ULTRALIMIT ALLOY AND PREPARATION METHOD THEREFOR

20220154347 · 2022-05-19

Assignee

KUNMING UNIVERSITY OF SCIENCE AND TECHNOLOGY (KUNMING, YUNNAN, CN)

Inventors

Cpc classification

International classification

Abstract

The present disclosure belongs to the field of preparation technology and provides an ultralimit alloy and a preparation method therefor. The ultralimit alloy comprises an alloy matrix. A bonding layer and a ceramic layer are successively deposited on a surface of the alloy matrix. The alloy matrix includes one of a magnesium alloy matrix, an aluminium alloy matrix, a titanium alloy matrix, an iron alloy matrix, a nickel alloy matrix, a copper alloy matrix, a zirconium alloy, and a tin alloy. For an ultralimit magnesium alloy, an ultralimit aluminium alloy, an ultralimit nickel alloy, an ultralimit titanium alloy, an ultralimit iron alloy and an ultralimit copper alloy, the bonding layer is a composite bonding layer, the ceramic layer is a composite ceramic layer, and the outside of the composite ceramic layer is further successively deposited with a reflecting layer, a catadioptric layer, an insulating layer and a carbon foam layer.

Claims

1. An ultralimit alloy, comprising an alloy matrix, wherein a composite bonding layer and a composite ceramic layer are successively deposited on a surface of the alloy matrix; the composite bonding layer includes a bonding layer deposited on the surface of the alloy matrix and a precious metal layer deposited on a surface of the bonding layer; the composite ceramic layer includes a ceramic A layer and a ceramic B layer; and the alloy matrix includes one of a magnesium alloy matrix, an aluminium alloy matrix, a nickel alloy matrix, a titanium alloy matrix, an iron alloy matrix, and a copper alloy matrix; Wherein, a reflecting layer, a catadioptric layer, an insulating layer, and a carbon foam layer are successively deposited outside the composite ceramic layer.

2. (canceled)

3. (canceled)

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6. (canceled)

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8. (canceled)

9. The ultralimit alloy according to claim 1, wherein a composition of the bonding layer is one or more of MCrAlY, NiAl, NiCr—Al and Mo alloy; MCrAlY is NiCrCoAlY, NiCoCrAlY, CoNiCrAlY or CoCrAlY; a composition of the precious metal layer is one of or an alloy of more of Au, Pt, Ru, Rh, Pd, and Ir.

10. The ultralimit alloy according to claim 1, wherein a composition of the ceramic A layer is YSZ or rare earth zirconate (RE.sub.2Zr.sub.2O.sub.7), and a composition of the ceramic B layer is ZrO.sub.2-RETaO.sub.4.

11. The ultralimit alloy according to claim 1, wherein a composition of the reflecting layer is one or more of REVO.sub.4, RETaO.sub.4, and Y.sub.2O.sub.3.

12. The ultralimit alloy according to claim 1, wherein a composition of the catadioptric layer is one or two of graphene and boron carbide, and the spatial distribution of the graphene and boron carbide are in a disorderly arranged state.

13. The ultralimit alloy according to claim 1, wherein a composition of the insulating layer is one or more of epoxy resin, phenolic resin, and ABS resin.

14. The ultralimit alloy according to claim 1, wherein a composition of the bonding layer is one or more of MCrAlY, NiAl, NiCr—Al and Mo alloy; MCrAlY is NiCrCoAlY, NiCoCrAlY, CoNiCrAlY or CoCrAlY; a composition of the precious metal layer is one of or an alloy of more of Au, Pt, Ru, Rh, Pd, and Ir; a composition of the ceramic A layer is YSZ or rare earth zirconate (RE.sub.2Zr.sub.2O.sub.7), and a composition of the ceramic B layer is ZrO.sub.2—RETaO.sub.4; a composition of the reflecting layer is one or more of REVO.sub.4, RETaO.sub.4, and Y.sub.2O.sub.3; a composition of the catadioptric layer is one or two of graphene and boron carbide, and the spatial distribution of the graphene and boron carbide are in a disorderly arranged state; and a composition of the insulating layer is one or more of epoxy resin, phenolic resin, and ABS resin.

15. A method for preparing the ultralimit alloy according to claim 1, comprising the following operations: operation 1: depositing a bonding layer on a surface of the alloy matrix; depositing a precious metal layer on a surface of the bonding layer, such that the bonding layer and the precious metal layer form a composite bonding layer; operation 2: depositing a ceramic A layer and a ceramic B layer on a surface of the composite bonding layer obtained in operation 1, such that the ceramic A layer and the ceramic B layer form a composite ceramic layer; operation 3: depositing a reflecting layer on a surface of the composite ceramic layer obtained in operation 2; operation 4: depositing a catadioptric layer on a surface of the reflecting layer obtained in operation 3; operation 5: depositing an insulating layer on a surface of the catadioptric layer obtained in operation 4; operation 6: depositing a carbon foam layer on a surface of the insulating layer obtained in operation 5, to form the ultralimit alloy.

16. The method for preparing the ultralimit alloy according to claim 15, wherein in operation 2, the ZrO.sub.2-RETaO.sub.4 forming the ceramic B layer has a shape of powder, the ZrO.sub.2-RETaO.sub.4 powder has a particle size of 10-70 μm, and particles of the ZrO.sub.2-RETaO.sub.4 powder are spherical.

17. The method for preparing the ultralimit alloy according to claim 15, wherein in operation 1, before the depositing of the bonding layer, a surface of the alloy matrix is subjected to pretreatment, wherein the pretreatment includes removal of oil stains and impurities; after the surface of the alloy matrix is pretreated, the surface of the alloy matrix is shot peened, such that a surface roughness of the alloy matrix is 60-100 μm.

