MCrAlY和AlCoCrFeNi高熵合金黏结层制备与研究进展

张渊; 李秀兰; 李伟; 周新军; 何归; 郭正宇

doi:10.16490/j.cnki.issn.1001-3660.2026.06.001

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表面技术 ›› 2026, Vol. 55 ›› Issue (6) : 1-17. DOI: 10.16490/j.cnki.issn.1001-3660.2026.06.001

腐蚀与防护

MCrAlY和AlCoCrFeNi高熵合金黏结层制备与研究进展

张渊, 李秀兰^*, 李伟, 周新军, 何归, 郭正宇

作者信息 +

Preparation and Research Progress of MCrAlY and AlCoCrFeNi High-entropy Alloy Bond Coatings

ZHANG Yuan, LI Xiulan^*, LI Wei, ZHOU Xinjun, HE Gui, GUO Zhengyu

Author information +

文章历史 +

摘要

随着航空发动机、燃气轮机的不断发展,在性能提升的同时热端部件温度也不断提高,为改善航空发动机、燃气轮机的热端部件在高温下的服役性能和延长寿命,对热障涂层性能的要求日益增加。黏结层的选择对于热障涂层的性能至关重要,本文通过黏结层成分设计、高温抗氧化性和改性方法分别介绍了MCrAlY黏结层和AlCoCrFeNi高熵合金黏结层,并归纳总结了两类黏结层的高温抗氧化性能和改性机理。传统MCrAlY黏结层在超过1 100 ℃下工作时会导致TGO生长速率快和界面附着力退化,将无法提供足够的高温抗氧化性能。而AlCoCrFeNi高熵合金黏结层在1 100 ℃的高温下能够形成保护性的α-Al₂O₃层,并且其氧化行为与MCrAlY黏结层相似。与MCrAlY黏结层相比,AlCoCrFeNi高熵合金展现出更优的热稳定性、更高的热硬度、更低的热导率以及更小的热膨胀系数。同时对几种制备工艺研究进展进行了介绍,归纳了制备流程和工艺参数对黏结层结构和性能的影响。在引入高熵合金黏结层体系中,AlCoCrFeNi高熵合金还因其独特的特性展现出优异的抗氧化性、热稳定性和机械性能,因此,AlCoCrFeNi高熵合金黏结层有望在高温环境下替代传统MCrAlY黏结层。最后,展望了黏结层成分设计和制备工艺的未来研究方向。

Abstract

With the continuous development of aeroengines and gas turbines, the temperature of hot-section components keeps rising with the improvement of performance. To enhance the service performance and prolong the lifespan of hot-section components under high temperature conditions, thermal insulation measures such as superalloys, cooling systems, and thermal barrier coatings (TBCs) must be adopted. However, the mechanical properties of superalloys deteriorate significantly above 1 100 ℃, and film cooling reduces engine efficiency. TBCs can overcome high-temperature limitations and deliver greater benefits. TBCs consist of a superalloy substrate, a bond coating (BC), a thermally grown oxide layer (TGO, primarily α-Al₂O₃), and a top coat (TC) ceramics. The TGO inevitably forms between the BC and TC at high temperature conditions, serving as the true bonding interface for the TC. Its characteristics and thickness directly determine the lifetime and failure mechanisms of TBCs. The high-temperature failure causes of TBCs include: (1) thermal stress induced by coefficient of thermal expansion (CTE) mismatch between BC and TC; (2) erosion caused by high-velocity particle impact; and (3) corrosion from CaO-MgO-Al₂O₃-SiO₂ (CMAS) particles in the atmosphere. These mechanisms are primarily related to the TC; therefore, the TC must possess low thermal conductivity, excellent high-temperature chemical stability, high thermal shock resistance, erosion resistance, high melting point, high CTE, and good fracture toughness. As the first coating layer in TBCs, the BC plays a critical role in enhancing adhesion between the TC and the substrate and preventing high-temperature oxidation of the alloy substrate, because the TC has a porous structure with high oxygen diffusivity. Under elevated temperature conditions, wrinkling, oxidation deformation, and aluminum depletion of the BC exacerbate thermal stress between the BC and the TC, leading to cracking and reduced bonding strength. In industrial practice, MCrAlY (M=Ni or/and Co) coatings are commonly used as bond coatings, where Cr and Al enhance oxidation and hot corrosion resistance, while the Y element improves the bonding strength of the oxide layer. However, as inlet temperatures continue to rise, conventional MCrAlY bond coatings suffer from rapid TGO growth and degraded interfacial adhesion when operating above 1 100 ℃, providing insufficient oxidation resistance. Therefore, there is an urgent need to develop new bond coating materials with higher temperature capability to break through the temperature limitations of conventional MCrAlY bond coatings. In recent years, high-entropy alloys (HEAs) have attracted considerable attention due to their unique compositions and superior properties. HEAs are originally defined as multi-component alloys containing five or more alloying elements, each added in equiatomic proportions with concentrations between 5% to 35%. Current research has extended this to simple solid solutions where the elemental composition is no longer limited to at least five principal elements, while the atomic fraction of each element remains at 5% to 35%. As a novel alloy system, HEAs possess a multi-principal-element structure and exhibit synergistic effects including high-entropy, sluggish diffusion, severe lattice distortion, and a "cocktail" effect. These break the inherent performance trade-offs of conventional alloys, demonstrating high hardness, superior heat resistance, strong corrosion resistance, excellent wear resistance, and oxidation resistance. Under high temperature conditions, HEAs can promote the formation of continuous, dense, and uniform TGO while regulating interdiffusion between the bond coating and the substrate, showing great potential as bond coating materials. The selection of bond coatings is crucial for TBCs performance. This paper separately introduces MCrAlY and AlCoCrFeNi HEAs bond coatings through composition design, high-temperature oxidation resistance, and modification methods, and summarizes the high-temperature oxidation performance and modification mechanisms of both bond coating types. It points out that conventional MCrAlY bond coatings operating above 1 100 ℃ lead to rapid TGO growth and interfacial adhesion degradation, failing to provide adequate high-temperature oxidation resistance. In contrast, AlCoCrFeNi HEAs bond coatings can form a protective α-Al₂O₃ scale at 1 100 ℃, exhibiting oxidation behavior similar to MCrAlY bond coatings. Compared with MCrAlY bond coatings, AlCoCrFeNi HEAs demonstrate superior thermal stability, higher hot hardness, lower thermal conductivity, and smaller coefficient of thermal expansion. The review also covers several preparation processes, summarizing the effects of processing flow and parameters on bond coating structure and properties. Within the HEAs bond coating system, AlCoCrFeNi HEAs further exhibit excellent oxidation resistance, thermal stability, and mechanical properties due to their unique characteristics. Therefore, AlCoCrFeNi HEAs bond coatings are promising candidates to replace conventional MCrAlY bond coatings in high-temperature environments. Finally, future research directions for bond coating composition design and preparation processes are proposed.

导出引用

张渊, 李秀兰, 李伟, 周新军, 何归, 郭正宇. MCrAlY和AlCoCrFeNi高熵合金黏结层制备与研究进展[J]. 表面技术. 2026, 55(6): 1-17

ZHANG Yuan, LI Xiulan, LI Wei, ZHOU Xinjun, HE Gui, GUO Zhengyu. Preparation and Research Progress of MCrAlY and AlCoCrFeNi High-entropy Alloy Bond Coatings[J]. Surface Technology. 2026, 55(6): 1-17

中图分类号： TG174.4

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