优化大气等离子喷涂工艺,降低TBC(热障涂层)生产成本.doc

TBC coating cost reduction by optimization of the Atmospheric Plasma Spray process 优化大气等离子喷涂工艺，降低TBC（热障涂层）生产成本 S. Mihm, T. Duda, Birr / CH, G. Thomas, H. Gruner, M?genwil / CH and B. Dzur, Ilmenau / D The global economic growth has triggered a dramatic increase in the demand for resources over the last few years, resulting in steady price increases for energy and raw materials. In the gas turbine manufacturing sector, process optimizations of cost-intensive production steps involve a heightened savings potential and form the basis for securing future competitive advantages in the market economy. 全球经济增长在过去的几年中引发了对资源需求急剧增加，导致能源和原材料价格稳步上涨。在燃气轮机制造业，对成本密集的生产工艺优化具有成本节约的潜力并为企业在将来市场经济的竞争中打下坚实的基础。 In this context, the atmospheric plasma spraying (APS) process for thermal barrier coatings (TBC) has been optimized. A constraint for the APS coating process optimization is the use of the existing coating equipment. 在这样的大背景下，热障涂层的大气等离子喷涂（APS）工艺得以改进优化。而工艺优化的一个限制条件在于现有涂层设备的使用。 Furthermore, the current coating quality and characteristics are not allowed to change in order to avoid new qualification and testing. 此外，为了避免重新资质进行额外测试，涂层质量和性能。 Using experience in atmospheric plasma spraying and empirically gained data, the process optimization plan included the variation of e.g. the plasma gas composition and flow rate, the electrical power, the arrangement and angle of the powder injectors to the plasma jet, the grain size distribution of the spray powder and the plasma torch movement procedure like spray distance, offset and iteration. In particular, plasma properties (enthalpy, velocity, temperature), powder injection conditions (injection point, injection speed, grain size distribution,) as well as the coating lamination (coating pattern, spraying distance) are examined. The optimized process and resulting coating was compared to the current situation by several diagnostics methods. 在以往大气等离子喷涂经验和日常获取的宝贵数据基础上，我们工艺优化计划包括等离子气