18. An ultralimit zirconium alloy, comprising a zirconium alloy matrix, wherein a surface of the zirconium alloy matrix is successively deposited with a bonding layer, a precious metal layer, a ceramic A layer, and a ceramic B layer; wherein a thickness of the bonding layer is 50-150 μm, a thickness of the precious metal layer is 10-20 μm, a thickness of the ceramic A layer is 50-80 μm, and a thickness of the ceramic B layer is 50-80 μm; a surface of the ceramic B layer is successively deposited with a seal coating layer with a thickness of 5-10 μm, a reflecting layer with a thickness of 10-15 μm, a catadioptric layer with a thickness of 10-15 μm, and an electrically insulating layer with a thickness of 15-20 μm.

19. (canceled)

20. The ultralimit zirconium alloy according to claim 18, wherein a composition of the bonding layer is MCrAlY, wherein MCrAlY is CoCrAlY, NiCoCrAlY or CoNiCrAlY; a composition of the precious metal layer is one of or an alloy of more of Pt, Ru, Rh, Pd, Ir, and Os.

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25. A method for preparing the ultralimit zirconium alloy according to claim 18, comprising the following operations: operation 1: depositing a bonding layer with a thickness of 50-150 μm on a surface of the zirconium alloy matrix; operation 2: depositing a precious metal layer with a thickness of 10-20 μm on a surface of the bonding layer; operation 3: depositing a ceramic A layer with a thickness of 50-80 μm on a surface of the precious metal layer; operation 4: depositing a ceramic B layer with a thickness of 50-80 μm on a surface of the ceramic A layer; operation 5: depositing a seal coating layer with a thickness of 5-10 μm on a surface of the ceramic B layer; operation 6: depositing a reflecting layer with a thickness of 10-15 μm on a surface of the seal coating layer; operation 7: depositing a catadioptric layer with a thickness of 10-15 μm on a surface of the reflecting layer; and operation 8: depositing an electrically insulating layer with a thickness of 15-20 μm on a surface of the catadioptric layer, to prepare the ultralimit zirconium alloy.

26. The method for preparing the ultralimit zirconium alloy according to claim 25, wherein in operation 1, before the depositing of the bonding layer, oil stains on a surface of the zirconium alloy matrix are removed; the surface of the zirconium alloy matrix is then sandblasted, such that a surface roughness of the zirconium alloy matrix is 60-100 μm.

27. An ultralimit tin alloy, wherein the ultralimit tin alloy is a weld material, comprising a tin alloy matrix, wherein a surface of the tin alloy matrix is successively deposited with a bonding layer, a ceramic layer, and a seal coating layer; wherein a thickness of the bonding layer is 50-180 μm, a thickness of the ceramic layer is 50-80 μm, a thickness of the seal coating layer is 5-15 μm, the seal coating layer is successively deposited with a reflecting layer with a thickness of 5-15 μm, a catadioptric layer with a thickness of 5-15 μm, and an insulating layer with a thickness of 10-25 μm.

28. (canceled)

29. (canceled)

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33. (canceled)

34. (canceled)

35. A method for preparing the ultralimit tin alloy according to claim 27, comprising the following operations: operation 1: depositing a bonding layer on a surface of a tin alloy matrix, and a thickness of the bonding layer is 50-180 μm; operation 2: preparing a ceramic layer on a surface of the bonding layer obtained in operation 1, and a thickness of the ceramic layer is 50-80 μm; operation 3: preparing a seal coating layer on a surface of the ceramic layer obtained in operation 2, and a thickness of the seal coating layer is 5-15 μm; operation 4: preparing a reflecting layer on a surface of the seal coating layer obtained in operation 3, and a thickness of the reflecting layer is 5-15 μm; operation 5: preparing a catadioptric layer on a surface of the reflecting layer obtained in operation 4, and a thickness of the catadioptric layer is 5-15 μm; and operation 6: preparing an insulating layer on a surface of the catadioptric layer obtained in operation 5, and a thickness of the insulating layer is 10-25 μm.

36. The method for preparing the ultralimit tin alloy according to claim 35, wherein in operation 1, before the depositing of the bonding layer, the surface of the tin alloy matrix is sandblasted, and then the surface of the tin alloy matrix after the sandblasting is subjected to a dust removal process; the tin alloy weld material deposited with a plurality of coating layers by operations 1-6 is allowed to stand for 5-10 hours at 50-80° C. for aging treatment.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0118] FIG. 1A is a schematic diagram of the ultralimit magnesium alloy (Embodiment 1), ultralimit aluminum alloy (Embodiment 2) and ultralimit nickel alloy (Embodiment 3) of the present disclosure.

[0119] FIG. 1B is a schematic diagram of the ultralimit titanium alloy (Embodiment 4), ultralimit iron alloy (Embodiment 5) and ultralimit copper alloy (Embodiment 6) of the present disclosure.

[0120] FIG. 2A shows creep test curves of Test Example 1 and Comparative Example 13 at 50 MPa and 900° C. according to Embodiment 1 (ultralimit magnesium alloy) of the present disclosure.

[0121] FIG. 2B shows creep test curves of Test Example 1 and Comparative Example 13 at 50 MPa and 900° C. according to Embodiment 2 (ultralimit aluminum alloy) of the present disclosure.

[0122] FIG. 2C shows creep test curves of Test Example 1 and Comparative Example 13 at 50 MPa and 1800° C. according to Embodiment 3 (ultralimit nickel alloy) of the present disclosure.

[0123] FIG. 2D shows creep test curves of Test Example 1 and Comparative Example 13 at 50 MPa and 1900° C. according to Embodiment 4 (ultralimit titanium alloy) of the present disclosure.

[0124] FIG. 2E shows creep test curves of Test Example 1 and Comparative Example 13 at 50 MPa and 1900° C. according to Embodiment 5 (ultralimit iron alloy) of the present disclosure.

[0125] FIG. 2F shows creep test curves of Test Example 1 and Comparative Example 13 at 50 MPa and 1300° C. according to Embodiment 6 (ultralimit copper alloy) of the present disclosure.

