环境障涂层——挑战与机遇
Environmental Barrier Coatings—Challenges and Opportunities
DOI: 10.12677/JAST.2018.63003, PDF,  被引量   
作者: 王 铀*, 刘赛月, 宫 雪, 贾 近, 张振国, 王 澜:哈尔滨工业大学材料科学系纳米表面工程研究室,黑龙江 哈尔滨;孟君晟:山东交通学院,船舶与轮机工程学院,山东 威海
关键词: 环境障涂层陶瓷基复合材料高温熔盐侵蚀水氧腐蚀稀土硅酸盐Environmental Barrier Coating Ceramic Matrix Composites High Temperature Molten Salt Corrosion Water Vapor Corrosion Rare Earth Silicate
摘要: 陶瓷基复合材料(CMCs)是新一代高推重比航空发动机高温部件的主要候选材料。然而在应用环境中,陶瓷基复合材料部件却面临着在高温水蒸气环境下存在性能退化(通称水氧腐蚀)及易受CMAS高温熔盐侵蚀的严峻挑战。而采用环境障涂层(EBC)可以使陶瓷基复合材料热端部件有效抵御发动机环境对基底表面的热腐蚀,提高其高温稳定性。本文在综述了环境障涂层研究的进展的基础上,分析了环境障涂层研究面临的挑战和机遇,提出了急需解决的技术问题。设计出多层多组分甚至多尺度结构的EBC涂层并通过选择适宜的涂层工艺得到高性能涂层,虽具有很大的挑战性,却能满足陶瓷基复合材料高温构件对EBC涂层的迫切需求。
Abstract: Ceramic matrix composites (CMCs) are the main candidates for the high thrust to weight ratio of high temperature aerocraft engine components. However, ceramic matrix composite components are faced with the challenges of performance degradation (commonly known as water vapor corrosion) and high temperature molten salt corrosion (CMAS) in the high temperature water vapor environment. The application of environmental barrier coating (EBC) can effectively resist the thermal corrosion on the substrate surface and improve the high temperature stability of CMCs. Based on the review of the progress in the research of EBCs, the challenges and opportunities in the research of EBCs are analyzed, and the technical problems urgently needed to be solved are put forward. Although it is very challenging to design a multi-layer multi-component or even multi-scale EBC coating and obtain a high-performance coating by selecting the appropriate process technology, it can meet the urgent need of EBC coating for ceramic matrix composite high-temperature components.
文章引用:王铀, 孟君晟, 刘赛月, 宫雪, 贾近, 张振国, 王澜. 环境障涂层——挑战与机遇[J]. 国际航空航天科学, 2018, 6(3): 17-29. https://doi.org/10.12677/JAST.2018.63003

参考文献

[1] 董志国, 王鸣, 李晓欣, 等. 航空发动机涡轮叶片材料的应用与发展[J]. 钢铁研究学报, 2011, 23(2): 455-457.
[2] Donald, I.W. and Mcmillan, P.W. (1976) Ceramic-Matrix Composites. Journal of Materials Science, 11, 949-972. [Google Scholar] [CrossRef
[3] Curtin, W.A. (1991) Theory of Mechanical Properties of Ceramic-Matrix Composites. Journal of the American Ceramic Society, 74, 2837-2845. [Google Scholar] [CrossRef
[4] Zhu, D.M., Miller, R.A. and Fox, D.S. (2008) Thermal and Environmental Barrier Coating Development for Advanced Propulsion Engine Systems. NASA TM-2008-215040.
[5] Ji, Y.P., Hwang, H.S., Kim, W.J., et al. (2002) Fabrication and Characterization of SiCf/SiC Composite by CVI Using the Whiskering Process. Journal of Nuclear Materials, 307, 1227-1231.
[6] Liu, H. and Tian, H. (2012) Mechanical and Microwave Dielectric Properties of SiCf/SiC Composites with BN Interphase Prepared by Dip-Coating Process. Journal of the European Ceramic Society, 32, 2505-2512. [Google Scholar] [CrossRef
[7] Zou, S. (2003) Development of SiCf/SiC Continuous Fiber Reinforced Ceramic Matrix Composites. International Materials Reviews, 8, 61-64.
[8] Wang, H., Zhou, X., Yu, J., et al. (2011) Microstructure, Mechanical Properties and Reaction Mechanism of KD-1 SiCf/SiC Composites Fabricated by Chemical Vapor Infiltration and Vapor Silicon Infiltration. Materials Science and Engineering: A, 528, 2441-2445. [Google Scholar] [CrossRef
[9] 胡燕萍. 美国正全力攻关下一代陶瓷基复合材料[J]. 国际航空, 2017(9): 43-45.
[10] Opila, E.J. and Hann, R.E. (1997) Paralinear Oxidation of CVD SiC in Water Vapor. Journal of the American Ceramic Society, 80, 197-205. [Google Scholar] [CrossRef
[11] Ustundag, E. and Fischman, G. (2008) High Temperature Corrosion of Oxide-Coated SiC in Water Vapor Atmosphere. John Wiley & Sons Ltd., 363-370.
