等离子喷涂ZrC基涂层逐道逐层沉积残余应力模拟与实验验证

doi:10.15541/jim20180450

无机材料学报 ›› 2019, Vol. 34 ›› Issue (7): 768-774.DOI: 10.15541/jim20180450

等离子喷涂ZrC基涂层逐道逐层沉积残余应力模拟与实验验证

谢玲玲^1,^2,³,牛亚然²(),王亮²,陈文亮¹,郑学斌²(),黄贞益³

^1. 南京航空航天大学机电学院, 南京 210016
^2. 中国科学院上海硅酸盐研究所特种无机涂层重点实验室, 上海 200050
^3. 安徽工业大学冶金工程学院, 马鞍山 243002

收稿日期:2018-09-21 修回日期:2018-11-28 出版日期:2019-07-20 网络出版日期:2019-06-26
作者简介:谢玲玲(1978-), 女, 博士研究生. E-mail:xll@ahut.edu.cn
基金资助:
中国科学院上海硅酸盐所重点实验室开放基金(KLICM201309);安徽省高校自然科学研究重点项目(KJ2017A804)

Residual Stresses of Plasma Sprayed ZrC-Based Coatings during Path-by-path and Layer-by-layer Deposition: Simulation and Experimental Verification

XIE Ling-Ling^1,^2,³,NIU Ya-Ran²(),WANG Liang²,CHEN Wen-Liang¹,ZHENG Xue-Bin²(),HUANG Zhen-Yi³

^1. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China
^2. Key Laboratory of Inorganic Coating Materials, Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai 200050, China
^3. Metallurgical Engineering College, Anhui University of Technology, Maanshan 243002, China

Received:2018-09-21 Revised:2018-11-28 Published:2019-07-20 Online:2019-06-26
Supported by:
Key Laboratory of Inorganic Coating Materials in Chinese Academy of Sciences(KLICM201309);Key Project of Natural Science in Anhui Provincial Department of Education(KJ2017A804)

摘要/Abstract

摘要：

采用商用ANSYS14.5软件, 依据复合梁增层力学模型, 采用逐道逐层累积模型模拟了C/C复合材料表面等离子喷涂ZrC基涂层沉积残余应力的特征, 分析了SiC过渡层、第二相(SiC, MoSi₂)和涂层厚度对ZrC基涂层残余应力的影响, 并进行了实验验证。结果表明, SiC过渡层有效缓解了涂层与基体的热失配应力。涂层体系的应力随着涂层厚度的增加逐渐减小, 符合应力松弛和叠加规律。在涂层内部的径向应力以拉应力为主, 基体中主要为压应力, 且在界面边缘存在压应力集中的极限区域, 易使涂层产生裂纹并沿界面扩展。该模拟采用逐道逐层累积的方法更逼近实际喷涂过程, 能更准确预测涂层的残余应力。

关键词: 等离子喷涂, ZrC基涂层, 有限元模拟, 逐道逐层沉积, 残余应力

Abstract:

Commercial ANSYS14.5 software was used to simulate the residual stress characteristics in the deposition process of plasma sprayed ZrC-based coatings on the surface of C/C composite substrates. The simulation combined the mechanical model of composite beam adding laminate layer, and the finite element model of accumulation of path-by-path and layer-by-layer. Effects of SiC transition layer, second phase (SiC, MoSi₂) and coating thickness on residual stresses of the ZrC-based coatings were analyzed and validated by experiments. All results show that the SiC transition layer effectively relieve thermal mismatch stress between the coating and the substrate. Stress of the coating decreases gradually with the increase of coating thickness, which conforms to the stress relaxation and superposition law. There exist tensile stress in the coating, and compressive stress in the substrate. Moreover, compressive stress concentration is found at the interface edge, which is easly induced cracks formation and propagation along the interface. Therefor, our simulation method in present study could simulate actual spray process and predict residual stress of the coatings accurately.

Key words: plasma spray, ZrC-based coatings, finite element simulation, path-by-path and layer-by-layer deposition, residual stress

中图分类号:

TQ174

谢玲玲, 牛亚然, 王亮, 陈文亮, 郑学斌, 黄贞益. 等离子喷涂ZrC基涂层逐道逐层沉积残余应力模拟与实验验证[J]. 无机材料学报, 2019, 34(7): 768-774.