[0126] FIG. 3A is a schematic diagram of the salt-spray corrosion test results of Test Example 1 and Comparative Example 13 according to Embodiment 1 (ultralimit magnesium alloy) of the present disclosure.

[0127] FIG. 3B is a schematic diagram of the salt-spray corrosion test results of Test Example 1 and Comparative Example 13 according to Embodiment 2 (ultralimit aluminum alloy) of the present disclosure.

[0128] FIG. 3C is a schematic diagram of the salt-spray corrosion test results of Test Example 1 and Comparative Example 13 according to Embodiment 3 (ultralimit nickel alloy) of the present disclosure.

[0129] FIG. 3D is a schematic diagram of the salt-spray corrosion test results of Test Example 1 and Comparative Example 13 according to Embodiment 4 (ultralimit titanium alloy) of the present disclosure.

[0130] FIG. 3E is a schematic diagram of the salt-spray corrosion test results of Test Example 1 and Comparative Example 13 according to Embodiment 5 (ultralimit iron alloy) of the present disclosure.

[0131] FIG. 3F is a schematic diagram of the salt-spray corrosion test results of Test Example 1 and Comparative Example 13 according to Embodiment 6 (ultralimit copper alloy) of the present disclosure.

[0132] FIG. 4 is a schematic diagram of the ultralimit zirconium alloy (Embodiment 7) of the present disclosure.

[0133] FIG. 5 shows high temperature creep test curves of Test Example 1 and Comparative Example 10 at 50 MPa and 2000° C. according to Embodiment 7 (ultralimit zirconium alloy) of the present disclosure.

[0134] FIG. 6 shows experimental curves of the salt-spray corrosion test of Test Example 1 and Comparative Example 10 according to Embodiment 7 (ultralimit zirconium alloy) of the present disclosure.

[0135] FIG. 7 is a schematic diagram of the ultralimit tin alloy weld material according to Embodiment 8 of the present disclosure.

[0136] FIG. 8 is a schematic diagram of a tin alloy weld material test piece in an experiment of Embodiment 8 of the present disclosure.

[0137] FIG. 9 shows high temperature tensile strength curves of Test Example 1 and Comparative Example 11 at 350° C. according to Embodiment 8 (ultralimit tin alloy weld material) of the present disclosure.

[0138] FIG. 10 shows experimental curves of the salt-spray corrosion test of Test Example 1 and Comparative Example 11 according to Embodiment 8 (ultralimit tin alloy weld material) of the present disclosure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Embodiment 1 (Ultralimit Magnesium Alloy)

[0139] In this embodiment, the ultralimit alloy is an ultralimit magnesium alloy, that is, the alloy matrix is a magnesium alloy.

[0140] The reference signs in FIG. 1A include: magnesium alloy matrix 1, composite bonding layer 2, bonding layer 21, precious metal layer 22, composite ceramic layer 3, ceramic A layer 31, ceramic B layer 32, reflecting layer 4, catadioptric layer 5, insulating layer 6, and carbon foam layer 7.

[0141] As shown in FIG. 1A, the present disclosure provides an ultralimit magnesium alloy. The ultralimit magnesium alloy includes a magnesium alloy matrix 1. The surface of the magnesium alloy matrix 1 is successively deposited with a composite bonding layer 2 with a thickness of 100-200 μm, a composite ceramic layer 3 with a thickness of 150-500 μm, a reflecting layer 4 with a thickness of 10-30 μm, a catadioptric layer 5 with a thickness of 10-30 μm, an insulating layer 6 with a thickness of 10-200 μm, and a carbon foam layer 7 with a thickness of 20-200 μm. The composite bonding layer 2 includes a bonding layer 21 deposited on the surface of the magnesium alloy matrix 1 and a precious metal layer 22 deposited on the surface of the bonding layer 21. The composition of the bonding layer 21 is one of or an alloy of more of MCrAlY, NiAl, NiCr—Al and Mo; MCrAlY is NiCrCoAlY, NiCoCrAlY, CoNiCrAlY or CoCrAlY. The composition of the precious metal layer 22 is one of or an alloy of more of Au, Pt, Ru, Rh, Pd, and Ir. The composite ceramic layer 3 includes a ceramic A layer 31 and a ceramic B layer 32. The ceramic A layer 31 is close to the precious metal layer 22, or, the ceramic B layer 32 is close to the precious metal layer 22. The composition of the ceramic A layer 31 is YSZ or rare earth zirconate (RE.sub.2Zr.sub.2O.sub.7, RE=Y, Nd, Eu, Gd, Dy or Sm). The composition of the ceramic B layer 32 is ZrO.sub.2-RETaO.sub.4; the ZrO.sub.2-RETaO.sub.4 is spherical in shape and has a particle size of 10-70 μm; the chemical formula of ZrO.sub.2-RETaO.sub.4 is RE.sub.1-x (Ta/Nb).sub.1-x(Zr/Ce/Ti).sub.2xO.sub.4, RE=Y, Nd, Eu, Gd, Dy, Er, Yb, Lu or Sm. The composition of the reflecting layer 4 is one or more of REVO.sub.4, RETaO.sub.4, and Y.sub.2O.sub.3, and RE=Y, Nd, Eu, Gd, Dy, Er, Yb, Lu or Sm. The composition of the catadioptric layer 5 is one or two of graphene and boron carbide, and the crystal structures of graphene and boron carbide are in a disorderly arranged state. The composition of the insulating layer 6 is one or more of epoxy resin, phenolic resin, and ABS resin.

[0142] The present disclosure uses ZrO.sub.2-RETaO.sub.4 as the ceramic B layer, which has the effects of low thermal conductivity and high expansion rate, and can reduce heat conduction; the ZrO.sub.2-RETaO.sub.4 prepared by the following method can meet the requirements of APS spraying technology.

