等离子喷涂热障涂层隔热性能分析方法

热障涂层材料已成为现代高性能航空发动机的关键材料,而隔热性能一直是评价热障涂层性能的一个重要指标。首先基于傅里叶导热定律,推导出一维稳态温度场的解析表达式,并讨论了陶瓷层厚度、陶瓷层上表面工作温度和金属基底下表面工作温度对热障涂层系统隔热性能的影响。设计了一种比较新颖的实验测试方法,成功实现了对热障涂层系统内部不同位置的温度进行实时测试和保存实验数据。结果表明,各个温度采集点的实验测试结果与理论预测结果吻合很好,说明提出的实验测试方法可以有效评估不同类型的热障涂层材料体系的隔热性能。     

热循环作用下圆筒基体热障涂层的失效过程分析

用等离子喷涂的方法在高温合金圆筒上制备热障涂层,通过红外线辐照圆筒外部对试件进行加热以及内部通冷却空气强制冷却的方法对热障涂层系统进行了热循环失效试验。利用有限元工具ABAQUS对热障涂层系统中的瞬时温度场与应力场进行了计算以分析热障涂层的失效原因。计算结果表明,试样处于稳态最高温度时以及降温过程开始的很短时间内,陶瓷层中出现较大的周向拉应力,该应力将导致热障涂层出现表面垂直裂纹;陶瓷层与粘接层界面的径向应力不足以引起界面的开裂,界面的起裂来源于垂直裂纹出现后所带来的边缘效应。     

等离子喷涂纳米结构与传统结构热障涂层的残余应力对比研究

热障涂层的残余应力是影响其服役寿研究不多.在45钢基体上,用超音速火焰喷涂NiCocrAlY打底层,再用大气等离子喷涂ZrO2-8%(质量分数)Y2O3(8YSZ)工作层,制备了纳米结构与传统结构2种类型的热障涂层(TBC).采用SEM、XRD对这2种涂层的粉末及涂层进行了组织结构分析,用纳米压痕仪测得了2种涂层的弹性模量.用X射线衍射应力测试仪测得了2种涂层的表层残余应力.结果表明:喷涂工艺参数相同条件下,对于打底层及工作层的厚度均相同的2种涂层,纳米结构热障涂层的表层残余应力比传统结构热障涂层约低24.7%;相同打底层的纳米结构热障涂层表层残余应力随着陶瓷层厚度增加而增加,陶瓷层厚度在240 um以下时,表层为残余压应力;厚度超过300 um时,表层为残余拉应力.最后提出了相应的物理力学模型.     

热障涂层寿命的计算机优化方法

作为进行热障涂层结构设计和制备参数设计的准备,本文在热障涂层寿命预测系统(本实验室研发)的基础上,研究开发了热障涂层寿命优化平台,对热障涂层的结构参数和制备参数进行了优化.制备参数主要包括热障涂层预氧化时间和粘结层粗糙度,热障涂层的结构参数包括了陶瓷层模量、陶瓷层厚度和粘结层厚度.     

一种新型CMAS耦合条件下热障涂层热循环实验方法

提出一种高温度梯度、燃气加热和CMAS(CaO-MgO-Al2O3-SiO2)沉积条件下热障涂层热循环实验方法,并对1200℃下CMAS沉积物对等离子喷涂热障涂层过早失效的影响因素进行讨论和分析。结果表明:无CMAS耦合条件下,热障涂层热循环寿命为573次;CMAS耦合条件下,热障涂层热循环寿命降低至70次。CMAS渗入会导致陶瓷层表层产生致密层和横向微裂纹增多。CMAS耦合条件下,热障涂层的失效以陶瓷层逐层剥离为主。     

界面具有垂直裂纹的热障涂层的失效模拟

采用有限元分析软件ANSYS构造了一个在热生长氧化层（TGO）与陶瓷层界面具有一个垂直裂纹的纳米结构热障涂层的有限元模型。并计算了在热震过程中裂纹处的应力分布图,及裂纹尖端的应力场强度因子K1变化图。计算结果表明：裂纹处存在应力集中现象,且裂纹尖端的应力场强度因子K1在热障涂层热循环的冷却过程中随着时间的延长而减小,且在冷却最开始阶段,温度梯度变化最大,K1值也变化最大,裂纹在冷却的初始具有最大的扩展可能性。且涂层最有可能发生开裂失效。     

