目的 探究不同激光参数下ZrO2陶瓷涂层激光烧蚀损伤行为与损伤机理。方法 采用大气等离子喷涂技术在铝合金基体上制备ZrO2陶瓷涂层,并通过自主搭建的激光烧蚀实验平台,对材料进行激光烧蚀实验,研究了ZrO2陶瓷涂层对激光的防护性能;采用分光光度计、X-射线衍射仪、扫描电子显微镜和光学显微镜分别对涂层的反射率、物相结构以及烧蚀前后的损伤形貌进行了测试与表征。结果 ZrO2涂层的反射率R约为97%,其耦合系数ε为3%,相比铝合金基材的耦合系数14%,降低了约79%;激光烧蚀后ZrO2陶瓷涂层的晶相由四方相转变为立方相;涂层损伤程度随激光功率的增加及光斑直径的减小而加强;激光烧蚀过后ZrO2陶瓷涂层烧蚀部位分为无影响区、轻影响区和高影响区,轻影响区表面平整,具有明显的晶界,晶界之间连接紧密;高影响区有大量裂纹的产生,且存在完全熔融和未完全熔融两部分。结论 激光辐照ZrO2陶瓷时,中心区域材料达到熔点逐步形成熔池;激光持续作用下,熔池不断扩大且材料发生飞溅,形成烧蚀损伤凹坑;当激光辐照停止后,熔池冷却过程中引起的热应力导致烧蚀坑表面微裂纹形成。
Abstract
ZrO2 ceramic coatings have emerged as a primary choice for laser protection due to their exceptional thermal stability, high melting point, low thermal conductivity, and phase transformation toughening characteristics. The unique high-temperature phase behavior of ZrO2 not only facilitates significant heat absorption during laser irradiation but also mitigates thermal stress and suppresses crack propagation through volume changes associated with its phase transformations. Furthermore, the relatively good thermal expansion match between ZrO2 coatings and metallic substrates enhances the reliability of the protective structure by reducing interfacial thermal stresses. Focusing on ZrO2 ceramic coatings, the work aims to investigate their ablation resistance and protective performance under various laser parameters. The ZrO2 ceramic coating was fabricated with the atmospheric plasma spraying (APS) technique. The substrate material was an aluminum alloy disk with a diameter of 80 mm and a thickness of 5 mm. Prior to coating deposition, the aluminum alloy substrate underwent surface preparation involving blasting with sand (e.g., white corundum) to enhance roughness and adhesion, followed by ultrasonic cleaning in absolute ethanol and drying. Laser ablation experiments were conducted through a self-built experimental platform equipped with a continuous-wave laser source. The material was ablated under different laser powers (2, 5, 8 kW) and spot diameters (3, 4.5, 6 cm), systematically evaluating the protective performance of the ZrO2 coating under these parameters. For specific parameter sets, a thermocouple was positioned at the center of the sample's back surface to monitor the temperature evolution in real time. Post-irradiation analysis involved comprehensive characterization of the coatings. Spectral reflectivity was measured with a spectrophotometer, phase structure was analyzed by X-ray diffraction (XRD), and damage morphology before and after ablation was examined through scanning electron microscopy (SEM) and optical microscopy. These techniques contributed to understanding the coating's reflective properties, phase stability under thermal load, and failure mechanisms. Results indicated that the ZrO2 coating exhibited a high reflectivity (R) of approximately 97%, with a laser coupling coefficient (ε) of 3%. This represented a 79% reduction compared to the coupling coefficient of the aluminum alloy substrate (14%). Phase analysis revealed that the crystal structure of the ZrO2 coating transitioned from the tetragonal phase to the cubic phase following laser ablation. The extent of coating damage intensified with the increasing laser power and the decreasing spot diameter. After laser ablation, the affected area of the ZrO2 coating was divided into three distinct zones: the unaffected zone, the slightly affected zone, and the highly affected zone. The slightly affected zone maintained a relatively smooth surface with clearly defined and well-connected grain boundaries. In contrast, the highly affected zone was characterized by the presence of extensive cracks and a mixture of fully melted and partially melted regions. When subjected to laser irradiation, the central region of the ZrO2 ceramic reached its melting point and formed a molten pool. The material subsequently entered both molten and vaporized states, leading to material splashing and ablation damage. Under continuous laser action, plasma was induced, while the bottom of the molten pool gradually transformed into a recast layer. After the laser irradiation ceased, thermal stress generated during the cooling of the molten pool resulted in the formation of microcracks on the surface of the ablation crater.
关键词
ZrO2涂层 /
铝合金基体 /
等离子喷涂 /
激光烧蚀 /
损伤机理
Key words
ZrO2 coating /
aluminum alloy substrate /
plasma spraying /
laser ablation /
damage mechanism
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基金
国家自然科学基金（12402409）; 四川省自然科学基金项目（2024NSFSC0958）
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