目的 针对未来航空发动机高推重比需求下SiCf/SiC陶瓷基复合材料用可磨耗封严涂层面临的高温抗氧化、热膨胀匹配及可磨耗性等关键问题,旨在开发一种新型可磨耗环境障涂层体系,并系统评价其高速摩擦磨损与高温燃气腐蚀行为。方法 采用超低压等离子喷涂+高能等离子喷涂,在9件SiCf/SiC外环试验件上制备Si/Yb2Si2O7(致密)/Yb2Si2O7(多孔)三层结构涂层。对其中6件进行高温高速可磨耗试验,条件为：温度1 100 ℃,叶尖线速度500 m/s,径向进给速率3~5 μm/s及200~300 μm/s。对其中3件进行高温燃气腐蚀试验,条件为：温度1350 ℃,腐蚀介质为钙镁铝硅沉积物（CMAS）+水蒸气,累积500 h。通过质量磨损比、高度磨损比（IDR）、形貌及能谱分析表征性能。结果 径向进给速率3~5 μm/s时,涂层质量磨损比为1.162%~3.377%,叶片质量磨损比≤0.081%,有效IDR为21.58%~24.39%,刮削面平整、无剥落;径向进给速率200 ~250 μm/s时,IDR为16.42%~20.07%,涂层仍良好,但300 μm/s时,涂层及基材整体被破坏。燃气腐蚀后,涂层整体质量损失仅0.012~0.026 g,表面出现冲蚀坑和微裂纹,但无大面积剥落;CMAS呈软冲蚀,与硅酸镱反应生成含孔洞的鼓包状产物,涂层截面完整,结合良好。结论 在径向进给速率≤250 μm/s时,涂层具有优异可磨耗性,能有效保护叶片。经1 350 ℃高温燃气+CMAS腐蚀后,涂层保持结构完整,仅发生局部耦合损伤。该涂层显著提升了SiCf/SiC复合材料的抗冲蚀与抗腐蚀性能。
Abstract
To solve the key problems faced by abradable seal coatings for SiCf/SiC ceramic matrix composites under the demand of high thrust-to-weight ratio of future aero-engines, such as high-temperature oxidation resistance, thermal expansion matching and abradability, the work aims to develop a new type of abradable environmental barrier coating system and systematically evaluate its high-speed friction and wear behavior and high-temperature gas corrosion behavior. A three-layer coating of Si/Yb2Si2O7(dense)/Yb2Si2O7 (porous) was prepared on 9 SiCf/SiC outer ring test pieces by ultra-low pressure plasma spraying combined with high-energy plasma spraying. Six pieces were subjected to high-temperature and high-speed abradable tests at 1 100 ℃, with a blade tip linear velocity of 500 m/s, and radial feed rates of 3-5 μm/s and 200-300 μm/s. Three pieces were subjected to high-temperature gas corrosion test (cumulative 500 h) at 1 350 ℃ in an atmosphere containing calcium- magnesium-aluminum-silicon sediments(CMAS) and water vapor. The properties were characterized by mass wear ratio, height wear ratio (IDR), morphology and energy spectrum analysis. When the radial feed rate was 3-5 μm/s, the coating mass wear ratio was 1.162%-3.377%, the blade mass wear ratio was ≤0.081%, the effective IDR was 21.58%-24.39%, and the scraped surface was flat without spalling. When the feed rate was 200-250 μm/s, the IDR was 16.42%-20.07%, and the coating remained in good condition, but the coating and the substrate were completely damaged at 300 μm/s. After gas corrosion, the overall weight loss of the coating was only 0.012-0.026 g, and erosion pits and microcracks appeared on the surface, but no large-area spalling occurred. CMAS exhibited soft erosion, and reacted with ytterbium silicate to form bulge-like products with pores. The cross-section of the coating was complete with good bonding. The coating exhibits excellent abradability when the radial feed rate is ≤250 μm/s, and can effectively protect the blade. After corrosion by 1 350 ℃ high-temperature gas and CMAS, the coating maintains structural integrity with only local coupled damage, which significantly improves the erosion resistance and corrosion resistance of SiCf/SiC composites.
In this work, high-quality nanostructured rare-earth silicate agglomerated powder feedstock is successfully prepared through process control. The powder feedstock exhibits excellent thermophysical properties, which are conducive to enhancing the CMAS corrosion resistance and thermal shock resistance of environmental barrier coatings (EBCs), thereby providing a solid material foundation for the fabrication of ultra-high-temperature nanostructured environmental barrier coatings. The corrosion behavior under a coupled 1 800 ℃ water vapor-oxygen-CMAS corrosive environment is simulated with an integrated combustion-environment coating testing platform. Meanwhile, by coupling with leading domestic high-temperature and high-speed abradability testing facilities, the corrosion resistance and abradability of coated typical components of high- pressure turbine outer ring blocks are evaluated. The coatings demonstrate outstanding abradability and corrosion resistance. Furthermore, an equivalent evaluation methodology for environmental barrier coatings under simulated service environments is successfully established, providing strong support for more accurate assessment of long-term service reliability of the coatings. This work will offer effective protection for ceramic matrix composite hot-section components in future advanced aerospace engines, promote the practical application of ceramic matrix composites and environmental barrier coatings in advanced engine models, and hold significant implications for the development of national defense and military capabilities in China.
关键词
可磨耗封严涂层 /
环境障涂层 /
SiCf/SiC复合材料 /
高速摩擦磨损 /
高温燃气腐蚀 /
CMAS
Key words
abradable seal coating /
environmental barrier coating /
SiCf/SiC composite /
high-speed friction and wear /
high-temperature gas corrosion /
CMAS
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