热障涂层的破坏机理与寿命预测

315201010CHINESEJOURNALOFSOLIDMECHANICSVol.31No.5October2010*周益春**刘奇星杨丽吴多锦毛卫国(,,,411105),.,,.,,,,,00.1,.,.,1000,,1[1,2].,,.(ThermalBarrierCoatings,TBCs),,,()1600,60%[3-7].,,1100-1600[8],700.:.,..2[3].1[2]Fig.1Developmentoflimitingtemperatureofgasturbineblade,,,.2,,(Substrate)(BondCoat,BC)(CeramicTopCoat,TC).,.(),,MCrAlY(MNiNiCo)PtAl,75-150m.,Y2O3ZrO2(YSZ),100-400m.***(10525211)(09JJ7004).30..Tel:[phone],E-mail:[e-mail].,,(ThermallyGrowthOxide,TGO),TGOAl2O3,TGO10m[3].2[3]Fig.2TurbinebladewithTBCsandcross-sectionofTBCsPadture[3]Science,.,,,,,[3].,,,.0.27-8wt.%Y2O3-ZrO2(7~8YSZ),,ZrO2;ZrO2,;,Y2O3,YSZ,ZrO2,,,.YSZ1200.,[9].,YSZ,[10-13].,:[14-19]..,MCrAlY,PtAl[3].,.0.3.,.,[8,20-29]:(1).2,,;(2).,,5055:.;(3).,,TGO;(4).,;(5).,.0.42070,NASAJ-75[30],,.,.,.,[31-35].XCr3+[36-48].,.:[28,49-58].1.,,[3].,,.1.1,.,..,,,,,.,()()[20,59-68].,,(TGO),[64,67].,,[20,59-67].Mao[68],,,,,.Ranjbar-Far[69],.TGO3.3,TBCBCTGO,TGO1m,286MPa-337MPa;TGO5m,511MPa-468MPa.BC,BC,TGO,BC.TBC,TGO,,,,TGO,TBC.506201031322,TGO(a)1m,(b)3m(c)5m[69]Fig.322intheTBCandBCwhenTGOthicknessis(a)1m,(b)3m(c)5m[69],,,,8-10m,,[70,71].,.1.2,[3,61,72-77]:,,,.,,,.4-5[3].,(APS)(EB-PVD),,.1.2.1APS4,APS4TBCs[3]Fig.4Schematicdiagramshowingthefailuremecha-nismsofAPSTBC,[3].(1):,,TGO,,/TGO.,3(a).(2):.,TGO/,,,TGO/.(3):5075:,.(4):TGO,TGO,TGO,TGO,,..3(c)[69].1.2.2EB-PVDEB-PVD,./TGOTGO/,[3],5.(1):/TGO,APS,EB-PVD.(2):TGO/,TGO,:TGO,;,;.(3):EB-PVD,,TGO.5TBC[3]Fig.5SchematicdiagramshowingthefailuremechanismsofEB-PVDTBC1.3,,,.,.1.3.1:(1),(TC)(BC)(Substrate).,(TGO).,[3].,10m,,2.(2).,,,.,[78],,()..1.3.2:(1),,.[61,72,79].:=E1-T(1),T(),,E.,,,.(2)[22-24,80-83].,5082010311600,,.,,.EB-PVD,.,.,[22-24,82,83].ZrO2,,.,,ZrO2.,,,.1.3.3,.(1)--[84].Gibbs,,--.,Gibbs:g=U-T+a=+,-aca(2),gGibbs,U,,T,,c,a,(+),(-),a.(2),,.Gibbs,:ij=gij,=-gT,=gc(3)ij,ij.,:cijkl=2gijkl,Rij=-2gijc,=-2gTc=-2gT2,ij=-2gijT,s=2gcc(4),cijkl,Raij-,a-.aC/(2T0),,C,ij-,sa.,--:ij=cijklij-ijT-a=+,-Raijca(5)=ijij+T+a=+,-aca(6)a=-Raklkl-aT+saca(7)(2)[24,85,86]:,,,,Na,S,P,V,,Na2SO4,.ZrO2,Y2O3MgO.Y2O3MgOZrO2:Y2O3+3SO32Y3++3SO2-4(8)MgO+SO3MgSO4(9)VP,,:Y2O3+V2O52YVO4(10)Y2O3+P2O52YPO4(11)ZrO2,ZrO2,,.(3)[25-29].,.,.,,.[25][26]APSEB-PVDTBCs,Al2O35095:.,,..APS,538,.,[25].(4)[25,87,88].,,..,,6-7[87].6,,,.,/,,,,.,,/,7.6[87]Fig.6Schematicdiagramofforeignobjectdamage7[87]Fig.7Coatingdelaminationcausedbyforeignobjectdamage1.3.4.(1).,...;[89].Schmidt[90]510201031,,,.Pindera[91]Hernandez[92],:,.[93]NiCoCrAlYYSZ,,,.,.(2).[94-97]....Zhou[94],..