热震中7YSZ热障涂层结构演变

doi:10.15541/jim20150199

无机材料学报 ›› 2015, Vol. 30 ›› Issue (12): 1261-1266.DOI: 10.15541/jim20150199 CSTR: 32189.14.10.15541/jim20150199

热震中7YSZ热障涂层结构演变

张小锋^1,2,3, 周克崧^1,2,3, 张吉阜^2,3, 张永^2,3, 刘敏^2,3, 邓春明^2,3

(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现代材料表面工程技术国家工程实验室, 广州510650; 3.广州有色金属研究院新材料研究所, 广州510650)

收稿日期:2015-04-23 修回日期:2015-06-09 出版日期:2015-12-20 网络出版日期:2015-11-24
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);国家“863”计划项目(2012AA03A512);National Basic Research Program of China (2012CB625100);National High-tech Research and Development Program of China (2012AA03A512)

Structure Evolution of 7YSZ Thermal Barrier Coating During Thermal Shock Testing

ZHANG Xiao-Feng^1,2,3, ZHOU Ke-Song^{1, 2,3}, ZHANG Ji-Fu^2,3, ZHANG Yong^2,3, LIU Min^2,3, DENG Chun-Ming^2,3

(1. School of Materials Science and Engineering, South China University of Technology, Guangzhou 510640, China; 2. National Engineering Laboratory for Modern Materials Surface Engineering Technology, Guangzhou Research Institute of Non-ferrous Metals, Guangzhou 510650, China; 3. Institute of New Materials, Guangzhou Research Institute of Non-ferrous Metals, Guangzhou 510650, China)

Received:2015-04-23 Revised:2015-06-09 Published:2015-12-20 Online:2015-11-24
About author:ZHANG Xiao-Feng. E-mail: zxf200808@126.com

摘要/Abstract

摘要：

采用低温超音速等离子喷涂(LT-HVOF)在镍基高温合金基体上制备了NiCoCrAlYTa粘结层, 使用大气等离子喷涂(APS)在粘结层上`制备了7wt%Y₂O₃-ZrO₂ (7YSZ) 陶瓷层。基于动态试验即热震实验研究了粘结层的扩散氧化机制, 探讨了陶瓷层的烧结及相变过程并观察了涂层的结构演变。实验结果表明: 动态热循环下随着热震次数的增加, 粘结层组元扩散氧化形成热生长氧化物(TGO)且厚度逐渐增加。此外, 粘结层组元在温度梯度下沿陶瓷层内部裂纹向高温区扩散, 最终在陶瓷层表面裂纹区域出现大量的金属氧化物, 同时粘结层组元的扩散有助于陶瓷层的烧结, 导致其显微硬度逐渐增大, 而粘结层由于Kirkendall效应, 其内部出现大量的孔洞导致其显微硬度逐渐降低。另外, 陶瓷层在相变及热循环应力的作用下表面出现了大尺度的宏观裂纹。

关键词: 热震, 热生长氧化物, 失效机理, 结构演变

Abstract:

Bond coating NiCoCrAlYTa was prepared on nickel-based superalloy by low temperature-high velocity oxygen flame (LT-HVOF). Then 7wt% Y₂O₃ stabilized ZrO₂ ceramic coating was fabricated on bond coating by air plasma spray (APS). Diffusion principles of bond coating were investigated under thermal cycle by using multi-functional flame tester. Sintering and phase transformation of ceramic coating were studied. The experiment results show that with thermal cycle increase, thermally grown oxide (TGO) forms at the interface of ceramic-bond coating and its thickness continuously increases. Besides, the bond coating further diffuses to surface of ceramic coating. Lots of oxides appears on the surface of ceramic coating nearing microcrack. Diffusion of bond coating to surface contributes to sintering of ceramic coating, which leads to increase of microhardness. Additionally, plenty of voids were appeares in bond coating for Kirkendall effect resulting in decrease of microhardness. Large-scale cracks are observed after thermal cycle due to phase transformation and thermal residual stress.

Key words: thermal shock, TGO, failure mechanism, structure evolution

中图分类号:

TQ174

张小锋, 周克崧, 张吉阜, 张永, 刘敏, 邓春明. 热震中7YSZ热障涂层结构演变[J]. 无机材料学报, 2015, 30(12): 1261-1266.

ZHANG Xiao-Feng, ZHOU Ke-Song, ZHANG Ji-Fu, ZHANG Yong, LIU Min, DENG Chun-Ming. Structure Evolution of 7YSZ Thermal Barrier Coating During Thermal Shock Testing[J]. Journal of Inorganic Materials, 2015, 30(12): 1261-1266.

