The adhesive strength in a coating-substrate system is of primary importance for the coating lifetime in service.However,the underlying mechanism is not fully understood due to the complex internal structure of compos...The adhesive strength in a coating-substrate system is of primary importance for the coating lifetime in service.However,the underlying mechanism is not fully understood due to the complex internal structure of composite coatings.In this study,the effect of substrate roughness on the adhesive strength of WCCo coatings was investigated by experiment and simulation.Results show that the adhesive strength is significantly affected by the roughness.In the case of the Ra<2μm,the adhesive strength is approximately 35–46 MPa.When the Ra is 4μm,the adhesive strength increases to nearly 60 MPa.A finite element model was developed to correlate the roughness with adhesive strength.It is found that the predicted values are well consistent with the experimental data.In addition,with the increase of the roughness,the residual stress would be changed from concentrated state to widespread state,which decreases the critical stress to result in crack propagation.That’s why a larger roughness can cause a higher adhesive strength.This study gives understanding on the mechanism of adhesive strength affected by roughness,which contributes to the parameter optimization with better performance.展开更多
To gain high efficiency and low fuel consumption, aluminum-based abradable seal coatings had been widely used in the compressor casing of aero engines or gas turbines owing to the low elastic modulus. However, the adh...To gain high efficiency and low fuel consumption, aluminum-based abradable seal coatings had been widely used in the compressor casing of aero engines or gas turbines owing to the low elastic modulus. However, the adhesive transfer phenomenon frequently occurs when the radial rubbing generates between titanium alloy blade tips and aluminum-based coating. It tends to increase scratch force and results in blades vibration and even engine jam. To eliminate this problem, a new lightweight epoxy-based abradable seal coating with high bonding strength was developed by an effective and porosity controllable mixing process that distributes spherical pores uniformly in the continuous matrix. A lightweight coating of 63% porosity with a hardness of 33.1(HR15 Y) can be reached when the content of hollow microspheres is 31 wt.%. The coating density is 0.5 g/cm3 and the bonding strength is as high as 18 MPa.The performance of the epoxy-based coating is comprehensively better than aluminum-based coatings in five essential indices. This study is expected to provide a new technical path for obtaining high-quality abradable seal coatings to guarantee the efficient and safe operation of compressors.展开更多
Plasma spray–physical vapor deposition(PS–PVD)is a unique technology that enables highly tailorable functional films and coatings with various rare metal elements to be processed.This technology bridges the gap betw...Plasma spray–physical vapor deposition(PS–PVD)is a unique technology that enables highly tailorable functional films and coatings with various rare metal elements to be processed.This technology bridges the gap between conventional thermal spray and vapor deposition and provides a variety of coating microstructures composed of vapor,liquid,and solid deposition units.The PS–PVD technique serves a broad range of applications in the fields of thermal barrier coatings(TBCs),environmental barrier coatings(EBCs),oxygen permeable films,and electrode films.It also represents the development direction of high-performance TBC/EBC preparation technologies.With the PS–PVD technique,the composition of the deposition unit determines the microstructure of the coating and its performance.When coating materials are injected into a nozzle and transported into the plasma jet,the deposition unit generated by a coating material is affected by the plasma jet characteristics.However,there is no direct in situ measurement method of material transfer and deposition processes in the PS–PVD plasma jet,because of the extreme conditions of PS–PVD such as a low operating pressure of*100 Pa,temperatures of thousands of degrees,and a thin and high-velocity jet.Despite the difficulties,the transport and transformation behaviors of the deposition units were also researched by optical emission spectroscopy,observation of the coating microstructure and other methods.This paper reviews the progress of PS–PVD technologies considering the preparation of advanced thermal barrier coatings from the perspective of the transport and transformation behaviors of the deposition units.The development prospects of new high-performance TBCs using the PS–PVD technique are also discussed.展开更多
Advanced thermal harrier coatings （TBCs） with better thermal barrier performance are required by both advanced gas turbine and air engine. In this work, novel bimodal TBCs with low thermal conductivity were deposite...Advanced thermal harrier coatings （TBCs） with better thermal barrier performance are required by both advanced gas turbine and air engine. In this work, novel bimodal TBCs with low thermal conductivity were deposited and characterized by a novel co-spray approach with both solid powder and suspension. Experimental and finite element analyses were used to optimize the process parameters to prepare the specific morphology nanostructure features. With a comprehensive understanding on the influence of spraying parameters on the morphology ofnano-particles, homogeneous nano-particle heaps with a large aspect ratio were introduced to conventional layered coatings by plasma co-spraying with suspension and solid powder. Co-sprayed bimodal microstructure composite coatings resulted from both wet suspension droplets and molten particle droplets exhibited low thermal conductivity. The thermal conductivity of the composite coating was 1/5 lower than that of the counterpart coatings by conventional plasma spraying with solid powder. This study sheds light to the structural tailoring towards the advanced TBCs with low thermal conductivity.展开更多
