Durability of YSZ coated Ti2AlC in 1300°C high velocity burner rig tests

A thermal barrier coating (TBC) system survived 500 hours in aggressive, 1300°C burner rig testing. The yttria-stabilized zirconia (7YSZ) TBC was plasma sprayed on an oxidation-resistant Ti₂AlC-type MAX phase and tested in a jet fuel burner at 100 m/s, using 5 hours cycles. No coating spallation or surface recession was observed; Al₂O₃-scale growth produced a slight 2.4 mg/cm² mass gain. The coating surface exhibited craze-cracked colonies of [111]_flourite textured columns, with no visible moisture attack. The 20 μm alumina scale remained intact under the YSZ face, about twice that producing failure for TBC/superalloy systems. TiO₂ nodules, initially formed on the uncoated backside, were removed, and Al₂O₃ was etched through volatile hydroxides formed in water vapor (~10%). Overall, the test indicated exceptional stability of the YSZ/Al₂O₃/Ti₂AlC system under turbine conditions due in large part to close thermal expansion matching.     

Sintering behavior of a nanostructured thermal barrier coating deposited using electro-sprayed particles

During high temperature service, a series of microstructure and phase evolutions occur in thermal barrier coatings (TBCs), which result in degradation of thermal insulation and durability. In this study, the sintering behavior of an air plasma sprayed 8 wt% YSZ coating deposited using electro-sprayed nanostructured particles (ESP) as feedstock powder was investigated and compared with conventional YSZ coating deposited using hollow spherical powders (HOSP). Due to the distinct asymmetric porous structure formed by nanosized YSZ particles, the ESP powder was partially melted in the plasma jet during the deposition, which resulted in the formation of a nanostructured coating that consisted of porous nanozones and dense zones. The ESP coating not only shows a significantly lower initial thermal conductivity of 0.70 W/mK, but also exhibits a stronger sintering resistance in terms of phase stability and thermal insulation compared to the conventional coating. When subjected to prolonged sintering at 1400°C for 128 hours, the thermal conductivity of the ESP coating would gradually increase to about half that of the HOSP coating at 1.29 W/mK. These differences are ascribed to the interaction among different sintering behavior between nanozones and dense zones.     

玻璃沉积物对La2Ce2O7/YSZ涂层高温下热冲击性能的影响

目的 为了探究玻璃沉积物CMAS(CaO-MgO-Al2O3-SiO2)对新型结构热障涂层在1250 ℃下的热冲击寿命的影响，揭示热障涂层的失效行为。方法 通过火焰喷涂技术将制备的CMAS粉体均匀地沉积到铈酸镧/氧化钇部分稳定二氧化锆双陶瓷层热障涂层(LC/YSZ DCL-TBCs)和梯度热障涂层(LC/YSZ FGM-TBCs)的表面，于1250 ℃热冲击实验中进行涂层样品的抗热冲击性能及失效机理研究。利用扫描电镜(SEM)和能谱仪(EDS)追踪CMAS的位置，观察CMAS与涂层反应层的厚度与形貌。采用X射线衍射仪(XRD)测试反应层产物，并总结其失效方式。结果 高温热冲击结果显示梯度涂层的热冲击寿命(435次)远高于双陶瓷层热障涂层的寿命(229次)，约为铈酸镧/氧化锆双陶瓷层热障涂层寿命的1.9倍。铈酸镧层与梯度层都能在一定程度上阻碍CMAS渗入涂层内部，提高其CMAS腐蚀条件下的热冲击寿命。双陶瓷层热障涂层与梯度热障涂层的失效均是以层状剥落为主，剥落层主要是CMAS与LC的反应层以及反应层下的烧结层，反应层是由Ca2(LaxCe1-x)8(SiO4)6O6-4x、萤石相和MgAl2O4等难熔氧化物组成，这层致密氧化物类似于密封层，能阻止CMAS继续渗入。结论 功能梯度结构具有比双陶瓷层结构更优异的抗CMAS热冲击性能和更好的应力耐受性。     

Density functional theory and machine learning guided search for RE2Si2O7 with targeted coefficient of thermal expansion

Density functional theory (DFT) calculations and machine learning (ML) methods are used to establish a relationship between the crystal structures of rare-earth (RE) disilicates (RE₂Si₂O₇) and their coefficient of thermal expansion (CTE). The DFT total energy data predict the presence of several energetically competing crystal structures, which is rationalized as one of the reasons for observing polymorphism. An ensemble of support vector regression models is trained to rapidly predict the CTE as a function of RE₂Si₂O₇ crystal chemistry. Experiments subsequently validated the structure and CTE predictions for Sm₂Si₂O₇.     

