Wide-temperature-range lubricating wear-resistant coating material, coating and preparation method

Abstract

The invention relates to the technical field of lubricating and wear-resistant coating materials, particularly provides a wide-temperature-range lubricating and wear-resistant coating material, and further provides a coating based on the coating material and a preparation method. The wide-temperature-range lubricating wear-resistant coating material provided by the invention is prepared from YSZ (Yttria Stabilized Zirconium) powder, YSZ coated CaF2 powder and YSZ coated AgTaO3 powder. The YSZ-coated CaF2 powder and the YSZ-coated AgTaO3 powder can play a lubricating role in different temperature ranges respectively, a temperature range complementary lubricating system is formed, the wear resistance of the material is remarkably improved, and the lubricating and wear-resisting functions in the whole temperature range from the room temperature to 1200 DEG C are achieved.

Description

Technical Field

[0001] This invention relates to the field of lubricating and wear-resistant coating materials, and more particularly to a wide-temperature-range lubricating and wear-resistant coating material, as well as a coating and its preparation method. Background Technology

[0002] With the development of modern industry, more and more mechanical movements need to be carried out in friction environments ranging from room temperature to high temperature. Furthermore, with the continuous improvement of the efficiency and performance of mechanical components, the energy density of friction surfaces is constantly increasing, and the friction temperature is also gradually rising. This places higher demands on the service performance of high-end equipment, especially in high-end fields such as aerospace and energy equipment, where wide-temperature-range friction performance has become a key factor restricting technological upgrades. Yttrium-stabilized zirconia (YSZ) is a commonly used thermal protection material with excellent high-temperature stability (>1100℃) and good compatibility with high-temperature alloy substrates. It is widely used as a bonding layer in thermal barrier coatings or as an independent high-temperature thermal protection coating. However, it inherently lacks active lubrication function and cannot meet the low-friction requirements of friction pairs.

[0003] To achieve lubrication and wear resistance of the coating across the entire temperature range from room temperature to 1200℃, it is necessary to introduce lubricating and reinforcing phases that can exist stably from room temperature to above 1100℃ and have different temperature ranges. For lubricating phase materials, soft metals such as Ag and Au, while possessing excellent ductility and low shear strength, can form a lubrication transfer film at the friction interface through dislocation thermal activation, achieving long-term friction reduction. However, these materials undergo oxidation at high temperatures, leading to failure. Alkaline earth metal fluorides such as CaF2 and BaF2, as typical high-temperature solid lubricants, soften due to the ductile-brittle transition at 500-1000℃ and exert a lubricating effect, but their brittleness at low temperatures exacerbates wear. Reinforcing phases, such as hard ceramic particles like Cr2O3, ZrB2, and TiC, can improve the coating's hardness and mechanical strength, reducing the wear rate, but cannot compensate for the temperature range gaps in the lubricating phase.

[0004] Based on the design concept of multiphase composites, researchers have developed various high-temperature solid lubricating wear-resistant coatings. The PS series composite coatings use Ni-based alloys as the binder phase and carbides / oxides as the hard phase to provide wear resistance. Lubrication functions in the medium-low and high-temperature ranges are achieved through Ag and fluoride dual lubricating phases, respectively. Currently, it has been iterated to the fourth generation and applied to aero-engine components. Friction and wear studies have been conducted on Al2O3, SiC, and other ceramic matrix composites at temperatures above 1100℃. However, the existing high-temperature lubricating wear-resistant coatings still have friction coefficients and wear rates as high as 0.5~0.6, which cannot meet the requirements for continuous lubrication across the entire temperature range from room temperature to 1200℃, high bonding strength, and ultra-high temperature wear resistance. Summary of the Invention

[0005] To address the aforementioned problems, this invention provides a wide-temperature-range lubricating and wear-resistant coating material. Through specific component design and proportioning, a temperature-range complementary lubrication system is formed, achieving lubrication and wear resistance across the entire temperature range from room temperature to 1200℃. Furthermore, this invention also provides a coating based on this material and its preparation method.

[0006] To address the aforementioned technical problems, in a first aspect, the present invention provides a wide-temperature-range lubricating and wear-resistant coating material, comprising YSZ powder, YSZ-coated CaF2 powder, and YSZ-coated AgTaO3 powder; wherein the amount of YSZ-coated CaF2 powder added is 0.1-12% of the mass of the YSZ powder, and the amount of YSZ-coated AgTaO3 powder added is 0.1-12% of the mass of the YSZ powder.

[0007] More preferably, the amount of YSZ-coated CaF2 powder added is 3-6% of the mass of the YSZ powder.

[0008] More preferably, the amount of YSZ-coated AgTaO3 powder added is 3-6% of the mass of the YSZ powder.

[0009] In this invention, YSZ-coated CaF2 powder and YSZ-coated AgTaO3 powder can respectively exert lubrication effects in different temperature ranges, forming a temperature-range complementary lubrication system of "low-temperature plastic lubrication - high-temperature softening lubrication". Simultaneously, by uniformly coating AgTaO3 and CaF2 powders with YSZ, this invention effectively suppresses the oxidation decomposition and volatilization loss of both powders under the high temperature of plasma spraying. This provides a composite powder raw material with good flowability, stable composition, and good adaptability to subsequent spraying processes. Consequently, the prepared coating exhibits high bonding strength with the substrate, stable microstructure, and excellent thermal shock resistance and low friction and wear characteristics over a wide temperature range, making it suitable for high-end equipment components under various high-temperature friction conditions.

[0010] Preferably, the coating material includes Mo powder, and the amount added is 0-12% of the mass of the YSZ powder. More preferably, the amount of Mo powder added is 3 to 6% of the mass of the YSZ powder.

