目的 在γ-TiAl合金表面制备TiAlCrY/YSZ复合涂层以提升其耐磨损性能。方法 采用双层辉光等离子金属技术和多弧离子镀技术,在γ-TiAl合金表面制备TiAlCrY/YSZ复合涂层,利用XRD、SEM对涂层表面物相以及形貌进行分析,使用数字显微硬度仪、微米划痕测试仪对涂层力学性能分析,采用往复式及高温球磨盘式摩擦磨损仪对基体和涂层进行磨损实验,采用SEM和激光共聚焦扫描显微镜观察二者表面磨损形貌并综合对比分析。结果 复合涂层表面主要物相为t-ZrO2,具有良好的热稳定性。YSZ层厚度为14~ 16 μm,TiAlCrY黏结层和扩散层厚度为8~10 μm,涂层总厚度为24 μm且均匀致密。力学性能测试结果表明,TiAlCrY扩散层有效缓解了基体与YSZ涂层界面性能差异,提高了结合强度与显微硬度。摩擦磨损结果表明,涂层的摩擦系数稳定且明显低于基体,在6.2 N载荷下涂层磨损体积仅为基体的12%。涂层的主要磨损机制为轻度磨粒磨损,而基体的磨损机制主要为磨粒磨损与黏着磨损。在500 ℃下,基体氧化膜形成和剥落,磨损程度加剧,主要以磨粒磨损为主,同时伴随不同程度的黏着和氧化磨损;涂层则主要经历轻微的氧化磨损和黏着磨损,比磨损率仅为基体的15%。结论 通过在γ-TiAl合金上制备TiAlCrY/YSZ复合涂层,深入研究涂层在摩擦磨损条件下的行为特点及失效机制,提高γ-TiAl合金在实际工程中的应用性能,有效解决了YSZ陶瓷层与γ-TiAl之间高温结合力差的问题,并显著提高其耐高温磨损性能。
Abstract
Under high-temperature service conditions, friction and wear are key factors affecting the performance of coatings and substrates. Especially under high-temperature and high-speed service conditions of aero-engine components, friction and wear will directly affect the performance of γ-TiAl alloys, resulting in shorter service life. The work aims to address the inherent low surface hardness and poor wear resistance of the alloy by developing and characterizing a TiAlCrY/YSZ composite coating deposited onto γ-TiAl. A functionally graded coating system was fabricated through double-glow plasma surface alloying (DG-PSA) to create a TiAlCrY diffusion/bonding layer and multi-arc ion plating (MAIP) to deposit an yttria-stabilized zirconia (YSZ) topcoat. X-ray diffraction (XRD) and scanning electron microscopy (SEM) were utilized to analyze the surface phase and morphology of the coating and digital micro-hardness tester and micron scratch tester were used to analyze the mechanical properties and bonding force of the coating. To analyze the wear patterns and differences between the coating and the substrate, reveal the synergistic mechanisms of adhesive wear, abrasive wear and oxidative wear under complex conditions and provide a theoretical basis for the coating design, CET-I type reciprocating friction and wear tester and UMT-2 type ball and disk friction and wear tester were used to conduct wear experiments on the substrate and the coating and SEM and laser confocal scanning microscope were employed to observe the surface wear morphologies of the substrate and the coating and make a comprehensive comparison and analysis. The XRD confirmed that the tetragonal zirconia (t-ZrO2) had good thermal stability as the dominant surface phase of the coating. The SEM revealed a dense, uniform coating structure: the YSZ layer was 14-16 μm and the underlying TiAlCrY diffusion/bonding layers were 8-10 μm, resulting in a total coating thickness of 24 μm. The results of mechanical property tests showed that the TiAlCrY diffusion layer effectively alleviated the difference between the interfacial properties of the substrate and the YSZ coating, and improved the bond strength and microhardness. The friction and wear results showed that the coefficient of friction of the coating was stable and significantly lower than that of the substrate and the wear volume of the coating was only 12% of that of the substrate under a load of 6.2 N. The main wear mechanism of the substrate was severe abrasive and adhesive wear. The main wear mechanism of the coating was mild abrasive wear. At 500 ℃, the substrate experienced oxide film formation and spallation, the degree of wear increasedand the abrasive wear predominated, accompanied by varying degrees of adhesive and oxidative wear. The coating, on the other hand, primarily experienced slight oxidative and adhesive wear and the specific wear rate was only 15% of that of the substrate. By depositing TiAlCrY/YSZ composite coatings on γ-TiAl alloys, the behavioral characteristics and failure mechanisms of the coatings under frictional wear conditions are studied, improving the application performance of γ-TiAl alloys in practical engineering, effectively solving the problem of insufficient bonding between the YSZ ceramic layer and γ-TiAl, and significantly improving its resistance to high-temperature wear performance.
