CN105865961A - Test apparatus for thermal shock life evaluation of thermal barrier coating - Google Patents
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Abstract
本发明提供一种热障涂层热冲击寿命评价试验装置，包含：加热系统、CMAS液料输送系统、冷却系统及控制系统；加热系统提供燃烧火焰射流，实现对试验试样加热高温环境进行模拟，并且实现一定温度梯度下的循环加热；CMAS液料输送系统在加热系统进行加热的同时输送CMAS悬浮液，CMAS悬浮液经空气射流雾化后以设定的角度和速率向燃烧火焰注入，以模拟CMAS的真实存在状态；冷却系统在加热结束后，通过一冷却气路对所述试验试样进行冷却；控制系统连接并控制加热系统、CMAS液料输送系统及冷却系统，实现高温、梯度温度、CMAS耦合环境条件下的热障涂层服役环境的模拟并对整个工艺试验流程进行自动控制。
The invention provides a thermal shock life evaluation test device for thermal barrier coatings, which includes: a heating system, a CMAS liquid material delivery system, a cooling system and a control system; the heating system provides a combustion flame jet to realize the simulation of the high-temperature environment of the test sample heating , and realize circulating heating under a certain temperature gradient; the CMAS liquid material delivery system delivers the CMAS suspension while the heating system is heating, and the CMAS suspension is atomized by the air jet and injected into the combustion flame at a set angle and speed to Simulate the actual state of CMAS; after the heating, the cooling system cools the test sample through a cooling air circuit; the control system connects and controls the heating system, CMAS liquid material delivery system and cooling system to achieve high temperature and gradient temperature , Simulating the service environment of thermal barrier coatings under CMAS coupled environmental conditions and automatically controlling the entire process test process.
Description
技术领域 technical field
本发明涉及一种热障涂层热冲击寿命评价试验装置，特别是一种耦合了高温、梯度温度、CMAS(即CaO-MgO-Al2O3-SiO2沉积物)环境条件下的热障涂层热冲击寿命评价试验装置，属于热喷涂涂层特殊服役环境模拟装置领域。 The invention relates to a thermal shock life evaluation test device for thermal barrier coatings, in particular to a thermal barrier coating coupled with high temperature, gradient temperature and CMAS (i.e. CaO-MgO-Al 2 O 3 -SiO 2 deposits) environmental conditions The utility model relates to a coating thermal shock life evaluation test device, which belongs to the field of thermal spray coating special service environment simulation devices.
背景技术 Background technique
提高发动机涡轮前进口温度是先进航空发动机的一大特征，目前先进发动机涡轮前温度已经达到近1800K，而涡轮叶片基体材料采用的DZ125远远不能满足承温需求，尽管在实际工况中，发动机涡轮叶片采用了气膜冷却结构技术，使航空发动机涡轮叶片表面温度与基体金属间形成了一定的梯度温度，但仍需要通过制备高效的氧化钇部分稳定氧化锆(YSZ)热障涂层来降低涡轮叶片表面的工作温度。 Increasing the inlet temperature before the engine turbine is a major feature of advanced aero-engines. At present, the temperature before the turbine of advanced engines has reached nearly 1800K, and the DZ125 used as the base material of the turbine blades is far from meeting the temperature requirements. Although in actual working conditions, the engine The turbine blade adopts the film cooling structure technology, so that a certain gradient temperature is formed between the surface temperature of the turbine blade of the aero-engine and the base metal, but it still needs to be reduced by preparing a high-efficiency yttria partially stabilized zirconia (YSZ) thermal barrier coating. The operating temperature of the turbine blade surface.
热障涂层具有大幅降低热端部件基体材料表面工作温度、提高其抗高温氧化腐蚀能力、延长部件使用寿命和提供可靠性等特点，制备热障涂层技术已成为先进航空发动机涡轮叶片制备的关键技术之一。此外，热障涂层(主要是氧化钇部分稳定氧化锆涂层)还具有提高基体材料抗冲刷和耐磨损烧蚀的能力，在舰船、能源以及汽车制造行业中也有着极为重要和广泛的应用前景。 Thermal barrier coatings have the characteristics of greatly reducing the surface operating temperature of the base material of the hot-end parts, improving its high-temperature oxidation and corrosion resistance, prolonging the service life of components, and providing reliability. One of the key technologies. In addition, thermal barrier coatings (mainly yttria partially stabilized zirconia coatings) also have the ability to improve the erosion resistance and abrasion resistance of the base material, and are also extremely important and widely used in the shipbuilding, energy and automobile manufacturing industries. application prospects.
航空发动机涡轮叶片热障涂层服役工况极为复杂，在近1800K高温的工作条件下，空中颗粒粉尘及燃油中的颗粒物会熔融并高速沉积在涡轮叶片上，形成的CaO-MgO-Al2O3-SiO2沉积物(简称CMAS)渗入热障涂层陶瓷层内部与稳定剂发生反应，降低涂层应变容限，加速YSZ涂层相失稳和烧结，同时冷却凝固后在涂层中产生较大的应力，从而导致涂层过早的剥离失效，大大降低了热障涂层的使用寿命和应用的可靠性。 The service conditions of thermal barrier coatings for aero-engine turbine blades are extremely complex. Under the high-temperature working conditions of nearly 1800K, airborne particulate dust and particles in fuel oil will melt and deposit on the turbine blades at a high speed, forming CaO-MgO-Al 2 O 3 -SiO 2 deposits (CMAS for short) penetrate into the ceramic layer of the thermal barrier coating to react with the stabilizer, reduce the strain tolerance of the coating, accelerate the phase instability and sintering of the YSZ coating, and at the same time form in the coating after cooling and solidification Larger stress, which leads to premature peeling failure of the coating, greatly reduces the service life and application reliability of the thermal barrier coating.
随着我国航空工业的快速发展，研究高温、梯度温度、CMAS耦合环境条件下引起的热障涂层失效机理及其防护技术受到了广泛关注。正确理解热障涂层在高温、梯度温度、CMAS耦合环境条件下的破坏特征和关键影响因素，有 助于研究现有热障涂层延寿技术，有助于开发新型超高温长寿命热障涂层。 With the rapid development of my country's aviation industry, research on the failure mechanism and protection technology of thermal barrier coatings caused by high temperature, gradient temperature, and CMAS coupling environmental conditions has received extensive attention. A correct understanding of the failure characteristics and key influencing factors of thermal barrier coatings under high temperature, gradient temperature, and CMAS coupled environmental conditions will help to study existing thermal barrier coating life extension technologies and to develop new ultra-high temperature and long-life thermal barrier coatings. layer.
