Eutectic Ceramic Thermal Barrier Material for High-Temperature Oxidation Resistance
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Solution Overview
Problem
Nickel-based superalloys used in hot-end components face limitations due to high temperature-induced oxidation, leading to decreased strength, toughness, and hardness, restricting their application in severe aviation environments.
Innovation Solution
A eutectic ceramic thermal barrier material is developed, comprising a nickel-based superalloy substrate with a NiCoCrAlY intermediate binding layer and an Al2O3/GdAlO3 or Al2O3/GdAlO3/ZrO2 eutectic ceramic cladding layer, achieved through laser cladding, enhancing bonding strength and providing high temperature and oxidation resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If nickel-based superalloys are used in hot-end components, then excellent high temperature strength and creep resistance are achieved, but oxidation resistance deteriorates at temperatures above 1080°C
Solution Approach 1:
The patent applies composite materials by creating a multi-layer structure consisting of a nickel-based superalloy substrate combined with a eutectic ceramic cladding layer (Al2O3/GdAlO3 or Al2O3/GdAlO3/ZrO2) and a NiCoCrAlY intermediate binding layer. This composite structure allows the nickel-based superalloy to maintain its excellent high temperature strength and creep resistance while the ceramic cladding layer provides superior oxidation resistance, enabling the component to operate reliably at temperatures exceeding 1080°C without suffering from oxidation degradation.
2Temperature
If temperature is increased to exceed 2000°C, then service environment capability is improved, but material strength and toughness decrease due to oxidation
Solution Approach 1:
The patent uses composite materials to enable service temperatures exceeding 2000°C by protecting the nickel-based superalloy substrate with a eutectic ceramic cladding layer that resists oxidation. The Al2O3/GdAlO3 or Al2O3/GdAlO3/ZrO2 ceramic coating maintains structural integrity at extreme temperatures while preventing oxidative degradation of the underlying metal, thus preserving strength and toughness properties that would otherwise deteriorate at such high temperatures.
Solution Approach 2:
The patent introduces a NiCoCrAlY intermediate binding layer as a mediator between the nickel-based superalloy substrate and the eutectic ceramic cladding layer. This intermediate layer facilitates strong bonding between the metal substrate and ceramic coating, ensuring that the protective ceramic layer remains firmly attached even at service temperatures exceeding 2000°C, thereby maintaining the component's mechanical properties under extreme thermal conditions.
3Reliability
If eutectic ceramic cladding layer is applied to enhance oxidation resistance, then high temperature resistance is improved, but bonding strength between layers may be compromised due to thermal expansion coefficient mismatch
Solution Approach 1:
The patent introduces a NiCoCrAlY intermediate binding layer as a mediator between the nickel-based superalloy substrate and the eutectic ceramic cladding layer. This intermediate layer has thermal expansion coefficients that are intermediate between those of the metal substrate and ceramic coating, thereby reducing thermal stress and preventing coating delamination during thermal cycling. The intermediate layer forms strong metallurgical bonds with both the substrate and ceramic layer, ensuring durable attachment while maintaining oxidation resistance.
Solution Approach 2:
The patent applies parameter changes by carefully controlling the composition and microstructure of the NiCoCrAlY intermediate binding layer to optimize its thermal expansion properties. By adjusting the alloying elements and processing parameters, the intermediate layer's thermal expansion coefficient is tuned to match the average of the substrate and ceramic layers, minimizing thermal mismatch stresses and preventing bonding failure during high temperature service.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The eutectic ceramic thermal barrier material exhibits improved high temperature resistance, oxidation resistance, and mechanical properties, effectively addressing the limitations of nickel-based superalloys by enhancing bonding strength and maintaining structural integrity in extreme conditions.
Implementation Method 1
Subjecting a nickel-based superalloy powder to laser cladding, and stacking layer by layer to obtain the nickel-based superalloy substrate
Implementation Method 2
Subjecting a NiCoCrAlY powder to laser cladding on a surface of the nickel-based superalloy substrate
Implementation Method 3
stacking layer by layer to obtain an intermediate binding layer
Implementation Method 4
the eutectic ceramic cladding layer comprises an Al2O3/GdAlO3 binary eutectic ceramic coating or an Al2O3/GdAlO3/ZrO2 ternary eutectic ceramic coating
Implementation Method 5
The NiCoCrAlY binding layer is used as the intermediate binding layer, which can effectively avoid the coating cracking failure caused by the difference of thermal expansion coefficient between the eutectic ceramic cladding layer and the nickel-based superalloy substrate
Data Source
AI summary
The disclosure provides a eutectic ceramic thermal barrier material and a preparation method thereof, which relates to the field of composite materials. The present disclosure provides a eutectic ceramic thermal barrier material comprising a nickel-based superalloy substrate, an intermediate binding layer and a eutectic ceramic cladding layer stacked sequentially; the intermediate binding layer comprises a NiCoCrAlY binding layer; the eutectic ceramic cladding layer comprises an Al2O3/GdAlO3 binary eutectic ceramic coating or an Al2O3/GdAlO3/ZrO2 ternary eutectic ceramic coating. The eutectic ceramic thermal barrier material provided by the present disclosure has good high temperature resistance, good oxidation resistance and excellent mechanical properties.