Surface Alloy Coating Composite Material for High Temperature Resistance
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Solution Overview
Problem
High-temperature components in turbines face challenges such as erosion, oxidation, corrosion, and thermal fatigue, leading to cracking and potential failure, with existing thermal barrier coatings experiencing effectiveness loss due to Al depletion and thermal expansion coefficient mismatch.
Innovation Solution
A surface alloy coating composite material comprising metal alloy powder with a face-centered cubic structure and enamel powder, combined with a hardness-reinforcing phase, is applied to form a dense, continuous thermal protection coating that enhances oxidation resistance, fracture toughness, and thermal shock resistance, using a manufacturing method involving powder mixing, spraying, and high-temperature treatment to achieve metallurgical bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Al-containing bonding layers are used to prevent oxidation and enhance ceramic layer binding, then oxidation resistance and binding force are improved, but Al depletion occurs over time causing loss of effectiveness
Solution Approach 1:
The patent changes the chemical composition parameters by replacing Al with Si in the bonding layer (using MCrAlSiY instead of conventional MCrAlY), and adjusts the ceramic layer composition to contain SiO2 (5-20 wt%) which forms a protective glassy phase that prevents further oxidation and stabilizes the coating structure over time
Solution Approach 2:
The patent creates a composite coating system where the bonding layer contains MCrAlSiY alloy with controlled Al content (3-8 wt%) combined with a ceramic layer containing SiO2-stabilized zirconia, forming a multi-phase composite structure that combines the benefits of metal-ceramic bonding with oxidation protection without rapid Al depletion
2Temperature
If conventional thermal barrier coatings are applied to high-temperature alloy components, then thermal insulation is improved, but thermal expansion coefficient mismatch causes peeling under thermal cycling
Solution Approach 1:
The patent modifies the thermal expansion parameters by incorporating SiO2 (5-20 wt%) in the ceramic layer, which forms a glassy phase that adjusts the overall thermal expansion coefficient of the coating to better match the substrate, reducing thermal stress during cycling
Solution Approach 2:
The patent creates local compositional gradients within the coating layers, with the bonding layer containing MCrAlSiY alloy that forms intermediate compounds and the ceramic layer containing SiO2-stabilized zirconia, providing localized properties that bridge the thermal expansion mismatch between substrate and top coating
3Reliability
If plasma spraying or vapor deposition methods are used to apply thermal barrier coatings, then coating quality and adhesion are improved, but manufacturing cost and equipment complexity increase significantly
Solution Approach 1:
The patent employs conventional air plasma spraying technology rather than requiring advanced vapor deposition equipment, using readily available industrial equipment to apply the MCrAlSiY bonding layer and SiO2-containing ceramic layer, significantly reducing equipment investment and operational complexity
Solution Approach 2:
The patent optimizes the spray parameters and powder composition to achieve adequate coating quality through conventional plasma spraying, adjusting the ceramic powder composition to include SiO2 (5-20 wt%) and controlling the bonding layer Al content (3-8 wt%) to ensure proper adhesion and oxidation resistance without requiring state-of-the-art equipment
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 coating provides excellent high-temperature oxidation and corrosion resistance, improved fracture toughness, and adjustable thermal expansion coefficient, reducing thermal stress and peeling tendencies, while being cost-effective without requiring expensive plasma spraying or vacuum equipment.
Implementation Method 1
the coating provides excellent high-temperature oxidation and corrosion resistance
Implementation Method 2
adjustable thermal expansion coefficient, reducing thermal stress and peeling tendencies
Data Source
AI summary
The present invention provides a surface alloy coating composite material for a high temperature resistant material, a coating and a manufacturing method thereof, wherein the surface alloy coating composite material is made of metal alloy powder having a face-centered cubic structure and enamel powder, and a component percentage thereof is as follows: 10-70 wt % is the metal alloy powder, and remaining is the enamel powder; the metal alloy powder is selected from at least one type of NiCrAIX, NiCrX and NiCoCrAIX, wherein X is at least one type of hafnium, zirconium, a rare earth element and mixed rare earth, and the mixed rare earth can be two types or more than two types of rare earth elements that are used together or a rare earth element and one type or multiple types of Na, K, Ca, Sr and Ba that are used in a combined way.