&#x003b1;-Al2O3生长型高温涂层/黏结层的研究进展

周博; 谢云; 彭晓

doi:10.16490/j.cnki.issn.1001-3660.2026.19.001

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表面技术 ›› 2026, Vol. 55 ›› Issue (19) : 1-20. DOI: 10.16490/j.cnki.issn.1001-3660.2026.19.001

专题——先进航空发动机及燃气轮机新型热障涂层技术及应用

α-Al₂O₃生长型高温涂层/黏结层的研究进展

周博, 谢云^*, 彭晓

作者信息 +

Research Progress on α-Al₂O₃ Growth-Type High-Temperature Coatings/Bond Coats

ZHOU Bo, XIE Yun^*, PENG Xiao

Author information +

文章历史 +

摘要

随着航空发动机涡轮前温度的持续提升,热障涂层作为保障热端部件可靠服役的关键技术也亟需革新,而热障涂层的性能与寿命与其黏结层密切相关,因此黏结层的选择至关重要。本文系统综述了高温涂层/黏结层中广泛使用的传统扩散型铝化物涂层、MCrAlY涂层,以及近年来迅速发展的AlCoCrFeNi系高熵合金涂层和难熔高熵合金涂层的研究进展,重点总结了成分设计、相结构调控、活性元素改性及制备工艺优化等对其抗高温氧化性能的影响机制。铝化物涂层方面,Re、Ru、Ir等元素与Pt共改性及Re基扩散障的构建显著提升了氧化膜的黏附性,并有效抑制了涂层与基体之间的元素相互扩散。MCrAlY涂层通过纳米晶化、活性元素（Y、Hf、Zr）掺杂以及激光重熔、激光冲击强化等技术,实现了抗氧化性能的多角度优化。AlCoCrFeNi系高熵合金涂层利用高熵合金的迟滞扩散效应、FCC+BCC的双相共晶特征,以及适量稀土与合金元素（Si、Nb、Pt）的协同作用等,有效促进了保护性α-Al₂O₃膜的快速形成与稳定生长。针对难熔高熵合金涂层抗氧化性不足的固有瓶颈,最新研究通过精确调控涂层的Al含量与相组成,使其在1 300 ℃以上生成了单一致密的α-Al₂O₃膜,展现出作为超高温涂层/黏结层的巨大应用潜力。最后,本文指出了活性元素作用机理、涂层与基体互扩散行为及涂层寿命预测模型等亟待完善与突破的关键科学问题,并对未来新型高温涂层/黏结层体系的设计与开发进行了前瞻性展望。

Abstract

With the continuous increase in thrust-to-weight ratios and turbine inlet temperatures of aero-engines, high-temperature protective coatings, as a key technology ensuring the service reliability of hot-section components, are in urgent need of innovation, the performance and lifespan of thermal barrier coatings are closely related to their bond coats, therefore, the selection of the bond coats is crucial. This review systematically summarizes recent research progress on four typical α-Al₂O₃ growth-type coatings: diffusion aluminide coatings, MCrAlY overlay coatings, AlCoCrFeNi-based high-entropy alloy coatings, and refractory high-entropy alloy coatings. The analysis focuses on the influence mechanisms of composition design, phase structure regulation, reactive element doping, and fabrication processes on their high-temperature oxidation resistance.
Diffusion aluminide coatings have long been used on hot-section components of aero-engines due to their ability to rapidly form a protective Al₂O₃ scale. However, during long-term service at high temperatures, they suffer from severe interdiffusion with the substrate, Al depletion, and the precipitation of detrimental TCP phases. Recent studies have shown that the introduction of Re, Ru elements, and Ir can effectively inhibit Al interdiffusion and improve oxide scale adhesion. Additionally, constructing a Re-based diffusion barrier between the coating and the substrate can effectively slow down the interdiffusion between the coating and the substrate, thereby significantly enhancing the high-temperature oxidation resistance of the coating.
MCrAlY coatings, as one of the most widely used high-temperature protective coatings, achieve a good balance between oxidation resistance and mechanical properties. In recent years, research focus has gradually shifted from traditional compositional optimization to the synergistic regulation of microstructure and interfacial stability. The addition of reactive elements such as Y, Hf, and Zr can improve oxide scale adhesion through interfacial pinning, while nanocrystallization or nanocomposite electrodeposition can promote the selective oxidation of Al and Cr and promote the fast formation of α-Al₂O₃. Post-treatment techniques such as laser remelting and laser shock peening can effectively eliminate pores and cracks introduced during coating preparation, significantly improving coating density and the spallation resistance of the oxide scale.
AlCoCrFeNi-based high-entropy alloy coatings, due to the unique effects of high-entropy alloys and their excellent oxidation resistance at high temperatures, show great potential as a new generation of high-temperature protective coatings. Researches indicate that Al content is a key factor determining their oxidation resistance; high Al content promote the formation of a stable α-Al₂O₃ scale, but it also increases the fraction of the BCC phase and reduces toughness. Therefore, the design of FCC+BCC dual-phase or eutectic microstructures has become an important approach to balance oxidation resistance and mechanical properties. The addition of appropriate amounts of elements such as Y, Hf, Si, Nb, and Pt can further promote the formation of α-Al₂O₃ and reduce stress in the oxide scale.
Refractory high-entropy alloy coatings, owing to their high melting points and excellent high-temperature strength, are considered important candidate materials for ultra-high-temperature protective coatings above 1 300 ℃. However, they tend to form volatile or non-protective oxides after oxidation, leading to insufficient oxidation resistance. Current researches mainly focus on improving their oxidation resistance by adding Al, Cr, Si, and rare earth elements. Recent studies have shown that by precisely controlling the Al content and phase structure, a single and dense α-Al₂O₃ scale can be formed at 1 300 ℃, demonstrating the application potential of refractory high-entropy alloys in ultra-high-temperature environments.
In summary, the development of high-temperature protective coatings has shifted from traditional single-component optimization to multi-alloying, synergistic microstructural design, and comprehensive regulation of interfacial stability. Future research should pay further attention to the mechanisms of reactive element action, coating-substrate interdiffusion behavior, and the stress evolution in oxide scales. Combining advanced methods such as CALPHAD, first-principles calculations, and machine learning will accelerate the design and development of novel ultra-high-temperature protective coatings to meet the demands of higher service temperatures in next-generation aero-engines.

导出引用

周博, 谢云, 彭晓. α-Al₂O₃生长型高温涂层/黏结层的研究进展[J]. 表面技术. 2026, 55(19): 1-20

ZHOU Bo, XIE Yun, PENG Xiao. Research Progress on α-Al₂O₃ Growth-Type High-Temperature Coatings/Bond Coats[J]. Surface Technology. 2026, 55(19): 1-20

中图分类号： TG174.4

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