Low-Pressure Plasma-Induced Physical Vapor Deposition of Advanced Thermal Barrier Coatings: Microstructures, Modelling and Mechanisms
Low-Pressure Plasma-Induced Physical Vapor Deposition of Advanced Thermal Barrier Coatings: Microstructures, Modelling and Mechanisms
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DOI：
10.1016/j.mtphys.2021.100481
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发表时间：
2021-07
影响因子：
11.5
通讯作者：
Sen-Hui Liu;J. Trelles;A. Murphy;Wenting He;Jia Shi;Shan Li;C. Li;Cheng-Xin Li;Hongbo Guo-Hongbo
中科院分区：
文献类型：
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作者：
Sen-Hui Liu;J. Trelles;A. Murphy;Wenting He;Jia Shi;Shan Li;C. Li;Cheng-Xin Li;Hongbo Guo-Hongbo
用来保护飞机和燃气轮机叶片的热障涂层主要是陶瓷涂层，由于采用了沉积方法，例如等离子喷涂，所以具有独特的微观结构。在过去的十年中，低压(50-200Pa)等离子喷涂-物理气相沉积(PS-PVD)被认为是在燃气轮机或航空发动机上获得高温性能先进的热障涂层的一种有前途的方法。然而，在温度大于12000℃、速度大于6000m/S的超声速(米级)多相(微米或纳米级)超声速超声速流场中的实验测量和数值模拟仍然存在挑战。由于超音速流动、漩涡流动、相变和激波的复杂相互作用，对封闭腔内的等离子体喷雾流动和传热传质的了解还不够充分。本文综述了利用PS-PVD制备热障陶瓷涂层的技术现状。通过计算流体力学模拟和实验，研究了不同腔压下陶瓷纳米团聚粉末低压等离子喷涂过程中的多相流动特性。论证了入射粒子的自遮蔽效应和低压等离子体羽流对衬底的传热传质强化作用。阐明了等离子体射流激波引起的陶瓷液滴的闪蒸和雾化现象。研究了低压等离子喷涂添加剂制备过程中准柱状陶瓷涂层的形成、作用及控制。最后，本文对本课题的未来进行了展望和存在的突出问题。
Thermal barrier coatings used to protect the blades of aircraft and gas turbine engines are primarily ceramic coatings with unique microstructures result of the deposition method used., for example, plasma spraying. Over the last decade, low-pressure (50–200 Pa) plasma spray - physical vapor deposition (PS - PVD) has been recognized as a promising method for obtaining advanced high-temperature performance thermal barrier coatings on gas turbines or aircraft engines. However, challenges still exist in experimental measurements and numerical modeling inside very large supersonic fluid fields (at the meter scale) with multiple phases (at micron- or nano-scale) at temperatures over 12000 K and velocities of over 6000 m/s. The plasma spray flow and heat and mass transfer in a closed chamber are not fully understood owing to the complicated interaction of the supersonic flow, swirling flow, phase transition and shock waves. This paper reviews the current state of technology in thermal barrier ceramic coatings obtained using PS-PVD. The multiphase flow characteristics during low-pressure plasma spraying using ceramic nano-agglomerated powders at different chamber pressures are studied via computational fluid dynamics modelling and experiment. The self-shadowing effect of impinging particles and the intensification of heat and mass transfer from the low-pressure plasma plume to the substrate are demonstrated. The flash vaporization and atomization of the ceramic droplets induced by the plasma jet shock waves are clarified. The formation, effects and control of quasi-columnar ceramic coatings in the additive manufacturing process of low-pressure plasma spraying are studied. Finally, this paper concludes with the future outlook and outstanding problems in this topic.