航机CMC热端部件用热喷涂涂层的机遇与挑战

doi:10.15541/jim20230565

无机材料学报 ›› 2024, Vol. 39 ›› Issue (10): 1077-1083.DOI: 10.15541/jim20230565 CSTR: 32189.14.10.15541/jim20230565

所属专题：【结构材料】热障与环境障涂层(202412)

• 专题评述 • 下一篇

航机CMC热端部件用热喷涂涂层的机遇与挑战

陶顺衍¹(), 杨加胜¹, 邵芳¹, 吴应辰¹^,², 赵华玉¹, 董绍明³, 张翔宇³, 熊瑛⁴

1.中国科学院上海硅酸盐研究所, 中国科学院特种无机涂层重点实验室, 上海 201899
2.中国科学院大学, 北京 100049
3.中国科学院上海硅酸盐研究所, 高性能陶瓷与超微结构国家重点实验室, 上海 200050
4.中国航发沈阳黎明航空发动机有限责任公司, 沈阳 110043

收稿日期:2024-03-25 修回日期:2024-05-27 出版日期:2024-10-20 网络出版日期:2024-10-09
作者简介:陶顺衍(1969-), 男, 研究员. E-mail: sytao@mail.sic.ac.cn
基金资助:
国家重点研发计划(2023YFB3711203);上海市自然科学基金面上项目(21ZR1472800)

Thermal Spray Coatings for Aircraft CMC Hot-end Components: Opportunities and Challenges

TAO Shunyan¹(), YANG Jiasheng¹, SHAO Fang¹, WU Yingchen¹^,², ZHAO Huayu¹, DONG Shaoming³, ZHANG Xiangyu³, XIONG Ying⁴

1. Key Laboratory of Inorganic Coating Materials CAS, Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai 201899, China
2. University of Chinese Academy of Sciences, Beijing 100049, China
3. State Key Laboratory of High Performance Ceramics and Superfine Microstructure, Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai 200050, China
4. AECC Shenyang Liming Aero-Engine Co., Ltd., Shenyang 110043, China

Received:2024-03-25 Revised:2024-05-27 Published:2024-10-20 Online:2024-10-09
About author:TAO Shunyan (1969-), male, professor. E-mail: sytao@mail.sic.ac.cn
Supported by:
National Key R＆D Program of China(2023YFB3711203);Natural Science Foundation of Shanghai(21ZR1472800)

摘要/Abstract

摘要：

随着航空发动机涡轮前燃气入口温度的不断攀升, 陶瓷基复合材料(Ceramic Matrix Composite, CMC)以其轻质、高强、抗氧化、对裂纹不敏感、耐温性能优异等特点, 成为新一代航空发动机高温部件的首选基体材料。但CMC存在抗高温水氧侵蚀性能不足等问题, 发动机CMC热端部件用热喷涂涂层成为亟待解决的技术瓶颈。本文结合国外航空发动机热端部件选材方案的更迭及工程应用实例, 分析了发动机热端部件采用高温合金+气膜冷却+热障涂层方案的技术局限性, 明确了CMC+适量气膜冷却+环境障碍涂层方案的技术优势; 综述了CMC用热与环境障碍涂层(Thermal and Environmental Barrier Coatings, TEBCs)和环境障碍可磨耗封严涂层(Environmental Barrier Coatings-Abradable Sealing Coatings, EBCs-ASCs)的研究进展、应用情况以及近些年国内外学者的研究成果; 辨析了面向更高温燃气来流时热喷涂环境障碍涂层面临的机遇与挑战, 为后续TEBCs的组分和结构设计以及制备明确了方向, 并对今后研究工作的重点进行了展望。

关键词: 热喷涂, 环境障碍涂层, 热与环境障碍涂层, 可磨耗封严涂层, 陶瓷基复合材料, 专题评述

Abstract:

