優(yōu)化大氣等離子噴涂工藝-降低tbc(熱障涂層)生產(chǎn)成本

1、TBCcoatingcostreductionbyoptimizationoftheAtmosphericPlasmaSprayprocess優(yōu)化大氣等離子噴涂工藝，降低TBC（熱障涂層）生產(chǎn)成本S.MihmT.DudaBirrCHG.ThomasH.GrunerMgenwilCHB.DzurIlmenauDTheglobaleconomicgrowthhastriggeredadramaticincreaseinthedemfreso

2、urcesoverthelastfewyearsresultinginsteadypriceincreasesfenergyrawmaterials.Inthegasturbinemanufacturingsectprocessoptimizationsofcostintensiveproductionstepsinvolveaheightenedsavingspotentialfmthebasisfsecuringfuturecomp

3、etitiveadvantagesinthemarketeconomy.全球經(jīng)濟(jì)增長(zhǎng)在過(guò)去的幾年中引發(fā)了對(duì)資源需求急劇增加，導(dǎo)致能源和原材料價(jià)格穩(wěn)步上漲。在燃?xì)廨啓C(jī)制造業(yè)，對(duì)成本密集的生產(chǎn)工藝優(yōu)化具有成本節(jié)約的潛力并能為企業(yè)在將來(lái)市場(chǎng)經(jīng)濟(jì)的競(jìng)爭(zhēng)中打下堅(jiān)實(shí)的基礎(chǔ)。Inthiscontexttheatmosphericplasmaspraying(APS)processfthermalbarriercoatings(TBC)hasbeeno

4、ptimized.AconstraintftheAPScoatingprocessoptimizationistheuseoftheexistingcoatingequipment.在這樣的大背景下，熱障涂層（TBC）的大氣等離子噴涂（APS）工藝得以改進(jìn)優(yōu)化。而APS制備涂層工藝優(yōu)化的一個(gè)限制條件在于現(xiàn)有涂層設(shè)備的使用。Furthermethecurrentcoatingqualityacteristicsarenotallowedt

5、ochangeindertoavoidnewqualificationtesting.此外，為了避免重新申請(qǐng)資質(zhì)以及進(jìn)行額外測(cè)試，還不能改變當(dāng)前的涂層質(zhì)量和性能。Usingexperienceinatmosphericplasmasprayingempiricallygaineddatatheprocessoptimizationplanincludedthevariationofe.g.theplasmagascompositionf

6、lowratetheelectricalpowerthearrangementangleofthepowderinjectstotheplasmajetthegrainsizedistributionofthespraypowdertheplasmatchmovementprocedurelikespraydistanceoffsetiteration.Inparticularplasmaproperties(enthalpyveloc

7、itytemperature)powderinjectionconditions(injectionpointinjectionspeedgrainsizedistribution)aswellasthecoatinglamination(coatingpatternsprayingdistance)areexamined.Theoptimizedprocessresultingcoatingwascomparedtothecurren

8、tsituationbyseveraldiagnosticsmethods.在以往大氣等離子噴涂經(jīng)驗(yàn)和日常獲取的寶貴數(shù)據(jù)基礎(chǔ)上，我們的工藝優(yōu)化計(jì)劃包括一系列的改變，如等離子氣體組成，流量；用電，布局及粉末注入等離子流的角度，粉末的粒徑分布、等離子槍的移動(dòng)（如噴距、偏差以及重復(fù)性等）。特別是等離子性能（焓值、速度以及溫度），注粉條件（注粉點(diǎn)、注粉速度、粒徑分布），以及還有涂層（涂層形式，噴涂距離）等方面做了重點(diǎn)研究。我們將優(yōu)化后的工藝及其

9、所制備的涂層與當(dāng)前普遍使用的幾種工藝采用不同的分析方法進(jìn)行了對(duì)比。Theimprovedprocessprovidessignificantlylowercostsbyachievingtherequirementofcomparablecoatingquality.Furthermeacontributionwasmadetoabettercomprehensionoftheatmosphericplasmasprayingofcer

10、amicsamethodffutureprocessdevelopmentsInadditiontoensurecoatingqualitythemanufacturingcostsarememeinfocusofcurrentdevelopments.除涂層質(zhì)量外，制造成本也越來(lái)越成為了當(dāng)前發(fā)展的焦點(diǎn)問(wèn)題。TheproductionofpousYSZcoatingsisdonebyAtmosphericplasmaspraying(A

11、PS).Usingthistechnologytheplasmatchconstructionisonelimitingfactfprocessimprovements.Fexamplevoltagepowerfluctuationsinfluencetheparticlepropertiesnegatively[2][3][4].Theuseofcylindricalnozzledesignlimitsthepossibilityof

12、adjustingtheplasmaflow.Byseveralnewplasmatchconcepts(multielectrodecadehighpower[5][6][7][8])newacteristicsareachievedwhichcancontributetoareductioninmanufacturingcost.ThetraditionalsinglecathodeanodeplasmatchbasedonF4MC

13、60isthemostwidelyusedsystemfyears.Especiallyinturbinemanufacturingthissystemisusedfcoatingcomponentswithcomplexgeometriesaccdingtothistargetedproductextensivemanipulationsequencesoftheplasmatchisrequired.多孔YSZ涂層通過(guò)大氣等離子工藝

14、（APS）進(jìn)行噴涂。而采用該項(xiàng)技術(shù)進(jìn)行工藝改造的關(guān)鍵限制因素是等離子槍的設(shè)計(jì)制造。如電壓和電流的波動(dòng)會(huì)影響到粉末顆粒的性能[2][3][4]。圓柱形噴嘴的使用限制了等離子流調(diào)整的可能性。通過(guò)采用一些新的設(shè)計(jì)理念（如多電極、串聯(lián)方式，大功率等[5][6][7][8]），等離子噴槍開(kāi)發(fā)了一些新的性能，從而能達(dá)到降低生產(chǎn)成本的目的?；贔4MC60基礎(chǔ)上制造的傳統(tǒng)單陰陽(yáng)極等離子噴槍系統(tǒng)已經(jīng)廣泛推廣并使用多年。特別是在輪機(jī)制造行業(yè)，該系統(tǒng)用于復(fù)

15、雜工件的噴涂，因?yàn)楣ぜY(jié)構(gòu)復(fù)雜，等離子噴槍的安裝工序就更繁雜一些。FthecoatingprocessofturbinecomponentswithpousYSZcoatingaposityclassof15%themanufacturingcostsexcludingwearpartsfadepreciatedequipmentlikeF4withtypicalcoatingparametersareshowninFig.2.輪機(jī)部件

16、的YSZ多孔涂層噴涂工藝（孔隙率大于15%）的成本計(jì)算在圖12中做了圖示說(shuō)明，采用典型參數(shù)進(jìn)行噴涂，費(fèi)用中不包含部件磨損和F4這樣的設(shè)備折舊費(fèi)用。Fig.2.costallocationofAPSprocessfpousYSZcoatingexcludingwearpartsdepreciatedequipment圖2：采用APS工藝制備多孔YSZ涂層的成本計(jì)算圖，部件磨損及設(shè)備折舊費(fèi)用不在計(jì)算范圍內(nèi)Plasmaparameterswi