目前，国内外关于热障涂层在高温、梯度温度、CMAS耦合环境条件下涂层热性能试验模拟装置很少，德国一家研究中心采用蠕动泵轴向输送方式将CMAS悬浮液注入火焰中，北航采用浴槽加热盐类物质获取腐蚀性气氛，通过生成腐蚀气体的方式对TBCs的腐蚀环境进行模拟。此外，国内还采用涂刷方式将腐蚀介质涂刷在陶瓷涂层表面，并置于高温炉中加热进行腐蚀环境模拟。虽然国内外已经开始重视热障涂层复杂服役环境相关的模拟试验装置的技术研究，但现有实验装置距离客观模拟高温、梯度温度、CMAS耦合环境条件下涂层热失效行为还有差距。开发一种接近热障涂层高温、梯度温度、CMAS耦合环境条件下涂层热性能试验模拟装置对此环境下热障涂层的失效行为进行有效表征，从而为热障涂层失效机理研究和提高热障涂层热性能研究提供实验依据，其重要作用无可替代。 At present, there are few domestic and foreign thermal barrier coating thermal performance test simulation devices under high temperature, gradient temperature, and CMAS coupling environmental conditions. A German research center uses a peristaltic pump to inject the CMAS suspension into the flame. Beihang University The corrosive atmosphere is obtained by heating salt substances in a bath, and the corrosive environment of TBCs is simulated by generating corrosive gas. In addition, brushing is also used in China to paint the corrosive medium on the surface of the ceramic coating, and place it in a high-temperature furnace for heating to simulate the corrosion environment. Although attention has been paid to the technical research on the simulation test device related to the complex service environment of thermal barrier coatings at home and abroad, there is still a gap between the existing experimental devices and the objective simulation of thermal failure behavior of coatings under high temperature, gradient temperature, and CMAS coupling environmental conditions. Develop a coating thermal performance test simulator close to thermal barrier coatings under high temperature, gradient temperature, and CMAS coupling environmental conditions to effectively characterize the failure behavior of thermal barrier coatings in this environment, so as to provide a basis for the research on the failure mechanism of thermal barrier coatings and Improving the thermal performance of thermal barrier coatings provides an experimental basis, and its important role is irreplaceable.
发明内容 Contents of the invention
本发明的目的是解决航空发动机涡轮叶片复杂服役环境的模拟难题，提供一种模拟高温、梯度温度、CMAS耦合环境条件下热障涂层热冲击寿命评价试验装置，为有效评估高温部件在复杂服役环境下的疲劳失效过程及可靠性提供重要的试验平台。 The purpose of the present invention is to solve the problem of simulating the complex service environment of aeroengine turbine blades, and provide a thermal shock life evaluation test device for thermal barrier coatings under the conditions of simulating high temperature, gradient temperature, and CMAS coupling environment, in order to effectively evaluate high temperature components in complex service The fatigue failure process and reliability in the environment provide an important test platform.
本发明的热障涂层热冲击寿命评价试验装置，其中，包含： The thermal shock life evaluation test device for thermal barrier coatings of the present invention includes:
一加热系统，用以提供一燃烧火焰射流，实现对试验试样加热高温环境进行模拟，并通过对所述试验试样的热障涂层的温度闭环反馈控制实现一定温度梯度下的循环加热； A heating system, which is used to provide a combustion flame jet to realize the simulation of the high-temperature environment for heating the test sample, and realize the cyclic heating under a certain temperature gradient through the closed-loop feedback control of the temperature of the thermal barrier coating of the test sample;
一CMAS液料输送系统，用于在所述加热系统进行加热的同时输送一CMAS悬浮液，所述CMAS悬浮液经空气射流雾化后以设定的角度和速率向燃烧火焰注入，以模拟CMAS的真实存在状态； A CMAS liquid material delivery system, used to deliver a CMAS suspension while the heating system is heating, and the CMAS suspension is atomized by an air jet and injected into the combustion flame at a set angle and speed to simulate CMAS the real state of existence;
一冷却系统，用以在所述加热系统加热结束后，通过一冷却气路对所述试验试样进行冷却； A cooling system, used to cool the test sample through a cooling air circuit after the heating system finishes heating;
一控制系统，连接并控制所述加热系统、所述CMAS液料输送系统及所述冷却系统，实现高温、梯度温度、CMAS耦合环境条件下的热障涂层服役环境的模拟并对整个工艺试验流程进行自动控制。 A control system, connecting and controlling the heating system, the CMAS liquid material delivery system and the cooling system, realizing the simulation of the service environment of the thermal barrier coating under high temperature, gradient temperature, and CMAS coupled environmental conditions and testing the entire process The process is automatically controlled.
上述的热障涂层热冲击寿命评价试验装置，其中，还包含一测温系统，用以实时监测所述试验试样的试验温度。 The thermal shock life evaluation test device of the thermal barrier coating further includes a temperature measurement system for real-time monitoring of the test temperature of the test sample.
上述的热障涂层热冲击寿命评价试验装置，其中，还包含一试样装卡机构，用以固定所述试验试样。 The above thermal shock life evaluation test device for thermal barrier coatings further includes a sample clamping mechanism for fixing the test sample.
上述的热障涂层热冲击寿命评价试验装置，其中，所述加热系统还包含： The above-mentioned thermal barrier coating thermal shock life evaluation test device, wherein the heating system also includes:
一燃气加热枪； a gas heating gun;
一移动支架，其上安装所述燃气加热枪，并通过一电机驱动以带动所述燃气加热枪移动； A mobile bracket, on which the gas heating gun is installed, and driven by a motor to drive the gas heating gun to move;
一自动点火机构，用于对所述燃气加热枪喷射的燃气流执行自动点火功能。 An automatic ignition mechanism is used for performing the automatic ignition function on the gas flow injected by the gas heating gun.