热障涂层应力产生机制及分布特征

热障涂层因优异的耐高温、耐磨损和耐腐蚀性等优点,被广泛应用在航空发动机等热端部件表面.热障涂层作为零件表面的服役载体,在外界热腐蚀、热梯度应力和机械载荷应力的作用下,易出现表面开裂及界面涂层剥落,这是限制热障涂层长时间使用的瓶颈问题.热障涂层由基体、粘接层、陶瓷层构成,涂层材料特性不同,界面处应力应变分布也不同,在外界载荷条件下,涂层与基体如何实现协同变形,应力如何传递等问题目前尚无明确解释.因此本文主要针对外加载荷作用下,热障涂层内部的应力传递及界面的应力分布问题进行研究.总结当前热障涂层的弹塑性应力模型和损伤应力模型,获得涂层界面应力分布规律,即弹塑性变形阶段,涂层界面应力于一端发生应力集中,并且基体与粘接层界面应力大约是陶瓷层与粘接层界面应力的四倍.随着载荷的增加,涂层表面损伤加剧,其剪滞模型的界面正应力更加符合四分之一椭圆函数,界面剪切应力呈反对称分布,应力分布特征为研究热障涂层在外载条件作用下对裂纹损伤演化行为的影响提供理论依据.     

燃气热循环下7YSZ热障涂层的微结构演变与阻抗谱特征

在1250℃燃气热循环条件下,测试热障涂层抗冷热冲击性能,以模拟发动机叶片的启动升温与关闭降温循环过程。采用电化学阻抗谱测试和扫描电镜(SEM)系统研究热循环过程中热生长氧化物(TGO)生长与YSZ陶瓷层微结构演变。结果表明:随着热循环次数增加,热障涂层内TGO不断生长变厚,在中频阶段的阻抗谱响应越来越显著。YSZ陶瓷层内部经历了微裂纹的萌生与扩展两个阶段。经过100次热循环后的YSZ层表现出与喷涂态涂层相似的阻抗特征,表明高温下烧结会使YSZ层产生的微裂纹在短时间内愈合。但经过300次热循环后的YSZ层表现出与喷涂态完全不同的阻抗谱,并随热循环次数增加,YSZ颗粒间隙阻抗值不断增加,表明YSZ内层产生了不可愈合的微裂纹,是导致YSZ层最终失效的主要因素。     

热循环条件下NiCrAlYSi/YSZ热障涂层层间损伤及元素扩散行为研究

采用真空电弧镀设备制备热障涂层(TBCs)中的NiCrAlYSi金属粘结层,采用电子束物理气相沉积工艺(EB-PVD)制备YSZ陶瓷层,利用带能谱仪的扫描电子显微镜对沉积态和热循环损伤后的热障涂层试样的形貌、组织结构以及元素成分进行分析,研究热障涂层从热循环初期到失效的过程中层间损伤及元素扩散行为。结果表明,随着热循环时间的延长,NiCrAlYSi/YSZ涂层先后经历快速氧化和氧化速率很低的阶段,1100h后由于陶瓷层脱落,粘结层继续氧化导致涂层增重突然增大。热循环初期,Zr、O向内扩散,Ni、Cr、Al向外扩散,TGO层中的Al元素供应充足,主要发生Al的选择性氧化;1100h后,TGO层中Al元素供应不足,Cr、Ni开始氧化,生成Al_(1.92)Cr_(0.08)O_3和镍铝氧化物。这种不均匀的氧化使局部涂层体积膨胀,裂纹萌生于TGO层,随着裂纹的增殖、生长,最终贯穿等轴晶区和TGO层,导致热障涂层失效。     

热传导对双陶瓷热障涂层隔热效果影响研究

为了更好地设计双陶瓷热障涂层结构,考察在制备和服役过程中热导率的变化对隔热效果的影响,建立了双陶瓷热障涂层半透明数学模型,采用有限元ANSYS软件模拟了稳态隔热效果.结果表明:顶层陶瓷层的热导率增大降低了隔热效果,且随顶层厚度增加隔热效果降低幅度增大;第2层陶瓷层的热导率增大降低了隔热效果,且随顶层厚度增加隔热效果降低幅度减小;陶瓷层半透明且衰减系数很小时,顶层厚度增加,隔热效果先快速后缓慢增加至不变甚至略有降低,且远低于相同条件下不透明时.顶层陶瓷层热导率变化对隔热效果影响大于第2层陶瓷层.     

梯度热障涂层热冲击性能研究

采用等离子喷涂的方法,分别获得了２ｍｍ ＺｒＯ２－ＮｉＣｒＡｌ和ＺｒＯ２－Ｎｉ／Ａｌ系梯度热障涂层。热冲击实验结果表明,两种涂层具有不同的失效机理。ＺｒＯ２－ＮｉＣｒＡｌ系的失效是由于基于基体氧化引起的涂层整体脱落;而ＺｒＯ２－Ｎｉ／Ａｌ系的失效是支径向裂纹扩展到Ｎｉ／Ａｌ底层氧化共同作用的结果。     