[12] Dong, N., Luan, X. and Cheng, L. (2008) Corrosion of C/SiC Composite in Water Vapor and Na2SO4 Vapor: Science and Engineering of Composite Materials. Science and Engineering of Composite Materials, 15, 121-130. [Google Scholar] [CrossRef
[13] Wellman, R., Whitman, G. and Nicholls, J.R. (2010) CMAS Corrosion of EB PVD TBCs: Identifying the Minimum Level to Initiate Damage. International Journal of Refractory Metals and Hard Materials, 28, 124-132. [Google Scholar] [CrossRef
[14] Zhu, D. (2015) Durability and CMAS Resistance of Advanced Environmental Barrier Coatings Systems for SiC/SiC Ceramic Matrix Composites. NASAGRC-E-DAA-TN20622.
[15] Poerschke, D.L., Hass, D.D., Eustis, S., et al. (2015) Stability and CMAS Resistance of Ytterbium-Silicate/Hafnate EBCs/TBC for SiC Composites. Journal of the American Ceramic Society, 98, 278-286. [Google Scholar] [CrossRef
[16] Eaton, H.E. and Linsey, G.D. (2002) Accelerated Oxidation of SiC CMC’s by Water Vapor and Protection via Environmental Barrier Coating Approach. Journal of the European Ceramic Society, 22, 2741-2747. [Google Scholar] [CrossRef
[17] Lee, K.N., Fox, D.S., Eldridge, J.I., et al. (2003) Upper Temperature Limit of Environmental Barrier Coatings Based on Mullite and BSAS. Journal of the American Ceramic Society, 86, 1299-1306. [Google Scholar] [CrossRef
[18] Harder, B.J., Ramirez-Rico, J., Almer, J.D., et al. (2012) Chemical and Mechanical Consequences of Environmental Barrier Coating Exposure to Cal-cium-Magnesium-Aluminosilicate. Journal of the American Ceramic Society, 94, 178-185.
[19] Latzel, S., Vaßen, R. and Stöver, D. (2005) New Environmental Barrier Coating System on Carbon-Fiber Reinforced Silicon Carbide Composites. Journal of Thermal Spray Technology, 14, 268-272. [Google Scholar] [CrossRef
[20] Shah, S.R. and Raj, R. (2010) Multilayer Design and Evaluation of a High Temperature Environmental Barrier Coating for Si-Based Ceramics. Journal of the American Ceramic Society, 90, 516-522. [Google Scholar] [CrossRef
[21] Bhatt, R.T., Choi, S.R., Cosgriff, L.M., et al. (2008) Impact Resistance of Environmental Barrier Coated SiC/SiC Composites. Materials Science and Engineering A, 476, 8-19. [Google Scholar] [CrossRef
[22] Ueno, S., Ohji, T. and Lin, H.T. (2007) Recession Behavior of a Silicon Nitride with Multi-Layered Environmental Barrier Coating System. Ceramic International, 33, 859-862. [Google Scholar] [CrossRef
[23] Xu, Y., Hu, X., Xu, F., et al. (2017) Rare Earth Silicate Environmental Barrier Coatings: Present Status and Prospective. Ceramic International, 43, 5847-5855. [Google Scholar] [CrossRef
[24] Emilien, D. and Gitzhofer, F. (2017) Thermal Cycling and High-Temperature Corrosion Tests of Rare Earth Silicate Environmental Barrier Coatings. Journal of Thermal Spray Technology, 26, 1823-1837.
[25] Ogura, Y., Kondo, M. and Mormoto, T. (1995) Y2SiO5 as Oxidation Resistant Coating for C/C Composites. Proceedings of the 10th International Conference on Composite Materials, Whistler, 14-18 August 1995.
[26] Webster, J.D., Westwood, M.E., Hayes, M.F.H., et al. (1998) Oxidation Protection Coatings for C/SiC Based on Yttrium Silicate. Journal of the European Ceramic Society, 18, 2345-2350. [Google Scholar] [CrossRef
[27] Huang, J.F., Zeng, X.R., Li, H.J., et al. (2004) SiC/Yttrium Silicate Multi-Layer Coating for Oxidation Protection of Carbon/Carbon Composites. Journal of Materials Science, 39, 7383-7385. [Google Scholar] [CrossRef
[28] Huang, J.F., Li, H.J., Zeng, X.R., et al. (2004) A New SiC/Yttrium Silicate/Glass Multi-Layer Oxidation Protective Coating for Carbon/Carbon Composites. Carbon, 42, 2356-2359. [Google Scholar] [CrossRef
[29] Huang, J.F., Li, H.J., Zeng, X.R., et al. (2006) Yttrium Silicate Oxidation Protection Coating for SiC Coated Carbon/Carbon Composites. Ceramic International, 32, 417-421. [Google Scholar] [CrossRef
[30] Alberto, J.F.C., Alberto, E., Matthew, R.S., et al. (2012) Structural and Kinetic Study of Phase Transitions in LaYSi2O7. Journal of the European Ceramic Society, 32, 2477-2486. [Google Scholar] [CrossRef
[31] Randall, H. and Hermes, E.E. (1990) Sol-Gel Coatings on Continuous Ceramic Fibers. Ceramic Engineering Science and Processing, 11, 1526-1538. [Google Scholar] [CrossRef
[32] Ohji, T. (2004) Environmental Barrier Coating on Silicon Nitride Challenges and Critical Issues. Proceedings of the 28th International Conference on Advance Ceramics and Compo-sites.