上述的热障涂层热冲击寿命评价试验装置，其中，所述CMAS液料输送系统还包含： The above-mentioned thermal shock life evaluation test device for thermal barrier coatings, wherein the CMAS liquid material delivery system also includes:
一CMAS液料输送装置，更包含： A CMAS liquid material conveying device, further comprising:
一雾化喷头，设置于所述加热系统的移动支架上，所述雾化喷头的后部具有一气体接口及一液体接口，所述气体接口通过一气管连接于一气源； An atomizing spray head, which is arranged on the movable bracket of the heating system, the rear part of the atomizing spray head has a gas interface and a liquid interface, and the gas interface is connected to a gas source through a gas pipe;
一消脉冲阻尼器，通过一柔性管连接于所述液体接口； An anti-pulse damper connected to the liquid interface through a flexible tube;
一定量输送泵，其上设置有一进液口及一出液口，所述出液口通过一柔性管连接于所述消脉冲阻尼器； A certain amount delivery pump is provided with a liquid inlet and a liquid outlet, and the liquid outlet is connected to the pulse elimination damper through a flexible tube;
一CMAS悬浮液专用储存容器，用以放置所述CMAS悬浮液，所述CMAS悬浮液专用储存容器通过一柔性管连接于所述进液口，所述定量输送泵输送所述CMAS悬浮液至所述雾化喷头。 A special storage container for the CMAS suspension, used to place the CMAS suspension, the special storage container for the CMAS suspension is connected to the liquid inlet through a flexible tube, and the quantitative delivery pump delivers the CMAS suspension to the The above atomizing nozzle.
上述的热障涂层热冲击寿命评价试验装置，其中，所述冷却系统还包含： The thermal shock life evaluation test device for thermal barrier coatings above, wherein the cooling system further includes:
一气源，用以提供一压缩空气；以及 an air source for providing compressed air; and
一冷却气路，用以输送所述气源产生的压缩空气至所述试验试样。 A cooling air path is used to deliver the compressed air generated by the air source to the test sample.
上述的热障涂层热冲击寿命评价试验装置，其中，所述测温系统还包含： The thermal shock life evaluation test device for thermal barrier coatings above, wherein the temperature measurement system also includes:
一热电偶，固定于所述试验试样上，测量所述试验试样的基体温度； A thermocouple, fixed on the test sample, measures the substrate temperature of the test sample;
一红外测温仪，用于测量所述试验试样的热障涂层的表面温度；以及 an infrared thermometer for measuring the surface temperature of the thermal barrier coating of the test specimen; and
一温度数据采集处理系统，连接所述热电偶和所述红外侧温仪并将采集处理后的温度数据传送至所述控制系统。 A temperature data acquisition and processing system, which connects the thermocouple and the infrared side thermometer and transmits the collected and processed temperature data to the control system.
上述的热障涂层热冲击寿命评价试验装置，其中，所述加热系统还包含一火焰探测器，所述火焰探测器的设置高度与所述燃气加热枪的一喷嘴中心平齐，以探测火焰点燃情况。 In the thermal shock life evaluation test device for thermal barrier coatings described above, the heating system further includes a flame detector, and the height of the flame detector is set at the same level as the center of a nozzle of the gas heating gun to detect flames. ignite the situation.
上述的热障涂层热冲击寿命评价试验装置，其中，所述加热系统还可包含一质量流量计，设置于所述燃气加热枪的一气体管路中，用以控制所述燃气火焰射流的流量。 In the above thermal shock life evaluation test device for thermal barrier coatings, the heating system may further include a mass flow meter, which is arranged in a gas pipeline of the gas heating gun to control the flow rate of the gas flame jet. flow.
上述的热障涂层热冲击寿命评价试验装置，其中，所述加热系统采用氧丙烷火焰作为热源。 In the above thermal shock life evaluation test device for thermal barrier coatings, the heating system uses a propylene oxide flame as a heat source.
上述的热障涂层热冲击寿命评价试验装置，其中，所述定量输送泵可为一脉冲频率可调式电磁隔膜泵。 In the above thermal shock life evaluation test device for thermal barrier coatings, the quantitative delivery pump can be an electromagnetic diaphragm pump with adjustable pulse frequency.
上述的热障涂层热冲击寿命评价试验装置，其中，所述消脉冲阻尼器可为一气室脉动阻尼器。 In the above thermal shock life evaluation test device for thermal barrier coatings, the pulsation damper may be a gas chamber pulsation damper.
上述的热障涂层热冲击寿命评价试验装置，其中，所述CMAS液料输送装置还包含一供液料阀门，所述供液料阀门安装于所述液体接口及所述消脉冲阻尼器之间的所述柔性管上且靠近所述雾化喷头的位置。 In the thermal shock life evaluation test device for thermal barrier coatings described above, the CMAS liquid material delivery device further includes a liquid supply valve, and the liquid supply valve is installed between the liquid interface and the pulse elimination damper On the flexible pipe between and close to the position of the atomizing nozzle.
上述的热障涂层热冲击寿命评价试验装置，其中，所述雾化喷头为一含有一中心单孔液体喷嘴和一环形雾化气体喷嘴的二流雾化喷头。 In the above thermal shock life evaluation test device for thermal barrier coatings, the atomizing nozzle is a two-flow atomizing nozzle including a central single-hole liquid nozzle and an annular atomizing gas nozzle.
上述的热障涂层热冲击寿命评价试验装置，其中，所述CMAS悬浮液由CMAS纳米粉末、少量分散剂、水或其他液体混合勾兑而成。 In the thermal shock life evaluation test device of the thermal barrier coating, the CMAS suspension is formed by mixing CMAS nano powder, a small amount of dispersant, water or other liquids.
上述的热障涂层热冲击寿命评价试验装置，其中，所述CMAS悬浮液专用储存容器中还包含一电动搅拌器，所述电动搅拌器设置于所述CMAS悬浮液中，通过接受一电驱动信号对所述CMAS悬浮液进行搅拌。 The above thermal shock life evaluation test device for thermal barrier coatings, wherein, the special storage container for the CMAS suspension also includes an electric stirrer, the electric stirrer is arranged in the CMAS suspension, and is driven by an electric Signal to stir the CMAS suspension.
