CN116445848B - Method for preparing ceramic coating with longitudinal crack growth capability - Google Patents

Method for preparing ceramic coating with longitudinal crack growth capability Download PDF

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CN116445848B
CN116445848B CN202310420288.7A CN202310420288A CN116445848B CN 116445848 B CN116445848 B CN 116445848B CN 202310420288 A CN202310420288 A CN 202310420288A CN 116445848 B CN116445848 B CN 116445848B
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ceramic coating
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resin layer
crack growth
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CN116445848A (en
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程涛涛
丁坤英
王志平
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Civil Aviation University of China
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    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/134—Plasma spraying
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/32—Processes for applying liquids or other fluent materials using means for protecting parts of a surface not to be coated, e.g. using stencils, resists
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/24—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials for applying particular liquids or other fluent materials
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/06—Metallic material
    • C23C4/073—Metallic material containing MCrAl or MCrAlY alloys, where M is nickel, cobalt or iron, with or without non-metal elements
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2518/00—Other type of polymers
    • B05D2518/10—Silicon-containing polymers

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Coating By Spraying Or Casting (AREA)

Abstract

A preparation method of a ceramic coating with longitudinal crack growth capability. The method comprises the steps of MK resin solution preparation, metal bonding layer preparation, first ceramic coating preparation, first MK resin layer preparation and solidification, second ceramic coating preparation, second MK resin layer preparation and solidification and the like. The invention has low cost and simple preparation process, only needs a small amount of absolute ethyl alcohol and MK resin raw materials, and can prepare the ceramic coating with longitudinal crack growth capability by respectively spraying a discontinuous MK resin layer on the inner part and the surface of the plasma spraying ceramic coating by using the reusable porous mask. On the basis of ensuring that the bonding strength of the ceramic coating is not obviously reduced, the longitudinal micro-cracking of the discontinuous MK resin layer in the thermal cycle process can consume thermal cycle energy, release thermal cycle internal stress and reduce crack expansion driving force at the interface of part of the ceramic coating/bonding layer, thereby obviously prolonging the thermal cycle life of the ceramic coating.

Description

Preparation method of ceramic coating with longitudinal crack growth capability
Technical Field
The invention belongs to the technical field of ceramic coating structure design and optimization, and particularly relates to a preparation method of a ceramic coating with longitudinal crack growth capability.
Background
Currently, ceramic coatings (thermal barrier coatings, high temperature seal coatings, etc.) prepared by plasma spray (APS) techniques have been widely used for hot end components of aircraft engines. However, ceramic coatings are prone to spalling failure problems due to the harsh service environment. There are two main mechanical causes that lead to the tendency of APS conventional ceramic coatings to flake off, one of which is the growth stress created by the volumetric growth of thermally grown oxides. The second cause is interface mismatch stress due to thermal expansion coefficient mismatch between superalloy substrate, bond coat, ceramic coating and Thermally Grown Oxide (TGO) layer. Therefore, one of the effective ways to increase the service life of ceramic coatings is to control the driving force for crack growth, i.e., to relieve the growing stress of the TGO layer that is growing during operation of the ceramic coating and the thermal mismatch stress at the ceramic coating/TGO interface.
Early researchers can prepare ceramic coating with a columnar structure by using an electron beam physical vapor deposition (EB-PVD) method, and can effectively release internal stress through the micro-cracking effect among a plurality of columns, so that the ceramic coating prepared by the EB-PVD method has better performance, but the EB-PVD method has high cost and low coating deposition efficiency. The post-developed plasma enhanced chemical vapor deposition technology (PE-CVD), laser chemical vapor deposition technology (L-CVD), plasma physical vapor deposition technology (PS-PVD), low-pressure plasma spraying thin coating technology (LPPS-TF) and the like can be used for preparing the ceramic coating with a columnar or columnar-like structure, so that the service life of the ceramic coating is prolonged to different degrees, but the method still has the problems of harsh raw material requirements, lower deposition efficiency, expensive equipment, complex coating forming process and the like.