XIE Ling-Ling, NIU Ya-Ran, WANG Liang, CHEN Wen-Liang, ZHENG Xue-Bin, HUANG Zhen-Yi. Residual Stresses of Plasma Sprayed ZrC-Based Coatings during Path-by-path and Layer-by-layer Deposition: Simulation and Experimental Verification[J]. Journal of Inorganic Materials, 2019, 34(7): 768-774.

图/表 16

图1 沉积第n层时复合梁增层力学模型示意图

Fig. 1 Schematic of mechanic model of complex beam due to deposition of nth layer

图2 涂层沉积过程模型

Fig. 2 Model of deposition process of coatings

图3 网格划分示意图

Fig. 3 Schematic of finite element mesh

表1 模型中基体与涂层材料的热物理性能参数[16,17]

Table 1 Thermo-physical performance parameters of the substrate and coating[16,17]

Material	T/ ℃	Ε/GPa	ρ/(kg·m^-3)	α/(×10^-6, K^-1)	ν	k/(W·m^-1·K^-1)	C/(J·kg^-1·K^-1)
C/C	25	70	1800	1.00	0.340	8.00	800
	200	-	-	3.58	-	8.13	934
	400	-	-	3.70	-	7.95	1115
	600	-	-	3.94	-	7.77	1239
	800	-	-	4.08	-	7.76	1344
	1000	-	-	4.20	-	8.21	1522
SiC	2300	448	3050	4.50	0.142	16.70	670
ZrC	20	348	6730	6.70	0.180	20.50	366
ZrC	3540	355	6730	6.70	0.191	20.50	366
MoSi₂	2030	440	6240	8.10	0.115	45.00	540

图4 径向应力在基体/涂层界面沿径向变化曲线(tc=0.35 mm)

Fig. 4 Change of radial stresses along radial direction at substrate/coatings interface (tc=0.35 mm)

图5 径向应力在涂层表面沿径向变化曲线(tc=0.35 mm)

Fig. 5 Change of radial stresses along radial direction at the surface of coatings (tc=0.35 mm)

图6 径向应力在过渡层/涂层界面沿径向变化(tc=0.35 mm)

Fig. 6 Change of radial stresses along radial direction at transition layer /coatings interface (tc=0.35 mm)

图7 涂层表面的径向应力沿径向变化曲线(tc=0.35mm)

Fig. 7 Change of radial stresses along radial direction at surface of coatings (tc=0.35 mm)

图8 各涂层的最大轴向应力比较

Fig. 8 Comparison of maximum axial stresses among coatings

图9 各涂层的最大剪切应力比较

Fig. 9 Comparison of maximum shear stresses among coatings

图10 涂层表面的最大等效应力变化

Fig. 10 Change of maximum equivalent stresses at coating surface

图11 逐层沉积过程中应力累积示意图[22]

Fig. 11 Superposition principle of residual stresses[22]

图12 涂层的表面形貌

Fig. 12 Surface morphologies of the coatings (a) ZS2; (b) ZrC; (c) ZM2

图13 C/C复合材料涂层的截面SEM照片(a)和涂层中Si的EDS面分析结果(b)

Fig. 13 Cross-section morphologies of coating on the C/C composites (a) and EDS mapping of Si distribution in the coating (b)

图14 径向应力在ZM4涂层表面的分布

Fig. 14 Radial residual stress distribution in the ZM4 coating surface (a) Without SiC transition layer; (b) With SiC transition layer

图15 涂层结构界面剥离应力示意图

Fig. 15 Schematic of interfacial peeling stress distributions of the coating (a) The maximum tensile stress at the edge; (b) The maximum compressive stress at the edge