[0011] Preferably, the coating material includes Cr2O3 powder, and the amount added is 0 to 12% of the mass of the YSZ powder.

[0012] More preferably, the amount of Cr2O3 powder added is 3 to 6% of the mass of YSZ powder.

[0013] This invention further incorporates Mo and Cr2O3 powders into the coating material, achieving lubrication and wear resistance across the entire temperature range from room temperature to 1200℃. YSZ, acting as the matrix framework, possesses high-temperature stability exceeding 1100℃ and excellent adhesion to high-temperature alloys, providing thermal barrier protection and structural support for the coating. Mo powder enhances material toughness, suppressing dislocation movement through solid solution strengthening and reducing plastic deformation wear. Cr2O3, as a ceramic hard phase, forms nanoscale reinforcing particles, increasing material hardness and effectively resisting wear. Simultaneously, the reinforcing effects of Mo and Cr2O3 powders, combined with YSZ-coated CaF2 and AgTaO3 powders, significantly improve the material's wear resistance. Furthermore, Mo and Cr2O3 strengthen the YSZ matrix through dispersed distribution, inhibiting lubricant phase loss. Preferably, the Y2O3 content in the YSZ powder is 7wt%~9wt%.

[0014] Preferably, the YSZ-coated CaF2 powder is prepared by the following method: preparing YSZ sol using a precursor salt and a solvent; the precursor salt includes yttrium salt and zirconium salt, and the Y2O3 content in the YSZ is 7%~9%; dispersing CaF2 powder in the YSZ sol and spray drying to obtain the YSZ-coated CaF2 powder; the mass ratio of CaF2 powder to YSZ in the YSZ sol is (2~3):1.

[0015] Preferably, the YSZ-coated AgTaO3 powder is prepared by the following method: preparing YSZ sol using a precursor salt and a solvent; the precursor salt includes yttrium salt and zirconium salt, and the Y2O3 content in the YSZ is 7%~9%; dispersing AgTaO3 powder in the YSZ sol, and spray drying to obtain the YSZ-coated AgTaO3 powder; the mass ratio of AgTaO3 powder to YSZ in the YSZ sol is (0.5~1.5):1.

[0016] Preferably, the AgTaO3 powder is prepared by the following method: Ag₂O (purity ≥ 99.7%) and Ta₂O₅ (purity ≥ 99.9%) were mixed at a molar ratio of (1.03~1.05):1 using a solid-state reaction method. After ball milling for 8~16 hours, the mixture was dried at 100℃~120℃ to obtain a mixed powder. The mixed powder was then calcined at 1050℃ with a heating rate controlled at 3℃ / min~5℃ / min for 8~16 hours to obtain AgTaO₃ powder. The specific chemical reaction formula is shown below: Ag2O + Ta2O5 → 2AgTaO3.

[0017] In one embodiment of the present invention, the CaF2 powder and AgTaO3 powder can be prepared into agglomerated particle powder by spray granulation before coating YSZ, so as to improve the coating uniformity, spray processability and coating performance. The specific process steps are as follows: Using water as the dispersion medium, CaF2 powder, binder, and surfactant are prepared into a slurry, with the solid content of the slurry controlled at 45wt%~55wt%. The slurry is then spray-granulated to obtain CaF2 particle powder with good flowability and agglomerated structure. The amount of binder is 1wt%~3wt%, and the amount of surfactant is 0.3wt%~12wt%.

[0018] Using water as the dispersion medium, AgTaO3 powder, binder, and surfactant are prepared into a slurry, with the solid content of the slurry controlled at 55wt%~65wt%. The slurry is then spray-granulated to obtain AgTaO3 particle powder with good flowability and agglomerated structure. The amount of binder is 1wt%~3wt%, and the amount of surfactant is 0.1wt%~5wt%.

[0019] In one embodiment of the present invention, the YSZ sol is prepared by the following method: ZrOCl2·8H2O is used as the inorganic zirconium source, and Y(NO3)3·6H2O is used as the inorganic yttrium source. The amounts of both are adjusted according to the final Y2O3 content in the YSZ to be 7wt%~9wt%. ZrOCl2·8H2O and Y(NO3)3·6H2O are dissolved in an ethanol-water mixed solution (ethanol:water volume ratio of 1:0.5~1:3). Then, while stirring, an ammonia solution with a pH of 11-12 is slowly added dropwise to promote the hydrolysis of ZrOCl2 and Y(NO3)3, thereby obtaining the YSZ precursor. Subsequently, the YSZ precursor is repeatedly washed with deionized water to remove Cl from the sol. - The degree of purification during the washing process was detected by AgNO3 titration. When no more white flocculent precipitate (i.e., AgCl) was formed in the filtrate, it indicated that Cl... - The surfactant has been completely removed. The washed YSZ precursor is redispersed in an aqueous solution containing the surfactant and reacted at 180℃~220℃ for 12h~24h to obtain the YSZ sol.

[0020] In one embodiment of the present invention, the YSZ-coated CaF2 powder is prepared by the following method: First, 1 wt% to 3 wt% of binder and 0.3 wt% to 12 wt% of surfactant are added to CaF2 powder, and water is used as the dispersion medium to prepare the slurry with a solid content controlled at 45 wt% to 55 wt%. Then, the slurry is spray-granulated to obtain agglomerated CaF2 particles with good flowability. Subsequently, the agglomerated CaF2 particles are dispersed in YSZ sol at a certain ratio, with the mass ratio of CaF2 to YSZ controlled at (2~3):1, to obtain a mixture. After stirring for 6 to 12 hours to ensure uniform dispersion, the mixture is sent to a spray granulation tower for spray drying to finally obtain YSZ-coated CaF2 powder.