关键词
γ-TiAl /
双辉等离子渗金属 /
多弧离子镀技术 /
TiAlCrY/YSZ复合涂层 /
摩擦磨损 /
磨损机制
Key words
γ-TiAl /
double-glow plasma surface alloying /
multi-arc ion plating technology /
TiAlCrY/YSZ composite coating /
friction and wear
{{custom_sec.title}}
{{custom_sec.title}}
{{custom_sec.content}}
参考文献
[1] POLLOCK T M.Alloy Design for Aircraft Engines[J]. Nature Materials, 2016, 15(8): 809-815.
[2] LI X B, XU H, XING W W, et al.Microstructural Evolution and Mechanical Properties of Forged β-Solidified γ-TiAl Alloy by Different Heat Treatments[J]. Transactions of Nonferrous Metals Society of China, 2022, 32(7): 2229-2242.
[3] XIA Z W, SHAN C W, ZHANG M H, et al.Machinability of γ-TiAl: A Review[J]. Chinese Journal of Aeronautics, 2023, 36(7): 40-75.
[4] YANG Y L, WANG C L, GESANG Y, et al.Fretting Wear Evolution of γ-TiAl Alloy[J]. Tribology International, 2021, 154: 106721.
[5] KIM Y W, DIMIDUK D M.Progress in the Understanding of Gamma Titanium Aluminides[J]. JOM, 1991, 43(8): 40-47.
[6] 苗润田. 某机第4级压气机转子叶片榫头折断故障分析[J]. 燃气涡轮试验与研究, 2003, 16(2): 34-37.
MIAO R T.An Analysis on Break Failure at Dovetail of the 4th Stage Compressor Blades of an Engine[J]. Gas Turbine Experiment and Research, 2003, 16(2): 34-37.
[7] CIAVARELLA M, DEMELIO G.A Review of Analytical Aspects of Fretting Fatigue, with Extension to Damage Parameters, and Application to Dovetail Joints[J]. International Journal of Solids and Structures, 2001, 38(10/11/ 12/13): 1791-1811.
[8] MARINHA D, BELMONTE M.Mixed-Ionic and Electronic Conduction and Stability of YSZ-Graphene Composites[J]. Journal of the European Ceramic Society, 2019, 39(2/3): 389-395.
[9] ARENA A, PRETE F, RAMBALDI E, et al.Nanostructured Zirconia-Based Ceramics and Composites in Dentistry: A State-of-the-Art Review[J]. Nanomaterials, 2019, 9(10): 1393.
[10] MORELLI S, BURSICH S, BOLELLI G, et al.Thermal Conductivity and Micromechanical Properties of Plasma- Sprayed Yttria-Stabilized Zirconia Thermal Barrier Coatings[J]. Surface and Coatings Technology, 2025, 513: 132498.
[11] STIGER M J, YANAR M M, TOPPING M G, et al.Thermal Barrier Coatings for the 21st Century[J]. International Journal of Materials Research, 1999, 90(12): 1069-1078.
[12] VASSEN R, STUKE A, STÖVER D. Recent Developments in the Field of Thermal Barrier Coatings[J]. Journal of Thermal Spray Technology, 2009, 18(2): 181-186.