[0143] ZrO.sub.2-RETaO.sub.4 is prepared by the following method. The method includes the following operations:

[0144] operation (1): pre-drying zirconium oxide (ZrO.sub.2) powder, rare earth oxide (RE.sub.2O.sub.3) powder and tantalum pentoxide (Ta.sub.2O.sub.5) powder, the pre-drying temperature is 600° C., and the pre-drying time is 8 hours; weighing zirconium oxide (ZrO.sub.2) powder, rare earth oxide powder RE.sub.2O.sub.3 and tantalum oxide (Ta.sub.2O.sub.5) powder according to a molar ratio of 2x:(1−x):(1−x), and adding the powders into the ethanol solvent to obtain a mixed solution, so that the molar ratio of RE:Ta:Zr in the mixed solution is (1−x):(1−x):2x; ball-milling the mixed solution using a ball mill for 10 hours, and the speed of the ball mill is 300 r/min;

[0145] drying the slurry obtained after ball milling using a rotary evaporator (model: N-1200B), the drying temperature is 60° C., and the drying time is 2 hours; sieving the dried powder through a 300-mesh sieve to obtain powder A;

[0146] operation (2): preparing powder B with a composition of ZrO.sub.2 doped with RETaO.sub.4 from the powder A obtained in operation (1) by a high-temperature solid-phase reaction method, the reaction temperature is 1700° C. and the reaction time is 10 hours; sieving the powder B with a 300-mesh sieve;

[0147] operation (3): mixing the powder B sieved in operation (2) with deionized water solvent and an organic bonding agent to obtain slurry C, the mass percentage of powder B in slurry C is 25%, the mass percentage of organic bonding agent in slurry C is 2%, and the rest is the solvent; the organic bonding agent is polyvinyl alcohol or gum arabic; drying the slurry C by a centrifugal atomization method to obtain dried granules D, the temperature during drying is 600° C., and the centrifugal speed is 8500 r/min;

[0148] operation (4): sintering the granules D obtained in operation (3) at 1200° C. for 8 hours, sieving the sintered granules D with a 300-mesh sieve to obtain ZrO.sub.2-RETaO.sub.4 ceramic powder having a particle size of 10-70 μm and a spherical shape.

[0149] Based on extensive experiments, the inventors conclude that within the parameter scope of the present disclosure, the prepared ultralimit magnesium alloys have the largest increase in service temperature, small increase in weight of the magnesium alloy and the best parameter ranges. In the present disclosure, 30 of the experiments are listed for description.

[0150] The parameters of Test Examples 1-30 of an ultralimit magnesium alloy and its preparation method according to the present disclosure are shown in Table 1-1, Table 1-2, and Table 1-3 (thickness unit: μm):

TABLE-US-00001 TABLE 1-1 Composition and thickness of each coating layer in Test Examples 1-10 of an ultralimit magnesium alloy and its preparation method Test Example 1 2 3 4 5 6 7 8 9 10 Composite Thickness of NiCrCoAlY 50 60 40 50 50 — — — — — bonding bonding layer CoCrAlY — — — — — — — — — — layer NiCoCrAlY — — — — — — — — — — CoNiCrAlY — — — — — — — — — — NiAl — — — — — 70 70 60 80 60 NiCr—Al — — — — — — — — — — Mo — — — — — — — — — — Thickness of Au 50 — — — — — 40 — — — precious metal Pt — 40 — — — — — 60 — — layer Ru — — 60 — — — — — 50 — Rh — — — 60 — — — — — 70 Pd — — — — 50 — — — — — Ir — — — — — 30 — — — — PT—Rh alloy — — — — — — — — — — Pd—Rh alloy — — — — — — — — — — Ru—Rh alloy — — — — — — — — — — Composite Thickness of YSZ 70 60 80 50 65 90 — — — — ceramic ceramic A layer Y.sub.2Zr.sub.2O.sub.7 — — — — — — 100 — — — layer Gd.sub.2Zr.sub.2O.sub.7 — — — — — — — 90 — — Nd.sub.2Zr.sub.2O.sub.7 — — — — — — — — 90 — Sm.sub.2Zr.sub.2O.sub.7 — — — — — — — — — 120 Eu.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Dy.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Sm.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Eu.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Nd.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Thickness of ZrO.sub.2—YTaO.sub.4 80 90 — 100 — — 90 — — ceramic B layer ZrO.sub.2—GdTaO.sub.4 — — 70 — 85 60 — 80 — — ZrO.sub.2—NdTaO.sub.4 — — — — — — — — 100 — ZrO.sub.2—SmTaO.sub.4 — — — — — — — — — 70 ZrO.sub.2—EuTaO.sub.4 — — — — — — — — — — ZrO.sub.2—DyTaO.sub.4 — — — — — — — — — — ZrO.sub.2—ErTaO.sub.4 — — — — — — — — — — ZrO.sub.2—YbTaO.sub.4 — — — — — — — — — — ZrO.sub.2—LuTaO.sub.4 — — — — — — — — — — Thickness of Y.sub.2O.sub.3 10 10 — — — — — — — — reflecting layer YVO.sub.4 — — — — 30 — — — — — NdVO.sub.4 — — — 20 — — — — — — SmVO.sub.4 — — 20 — — — — — — — EuVO.sub.4 — — — — — 10 — — — — GdVO.sub.4 — — — — — — 15 — — — DyVO.sub.4 — — — — — — — — — 10 ErVO.sub.4 — — — — — — — — 20 — YbVO.sub.4 — — — — — — — 10 — — LuVO.sub.4 — — — — — — — — — — YTaO.sub.4 — — — — — — — — — — NdTaO.sub.4 — — — — — — — — — — SmTaO.sub.4 — — — — — — — — — — EuTaO.sub.4 — — — — — — — — — - GdTaO.sub.4 — — — — — — — — — — DyTaO.sub.4 — — — — — — — — — — ErTaO.sub.4 — — — — — — — — — — YbTaO.sub.4 — — — — — — — — — — LuTaO.sub.4 — — — — — — — — — — Y.sub.2O.sub.3 and EuVO.sub.4 — — — — — — — — — — YVO.sub.4 and EuTaO.sub.4 — — — — — — — — — — Y.sub.2O.sub.3 and LuTaO.sub.4 — — — — — — — — — — YVO.sub.4 and LuTaO.sub.4 — — — — — — — — — — Thickness of Graphene 10 10 20 20 20 10 — — — — catadioptric layer Boron carbide — — — — — — 30 15 25 20 Thickness of Epoxy resin 15 10 — — — — 20 — — 10 insulating layer Phenolic resin — — 20 20 — — — — 15 — ABS resin — — — — 50 100 — 10 — — Thickness of carbon foam layer 20 20 20 20 100 200 30 25 20 35

