【摘要】 单一烧蚀相调控YSZ涂层抗烧蚀性能存在作用时效短、生成的产物保护单一等问题，无法提供长时可靠的冷却降温效果。利用固相混合法制备四种Al/Zn/Cu复合烧蚀相发汗粉体(YSZ1-YSZ4)。通过爆炸喷涂工艺在聚酰亚胺树脂基复合材料上制备Cu/Al/Zn掺杂YSZ(发汗层)+NiCrAlY(金属过渡层)+Al(底层)构成的三层发汗热障涂层并开展烧蚀试验。结果表明：四种不同配比复合烧蚀相发汗粉体呈现YSZ陶瓷包覆Cu、Al和Zn等烧蚀相的结构；YSZ1、YSZ2和YSZ4粉体第一个吸热峰温度分别为417、418和417℃；YSZ1、YSZ3和YSZ4粉体第二个吸热峰温度分别为656、653和654℃；烧蚀相在涂层中呈现微米级厚度的条带状的分布和烧蚀相包覆YSZ未融颗粒的两种形态。烧蚀试验后，YSZ2、YSZ3和YSZ4涂层宏观表面出现明显裂纹，涂层组织结构已被破坏。YSZ1涂层的发汗层出现垂直裂纹但未造成更深的影响。涂层的发汗降温冷却作用主要受Zn和Al烧蚀相熔化吸热影响，Cu烧蚀相间接提升涂层的整体冷却效果。研究结果开创了新的多组元改性抗烧蚀防护体系，为航空发动机外涵机匣的涂层防护提供了新的改性路径。更多还原

【Abstract】 Polyimide resin matrix composites are used in aero-engine bypass casings, effectively reducing engine weight. However, these composites are susceptible to thermal damage during service. Preparing an anti-ablation coating on the surface of polyimide resin matrix composites improves their high-temperature performance. Previous studies have shown that adding a single ablation phase to yttria-stabilized zirconia(YSZ) coating can enhance its ablation resistance, although certain limitations remain. Resin matrix composites are widely used in aero-engines, but the limited heat resistance of the resin matrix makes them vulnerable to thermal damage at high temperatures. In this study, three types of Cu/Al/Zn composite ablation phases were added to an existing YSZ coating to investigate their synergistic effect on the ablation resistance of sweating thermal barrier coatings. Four types of Al/Zn/Cu composite ablative powders(YSZ1–YSZ4) were prepared using a solid-phase mixing method. A three-layer sweating thermal barrier coating—Al/Zn/Cu-doped YSZ(sweating layer) + Ni CrAlY(metal transition layer) + Al(bottom layer)—was fabricated on polyimide resin matrix composites by explosive spraying, followed by ablation testing. A thermal synchronous analyzer was used to measure the heat absorption and release behavior of the four powders. The surface and cross-sectional morphologies of the powders and coatings before and after ablation were characterized using scanning electron microscopy. Based on the ablation results, the influence of the Cu/Al/Zn ablation phases on YSZ coating performance and the synergistic enhancement mechanism were analyzed. The results showed that the four composite ablative phase powders with different ratios exhibited the structure of YSZ ceramic particles coated with Cu, Al, and Zn ablative phases. The first endothermic peak temperatures of YSZ1, YSZ2, and YSZ4 powders were 417 °C, 418 °C, and 417 °C, respectively. The second endothermic peak temperatures of YSZ1, YSZ3, and YSZ4 powders were 656 °C, 653 °C, and 654 °C, respectively. The ablative phases in the coating were distributed in strip-like regions with micron-scale thickness and appeared as ablative-phase-coated, unmelted YSZ particles. After ablation testing, significant surface cracking and internal structural damage occurred in YSZ2, YSZ3, and YSZ4 coatings. The sweating layer of the YSZ1 coating exhibited vertical cracks but no deeper structural degradation. Zn and Al influenced the first and second endothermic peak temperatures of the powders, respectively. The transpiration-cooling effect of the coating was primarily governed by the melting and heat absorption of the Zn and Al ablative phases, while the Cu phase indirectly enhanced the overall cooling effect. Among the coatings, YSZ1 demonstrated the best ablation resistance. The synergistic mechanism of the three Cu/Al/Zn composite ablation phases was attributed to the low melting point of Zn, which reduced coating temperature through endothermic evaporation; the strong heat absorption capacity of Al, which melted and filled coating pores; and the high thermal conductivity of Cu, which diffused heat to the lower-melting point phases of Zn and Al, thereby indirectly improving cooling efficiency. This study establishes a new multi-component modified anti-ablation protection system and provides a novel modification pathway for coating protection of aero-engine bypass casings.更多还原