Influence of interface morphology on erosion failure of thermal barrier coatings

The thermal barrier coating system (TBCs) has complex structure and works in severe service environment. Erosion is one of the main factors causing the failure of TBCs. In the present study, the particle erosion process of atmospheric plasma sprayed (APS) thermal barrier coatings at elevated temperature was simulated by the finite element method. The effects of interface morphology on the penetration depth, particle ricochet velocity and interface stress state were studied, and the key parameters such as particle size, initial velocity and erosion position were also considered. The cosine curve with constant wavelength and varying amplitude was used to represent different interface roughness of TBCs. The results show that the interface morphology has little effect on the penetration depth of top coat (TC) and the particle ricochet velocity. The influence of particle erosion position related to the interface morphology is obvious. Basically, the greater the interface roughness is, the more violent the interfacial stress fluctuation is. During the erosion process, the stress in the middle of the interface is significantly higher than that at other positions. These results facilitate understanding of the particle erosion failure mechanism of APS TBCs. The influence of interface morphology should be considered in erosion research.     

Design,synthesis, characterization,and aging properties of a new end-capped three-dimensional high-refractive index hybrid organic–inorganic polysiloxane

The actual need for hybrid organic–inorganic polysiloxanes is very high due to their importance in optoelectronic applications, especially for the preparation of anti- and low-reflection layers, photopatterned overcoats, flexible hard coats, and glass and metal coatings. However, such three-dimensional hybrid polysiloxanes have very often a limited shelf life and aged very rapidly. Consequently, this type of polymer may require to be stored at cold temperatures and needs to be dilute in organic solvent to a very low solid content, which are unprofitable conditions for commercialization purposes. Therefore, there is an urgent demand to prepare three-dimensional polysiloxanes, which are more resistant toward aging processes. Herein, a new hybrid three-dimensional polysiloxane has been designed and synthesized from three different silane precursors using the sol–gel technology, and characterized using gel permeation chromatography, ¹H, ¹³C, and ²⁹Si nuclear magnetic resonance and MS spectroscopies. One-fourth of the silanol groups present in the polysiloxane have been protected with chlorotrimethylsilane. The refractive index of the silicon wafer coated with the new polysiloxane was found to be 1.53, which is higher compare to traditional values. Importantly, the new protected three-dimensional polysiloxane did not age after being stored at T = 40°C for 3 weeks.     

Influence of Al content and post-annealing on synthesis and mechanical properties of plasma sprayed Cr–Al–C composite coatings

Due to ultra-high temperature and short reaction time, it was very challenging to produce high purity MAX phase by plasma spraying. In this study, Cr–Al-graphite agglomerated powders with different Al additions (x = 0.2–1.5) was used to prepare Cr–Al–C composite coatings by atmospheric plasma spraying followed with annealing. Results showed that the as-sprayed coatings displayed typical lamellar structure, mainly composed of Cr–C binary carbides (Cr₇C₃ and Cr₂₃C₆) and residual Al. After annealing at 700 °C, the newly formed Cr₂AlC phase increased significantly in the coatings. The higher addition of Al, the more Cr₂AlC phase formed after annealing. The enhanced atomic diffusion, sufficient Al source and existence of (Cr, Al)C_x contributed to the formation of Cr₂AlC under annealing. Annealing treatment improved the hardness of the coating, but with the increase of Cr₂AlC phase content, the hardness decreased slightly. The Al content and post-annealing had a synergistic effect on the formation of Cr₂AlC phase in the sprayed coatings. This provided an effective route to control the Cr₂AlC content in sprayed Cr–Al–C composite coatings.     