Thermal barrier coatings (TBCs) enable the hot section part to work at high temperatures owing to their thermal barrier effect on the base metal components. However, localized spallation in the ceramic top-coat might ...Thermal barrier coatings (TBCs) enable the hot section part to work at high temperatures owing to their thermal barrier effect on the base metal components. However, localized spallation in the ceramic top-coat might occur after long duration of thermal exposure or thermal cycling. To comprehensively understand the damage of the top-coat on the overall hot section part, effects of diameter and tilt angle of the spallation on the temperature redistribution of the substrate and the top-coat were investigated. The results show that the spallation diameter and tilt angle both have a significant effect on the temperature redistribution of the top-coat and the substrate. In the case of the substrate, the maximum temperature increment is located at the spallation center. Meanwhile, the surface (depth) maximum temperature increment, having nothing to do with the tilt angle, increases with the increase of the spallation diameter. In contrast, in the case of the top-coat, the maximum temperature increment was located at the sharp corner of the spallation area, and the surface (depth) maximum temperature increment increases with the increase of both the spallation diameter and the tilt angle. Based on the temperature redistribution of the substrate and the top-coat affected by the partial spallation, it is possible to evaluate the damage effect of spalled areas on the thermal capability of TBCs.展开更多
Large degradation in thermal insulation and strain tolerance is a main headache and a primary cause of the failure for plasma-sprayed thermal barrier coatings(TBCs)during service.One mechanism behind such degradation ...Large degradation in thermal insulation and strain tolerance is a main headache and a primary cause of the failure for plasma-sprayed thermal barrier coatings(TBCs)during service.One mechanism behind such degradation is the healing of interlamellar pores formed by multiple connections between edges of a pore,which significantly speeds up healing during thermal exposure.The objective of this study is to obtain sintering-resistant TBCs by tailoring the width of interlamellar pores to avoid multiple connections.Firstly,the mechanism responsible for the multiple connections was revealed.The splat surfaces before and after thermal treatments were characterized via an atomic force microscope(AFM).The roughening of the pore surface occurs during thermal exposure,along with the grain growth inside the splats.Consequently,the local surface height increases,which causes multiple connections and healing of the interlamellar pores.Secondly,critical widths of the interlamellar pores for avoiding the multiple connections during thermal exposure are established by correlating the extent of surface roughening with the growth of individual grains.The height increase of the splat surface and the growth of the grain size(D)were found to increase with the exposure temperature and duration.A relationship linking the height increase and the growth of the grain size induced by thermal exposure in plasma-sprayed ceramic splats was obtained.Finally,composite TBCs were prepared to form wide interlamellar pores in the coatings.Using this design,the increases in the thermal conductivity(λ)and the elastic modulus(E)can be prevented to a large extent.Thus,sintering-resistant TBCs that maintain high thermal insulation and strain tolerance,even afer long thermal exposure,can be created.展开更多
Double-layered thermal barrier coatings(DL-TBCs)have been developed to meet multiple service requirements,such as low thermal conductivity,high thermal stability,and high fracture toughness.Conventional DL-TBCs are of...Double-layered thermal barrier coatings(DL-TBCs)have been developed to meet multiple service requirements,such as low thermal conductivity,high thermal stability,and high fracture toughness.Conventional DL-TBCs are often designed on the basis of equal total thickness to have long lifespans,which may weaken the thermal insulation.The reason is that the single-scale designed structure often has opposite effects on the thermal and mechanical properties.To enhance both the thermal insulation and lifespan,this work designed durable DL-TBCs at multiple scales under equivalent thermal insulation.The macroscopic thickness ratio of the top layer to the bottom layer was tailored to optimize the total and single thicknesses,and the microscopic pore size in the top layer was tailored to resist sintering.Six groups of samples with different thickness ratios were prepared.The thermal cycling test revealed that the lifespan of DL-TBCs first increases but then decreases with increasing thickness ratio.The optimized thickness ratio is 2:3 for DL-TBCs,which have the largest lifespan among the six groups.The cross-sectional morphologies revealed that the failure mode changed from the spallation of the top layer to the delamination of the total double layers.The long lifespan of the optimized DL-TBCs stems from the cotailored thickness ratio and porous structure in the top layer to lower the total cracking driving force.展开更多