参考文献 26

[1]	LI HE-JUN, XUE HUI, FU QIAN-GANG , et al. Research status and prospect of anti-oxidation coatings for carbon/carbon composites. Journal of Inorganic Materials, 2010,25(4):338-343.
[2]	WANG YA-LEI, XIONG XIANG, LI GUO-DONG , et al. Preparation and ablation properties of Hf(Ta)C co-deposition coating for carbon/carbon composites. Corrosion Science, 2013,66:177-182. DOI URL
[3]	FU QIAN-GANG, LI HE-JUN, WANG YONG-JIE , et al. Multilayer oxidation protective coating for C/C composites from room temperature 1500 ℃. Surface & Coating Technology, 2010,204:1831-1835.
[4]	ZENG YI, XIONG XIANG, GUO SHUN , et al. SiC/SiC- YAG-YSZ oxidation protective coatings for carbon/carbon composites. Corrosion Science, 2013,70:68-73. DOI URL
[5]	WANG SHAO-LEI, LI HONG, REN MU-SU , et al. Fabrication and ablation performances of ZrC-SiC-C/C composites. Acta Materiae Compositae Sinica, 2017,34(5):1040-1047.
[6]	NIU YA-RAN, ZHENG XU-EBIN, DING CHUAN-XIAN . Fabrication and characterization of plasma-sprayed oxidation-resistant coatings. Thermal Spray Technology, 2011,3(3):1-9.
[7]	NIU YA-RAN, WANG HONG-YAN, LI HONG , et al. Dense ZrB₂-MoSi₂ composite coating fabricated by low pressure plasma spray (LPPS). Ceramics International, 2013,39(8):9773-9777. DOI URL
[8]	YAO DONG-JIA, LI HE-JUN, WU HENG , et al. Ablation resistance of ZrC/SiC gradient coating for SiC-coated carbon/carbon composites prepared by supersonic plasma spraying. Journal of the European Ceramic Society, 2016,36(15):3739-3746. DOI URL
[9]	JIA YU-JUN, LI HE-JUN, FU QIAN-GANG , et al. Ablation resistance of supersonic atmosphere plasma spraying ZrC coating doped with ZrO₂ for SiC-coated carbon/carbon composites. Corrosion Science, 2017,123:40-54. DOI URL
[10]	ARAUJO P, CHICOT D, STAIA M , et al. Residual stresses and adhesion of thermal spray coatings. Surface Engineering, 2013,21(1):35-40.
[11]	KURODA S, DENDO T, KITAHARA S . Quenching stress in plasma sprayed coatings and its correlation with the deposit microstructure. Journal of Thermal Spray Technology, 1995,4(1):75-84. DOI URL
[12]	WANG L, ZHONG X H, ZHAO Y X , et al. Design and optimization of coating structure for the thermal barrier coatings fabricated by atmospheric plasma spraying via finite element method. Journal of Asian Ceramic Societies, 2014(2):102-116.
[13]	LI YAN-PING, ZHAO WAN-HUA, LU BING-HENG . Prediction and control of residual stresses in thermal sprayed coatings. Engineering Mechanics, 2005,22(5):236-240.
[14]	GHAFOURHI-AZAR R, MOSTAGHIMIJ, CHANDRA S . Modeling development of residual stresses in thermal spray coatings. Computational Materials Science, 2006,35(1):13-26. DOI URL
[15]	YANG JIA-SHENG, YU JIAN-HUA, ZHONG XING-HUA , et al. Experimental and numerical investigation of residual stresses in plasma-sprayed thermal barrier coatings. Journal of Inorganic Materials, 2013,28(12):1381-1386.
[16]	BANSAL N P . Handbook of ceramic composites. Springer, 2006: 207.
[17]	YI FA-JUN, ZHANG WEI, MENG SONG-HE , et al. An experimental study on thermophysical properties of C/C composites at elevated temperature. Journal of Astronautics, 2002,23(5):85-88.
[18]	LI ZHAN-CHANG, JIA HONG-SHENG, MA HONG-AN , et al. FEM analysis on the effect of cobalt content on thermal residual stress in polycrystalline diamond compact (PDC). Science China: Physics, Mechanics&Astronomy, 2012(55):639-643.
[19]	LU PING, LIU ZUOMING . Mixed-mode of elastic modulus composites based on the α factor. Journal of Wuhan University of Technology, 2008,9(30):19-22.
[20]	ZHANG XIAN-CHENG, GONG JIAN-MING, TU SHAN-DONG , et al. The effect of coating size and material property on the residual stress in plasma spraying. Journal of Nanjing University of Technology, 2003,25(1):63-68.
[21]	徐少辉 . 等离子喷涂工艺参数对ZrB₂-SiC-ZrC涂层组织及结合强度的影响. 哈尔滨: 哈尔滨理工大学硕士学位论文, 2017,3:33.
[22]	NIU LI-PING, ZHANG TING-AN, SHI GUAN-YONG , et al. Residual stresses of plasma-spraying coating of thin-walled part. Journal of Northeastern University (Natural Science), 2011,32(10):1448-1451.
[23]	SINGH H, SIDHU B S, PURI D , et al. Use of plasma spray technology for deposition of high temperature oxidation/corrosion resistant coatings-a review. Mater. Corros., 2015,58(2):92-102.
[24]	SCHNEIBEL J H, RAWN C J, PAYZANT E A , et al. Controlling the thermal expansion anisotropy of Mo₅Si₃ and Ti₅Si₃ silicides. Intermetallics, 2014,12(7/8/9):845-850.
[25]	FEI XIAO-AI, NIU YA-RAN, JI HENG , et al. A comparative study of MoSi₂ coatings manufactured by atmospheric and vacuum plasma spray processes. Ceramics International, 2011(37):813-817.
[26]	张显程 . 面向再制造的等离子喷涂结构完整性及寿命预测基础研究. 上海: 上海交通大学博士学位论文, 2007,6:89-90.