海藻酸钙固定化零价铁抗团聚及堵塞的作用机制

以海藻酸钠（SA）、氯化钙、微米零价铁（MZVI）为原料，制备了海藻酸钙（CA）固定化MZVI填料（CAZ），通过静态烧杯实验和动态PRB模型实验，探讨了CA运用对Cr(Ⅵ)的去除性能的影响，并通过电镜扫描分析了CA避免团聚、堵塞机制。实验结果表明，CA凝胶颗粒的运用能显著提升MZVI的除Cr(Ⅵ)性能，CAZ相比MZVI对Cr(Ⅵ)的去除率和反应速率分别提升7.1倍、23.0倍；MZVI利用率的提高是CAZ反应器处理Cr(Ⅵ)水量显著大于MZVI反应器的主要原因，MZVI反应速率的提高是CAZ反应器出水Cr(Ⅵ)浓度显著低于MZVI反应器的主要原因。电镜扫描结果表明，SA与氯化钙交联形成的CA具有丰富的骨架孔道结构，具有骨架支撑作用，能有效克服MZVI颗粒因重力作用导致团聚、降低比表面积的缺陷。CA表层固定的MZVI颗粒与Cr(Ⅵ)反应生成的(Fe_xCr_1-x)(OH)₃ 络合沉淀会冲破CA表层外壳，释放到零价铁-渗透反应墙（Fe⁰-PRB）系统中，导致PRB反应初期出现堵塞现象；大部分MZVI颗粒被固定在CA内部，CA内部有较多孔隙结构，这些孔隙结构会控制(Fe_xCr_1-x)(OH)₃ 络合沉淀释放，从而缓解了Fe⁰-PRB后期长期运行持续堵塞的问题。     

高熵合金AlCrTaTiZrRu/(AlCrTaTiZrRu)N0.7扩散阻挡层的制备与性能研究

目的 验证15 nm厚度AlCrTaTiZrRu/(AlCrTaTiZrRu)N0.7的势垒层热稳定性和扩散阻挡性能。方法 采用直流磁控溅射技术在n型Si(111)基片上真空溅射沉积15 nm的AlCrTaTiZrRu(3 nm)/(AlCrTaTiZrRu)N0.7 (12 nm)双层阻挡层，随后在双层AlCrTaTiZrRu/(AlCrTaTiZrRu)N0.7薄膜的顶部沉积50 nm厚的Cu膜，最终制得Cu/AlCrTaTiZrRu/(AlCrTaTiZrRu)N0.7/Si复合薄膜试样。将样品在真空退火炉中分别进行600~900 ℃高温退火30 min，以模拟最恶劣的应用环境。用场发射扫描电镜(FE-SEM)、X射线衍射仪(XRD)、能谱分析仪(EDS)、四探针电阻测试仪(FPP)以及原子力显微镜(AFM)对试样的表面形貌、物相组成、化学成分、方块电阻和粗糙度进行表征分析。结果 沉积态AlCrTaTiZrRu/(AlCrTaTiZrRu)N0.7薄膜呈现非晶结构，与Cu膜和Si衬底的结合良好。在800 ℃退火后，Cu/AlCrTaTiZrRu/(AlCrTaTiZrRu)N0.7/Si薄膜系统结构完整，膜层结构界面之间未出现分层现象，表面Cu颗粒团聚现象加剧，Si衬底和Cu膜表面未发现Cu-Si化合物生成，薄膜方阻保持在较低的0.070 ?/sq;900 ℃退火后，薄膜系统未出现层间分离和空洞现象，Cu膜表面形成孤立的大颗粒Cu-Si化合物，薄膜电阻率大幅上升。结论AlCrTaTiZrRu/(AlCrTaTiZrRu)N0.7双层结构在800 ℃退火后仍能有效抑制Cu与Si相互扩散，其非晶结构增强了Cu/HEA/HEAN0.7/Si体系的热稳定性和扩散阻挡性。     

