Research Progress on Microstructure and Preparation Methods for MCrAlY Bond Coats
CHEN Shoudong1,2
1.Faculty of Materials Science and Engineering, Kunming University of Science and Technology, Kunming 650093 2.School of Mechanical Engineering, Tongling University, Tongling 244061
Abstract: Thermal barrier coatings (TBCs) are one of the most advanced high temperature protective coatings and being wildly used in aeronautic, astronautics, motor industry and heat power station, for their good performance at thermal barrier and oxidation resistance. TBC together with the advanced high-performance air film cooling technology, high temperature structural materials are regarded as three key technologies for advanced aero-engines high pressure turbine blade. TBC is the important protection technique in order to protect substrate metal and improve the service life of aircraft engines and gas turbines. Thermal barrier coatings consist of three parts: the bond coat (BC), the thermally grown oxide (TGO), and the ceramic top coat (TC). A metallic bond coat (MCrAlY) between the ceramic top coat and Ni-base superalloy provides oxidation resistance for the base material and adherence of ceramic coating. Its physical and mechanical properties, in particular coefficient of thermal expansion as well as yield and creep strength, are crucial for the TBC system performance. The TGO does not appear until the TBC system encounters elevated temperature. At the beginning of TGO growth, the TGO layer functions as an oxidation barrier coating which suppresses the formation of other detrimental oxides during extended thermal exposure. The TGO then thickens and the degradation of the MCrAlY bond coat during TBCs high-temperature sever due to oxidation and interdiffusion with the substrate alloy, eventually contributing to TBCs spallation, incapable of protecting blades from high-temperature and oxidation environment, resulting in severe accidents and economic loss. The high-temperature oxidation resistance of bond coat determines lifetime of TBC, in which compositions design and manufacture method of the bond coat are the main reason influencing the high-temperature oxidation resistance of bond coat. The bond coat-rela-ted developments in the recent years have mainly concentrated on defining of new bond coat compositions and/or multilayered bond coats, deve-loping new diffusion barriers to minimize interdiffusion issues, constructing the thermodynamic-kinetic model and varying manufacturing technologies. TBCs with MCrAlY (M=Ni, Co or Ni+Co) bond coat is the most advanced high temperature protective coatings with good high temperature performance which can produce large temperature drop on the metal parts, prolong the service life of the engine parts and improve the thermal efficiency of engine parts. Searching for new bond coats (BC) for thermal barrier coatings has become one of the research focus in the TBCs field. The performance of MCrAlY (M=Ni, Co or Ni+Co) bond coats for thermal barrier coatings is substantially affected by the contents of Ni, Co, Cr and Al as well as minor additions of Y, Hf, Zr, Ta, Si, and noble metal, etc., but also by manufacturing-related properties such as coating thickness, porosity, surface roughness, and oxygen content. An in-depth understanding of the high temperature protection of TBCs is important to further developing new advanced bond coats material in the future. Currently, the traditional fabrication technology of TBCs mainly includes atmospheric plasma spraying (APS) and electron beam physical vapor deposition (EB-PVD). The lamellar TBCs fabricated by APS possess have high deposition rate, good thermal insulation performance and bad thermal shock resistance whereas the columnar TBCs deposited by EB-PVD have good thermal shock resistance and strain tolerance, poor thermal insulation performance, low deposition rate and high cost. To meet these demands of the next-generation aero-engines with higher thrust weight ratio, developing a new material system and new manufacture method for TBCs is necessary.In this paper, we review the recent progress and application of MCrAlY bond coats for TBCs, the background, application and advantages of the MCrAlY bond coats are presented, and the state of the art in BC is summarized from the viewpoint of composition optimizing, microstructure, degradation and manufacture methods.
作者简介: 陈守东,博士,铜陵学院机械工程学院讲师。2010年7月本科毕业于铜陵学院机械工程学院,2016年7月在东北大学轧制技术及连轧自动化国家重点实验室材料加工工程取得博士学位,2018年1月至今在昆明理工大学进行博士后研究工作。主要从事热障涂层体系设计及第一性原理计算的研究工作,以第一作者身份在International Journal of Mechanical Sciences、Transactions of Nonferrous Metals Society of China、《金属学报》中英文版等SCI学术期刊发表研究论文30余篇。
引用本文:
陈守东. MCrAlY粘结层的微观组织及制备方法研究进展[J]. 材料导报, 2019, 33(15): 2582-2588.
CHEN Shoudong. Research Progress on Microstructure and Preparation Methods for MCrAlY Bond Coats. Materials Reports, 2019, 33(15): 2582-2588.
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2019, Vol. 33 
