激光重熔等离子喷涂纳米氧化锆热障涂层组织与性能研究
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摘要
随着现代航空航天工业的发展,常规热障涂层已经不能满足高温热端部件日益提高的性能要求。因此研究工作者开始将纳米技术、激光重熔表面处理技术与等离子喷涂技术结合起来,期望获得具有更好性能的热障涂层。
本文采用大气等离子喷涂纳米氧化锆(ZrO_2-8%Y_2O_3)团聚粉末制备了纳米氧化锆热障涂层,并利用连续CO_2激光对其进行重熔处理。以常规热障涂层作为比较对象,系统地研究了纳米氧化锆热障涂层和激光重熔涂层的组织结构、物相组成和性能特点(抗热冲击性能、耐摩擦磨损性能、高温稳定性能)。
纳米氧化锆热障涂层组织结构及其性能试验结果分析表明:纳米氧化锆热障涂层展现出独特的纳米-微米复合结构,主要由柱状晶和未熔融或部分熔融纳米颗粒组成。非平衡四方相是纳米氧化锆热障涂层的主要物相,涂层不含有单斜相。和常规热障涂层相比,纳米氧化锆热障涂层拥有更好的抗热冲击性能。这主要得益于其相对致密的结构以及微裂纹、纳米晶粒、小孔径孔隙的应力缓释作用。纳米氧化锆热障涂层高温稳定性能性能试验结果表明,涂层晶粒度随着服役温度和服役时间的增加而增加,但是仍保持纳米结构;涂层物相组成不随服役环境的变化而变化。因此纳米氧化锆热障涂层拥有很好的高温稳定性能。纳米结构涂层的耐高温摩擦磨损性能优于常规热障涂层。
激光重熔试验结果显示,随着激光重熔工艺参数的变化,重熔涂层很容易产生“凹坑”、“涂层剥落”、“气孔”等缺陷。但是通过优化激光重熔工艺参数是可以获得质量良好、无缺陷的激光重熔涂层。随着激光比能量的逐渐增加,涂层组织结构由单一的柱状晶逐渐变为柱状晶和等轴晶的复合结构。激光重熔涂层的X射线衍射结果证实了重熔涂层的组织分析结果。激光重熔表面处理可以显著提高热障涂层的抗热冲击性能,表面等轴晶对外界腐蚀介质的封闭作用、断面柱状晶和表面网状微裂纹的热应力缓释机制,是拥有复合结构的重熔涂层展现出最优抗热冲击性能的主要原因。
通过以上试验分析可以得出,将纳米技术和激光重熔表面处理技术与等离子喷涂技术结合起来制备热障涂层是提高热障涂层性能的非常有前景的工艺方法。
It is gradually difficult for conventional thermal barrier coatings (TBCs) to satisfy the increasing requirements for the performance of the high temperature components with the development of modern aeronautic and space industry. So the nanometer technology and laser glazing are combined with atmospheric plasma spraying in order to prepare TBCs with better performance.
In the thesis the nanostructured zirconia TBCs were manufactured by atmospheric plasma spraying using the nanostructured zirconia agglomerated powders, and the CO_2 laser beam with the continuous wave was applied to the laser glazing of nanostructured TBCs. And the microstructures, phase composition and properties (thermal shock resistance, friction and wear property and high temperature stability) of nanostructured TBCs and as-glazed TBCs were systematically investigated compared to conventional TBCs.
The experimental results of microstructures and properties of the nanostructured TBCs indicated that the nanostructured TBCs exhibited a unique complex microstructure consisting of columnar grains and non-melted or partial melted nanosized particles. XRD analysis showed that the metastable tetragonal phase was the major predominant phase of the nanostructured TBCs without the presence of monoclinic phase. The nanostructured TBCs possessed better thermal shock resistance than conventional TBCs. This phenomenon was ascribed to the relatively densified coating, microcracks, nanosized grains and fine porosity which can effectively release the thermal stress. And the thermal stress was the main reason leading to the failure of nanostructured TBCs. The results of the high temperature stability of nanostuctured TBCs demonstrated that the grain size of the coatings increased with the increasing testing temperature and time, but the grain size was still lower than 100nm; and the phase composition of the coatings didn't change with the different temperature and time. So the nanostructured TBCs had better high temperature stability in terms of the change tendency of grain size and phase composition. The nanostructured TBCs can improve the wear property of the TBCs compared to the conventional coatings.