[13] CHEN L B.Yttria-Stabilized Zirconia Thermal Barrier Coatings—A Review[J]. Surface Review and Letters, 2006, 13(5): 535-544.
[14] 丁坤英, 于建海, 高元. 多孔YSZ涂层的制备和可磨耗性[J]. 焊接学报, 2017, 38(1): 56-60.
DING K Y, YU J H, GAO Y.Abradable Properties of Porous YSZ Coatings[J]. Transactions of the China Welding Institution, 2017, 38(1): 56-60.
[15] WEI D B, LI M F, ZHOU X, et al.Preparation of NiCr/YSZ Two-Layered Burn-Resistant Coating on γ-TiAl Alloys Based on Plasma Surface Metallurgy and Ion Plating Methods[J]. Journal of Mining and Metallurgy, Section B: Metallurgy, 2021, 57(1): 83-96.
[16] PAN Y Y, HAN D J, HUANG S S, et al.Thermal Insulation Performance and Thermal Shock Resistance of Plasma-Sprayed TiAlCrY/Gd2Zr2O7 Thermal Barrier Coating on γ-TiAl Alloy[J]. Surface and Coatings Technology, 2023, 468: 129715.
[17] PAN Y Y, LIANG B, HONG D, et al.Effect of TiAlCrNb Buffer Layer on Thermal Cycling Behavior of YSZ/ TiAlCrY Coatings on γ-TiAl Alloys[J]. Surface and Coatings Technology, 2022, 431: 128000.
[18] HU X Y, KIET A T, DENG G Y, et al.Tribological Performance Evaluation of YSZ-NiCrAlY Gradient Materials by Tribometer and Nanoscratch[J]. Tribology International, 2025, 202: 110292.
[19] KIM D J, SEO D Y, HUANG X, et al.Cyclic Oxidation Behavior of a Beta Gamma Powder Metallurgy TiAl- 4Nb-3Mn Alloy Coated with a NiCrAlY Coating[J]. Surface and Coatings Technology, 2012, 206(13): 3048-3054.
[20] TANG Z L, WANG F H, WU W T.Effect of MCrAIY Overlay Coatings on Oxidation Resistance of TiAl Intermetallics[J]. Surface and Coatings Technology, 1998, 99(3): 248-252.
[21] HAN D J, PAN Y Y, NIU Y R, et al.Isothermal Oxidation Resistance and Microstructure Evolution of VPS-TiAlCrY Coating on TiAl Single Crystals at 1 100-1 200 ℃[J]. Corrosion Science, 2022, 208: 110664.
[22] SWADŹBA R, BAUER P P. Microstructure Formation and High Temperature Oxidation Behavior of Ti-Al-Cr- Y-Si Coatings on TiAl[J]. Applied Surface Science, 2021, 562: 150191.
[23] PAN Y Y, LIANG B, NIU Y R, et al.Thermal Shock Behaviors of Plasma Sprayed YSZ/TiAlCrY System on TiAl Alloys[J]. Ceramics International, 2022, 48(5): 6199-6207.
[24] SWADŹBA R, BAUER P P. High Resolution STEM Investigations of TGO Formed in TBCS on γ-TiAl with CHC-PVD TiAlCrYSi Bond Coatings[J]. Corrosion Science, 2022, 200: 110225.
[25] XU Z, HUANG J, XU Z F, et al.Plasma Surface Metallurgy of Materials Based on Double Glow Discharge Phenomenon[J]. American Journal of Physics and Applications, 2021, 9(4): 70.
[26] XU Z, WU H Y, HUANG J, et al.A Series of Plasma Innovation Technologies by the Double Glow Discharge Phenomenon[J]. AIP Advances, 2023, 13(9): 095308.
[27] YUAN S, LIN N M, ZENG Q F, et al.Recent Developments in Research of Double Glow Plasma Surface Alloying Technology: A Brief Review[J]. Journal of Materials Research and Technology, 2020, 9(3): 6859-6882.