Another way to release internal stress of ceramic coating is micro-crack technology, and at home and abroad scholars can prepare ceramic coating with longitudinal cracks similar to columnar crystal gap in EB-PVD coating by using suspension plasma spraying technology (SPS) and solution precursor plasma spraying technology (SPPS), which has internal stress release function, thereby improving strain tolerance and service life of ceramic coating. However, the SPS and SPPS have complex coating forming processes, and the solvent in the suspension or solution precursor volatilizes to absorb a large amount of heat, so that the spraying distance is greatly reduced compared with the plasma spraying technology, and the stability and controllability of the coating preparation process are reduced. In 2013 and 2014, lisa Pin and Lu Zhe and the like sequentially propose a method for generating net-shaped cracks and longitudinal cracks by concentrated surface heating by Sol-Gel (Sol-Gel) +high-temperature heat treatment, so that the service life of the ceramic coating is prolonged to different degrees. However, the crack morphology generated by Sol-gel+high temperature treatment is irregular, the density is uncontrollable, plasma spray coating in some cracking areas is difficult to fill, so that the service life of the thermal barrier coating with the structure is unstable, the method of generating longitudinal cracks by concentrated surface heating is utilized, the density is not high, the distribution is uneven, the continuous growth of transverse cracks is easy to occur, and the effect of improving the coating performance is limited. In 2018, zengJinyan and the like implant microcracks in the ceramic coating by adopting an APS combined dry ice blasting technology, and the vertical microcracks in the coating not only reduce thermal stress, but also improve the strain tolerance of the ceramic coating, thereby prolonging the service life of the ceramic coating. However, this method cannot control the generation of transverse microcracks, and is prone to delamination failure caused by continuous growth of transverse microcracks.
The research adopts a certain technology or method to optimize the microscopic morphology or microstructure of the ceramic coating, and improves the thermal cycle cracking resistance of the ceramic coating by releasing the growing stress of the TGO layer and the thermal mismatch stress at the interface of the ceramic surface layer and the TGO layer, which are continuously increased in the working process, however, the method still has the problems of high preparation cost, low production efficiency, high technical difficulty, poor effect and the like.
Disclosure of Invention
In order to solve the problems, the invention aims to provide a preparation method of a ceramic coating with longitudinal crack growth capability.
In order to achieve the above object, the preparation method of the ceramic coating with longitudinal crack growth capability provided by the invention comprises the following steps in sequence:
1) Preparing MK resin solution by stirring absolute ethyl alcohol as solvent and MK resin as solute by using a magnetic stirrer;
2) Preparing a metal bonding layer, namely spraying CoCrAlY powder on the surface of a nickel-based alloy matrix by utilizing a plasma spraying technology to prepare the metal bonding layer;
3) Preparing a first ceramic coating, namely spraying YSZ powder (with the mark AI-1075) on the surface of the metal bonding layer by using a plasma spraying technology to prepare the first ceramic coating;
4) Preparing a first MK resin layer, namely spraying the MK resin solution prepared in the step 1) on the surface of the first ceramic coating layer by using a porous mask plate and a spraying gun to prepare the first MK resin layer with a longitudinal crack growth function;
5) The first MK resin layer is solidified, namely the nickel-based alloy substrate with the MK resin layer prepared in the step 4) is placed in a high-temperature electric furnace for heating and heat curing;
6) Preparing a second ceramic coating, namely repeating the step 3), and preparing the second ceramic coating on the surface of the first MK resin layer;
7) Preparing a second MK resin layer, namely repeating the step 4), and preparing the second MK resin layer on the surface of the second ceramic coating layer;
8) And (5) curing the second MK resin layer, namely repeating the step 5), thereby preparing the ceramic coating with the longitudinal crack growth capability.
In the step 1), the weight ratio of the absolute ethyl alcohol to the MK resin is 30-40:5-7, the rotating speed of the magnetic stirrer is 700-800 r/min, the stirring time is 14-16 h, and the stirring temperature is room temperature.