TABLE-US-00002 TABLE 1-2 Composition and thickness of each coating layer in Test Examples 11-20 of an ultralimit magnesium alloy and its preparation method Test Example 11 12 13 14 15 16 17 18 19 20 Composite Thickness of NiCrCoAlY — — — — — — — — — — bonding bonding layer CoCrAlY 70 — — — — — — — — — layer NiCoCrAlY — 100 — — — — — — — — CoNiCrAlY — — 75 — — 65 — — — 55 NiAl — — — — 100 — — — — — NiCr—Al — — — 80 — — — 80 — — Mo — — — — — — 105 — 95 — Thickness of Au — — — — — — 75 — — — precious metal Pt — — — — — 105 — — 75 — layer Ru — — — — — — — 100 — — Rh — — — — — — — — — 125 Pd — — — — — — — — — — Ir — — — — — — — — — — PT—Rh alloy 90 — — — 60 — — — — — Pd—Rh alloy — 60 — 95 — — — — — — Ru—Rh alloy — — 90 — — — — — — — Composite Thickness of YSZ — — — — — 80 — — — — ceramic ceramic A layer Y.sub.2Zr.sub.2O.sub.7 — — — — — — 140 — — — layer Gd.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Nd.sub.2Zr.sub.2O.sub.7 — — — — — — — 100 — — Sm.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Eu.sub.2Zr.sub.2O.sub.7 50 — — — — — — — 110 — Dy.sub.2Zr.sub.2O.sub.7 — 70 — — — — — — — — YSZ and Sm.sub.2Zr.sub.2O.sub.7 — — 90 — — — — — — 180 YSZ and Eu.sub.2Zr.sub.2O.sub.7 — — — 60 — — — — — — YSZ and Nd.sub.2Zr.sub.2O.sub.7 — — — — 100 — — — — — Thickness of ZrO.sub.2—YTaO.sub.4 — — — — — 120 — — — — ceramic B layer ZrO.sub.2—GdTaO.sub.4 — — — — — — — 50 — — ZrO.sub.2—NdTaO.sub.4 — — — — — — 60 — — — ZrO.sub.2—SmTaO.sub.4 — — — — — — — — 70 — ZrO.sub.2—EuTaO.sub.4 130 — — — — — — — — 100 ZrO.sub.2—DyTaO.sub.4 — 90 — — — — — — — — ZrO.sub.2—ErTaO.sub.4 — — 70 — — — — — — — ZrO.sub.2—YbTaO.sub.4 — — — 90 — — — — — — ZrO.sub.2—LuTaO.sub.4 — — — — 60 — — — — — Thickness of Y.sub.2O.sub.3 — — — — — — — — — — reflecting layer YVO.sub.4 — — — — — — — — — — NdVO.sub.4 — — — — — — — — — — SmVO.sub.4 — — — — — — — — — — EuVO.sub.4 — — — — — — — — — — GdVO.sub.4 — — — — — — — — — — DyVO.sub.4 — — — — — — — — — — ErVO.sub.4 — — — — — — — — — — YbVO.sub.4 — — — — — — — — — — LuVO.sub.4 — — — — — — — 20 — — YTaO.sub.4 — — — — — — — — — 18 NdTaO.sub.4 — — — — — — — — 25 — SmTaO.sub.4 — — — — — — — — — — EuTaO.sub.4 — — — — — — — — — — GdTaO.sub.4 — — — — — — — — — — DyTaO.sub.4 — — — — — — — — — — ErTaO.sub.4 — — — — — — 15 — — — YbTaO.sub.4 — — - — — 10 — — — — LuTaO.sub.4 — — — — 20 — — — — — Y.sub.2O.sub.3 and EuVO.sub.4 15 — — — — — — — — — YVO.sub.4 and EuTaO.sub.4 — 20 — — — — — — — — Y.sub.2O.sub.3 and LuTaO.sub.4 — — 10 — — — — — — — YVO.sub.4 and LuTaO.sub.4 — — — 15 — — — — — — Thickness of Graphene 15 30 — — 25 — 20 — — 23 catadioptric layer Boron carbide — — 15 20 — 25 — 30 23 — Thickness of Epoxy resin 15 — — 15 — — 25 30 — 35 insulating layer Phenolic resin — 10 — — — — — — 200 — ABS resin — — 20 — 10 20 — — — — Thickness of carbon foam layer 30 40 45 50 70 50 60 80 100 200