[28] WEI D B, LI F K, WEI X F, et al.Microstructure, Nano-Mechanical Characterization, and Fretting Wear Behavior of Plasma Surface Cr-Nb Alloying on γ-TiAl[J]. Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology, 2021, 235(5): 1012-1024.
[29] HAN D J, TONG Z P, PAN X, et al.Oxidation and Thermal Shock Resistance of TiAlCrY/YSZ Thermal Barrier Coating on Single-Crystal TiAl Alloys[J]. Journal of Materials Research and Technology, 2025, 35: 4859-4869.
[30] NOVIKOV V Y, BERESNEV V М, KOLESNIKOV D A, et al.Structure and Mechanical Properties of Multilayer Coatings (TiAlCrY)N/ZrN[J]. Problems of Atomic Science and Technology, 2019: 116-120.
[31] 徐重, 张艳梅, 张平则, 等. 双层辉光等离子表面冶金技术[J]. 热处理, 2009, 24(1): 1-11.
XU C, ZHANG Y M, ZHANG P Z, et al.Double Glow Plasma Surface Metallurgy Technology[J]. Heat Treatment, 2009, 24(1): 1-11.
[32] 徐重. 我国在金属材料表面工程领域的一项重大原创性技术——双辉光等离子表面冶金技术[J]. 热处理, 2020, 35(6): 1-14.
XU Z.A Major Original Innovation Technology in Field of Metal Material Surface Engineering in China—Double Glow Plasma Surface Metallurgy Technology[J]. Heat Treatment, 2020, 35(6): 1-14.
[33] TAM P L, ZHOU Z F, SHUM P W, et al.Oxidation Resistance of Multicomponent CrTiAlN Hard Coatings at Elevated Temperatures[J]. Advanced Materials Research, 2009, 75: 37-42.
[34] MERCER C, WILLIAMS J R, CLARKE D R, et al.On a Ferroelastic Mechanism Governing the Toughness of Metastable Tetragonal-Prime (t′) Yttria-Stabilized Zirconia[J]. Proceedings: Mathematical, Physical and Engineering Sciences, 2007, 463(2081): 1393-1408.
[35] STUBICAN V S, HINK R C, RAY S P.Phase Equilibria and Ordering in the System ZrO2-Y2O3[J]. Journal of the American Ceramic Society, 1978, 61(1/2): 17-21.
[36] LANG F Q, YU Z M.The Corrosion Resistance and Wear Resistance of Thick TiN Coatings Deposited by Arc Ion Plating[J]. Surface and Coatings Technology, 2001, 145(1/2/3): 80-87.
[37] FEINBERG A, PERRY C H.Structural Disorder and Phase Transitions in ZrO2-Y2O3 System[J]. Journal of Physics and Chemistry of Solids, 1981, 42(6): 513-518.
[38] BAKHSHESHI-RAD H R, HAMZAH E, ISMAIL A F, et al. Microstructural, Mechanical Properties and Corrosion Behavior of Plasma Sprayed NiCrAlY/Nano-YSZ Duplex Coating on Mg-1.2Ca-3Zn Alloy[J]. Ceramics International, 2015, 41(10): 15272-15277.
[39] YANG G J, CHEN Z L, LI C X, et al.Microstructural and Mechanical Property Evolutions of Plasma-Sprayed YSZ Coating during High-Temperature Exposure: Comparison Study between 8YSZ and 20YSZ[J]. Journal of Thermal Spray Technology, 2013, 22(8): 1294-1302.
[40] YANG L, ZHONG Z C, ZHOU Y C, et al.Acoustic Emission Assessment of Interface Cracking in Thermal Barrier Coatings[J]. Acta Mechanica Sinica, 2016, 32(2): 342-348.
[41] BAI L Y, YI G W, WAN S H, et al.Comparison of Tribological Performances of Plasma Sprayed YSZ, YSZ/Ag, YSZ/MoO3 and YSZ/Ag/MoO3 Coatings from 25 to 800 ℃[J]. Wear, 2023, 526: 204944.
PDF(22579 KB)
渝公网安备 50010702501715号 渝ICP备15012534号-3