等离子喷涂ZrC基涂层逐道逐层沉积残余应力模拟与实验验证

Residual Stresses of Plasma Sprayed ZrC-Based Coatings during Path-by-path and Layer-by-layer Deposition: Simulation and Experimental Verification

RichHTML

PDF (PC)

可视化

被引次数

摘要/Abstract

引用本文

使用本文

图/表 16

参考文献 26

相关文章 15

编辑推荐

Metrics

本文评价

[1]	潘洋洋, 梁波, 洪督, 祁志祥, 牛亚然, 郑学斌. TiAl合金表面TiAlCrY/YSZ涂层高温长时间服役性能[J]. 无机材料学报, 2023, 38(1): 105-112.
[2]	洪督, 牛亚然, 李红, 钟鑫, 郑学斌. 等离子喷涂TiC-Graphite复合涂层摩擦磨损性能[J]. 无机材料学报, 2022, 37(6): 643-650.
[3]	代钊,王铭,王双,李静,陈翔,汪大林,祝迎春. 氧化锆基微量元素共掺杂羟基磷灰石增韧涂层研究[J]. 无机材料学报, 2020, 35(2): 179-186.
[4]	范佳锋,张小锋,周克崧,刘敏,邓畅光,邓春明,牛少鹏,邓子谦. 镀铝改性对PS-PVD 7YSZ热障涂层抗CMAS腐蚀影响机制[J]. 无机材料学报, 2019, 34(9): 938-946.
[5]	周炎哲, 刘敏, 杨焜, 曾威, 宋进兵, 邓春明, 邓畅光. 大气等离子喷涂MoSi₂-30Al₂O₃电热涂层的组织结构及性能[J]. 无机材料学报, 2019, 34(6): 646-652.
[6]	陈书赢, 马国政, 何鹏飞, 刘喆, 刘明, 邢志国, 王海斗, 王海军. 基于粒子飞行特性及铺展行为的WC-10Co4Cr涂层孔隙形成机理研究[J]. 无机材料学报, 2018, 33(8): 895-902.
[7]	张小锋, 周克崧, 刘敏, 邓春明, 牛少鹏, 许世鸣. 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.
[8]	孙旭轩, 陈宏飞, 杨光, 刘斌, 高彦峰. YSZ-Ti₃AlC₂热障涂层及其高温自愈合行为[J]. 无机材料学报, 2017, 32(12): 1269-1274.
[9]	朱明康, 董显林, 陈莹, 丁国际, 王根水. 残余应力对SrRuO₃薄膜磁学及电输运性能的影响[J]. 无机材料学报, 2017, 32(1): 75-80.
[10]	于方丽, 白宇, 吴秀英, 王海军, 吴九汇. 等离子喷涂镍基可磨耗封严涂层抗腐蚀及耐磨性能分析[J]. 无机材料学报, 2016, 31(7): 687-693.
[11]	包亦望, 刘正权. 钢化玻璃自爆机理与自爆准则及其影响因素[J]. 无机材料学报, 2016, 31(4): 401-406.
[12]	毛金元, 刘敏, 毛杰, 邓春明, 曾德长, 徐林. 等离子喷涂制备ZrB₂-MoSi₂复合涂层及其抗氧化性能[J]. 无机材料学报, 2015, 30(3): 282-286.
[13]	张小锋, 周克崧, 宋进兵, 邓春明, 牛少鹏, 邓子谦. 等离子喷涂-物理气相沉积7YSZ热障涂层沉积机理及其CMAS腐蚀失效机制[J]. 无机材料学报, 2015, 30(3): 287-293.
[14]	陈丹, 王玉, 白宇, 王运会, 赵蕾, 付倩倩, 王海军, 韩志海. 等离子喷涂中雷诺数对熔滴扁平化行为的影响[J]. 无机材料学报, 2015, 30(1): 65-70.
[15]	易德亮, 吴成铁, 马旭兵, 季珩, 郑学斌, 常江. 真空和大气等离子喷涂镁黄长石生物活性涂层的对比研究[J]. 无机材料学报, 2014, 29(2): 172-178.