TABLE-US-00003 TABLE 1-3 Composition and thickness of each coating layer in Test Examples 21-30 of an ultralimit magnesium alloy and its preparation method Test Example 21 22 23 24 25 26 27 28 29 30 Composite Thickness of NiCrCoAlY 65 — 40 — — — — — — 45 bonding bonding layer CoCrAlY — 50 — — — — — — — — layer NiCoCrAlY — — — — — 20 — — — — CoNiCrAlY — — — — 60 — — — — — NiAl — — — 30 — — — — — — NiCr—Al — — — — — — 80 100 — — Mo — — — — — — — — 65 — Thickness of Au 55 — — — — — — — — 65 precious metal Pt — 70 — — — — — — — — layer Ru — — 60 — 40 — — — 65 — Rh — — — 70 — — — — — — Pd — — — — — 80 — — — — Ir — — — — — — 80 — — — PT—Rh alloy — — — — — — — 100 — — Pd—Rh alloy — — — — — — — — — — Ru—Rh alloy — — — — — — — — — — Composite Thickness of YSZ 90 — — — — — — — — 70 ceramic ceramic A layer Y.sub.2Zr.sub.2O.sub.7 — 50 — — — — — 90 — — layer Gd.sub.2Zr.sub.2O.sub.7 — — — — — 80 — — — — Nd.sub.2Zr.sub.2O.sub.7 — — 150 — — — 300 — 85 — Sm.sub.2Zr.sub.2O.sub.7 — — — 100 80 — — — — — Eu.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Dy.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Sm.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Eu.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Nd.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — ZrO.sub.2—YTaO.sub.4 — — — — — — — — — 100 ZrO.sub.2—GdTaO.sub.4 — — — — — — — — — — ZrO.sub.2—NdTaO.sub.4 — — — — — — — — 75 — Thickness of ZrO.sub.2—SmTaO.sub.4 — — — — — — — — — — ceramic B layer ZrO.sub.2—EuTaO.sub.4 — — — — — — — — — — ZrO.sub.2—DyTaO.sub.4 80 — — — — — — 100 — — ZrO.sub.2—ErTaO.sub.4 — — — — 90 — 200 — — — ZrO.sub.2—YbTaO.sub.4 — 150 — — — 100 — — — — ZrO.sub.2—LuTaO.sub.4 — — 50 70 — — — — — — Thickness of Y.sub.2O.sub.3 — — — — — — — — — 20 reflecting layer YVO.sub.4 — — — — — — — — — — NdVO.sub.4 — — — — — — — — — — SmVO.sub.4 — — — — — — — — — — EuVO.sub.4 — — — — — — — — — — GdVO.sub.4 — — — — — — — — — — DyVO.sub.4 — — — 22 — — — — — — ErVO.sub.4 — — — — — 10 — — — — YbVO.sub.4 — — — — — — — — — — LuVO.sub.4 — — — — — — — — — — YTaO.sub.4 — — — — — — — — — — NdTaO.sub.4 — — — — — — — — — — SmTaO.sub.4 18 — — — — — — — — — EuTaO.sub.4 — — 12 — — — — — — — GdTaO.sub.4 — — — — 15 — — — — — DyTaO.sub.4 — 12 — — — — — — — — ErTaO.sub.4 — — — — — — — 30 — — YbTaO.sub.4 — — — — — — 28 — — — LuTaO.sub.4 — — — — — — — — 30 — Y.sub.2O.sub.3 and EuVO.sub.4 — — — — — — — — — — YVO.sub.4 and EuTaO.sub.4 — — — — — — — — — — Y.sub.2O.sub.3 and LuTaO.sub.4 — — — — — — — — — — YVO.sub.4 and LuTaO.sub.4 — — — — — — — — — — Thickness of Graphene 15 28 — 18 — 13 10 10 — 20 catadioptric layer Boron carbide — — 18 — 13 — — — 15 — Thickness of Epoxy resin — 10 — — — 180 — 160 — 15 insulating layer Phenolic resin 30 — — 80 100 — — — — — ABS resin — — 60 — — — 150 — 170 — Thickness of carbon foam layer 130 150 160 170 175 180 185 190 200 30

[0151] Take Test Example 1 of Embodiment 1 as an example to illustrate another technical solution of the present disclosure, that is, a method for preparing an ultralimit magnesium alloy. A method for preparing an ultralimit magnesium alloy, including the following operations:

[0152] Operation 1: in this test example, AM50A magnesium alloy serves as the magnesium alloy matrix, and the oil stains and impurities on the surface of magnesium alloy matrix are removed by a soaking method. First, the magnesium alloy matrix is soaked in an emulsified detergent or an alkali solution; the main components of the emulsified detergent are ethanol and surfactant, and the main components of the alkali solution are sodium hydroxide, trisodium phosphate, sodium carbonate and sodium silicate; in this test example, the magnesium alloy matrix is soaked in the alkali solution. The pH value of the alkali solution is adjusted to between 10-11, and then the magnesium alloy matrix is soaked in the alkali solution for 0.5-1.5 h and then taken out. In this test example, the soaking time is 1 hour. Then, the magnesium alloy matrix is rinsed with clean water and dried. The surface of the magnesium alloy matrix is shot peened by a shot peening machine. The shot peening machine used is a JCK-SS500-6A automatic transmission shot peening machine. The shot peening material used is any one of iron sand, glass shot and ceramic shot. In this test example, iron sand is used, and the particle size of the iron sand may be 0.3-0.8 mm; the particle size of the iron sand in this test example is 0.5 mm. The surface roughness of the magnesium alloy matrix after shot peening is 60-100 μm. In this test example, the surface roughness of the magnesium alloy matrix is 80 μm, which facilitates the bonding of the coating layer to the magnesium alloy matrix.

[0153] Operation 2: a composite bonding layer is deposited on the surface of the AM50A magnesium alloy after the shot peening. First, a layer of NiCrCoAlY is sprayed on the surface of the magnesium alloy matrix as the bonding layer by HVOF or supersonic arc spraying method. In this test example, the HVOF method is used; the powder particle size during spraying is 25-65 μm, the oxygen flow rate is 2000SCFH, the kerosene flow rate is 18.17 LPH, the carrier gas is 12.2SCFH, the powder feed rate is 5 RPM, the barrel length is 5 in, and the spraying distance is 254 mm.

[0154] Then, a layer of Au is deposited on the NiCrCoAlY as a precious metal layer by a EB-PVD method, such that a composite bonding layer is formed. The gas pressure when depositing Au is less than 0.01 Pa; in this test example, the gas pressure is 0.008 Pa, and the ratio of the temperature of the magnesium alloy matrix to the melting point of the magnesium alloy matrix is less than 0.3. The thickness of the deposited bonding layer is 50 μm, and the thickness of the precious metal layer is 50 μm.