(3).TGO[61,73,98-101].,O.,AlO,-Al2O3,,,.,,10m.TGO,3[69],TGO1m5m,2.TGO,,TGO.,,.TGO,.2.,,,,,,,(),,.,,,.2.1,,...HutchinsonEvans[102,103].[31,32,102,103].,.2.1.1,AnstisLawn[33]:KIC=KI=EH1/2Pc3/2(12)P,EH,,=0.0160.004,c.Lawn[34]:Pc3/2=KIC-(4/)rt1/2+2trc-1/2(13)5115:=(E/H)1/2,P/c3/2,c-1/2,2tr/(),KIC-(4/)rt1/2/.P,P/c3/2c-1/2,,,KICr.Lesage[35](12),:KIC=EH1/2iPc3/2(14)(E/H)i.,,:EH1/2i=(E/H)1/2C1+(HC/HS)1/2+(E/H)1/2S1+(HS/HC)1/2(15)SC.2.1.2,,,,,15%NaOH()80.8...8Fig.8Theschemeofinterfacefracturetough-nessmeasurementusingbubblemethodSuo,HutchinsonZhou[30,103],:KIC=m2-Nr|r=aAhcos+Mr|r=aIh3sin(+r)KIIC=m2-Nr|r=aAhcos-Mr|r=aIh3sin(+r)(16):Nr|r=a=23k22hMr|r=a=m/(2k22)kI0(k)/I1(k)-2h2C01NrMrr=a.,,:=tan-1sin-cos(+)cos+sin(+)(17):m=(1-)/(1-2),=IA(Nr|r=a)hMr|r=aDundurs,:=(2+1)-(1+1)(2+1)+(1+1)=(2-1)-(1-1)(2+1)+(1+1)=12A=11+(4+62+33),I=112(1+3)sin=62(1+)AI,=1+1-=h/a,,,.(16)(17)[30][103].2.2,.:,:TGO[36,37];TGO[38-41].,512201031,,[42-45][48].2.2.1XRamanCr3+[36,37].Cr3+ZrO2,.,:,,.,,,,.8YSZ(8wt.%Y2O3-ZrO2),640cm-1[37],:=uu(18)(cm-1),u(Piezo-spectroscopicCoefficient,PSC),u.8YSZ,(18)u.,Mao8YSZuN[37]:u=37.6exp(-N/25.9)+13.0(19),X.2.2.2(Impedancespectroscopy,IS)TGO,,TGO.,Song[38]Zhang[39]Yang[40]TGOTGOTGO.,,,,12601296,.,,.(9(a))[38-40],,TGO,,TGO.10(a)[38-40].(9(b))[41],,TGO9(a),(b)Fig.9Themicrostructureof(a)EB-PVD,(b)APSthermalbarriercoatingsafteroxidation5135:10(a),(b)Fig.10Theequivalentcircuitmodelfor(a)EB-PVD,(b)APSthermalbarriercoatings,,,,,,10(b)[41].RS,CTMTGO(:NiO,CoO,Cr2O3,Ni(Cr,Al)2O4Al2O3).ZCPE(CPE),,[39,41].11TGOFig.11RelationshipbetweentheresistanceandthevolumefractionofTGOinthebondcoat11TGOTGO,,TGOTGO.TGO10%(100h),TGO,TGO,NiCrAlYTGO,TGO.,TGO,.(2000h),TGOTGO[38,41].2.2.3,.,,.,.,Ma[42],Yang[43];Rudolphi[44],12,,,,;32,,15,,,,.51420103112[44]Fig.12Thefailureprocessandacousticemissioncharacteristicofthermalbarriercoatings,..,TBCs,:(1),;(2),;(3).,TBCs,,,.,TBCs,.,,db8,5,,[45].(),13.,,,,,,.,,.13Fig.13Thedistributionofacousticemissionsignalsin-ducedbydifferentfailuremodesversustimeanditsstress-strainbehaviorduringthetensiletestofthermalbarriercoatings,,,,:N=Atk+B(20)5155:N,t,Ak.t,(20)t,(20):N=ak+B(21):(1);(2),;(3)[45],,.(4).14,,.14Fig.14Thespatio-temporalsourcedistributionofacousticemissionsignalstriggeredbysurfaceverticalandinterfacecrackinginthermalbarriercoatings,TBCs,.?,,,:?,,[46,47],,,.80,,[46].,()(),[47].TBCs,,,TBCs.2.2.4,.,.,,,.,.,.15[48],(CO2),1,,2,21,.,[104][105].,,.,Padture51620103115Fig.15Experimentalschemeofthermalpropertiesmeas-urementusingthermalwaveimagetechniqueHutchinsonScience22(20088):[3,106].,,,:(1);(2);