上述的热障涂层热冲击寿命评价试验装置，其中，所述冷却系统包含一质量流量计，设置于所述冷却气路中，用以控制所述试验试样的冷却气流量。 In the above thermal shock life evaluation test device for thermal barrier coatings, wherein the cooling system includes a mass flow meter installed in the cooling air path to control the cooling air flow of the test sample.
上述的热障涂层热冲击寿命评价试验装置，其中，所述试样装卡机构采用枷板式装卡结构。 In the above thermal shock life evaluation test device for thermal barrier coatings, the sample clamping mechanism adopts a flail-type clamping structure.
上述的热障涂层热冲击寿命评价试验装置，其中，还包含一机箱，所述试样装卡机构、所述加热系统、所述红外测温仪以及所述冷却气路设置于所述机箱内。 The above thermal shock life evaluation test device for thermal barrier coatings further includes a chassis, the sample clamping mechanism, the heating system, the infrared thermometer and the cooling gas path are arranged in the chassis Inside.
针对于现有技术，本发明的热障涂层热冲击寿命评价试验装置具有以下 优点： For the prior art, the thermal barrier coating thermal shock life evaluation test device of the present invention has the following advantages:
1.通过对燃气加热枪的功率和加热距离的控制进行加热温度的精确控制，实现对试样加热高温环境(＜2000K)的模拟； 1. By controlling the power of the gas heating gun and the heating distance, the heating temperature can be precisely controlled to realize the simulation of the sample heating high temperature environment (<2000K);
2.通过质量流量计控制试验试样的冷却气流量，通过温度闭环控制系统进行背冷控温，实现一定温度梯度条件下的热冲击寿命试验； 2. The cooling air flow rate of the test sample is controlled by the mass flow meter, and the back cooling temperature is controlled by the temperature closed-loop control system to realize the thermal shock life test under a certain temperature gradient condition;
3.通过特殊设计的CMAS液料输送系统，将纳米粉末悬浮液制备成雾化射流，并将这种雾化射流和燃气火焰射流混合实现航空发动机涡轮叶片热障涂层复杂服役工况的有效模拟； 3. Through the specially designed CMAS liquid material delivery system, the nano-powder suspension is prepared into an atomized jet, and the atomized jet is mixed with the gas flame jet to realize the effective operation of the thermal barrier coating of the aero-engine turbine blade under complex service conditions. simulation;
4.脉冲频率可调式电磁隔膜泵能够实现精确和定量输送CMAS悬浮液；气室脉动阻尼器，通过调整气囊预制压力可以消除绝大部分由于脉冲频率可调式电磁隔膜泵脉冲造成的输送压力和流量的脉动； 4. The electromagnetic diaphragm pump with adjustable pulse frequency can realize accurate and quantitative delivery of CMAS suspension; the air chamber pulsation damper can eliminate most of the delivery pressure and flow caused by the pulse of the adjustable pulse frequency electromagnetic diaphragm pump by adjusting the prefabricated pressure of the air bag the pulsation;
5.二流雾化是在喷头出口由空气射流雾化CMAS悬浮液，雾化和分散比较充分，接近CMAS的真实存在状态； 5. The second-flow atomization is to atomize the CMAS suspension by air jet at the outlet of the nozzle, the atomization and dispersion are relatively sufficient, and it is close to the real state of CMAS;
6.通过增加一个机箱，能够以保证试验时的安全性问题及试验装置的美观； 6. By adding a chassis, it can ensure the safety of the test and the beauty of the test device;
7.控制系统采用PLC自动控制整个试验工艺流程，试验机操作界面为触摸屏方式，可根据不同的参数监测，通过菜单选择：如温度模块、速度模块、悬浮液流量模块、雾化气压力模块、试验方式模块等进行试验操作。试验机人机界面友好，操作快捷；现场数据同时传送到后台计算机保存、分析，方便用户查询数据。 7. The control system adopts PLC to automatically control the whole test process. The operation interface of the test machine is a touch screen, which can be monitored according to different parameters and selected through the menu: such as temperature module, speed module, suspension flow module, atomization gas pressure module, Test mode modules, etc. for test operations. The testing machine has a friendly man-machine interface and quick operation; the field data is simultaneously transmitted to the background computer for storage and analysis, which is convenient for users to query data.
附图说明 Description of drawings
图1是本发明热障涂层热冲击寿命评价试验装置的实施例结构示意图； Fig. 1 is a structural schematic diagram of an embodiment of a thermal shock life evaluation test device for a thermal barrier coating of the present invention;
图2是本发明热障涂层热冲击寿命评价试验装置的CMAS液料输送系统的结构示意图。 Fig. 2 is a structural schematic diagram of the CMAS liquid material delivery system of the thermal barrier coating thermal shock life evaluation test device of the present invention.
其中，附图标记 Among them, reference signs
11-燃气加热枪 11-Gas heat gun
111-燃气加热枪的喷嘴 111-Nozzle of gas heating gun
12-移动支架 12-Mobile stand
121-链轮 121-sprocket
122链条 122 chain
13-自动点火机构 13-Automatic ignition mechanism
15-支架 15-bracket
211-二流雾化喷头 211-Second flow atomizing nozzle
211a-二流雾化喷头气体接口 211a-Second-flow atomization nozzle gas interface
211b-二流雾化喷头液体接口 211b-Second-flow atomizing nozzle liquid interface
212-气室脉动阻尼器 212-Air chamber pulsation damper
213-脉冲频率可调式电磁隔膜泵 213-Pulse Frequency Adjustable Electromagnetic Diaphragm Pump
214-调压阀 214-Pressure regulating valve
215-供液料阀门 215-Liquid supply valve
22-CMAS悬浮液专用储存容器 22-CMAS special storage container for suspension
221-电动搅拌器 221-electric mixer
222-CMAS悬浮液， 222-CMAS Suspension,
31-冷却气路 31-cooling gas path
5-试样装卡机构 5-Sample loading mechanism
61-热电偶 61-Thermocouple
62-红外测温仪 62-Infrared Thermometer
63-温度数据采集处理系统 63-Temperature data acquisition and processing system
7-气管 7- Trachea
8-柔性管 8-flexible pipe
9-试验试样 9-Test Specimen
10-机箱 10-Chassis
具体实施方式 detailed description
下面结合附图和具体实施例对本发明技术方案进行详细的描述，以更进一步了解本发明的目的、方案及功效，但本发明并不以此为限。 The technical solutions of the present invention will be described in detail below in conjunction with the accompanying drawings and specific embodiments, so as to further understand the purpose, solutions and effects of the present invention, but the present invention is not limited thereto.
