航空发动机叶片热障涂层技术Aircraft-Enginer-TBC-benchmark

1/Confidential/2/27/2020TechBenchmarkTurbineBladesCoatingHighTempProtectiveCoatingtechforSXTurbineBlades2/Confidential/2/27/2020OperatingConditionofTurbineBladesJourneythroughajetengineFanLPCHPCHPTLPT3/Confidential/2/27/2020DataforTurbineBlades•HighTemperature:~1400oC•HighPressure:~40atm•HighRotatingSpeed:~11,000rpm•Centrifugalforce,airflowimpactandvibration•Oxidationanderosion•ThermalMechanicalCyclingHPTbladelifetime:•Currently:16,000hours(2~3years)•Expected:30,000+hoursRoughestimateofcost:•AsetofbladesforHPT:1.5Mgbp•Refurbishment:0.3Mto1Mgbp4/Confidential/2/27/2020Outline•ProjectCharter(NBlocker)•TBCSystem•CurrentTech–Technologies–Applications•KeyPlayers•OurApproaches•Appendix5/Confidential/2/27/2020ProjectBackgroundDevelopcost-effectivealuminideandTBCcoatingonNibasedalloys•CustomerMQTD,Avaiation•ProjectObjective:Highquality&costeffectivecoatingprocess•Operatingcondition:Stage1TurbineBlades(HPT)•Substrate:Ni-baseSuperalloy/SX(N5)•Coating:BondCoat(NiAl,MCrAlY,PtAl)&TGO(Al2O3)TBC(8YSZ)•EvaluationCriteria:ThermalcyclingtestMicrostructure*Adhesivestrength,Oxidationresistance,Phasestability,Thicknesshomogeneity,Costestimation6/Confidential/2/27/2020TBCSystemTemperaturevs.Lifetime7/Confidential/2/27/2020TBCStructure&FailureLayerFunctionRequirementt/µmMaterialTechniqueTBCtopcoatThermallyinsulatingLowk,highCTE,porousmorphology100~400YSZAPS,EBPVDTGOOxidationresistanceDensealumina1-10Al2O3-BondCoatAluminide,Solidadhesion,transitionGradientlayer,Phasestability50-100NiAlPtAlMCrAlYCVD,PackCemPlating,CVDVPS,HVOF,EB•Rupture:CTEmismatch,sharpthermalgradient,thermomechanicalcycling•Delamination:TGO,degradationofbondcoating,•Incipientcracknucleate&grow:thermomechanicalfatigue•Inclusion:Processingmethodderived•FOD(foreignobjectdamage),CMAS(Calcia,Magnesia,AluminaandSilica)8/Confidential/2/27/2020EB-PVDAdvantages•Strongadherence,wearresistance•Dense,atom/ionevaporation•ColumnargrainDrawbacks•Hightemp•Vacuum•HighcostApplications•Topcoat/MCrAlY•Toolcoating•Functionalfilm9/Confidential/2/27/2020PlasmaSprayingAdvantages•Lamellarstrip•Lowk•Compositioncontrol•ThicknesscapabilityDrawbacks•Partiallymeltedparticle•Cracks•PorositiesApplications•TopcoatAPS•BondcoatLPPS•Corrosion/Wearresistance10/Confidential/2/27/2020FrontRunnersUSAUCSB*NovelTBCmaterial,microstructureUSAUnivofConnecticut*Spallationmodel,lifetimepredictionUSAUnivofPittsburghFailureanalysis,bondcoatmodificationGermanyDLR-GermanAerospaceCenterMorphology,porosityUkrainePEW,PatonElectricWeld.InstProcesspara,materialUSAUnivofVirginia*EBDVD,systematicalexp&simulationAcademicUSAGEAircraftEngineEBPVD,PlasmasprayUKRolls-Royce(England)EBPVD,PlasmasprayUSAPrat&Whitney(US&Cannada)EBPVD,PlasmasprayUSAPRAXAIRS.T.Tech,INC.EBPVDUSAChromalloyNo.1~5,6(UK)EBPVDGermanySulzerMetcoInc.PlasmasprayIndustrialBeijingBIAMBJInstofAeroMatEBPVDprocessBeijingBUAABJUnivofAviation&AstronauticsLowkmaterial,EBPVDShenyangInstitueofMetalResearch.CASHVOF/detonationsprayAcademiclocallyShenyangShenyangLimingAeroEngineEBPVD,PlasmaXi'anXIANAEROENGINEEBPVD,plasmaChengduSichuanChengfaAeroCo.LtdPlasma,EBPVDGuizhouLiyangAeroEngineEBPVDIndustriallocally11/Confidential/2/27/2020FocusofEffortsApproaches:•Improvecoatingmaterial•CoatingStructureDesign*•Coatingmicrostructure*•ProcessingPara.Optim.•Brand-newprocess/tech*•Rareearthadditive•Multilayerandcontinualgradientlayer•Verticalmicrocrackle•Porousor3DMeshstructure•Hollowceramicparticle•Microcrystalcoating•Amorphousphase•PackCementation•EB-DirectedVaporDeposition•Thermalchemicalreaction12/Confidential/2/27/2020PotentialCoatingTechnologiesProcessesAdvantageDrawbackApplicationSHS/CombustionSynthesis•Noheatsource•Highefficiency•Lowcost•Inclusion•Thicknesscontrol•Powderprep.•Sintering•WeldingMicroSparkDeposition•Metallurgicalbonding•Variouscoatingmaterials•Electrodemaking•Microcrack•Wearresistancecoating•ColdweldingSol-gel•LowTemp.•Dopant•Lowcost•Longcycle•Percursor•Crack/Inclusion•Nanopowder•Toolcoating•SensorfilmSputteringDeposition•Dense•LowTemp.•Lowrate•HighEquip.cost•Ionimplantation•FilmPLD•Highrate•Highpowerdensity•Flexiblecontrol•Complication•MorePara.•Plume•Biomedical•Solarcells•Super-conductor13/Confidential/2/27/2020SHS/CombustionsynthesisAdvantages•EnergyEfficient•Lowcost•SolidadhesionDrawbacks•Inclusion•ProcesscontrolApplications•Powderprep.•CeramicsSinteringTargetMaterials•Ni+Al=NiAl-118.4kJ/mol(RT)•Cr2O3+2Al=Al2O3+2Cr-549.7kJ/mol(RT)•3NiO+2Al=Al2O3+3Ni-954.9kJ/mol(RT)•Zr+O2=ZrO2-1097.5kJ/mol(RT)•2Y+O2=Y2O3-1913.3kJ/mol(RT)14/Confidential/2/27/2020MicroSparkDepositionAdvantages•Metallurgicalbonding•VariouscoatingmaterialsDrawbacks•Electrodemaking•MicrocrackApplications•Wearresistancecoating•ColdweldingTodepositconsumableelectrodesofalloys/intermetalliccompoundsontheworkpiecebymeansofmicroelectricsparksatfrequenciesof10-1000persecondfor10-6-10-5secondsperspark.Directcurrentheatedtheelectrodeupto8,000-25,000oConlyatcontactareas,transfersasmallquantityoftheelectrodetotheworkpiecetoformastrongmetallurgicalbonding.15/Confidential/2/27/2020TechRoadmap16/Confidenti