[0021] In one embodiment of the present invention, the YSZ-coated AgTaO3 powder is prepared by the following method: First, 1 wt% to 3 wt% of a binder and 0.1 wt% to 5 wt% of a surfactant are added to the AgTaO3 powder, and water is used as the dispersion medium to prepare the slurry with a solid content controlled at 55 wt% to 65 wt%. Then, the slurry is spray-granulated to obtain AgTaO3 particles with good flowability. Subsequently, the AgTaO3 particles are dispersed in YSZ sol at a certain ratio, with the mass ratio of AgTaO3 to YSZ controlled at (0.5 to 1.5):1, to obtain a mixture. After stirring for 6 to 12 hours to ensure uniform dispersion, the mixture is sent to a spray granulation tower for spray drying to finally obtain the YSZ-coated AgTaO3 powder.

[0022] In the YSZ sol preparation, the surfactants in this invention primarily promote the uniform dispersion of YSZ precursor particles and prevent agglomeration. In the coating powder preparation, they mainly improve the dispersibility of AgTaO3 and CaF2 powders in water, ensuring slurry uniformity. They also withstand spray drying temperatures, preventing decomposition or residual impurities from affecting coating performance. Furthermore, they are compatible with ethanol-water mixed solvents, binders, and other components, without undergoing chemical reactions. Any surfactant meeting the aforementioned requirements can be used in the embodiments of this invention. For example, the surfactants in the embodiments of this invention can be anionic, cationic, or nonionic surfactants. Among them, anionic surfactants can be selected from AOT (sodium bis(ethylhexyl)succinate sulfonate), SDB (sodium dodecylbenzene sulfonate), SDS (sodium dodecyl sulfate), etc.; cationic surfactants can be selected from CTAC (hexadecyltrimethylammonium chloride), DTAB (dodecyltrimethylammonium bromide), CTAB (hexadecyltrimethylammonium bromide), etc.; nonionic surfactants can be selected from Triton-100 (nonylphenol polyoxyethylene ether), Npn (nonylphenol polyoxyethylene ether surfactant), Tween-40 (60, 80), Span-40 (60, 80), etc. In the embodiments of the present invention, the surfactant is preferably a polycarboxylate polymeric surfactant, such as PAAS (sodium polyacrylate), PMAS (sodium polymethacrylate), MA-AA (maleic anhydride-acrylic acid copolymer), etc.

[0023] In this embodiment of the invention, the binder must be selected to provide the bonding force required for particle agglomeration during spray drying, and simultaneously be able to completely decompose or volatilize in subsequent processing, leaving no impurities that affect coating performance. For example, the binder in this invention can be selected from water-soluble organic binders, inorganic binders, emulsion-type binders, etc. Specifically, water-soluble organic binders can be selected from CMC (carboxymethyl cellulose), PVA (polyvinyl alcohol), PVP (polyvinylpyrrolidone), gum arabic, etc.; inorganic binders can be selected from silica sol, alumina sol, etc.; and emulsion-type binders can be selected from acrylic emulsions, etc. In this embodiment of the invention, the binder is preferably PVA adhesive.

[0024] Secondly, the present invention also provides a method for preparing the above-mentioned wide-temperature-range lubricating and wear-resistant coating material, comprising the following steps: YSZ-coated CaF2 powder, YSZ-coated AgTaO3 powder, and YSZ powder are mixed evenly using a powder mixer to obtain the wide-temperature-range lubricating and wear-resistant coating material. The amount of YSZ-coated CaF2 powder added is 0.1~12% of the mass of the YSZ powder, and the amount of YSZ-coated AgTaO3 powder added is 0.1~12% of the mass of the YSZ powder.

[0025] Furthermore, the preparation method of the wide-temperature-range lubricating and wear-resistant coating material includes the following steps: using a powder mixer to uniformly mix YSZ-coated CaF2 powder, YSZ-coated AgTaO3 powder, Mo powder, and YSZ powder to obtain the wide-temperature-range lubricating and wear-resistant coating material; the amount of YSZ-coated CaF2 powder added is 0.1~12% of the mass of the YSZ powder, the amount of YSZ-coated AgTaO3 powder added is 0.1~12% of the mass of the YSZ powder, and the amount of Mo powder added is 0~12% of the mass of the YSZ powder.

[0026] Furthermore, the preparation method of the wide-temperature-range lubricating and wear-resistant coating material includes the following steps: using a powder mixer to uniformly mix YSZ-coated CaF2 powder, YSZ-coated AgTaO3 powder, Cr2O3 powder, and YSZ powder to obtain the wide-temperature-range lubricating and wear-resistant coating material; the amount of YSZ-coated CaF2 powder added is 0.1~12% of the mass of the YSZ powder, the amount of YSZ-coated AgTaO3 powder added is 0.1~12% of the mass of the YSZ powder, and the amount of Cr2O3 powder added is 0~12% of the mass of the YSZ powder.

[0027] Furthermore, the preparation method of the wide-temperature-range lubricating and wear-resistant coating material includes the following steps: using a powder mixer to uniformly mix YSZ-coated CaF2 powder, YSZ-coated AgTaO3 powder, Mo powder, Cr2O3 powder, and YSZ powder to obtain the wide-temperature-range lubricating and wear-resistant coating material; the amount of YSZ-coated CaF2 powder added is 0.1~12% of the mass of the YSZ powder, the amount of YSZ-coated AgTaO3 powder added is 0.1~12% of the mass of the YSZ powder, the amount of Mo powder added is 0~12% of the mass of the YSZ powder, and the amount of Cr2O3 powder added is 0~12% of the mass of the YSZ powder.