Anisotropic Thermal Diffusivities of Plasma-Sprayed Thermal Barrier Coatings

Thermal barrier coatings (TBCs) are used to shield the blades of gas turbines from heat and wear. There is a pressing need to evaluate the thermal conductivity of TBCs in the thermal design of advanced gas turbines with high energy efficiency. These TBCs consist of a ceramic-based top coat and a bond coat on a superalloy substrate. Usually, the focus is on the thermal conductivity in the thickness direction of the TBC because heat tends to diffuse from the surface of the top coat to the substrate. However, the in-plane thermal conductivity is also important in the thermal design of gas turbines because the temperature distribution within the turbine cannot be ignored. Accordingly, a method is developed in this study for measuring the in-plane thermal diffusivity of the top coat. Yttria-stabilized zirconia top coats are prepared by thermal spraying under different conditions. The in-plane and cross-plane thermal diffusivities of the top coats are measured by the flash method to investigate the anisotropy of thermal conduction in a TBC. It is found that the in-plane thermal diffusivity is higher than the cross-plane one for each top coat and that the top coats have significantly anisotropic thermal diffusivity. The cross-sectional and in-plane microstructures of the top coats are observed, from which their porosities are evaluated. The thermal diffusivity and its anisotropy are discussed in detail in relation to microstructure and porosity.     

车室内人体热舒适性的计算模型

在车室内热环境计算的基础上,借助于人体热调节系统以及人体生物热方程计算了人体温度场的分布,并且利用当量温度Teq去评价不同环境下人体的热舒适性。文中完成了一个典型算例,预测了司机与乘客的热舒适性问题,并与国外提供的热舒适范围作了比较,结果令人满意。显然,这一研究对进一步改进车室内环境的控制方法具有重要的指导意义。     

Characterization of Thermal Barrier Coatings Using Thermal Methods

Although low thermal conductivity was one of the major reasons for the development of thermal barrier coatings (TBCs) based on yttria stablilized zirconia (YSZ), its mechanical properties are often considered crucial in failure analysis and assessment of coatings. Thermal properties usually are treated as just basic material parameters and have not been utilized widely in TBC characterization and failure analysis. In fact, thermal transport properties such as thermal conductivity and thermal diffusivity are closely related to the microstructural changes of the TBC. In this paper, a brief overview of characterization of TBCs using thermal thermophysical properties and temperature mapping is presented.     

热障涂层热导率的研究进展

简要回顾了热障涂层体系的发展,讨论了氧化锆陶瓷材料的传热规律,包括涂层微观结构、陶瓷成分等因素的影响.同时指出了改进陶瓷涂层热导率的方法和开发适用于更高温度下的陶瓷涂层材料的指导原则,并详细介绍了改善热障涂层热导率的研究现状.     

Influence of Thermal Strain on Thermal Properties of Composites

The temperature dependence of the thermal expansion characteristics of the AS21 magnesium alloy, AS21–25 vol% Saffil fiber composite and the Mg-10 vol% Saffil fiber composite has been measured in the temperature range from 20 to 380°C. The expansion characteristics were influenced by the residual and thermal strains. The residual strain was removed within the first thermal cycle. The relative elongation of the tensile pre-deformed AS21–25 vol% Saffil fiber composite is lower than that for the sample without deformation and for the composite pre-deformed in compression. The anisotropy of the thermal expansion is demonstrated on the Mg-10 vol% Saffil fiber composite. The coefficient of thermal expansion (CTE) in the transverse direction (TD) (the planes of the short Saffil fibers are laid perpendicular to the axis of the sample) is higher than the CTE in the longitudinal direction (LD) (the planes of the short Saffil fibers are laid parallel to the axis of the sample). The anisotropy and the thermal strain influence the thermal diffusivity for AS21 composites investigated at temperatures between 20 and 380°C.Paper presented at the Seventeenth European Conference on Thermophysical Properties, September 5-8, 2005, Bratislava, Slovak Republic.     

基于暖体假人的热环境评价指标

由于暖体假人的对流及辐射散热特性与实际人体非常接近，因此，在热环境工效学研究中发挥着突出的作用。该文介绍了几种通过暖体假人实验得到的热环境评价指标，提出了用暖体假人测定湿球黑球温度的好处，给出了各指标的计算公式，并对它们作了简单的分析。最后，将各指标与平均辐射温度进行了列表对比。     

A Method for Thermal Diffusivity Determination of Thermal Insulators

A so-called “three-point” (3P) method has been developed for thermal diffusivity measurements of thermal insulating materials. One side of a cylindrical specimen, sandwiched between two thin metal plates, is subjected to intense light from an incandescent lamp to generate a thermal perturbance. The temperature response is measured in three locations along the test specimen. Thermocouples are located at the front and rear faces of the specimen, and the third is placed inside the specimen at a known location. The two outside temperatures are used as boundary conditions, and the unknown thermal diffusivity is calculated from the third temperature versus time curve. The method combines the advantages of rapid transient non-contact heating methods with the well-defined boundary conditions of steady-state methods. The results of the 3P method are compared with those from steady-state methods for a micro-porous insulation material and for a honeycomb structure.