In the step 2), the voltage of the plasma spraying is 40-41V, the current is 780-800A, the powder feeding rate is 30-35 g/min, the spraying distance is 100-120 mm, and the thickness of the metal bonding layer is 100-150 mu m.
In the step 3) and the step 6), the voltage of the plasma spraying is 40.5-41.5V, the current is 790-810A, the powder feeding rate is 35-40 g/min, the spraying distance is 100-120 mm, and the thickness of the first ceramic coating is 200-250 mu m.
In the step 4) and the step 7), the pressure of the spraying gun is 0.5-0.6 MPa, the spraying distance is 150-200 mm, and the using amount of the sprayed MK resin solution is 8-10 ml/506mm 2.
In the step 5) and the step 8), the heating curing temperature of the high-temperature electric furnace is 600-800 ℃ and the curing time is 25-35 min.
The preparation method of the ceramic coating with the longitudinal crack growth capability has the following advantages:
(1) The cost is low, the preparation process is simple, only a small amount of anhydrous ethanol and MK resin raw materials are used, a discontinuous MK resin layer is respectively sprayed on the inner part and the surface of the plasma sprayed ceramic coating by using the reusable porous mask plate, and the ceramic coating with longitudinal crack growth capacity can be prepared.
(2) The discontinuous MK resin prepared based on the porous mask plate can prevent continuous growth of transverse cracks, and on the basis of ensuring that the bonding strength of the ceramic coating is not obviously reduced, the longitudinal micro-cracking of the discontinuous MK resin layer in the thermal cycle process can consume thermal cycle energy, release thermal cycle internal stress and reduce crack expansion driving force at the interface of part of the ceramic coating/bonding layer, so that the thermal cycle life of the ceramic coating is obviously prolonged.
Drawings
FIG. 1 shows the microscopic morphology of a discontinuous MK resin layer prepared using a spray gun, where (a) and (b) are at magnifications of 200 and 20, respectively.
FIG. 2 is a cross-sectional profile of a ceramic coating with longitudinal crack growth capability provided by the invention prior to thermal cycling.
FIG. 3 shows the cross-sectional morphology of the ceramic coating with longitudinal crack growth capability provided by the invention after 50 thermal cycles (one thermal cycle process is that the temperature is kept at 1100 ℃ for 15min, and compressed air is cooled for 15 min).
FIG. 4 shows the cross-sectional morphology of a ceramic coating with longitudinal crack growth capability provided by the invention after 150 thermal cycles (one thermal cycle process is heat preservation at 1100 ℃ for 15min, and compressed air cooling for 15 min).
Detailed Description
The following detailed description of embodiments of the invention is exemplary and intended to be illustrative of the invention and not to be construed as limiting the invention.