[0028] Thirdly, the present invention also provides a coating, including a top layer, wherein the top layer is prepared using the wide temperature range lubricating and wear-resistant coating material provided by the present invention.

[0029] Preferably, the coating further includes an adhesive layer for laminating onto the substrate, and the surface layer is laminating onto the adhesive layer. The adhesive layer is prepared from MCrAlY alloy powder. The MCrAlY alloy powder is selected from at least one of NiCrAlY, CoCrAlY, or NiCoCrAlY, and has a particle size of 20 μm to 110 μm.

[0030] In this invention, the adhesive layer is prepared using MCrAlY alloy powder, which can form a good metallurgical bond with the high-temperature alloy substrate. The Cr and Al elements contained therein form a dense oxide layer at the interface, effectively preventing the high-temperature oxidizing medium from corroding the substrate. At the same time, the addition of Y element enhances the bonding force between the oxide layer and the substrate, reduces the risk of interface peeling, and provides a stable base support for the entire coating system. The top layer uses the aforementioned wide-temperature-range lubricating and wear-resistant coating material. With the high-temperature stability of the YSZ substrate, the complementary lubricating effects of YSZ-coated AgTaO3 and YSZ-coated CaF2 in different temperature ranges, and the synergistic enhancement of coating hardness and toughness by Mo and Cr2O3, the coating can maintain a low coefficient of friction and excellent wear resistance across the entire temperature range from room temperature to 1200℃.

[0031] In this invention, a good performance match is formed between the adhesive layer and the top layer. The thermal expansion coefficient of the adhesive layer is between that of the substrate and the top layer, which effectively alleviates the thermal stress generated by the coating during thermal cycling and avoids cracking or peeling caused by thermal mismatch. The lubricating phase in the top layer can continuously play a lubricating role on the basis of the stable interface provided by the adhesive layer, while the reinforcing phase further consolidates the structural strength of the coating. This makes the entire coating system not only have high bonding strength and good high temperature oxidation resistance, but also maintain stable lubrication and wear resistance during long-term wide temperature range service.

[0032] Preferably, the thickness of the adhesive layer is 25μm to 75μm.

[0033] In this invention, the thickness of the adhesive layer is preferably 25μm to 75μm. This ensures effective bonding with the substrate and surface layer while avoiding thermal stress concentration due to excessive thickness. The preferred thickness range ensures that the MCrAlY alloy powder uniformly covers the substrate surface during plasma spraying, providing stable support for the coating through metallurgical bonding and mechanical interlocking. Simultaneously, the transition effect of its thermal expansion coefficient effectively buffers the thermal mismatch stress between the substrate and the surface layer, reducing the risk of coating cracking. If the thickness is too thin, it is difficult to form a continuous and complete protective and transition layer; if it is too thick, excessive internal stress may cause peeling.

[0034] Preferably, the thickness of the surface layer is 100μm to 300μm.

[0035] In this invention, the thickness of the surface layer is preferably 100μm to 300μm, which balances lubrication and wear resistance with overall coating stability. This preferred thickness range provides sufficient lubricating phase (AgTaO3, CaF2) and structural support (YSZ, Cr2O3, Mo) for wide-temperature-range lubrication, ensuring continuous performance during long-term friction and preventing coating failure due to rapid wear. Simultaneously, this thickness is well-suited for plasma spraying processes, guaranteeing coating density and uniformity. If the thickness is too thin, insufficient lubricating phase reserves will lead to easy wear through; if too thick, self-weight or thermal stress may result in poor bonding with the adhesive layer, affecting overall service performance.

[0036] Preferably, the matrix is ​​selected from high-temperature alloy matrices, such as nickel-based high-temperature alloys, cobalt-based high-temperature alloys, and iron-based high-temperature alloys. Specifically, nickel-based high-temperature alloys can be selected from Inconel 718, Inconel 625, GH4169, GH3030, etc.; cobalt-based high-temperature alloys can be selected from Stellite 6, Stellite 12, GH5188, etc.; and iron-based high-temperature alloys can be selected from GH2132, GH1131, etc.

[0037] Fourthly, the present invention also provides a method for preparing the above-mentioned coating, comprising the following steps: S1. Spray the adhesive layer preparation material onto the substrate surface to obtain the adhesive layer; S2. Spray the wide temperature range lubricating and wear-resistant coating material onto the surface of the adhesive layer to form a surface layer, thereby obtaining the coating.

[0038] Preferably, in step S1, before spraying, the substrate is first sandblasted with a gas pressure of 0.1MPa to 0.4MPa, a sandblasting distance of 100mm to 300mm, and a sandblasting angle of 45° to 90°.

[0039] Preferably, in step S1, the spraying is performed using plasma spraying equipment with a spraying power of 30kW~40kW and a spraying distance of 100mm~200mm.

[0040] Preferably, in step S2, the spraying is performed using plasma spraying equipment with a spraying power of 35kW~45kW and a spraying distance of 100mm~200mm.

