目的 建立喷丸强度与NiCrAlYSi黏结层热障涂层多维度性能的量化对应关系,揭示黏结层表面形貌调控TGO生长与界面失效的内在机理,确定适配EB-PVD陶瓷面层的最优喷丸工艺区间,为该类涂层工程改性提供定量试验依据。方法 以IC10镍基高温合金为基体,制备梯度喷丸强化NiCrAlYSi黏结层,再沉积YSZ陶瓷面层构建完整热障涂层体系;测试涂层表面粗糙度与界面结合强度,开展1 100 ℃高温循环氧化试验,结合SEM-EDS表征手段,观测界面微观结构并分析TGO层演化规律。结果 未喷丸试样粗糙度1.82 μm,0.05~0.1 A喷丸后降至0.99 μm,喷丸强度继续提高粗糙度回升;涂层结合强度呈先升后降趋势,0.10~0.15 A时达到峰值72.2 MPa,较原始试样提升10%;0.05~0.15 A试样循环氧化寿命可达600~700 h;高喷丸强度造成界面显著起伏,EDS点扫描证实TGO内生成Ni-Cr-Al尖晶石脆性混合氧化物,涂层寿命仅400~500 h。结论 0.05~0.15 A为该涂层体系最优喷丸区间;适度喷丸可压实表层孔隙,有利于弱化界面应力集中;过高喷丸引入表面缺陷,加速TGO劣化和裂纹扩展;涂层失效源于凹凸界面引发应力集中、TGO破损造成裂纹连通与陶瓷层剥落,平整致密的黏结界面是提升涂层高温服役性能的关键。
Abstract
In this work, gradient shot-peening strengthening treatments of varying intensity were performed on vacuum-arc-deposited NiCrAlYSi bond coats. EB-PVD yttria-stabilized zirconia (YSZ) top coats were subsequently deposited to fabricate integrated thermal barrier coating (TBC) systems on IC10 nickel-based superalloy substrates. This study quantitatively revealed how shot-peening intensity regulated bond-coat surface status, interfacial features, bonding performance and cyclic oxidation resistance. It clarified the coupling mechanism among surface topography, thermally-grown oxide (TGO) evolution, brittle spinel oxide formation and stress-induced interfacial crack initiation, and determined the shot-peening process window compatible with EB-PVD ceramic top coats for practical engineering application.
Two types of IC10 superalloy specimens were prepared: ϕ25.4 mm×7 mm cylindrical samples for bonding-strength measurement and 30 mm×10 mm×1.5 mm plates for cyclic oxidation and microstructural characterization. NiCrAlYSi bond coats with thickness of 20-40 μm were deposited by vacuum arc plating at an arc current of 650 A and substrate bias of 20 V, followed by vacuum diffusion treatment at 900 ℃ for 3 h. Five gradient shot-peening groups were designed with AZB150 ceramic shots: 0 A (unpeened reference), 0.05-0.10 A, 0.10-0.15 A, 0.15-0.20 A and 0.20-0.25 A. Afterwards, 80-120 μm thick YSZ top coats were prepared via EB-PVD. A white-light interferometer was adopted to acquire surface roughness and three-dimensional profiles. Bonding strength was tested with an INSTRON 5882 tensile tester in accordance with the AETF68A standard. Cyclic oxidation tests were conducted at 1 100 ℃ following AETM189A; each cycle included 55 min high-temperature holding and 5 min air-cooling, and coating failure was defined by the normalized mass change ΔG ≤0. SEM-EDS operated at 15 kV was employed to characterize interfacial microstructures and elemental distributions across bond-coat/TGO interfaces.
Quantitative results showed that surface roughness varied non-monotonically with peening intensity. The unpeened sample exhibited a roughness of 1.82 μm. Moderate peening of 0.05-0.10 A compacted surface pores and flattens sharp protrusions, reducing roughness to 0.99 μm. Further increasing peening intensity regenerated severe surface undulation, and the roughness rebounded to 1.78 μm at 0.20-0.25 A. Bonding strength rose first and then declined, reaching a peak of 72.2 MPa under 0.10-0.15 A peening, which was 10% higher than 63.7 MPa of the original sample. Excessive peening introduced surface indentations and geometric discontinuities, which significantly deteriorated interfacial bonding performance.
In 1 100 ℃ cyclic oxidation tests, TBCs treated by 0.05-0.15 A shot peening achieved a service lifetime of 600-700 h. Their smooth interfaces facilitated uniform growth of protective α-Al2O3 dominated TGO layers. In comparison, samples subjected to high-intensity peening (0.20-0.25 A) only survived 400-500 h. After 300 thermal cycles, SEM-EDS verified the formation of brittle Ni-Cr-Al spinel mixed oxides within TGO. Severe interfacial undulations created additional oxygen diffusion pathways and generated stress-concentration sites. Under cyclic thermal loading, microcracks initiated, propagated and interconnected, eventually triggering large-area ceramic spallation. Distinct from previous researches merely focusing on residual-stress modification, this work proves that interfacial topography plays a dominant role. The optimal peening window for this TBC system is identified as 0.05-0.15 A. Smooth and dense bond-coat interfaces relieve stress concentration and restrain brittle-oxide formation, which is critical for improving high-temperature service reliability. This study provides quantitative experimental support for surface modification of aero-engine hot-section components.
关键词
热障涂层 /
喷丸强化 /
表面粗糙度 /
结合强度 /
循环氧化 /
失效机理
Key words
thermal barrier coating /
shot peening strengthening /
surface roughness /
bonding strength /
cyclic oxidation /
failure mechanism
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基金
前沿探索项目（KJ42250521）; 稳定支持项目（KZ0C240599）
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