大气等离子体喷涂的单片层研究进展

doi:10.15541/jim20160461

摘要/Abstract

摘要：

大气等离子体喷涂技术是一种常用的涂层制备工艺。作为所制备涂层的结构基元, 单片层的形貌特征及堆叠行为决定了涂层的微结构, 对涂层性能产生显著影响。本文较为系统地综述了与熔滴自身理化状态相关的主体因素、与沉积涂层的衬底相关的客体因素以及环境因素等对单片层形成过程的影响, 着重分析了粉体尺寸、衬底预热过程等产生的多种不同影响及其之间的关联性, 并通过对所述文献涉及实验方法各自特点的比较, 提出未来的实验和模拟研究或都将向着与真实生产条件更加接近的方向发展。

关键词: 大气等离子体喷涂, 热障涂层, 熔滴, 单片层, 综述

Abstract:

Atmospheric plasma spraying (APS) is a well-established method to fabricate coatings. Since the coatings are piled up with splat, the morphology of splats is of significant importance for the microstructure and performance of coatings deposited by APS. In the current review, the influences of parameters in spraying processes on formation of splats were divided into three categories, namely the droplet-related factors, substrate-related factors and environmental-related factors. The influence of above mentioned factors on morphology of splats were systematically introduced. Among them, effect of powder size and substrates preheating were emphatically discussed. Future research direction was also pointed out based on the reviewed literature in this paper.

Key words: atmospheric plasma spraying, thermal barrier coatings, droplet, splat, review

中图分类号:

TQ174

李大川, 赵华玉, 钟兴华, 陶顺衍. 大气等离子体喷涂的单片层研究进展[J]. 无机材料学报, 2017, 32(6): 571-580.

LI Da-Chuan, ZHAO Hua-Yu, ZHONG Xing-Hua, TAO Shun-Yan. Research Progresses of Atmospheric Plasma Sprayed Splat[J]. Journal of Inorganic Materials, 2017, 32(6): 571-580.

图/表 9

图1 常见的等离子体喷枪结构示意图

Fig. 1 Schematic drawing of typical plasma torch

表1 不同轴向位置处颗粒的直径、速率及温度的平均值[12]

Table 1 Average values of the particle size, velocity and temperature at different radial positions from the plasma jet center line[12]

Radial position /mm	Average particle diameter /μm	Average particle velocity/(m·s^-1)	Average particle temperature /K
+50	25.7	236	3310
+40	26.3	247	3342
+30	27.8	254	3392
+20	30.3	248	3430
+10	32.3	233	3420
0	36.5	228	3400
-10	37.0	215	3340
-20	38.2	209	3310
-30	42.3	199	3294
-40	44.3	191	3270
-50	45.6	188	3250

图2 市售Oerlikon Metco公司部分陶瓷粉体原料的外观和内部特征[13]

Fig. 2 Shape and interior morphologies of the ceramic powder provided by Oerlikon Metco[13]

图3 模拟完全熔融与半熔融状态镍金属颗粒形成单片层过程[17]

Fig. 3 Computer-generated images of the normal impact of a molten and a semi-molten nickel droplet[17]

图4 测量钼液滴冷却时间的设备及其原理[26]

Fig. 4 Schematic of the experimental setup and typical signals collected during an impact of a molybdenum droplet on a smooth glass substrate[26]

图5 碰撞初期的激冷导致单片层呈溅射状的机理[34]

Fig. 5 Comparison of cooling and solidiﬁcation processes inside the splat deposited onto substrates at a temperature above (left) and below (right) transition temperature[34]

图6 在经过刻蚀处理的硅表面铺展的YSZ熔滴形貌[40]

Fig. 6 SEM images of YSZ splats on patterned silicon surface[40]

图7 经不同温度预氧化处理后的不锈钢表面形貌、所沉积镍单片层的形貌以及单片层形成过程中冷却速率的对比[39]

Fig. 7 Surface topologies of stainless steel surfaces either non-oxidized or preoxidized at different temperatures, images of nickel splats after solidification and cooling curves of splats[39]

图8 温度、气压和基体表面成分对铜单片层外形及晶粒尺寸的影响[28]

Fig. 8 Grain size in a cross-section of the splat obtained in different ambient pressures[28](a) on stainless steel in atmospheric pressure; (b) on gold-coated stainless steel in atmospheric pressure; (c) on stainless steel under low pressure; and (d) on gold-coated stainless steel under low pressure

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