[0041] Compared with the prior art, the present invention has the following beneficial effects: The wide-temperature-range lubricating and wear-resistant coating material and the coating based on this material provided by this invention achieve high bonding strength, low coefficient of friction across the entire temperature range, and excellent thermal shock resistance. Specifically, the bonding strength between the coating and the substrate is not less than 40 MPa, ensuring structural stability during service. The coefficient of friction is stably controlled below 0.5 across the entire temperature range from room temperature to 1200°C, effectively reducing friction loss. Simultaneously, the coating can withstand at least 1000 thermal shocks at 1200°C, enabling long-term use under conditions of drastic temperature changes, thus solving the technical pain point of traditional coatings that struggle to simultaneously achieve high-temperature lubrication, wear resistance, and thermal stability. Attached Figure Description

[0042] Figure 1 The coefficient of friction of the coating obtained in Example 4 of this invention at room temperature; Figure 2 The coefficient of friction of the coating obtained in Example 4 of this invention at 200°C; Figure 3 The coefficient of friction of the coating obtained in Example 4 of this invention at 400°C; Figure 4 The coefficient of friction of the coating obtained in Example 4 of this invention at 600°C; Figure 5 The coefficient of friction of the coating obtained in Example 4 of this invention at 800°C; Figure 6 The coefficient of friction of the coating obtained in Example 4 of this invention at 1000°C; Figure 7 The coefficient of friction of the coating obtained in Example 4 of this invention at 1200°C. Detailed Implementation

[0043] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the specific embodiments will be briefly introduced below. Obviously, the embodiments described below are some embodiments of the present invention. For those skilled in the art, other embodiments can be obtained based on these embodiments without creative effort.

[0044] Where specific experimental steps or conditions are not specified in the embodiments, they can be performed according to the conventional experimental steps or conditions described in the literature in this field. All raw materials or instruments used are commercially available conventional products, including but not limited to those used in the embodiments of this application.

[0045] In the embodiments and comparative examples of this invention, the AgTaO3 powder used was prepared by the following method: Ag₂O (purity ≥ 99.7%) and Ta₂O₅ (purity ≥ 99.9%) were mixed at a molar ratio of 1.04:1 using a solid-state reaction method. After ball milling for 12 hours, the mixture was dried at 105℃ to obtain a mixed powder. The resulting mixed powder was then calcined at 1050℃ with a heating rate controlled at 4℃ / min for 12 hours to obtain high-purity AgTaO₃ powder. The specific chemical reaction is shown below: Ag₂O + Ta₂O₅ → 2AgTaO₃.

[0046] In the embodiments and comparative examples of this invention, the YSZ sol used was prepared by the following method: ZrOCl2·8H2O was used as the inorganic zirconium source, and Y(NO3)3·6H2O was used as the inorganic yttrium source. The amounts of both were adjusted to ensure that the final Y2O3 content in the obtained YSZ was 8 wt%. ZrOCl2·8H2O and Y(NO3)3·6H2O were dissolved in an ethanol-water mixture (ethanol:water volume ratio 1:1). Then, while stirring, an ammonia solution with a pH of 11-12 was slowly added dropwise to promote the hydrolysis of ZrOCl2 and Y(NO3)3, yielding the YSZ precursor. Subsequently, the YSZ precursor was repeatedly washed with deionized water to remove Cl from the sol. - The degree of purification during the washing process was detected by AgNO3 titration. When no more white flocculent precipitate (i.e., AgCl) was formed in the filtrate, it indicated that Cl... - The YSZ precursor has been fully removed. The washed YSZ precursor was redispersed in an aqueous solution containing surfactant (PAAS) and reacted at 200°C for 16 h to obtain YSZ sol.

[0047] In the embodiments and comparative examples of this invention, the YSZ-coated CaF2 powder used was prepared by the following method: First, 2 wt% binder (PVA adhesive) and 6 wt% surfactant (PAAS) were added to CaF2 powder, and water was used as the dispersion medium to prepare the slurry with a solid content controlled at 50 wt%. Then, the slurry was spray-granulated to obtain CaF2 particles with good flowability. The agglomerated CaF2 particles were then dispersed in YSZ sol at a certain ratio, with the mass ratio of CaF2 to YSZ controlled at 2.5:1, to obtain a mixture. After stirring for 9 hours to ensure uniform dispersion, the mixture was sent to a spray granulation tower for spray drying, finally obtaining YSZ-coated CaF2 powder.

[0048] In the embodiments and comparative examples of this invention, the YSZ-coated AgTaO3 powder used was prepared by the following method: First, 2 wt% binder (PVA adhesive) and 2.5 wt% surfactant (PAAS) were added to AgTaO3 powder, and water was used as the dispersion medium to prepare the slurry with a solid content controlled at 60 wt%. Then, the slurry was spray-granulated to obtain AgTaO3 particles with good flowability. The agglomerated AgTaO3 particles were then dispersed in YSZ sol at a certain ratio, with the mass ratio of AgTaO3 to YSZ controlled at 1:1, to obtain a mixture. After stirring for 9 hours to ensure uniform dispersion, the mixture was sent to a spray granulation tower for spray drying, finally obtaining YSZ-coated AgTaO3 powder.

[0049] In the embodiments and comparative examples of this invention, the substrate used is GH5188 high-temperature alloy.

[0050] In the embodiments and comparative examples of this invention, the raw material used to prepare the adhesive layer is NiCrAlY powder with a particle size of 50 μm.

[0051] Example 1 This embodiment provides a wide temperature range lubricating and wear-resistant coating material, including YSZ powder, YSZ-coated CaF2 powder, and YSZ-coated AgTaO3 powder; the amount of YSZ-coated CaF2 powder added is 6% of the mass of YSZ powder, and the amount of YSZ-coated AgTaO3 powder added is 6% of the mass of YSZ powder; the YSZ powder is 8YSZ powder (i.e., ZrO2 (8wt%Y2O3)).

[0052] The method for preparing a wide-temperature-range lubricating and wear-resistant coating material provided in this embodiment includes the following steps: By mass fraction, 6 parts of YSZ-coated CaF2 powder, 6 parts of YSZ-coated AgTaO3 powder, and 100 parts of YSZ powder were mixed evenly using a powder mixer for 2 hours to obtain a wide-temperature-range lubricating and wear-resistant coating material.