Capped inhibitor-loaded halloysite nanoclay-based self-healing silica coatings for corrosion protection of mild steel

The effect of polymeric nanocapsule capping in benzotriazole encapsulated into halloysite nanoclay (HNTs) dispersed into hybrid silica coatings was investigated for corrosion protection of mild steel. Optimization of the amount of inhibitor-loaded halloysite nanotubes with and without capping in the coating sol was carried out. The prepared formulations were dip-coated on mild steel substrates using dip-coater and then cured at 130 °C for 1 h. Surface morphology and elemental analysis of the nanoclay were studied using scanning electron microscopy and energy dispersive X-ray spectroscopy. X-ray diffraction and Fourier Transform Infrared spectroscopy analyses were carried out to confirm the encapsulation and capping of the halloysite nanoclay. The anti-corrosion and autonomic-healing properties of bare and coated substrates in 3.5 wt% NaCl solution were studied using electrochemical impedance spectroscopy, potentiodynamic polarization measurements and scanning vibrating electrode technique for varying exposure times. The coatings generated from the capped inhibitor-loaded HNTs dispersed sol-gel matrix was seen to provide higher corrosion resistance when compared to uncapped HNT based silica coatings. Electrochemical studies carried out for capped inhibitor-loaded HNT based coatings have shown an increase in charge transfer resistance to 10⁸ Ω cm² from 10⁶ Ω cm² of uncapped inhibitor-loaded HNT based coatings.     

电沉积耐磨减摩纳米复合镀层的研究进展

纳米复合镀层比常规镀层具有更高的硬度和更加优良的摩擦学性能.评述了纳米复合镀层的电沉积工艺,包括纳米颗粒前处理、纳米颗粒添加量、电流、镀液pH值、镀液温度和搅拌方式等对镀层中纳米颗粒含量、镀层表面形貌及微观结构的影响,对纳米复合镀层摩擦学性能以及纳米颗粒耐磨减摩机理的研究进行了综述.     

等离子喷涂ZrO2涂层的火焰喷烧和水淬热冲击

研究了等离子喷涂ZrO2涂层在水淬和火焰喷烧两种条件下的热冲击性能,采用ANSYS软件对两种条件下涂层的热冲击性能进行了有限元计算.结果表明:水淬条件下垂直裂纹主要分布在距离涂层中心12mm的范围内,随着热冲击次数的增加垂直裂纹最终进入次表层,靠近中心处裂纹扩展较快;火焰喷烧条件下,垂直裂纹分布在距离涂层中心10mm的范围内,随着热冲击次数的增加裂纹在表面层和次表层界面处发生偏转,中心处裂纹扩展较快;火焰喷烧条件下涂层的抗热震性能优于水淬条件,涂层中的孔隙加速了两种条件下裂纹的扩展.     

An overview on novel thermal barrier coatings

Thermal barrier coatings (TBCs) offer the potential to significantly improve efficiencies of aero engines as well as stationary gas turbines for power generation. On internally cooled turbine parts, temperature gradients of the order of 100-150℃ can be achieved. TBCs, typically consisting of an yttrium stabilized zirconia top coat and a metallic bond coat deposited onto a superalloy substrate, are mainly used to extend lifetime. Further efficiency improvements require TBCs being an integral part of the component which requires reliable and predictable TBC performance. TBCs produced by electron beam physical vapor deposition (EbPVD) or plasma spray (PS) deposition are favored for high performance applications. The paper highlights critical R&D needs for advanced TBC systems with a special focus on reduced thermal conductivity and life prediction needs. To further enhance the efficiency of gas turbines, higher temperature and a longer lifetime of the coating are needed for the next generation of TBCs. This paper presents the development of new materials, new deposition technologies, and new concept for application as novel TBCs. This paper summarizes the basic properties of conventional thermal barrier coatings. Based on our own investigation, we reviewed the progress on materials and technologies of novel thermal barrier coatings. Except yttria stabilized zirconia, other materials such as lanthanum zirconate and rare earth oxides are also promising materials for thermal barrier coatings. Nanostructure thermal barrier coating is presented as a new concept. This paper also summarizes the technologies for depositing the thermal barrier coatings.     

Current situation and development tendency of thermal spraying materials in China

Current situation and development tendency of thermal spraying materials in China@于月光$Beijing General Research Institute of Mining & Metallurgy Beijing 100044 , China