Thermal barrier coatings(TBCs)can effectively protect the alloy substrate of hot components in aeroengines or land-based gas turbines by the thermal insulation and corrosion/erosion resistance of the ceramic top coat....Thermal barrier coatings(TBCs)can effectively protect the alloy substrate of hot components in aeroengines or land-based gas turbines by the thermal insulation and corrosion/erosion resistance of the ceramic top coat.However,the continuous pursuit of a higher operating temperature leads to degradation,delamination,and premature failure of the top coat.Both new ceramic materials and new coating structures must be developed to meet the demand for future advanced TBC systems.In this paper,the latest progress of some new ceramic materials is first reviewed.Then,a comprehensive spalling mechanism of the ceramic top coat is summarized to understand the dependence of lifetime on various factors such as oxidation scale growth,ceramic sintering,erosion,and calcium–magnesium–aluminium–silicate(CMAS)molten salt corrosion.Finally,new structural design methods for high-performance TBCs are discussed from the perspectives of lamellar,columnar,and nanostructure inclusions.The latest developments of ceramic top coat will be presented in terms of material selection,structural design,and failure mechanism,and the comprehensive guidance will be provided for the development of next-generation advanced TBCs with higher temperature resistance,better thermal insulation,and longer lifetime.展开更多
Genomic in situ hybridization banding （GISH-banding）, a technique slightly modified from conventional GISH, was used to probe the Chinese native rye （Secale cereale L.） DNA, and enabled us to visualize the individ...Genomic in situ hybridization banding （GISH-banding）, a technique slightly modified from conventional GISH, was used to probe the Chinese native rye （Secale cereale L.） DNA, and enabled us to visualize the individual rye chromosomes and create a universal reference karyotype of the S. cereale chromosome 1R to 7R. The GISH-banding approach used in the present study was able to discriminate S. cereale chromosomes or segments in the wheat （Triticum aestivum L.） background, including the Triticale, wheat-rye addition and translocation lines. Moreover, the GISH-banding pattern of S. cereale subsp. Afghanicum chromosomes was consistent with that of Chinese native rye cv. Jingzhou rye; whereas the GISH-banding pattern of Secale vavilovii was different from that of S. cereale, indicating that GISH-banding can be used to study evolutionary polymorphism in species or subspecies of Secale. In addition, the production and application of GISH-banding to the study of adenine-thymine-riched heterochromaUn is discussed.展开更多
基金supported financially by the China Scholarship Council(CSC,No.2017GXZ020849)the Fundamental Research Funds for the Central Universitiesthe National Program for Support of Top-notch Young Professionals.
文摘The adhesive strength in a coating-substrate system is of primary importance for the coating lifetime in service.However,the underlying mechanism is not fully understood due to the complex internal structure of composite coatings.In this study,the effect of substrate roughness on the adhesive strength of WCCo coatings was investigated by experiment and simulation.Results show that the adhesive strength is significantly affected by the roughness.In the case of the Ra<2μm,the adhesive strength is approximately 35–46 MPa.When the Ra is 4μm,the adhesive strength increases to nearly 60 MPa.A finite element model was developed to correlate the roughness with adhesive strength.It is found that the predicted values are well consistent with the experimental data.In addition,with the increase of the roughness,the residual stress would be changed from concentrated state to widespread state,which decreases the critical stress to result in crack propagation.That’s why a larger roughness can cause a higher adhesive strength.This study gives understanding on the mechanism of adhesive strength affected by roughness,which contributes to the parameter optimization with better performance.
基金the National Science and Technology Major Project(No.2017-VII-0012-0107)the National Program for Support of Top-notch Young Professionals。
文摘To gain high efficiency and low fuel consumption, aluminum-based abradable seal coatings had been widely used in the compressor casing of aero engines or gas turbines owing to the low elastic modulus. However, the adhesive transfer phenomenon frequently occurs when the radial rubbing generates between titanium alloy blade tips and aluminum-based coating. It tends to increase scratch force and results in blades vibration and even engine jam. To eliminate this problem, a new lightweight epoxy-based abradable seal coating with high bonding strength was developed by an effective and porosity controllable mixing process that distributes spherical pores uniformly in the continuous matrix. A lightweight coating of 63% porosity with a hardness of 33.1(HR15 Y) can be reached when the content of hollow microspheres is 31 wt.%. The coating density is 0.5 g/cm3 and the bonding strength is as high as 18 MPa.The performance of the epoxy-based coating is comprehensively better than aluminum-based coatings in five essential indices. This study is expected to provide a new technical path for obtaining high-quality abradable seal coatings to guarantee the efficient and safe operation of compressors.