[0053] This embodiment also provides a coating, including an adhesive layer for laminating onto a substrate and a top layer laminating onto the adhesive layer. The adhesive layer is prepared from NiCrAlY powder with a particle size of 50 μm and a thickness of 45 μm. The top layer is prepared from the wide temperature range lubricating and wear-resistant coating material provided in this embodiment, with a thickness of 200 μm.

[0054] The coating preparation method provided in this embodiment includes the following steps: (1) Surface roughening treatment: The substrate is sandblasted using a sandblasting machine. The purpose is to activate the surface of the substrate to improve the bonding strength of the coating. The gas pressure is 0.3MPa, the sandblasting distance is 200mm, and the sandblasting angle is 60°. The surface of the roughened substrate has a uniform color and no reflection. (2) Preparation of coating adhesive layer: NiCrAlY powder was sprayed onto the surface of the high-temperature alloy after texturing treatment using a plasma spraying equipment to prepare an adhesive layer. The spraying power was 35kW, the spraying distance was 150mm, and the thickness of the adhesive layer was 45μm. (3) Coating surface preparation: A wide temperature range lubricating and wear-resistant coating material is sprayed onto the surface of the coating with the adhesive layer using a plasma spraying equipment. The spraying power is 40kW, the spraying distance is 150mm, and the surface thickness is 200μm to obtain the coating.

[0055] Example 2 This embodiment provides a wide temperature range lubricating and wear-resistant coating material, including YSZ powder, YSZ-coated CaF2 powder, YSZ-coated AgTaO3 powder, and Cr2O3 powder; the amount of YSZ-coated CaF2 powder added is 3% of the mass of YSZ powder, the amount of YSZ-coated AgTaO3 powder added is 3% of the mass of YSZ powder, and the amount of Cr2O3 powder added is 6% of the mass of YSZ powder; the YSZ powder is 8YSZ powder (i.e., ZrO2 (8wt%Y2O3)).

[0056] The method for preparing a wide-temperature-range lubricating and wear-resistant coating material provided in this embodiment includes the following steps: By mass fraction, 3 parts of YSZ-coated CaF2 powder, 3 parts of YSZ-coated AgTaO3 powder, 6 parts of Cr2O3 powder and 100 parts of YSZ powder were mixed evenly using a powder mixer for 2 hours to obtain a wide temperature range lubricating and wear-resistant coating material.

[0057] This embodiment also provides a coating, including an adhesive layer for laminating onto a substrate and a top layer laminating onto the adhesive layer. The adhesive layer is prepared from NiCrAlY powder with a particle size of 50 μm and a thickness of 45 μm. The top layer is prepared from the wide temperature range lubricating and wear-resistant coating material provided in this embodiment, with a thickness of 200 μm.

[0058] The coating preparation method provided in this embodiment includes the following steps: (1) Surface roughening treatment: The substrate is sandblasted using a sandblasting machine. The purpose is to activate the surface of the substrate to improve the bonding strength of the coating. The gas pressure is 0.3MPa, the sandblasting distance is 200mm, and the sandblasting angle is 60°. The surface of the roughened substrate has a uniform color and no reflection. (2) Preparation of coating adhesive layer: NiCrAlY powder was sprayed onto the surface of the high-temperature alloy after texturing treatment using a plasma spraying equipment to prepare an adhesive layer. The spraying power was 35kW, the spraying distance was 150mm, and the thickness of the adhesive layer was 45μm. (3) Coating surface preparation: A wide temperature range lubricating and wear-resistant coating material is sprayed onto the coating surface covered with the adhesive layer using a plasma spraying equipment. The spraying power is 40kW, the spraying distance is 150mm, and the surface thickness is 200μm to obtain the coating.

[0059] Example 3 This embodiment provides a wide temperature range lubricating and wear-resistant coating material, including YSZ powder, YSZ-coated CaF2 powder, YSZ-coated AgTaO3 powder, and Mo powder; the amount of YSZ-coated CaF2 powder added is 3% of the mass of YSZ powder, the amount of YSZ-coated AgTaO3 powder added is 3% of the mass of YSZ powder, and the amount of Mo powder added is 6% of the mass of YSZ powder; the YSZ powder is 8YSZ powder (i.e., ZrO2 (8wt%Y2O3)).

[0060] The preparation method of the wide temperature range lubricating and wear-resistant coating material in this embodiment includes the following steps: By mass fraction, 3 parts of YSZ-coated CaF2 powder, 3 parts of YSZ-coated AgTaO3 powder, 6 parts of Mo powder and 100 parts of YSZ powder were mixed evenly using a powder mixer for 2 hours to obtain a wide temperature range lubricating and wear-resistant coating material.

[0061] This embodiment also provides a coating, including an adhesive layer for laminating onto a substrate and a top layer laminating onto the adhesive layer. The adhesive layer is prepared from NiCrAlY powder with a particle size of 50 μm and a thickness of 45 μm. The top layer is prepared from the wide temperature range lubricating and wear-resistant coating material provided in this embodiment, with a thickness of 200 μm.

[0062] The coating preparation method provided in this embodiment includes the following steps: (1) Surface roughening treatment: The substrate is sandblasted using a sandblasting machine. The purpose is to activate the surface of the substrate to improve the bonding strength of the coating. The gas pressure is 0.3MPa, the sandblasting distance is 200mm, and the sandblasting angle is 60°. The surface of the roughened substrate has a uniform color and no reflection. (2) Preparation of coating adhesive layer: NiCrAlY powder was sprayed onto the surface of the high-temperature alloy after texturing treatment using a plasma spraying equipment to prepare an adhesive layer. The spraying power was 35kW, the spraying distance was 150mm, and the thickness of the adhesive layer was 45μm. (3) Coating surface preparation: A wide temperature range lubricating and wear-resistant coating material is sprayed onto the surface of the coating with the adhesive layer using a plasma spraying equipment. The spraying power is 40kW, the spraying distance is 150mm, and the surface thickness is 200μm to obtain the coating.