图/表 11

图1 高温合金基体加工尺寸

Fig. 1 Processing size of superalloy substrate

表1 LT-HVOF喷涂粘结层参数

Table 1 Parameters of NiCoCrAlYTa coating by LT-HVOF

Materials	Petrol /(L•h^-1)	Oxygen /(L•min^-1)	Combustor chamber pressure /MPa	Feed rate /(×10^-3, m³·min^-1)	Stand-off distance /mm
NiCoCrAlYTa	13	800	60	8	150

表2 APS喷涂7YSZ陶瓷层参数

Table 2 Parameters of 7YSZ coating by APS

Materials	Current/A	Voltage/V	Ar/slpm	H₂/slpm	Carrier gas Ar /slpm	Feed rate /(r•min^-1)	Stand-off distance/mm
7YSZ	680	67	45	5	4	2	110

图2 多功能燃气冲击实验仪

Fig. 2 Multi-functional flame tester

图3 (a)原始喷涂态陶瓷-金属界面和(b)热震1000次后陶瓷-金属界面形貌

Fig. 3 Interface micrographs of as-sprayed TBC (a) and TBC after 1000 cycles(b)

图4 TGO厚度随热震次数的变化

Fig. 4 Relationship between TGO thickness and cycle number

图5 (a)喷涂态陶瓷表面和(b)FIB切割后涂层断面形貌

Fig. 5 Morphologies of (a) surface of as-sprayed ceramic coating and (b) cross section milled by FIB

图6 热震1000次后涂层表面形貌(a)和其表面疏松反应物EDS分析(b)

Fig. 6 Surface morphology of ceramic coating after 1000 cycles (a) and EDS analysis of the reaction on the surface (b)

图7 陶瓷层与粘结层断面显微硬度与热震次数的关系

Fig. 7 Relationship between microhardness and cycle number consisted of ceramic and bond coating

图8 涂层的XRD图谱

Fig. 8 XRD patterns of powders and ceramic coating. (a) 7YSZ powders; (b) as-sprayed TBC; (c) 100 cycles; (d) 300 cycles; (e) 600 cycles; (f) 1000 cycles

图9 热震1000次后涂层表面形貌

Fig. 9 Surface morphology of ceramic coating after 1000 cycles

参考文献 19

[1]	CLARKE D R, LEVI C G.Materials design for the next generation thermal barrier coatings.Annual Review Mater. Research, 2003, 33: 383-417.
[2]	GURRAPPA I, RAO A S.Thermal barrier coatings for enhanced efficiency of gas turbine engines.Surf. Coat. Technol., 2006, 201(6): 3016-2029.
[3]	MIHM S, DUDA T, GRUNER H, et al.Method and process development of advanced atmospheric plasma spraying for thermal barrier coatings.J. Ther. Spray Technol., 2012, 21(3/4): 400-408.
[4]	GUAN H R, LI M H, SUN X F, et al.Investigation on oxidation and failure of the thermal barrier coating deposition on superalloy.Acta Metallurgica Sinica, 2002, 38(11): 1133-1140.
[5]	PADTURE N P, GELL M, JORDAN E H.Thermal barrier coatings for gas-turbine engine applications.Science, 2002, 296(5566): 280-284.
[6]	EVANSA A G, MUMMA D R, HUTCHINSORB J W, et al.Mechanisms controlling the durability of thermal barrier coatings.Progress in Mater. Sci., 2001, 46(5): 505-553.
[7]	HUA J J, ZHANG L P, LIU Z W, et al.Progress of research on the failure mechanism of thermal barrier coatings.J. Inorg. Mater., 2012, 27(7): 680-686.
[8]	OKAZAKI M, YAMAGISHI S, YAMAZAKI Y, et al.Adhesion strength of ceramic top coat in thermal barrier coatings subjected to thermal cycles: Effects of thermal cycle testing method and environment.International J. Fatigue, 2013, 53: 33-39
[9]	MAGNUS J, HAKAN B.Crack initiation and propagation in air plasma sprayed thermal barrier coatings, testing and mathematical modeling of low cycle fatigue behavior.Mater. Sci. Eng. A, 2004, 379(1/2): 45-57.
[10]	SU L C, ZHANG W X, SUN Y L, et al.Effect of TGO creep on top-coat cracking induced by cyclic displacement instability in a thermal barrier coating system.Surf. Coat. Technol., 2014, 254(15): 410-417.
[11]	MA K K, M J L. Isothermal oxidation behavior of cryomilled NiCrAlY bond coat: homogeneity and growth rate of TGO.Surf. Coat. Technol., 2011, 205(21/22): 5178-5185.
[12]	CHEN W R, WU X, MARPLE B R, et al.Pre-oxidation and TGO growth behavior of an air-plasma-sprayed thermal barrier coating.Surf. Coat. Technol., 2008, 202(16): 3787-3796.
[13]	ZHU D M, MILLER R A.Investigation of thermal high cycle and low cycle fatigue mechanisms of thick thermal barrier coatings.Mater. Sci. Eng. A, 1998, 245(2): 212-223.
[14]	CAO X Q, Vassen S R D. Ceramic materials for thermal barrier coatings.J. Eur. Ceram. Soc., 2004, 24(1): 1-10.
[15]	HERNANDEZA M T, KARLSSONA A M, BARTSCHB M.On TGO creep and the initiation of a class of fatigue cracks in thermal barrier coatings.Surf. Coat. Technol., 2009, 203(23): 3549-3558
[16]	MARTENAA M, BOTTOB D, FINOA P, et al.Modelling of TBC system failure: stress distribution as a function of TGO thickness and thermal expansion mismatch.Eng. Failure Analysis, 2006, 13(3): 409-426.
[17]	MARINO K A, BERIT H, EMILY A.et al.Atomic-scale insight and design principles for turbine engine thermal barrier coatings from theory.PNAS, 2011, 108(14): 5480-5487.
[18]	TOMIMATSU T, ZHU S, KAGAWA Y.Effect of thermal exposure on stress distribution in TGO layer of EB-PVD TBC.Acta Materialia, 2003, 51(8): 2397-2405.
[19]	GARVIE R C, HANNINK R H, PASCOE R T.Ceramic steel?Nature, 1975, 258(25): 703-704.

