.Progress and research of laser prepared thermal barrier coatings[J].J Shenyang Institute of Technology,2000,19(1):1-7.张罡,梁勇.激光制备陶瓷热障涂层的研究和发展[J].沈阳工业学院学报,2000,19(1):1-7.
19 Guo Hongbo,Gong Shengkai,Xu Huibin,et al..Development of EB-PVD gradient thermal barrier coatings and their thermal fatigue behavious[J].Acta Metallurgica Sinica,2000,36(7):703-706.郭洪波,宫声凯,徐惠彬,等.EB-PVD梯度热障涂层的制备及其热疲劳性能[J].金属学报,2000,36(7):703-706.
20 He Shimei,He Limin,Mu Rende,et al..Effect of incontinuous deposition on the cyclic oxidation behavior of EB-PVD TBCs[J].Rare Metal Materials and Engineering,2007,36(3):702-705.贺世美,何利民,牟仁德,等.EB-PVD非连续沉积对热障涂层热循环氧化性能的影响[J].稀有金属材料与工程,2007,36(3):702-705.
21 Yu Haitao,Song Xiwen,Mu Rende.Thermal cycle characteristics of YSZ TBCs deposited by EB-PVD[J].Aeroengine,2010,36(6):50-57.于海涛,宋希文,牟仁德.电子束物理气相沉积YSZ热障涂层热循环性能[J].航空发动机,2010,36(6):50-57.
22 E W Douglas,A M Robert,I E Jeff,et al..Tailored microstructure of EB-PVD 8YSZ thermal barrier coatingswith low thermal conductivity and high thermal reflectivity for turbine applications[J].Surf Coat Technol,2005,190(1):132-149.
23 Zhi Xiang,Zhao Jianfeng,Cai Jun.Effect of process parameters on forming quality of fusion zone in laser cladding[J].Laser&Optoelectronics Progress,2011,48(10):101403.智翔,赵剑峰,蔡军.激光熔覆修复工艺参数对熔合区成形质量的影响[J].激光与光电子学进展,2011,48(10):101403.
24 Zhu Gangxian,Zhang Anfeng,Li Dichen.Effect of process parameters on surface smoothness in laser cladding[J].Chinese J Lasers,2010,37(1):296-301.朱刚贤,张安峰,李涤尘.激光熔覆工艺参数对熔覆层表面平整度的影响[J].中国激光,2010,37(1):296-301.
25 Yuan Qinglong,Feng Xudong,Cao Jingjing,et al..Research on microstructure of Ni-based alloy coating by laser cladding[J].Chinese J Lasers,2010,37(8):2116-2120.袁庆龙,冯旭东,曹晶晶,等.激光熔覆镍基合金涂层微观组织研究[J].中国激光,2010,37(8):2116-2120.
26 M F Morks,N F Fahim,T Muster,et al..In-situ synthesis of functional silica nanoparticles for enhancement the corrosion resistance of TBCs[J].Surf Coat Technol,2013,225:106-111.
27 Y T Pei,J H Ouyang,T C Lei.Laser cladding of ZrO2-(Ni alloy)composite coating[J].Surf Coat Technol,1996,81(2-3):131-135.
28 K M Jasim,R D Rawlings,D R F West.Thermal barrier coatings produced by laser cladding[J].J Mater Sci,1990,25(12):4943-4948.
29 J H Ouyang,S Nowotny,A Richter,et al..Characterization of laser clad yttria partially-stabilized ZrO2ceramic layers on steel 16MnCr5[J].Surf Coat Technol,2001,137(1):12-20.
30 Wang Dongsheng,Tian Zongjun,Wang Jingwen,et al..A method of crack control in laser cladding process with changing power density distribution of laser beam[J].Chinese J Lasers,2011,38(1):0103004.王东生,田宗军,王泾文,等.一种通过改变激光功率密度分布控制熔覆层裂纹的方法[J].中国激光,2011,38(1):0103004.
31 Zhou Shengfeng,Du Nan,Zeng Xiaoyan.The Method of Functionally Graded Thermal Coating by Laser Induction Hybrid Rapid Cladding[P].Chinese Patent,CN101748402A,2010-06-23.周圣丰,杜楠,曾晓雁.激光感应复合熔覆梯度功能热障涂层的方法[P].中国专利,CN101748402A,2010-06-23.
32 Zhou Shengfeng,Dai Xiaoqin,Zhang Tianyou,et al..Functionally graded YSZ/NiCrAlY coating prepared by laser induction hybrid rapid cladding[J].Chinese J Lasers,2013,40(4):0403004.周圣丰,戴晓琴,张天佑,等.激光感应复合快速熔覆功能梯度YSZ/NiCrAlY涂层的研究[J].中国激光,2013,40(4):0403004.