[0063] Example 4 This embodiment provides a wide temperature range lubricating and wear-resistant coating material, including YSZ powder, YSZ-coated CaF2 powder, YSZ-coated AgTaO3 powder, Mo powder, and Cr2O3 powder; the amount of YSZ-coated CaF2 powder added is 3% of the mass of YSZ powder, the amount of YSZ-coated AgTaO3 powder added is 3% of the mass of YSZ powder, the amount of Mo powder added is 3% of the mass of YSZ powder, and the amount of Cr2O3 powder added is 3% of the mass of YSZ powder; the YSZ powder is 8YSZ powder (i.e., ZrO2 (8wt%Y2O3)).

[0064] The method for preparing a wide-temperature-range lubricating and wear-resistant coating material provided in this embodiment includes the following steps: By mass fraction, 3 parts of YSZ-coated CaF2 powder, 3 parts of YSZ-coated AgTaO3 powder, 3 parts of Mo powder, 3 parts of Cr2O3 powder, and 100 parts of YSZ powder were mixed evenly using a powder mixer for 2 hours to obtain a wide-temperature-range lubricating and wear-resistant coating material.

[0065] This embodiment also provides a coating, including an adhesive layer for laminating onto a substrate and a top layer laminating onto the adhesive layer. The adhesive layer is prepared from NiCrAlY powder with a particle size of 50 μm and a thickness of 45 μm. The top layer is prepared from the wide temperature range lubricating and wear-resistant coating material provided in this embodiment, with a thickness of 200 μm.

[0066] The coating preparation method provided in this embodiment includes the following steps: (1) Surface roughening treatment: The substrate is sandblasted using a sandblasting machine. The purpose is to activate the surface of the substrate to improve the bonding strength of the coating. The gas pressure is 0.3MPa, the sandblasting distance is 200mm, and the sandblasting angle is 60°. The surface of the roughened substrate has a uniform color and no reflection. (2) Preparation of coating adhesive layer: NiCrAlY powder was sprayed onto the surface of the high-temperature alloy after texturing treatment using a plasma spraying equipment to prepare an adhesive layer. The spraying power was 35kW, the spraying distance was 150mm, and the thickness of the adhesive layer was 45μm. (3) Coating surface preparation: A wide temperature range lubricating and wear-resistant coating material is sprayed onto the surface of the coating with the adhesive layer using a plasma spraying equipment. The spraying power is 40kW, the spraying distance is 150mm, and the surface thickness is 200μm to obtain the coating.

[0067] Comparative Example 1 The coating material provided in this comparative example includes YSZ powder and YSZ-coated CaF2 powder; the amount of YSZ-coated CaF2 powder added is 6% of the mass of YSZ powder; the YSZ powder is 8YSZ powder (i.e., ZrO2 (8wt%Y2O3)). The method for preparing the coating material provided in this comparative example includes the following steps: By mass fraction, 6 parts of YSZ-coated CaF2 powder and 100 parts of YSZ powder were mixed evenly using a powder mixer for 2 hours to obtain the coating material.

[0068] The coating provided in this comparative example includes an adhesive layer for laminating onto a substrate and a top layer laminating onto the adhesive layer. The adhesive layer is prepared from NiCrAlY powder with a particle size of 50 μm and a thickness of 45 μm. The top layer is prepared from the coating material provided in this comparative example and has a thickness of 200 μm.

[0069] The coating preparation method provided in this comparative example includes the following steps: (1) Surface roughening treatment: The substrate is sandblasted using a sandblasting machine. The purpose is to activate the surface of the substrate to improve the bonding strength of the coating. The gas pressure is 0.3MPa, the sandblasting distance is 200mm, and the sandblasting angle is 60°. The surface of the roughened substrate has a uniform color and no reflection. (2) Preparation of coating adhesive layer: NiCrAlY powder was sprayed onto the surface of the high-temperature alloy after texturing treatment using a plasma spraying equipment to prepare an adhesive layer. The spraying power was 35kW, the spraying distance was 150mm, and the thickness of the adhesive layer was 45μm. (3) Coating surface preparation: A wide temperature range lubricating and wear-resistant coating material is sprayed onto the surface of the coating with the adhesive layer using a plasma spraying equipment. The spraying power is 40kW, the spraying distance is 150mm, and the surface thickness is 200μm to obtain the coating.

[0070] Performance testing: The coatings obtained in Examples 1-4 and Comparative Example 1 were tested: The coating bonding strength was tested according to the HB5476 test method for thermal spray coating bonding strength.

[0071] Wear resistance was assessed using an MMQ-02G ball-and-disc high-temperature friction and wear testing machine. The wear material was GH5188 high-temperature alloy, the test duration was 30 minutes, and the load was 10 N. The coefficient of friction for the coating prepared in Example 4 from room temperature to 1200°C was as follows: Figures 1-7 As shown.

[0072] Thermal shock resistance was tested in accordance with Q / AVIC 06016.2-2013 "Coatings Thermal Shock Test Method Part 2: Flame Heating Method" (test temperature 1200℃).

[0073] The specific test results are shown in Table 1.

