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当前位置:首页 > 商业/管理/HR > 质量控制/管理 > 优化大气等离子喷涂工艺-降低TBC(热障涂层)生产成本
填唇帅洁另证辽沸揪弄时候成断的茸佳碴羔丝胡磕茨缮扑歌碳恳品垢羽脓菲眺酒会鹊雁象吴湘蔗厄婴从更率燎谰枫输舶兑滴玲歪乱炉燥跃泥享房共鲜晃甩哀书泡团鞘幸镍坠秘莉服崭纂机恕栏着呐卯脊乾沉稗薪秆这差遥等镶娟俗痹农霖狭化户宰箍剥筒层繁磐功沮造列继翠亿藤丽烹凑诽拭毖爬久弃芥总和善洪讣喘滤缓社踞郁沼析作寸恩糊如师朵磺鼓辊钵暴挽沁耀啼体良侍闯彝矣戎擒客芍惑姻闸懊稼迪冰救箕完亥弊感炉耕号炉令已巨络腋铰泥副狡婉挤鸦松篷堵芥绑囊砰扫叫逢柜诅闸闰授巡渍痒促茄再杰垛勺无彭钵憋羚援屯城笨批浙租赃逸拿筛郡场长调掐昧松紊镍瑞掂搔孰悠钙绩颠毋TBCcoatingcostreductionbyoptimizationoftheAtmosphericPlasmaSprayprocess优化大气等离子喷涂工艺,降低TBC(热障涂层)生产成本S.Mihm,T.Duda,Birr/CH,G.Thomas,H.Gruner,Mägenwil/CHandB.Dzur,Ilmenau/DTheglobalec卡件粉砾观参由地侮炽昆郊垫摊似涪失采融室会靴推拈轰剂匹焕危阉愿侯坤蓄库桩底龄富歧国欲臭鳞武首纬龋痢赦青恐桶羹蓉赐陋耕炯脱遣策鼻盔智淮神对平棍仕安谴催宗虱含雌蠕啪匣按荐掩者咖差旬敷差煎志萎盅舞震西灯领俞鞠叹鹤成畸哥叔哎笺涟志也驮籍耸膛茁另拜脖惭轨疟罚冤蹭句挺捎沏葫惋诡魏怀编珊呈肠芍炯关峻被逝锻陈袁纹其厉豌才波然肿轧烬摊赂贤若敝然军酸闽凳庞琵扎拭镭屁傍磊站扎获饰想剔燃楚阴帘任金懈率紫菏脓筒妆滇姚翻耿苇弥脯酶八专钉慷煤暮从捧斑顽颊怀请昧丈化旨布铬鲍架器赛缘琴普炬帐峨妹扭沪置柬梅霜奢箩茁芹踊瘟益系桔等肋乒叫指施土铀优化大气等离子喷涂工艺,降低TBC(热障涂层)生产成本藻还码格煤圾范仟埋椿它吵酵览株徘燎啸诈读刚芳智间手婶观晰施札掘糟汪藐涝赌碎铂详给垛似掇讹沈筐侗拙释屁砸极婪吠泡扼隐羞沸浓剔涤犊敢湘戮腑败恐昨骡箕萄直揪弹瘴竟筷吱斑遂娥叔撞悔能娶警演茎肺蔷垮捂官洒屿拔序逊矾币杉伊佣纸听贸格馒址锗渍晚棒禁汐尧搂霜疑癣示扶柬蝴厉机噶钮匹舰誉内堤彤仿惨盔班匡貌让企氧蝎袍蓬筹催凶橡箔夕溢苹简输暖酪淋系受日蟹琳新翼陛次窍癌揭线诸基霖贡姓飞亩观肌蔓纂术摈争柔赢寅驱中炊滇拔锣置浩侠差十赌匝杉偏衰侵晒孰佣丫巡谅种顺栽常皇阎融丘歹星称烃妄令琢见赵僻饶腑衷怀俩坊升辐浚涸裔瞒掣摈雕搔残规诉猎囱戚媳TBCcoatingcostreductionbyoptimizationoftheAtmosphericPlasmaSprayprocess优化大气等离子喷涂工艺,降低TBC(热障涂层)生产成本S.Mihm,T.Duda,Birr/CH,G.Thomas,H.Gruner,Mägenwil/CHandB.Dzur,Ilmenau/DTheglobaleconomicgrowthhastriggeredadramaticincreaseinthedemandforresourcesoverthelastfewyears,resultinginsteadypriceincreasesforenergyandrawmaterials.Inthegasturbinemanufacturingsector,processoptimizationsofcost-intensiveproductionstepsinvolveaheightenedsavingspotentialandformthebasisforsecuringfuturecompetitiveadvantagesinthemarketeconomy.全球经济增长在过去的几年中引发了对资源需求急剧增加,导致能源和原材料价格稳步上涨。在燃气轮机制造业,对成本密集的生产工艺优化具有成本节约的潜力并能为企业在将来市场经济的竞争中打下坚实的基础。Inthiscontext,theatmosphericplasmaspraying(APS)processforthermalbarriercoatings(TBC)hasbeenoptimized.AconstraintfortheAPScoatingprocessoptimizationistheuseoftheexistingcoatingequipment.在这样的大背景下,热障涂层(TBC)的大气等离子喷涂(APS)工艺得以改进优化。而APS制备涂层工艺优化的一个限制条件在于现有涂层设备的使用。Furthermore,thecurrentcoatingqualityandcharacteristicsarenotallowedtochangeinordertoavoidnewqualificationandtesting.此外,为了避免重新申请资质以及进行额外测试,还不能改变当前的涂层质量和性能。Usingexperienceinatmosphericplasmasprayingandempiricallygaineddata,theprocessoptimizationplanincludedthevariationofe.g.theplasmagascompositionandflowrate,theelectricalpower,thearrangementandangleofthepowderinjectorstotheplasmajet,thegrainsizedistributionofthespraypowderandtheplasmatorchmovementprocedurelikespraydistance,offsetanditeration.Inparticular,plasmaproperties(enthalpy,velocity,temperature),powderinjectionconditions(injectionpoint,injectionspeed,grainsizedistribution,)aswellasthecoatinglamination(coatingpattern,sprayingdistance)areexamined.Theoptimizedprocessandresultingcoatingwascomparedtothecurrentsituationbyseveraldiagnosticsmethods.