The experimental results of laser glazing demonstrated that laser glazing was so sensitive to the processing parameters. The surface of the as-glazed coatings exhibited different defects such as surface color change, craters, porosity, exfoliation if the processing parameters couldn't be properly adjusted. But the defects-free as-glazed coatings can be prepared through the optimization of the laser glazing conditions. SEM observation indicated that the microstructure of the as-glazed coatings changed from single columnar grains to a combination of columnar grains in the fracture and equiaxed grains on the surface with the increase of laser energy density. The results of XRD analysis were consistent with the SEM examination. Laser glazing can notalbly enhance the life-time of TBCs with the possibility to double the number of cycles compared to the nanostructured TBCs. The two main reasons for the improvement of thermal shock resistance were to: (i) effectively decrease the permeability of the corrosion medium to the bond coat by equiaxed grain on the surface; (ii) relax the thermal stress extensively by the columnar grain and net-microcracks and increase the strain compliance of the as-glazed coatings.
So it can be pointed out that the hybrid process that the nanometer technology and laser glazing are combined with atmospheric plasma spraying to prepare TBCs has been revealing a high potential for the improvement of TBCs properties.
本文采用大气等离子喷涂纳米氧化锆(ZrO_2-8%Y_2O_3)团聚粉末制备了纳米氧化锆热障涂层,并利用连续CO_2激光对其进行重熔处理。以常规热障涂层作为比较对象,系统地研究了纳米氧化锆热障涂层和激光重熔涂层的组织结构、物相组成和性能特点(抗热冲击性能、耐摩擦磨损性能、高温稳定性能)。
纳米氧化锆热障涂层组织结构及其性能试验结果分析表明:纳米氧化锆热障涂层展现出独特的纳米-微米复合结构,主要由柱状晶和未熔融或部分熔融纳米颗粒组成。非平衡四方相是纳米氧化锆热障涂层的主要物相,涂层不含有单斜相。和常规热障涂层相比,纳米氧化锆热障涂层拥有更好的抗热冲击性能。这主要得益于其相对致密的结构以及微裂纹、纳米晶粒、小孔径孔隙的应力缓释作用。纳米氧化锆热障涂层高温稳定性能性能试验结果表明,涂层晶粒度随着服役温度和服役时间的增加而增加,但是仍保持纳米结构;涂层物相组成不随服役环境的变化而变化。因此纳米氧化锆热障涂层拥有很好的高温稳定性能。纳米结构涂层的耐高温摩擦磨损性能优于常规热障涂层。
激光重熔试验结果显示,随着激光重熔工艺参数的变化,重熔涂层很容易产生“凹坑”、“涂层剥落”、“气孔”等缺陷。但是通过优化激光重熔工艺参数是可以获得质量良好、无缺陷的激光重熔涂层。随着激光比能量的逐渐增加,涂层组织结构由单一的柱状晶逐渐变为柱状晶和等轴晶的复合结构。激光重熔涂层的X射线衍射结果证实了重熔涂层的组织分析结果。激光重熔表面处理可以显著提高热障涂层的抗热冲击性能,表面等轴晶对外界腐蚀介质的封闭作用、断面柱状晶和表面网状微裂纹的热应力缓释机制,是拥有复合结构的重熔涂层展现出最优抗热冲击性能的主要原因。
通过以上试验分析可以得出,将纳米技术和激光重熔表面处理技术与等离子喷涂技术结合起来制备热障涂层是提高热障涂层性能的非常有前景的工艺方法。
It is gradually difficult for conventional thermal barrier coatings (TBCs) to satisfy the increasing requirements for the performance of the high temperature components with the development of modern aeronautic and space industry. So the nanometer technology and laser glazing are combined with atmospheric plasma spraying in order to prepare TBCs with better performance.