[0074] Table 1 As shown in Table 1, the coatings prepared in Examples 1-4 all withstand more than 1000 thermal shock cycles at 1200℃, exhibiting excellent thermal shock resistance. Example 1 (containing only YSZ-coated CaF2 / YSZ-coated AgTaO3) achieved 1540 thermal shock cycles, slightly higher than Comparative Example 1, indicating that the synergistic effect of AgTaO3 and CaF2 enhances thermal shock stability. Example 4 (containing both Mo and Cr2O3) achieved 1460 thermal shock cycles, comparable to Example 1, demonstrating good compatibility between the reinforcing and lubricating phases in this invention, without any reduction in thermal stability due to the addition of additional components. The bonding strength of the coatings prepared in Examples 1-4 ranges from 42.5 to 60.5 MPa, all exceeding the technical requirement of ≥30 MPa and close to that of Comparative Example 1, indicating that this invention achieves a stable bond between the coating and the substrate through adhesive layer structure design and process optimization. Examples 1-4 exhibited low friction coefficients across the entire temperature range from room temperature to 1200℃. Example 1, through the complementary use of "AgTaO3 low-temperature lubrication + CaF2 high-temperature lubrication," controlled the friction coefficient at 0.26~0.44 from room temperature to 1200℃. Example 4 performed best, with a friction coefficient as low as 0.19~0.33 across the entire temperature range and minimal fluctuation, indicating that the synergistic effect of Mo and Cr2O3 further optimized the friction reduction effect of the lubricating phase, achieving "low friction + stable fluctuation" across the entire temperature range. In contrast, Comparative Example 1 only showed good lubrication at high temperatures, with a friction coefficient as high as 0.39~0.53 at medium and low temperatures (room temperature to 400℃), failing to achieve effective lubrication across the entire temperature range.

[0075] The advantages of Comparative Example 1 in terms of bonding strength and thermal shock resistance stem from its simple composition and low addition amount, resulting in improved interfacial stability. In contrast, Examples 1-4, by introducing components such as AgTaO3, Mo, and Cr2O3, although resulting in slightly lower bonding strength and thermal shock cycles due to multiphase synergy, successfully achieved lubrication and wear resistance with a friction coefficient of <0.5 across the entire temperature range from room temperature to 1200℃, better meeting the comprehensive requirements of high-end equipment for "wide-temperature-range lubrication + wear resistance + stability".

[0076] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the scope of protection of this invention.

Claims

1. A wide-temperature-range lubricating and wear-resistant coating material, characterized in that, It includes YSZ powder, YSZ-coated CaF2 powder, and YSZ-coated AgTaO3 powder; the amount of YSZ-coated CaF2 powder added is 0.1~12% of the mass of the YSZ powder, and the amount of YSZ-coated AgTaO3 powder added is 0.1~12% of the mass of the YSZ powder.

2. The wide-temperature-range lubricating and wear-resistant coating material as described in claim 1, characterized in that, The coating material includes Mo powder, and the amount added is 0-12% of the mass of the YSZ powder.

3. The wide-temperature-range lubricating and wear-resistant coating material as described in claim 1, characterized in that, The coating material includes Cr2O3 powder, and the amount added is 0~12% of the mass of the YSZ powder.

4. The wide-temperature-range lubricating and wear-resistant coating material as described in any one of claims 1 to 3, characterized in that, The YSZ-coated CaF2 powder was prepared using the following method: YSZ sol was prepared using precursor salts and solvents; the precursor salts included yttrium salts and zirconium salts, and the Y2O3 content in the YSZ was 7%~9%; CaF2 powder is dispersed in the YSZ sol and spray-dried to obtain the YSZ-coated CaF2 powder; the mass ratio of CaF2 powder to YSZ in the YSZ sol is (2~3):

1.

5. The wide-temperature-range lubricating and wear-resistant coating material as described in any one of claims 1 to 3, characterized in that, The YSZ-coated AgTaO3 powder was prepared using the following method: YSZ sol was prepared using precursor salts and solvents; the precursor salts included yttrium salts and zirconium salts, and the Y2O3 content in the YSZ was 7%~9%; AgTaO3 powder is dispersed in the YSZ sol and spray-dried to obtain YSZ-coated AgTaO3 powder; the mass ratio of AgTaO3 powder to YSZ in the YSZ sol is (0.5~1.5):

1.

6. A coating, characterized in that, Includes a surface layer, wherein the raw material for preparing the surface layer is the wide temperature range lubricating and wear-resistant coating material as described in any one of claims 1-5.

7. The coating as described in claim 5, characterized in that, The coating further includes an adhesive layer, which is used to be laminated onto the substrate. The surface layer is laminated onto the adhesive layer. The raw material for preparing the adhesive layer is selected from MCrAlY alloy powder. The MCrAlY alloy powder is selected from at least one of NiCrAlY, CoCrAlY or NiCoCrAlY, and has a particle size of 20μm to 110μm.

8. The coating as described in claim 6, characterized in that, The thickness of the adhesive layer is 25μm~75μm; and / or The thickness of the surface layer is 100μm~300μm.

9. A method for preparing the coating according to any one of claims 6 to 8, characterized in that, Includes the following steps: S1. Spray the adhesive layer preparation material onto the substrate surface to obtain the adhesive layer; S2. Spray the wide temperature range lubricating and wear-resistant coating material onto the surface of the adhesive layer to form a surface layer, thereby obtaining the coating.

10. The method for preparing the coating as described in claim 9, characterized in that, In step S1, before spraying, the substrate is first sandblasted at a gas pressure of 0.1 MPa to 0.4 MPa, a sandblasting distance of 100 mm to 300 mm, and a sandblasting angle of 45° to 90°; and / or In step S1, the spraying is performed using plasma spraying equipment with a spraying power of 30kW~40kW and a spraying distance of 100mm~200mm; and / or In step S2, the spraying is performed using plasma spraying equipment with a spraying power of 35kW~45kW and a spraying distance of 100mm~200mm.

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