用于热密封组件的编织弹簧弹性性能分析

针对耐高温动态热密封组件中的常用元件弹性支架编织弹簧,研究了其压缩率、装配方式、热暴露温度等参数对其弹性性能的影响,并讨论了编织弹簧高温弹性失效的原因。研究结果表明,合金的氧化是编织弹簧高温回弹率降低的主要原因,在温度低于800℃、压缩率小于50%的服役条件下,编织弹簧的回弹率不小于95%,在航天热密封领域有广阔的应用前景。     

CMAS对热障涂层界面裂纹和残余应力的影响

随着航空发动机涡轮叶片工作温度的提升,使得一种主要由CaO,MgO,Al₂O₃和SiO₂组成的玻璃态物质(CMAS)对热障涂层的危害越来越严重,从而对热障涂层的性能和耐久性有了更高的要求。本文以电子束物理气相沉积热障涂层为研究对象,利用有限元方法研究了CMAS的渗入对界面裂纹扩展及CMAS对陶瓷层(TC)内部残余应力的影响规律。采用波长固定、振幅变化的正弦曲线表示不同粗糙度的涂层界面,同时考虑了CMAS的弹性模量变化的影响及不同界面形貌与CMAS之间的相互作用。结果表明：CMAS弹性模量的增加对界面裂纹具有抑制作用,并且TGO幅值和厚度越小,抑制作用越明显。CMAS弹性模量对TC层最大残余应力S₂₂的影响存在临界点,在临界点之前,CMAS弹性模量的变化对TC层最大残余应力的影响较大,随着CMAS弹性模量的增加,TC层最大残余应力大幅度减小；在临界点之后,TC层最大残余应力基本不受CMAS弹性模量变化的影响。这些结果对电子束物理气相沉积喷涂的热障涂层失效机理的研究具有重要意义,可以为热障涂层界面的优化提供指导。     

Development of blown film linear low-density polyethylene–clay nanocomposites: Part A: Manufacturing process and morphology

In this study, linear low-density polyethylene (LLDPE)/clay nanocomposites with different clay contents were prepared by melt intercalation using two different compatibilizers: maleic anhydride grafted styrene–ethylene–butylene–styrene and maleic anhydride grafted polyethylene (PE-g-MA). Melt intercalation was achieved by twin extrusion and nanocomposite films were produced by blown film extrusion. Effects of clay and compatibilizer fractions and type of compatibilizer on the structure, permeability, and the barrier properties of the nanocomposite films were investigated. PE-g-MA was shown to notably improve the dispersion of clay layers in the polyethylene matrix, and this was examined by atomic force microscopy and X-ray diffraction. The latter tests have also highlighted the importance of the screw configuration: the presence of mixing elements favors the dispersion and distribution of nanoclay. Moreover, differential scanning calorimetry results have shown no significant effect of the clay on the crystallinity of the composite while thermogravimetric analysis tests have demonstrated a decrease of onset and peak of decomposition temperatures. Finally, barrier properties toward water vapor transmission were measured. It was proven that not also clay, but the compatibilizer participated in decreasing the permeability of the film. © 2019 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2020 , 137, 48589.     

Evolution of internal cracks and residual stress during deposition of TBC

Thermal barrier coating (TBCs) are ceramic coatings that are deposited on metallic substrates to provide high thermal resistance. Residual stress is among the critical factors that affect the performance of TBCs. It evolves during the process of coating deposition and in-service loading. High residual stresses result in significant cracking and premature delamination of the TBC layer. In the present study, a hybrid computational approach is used to predict the evolution of internal cracks and residual stress in TBC. Smooth particle hydrodynamics (SPH) is first used to model the deposition of yttria-stabilized zirconia (YSZ) layer that contains various interfaces and micropores on a steel substrate. Then, three-dimensional (3D) finite element analysis is utilized to predict the evolution of internal cracks and residual stress in the ceramic coating layer. It is found that multiple cracks emerge during the solidification of the coating layer due to the development of high tensile (quenching) stresses. The cracking density is higher at regions near the coating interface. It is also found that compressive (residual) stresses are developed when the deposited coating is cooled to room temperature. The residual stress state is equibiaxial and nonlinear across the thickness/width of the TBC layer. The residual stress profile predicted compares well with that of hole drilling experiments.