[0155] Operation 3: a layer of YSZ is sprayed on the surface of the bonding layer as a ceramic A layer by APS, HVOF, PS-PVD or EB-PVD method; in this test example, the APS method is used. Then, a layer of YTaO.sub.4 is sprayed on the ceramic A layer as a ceramic B layer by the APS method, such that a composite ceramic layer is formed. The thickness of the ceramic A layer is 70 μm, and the thickness of the ceramic B layer is 80 μm.

[0156] Operation 4: a layer of Y.sub.2O.sub.3 transparent ceramic material is sprayed on the surface of the ceramic B layer as a reflecting layer by HVOF, PS-PVD or EB-PVD method; in this test example, the HVOF method is used. The thickness of the sprayed reflecting layer is 10 μm.

[0157] Operation 5: graphene and micron-sized carbon powder material are uniformly mixed with each other, and then the mixed powder is introduced into a solution for ultrasonic vibration mixing. In this test example, the solution is an ethanol solution with 1% dispersant. The micron-sized carbon powder is separated from the mixed solution by a filter paper. The solution mixed with graphene is brushed on the surface of the reflecting layer as a catadioptric layer. Then, the magnesium alloy brushed with the graphene catadioptric layer is placed in a drying oven and dried at 60° C. for 2 hours. The thickness of the brushed catadioptric layer is 10 μm.

[0158] Operation 6: a layer of epoxy resin is brushed on the surface of the catadioptric layer as an insulating layer, and the thickness of the insulating layer is 10 μm.

[0159] Operation 7: a layer of carbon foam layer is brushed on the insulating layer. The thickness of the carbon foam layer is 20 μm. The ultralimit magnesium alloy is obtained.

[0160] The only difference between Test Examples 2-29 and Test Example 1 is that the parameters as shown in Table 1-1 are different. The difference between Test Example 30 and Test Example 1 is that the spraying sequence of the ceramic A layer and the ceramic B layer in operation 3 is different.

[0161] Experiments:

[0162] 13 groups of Comparative Examples are provided to perform comparative experiments with Test Examples 1-30. The parameters of Comparative Examples 1-12 are shown in Table 1-4 (thickness unit: μm):

TABLE-US-00004 TABLE 1-4 Composition and thickness of each coating layer in Comparative Examples 1-12 Comparative Example 1 2 3 4 5 6 7 8 9 10 11 12 Composite Thickness of NiCrCoAlY 45 — — — 50 — — — — — — — bonding bonding layer NiAl — 60 — — — 70 50 — — — — — layer NiCr—Al — — 40 — — — — 30 — — — — Mo — — — 20 — — — — — 90 — 45 Thickness of Au — 30 — — — — — 60 — — — — precious metal Pt — — 40 — — — — — 50 — — — layer Ru — — — 60 — — — — — — — — Rh — — — — 50 — — — — — — — Pd — — — — — 30 — — — — — — Ir — — — — — — 60 — — — — — Composite Thickness of YSZ — — 60 55 — — — — — — — — ceramic ceramic A layer Y.sub.2Zr.sub.2O.sub.7 50 — — — 35 — — — — — — — layer Gd.sub.2Zr.sub.2O.sub.7 — 45 — — — — — — — — — — Nd.sub.2Zr.sub.2O.sub.7 — — — — — 100 — — — — — — Sm.sub.2Zr.sub.2O.sub.7 — — — — — — 150 — — — — — Eu.sub.2Zr.sub.2O.sub.7 — — — — — — — 150 — — — — Dy.sub.2Zr.sub.2O.sub.7 — — — — — — — — 80 — — — Thickness of ZrO.sub.2—YTaO.sub.4 40 — — — — — — — — — — — ceramic B layer ZrO.sub.2—GdTaO.sub.4 — — — 30 — — — — — — — — ZrO.sub.2—NdTaO.sub.4 — 50 — — — — — — — — — — ZrO.sub.2—SmTaO.sub.4 — — — — — — — 100 — — — — ZrO.sub.2—EuTaO.sub.4 — — 20 — — — — — — — — — ZrO.sub.2—DyTaO.sub.4 — — — — — 150 — — — — — — ZrO.sub.2—ErTaO.sub.4 — — — — 30 — — — — — — — ZrO.sub.2—YbTaO.sub.4 — — — — — — 80 — — — — — ZrO.sub.2—LuTaO.sub.4 — — — — — — — — 100 — — — Thickness of Y.sub.2O.sub.3 5 — — — — — — — — 20 — — reflecting layer YVO.sub.4 — 8 — — — — — — 35 — — — GdVO.sub.4 — — 5 — — — 38 — — — — 20 YTaO.sub.4 — — — 35 — — — 8 — — — — GdTaO.sub.4 — — — — 8 35 — — — — — — Thickness of Graphene 5 — 9 — 35 38 — 45 50 20 20 20 catadioptric layer Boron carbide — 8 — 6 — — 40 — — — — — Thickness of Epoxy resin 5 — — — 25 — 30 — — 15 15 15 insulating layer Phenolic resin — 9 — — — — — — 40 — — — ABS resin — — 8 5 — 28 — 35 — — — — Thickness of carbon foam layer 15 10 18 5 250 220 230 260 280 10 10 —

[0163] The only difference between Comparative Examples 1-12 and Test Example 1 is that the parameters as shown in Table 1-3 are different; the Comparative Example 13 uses AM50A magnesium alloy.

[0164] The following experiments are performed using the magnesium alloys provided in Test Examples 1-30 and Comparative Examples 1-13:

[0165] High Temperature Creep Test:

[0166] The magnesium alloys provided in Test Examples 1-30 and Comparative Examples 1-13 are processed into columnar test pieces with a length of 187 mm and a diameter of 16 mm. The high temperature creep test is carried out with an electronic high temperature creep rupture strength test machine (model: RMT-D5).