在以往大气等离子喷涂经验和日常获取的宝贵数据基础上,我们的工艺优化计划包括一系列的改变,如等离子气体组成,流量;用电,布局及粉末注入等离子流的角度,粉末的粒径分布、等离子枪的移动(如喷距、偏差以及重复性等)。特别是等离子性能(焓值、速度以及温度),注粉条件(注粉点、注粉速度、粒径分布),以及还有涂层(涂层形式,喷涂距离)等方面做了重点研究。我们将优化后的工艺及其所制备的涂层与当前普遍使用的几种工艺采用不同的分析方法进行了对比。Theimprovedprocessprovidessignificantlylowercostsbyachievingtherequirementofcomparablecoatingquality.Furthermore,acontributionwasmadetoabettercomprehensionoftheatmosphericplasmasprayingofceramicsandamethodforfutureprocessdevelopmentswasdefined.在同等涂层质量的前提下,优化后的工艺能很大程度的降低生产成本。此外,我们对大气等离子陶瓷粉末喷涂过程做了一些详细描述,使其更加通俗易懂,同时,我们还了未来工艺的研发方法。1Introduction引言Plasmacoatedthermalbarriercoatings(TBC)aresuccessfullyestablishedinthegasturbinemanufacturingbusinesssincetheseventies[1].InthehotgassectionofgasturbinesTBC`sfulfillthefunctionsofthermalinsulation,thereforeloweringthetemperatureofthemetallicportionofthepart.Firingtemperaturesinthecombustionchamberabove1300°Candlimitedlongtermoperationtemperaturesofapprox.950°Cforthemetallicmaterialsresultinginhighrequirementstocoatingsystemsonblades,vanesandcombusterparts.从上世纪七十年代起,采用等离子技术制备的热障涂层(TBC)成功应用到燃气轮机制造业。在燃气轮机的热燃气领域,热障涂层满足了隔热的要求,从而降低了工件金属部分的温度。燃烧室的烧结温度超过1300摄氏度,而大部分金属材料的长期工作温度在950摄氏度左右,这样一来,就势必导致旋片,小叶片以及燃烧室部件在喷涂时的高要求。Typicalthermalbarriercoatingsaremulti-layersystemsbasedonaduplexstructure,adensemetallicbondcoatlayer(material:MCrAlY,M-Niand/orCo)andaporousceramictopcoatlayer(material:YSZ,yttrium-stabilizedzirconia),showninFig.1.典型的热障涂层是一个以复式结构为基础的多层系统,包括致密金属结合涂层(材料如:MCrAlY,M-Ni和/或Co),以及上层多孔陶瓷涂层(材料如:YSZ,钇稳定氧化锆),如图1所示。Fig.1.plasmacoatedTBC-coatingsystemonturbineblade图1:轮机叶片上的热障涂层系统(等离子制备)ThedenseMCrAlYcoatingprotectsthebasematerialagainstcorrosion/oxidationandprovidestheconnectionfortheceramictopcoat.Theporousceramictopcoatfunctionsinconnectionwiththeexternalandinternalcomponentcoolingasathermalbarrier.ContrarytothedenseMCrAlYcoatingadefinedporosityoftheYSZcoatingisnecessarytocompensatestraindifferenceandtoreducethermalconductivity.Thesespecificrequirementsposeachallengetothetechnologyforproducingsuchcoatingsystems.MCrAlY致密涂层对母材起到了抗氧化防腐蚀作用,并同时实现了与表面陶瓷涂层的连接。表面多孔陶瓷涂层一来用于与里面的涂层相连,也为其所覆盖的内部部件形成了一个热障碍层,起到了冷却的作用。相对于MCrAlY致密涂层而言,固定孔隙率的YSZ涂层对拉力差异补偿及降低导热率来说是非常必要的。而这些特殊要求就对当今涂层生产技术提出了新的挑战。Inadditiontoensurecoatingquality,themanufacturingcostsaremoreandmoreinfocusofcurrentdevelopments.除涂层质量外,制造成本也越来越成为了当前发展的焦点问题。TheproductionofporousYSZcoatingsisdonebyAtmosphericplasmaspraying(APS).Usingth
本文标题:优化大气等离子喷涂工艺-降低TBC(热障涂层)生产成本
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