With the rising of the gas inlet temperature in front of the turbine of aero-engine, ceramic matrix composites (CMCs) have emerged as the preferred matrix material for the new generation of high-temperature components in aero-engine due to their light weight, high strength, oxidation resistance, insensitivity to crack, and excellent temperature durability. However, because of their limited resistance to high temperature water vapor and oxygen erosion, development of thermal spray coating technology for hot-end components of CMCs engines has become an urgent challenge to be overcome. In this paper, based upon changes of material selection strategies and application examples of foreign aero-engines, technical limitations of the employed superalloys + film cooling + thermal barrier coatings (TBCs) for hot-end components of aero-engines were analyzed, and technical advantages of the utilized CMCs + appropriate film cooling + environmental barrier coatings (EBCs) were consolidated. Thermal and environmental barrier coatings (TEBCs) and environmental barrier coatings-abradable sealing coatings (EBCs-ASCs) for CMCs were reviewed on the basis of recent research findings from domestic and oversea scholars. Finally, opportunities and challenges associated with thermal spraying EBCs for higher temperature gas flow were analyzed, and the direction of design and preparation on a certain composition and structure for TEBCs was clarified, among which the focal points of future research endeavors were prospected.

Key words: thermal spraying, environmental barrier coating, thermal and environmental barrier coating, abradable sealing coating, ceramic matrix composite, perspective

中图分类号:

TQ174

陶顺衍, 杨加胜, 邵芳, 吴应辰, 赵华玉, 董绍明, 张翔宇, 熊瑛. 航机CMC热端部件用热喷涂涂层的机遇与挑战[J]. 无机材料学报, 2024, 39(10): 1077-1083.

TAO Shunyan, YANG Jiasheng, SHAO Fang, WU Yingchen, ZHAO Huayu, DONG Shaoming, ZHANG Xiangyu, XIONG Ying. Thermal Spray Coatings for Aircraft CMC Hot-end Components: Opportunities and Challenges[J]. Journal of Inorganic Materials, 2024, 39(10): 1077-1083.

图/表 10

图1 不同推重比航空发动机对应的燃气入口温度

Fig. 1 Inlet gas temperatures corresponding to aero-engines with different thrust-weight ratios

图2 高温合金材料工艺发展对发动机性能提升的贡献度[1]

Fig. 2 Contribution of changes in high temperature alloy process to engine performance improvement [1]

图3 NOx排放与燃烧室出口温度之间的关系[2]

Fig. 3 Relationship between NOx emission and combustion chamber outlet temperature[2]

图4 发动机热端部件选材方案及其承温特性[5-6]

Fig. 4 Material selection scheme and its corresponding temperature bearing characteristics of engine hot-end components[5-6]

图5 用于CFM Leap-1A和Leap-1B发动机的CMC涡轮外环涂层构件[1]

Fig. 5 Shroud ring coating components of CMC turbine for CFM Leap-1A and Leap-1B engines[1]

图6 APS-EBCs与APS-TBCs的近红外波段光谱反射率

Fig. 6 Near-infrared spectral reflectance of APS-EBCs and APS-TBCs

图7 TEBCs功能分区的多层结构设计

Fig. 7 Designed TEBCs with multi-layer structure of functional partition

图8 典型陶瓷材料的水氧腐蚀速率与热膨胀系数的关系[24]

Fig. 8 Relationship between the water-oxygen corrosion rate and the thermal expansion coefficient of ceramic materials[24]

图9 用于高温合金材质一级涡轮外环的TBCs-ASCs[40]

Fig. 9 TBC-ASCs for shroud ring of the first stage turbine of high temperature alloy material[40]

图10 Sulzer Innotec刮磨试验台示意图[44]

Fig. 10 Schematic drawing of the Sulzer Innotec abradability test rig [44] The oxygen / propane high temperature gas is used to heat the test piece, which can be heated to 1200 ℃; Scratch speed: 50-450 m/s; Feed rate: 1.5-3000 μm/s

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航机CMC热端部件用热喷涂涂层的机遇与挑战

Thermal Spray Coatings for Aircraft CMC Hot-end Components: Opportunities and Challenges

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