本发明提供了一种热障涂层热冲击寿命评价试验装置，用以有效评估高温部件在复杂服役环境下的疲劳失效过程及可靠性。请参照图1及图2，图1是本发明热障涂层热冲击寿命评价试验装置的实施例结构示意图；图2是本发明热障涂层热冲击寿命评价试验装置的CMAS液料输送系统的结构示意图。如 图1及图2所示，该热障涂层热冲击寿命评价试验装置包含加热系统、CMAS液料输送系统、冷却系统以及控制系统；加热系统用以提供一燃烧火焰射流，实现对试验试样9加热高温环境进行模拟，并通过对热障涂层的温度闭环反馈控制实现一定温度梯度下的循环加热；CMAS液料输送系统用于在加热系统进行加热的同时输送CMAS悬浮液222，CMAS悬浮液222经空气射流雾化后以设定的角度和速率向燃烧火焰注入，以模拟CMAS的真实存在状态；冷却系统用以在加热系统加热结束后，所述试验试样进行冷却；控制系统连接并控制加热系统、CMAS液料输送系统及冷却系统，实现高温、梯度温度、CMAS耦合环境条件下的热障涂层服役环境的模拟并对整个工艺试验流程进行自动控制。 The invention provides a thermal shock life evaluation test device for a thermal barrier coating, which is used to effectively evaluate the fatigue failure process and reliability of high-temperature components in complex service environments. Please refer to Figure 1 and Figure 2, Figure 1 is a schematic structural diagram of an embodiment of the thermal barrier coating thermal shock life evaluation test device of the present invention; Figure 2 is the CMAS liquid material delivery system of the thermal barrier coating thermal shock life evaluation test device of the present invention Schematic diagram of the structure. As shown in Figures 1 and 2, the thermal shock life evaluation test device for thermal barrier coatings includes a heating system, a CMAS liquid material delivery system, a cooling system, and a control system; the heating system is used to provide a combustion flame jet to realize the test Sample 9 is used to simulate the heating of the high-temperature environment, and realize the cyclic heating under a certain temperature gradient through the closed-loop feedback control of the temperature of the thermal barrier coating; the CMAS liquid material delivery system is used to deliver the CMAS suspension 222 while the heating system is heating. After the suspension 222 is atomized by the air jet, it is injected into the combustion flame at a set angle and speed to simulate the real state of CMAS; the cooling system is used to cool the test sample after the heating system finishes heating; the control system Connect and control the heating system, CMAS liquid material delivery system and cooling system to realize the simulation of the thermal barrier coating service environment under high temperature, gradient temperature and CMAS coupled environmental conditions and automatically control the entire process test process.
其中，加热系统包含：一燃气加热枪11、一移动支架12及一自动点火机构13，燃气加热枪11安装于移动支架12上，移动支架12通过一电机驱动，再带动移动支架12底部安装的链轮121，进而带动套装于链轮上的链条122，最终带动所述燃气加热枪进行水平或左右方向的移动，自动点火机构13用于对所述燃气加热枪喷射的燃气流执行自动点火功能。其中，以氧丙烷火焰作为燃气加热枪11的热源为一较佳的实施方式。其中，还以加热系统还包含一火焰探测器(图未示)及一质量流量计(图未示)为较佳实施方式，火焰探测器(图未示)通过一支架(图未示)设置于燃气加热枪11的一侧，其高度与燃气加热枪11的喷嘴111中心平齐，用以监测火焰点燃情况；质量流量计安装于燃气加热枪11的一气体管路中，用以控制燃气火焰射流的流量。 Among them, the heating system includes: a gas heating gun 11, a mobile bracket 12 and an automatic ignition mechanism 13, the gas heating gun 11 is installed on the mobile bracket 12, the mobile bracket 12 is driven by a motor, and then drives the bottom of the mobile bracket 12 The sprocket 121 further drives the chain 122 set on the sprocket, and finally drives the gas heating gun to move horizontally or left and right. The automatic ignition mechanism 13 is used to perform the automatic ignition function on the gas flow injected by the gas heating gun . Wherein, it is a preferred embodiment to use oxypropane flame as the heat source of the gas heat gun 11 . Wherein, the heating system also includes a flame detector (not shown) and a mass flow meter (not shown) as a preferred embodiment, the flame detector (not shown) is set through a bracket (not shown) On one side of the gas heating gun 11, its height is flush with the center of the nozzle 111 of the gas heating gun 11 to monitor the ignition of the flame; the mass flow meter is installed in a gas pipeline of the gas heating gun 11 to control the gas The flow of flame jets.
其中，CMAS液料输送系统包含CMAS液料输送装置21和CMAS悬浮液专用储存容器22。 Wherein, the CMAS liquid material delivery system includes a CMAS liquid material delivery device 21 and a special storage container 22 for CMAS suspension.
