张石华,金洋,邸宝永,王者,丁坤英.闪烧工艺对YSZ热障涂层结构和耐久性的影响[J].表面技术,2025,54(3):220-229.
ZHANG Shihua,JIN Yang,DI Baoyong,WANG Zhe,DING Kunying.Effect of Flash Sintering on the Structure and Durability of YSZ Thermal Barrier Coatings[J].Surface Technology,2025,54(3):220-229 |
| 闪烧工艺对YSZ热障涂层结构和耐久性的影响 |
| Effect of Flash Sintering on the Structure and Durability of YSZ Thermal Barrier Coatings |
| 投稿时间：2024-07-03 修订日期：2024-10-14 |
| DOI：10.16490/j.cnki.issn.1001-3660.2025.03.020 |
| 中文关键词: 闪烧 热障涂层 致密度 耐久性 力学性能 |
| 英文关键词:flash sintering thermal barrier coatings density durability mechanical properties |
| 基金项目:天津市重点研发计划转制院所扶持项目(22YFFCYS00080);天津市航空装备安全性与适航技术创新中心开放基金(JCZX-2022-KF-01) |
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| Author | Institution |
| ZHANG Shihua | Tianjin Key Laboratory of Civil Aircraft Airworthiness and Maintenance,Tianjin 300300, China |
| JIN Yang | Tianjin Key Laboratory of Civil Aircraft Airworthiness and Maintenance,Tianjin 300300, China ;Tianjin Aviation Equipment Safety and Airworthiness Technology Innovation Center, Civil Aviation University of China, Tianjin 300300, China |
| DI Baoyong | Tianjin Mechanical Coating Research Co., Ltd., Tianjin 300300, China |
| WANG Zhe | Tianjin Key Laboratory of Civil Aircraft Airworthiness and Maintenance,Tianjin 300300, China |
| DING Kunying | Tianjin Key Laboratory of Civil Aircraft Airworthiness and Maintenance,Tianjin 300300, China |
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| 中文摘要: |
| 目的 提高采用等离子喷涂制备的YSZ热障涂层的服役寿命。方法 采用闪烧技术对通过大气等离子喷涂后的热障涂层进行二次处理，以提升其耐久性。使用多种分析表征方法系统地分析闪烧前后热障涂层的孔隙率、力学性能和相组成，并利用热循环和高温氧化实验对比闪烧处理前后涂层的耐久性。结果 经过闪烧处理后，YSZ热障涂层仍呈现为t'-ZrO2，其表面的孔隙和微裂纹得到有效改善，闪烧处理使得陶瓷层融合，形成板块状，其孔隙率降低了83.68%，脆性指数下降了31.60%。经过重复实验验证，闪烧技术在应用中表现出良好的稳定性。经过100次热循环后，喷涂态涂层的脱落率接近40%，而闪烧涂层最大脱落率仅接近10%。在高温氧化过程中，当氧化温度在1 100 ℃以上时，TGO的生长速率明显加快，经过500 h、1 200 ℃高温氧化，闪烧涂层的TGO层厚度比喷涂态涂层的厚度降低了30.00%，闪烧涂层在500 h的TGO厚度与喷涂态涂层在100 h时相当。结论 闪烧处理有效促进了YSZ热障涂层的致密化，提高了涂层的力学性能，改善了大气等离子喷涂涂层的损伤容限，延长了涂层在热循环下和高温氧化下的耐久性。 |
| 英文摘要: |
| Thermal barrier coatings (TBCs) based on yttria-stabilized zirconia (YSZ) are essential for the protection of nickel-based alloy blades, predominantly fabricated via air plasma spraying (APS). However, due to the inherent limitations of APS, the actual service life of YSZ TBCs does not meet practical requirements. Consequently, enhancing the service life of YSZ TBCs is crucial for practical application. The work aims to use flash sintering (FS) as an innovative post-treatment method for YSZ TBCs prepared by APS to significantly improve the durability. A systematic analysis was performed on the porosity, mechanical properties (including hardness, fracture toughness, and brittleness index), and phase composition of the coatings before and after flash sintering treatment with a Scanning Electron Microscope (SEM), X-ray Diffraction Spectrometer (XRD), and Vickers hardness tester. Additionally, the thermal cycling and high-temperature oxidation trials, facilitated by a combustion chamber experimental setup and a high-temperature furnace, were employed to thoroughly assess the enhanced durability of the coatings after FS treatment. The results revealed that the YSZ TBCs both exhibited tetragonal zirconia (t'-ZrO2) before and after flash sintering treatment. The porosity and microcracks on the coating surface were effectively alleviated, resulting in a lamellar microstructure with an 83.68% reduction in porosity and a 31.60% decrease in brittleness index, thereby significantly enhancing the mechanical properties. After flash sintering treatment, the porosity, fracture toughness, and brittleness index of the YSZ thermal barrier coatings reached 3.47%, 2.44 MPa.m1/2, and 3.94 µm−1/2, respectively. Pearson linear correlation fitting revealed a good fit between multiple parameters (e.g., porosity, hardness, fracture toughness, and brittleness index) of the coatings after flash sintering treatment and current density, with adjusted R2 values exceeding 0.91 for all. The actual performance of the YSZ thermal barrier coatings was effectively regulated based on current density. Repeated validation under the same process parameters showed that the coefficients of variation for porosity, fracture toughness, and brittleness index were 0.273, 0.077, and 0.062, respectively, demonstrating the good stability of flash sintering technology for the secondary treatment of YSZ TBCs. After 100 thermal cycles, the spallation area ratio of the APS-TBC was approximately 40%, displaying irregular spallation edges and extensive spallation regions, whereas the maximum spallation ratio of the FS-TBC was nearly 10%. During high-temperature oxidation, the growth rate of the thermally grown oxide (TGO) layer significantly accelerated when the oxidation temperature exceeded 1 100 ℃, with temperature exerting a more substantial effect than oxidation time. TGO growth predominantly occurred in the early stages of oxidation. Following 500 hours of oxidation at 1 200 ℃, the TGO layer thickness of the FS-TBC was reduced by 30.00% compared to the APS-TBC, with the TGO thickness of the FS-TBC after 500 hours equivalent to that of the APS-TBC after 100 hours. The TGO growth rates for APS-TBC and FS-TBC within the first 50 hours were 0.092 µm/h and 0.050 µm/h at 1 200 ℃, respectively. During the period of 50 to 500 hours, the TGO growth rates for APS-TBC and FS-TBC were 0.008 µm/h and 0.007 µm/h at 1 200 ℃, respectively. Overall, flash sintering treatment significantly promotes the densification of YSZ TBCs and engenders pronounced improvements in mechanical properties, damage tolerance, and overall durability under both thermal cycling and high-temperature oxidizing conditions, evidencing FS's potential as an effective secondary treatment for enhancing the performance of APS-prepared YSZ TBCs. |
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