Thermal spraying of thick film systems - process optimization by means of residual stress and residual stress stability

厚膜系统热喷涂 - 通过残余应力和残余应力稳定性优化工艺

• 批准号: 230530734
• 负责人: Dr.-Ing. Jens Gibmeier
• 金额: --
• 依托单位: Institut für Angewandte Materialien - Werkstoffkunde (IAM-WK)
• 依托单位国家: 德国
• 项目类别: Research Grants
• 财政年份: 2013
• 资助国家: 德国
• 起止时间: 2012-12-31 至 2018-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/230530734?language=en
• 关键词: Thermal; spraying; thick; film; systems

The residual stress (RS) distribution in coating systems in particular atthe interfaces is essential for the fatigue and failure behavior ofcoated components. The RS distribution induced by the coatingprocess can be optimized to fit the technical requirements of thecomponents by adapting the coating parameters. Within the scope ofthe first funding period of the research project a practicable measuringand evaluation strategy based on the incremental hole drilling methodfor analysis of local residual stress depth distributions for thick filmsystems was developed and provided. Subsequently, this methodicalapproach was successfully applied to thermally sprayed YSZ thermalbarrier coatings and MCF chromium vapor protective layers for solidoxide fuel cell (SOFC) applications. In the course of the continuationof the research project the measuring and evaluation strategy will beadapted and extended (a) to functional graded materials (FGM) and(b) to cold sprayed materials. In the following, the residual stressresults will be used for adjustment of the coating process parameters.For the FGM tungsten containing layers will be deposited onEUROFER steel substrates, while the tungsten content will begradually increased by the supply of the powder mixtures until puretungsten will be achieved for the top layer. Possible applications ofsuch FGM layers are e.g. materials for application in fusion reactors,where tungsten is used as protective coating of the ferritic-martensiticEURPOFER steel. Here, knowledge about residual stresses isessential for the assessment of the mechanical integrity and the lifetimeof layered components. A further application that will be analyzedusing the same analysis probe is on cold sprayed layers, which will beused for the repair of localized damaged high temperature parts (e.g.turbine blades). First successful preliminary test were performed forcold prayed nickel-base substrates. For the repair of localizeddamaged components knowledge about the residual stressdistribution induced by the repair process is of crucial importance.Application of the incremental hole drilling method can directly beapplied at the thermally sprayed component. Furthermore, in additionto residual stress analyses on thermal sprayed YSZ-coatingsperformed in the first funding period data of neutronographicdiffraction analyses, which are already carried out at the instrumentStressSpec at FRM II (Garching), will be evaluated. Based on thisevaluation a holistic assessment of the residual stress results will bemade. Since, so called ´through-surface-scans´ were performed, thedata evaluation is very elaborate und requires inter alia the correctionof surface effects which occur at the very surface as well as at theinterfaces of the layered structure.

涂层系统中的残余应力（RS）分布，特别是界面处的残余应力分布，对涂层构件的疲劳和失效行为至关重要。通过调整镀膜工艺参数，可以优化镀膜过程引起的RS分布，使其符合组件的技术要求。在研究项目的第一个资助期的范围内，开发并提供了一种基于增量钻孔法的实用测量和评估策略，用于分析厚膜系统的局部残余应力深度分布.随后，这种methodicalapproach成功地应用于热喷涂YSZ热障涂层和MCF铬蒸气保护层的固体氧化物燃料电池（SOFC）的应用。在研究项目的继续过程中，测量和评估策略将被调整和扩展（a）到功能梯度材料（FGM）和（B）到冷喷涂材料。在下文中，残余应力结果将用于调整涂层工艺参数。对于FGM，含钨涂层将沉积在EUROFER钢基体上，同时钨含量将通过供应粉末混合物逐渐增加，直到顶层达到纯钨。这种FGM层的可能应用是例如用于聚变反应堆的材料，其中钨用作铁素体-马氏体EURPOFER钢的保护涂层。在这里，关于残余应力的知识对于评估分层部件的机械完整性和寿命是必不可少的。使用相同的分析探头进行分析的另一个应用是冷喷涂层，用于修复局部受损的高温部件（例如涡轮机叶片）。首次成功地对冷喷涂镍基基板进行了初步试验。对于局部损伤构件的修复，了解修复过程中残余应力的分布是至关重要的，采用增量钻孔法可以直接应用于热喷涂构件.此外，除了在第一个资助期内对热喷涂YSZ涂层进行的残余应力分析外，还将对已经在FRM II（Garching）的仪器StressSpec上进行的中子衍射分析数据进行评估。在此基础上，对残余应力结果进行整体评估.由于进行了所谓的“穿透表面扫描”，因此数据评估非常复杂，阿利亚需要校正在层状结构的表面以及界面处发生的表面效应。

项目成果

Investigations on the Initial Stress Evolution During Atmospheric Plasma Spraying of YSZ by In Situ Curvature Measurement

• DOI: 10.1007/s11666-016-0398-4
• 发表时间: 2016-03
• 期刊: Journal of Thermal Spray Technology
• 影响因子: 3.1
• 作者: M. Mutter;G. Mauer;R. Mücke;R. Vaßen;H. C. Back;J. Gibmeier

Systematic Investigation on the Influence of Spray Parameters on the Mechanical Properties of Atmospheric Plasma-Sprayed YSZ Coatings

• DOI: 10.1007/s11666-018-0697-z
• 发表时间: 2018-04
• 期刊: Journal of Thermal Spray Technology
• 影响因子: 3.1
• 作者: M. Mutter;G. Mauer;R. Mücke;O. Guillon;R. Vaßen

Vacuum plasma spraying of functionally graded tungsten/EUROFER97 coatings for fusion applications

• DOI: 10.1016/j.fusengdes.2018.06.006
• 发表时间: 2018-08
• 期刊: Fusion Engineering and Design
• 影响因子: 1.7
• 作者: R. Vaßen;Karl-Heinz Rauwald;O. Guillon;J. Aktaa;T. Weber;H. C. Back;D. Qu;J. Gibmeier

Study of stability of microstructure and residual strain after thermal loading of plasma sprayed YSZ by through surface neutron scanning

• DOI: 10.1016/j.physb.2017.12.014
• 发表时间: 2017-12
• 期刊: Physica B: Condensed Matter
• 作者: J. Gibmeier;H. C. Back;M. Mutter;F. Vollert;J. Rebelo-Kornmeier;R. Mücke;R. Vaßen

Application of the Incremental Hole-Drilling Method on Thick Film Systems—An Approximate Evaluation Approach

渐进式钻孔方法在厚膜系统上的应用——一种近似评估方法

• DOI: 10.1007/s11340-014-9962-3
• 发表时间: 2015
• 期刊: Experimental Mechanics
• 影响因子: 2.4
• 作者: E. Held;J. Gibmeier
• 通讯作者: J. Gibmeier