目的 研究LaZrCeO热障涂层体系的火焰热冲击性能及失效行为机制。方法 随着发动机推重比和热效率需求的不断提高,开发新型耐高温、低热导率、抗烧结热障涂层体系成为研究热点,通过Ce4+引入锆酸镧（La2Zr2O7）体系可进一步调控热导率、相稳定性等性能,而锆酸镧体系涂层较低的热膨胀系数和断裂韧性使其难以作为单层陶瓷层沉积在金属底层表面,YSZ层可有效缓解层间热膨胀不匹配并减小层间应力。本工作综合上述优势,采用一步法连续电子束物理气相沉积技术在基体表面制备了LaZrCeO/YSZ双陶瓷层结构热障涂层,并对涂层的相结构组成、微观组织形貌进行了表征分析,对涂层的高温火焰热冲击性能进行了测试,并分析阐述了其失效行为模式。结果 LaZrCeO展现了烧绿石及萤石复相结构,并且在沉积过程中形成元素交替变化的微观层状结构,LaZrCeO/YSZ热导率大幅降低,双层结构缓解了LaZrCeO热膨胀系数低的问题,在1 300 ℃火焰热冲击下,LaZrCeO/YSZ双陶瓷层寿命达到2 685次,相较于LaZrCeO及YSZ单层结构热障涂层寿命提升10倍以上。结论 LaZrCeO/YSZ双陶瓷层热障涂层展现了优异的抗火焰热冲击性能,在火焰热冲击过程中形成了2种主要失效行为机制,一种是热生长氧化层不断增厚导致应力累积,裂纹在层内萌生并扩展;另一种是LaZrCeO陶瓷层元素层状分布的扩散行为导致烧结裂纹形成。
Abstract
Thermal Barrier Coatings (TBCs), as critical protective materials for turbine blades in modern aero engines and gas turbines, significantly enhance the service temperature limits and durability of superalloy components through their exceptional thermal insulation and oxidation resistance. With the continuous demand for higher thrust-to-weight ratios and thermal efficiency in engines, the development of novel ceramic topcoat materials with elevated temperature resistance, low thermal conductivity, and superior sintering resistance has become a research priority. Among these, rare earth doped lanthanum zirconate (La2Zr2O7) based materials are regarded as one of the most promising candidates due to their low thermal conductivity, high phase stability, and excellent anti-sintering properties. In particular, the Ce-doped LaZrCeO system can further optimize the thermal expansion coefficient and suppress oxygen diffusion through the incorporation of Ce4+ ions. However, its failure mechanisms under high-temperature flame thermal shock conditions remain to be systematically investigated for simulating and predicting the TBCs service lifetime under practical condition of aero engine. To address this research gap, LaZrCeO top layer and YSZ intermediate layer (LaZrCeO/YSZ) were deposited via single-step electron beam physical vapor deposition (EB-PVD) onto Ni-based superalloy substrate. The unique architecture was designed to combine the excellent thermal insulation properties of LaZrCeO layer with the proven fracture toughness of YSZ layer. LaZrCeO ceramic showed pyrochlore with fluorite composite phase structure under XRD scanning results. Detailed microstructural characterization through SEM equipped with EDS revealed a novel alternating layered morphology inside the LaZrCeO coat, consisting of periodic variations in Zr, Ce cation concentration. The thermal conductivity of LaZrCeO/YSZ decreased distinctly and the duplex layer structure relieved the lower thermal expansion coefficient of LaZrCeO. The as-deposited coatings were subjected to high-temperature flame thermal shock tests, which directly impinged the coating surface with a 1 300 ℃ flame, followed by forced air cooling to simulate extreme thermal transients. The LaZrCeO/YSZ double ceramic layer system demonstrated an exceptional thermal cycling lifetime, surviving 2 685 cycles before failure, which was approximately 10 times longer than single layer LaZrCeO coating. Post-test analysis through cross-sectional SEM and elemental mapping showed that the LaZrCeO/YSZ coating exhibited two kinds of primary failure behaviors. The first failure mode was the growth of the TGO layer at the bond coat/ceramic layer interface. The TGO thickening increased the stress concentration, leading to crack initiation and subsequent propagation. In addition, the pyrochlore and fluorite composite structure created a certain amount of oxygen vacancy defects, which provided diffusion pathways for atomic migration and facilitated the slight sintering state within the LaZrCeO layer under 1 300 ℃ thermal shocks. Meanwhile, the alternating chemical distribution in the LaZrCeO layer induced localized differences in sintering rate and stiffness, creating micro-regions of stress concentration that served as preferential sites for intra-layer crack nucleation and evolution. This secondary failure mode, which originated within the ceramic top layer itself rather than exclusively at the interface, represented a newly identified mechanism in doped zirconate TBCs. This work not only demonstrates the superior performance of a novel LaZrCeO/YSZ double ceramic layer TBCs but also provides original insights into the role of microstructural heterogeneity in affecting sintering behavior and crack propagation paths. These findings underline the importance of engineering microstructural architectures in future TBC designs for ultra-high-temperature applications.
关键词
热障涂层 /
电子束物理气相沉积 /
显微结构 /
热冲击 /
失效形式
Key words
thermal barrier coatings /
electron beam physical vapour deposition /
microstructure /
thermal shock /
failure mode
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基金
国家科技重大专项项目（J2019-Ⅶ-0010-0150）; 超高温耐蚀热障涂层技术项目（30204）; 国家自然科学基金项目（52202073）
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