基金financially supported by the National Key R&D Plan(No.2017YFB0306103)the Fundamental Research Funds for the Central Universitiesthe National Program for Support of Top-notch Young Professionals。
文摘Plasma spray–physical vapor deposition(PS–PVD)is a unique technology that enables highly tailorable functional films and coatings with various rare metal elements to be processed.This technology bridges the gap between conventional thermal spray and vapor deposition and provides a variety of coating microstructures composed of vapor,liquid,and solid deposition units.The PS–PVD technique serves a broad range of applications in the fields of thermal barrier coatings(TBCs),environmental barrier coatings(EBCs),oxygen permeable films,and electrode films.It also represents the development direction of high-performance TBC/EBC preparation technologies.With the PS–PVD technique,the composition of the deposition unit determines the microstructure of the coating and its performance.When coating materials are injected into a nozzle and transported into the plasma jet,the deposition unit generated by a coating material is affected by the plasma jet characteristics.However,there is no direct in situ measurement method of material transfer and deposition processes in the PS–PVD plasma jet,because of the extreme conditions of PS–PVD such as a low operating pressure of*100 Pa,temperatures of thousands of degrees,and a thin and high-velocity jet.Despite the difficulties,the transport and transformation behaviors of the deposition units were also researched by optical emission spectroscopy,observation of the coating microstructure and other methods.This paper reviews the progress of PS–PVD technologies considering the preparation of advanced thermal barrier coatings from the perspective of the transport and transformation behaviors of the deposition units.The development prospects of new high-performance TBCs using the PS–PVD technique are also discussed.
基金supported by the National Basic Research Program of China(No.2013CB035701)the Fundamental Research Funds for the Central Universitiesthe National Program for Support of Top-notch Young Professionals
文摘Advanced thermal harrier coatings （TBCs） with better thermal barrier performance are required by both advanced gas turbine and air engine. In this work, novel bimodal TBCs with low thermal conductivity were deposited and characterized by a novel co-spray approach with both solid powder and suspension. Experimental and finite element analyses were used to optimize the process parameters to prepare the specific morphology nanostructure features. With a comprehensive understanding on the influence of spraying parameters on the morphology ofnano-particles, homogeneous nano-particle heaps with a large aspect ratio were introduced to conventional layered coatings by plasma co-spraying with suspension and solid powder. Co-sprayed bimodal microstructure composite coatings resulted from both wet suspension droplets and molten particle droplets exhibited low thermal conductivity. The thermal conductivity of the composite coating was 1/5 lower than that of the counterpart coatings by conventional plasma spraying with solid powder. This study sheds light to the structural tailoring towards the advanced TBCs with low thermal conductivity.
基金the National Basic Research Program of China，the National Natural Science Foundation of China，the Fundamental Research Funds for the Central Universities, and the National Program for Support of Top-notch Young Professionals
文摘Thermal barrier coatings (TBCs) enable the hot section part to work at high temperatures owing to their thermal barrier effect on the base metal components. However, localized spallation in the ceramic top-coat might occur after long duration of thermal exposure or thermal cycling. To comprehensively understand the damage of the top-coat on the overall hot section part, effects of diameter and tilt angle of the spallation on the temperature redistribution of the substrate and the top-coat were investigated. The results show that the spallation diameter and tilt angle both have a significant effect on the temperature redistribution of the top-coat and the substrate. In the case of the substrate, the maximum temperature increment is located at the spallation center. Meanwhile, the surface (depth) maximum temperature increment, having nothing to do with the tilt angle, increases with the increase of the spallation diameter. In contrast, in the case of the top-coat, the maximum temperature increment was located at the sharp corner of the spallation area, and the surface (depth) maximum temperature increment increases with the increase of both the spallation diameter and the tilt angle. Based on the temperature redistribution of the substrate and the top-coat affected by the partial spallation, it is possible to evaluate the damage effect of spalled areas on the thermal capability of TBCs.
基金supported by the National Science and Technology Major Project(Grant No.2019-VII-0007-0147)the Young Elite Scientists Sponsorship Program by China Association for Science and Technology(CAST)(Grant No.YESS20200083)the Fundamental Research Funds for the Central Universities(Grant No.xzy012022057).