Example 1:
the preparation method of the ceramic coating with the longitudinal crack growth capability provided by the embodiment comprises the following steps in sequence:
1) Preparing MK resin solution by stirring absolute ethyl alcohol as solvent and MK resin as solute by a magnetic stirrer, wherein the weight ratio of the absolute ethyl alcohol to the MK resin is 30:5, the rotating speed of the magnetic stirrer is 700r/min, the stirring time is 14h, and the stirring temperature is room temperature;
2) Preparing a metal bonding layer by spraying CoCrAlY powder (with the mark of CO 110) on the surface of a nickel-based alloy matrix by using a plasma spraying technology, wherein the voltage of plasma spraying is 40V, the current is 780A, the powder feeding rate is 30g/min, the spraying distance is 100mm, and the thickness of the metal bonding layer is 100 mu m;
3) Preparing a first ceramic coating, namely spraying YSZ powder (with the mark of AI-1075) on the surface of the metal bonding layer by utilizing a plasma spraying technology to prepare the first ceramic coating, wherein the plasma spraying voltage is 40.5V, the current is 790A, the powder feeding rate is 35g/min, the spraying distance is 100mm, and the thickness of the first ceramic coating is 200 mu m;
4) Preparing a first MK resin layer, namely spraying the MK resin solution prepared in the step 1) on the surface of the first ceramic coating by using a porous mask plate and a spraying gun to prepare the first MK resin layer with a longitudinal crack growth function, wherein the pressure of the spraying gun is 0.5MPa, the spraying distance is 150mm, and the using amount of the sprayed MK resin solution is 8ml/506mm 2;
5) The first MK resin layer is cured, namely the nickel-based alloy substrate with the MK resin layer prepared in the step 4) is placed in a high-temperature electric furnace for heating and curing, the curing temperature is 600 ℃, and the curing time is 25min;
6) Repeating the step 3), preparing a second ceramic coating on the surface of the first MK resin, wherein the plasma spraying voltage is 40.5V, the current is 790A, the powder feeding rate is 35g/min, the spraying distance is 100mm, and the thickness of the second ceramic coating is 200 mu m;
7) The second layer MK resin layer is prepared by repeating the step 4), the second layer MK resin layer is prepared on the surface of the second layer ceramic coating, the pressure of a spraying gun is 0.5MPa, the spraying distance is 150mm, and the dosage of sprayed MK resin solution is 8ml/506mm 2;
8) And (3) curing the second MK resin layer, namely repeating the step 5), wherein the curing temperature is 600 ℃ and the curing time is 25 minutes, so that the ceramic coating with the longitudinal crack growth capability is prepared.
Example 2:
the preparation method of the ceramic coating with the longitudinal crack growth capability provided by the embodiment comprises the following steps in sequence:
1) Preparing MK resin solution by stirring absolute ethyl alcohol as solvent and MK resin as solute by using a magnetic stirrer, wherein the weight ratio of the absolute ethyl alcohol to the MK resin is 35:6, the rotating speed of the magnetic stirrer is 750r/min, the stirring time is 15h, and the stirring temperature is room temperature;
2) The preparation of the metal bonding layer comprises the step of spraying CoCrAlY powder (with the trade name of CO 110) on the surface of a nickel-based alloy matrix by utilizing a plasma spraying technology to prepare the metal bonding layer, wherein the voltage of plasma spraying is 40.5V, the current is 790A, the powder feeding speed is 32g/min, the spraying distance is 110mm, and the thickness of the metal bonding layer is 120 mu m. ;
3) Preparing a first ceramic coating, namely spraying YSZ powder (with the mark of AI-1075) on the surface of the metal bonding layer by utilizing a plasma spraying technology to prepare the first ceramic coating, wherein the plasma spraying voltage is 41V, the current is 800A, the powder feeding rate is 37g/min, the spraying distance is 110mm, and the thickness of the first ceramic coating is 220 mu m;
4) Preparing a first MK resin layer, namely spraying the MK resin solution prepared in the step 1) on the surface of the first ceramic coating by using a porous mask plate and a spraying gun to prepare the first MK resin layer with a longitudinal crack growth function, wherein the pressure of the spraying gun is 0.55MPa, the spraying distance is 170mm, and the using amount of the sprayed MK resin solution is 9ml/506mm 2;
5) The first MK resin layer is cured, namely the nickel-based alloy substrate with the first MK resin layer prepared in the step 4) is placed in a high-temperature electric furnace for heating and curing, the curing temperature is 700 ℃, and the curing time is 30min;
6) The second ceramic coating is prepared by repeating the step 3), preparing a second ceramic coating on the surface of the first MK resin layer, wherein the plasma spraying voltage is 41V, the current is 800A, the powder feeding rate is 37g/min, the spraying distance is 110mm, and the thickness of the second ceramic coating is 220 mu m;
7) The second layer MK resin layer is prepared by repeating the step 4), the second layer MK resin layer is prepared on the surface of the second layer ceramic coating, the pressure of a spraying gun is 0.55MPa, the spraying distance is 170mm, and the using amount of the sprayed MK resin solution is 9ml/506mm 2;
8) And (3) curing the second MK resin layer, namely repeating the step 5), wherein the curing temperature is 700 ℃ and the curing time is 30min, so that the ceramic coating with the longitudinal crack growth capability is prepared.