[33] Tian, Z.L., Zheng, L.Y., Wang, J.M., et al. (2016) Theoretical and Experimental Determination of the Major Thermo-Mechanical Properties of RE2SiO5 (RE = Tb, Dy, Ho, Er, Tm, Yb, Lu, and Y) for Environmental and Thermal Barrier Coating Applications. Journal of the European Ceramic Society, 36, 189-202. [Google Scholar] [CrossRef
[34] Wang, J.Y., Zhou, Y.C. and Lin, Z.J. (2007) Mechanical Properties and Atomistic Deformation Mechanism of Υ-Y2Si2O7 from First-Principles Investigations. Acta Materialia, 55, 6019-6026.
[35] Lee, K.N., Fox, D.X. and Bansal, N.P. (2005) Rare Earth Silicate Environmental Barrier Coating for SiC/SiC Composites and Si3N4 Ceramics. Journal of the European Ceramic Society, 25, 1705-1715. [Google Scholar] [CrossRef
[36] Fauchais, P. (2004) Topical Review: Understanding Plasma Spraying. Journal of Physics D—Applied Physics, 37, 86-108. [Google Scholar] [CrossRef
[37] Vardelle, M., Vardelle, A., Leger, A.C., et al. (1995) Influence of Particle Parameters at Impact on Splat Formation and Solidification in Plasma Spraying Processes. Journal of Thermal Spray Technology, 4, 50-58. [Google Scholar] [CrossRef
[38] Liang, B. and Ding, C. (2005) Thermal Shock Resistances of Nanostructured and Conventional Zirconia Coatings Deposited by Atmospheric Plasma Spraying. Surface Coating Technology, 197, 185-192. [Google Scholar] [CrossRef
[39] Environmental Barrier Coatings (EBCs) for Ceramic Gas Turbine Components. National Technology Transfer Center, TOP3-00165. http://www.ideaconnection.com/technology-for-sale/mechanical-engineering-40.html
[40] Chen, G., Lee, K.N. and Tewari, S.N. (2007) Slurry Development for the Deposition of a GdSiO4 + Mullite Environmental Barrier Coating on Silicon Carbide. Journal of Ceramic Processing Research, 8, 142-144.
[41] 邱海鹏, 韩立军, 丁海英, 等. 超高温碳化硅基复合材料表面涂层的研究进展[J]. 功能材料, 2004, 35(1): 1735-1740.
[42] 张小峰, 周克崧, 刘敏, 等. 等离子喷涂-物理气相沉积Si/莫来石/Yb2SiO5环境障涂层[J]. 无机材料学报, 2018, 33(3): 325-330.
[43] Lee, K.N. (2014) Environmental Barrier Coatings (EBCs) for SiCf/SiC Ceramic Matrix Composites: Materials, Modeling, and Technology. John Wiley & Sons, Hoboken.
[44] Zhang, X.F., Zhou, K.S. and Xu, W. (2015) In Situ Synthesis of α-Alumina Layer on Thermal Barrier Coating for Protection against CMAS (CaO-MgO-Al2O3-SiO2 ) Corrosion. Surface Coating Technology, 261, 54-59. [Google Scholar] [CrossRef
[45] Price, J., Kimmel, J., Chen, X., et al. (2006) Advanced Materials for Mercury 50 Gas Turbine Combustion System. ASME TURBO EXPO, Power for Land, Sea & Air, Reno/Tahoe, 6-9 June 2005, 261-267.
[46] More, K.L. and Tortorelli, P.F. (2002) Continuous Fiber Ceramic Composites (CFCCs) for Industrial Gas Turbines. http://infohouse.p2ric.org/ref/20/19276.pdf
[47] Mei, H., Cheng, L.F., Luan, X.G., et al. (2006) Simulated Environment Testing System for Advanced Ceramic Matrix Composites. International Journal of Applied Ceramic Technology, 3, 252-257. [Google Scholar] [CrossRef
[48] Mei, H., Cheng, L. and Zhang, L. (2007) Modeling the Effects of Thermal and Mechanical Load Cycling on a C/SiC Composite in Oxygen/Argon Mixtures. Carbon, 45, 2195-2204. [Google Scholar] [CrossRef
[49] Mei, H., Cheng, L. and Zhang, L. (2006) Behavior of Two-Dimensional C/SiC Composites Subjected to Thermal Cycling in Controlled Environments. Carbon, 44, 121-127. [Google Scholar] [CrossRef
[50] 栾新刚. 3D C/SiC在复杂耦合环境中的损伤机理与寿命预测[D]: [博士学位论文]. 西安: 西北工业大学, 2007.