热震中7YSZ热障涂层结构演变

Structure Evolution of 7YSZ Thermal Barrier Coating During Thermal Shock Testing

RichHTML

PDF (PC)

可视化

被引次数

摘要/Abstract

引用本文

使用本文

图/表 11

参考文献 19

相关文章 15

编辑推荐

Metrics

本文评价

[1]	郑斌, 康凯, 张青, 叶昉, 解静, 贾研, 孙国栋, 成来飞. 前驱体转化陶瓷法制备Ti₃SiC₂陶瓷及其热稳定性研究[J]. 无机材料学报, 2024, 39(6): 733-740.
[2]	王博, 蔡德龙, 朱启帅, 李达鑫, 杨治华, 段小明, 李雅楠, 王轩, 贾德昌, 周玉. SrAl₂Si₂O₈增强BN陶瓷的力学性能及抗热震性能[J]. 无机材料学报, 2024, 39(10): 1182-1188.
[3]	郝鸿渐, 李海燕, 万德田, 包亦望, 李月明. 莫来石/氧化铝预应力涂层增强氧化铝的弯曲强度和抗热震性能[J]. 无机材料学报, 2022, 37(12): 1295-1301.
[4]	张亚晨, 孟佳, 蔡坤, 盛晓晨, 乐军, 宋力昕. 基于声发射技术的Si-Cr-Ti高温抗氧化涂层弯曲失效机理研究[J]. 无机材料学报, 2021, 36(11): 1185-1192.
[5]	冀晓鹃,于月光,卢晓亮. 杂质对氧化锆热障涂层性能的影响[J]. 无机材料学报, 2020, 35(6): 669-674.
[6]	王亚楠, 李华, 王正坤, 厉青峰, 练晨, 何鑫. 扩散应力诱导的锂离子电池失效机理研究进展[J]. 无机材料学报, 2020, 35(10): 1071-1087.
[7]	王林, 丁坤英, 林小娉, 李泽, 郑润国, 杨连威. 8YSZ双层热障涂层缺陷演变与微裂纹水浸超声宏观检测[J]. 无机材料学报, 2019, 34(12): 1265-1271.
[8]	叶长辉, 顾瑜佳, 王贵欣, 毕丽丽. 银纳米线透明导电薄膜的失效机理研究[J]. 无机材料学报, 2019, 34(12): 1257-1264.
[9]	张小锋, 周克崧, 刘敏, 邓春明, 邓畅光, 陈焕涛. 镀铝表面改性7YSZ纳米热障涂层热震性能分[J]. 无机材料学报, 2017, 32(9): 973-979.
[10]	陈宇方, 李宇杰, 郑春满, 谢凯, 陈重学. 富锂层状氧化物正极材料研究进展[J]. 无机材料学报, 2017, 32(8): 792-800.
[11]	阳明明, 莫亚娟, 王晓丹, 曾雄辉, 刘雪华, 黄俊, 张纪才, 王建峰, 徐科. AlN: Er薄膜在不同退火温度下应力诱导的微观结构演变[J]. 无机材料学报, 2016, 31(3): 285-290.
[12]	马榕彬, 程旭东, 邹隽, 李秦煜, 黄霞. SiC纤维/YSZ复合热障厚涂层韧性及热震性能研究[J]. 无机材料学报, 2016, 31(2): 190-194.
[13]	田卓, 段小明, 杨治华, 贾德昌, 周玉. AlN添加量对BN基复合陶瓷热学性能与抗热震性的影响[J]. 无机材料学报, 2014, 29(5): 503-508.
[14]	华佳捷, 张丽鹏, 刘紫微, 王墉哲, 林初城, 曾毅, 郑学斌 . 热障涂层失效机理研究进展[J]. 无机材料学报, 2012, 27(7): 680-686.
[15]	罗朝华, 江东亮, 张景贤, 林庆玲, 陈忠明, 黄政仁. Na₂O-B₂O₃-SiO₂玻璃焊料连接碳化硅陶瓷接口抗热震性能[J]. 无机材料学报, 2012, 27(3): 234-238.