文摘Large degradation in thermal insulation and strain tolerance is a main headache and a primary cause of the failure for plasma-sprayed thermal barrier coatings(TBCs)during service.One mechanism behind such degradation is the healing of interlamellar pores formed by multiple connections between edges of a pore,which significantly speeds up healing during thermal exposure.The objective of this study is to obtain sintering-resistant TBCs by tailoring the width of interlamellar pores to avoid multiple connections.Firstly,the mechanism responsible for the multiple connections was revealed.The splat surfaces before and after thermal treatments were characterized via an atomic force microscope(AFM).The roughening of the pore surface occurs during thermal exposure,along with the grain growth inside the splats.Consequently,the local surface height increases,which causes multiple connections and healing of the interlamellar pores.Secondly,critical widths of the interlamellar pores for avoiding the multiple connections during thermal exposure are established by correlating the extent of surface roughening with the growth of individual grains.The height increase of the splat surface and the growth of the grain size(D)were found to increase with the exposure temperature and duration.A relationship linking the height increase and the growth of the grain size induced by thermal exposure in plasma-sprayed ceramic splats was obtained.Finally,composite TBCs were prepared to form wide interlamellar pores in the coatings.Using this design,the increases in the thermal conductivity(λ)and the elastic modulus(E)can be prevented to a large extent.Thus,sintering-resistant TBCs that maintain high thermal insulation and strain tolerance,even afer long thermal exposure,can be created.
基金supported by the National Natural Science Foundation of China(No.52371075)the National Training Program of Innovation and Entrepreneurship for Undergraduates,the Young Elite Scientists Sponsorship Program by CAST(No.YESS20200083)+1 种基金the Young Talent Fund of the University Association for Science and Technology in Shaanxi,China(No.20190403)the Fundamental Research Funds for the Central Universities(No.xzy012022057).
文摘Double-layered thermal barrier coatings(DL-TBCs)have been developed to meet multiple service requirements,such as low thermal conductivity,high thermal stability,and high fracture toughness.Conventional DL-TBCs are often designed on the basis of equal total thickness to have long lifespans,which may weaken the thermal insulation.The reason is that the single-scale designed structure often has opposite effects on the thermal and mechanical properties.To enhance both the thermal insulation and lifespan,this work designed durable DL-TBCs at multiple scales under equivalent thermal insulation.The macroscopic thickness ratio of the top layer to the bottom layer was tailored to optimize the total and single thicknesses,and the microscopic pore size in the top layer was tailored to resist sintering.Six groups of samples with different thickness ratios were prepared.The thermal cycling test revealed that the lifespan of DL-TBCs first increases but then decreases with increasing thickness ratio.The optimized thickness ratio is 2:3 for DL-TBCs,which have the largest lifespan among the six groups.The cross-sectional morphologies revealed that the failure mode changed from the spallation of the top layer to the delamination of the total double layers.The long lifespan of the optimized DL-TBCs stems from the cotailored thickness ratio and porous structure in the top layer to lower the total cracking driving force.
文摘Thermal barrier coatings(TBCs)can effectively protect the alloy substrate of hot components in aeroengines or land-based gas turbines by the thermal insulation and corrosion/erosion resistance of the ceramic top coat.However,the continuous pursuit of a higher operating temperature leads to degradation,delamination,and premature failure of the top coat.Both new ceramic materials and new coating structures must be developed to meet the demand for future advanced TBC systems.In this paper,the latest progress of some new ceramic materials is first reviewed.Then,a comprehensive spalling mechanism of the ceramic top coat is summarized to understand the dependence of lifetime on various factors such as oxidation scale growth,ceramic sintering,erosion,and calcium–magnesium–aluminium–silicate(CMAS)molten salt corrosion.Finally,new structural design methods for high-performance TBCs are discussed from the perspectives of lamellar,columnar,and nanostructure inclusions.The latest developments of ceramic top coat will be presented in terms of material selection,structural design,and failure mechanism,and the comprehensive guidance will be provided for the development of next-generation advanced TBCs with higher temperature resistance,better thermal insulation,and longer lifetime.
基金the National Natural Science Foundation of China (30671288and 30730065)
文摘Genomic in situ hybridization banding （GISH-banding）, a technique slightly modified from conventional GISH, was used to probe the Chinese native rye （Secale cereale L.） DNA, and enabled us to visualize the individual rye chromosomes and create a universal reference karyotype of the S. cereale chromosome 1R to 7R. The GISH-banding approach used in the present study was able to discriminate S. cereale chromosomes or segments in the wheat （Triticum aestivum L.） background, including the Triticale, wheat-rye addition and translocation lines. Moreover, the GISH-banding pattern of S. cereale subsp. Afghanicum chromosomes was consistent with that of Chinese native rye cv. Jingzhou rye; whereas the GISH-banding pattern of Secale vavilovii was different from that of S. cereale, indicating that GISH-banding can be used to study evolutionary polymorphism in species or subspecies of Secale. In addition, the production and application of GISH-banding to the study of adenine-thymine-riched heterochromaUn is discussed.