CMAS液料输送装置21更包含：一个二流雾化喷头211、一个气室脉动阻尼器212及一脉冲频率可调式电磁隔膜泵213。二流雾化喷头211按照一设定的角度和距离安装于移动支架12上并位于燃气加热枪11的上方，其中以二流雾化喷头211与燃气加热枪11的间隔30mm且二流雾化喷头211与燃气加热枪11所喷射的火焰中心轴向间隔30mm，二流雾化喷头211并与燃气加热枪11喷射的火焰中心形成一角度为10°的锐角为一较佳的实施方式。二流雾化喷头211包含中心单孔液体喷嘴和环形雾化气体喷嘴，其后部具有两个接口，即气体接口211a及液体接口211b，气体接口211a通过气管7连接于气 源(图未示)，气体接口211a及气源之间还可设有一调压阀214，用以调节气压(图未示)；气室脉动阻尼器212通过柔性管8连接于液体接口211b；脉冲频率可调式电磁隔膜泵213位于气室脉动阻尼器212的上游(来流方向)，脉冲频率可调式电磁隔膜泵213的出液口并通过柔性管8连接于气室脉动阻尼器212。其中，以本装置还包含一个供液料阀门215，供液料阀门215安装于液体接口211b及气室脉动阻尼器212之间的柔性管8上为较佳实施方式。本实施例中定量输送泵为一脉冲频率可调式电磁隔膜泵，但本发明并不以此为限。 The CMAS liquid material delivery device 21 further includes: a second-flow atomizing nozzle 211 , an air chamber pulsation damper 212 and an electromagnetic diaphragm pump 213 with adjustable pulse frequency. The two-stream atomizing nozzle 211 is installed on the mobile bracket 12 according to a set angle and distance and is located above the gas heating gun 11, wherein the distance between the two-stream atomizing nozzle 211 and the gas heating gun 11 is 30 mm and the two-stream atomizing nozzle 211 is connected to the gas heating gun 11. The center of the flame sprayed by the gas heating gun 11 is separated by 30mm in the axial direction, and the two-flow atomizing nozzle 211 forms an acute angle of 10° with the center of the flame sprayed by the gas heating gun 11, which is a preferred embodiment. The two-stream atomizing spray head 211 includes a central single-hole liquid nozzle and an annular atomizing gas nozzle, and its rear part has two interfaces, namely a gas interface 211a and a liquid interface 211b, and the gas interface 211a is connected to the gas source (not shown) through the gas pipe 7 A pressure regulating valve 214 can also be provided between the gas interface 211a and the gas source to adjust the air pressure (not shown); the air chamber pulsation damper 212 is connected to the liquid interface 211b through a flexible tube 8; pulse frequency adjustable electromagnetic diaphragm The pump 213 is located upstream of the air chamber pulsation damper 212 (incoming flow direction), and the liquid outlet of the pulse frequency adjustable electromagnetic diaphragm pump 213 is connected to the air chamber pulsation damper 212 through a flexible tube 8 . Wherein, the device further includes a liquid supply material valve 215, and the liquid supply material valve 215 is installed on the flexible pipe 8 between the liquid interface 211b and the air chamber pulsation damper 212, which is a preferred embodiment. In this embodiment, the quantitative delivery pump is an electromagnetic diaphragm pump with adjustable pulse frequency, but the present invention is not limited thereto.
CMAS悬浮液专用储存容器22，用以放置CMAS悬浮液222，通过柔性管8连接于脉冲频率可调式电磁隔膜泵213的进液口。其中，以CMAS悬浮液专用储存容器22还包含一电动搅拌器221，设置于CMAS悬浮液专用储存容器22中，通过接受一电驱动信号对CMAS悬浮液222进行搅拌为较佳实施方式。其中，CMAS悬浮液222为由CMAS纳米粉末、少量分散剂、水或其他液体混合勾兑而成。 The special storage container 22 for the CMAS suspension is used to place the CMAS suspension 222, and is connected to the liquid inlet of the electromagnetic diaphragm pump 213 with adjustable pulse frequency through the flexible tube 8. Wherein, the special storage container 22 for the CMAS suspension also includes an electric stirrer 221, which is arranged in the special storage container 22 for the CMAS suspension, and it is a preferred embodiment to stir the CMAS suspension 222 by receiving an electric driving signal. Wherein, the CMAS suspension 222 is formed by mixing and blending CMAS nanopowder, a small amount of dispersant, water or other liquids.
其中，冷却系统包含：气源(图未示)及一冷却气路31。气源(图未示)用以提供压缩空气；冷却气路31连接气源(图未示)并输送气源产生的压缩空气至所述试验试样9。其中，冷却系统还包含一质量流量计(图未示)，质量流量计安装于冷却气路31中，用以控制冷却试验试样9时的冷却气流量。 Wherein, the cooling system includes: an air source (not shown in the figure) and a cooling air path 31 . The air source (not shown) is used to provide compressed air; the cooling air circuit 31 is connected to the air source (not shown) and delivers the compressed air generated by the air source to the test sample 9 . Wherein, the cooling system also includes a mass flow meter (not shown in the figure), and the mass flow meter is installed in the cooling air passage 31 to control the cooling air flow when cooling the test sample 9 .
在本实施例中，该热障涂层热冲击寿命评价试验装置还包含测温系统，连接于控制系统，用以实时监测试验试样9的试验温度，测温系统包含：一热电偶61、一红外测温仪62及温度数据采集处理系统63(图未示)。热电偶61固定于试验试样9上；红外测温仪62设置于加热系统的一侧，用于测量所述试验试样的热障涂层的表面温度；温度数据采集处理系统63(图未示)，连接热电偶61和红外侧温仪62并将采集处理后的温度数据传送至所述控制系统。 In this embodiment, the thermal shock life evaluation test device for thermal barrier coatings also includes a temperature measurement system connected to the control system for monitoring the test temperature of the test sample 9 in real time. The temperature measurement system includes: a thermocouple 61, An infrared thermometer 62 and a temperature data acquisition and processing system 63 (not shown). A thermocouple 61 is fixed on the test sample 9; an infrared thermometer 62 is arranged on one side of the heating system for measuring the surface temperature of the thermal barrier coating of the test sample; a temperature data acquisition and processing system 63 (not shown in the figure) shown), connect the thermocouple 61 and the infrared side thermometer 62 and transmit the collected and processed temperature data to the control system.
该热障涂层热冲击寿命评价试验装置还包含试样装卡机构5，用以固定试验试样9，其中试样装卡机构5采用枷板式装卡结构为较佳实施方式。 The thermal barrier coating thermal shock life evaluation test device also includes a sample clamping mechanism 5 for fixing the test sample 9, wherein the sample clamping mechanism 5 adopts a flail-type clamping structure as a preferred embodiment.
在本实施例中，本发明的热障涂层热冲击寿命评价试验装置的试验试样9的热障涂层分别采用了大气等离子及超音速等离子的方式进行喷涂，但本发明并不以此为限，在其他实施例中热障涂层还可采用其他方式进行喷涂。 In this embodiment, the thermal barrier coating of the test sample 9 of the thermal barrier coating thermal shock life evaluation test device of the present invention is sprayed by means of atmospheric plasma and supersonic plasma respectively, but the present invention does not rely on this In other embodiments, the thermal barrier coating can also be sprayed in other ways.
