Enhanced Characteristics of HVOF-sprayed MCrAlY Bond Coats for TBC Applications

This study is focused on the variation of the microstructures of different CoNiCrAlY bond coats sprayed by the high-velocity oxy-fuel (HVOF) process for thermal barrier coating (TBC) applications. Three different size fractions of the CoNiCrAlY bond coat powder have been considered for this investigation: AMDRY 9951 (5-37 μm), AMDRY 9954 (11-62 μm), and AMDRY 995C (45-75 μm). The influence of HVOF process parameters and process conditions have been studied in detail to achieve quality bond coats in terms of low porosity level, low oxygen content, and high surface roughness. The results have been promising and have shown that dense bond coats with low porosity can be achieved by HVOF spraying through the appropriate selection of powder size and process parameters. Importantly, HVOF bond coats appear to be competitive to VPS bond coats in terms of its oxygen content and high surface roughness.     

Overview of Small Punch Test

Metals and Materials International - Small Punch Test (SPT) is an evolving small specimen test technique which has the potential to extract the mechanical properties from small volume specimens....     

Diffusion Cells and Chemical Failure of MCrAlY Bond Coats in Thermal-Barrier Coating Systems

It is proposed that bond coats in thermal-barrier coating (TBC) systems, particularly those deposited by plasma spraying, can contain regions which are diffusionally isolated from the bulk of the coating. This can arise through the internal formation of alumina layers as a consequence of the ingress of molecular oxygen into the relatively porous structure. Such isolated regions, termed diffusion cells, will experience enhanced depletion of aluminum as a result of the continued thickening of the alumina layer at their surface. This process has been demonstrated for a CoNiCrAlY bond coat after oxidation in air at 1100°C. A consequence of this enhanced depletion is that chemical failure will occur sooner in diffusion cells and voluminous breakaway oxides will form above them at the interface of the bond coat and the ceramic top coat. The associated spatial variation in oxidation and displacement rates across the surface of the bond coat are expected to aid delamination of the outer ceramic layer.     

小冲孔蠕变试验技术

小冲孔蠕变试验技术是获取在役构件蠕变性能的一种新方法，由于它具有接近无损取样的特点，因此受到学术界和工业界的广泛重视。本文简要回顾了小冲孔蠕变试验技术的发展及应用，重点介绍了典型小冲孔蠕变试验装置的组成及结构，指出了小冲孔蠕变试验技术目前存在的问题和广阔的应用前景。     

The Influence of the Coating Deposition Process on the Interdiffusion Behavior Between Nickel-Based Superalloys and MCrAlY Bond Coats

In this work, interdiffusion between two nickel-based superalloys and two MCrAlY bond coats is investigated. The MCrAlY bond coats were applied using two different spraying processes, high velocity oxygen fuel spraying (HVOF) and low-pressure plasma spraying. Of primary interest is the evolution of Kirkendall porosity, which can form at the interface between substrate and bond coat and depends largely on the chemical compositions of the coating and substrate. Experimental evidence further suggested that the formation of Kirkendall porosity depends on the coating deposition process. Formation of porosity at the interface causes a degradation of the bonding strength between substrate and coating. After coating deposition, the samples were annealed at 1050 °C for up to 2000 h. Microstructural and compositional analyses were performed to determine and evaluate the Kirkendall porosity. The results reveal a strong influence of both the coating deposition process and the chemical compositions. The amount of Kirkendall porosity formed, as well as the location of appearance, is largely influenced by the coating deposition process. In general, samples with bond coats applied by means of HVOF show accelerated element diffusion. It is hypothesized that recrystallization of the substrate material is a main root cause for these observations.     

Characterization of Solder Joint Reliability Using Cyclic Mechanical Fatigue Testing

This article summarizes the mechanics of two mechanical fatigue methods, cyclic bending fatigue and shear fatigue, in inducing failure in solder joints in package assemblies, and it presents the characteristics of fatigue failures resulting from these methods using example cases of Sn-Pb eutectic and Sn-rich Pb-free solder alloys. Numerical simulation suggests that both testing configurations induce fatigue failure by the crack-opening mode. In the case of bending fatigue, the strain induced by the bending displacement is found to be sensitive to chip geometry, and it induces fatigue cracks mainly at the solder matrix adjacent to the printed circuit board interface. In case of shear fatigue, the failure location is firmly fixed at the solder neck, created by solder mask, where an abrupt change in the solder geometry occurs. Both methods conclude that the Coffin–Manson model is the most appropriate model for the isothermal mechanical fatigue of solder alloys. An analysis of fatigue characteristics using the frame of the Coffin–Manson model produces several insightful results, such as the reason why Pb-free alloys show higher fatigue resistance than Sn-Pb alloys even if they are generally more brittle. Our analysis suggests that it is related to higher work hardening. All these results indicate that mechanical fatigue can be an extremely useful method for fast screening of defective package structures and also in gaining a better understanding of fatigue failure mechanism and prediction of reliability in solder joints.     