Example 3:
the preparation method of the ceramic coating with the longitudinal crack growth capability provided by the embodiment comprises the following steps in sequence:
1) Preparing MK resin solution by stirring absolute ethyl alcohol as solvent and MK resin as solute by a magnetic stirrer, wherein the weight ratio of the absolute ethyl alcohol to the MK resin is 40:7, the rotating speed of the magnetic stirrer is 800r/min, the stirring time is 16h, and the stirring temperature is room temperature;
2) The preparation of the metal bonding layer comprises the step of spraying (CoCrAlY powder, trade name CO 110) on the surface of a nickel-based alloy matrix by utilizing a plasma spraying technology to prepare the metal bonding layer, wherein the voltage of plasma spraying is 41V, the current is 800A, the powder feeding rate is 35g/min, the spraying distance is 120mm, and the thickness of the metal bonding layer is 150 mu m. ;
3) Preparing a first ceramic coating, namely spraying YSZ powder (with the mark of AI-1075) on the surface of the metal bonding layer by utilizing a plasma spraying technology to prepare the first ceramic coating, wherein the plasma spraying voltage is 41.5V, the current is 810A, the powder feeding rate is 40g/min, the spraying distance is 120mm, and the thickness of the first ceramic coating is 250 mu m;
4) Preparing a first MK resin layer, namely spraying the MK resin solution prepared in the step 1) on the surface of the first ceramic coating by using a porous mask plate and a spraying gun to prepare the first MK resin layer with a longitudinal crack growth function, wherein the pressure of the spraying gun is 0.6MPa, the spraying distance is 200mm, and the consumption of the sprayed MK resin solution is 10ml/506mm 2;
5) The first MK resin layer is cured, namely the nickel-based alloy substrate with the first MK resin layer prepared in the step 4) is placed in a high-temperature electric furnace for heating and curing, the curing temperature is 800 ℃, and the curing time is 35min;
6) Preparing a second ceramic coating layer by repeating the step 3), preparing a second ceramic coating layer on the surface of the first MK resin layer, wherein the voltage of plasma spraying is 41.5V, the current is 810A, the powder feeding rate is 40g/min, the spraying distance is 120mm, and the thickness of the second ceramic coating layer is 250 mu m;
7) The second layer MK resin layer is prepared by repeating the step 4), the second layer MK resin layer is prepared on the surface of the second layer ceramic coating, the pressure of a spraying gun is 0.6MPa, the spraying distance is 200mm, and the dosage of sprayed MK resin solution is 10ml/506mm 2;
8) And (3) curing the second MK resin layer, namely repeating the step 5), wherein the curing temperature is 800 ℃ and the curing time is 35min, so that the ceramic coating with the longitudinal crack growth capability is prepared.
FIG. 1 shows the microscopic morphology of a discontinuous MK resin layer prepared using a spray gun, where (a) and (b) are at magnifications of 200 and 20, respectively. As can be seen from FIG. 1, the MK resin layer prepared based on the shadowing effect of the round hole shaped mask plate exhibits a discontinuous arrangement on the ceramic coating.
FIG. 2 is a cross-sectional profile of a ceramic coating with longitudinal crack growth capability provided by the invention prior to thermal cycling. As can be seen from FIG. 2, after two discontinuous MK resin layers are added, no obvious interface exists in the cross-sectional morphology of the novel ceramic coating, the ceramic coating is well combined with the discontinuous MK resin layers, and the novel ceramic coating does not crack before thermal cycling.