其中，该热障涂层热冲击寿命评价试验装置还包含机箱10，用以放置试样装卡机构5、加热系统、红外测温仪16以及冷却气路31为较佳实施方式，这样既可以保证试验时的安全性问题，还增加了本装置的美观性，但本发明并不以此为限。 Wherein, the thermal barrier coating thermal shock life evaluation test device also includes a chassis 10, which is a preferred embodiment for placing the sample clamping mechanism 5, heating system, infrared thermometer 16 and cooling gas path 31, so that it can To ensure the safety of the test, it also increases the aesthetics of the device, but the present invention is not limited thereto.
再请参阅图1，该热障涂层热冲击寿命评价试验装置还包含一个支架15，其上放置试样装卡机构5及加热系统，用以实现试样装卡机构5及加热系统在同一水平面，进而保证加热时燃气加热枪11能更好对准试验试样9，但本发明并不以此为限。 Referring to Fig. 1 again, this thermal barrier coating thermal shock life evaluation test device also includes a bracket 15, on which the sample clamping mechanism 5 and the heating system are placed, so as to realize the sample clamping mechanism 5 and the heating system in the same The horizontal plane ensures that the gas heating gun 11 can be better aligned with the test sample 9 during heating, but the present invention is not limited thereto.
再请参阅图2，说明CMAS液料输送系统的工作过程，启动脉冲频率可调式电磁隔膜泵213，CMAS悬浮液专用储存容器22中的CMAS悬浮液222从脉冲频率可调式电磁隔膜泵213的进液口流入并从脉冲频率可调式电磁隔膜泵213的出液口流出；脉冲频率可调式电磁隔膜泵213作的间歇性造成管路中压力和流量的相应脉动，为克服脉动，在管路中特别安装有气室脉动阻尼器212，通过合理调整气室压力可以克服绝大部分的液体压力脉动以及流量脉动。CMAS悬浮液222通过供液料阀门215均匀送入二流雾化喷头211，从二流雾化喷头211的中心单孔液体喷嘴出。雾化气体为压缩空气，气源(图未示)提供的雾化气体通过调压阀214送到二流雾化喷头211，从二流雾化喷头211的环形雾化气体喷嘴喷出。两股射流在剪切力和自身动能作用下形成雾化射流。 Please refer to Fig. 2 again, explain the working process of CMAS liquid material conveying system, start pulse frequency adjustable electromagnetic diaphragm pump 213, the CMAS suspension liquid 222 in the special storage container 22 of CMAS suspension liquid enters from pulse frequency adjustable electromagnetic diaphragm pump 213 The liquid port flows into and flows out from the liquid outlet of the pulse frequency adjustable electromagnetic diaphragm pump 213; the intermittent operation of the pulse frequency adjustable electromagnetic diaphragm pump 213 causes the corresponding pulsation of the pressure and flow in the pipeline, in order to overcome the pulsation, in the pipeline The air chamber pulsation damper 212 is specially installed, and most of the liquid pressure pulsation and flow pulsation can be overcome by adjusting the air chamber pressure reasonably. The CMAS suspension 222 is evenly sent into the second-stream atomization nozzle 211 through the liquid supply valve 215, and exits from the central single-hole liquid nozzle of the second-stream atomization nozzle 211. The atomizing gas is compressed air, and the atomizing gas provided by the gas source (not shown in the figure) is sent to the second-stream atomizing nozzle 211 through the pressure regulating valve 214, and is sprayed from the annular atomizing gas nozzle of the second-stream atomizing nozzle 211. The two jets form an atomized jet under the action of shear force and their own kinetic energy.
下面结合图1及图2说明热障涂层热冲击寿命评价试验装置工作过程，进行高温、梯度温度、CMAS耦合环境条件下热障涂层热冲击寿命试验时，首先进行CMAS液料输送装置准备工作：安装二流雾化喷头211与燃气加热枪11，然后开启CMAS液料输送系统，设置CMAS液料输送装置工作参数，确定CMAS悬浮液222输送流量及压缩空气压力，并在CMAS悬浮液专用储存容器22中注入CMAS悬浮液222，通过电动搅拌器221保证试验过程中CMAS悬浮液222一直处于均匀搅拌状态。 The working process of the thermal shock life evaluation test device for thermal barrier coatings will be described below in conjunction with Figure 1 and Figure 2. When conducting thermal shock life tests of thermal barrier coatings under high temperature, gradient temperature, and CMAS coupling environmental conditions, the CMAS liquid material delivery device should be prepared first. Work: Install the second-stream atomizing nozzle 211 and the gas heating gun 11, then turn on the CMAS liquid material delivery system, set the working parameters of the CMAS liquid material delivery device, determine the delivery flow rate and compressed air pressure of the CMAS suspension 222, and store them in the CMAS suspension dedicated storage The CMAS suspension 222 was injected into the container 22, and the electric stirrer 221 was used to ensure that the CMAS suspension 222 was in a state of uniform stirring during the test.
开始试验时，将试验试样9背面焊好热电偶61后安装在试样装卡机构5上，然后启动自动点火机构13自动点火，并通过PLC程序控制一电机(图未示)驱动链轮121转动，进而带动链条122，从而控制移动支架12将加热枪11移动到试验试样9前方，按照试验要求的加热速度、加热温度加热试样，当正面温度达到设定值后进入保温阶段，此时将CMAS悬浮液222通过二流 雾化喷头211以喷雾形态注入焰流；保温过程中可根据试验要求对试验试样9进行背冷控温，保证试验试样9的涂层正面及基体背面一定的梯度温度；达到保温时间后，加热自动停止，同时CMAS悬浮液222喷覆完毕，将氧丙烷燃气加热枪11及二流雾化喷头211快速移开，同时开启试样冷却气路31对试验试样9进行压缩空气快速冷却，直到将试验试样9冷却到试验要求的温度，关断冷却气路31，再由PLC控制加热系统重新自动点火，重新开始下一个工作循环，如此往复循环直到涂层表面出现开裂剥离，直至涂层剥落(一般设定剥落面积达20％为失效)，试验终止。 When starting the test, install the thermocouple 61 on the back of the test sample 9 and install it on the sample clamping mechanism 5, then start the automatic ignition mechanism 13 to ignite automatically, and control a motor (not shown) to drive the sprocket through the PLC program 121 rotates, and then drives the chain 122, thereby controlling the mobile bracket 12 to move the heating gun 11 to the front of the test sample 9, heating the sample according to the heating speed and heating temperature required by the test, and entering the heat preservation stage when the front temperature reaches the set value. At this time, the CMAS suspension 222 is injected into the flame flow in the form of a spray through the second-flow atomizing nozzle 211; during the heat preservation process, the test sample 9 can be cooled and controlled according to the test requirements to ensure that the coating front and the substrate back of the test sample 9 A certain gradient temperature; after the holding time is reached, the heating will stop automatically, and at the same time the CMAS suspension 222 is sprayed, and the oxypropane gas heating gun 11 and the second-flow atomization nozzle 211 are quickly removed, and the sample cooling air circuit 31 pairs of tests are opened at the same time Sample 9 is rapidly cooled by compressed air until the test sample 9 is cooled to the temperature required by the test, the cooling air circuit 31 is turned off, and then the heating system is automatically re-ignited by the PLC control, and the next working cycle is restarted, and the reciprocating cycle continues until Cracks and peeling appear on the surface of the coating until the coating peels off (generally set the peeling area to 20% as failure), and the test is terminated.