Influence of Bond Coats on the Microstructure and Mechanical Behaviors of HVOF-Deposited TiAlNb Coatings

Hot dip galvanizing has been extensively employed for corrosion protection of steel structures. However, during the process of galvanization, the corrosion in molten zinc brings many problems to galvanization industry. In this study, as a material of corrosion resistance to molten zinc intended for application in Hot-dip galvanization, HVOF Ti_28.15Al_63.4Nb_8.25Y (at.%) coatings with different bond coats (NiCr5Al, NiCoCrAlY, CoCrAlYTaSi, and NiCr80/20) were deposited onto 316L stainless steel substrate, respectively. The influences of different bond coats on HVOF Ti_28.15Al_63.4Nb_8.25Y coatings were investigated. The results showed that bond coat had an obvious influence on improving the mechanical properties of HVOF Ti_28.15Al_63.4Nb_8.25Y coatings. HVOF Ti_28.15Al_63.4Nb_8.25Y coatings with NiCoCrAlY bond coat displayed the best mechanical properties. However, bond coats had no obvious effects on the microstructure, porosity, and hardness of HVOF Ti_28.15Al_63.4Nb_8.25Y top coatings. The effects of as-received powder morphology and grain size on the characteristics of coatings were also discussed.     

铂改性铝化物涂层的热生长层内应力研究

研究了镍基高温合金热障涂层系统中铂改性铝化物粘结层在空气中非连续高温氧化生成的Al2O3层内应力状态及相应的粘结层微观结构。利用Raman光激发荧光谱技术,发现铂铝粘结层在900℃氧化初期生成了θ-和α-Al2O3,而在1100℃氧化时,表面则形成连续致密的α-Al2O3层。通过α-Al2O3的光激发荧光谱偏移量,计算得到了热障涂层中热生长层的内压应力略高于3.0GPa。铂改性铝化物涂层表面Al2O3"背脊"处的内应力相对较低,同时由于没有陶瓷层的压制,生成的Al2O3起伏较大,并发生局部的Al2O3脱落。随氧化时间延长,由于Al元素沿晶界扩散较快,导致更多的γ′-Ni3Al在粘结层晶界处形成,粘结层中基本相β-NiAl向γ′-Ni3Al转变,改变了粘结层本身的热膨胀系数,引起热生长层中内应力变化。     

异形小凸模的3点固定法

介绍了异形小凸模3点固定法的原理、结构和设计要点。并对比以往传统的固定方法。3点固定法通用性强，加工工序简单，凸模装配方便，更换容易。     

微冲压法评定铝合金焊接接头局部力学性能

铝合金焊接接头存在力学性能不均匀性,准确测定不同区域的局部力学性能,对评定整体接头性能和改善焊接工艺是十分必要的.文章提出了微冲压试验方法,并通过有限元反向模拟计算可以间接得出材料局部的本构关系.同时利用拉伸试验验证该方法的准确性.另外对5052铝合金焊接接头局部力学性能进行了测试,其分布特征与硬度值分布基本相似.该研究为焊接接头局部本构关系的表征提供了理论依据和新的试验方法.     

Bond Characterization of Plasma Sprayed Zirconium on Uranium Alloy by Microcantilever Testing

The future production of low enriched uranium nuclear fuel for test reactors requires a well-adhered diffusion barrier coating of zirconium (Zr) on the uranium/molybdenum (U-Mo) alloy fuel. In this study, the interfacial bond between plasma sprayed Zr coatings and U-Mo fuel was characterized by microcantilever beam testing. Test results revealed the effect of specific flaws such as cracks and pores on the bonding of interfaces with a sampling area of approximately 20 μm². TEM examination showed the Zr/U-Mo interface to contain rows of very fine grains (5-30 nm) with the Zr in contact with UO₂. Bond characteristics of plasma sprayed samples were measured that are similar to those of roll bonded samples showing the potential for plasma sprayed Zr coatings to have high bond strength.     

基于小冲杆试验技术测定铝合金点焊调质熔核力学性能

为了减少或避免铝合金在电阻点焊时出现气孔、裂纹、咬边、焊缝成形差等缺陷,提高点焊质量,笔者考虑采用加入不同微量合金元素的方法,并试后通过小冲杆试验来检测调质熔核的力学性能。试验证明,该方法是很有效的,通过添加微量元素,熔核的力学性能得到了显著的提高。同时,证实了利用小冲杆试验技术来检测铝合金点焊调质熔核的力学性能这种方法也是可行的。     

Mechanical Characterization of Mesoscale Interfaces Using Indentation Techniques

Mesoscale interfaces and interphases play a central role in controlling the many macroscale mechanical properties and performance characteristics of structural materials. Modern instrumented indenters present an unprecedented opportunity to measure, reliably and consistently, the local mechanical responses at a multitude of length scales ranging from tens of nanometers to hundreds of microns. When these high-fidelity measurements are combined with rigorous data analyses protocols, it is possible to systematically study the mechanical role of individual mesoscale interfaces and quantify their contributions to the overall mechanical response of the material system. The advantages of these new measurement and analyses protocols as well as the potential for development and implementation of novel high-throughput assays is discussed.     