Fig. 3 and fig. 4 show the cross-sectional morphology of the ceramic coating with longitudinal crack growth capability provided by the invention after 50 and 150 thermal cycles, respectively. As can be seen from fig. 3, after 50 thermal cycles, the novel ceramic coating showed significant longitudinal cracks in the ceramic coating, almost no significant transverse cracks, and the bond between the ceramic coating and the metallic bond coat remained good. As can be seen from fig. 4, with the increasing number of thermal cycles, after 150 thermal cycles, the novel ceramic coating has an obvious sintering phenomenon, but the ceramic coating is still mainly provided with longitudinal cracks, only has a small number of transverse cracks, and only has slight cracks at the interface of the ceramic coating and the metal bonding layer.
The ceramic coating with the longitudinal crack growth capability has the advantages that on one hand, discontinuous MK resin prepared based on the porous mask plate can prevent continuous growth of transverse cracks, so that the bonding strength of the novel ceramic coating is ensured not to be obviously reduced, on the other hand, the longitudinal micro-cracking of the discontinuous MK resin layer in the thermal cycle process can consume thermal cycle energy, release thermal cycle internal stress, reduce crack expansion driving force at the interface of part of the ceramic coating/bonding layer, and obviously improve the thermal cycle life of the novel ceramic coating.

Claims (6)

1. A preparation method of a ceramic coating with longitudinal crack growth capability is characterized by comprising the following steps in sequence:
1) Preparing MK resin solution by stirring absolute ethyl alcohol as solvent and MK resin as solute by using a magnetic stirrer;
2) Preparing a metal bonding layer, namely spraying CoCrAlY powder on the surface of a nickel-based alloy matrix by utilizing a plasma spraying technology to prepare the metal bonding layer;
3) Preparing a first ceramic coating by spraying YSZ powder on the surface of the metal bonding layer by using a plasma spraying technology;
4) Preparing a first MK resin layer, namely spraying the MK resin solution prepared in the step 1) on the surface of the first ceramic coating layer by using a porous mask plate and a spraying gun to prepare the first MK resin layer with a longitudinal crack growth function;
5) The first MK resin layer is solidified, namely the nickel-based alloy substrate with the MK resin layer prepared in the step 4) is placed in a high-temperature electric furnace for heating and heat curing;
6) Preparing a second ceramic coating, namely repeating the step 3), and preparing the second ceramic coating on the surface of the first MK resin layer;
7) Preparing a second MK resin layer, namely repeating the step 4), and preparing the second MK resin layer on the surface of the second ceramic coating layer;
8) And (5) curing the second MK resin layer, namely repeating the step 5), thereby preparing the ceramic coating with the longitudinal crack growth capability.
2. The method for preparing the ceramic coating with the longitudinal crack growth capability according to claim 1, wherein in the step 1), the weight ratio of the anhydrous ethanol to the MK resin is 30-40:5-7, the rotating speed of the magnetic stirrer is 700-800 r/min, the stirring time is 14-16 h, and the stirring temperature is room temperature.
3. The method for preparing a ceramic coating with longitudinal crack growth capability according to claim 1, wherein in the step 2), the plasma spraying voltage is 40-41V, the current is 780-800A, the powder feeding rate is 30-35 g/min, the spraying distance is 100-120 mm, and the thickness of the metal bonding layer is 100-150 μm.
4. The method for preparing a ceramic coating with longitudinal crack growth capability according to claim 1, wherein in the step 3) and the step 6), the plasma spraying voltage is 40.5-41.5V, the current is 790-810A, the powder feeding rate is 35-40 g/min, the spraying distance is 100-120 mm, and the thickness of the first ceramic coating is 200-250 μm.
5. The method for preparing a ceramic coating with longitudinal crack growth capability according to claim 1, wherein in the step 4) and the step 7), the pressure of the spraying gun is 0.5-0.6 MPa, the spraying distance is 150-200 mm, and the amount of the sprayed MK resin solution is 8-10 ml/506mm 2.
6. The method for preparing a ceramic coating with longitudinal crack growth capability according to claim 1, wherein in the step 5) and the step 8), the heating curing temperature of the high-temperature electric furnace is 600-800 ℃ and the curing time is 25-35 min.
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