试验结束后，卸下二流雾化喷头211，将容器中的剩余CMAS悬浮液222清洗，并接入一定量纯净水。开启CMAS液料输送系统清洗功能，将管路中剩余CMAS悬浮液222排出，重复清洗多次，直至二流雾化喷头211喷出的液体形成较为清澈的水为止。 After the test, the second-flow atomizing nozzle 211 was removed, the remaining CMAS suspension 222 in the container was cleaned, and a certain amount of pure water was inserted. Turn on the cleaning function of the CMAS liquid material delivery system, discharge the remaining CMAS suspension 222 in the pipeline, and repeat the cleaning several times until the liquid sprayed by the second-stream atomizing nozzle 211 forms relatively clear water.
试验装置控制系统整体基于PLC实现，通过控制程序，实现整个工艺试验流程的自动控制。 The overall control system of the test device is implemented based on PLC, and the automatic control of the entire process test process is realized through the control program.
以下示例用以说明不同的试验试样制备工艺、不同的试验参数下试验试样的试验情况。 The following examples are used to illustrate the test conditions of test samples under different test sample preparation processes and different test parameters.
应用示例1： Application example 1:
试样热障涂层采用大气等离子喷涂，涂层厚度250μm。试样正面加热至1200℃，背面冷却温度保持在900℃，保温5min。CMAS耦合试验时，液料输送流量为10LPM，压缩空气压力为0.04MPa，CMAS悬浮液浓度为0.1％。经过107次耦合试验后，试样表面有明显的CMAS物质沉积，同时试样表面有明显的涂层剥落，剥落面积达到表面涂层的20％，并且露出部分粘结层。 The sample thermal barrier coating was sprayed by atmospheric plasma, and the coating thickness was 250 μm. The front side of the sample is heated to 1200°C, and the cooling temperature on the back side is kept at 900°C for 5 minutes. During the CMAS coupling test, the liquid material delivery flow rate is 10LPM, the compressed air pressure is 0.04MPa, and the CMAS suspension concentration is 0.1%. After 107 coupling tests, the surface of the sample had obvious deposition of CMAS substances, and at the same time, the surface of the sample had obvious coating peeling, and the peeling area reached 20% of the surface coating, and part of the bonding layer was exposed.
应用示例2： Application example 2:
试样热障涂层采用超音速等离子喷涂，涂层厚度250μm。试样正面加热至1200℃，背面冷却温度保持在900℃，保温5min。CMAS耦合试验时，液料输送流量为10LPM，压缩空气压力为0.04MPa，CMAS悬浮液浓度为1％。经过20次耦合循环后，试样表面有较为明显的CMAS沉积物，但未造成涂层失效，经过31次耦合试验后，中心区域涂层有明显CMAS沉积，且发生部分涂层剥落，涂层失效。 The sample thermal barrier coating was sprayed by supersonic plasma, and the thickness of the coating was 250 μm. The front side of the sample is heated to 1200°C, and the cooling temperature on the back side is kept at 900°C for 5 minutes. During the CMAS coupling test, the liquid material delivery flow rate is 10LPM, the compressed air pressure is 0.04MPa, and the CMAS suspension concentration is 1%. After 20 coupling cycles, there were obvious CMAS deposits on the surface of the sample, but the coating did not fail. After 31 coupling tests, the coating in the central area had obvious CMAS deposition, and part of the coating peeled off. invalidated.
应用示例3： Application example 3:
试样热障涂层超音速等离子喷涂，涂层厚度250μm。试样正面加热至1200℃，背面冷却温度保持在900℃，保温5min。CMAS耦合试验时，液料输送流量为10LPM，压缩空气压力为0.04MPa，CMAS悬浮液浓度为1％。经过20次耦合循环后，试样表面有少量的CMAS沉积物，经过60次试验后，试样中心区域涂层有明显CMAS沉积，82次试验后，中心区域涂层明显剥落，且有CMAS物质再次沉积在剥落区域。 The sample thermal barrier coating is supersonic plasma sprayed, and the coating thickness is 250 μm. The front side of the sample is heated to 1200°C, and the cooling temperature on the back side is kept at 900°C for 5 minutes. During the CMAS coupling test, the liquid material delivery flow rate is 10LPM, the compressed air pressure is 0.04MPa, and the CMAS suspension concentration is 1%. After 20 coupling cycles, there is a small amount of CMAS deposits on the surface of the sample. After 60 tests, the coating in the central area of the sample has obvious CMAS deposition. After 82 tests, the coating in the central area is obviously peeled off, and there are CMAS substances Deposit again on flaking areas.
当然，本发明还可有其它多种实施例，在不背离本发明精神及其实质的情况下，熟悉本领域的技术人员当可根据本发明作出各种相应的改变和变形，但这些相应的改变和变形都应属于本发明所附的权利要求的保护范围。 Certainly, the present invention also can have other multiple embodiments, without departing from the spirit and essence of the present invention, those skilled in the art can make various corresponding changes and deformations according to the present invention, but these corresponding Changes and deformations should belong to the scope of protection of the appended claims of the present invention.
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