热喷涂陶瓷层与金属粘结层的界面调控及其强度研究

Research on Interface Control and Bonding Strength of Thermal Spraying Ceramic Top-Coats and Metal Bond-Coats

热喷涂陶瓷涂层具有优异的耐磨、防腐、隔热等性能,能赋予金属/合金零部件良好的极端环境服役性能,被广泛应用于航空航天、军事、交通运输等领域机械零部件表面,是极端环境服役零部件表面防护的最佳选择之一。为减小基体与陶瓷涂层的应力梯度,喷涂陶瓷涂层过程中通常先在基体表面制备一层金属或合金粘结层。由于陶瓷的热膨胀系数、弹性模量、晶体结构等与金属或合金粘结层的差异较大,因此粘结层与陶瓷层的界面力学性能直接决定了整个材料的服役寿命,成为制约该领域快速发展的瓶颈之一。综述了热喷涂陶瓷层与粘结层界面的最新研究进展,介绍了双层结构涂层的耦合界面、双层结构涂层的原位氧化物钉扎界面、使界面模糊化的连续梯度过渡界面和纳米复合连续梯度过渡界面;系统地综述了通过制备工艺、界面结构和粘结层材料优化进行界面调控的研究;并对不同界面结构的涂层粘结强度进行对比分析;最后总结了热喷涂粘结层与陶瓷层界面研究现阶段面临的突出问题和未来的发展方向。

Thermal spraying ceramic coating has excellent wear resistance,corrosion resistance,thermal insulation and other properties,which can give metal/alloy parts good extreme environmental service properties.It is one of the best choices for surface protection of extreme environmental service parts,and is widely used in mechanical parts in aerospace,military,transportation and other fields.In order to reduce the stress gradient between the substrate and the ceramic coating,the alloy/metal bond-coats is usually prepared on the surface of the substrate.Because the thermal expansion coefficient,elastic modulus and crystal structure of ceramic top-coats are quite different from the metal/alloy bond-coats,the interface mechanical properties directly determine the service life of the entire material,which has become one of the bottlenecks restricting the rapid development of this field.Based on this,the recent research progress of the interface between the thermal spraying bond-coats and the ceramic top-coats is reviewed.The coupling interface of the double layer structure coating,the in-situ oxide nailing interface of the double layer structure coating,the continuous gradient transition interface that blurs the interface and the optimized nanocomposite continuous gradient transition interface are introduced.The coating bond strength with different interface structures is compared.Finally,the outstanding problems and the future development direction of the interface between thermal spraying bond-coats and ceramic top-coats are summarized.