粗糙度对热障涂层冲蚀失效的影响及模型建立

doi:10.3724/SP.J.1077.2014.13342

无机材料学报 ›› 2014, Vol. 29 ›› Issue (3): 294-300.DOI: 10.3724/SP.J.1077.2014.13342 CSTR: 32189.14.SP.J.1077.2014.13342

粗糙度对热障涂层冲蚀失效的影响及模型建立

张小锋^1,2, 周克崧^1,2, 张吉阜², 韩滔², 宋进兵², 刘敏²

(1. 华南理工大学材料科学与工程学院广州510640; 2. 广州有色金属研究院新材料研究所, 广州510650)

收稿日期:2013-07-01 修回日期:2013-08-15 出版日期:2014-03-20 网络出版日期:2014-02-18
作者简介:张小锋(1986-), 男, 博士研究生. E-mail:zxf200808@126.com
基金资助:
国家“973计划”项目(2012CB625100) National Basic Research Program of China “973 Program” (2012CB625100)

Erosion Failure Mechanism and Model Establishment of Thermal Barrier Coatings Based on Roughness

ZHANG Xiao-Feng^{1, 2}, ZHOU Ke-Song^{1, 2}, ZHANG Ji-Fu², HAN Tao², Song Jin-Bing², LIU-Min²

(1. School of Materials Science and Engineering, South China University of Technology, Guangzhou 510640, China; 2. Institute of New Materials, Guangzhou Research Institute of Non-ferrous Metals, Guangzhou 510650, China)

Received:2013-07-01 Revised:2013-08-15 Published:2014-03-20 Online:2014-02-18
About author:ZHANG Xiao-Feng. E-mail:zxf200808@126.com

摘要/Abstract

摘要：

采用气体喷砂试验机研究了大气等离子喷涂(APS) ZrO₂-7%Y₂O₃(7YSZ)热障涂层的冲蚀失效机理, 分析了陶瓷层表面粗糙度对热障涂层冲蚀磨损率及失效行为的影响, 研究了基于多孔层状的热障涂层在常温高速粒子90°攻角下的冲蚀失效特征, 探讨了多孔层状结构对涂层冲蚀失效演变机制的作用, 此外, 建立了基于粗糙度的冲蚀失效数学模型。研究结果表明: 冲蚀磨损率与陶瓷层表面粗糙度呈线性递增关系; 涂层在高速粒子冲蚀下多孔层状结构加剧了涂层的冲蚀失效; 涂层表面在粒子冲蚀下承受着非均匀、非连续的压-压脉动循环载荷, 在微凸粗糙表面承载着正应力和切应力的相互作用; 正应力迫使涂层出现凹坑, 切应力易导致涂层出现沟槽, 并同时以原喷涂态表面网状裂纹为策源地诱发裂纹在粒子晶界和层间界面萌生扩展导致涂层产生粒子和片状剥落, 最终涂层显示出典型的磨粒磨损和低周疲劳失效形式。

关键词: 热障涂层, 冲蚀机理, 粗糙度

Abstract:

Erosion failure mechanism of atmospheric plasma sprayed (APS) ZrO₂-7%Y₂O₃(7YSZ) thermal barrier coatings (TBCs) was studied with a san-blasting erosion tester. The failure features of TBCs with laminar and porous structure were investigated using impingement angle 90° at room temperature. Effect of porous and laminar structure on erosion rate was analyzed. Moreover, regarding the failure factors, the relation of ceramic coating roughness and erosion rate was analyzed and their mathematic model was established. The experimental results indicate that the factors of porous and laminar structures play an important role in crack propagation in TBCs. For the TBCs with ununiform, discontinuous pressure-pressure pulsating cyclic load under impact of high velocity particles, the ceramic coatings are loaded with normal stress and shear stress, in which the normal stress leads to appearance of pit in ceramic coating and the shear stress leads to grooves. Meanwhile, the crack propagation in grain boundaries and interfaces of laminar structure will appear based on the net cracks on ceramic coating surface in sprayed TBCs, which will lead to particle exfoliation and flaky debris. So the erosion failures of TBCs follows abrasive wear and low cycle fatigue mode. The relevance between ceramic coating roughness and erosion rate indicates an increased linear relation.

Key words: thermal barrier coating, erosion mechanism, roughness

中图分类号:

TQ174

张小锋, 周克崧, 张吉阜, 韩滔, 宋进兵, 刘敏. 粗糙度对热障涂层冲蚀失效的影响及模型建立[J]. 无机材料学报, 2014, 29(3): 294-300.

ZHANG Xiao-Feng, ZHOU Ke-Song, ZHANG Ji-Fu, HAN Tao, Song Jin-Bing, LIU-Min. Erosion Failure Mechanism and Model Establishment of Thermal Barrier Coatings Based on Roughness[J]. Journal of Inorganic Materials, 2014, 29(3): 294-300.

图/表 9

图1 NiCoCrAlYTa粉末(a)和7YSZ粉末(b)的SEM照片

Fig. 1 SEM images of NiCoCrAlYTa powders (a) and 7YSZ powders (b)

图2 气体喷砂冲蚀试验机示意图

Fig. 2 Schematic diagram of san-blasting erosion tester

图3 不同粗糙度陶瓷面层的3D形貌

Fig. 3 3D topologies of ceramic coating with different roughnesses

图4 不同陶瓷层粗糙度样品的冲蚀率与时间关系

Fig. 4 Relationship between erosion rate and time for ceramic coating with different roughnesses

图5 冲蚀率(ER)与陶瓷面层粗糙度(Ra)之间的关系

Fig. 5 Relation between erosion rate (ER) and roughness (Ra) for ceramic coating

图6 陶瓷面层样品不同放大倍率微观形貌

Fig. 6 Different magnification surface microstructures of ceramic coating Protection district, (a1, a2); Erosion district after erosion for 120 s, (b1, b2, b3)

图7 保护区和冲蚀区断面显微照片

Fig. 7 Cross-sectional microstructures of protection district and erosion district Whole district (a), protection district (b), erosion district (c-f) after erosion for 120 s

图8 90°攻角下涂层冲蚀失效模型

Fig. 8 Sand-blasting erosion failure model under 90°

图9 不同粗糙度陶瓷层样品的冲蚀示意图

Fig. 9 Erosion schematics of ceramic coating with different roughnesses

参考文献 19

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粗糙度对热障涂层冲蚀失效的影响及模型建立

Erosion Failure Mechanism and Model Establishment of Thermal Barrier Coatings Based on Roughness

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