In the thesis the nanostructured zirconia TBCs were manufactured by atmospheric plasma spraying using the nanostructured zirconia agglomerated powders, and the CO_2 laser beam with the continuous wave was applied to the laser glazing of nanostructured TBCs. And the microstructures, phase composition and properties (thermal shock resistance, friction and wear property and high temperature stability) of nanostructured TBCs and as-glazed TBCs were systematically investigated compared to conventional TBCs.
The experimental results of microstructures and properties of the nanostructured TBCs indicated that the nanostructured TBCs exhibited a unique complex microstructure consisting of columnar grains and non-melted or partial melted nanosized particles. XRD analysis showed that the metastable tetragonal phase was the major predominant phase of the nanostructured TBCs without the presence of monoclinic phase. The nanostructured TBCs possessed better thermal shock resistance than conventional TBCs. This phenomenon was ascribed to the relatively densified coating, microcracks, nanosized grains and fine porosity which can effectively release the thermal stress. And the thermal stress was the main reason leading to the failure of nanostructured TBCs. The results of the high temperature stability of nanostuctured TBCs demonstrated that the grain size of the coatings increased with the increasing testing temperature and time, but the grain size was still lower than 100nm; and the phase composition of the coatings didn't change with the different temperature and time. So the nanostructured TBCs had better high temperature stability in terms of the change tendency of grain size and phase composition. The nanostructured TBCs can improve the wear property of the TBCs compared to the conventional coatings.
The experimental results of laser glazing demonstrated that laser glazing was so sensitive to the processing parameters. The surface of the as-glazed coatings exhibited different defects such as surface color change, craters, porosity, exfoliation if the processing parameters couldn't be properly adjusted. But the defects-free as-glazed coatings can be prepared through the optimization of the laser glazing conditions. SEM observation indicated that the microstructure of the as-glazed coatings changed from single columnar grains to a combination of columnar grains in the fracture and equiaxed grains on the surface with the increase of laser energy density. The results of XRD analysis were consistent with the SEM examination. Laser glazing can notalbly enhance the life-time of TBCs with the possibility to double the number of cycles compared to the nanostructured TBCs. The two main reasons for the improvement of thermal shock resistance were to: (i) effectively decrease the permeability of the corrosion medium to the bond coat by equiaxed grain on the surface; (ii) relax the thermal stress extensively by the columnar grain and net-microcracks and increase the strain compliance of the as-glazed coatings.
So it can be pointed out that the hybrid process that the nanometer technology and laser glazing are combined with atmospheric plasma spraying to prepare TBCs has been revealing a high potential for the improvement of TBCs properties.
引文
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[2]林锋,蒋显亮.热障涂层的研究进展[J].功能材料,2003,34(3):254-261.
[3]Maurice Gell.Application opportunities for nanostructured materials and coatings[J].Materials Science and Engineering,1995,A204:246-251.
[4]Ping Wu,Hongrnei Jin,Yi Li.Correlation of chemical element properties and additive behaviors of ternary zinc compounds[J].Calp had,2002,26(1):55-62.
[5]郭铁波,周细应,林文松等.纳米热喷涂技术的研究现状与展望[J].表面技术,2003,32(4):1-3.
[6]梁志芳,李午申,王迎娜.热喷涂制备纳米涂层的研究现状与展望[J].焊接学报,2003,24(6):94-98.
[7]Xin Wang,Ping Xiao,et al.Laser processing of yttria stabilized zirconia/alumina coatings on Fecralloy substrates[J].Surface & Coatings Technology,2004,187:370-376.
[8]H.L.Tsai,P.C.Tsai.Performance of laser-glazed plasma-sprayed (ZrO_2-12wt.%Y_2O_3)/(Ni-22wt.%Cr-10wt.%Al-1wt.%Y) thermal barrier coatings in cyclic oxidation tests[J].Surface & Coatings Technology,1995,71:53-59.
[9]江志强,席守谋,李华伦.激光重熔等离子喷涂陶瓷涂层的研究与发展[J].材料工程,1999,20(1):46-48.
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