Performance of Bond Coats Modified by Platinum Group Metals for Applications in Thermal Barrier Coatings

We have investigated the partial replacement of Pt with other less expensive Pt group metals on the properties of γ′ + γ bond coats used in thermal barrier coatings (TBCs) deposited on a nickel-base superalloy. The microstructure, thermal stability, oxidation behavior and performance in TBC systems of bond coats synthesized with Pt + Ru, Pt + Ir and Pt + Rh are compared with those of a reference bond coat synthesized with Pt. Yttria-stabilized zirconia has been employed as top coat in all coating systems. It is shown that at high temperatures all bond coats are degraded by interdiffusion and oxidation, however, with different kinetics. The lifetime of each TBC system is found to be limited by the cohesion between the thermally grown oxide and underlying bond coat. Differences in the behavior of various bond coats are correlated with their properties. Among the three Pt group metals investigated, the properties of the Pt + Ru bond coat are shown to closely approach those of the Pt bond coat. It is concluded that Ru with much lower cost presents a potential candidate for reducing the consumption of Pt.     

Experimental Characterization and Material-Model Development for Microphase-Segregated Polyurea: An Overview

Numerous experimental investigations reported in the open literature over the past decade have clearly demonstrated that the use of polyurea external coatings and/or inner layers can substantially enhance both the blast resistance (the ability to withstand shock loading) and the ballistic performance (the ability to defeat various high-velocity projectiles such as bullets, fragments, shrapnel, etc. without penetration, excessive deflection or spalling) of buildings, vehicles, combat-helmets, etc. It is also well established that the observed high-performance of polyurea is closely related to its highly complex submicron scale phase-segregated microstructure and the associated microscale phenomena and processes (e.g., viscous energy dissipation at the internal phase boundaries). As higher and higher demands are placed on blast/ballistic survivability of the foregoing structures, a need for the use of the appropriate transient nonlinear dynamics computational analyses and the corresponding design-optimization methods has become ever apparent. A critical aspect of the tools used in these analyses and methods is the availability of an appropriate physically based, high-fidelity material model for polyurea. There are presently several public domain and highly diverse material models for polyurea. In the present work, an attempt is made to critically assess these models as well as the experimental methods and results used in the process of their formulation. Since these models are developed for use in the high-rate loading regime, they are employed in the present work, to generate the appropriate shock-Hugoniot relations. These relations are subsequently compared with their experimental counterparts in order to assess the fidelity of these models.     

Oxidation Control with Chromate Pretreatment of MCrAlY Unmelted Particle and Bond Coat in Thermal Barrier Systems

MCrAlY alloy bond coat is widely used in thermal barrier coating (TBC) systems to protect substrates from high-temperature oxidizing environments. However, failure of the ceramic topcoat can occur due to a thermally grown oxide (TGO) that grows at the interface between the bond coat and the topcoat. In this study, the effect of chromate treatment was investigated. Prior to topcoat deposition, a thin film of Cr₂O₃ was formed on the bond coat surface. High-temperature oxidation tests were carried out, and the oxidation rates were determined by inspection of cross sections. Similar oxidation tests were carried out using MCrAlY powder material assumed to be unmelted particles. As a result, the chromate-treated bond coat showed outstanding oxidation resistance. Calculations that take into account the oxidation of particles in the topcoat indicated the generation of internal stress to cause local fracture of the topcoat.     

纳米压入技术表征薄膜（涂层）的力学性能

采用纳米压入技术测试薄膜（涂层）的力学性能日益受到关注。测试过程中可自动记录载荷－压深曲线,能够获取薄膜（涂层）的硬度、弹性模量、薄膜（涂层）自身结合强度、膜基界面结合强度、残留应力、屈服强度以及应变硬化率等力学性能数据。本文扼要介绍了纳米压入技术表征薄膜（涂层）力学性能的测试原理。     

化学机械抛光中的接触状态研究概述

化学机械抛光是获取高表面平整度的有效关键技术,获得了广泛的研究和应用,其表面材料的去除作用依赖于所处的真实接触状态。归纳了抛光垫/晶圆相互作用的形式,即相互滑过而没有直接接触、混合润滑和直接接触。分析了接触状态及其转变过程中的影响因素,包括抛光垫的变形、釉化和磨损,抛光液中磨粒的影响及表面活性剂对钝化层厚度的改变等。重点总结了化学机械抛光中接触状态问题的研究进展,包括光学显微镜测量计算接触面积比、薄膜传感器测量接触面积比、利用双发射激光诱导荧光技术测量抛光液厚度、抛光垫表面形貌演变对材料去除速率的建模等方法的特点及存在的问题。最后提出了纳米间隙测量技术测量化学机械抛光中接触率动态变化,从而得到真实接触状态和接触状态转变规律的新思路。