[0167] The test pieces of Test Examples 1-30 and Comparative Examples 1-13 are placed into the electronic high temperature creep rupture strength test machine, and the test machine is started to heat up the test machine. During the heating process, the test pieces are in a stress-free state (in a stress-free state, the test pieces can expand freely; the high-temperature creep means that the deformation increases with time under the combined action of temperature and stress, therefore, the heating rate has no influence on the creep). When the temperature of the test machine reaches 900° C., the stress of the test machine is adjusted to 50 MPa, and the high temperature creep test is carried out. Take Test Example 1 and Comparative Example 13 as examples, the experimental results are shown in FIG. 2A (in FIG. 2A, (A) represents Comparative Example 13, and (B) represents Test Example 1). The specific experimental results of Test Examples 1-30 and Comparative Examples 1-13 are shown in Table 1-5.

[0168] It can be observed from FIG. 2A that there are three stages of creep in both test pieces (A) and (B). However, when the temperature exceeds the melting point of AM50A magnesium alloy, the creep rupture of test piece (A) occurs within a very short period of time. Therefore, it can be concluded that AM50A magnesium alloy can hardly carry loads at a temperature higher than its melting point. Compared with test piece (A), the creep resistance of test piece (B) is significantly improved. The steady-state creep time of the test piece (B) is longer. It can be observed that after a long steady-state creep stage, the creep curve enters an accelerated creep stage, and the creep rupture occurs. Therefore, it can be concluded that, compared with the original AM50A magnesium alloy, the ultralimit magnesium alloy provided by the present disclosure maintains good mechanical properties without rupturing at a temperature exceeding the melting point of AM50A magnesium alloy, and has excellent high-temperature resistance.

[0169] Salt-Spray Corrosion Test:

[0170] The magnesium alloys provided in Test Examples 1-30 and Comparative Examples 1-13 are processed into test pieces of 50 mm×25 mm×2 mm, and then subjected to degreasing, rust removal, cleaning and drying. YWX/Q-250B salt-spray corrosion tester serves as the test equipment, and an atmospheric corrosive environment of GB/T2967.3-2008 is simulated.

[0171] The test pieces provided by Test Examples 1-30 and Comparative Examples 1-13 are hung in the test equipment, the test equipment is adjusted to a temperature of 50±1° C. and pH of 3.0-3.1, and then the test pieces are continuously sprayed with NaCl solution with a concentration of 5±0.5%. Taking Test Example 1 and Comparative Example 13 as examples, after continuously spraying a 5±0.5% NaCl solution on the test pieces for 8 h, 24 h, 48 h and 72 h, the weight loss rate of the test pieces is shown in FIG. 3A (in FIG. 3A, (A) represents Comparative Example 13, and (B) represents Test Example 1). The specific experimental results of Test Examples 1-30 and Comparative Examples 1-13 are shown in Table 1-5.

[0172] It can be concluded from FIG. 3A that test pieces (A) and (B) have obviously different corrosion patterns. For test piece (A), the corrosion weight loss value tends to increase as the corrosion time extends. In the early stage of corrosion (8-24 h), there is an oxidation film on the surface of the test pieces, which prevents the magnesium alloy matrix from contacting the solution; the corrosion rate is low. In the middle stage of corrosion (24-48 h), the Cl.sup.− in the solution has penetrated the oxidation film, and a large amount of Cl.sup.− is adsorbed on the matrix, which increases the corrosion pit points and deepens the original corrosion pit points; the corrosion rate is obviously accelerated. After 48 hours of continuous spraying, the corrosion products are evenly distributed and the thickness increases, covering almost the entire surface of the test piece. Cl.sup.− needs to pass through the corrosion products to contact the magnesium alloy matrix, which reduces the amount of Cl.sup.− adsorbed on the matrix surface and reduces the corrosion rate. In general, the corrosion loss weight of test piece (A) is much higher than that of test piece (B). Basically, the test piece (B) has no corrosion due to the existence of the coating layers, and the mass of the test piece (B) has hardly changed. Therefore, the ultralimit magnesium alloy provided by the present disclosure has good corrosion resistance.

[0173] The experimental results are shown in Table 1-5: (A. the steady creep time of the test pieces under 50 Mpa and 900° C. (min); B. the time when creep rupture of the test pieces happens under 50 Mpa and 900° C. (min); C. the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 8 hours; D. the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 24 hours; E. the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 48 hours; F. the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 72 hours))

TABLE-US-00005 TABLE 1-5 Experimental results of high temperature creep test and salt-spray test A B C D E F Test Example 1 170 300 0 0.01 0.03 0.13 Test Example 2 165 290 0 0.03 0.08 0.21 Test Example 3 165 290 0.015 0.04 0.08 0.21 Test Example 4 160 290 0.014 0.03 0.12 0.25 Test Example 5 160 295 0 0.02 0.09 0.23 Test Example 6 150 295 0 0.02 0.08 0.23 Test Example 7 150 280 0.015 0.02 0.09 0.22 Test Example 8 165 290 0 0.03 0.07 0.23 Test Example 9 165 290 0.016 0.02 0.09 0.25 Test Example 10 160 295 0 0.03 0.08 0.21 Test Example 11 160 295 0 0.04 0.08 0.21 Test Example 12 150 290 0.014 0.05 0.07 0.22 Test Example 13 150 285 0 0.03 0.08 0.23 Test Example 14 160 280 0 0.05 0.17 0.24 Test Example 15 160 280 0 0.05 0.08 0.23 Test Example 16 150 285 0 0.04 0.08 0.22 Test Example 17 150 290 0.05 0.02 0.06 0.21 Test Example 18 165 295 0.016 0.02 0.06 0.21 Test Example 19 160 290 0.016 0.03 0.06 0.21 Test Example 20 155 290 0 0.04 0.06 0.22 Test Example 21 155 290 0 0.05 0.08 0.22 Test Example 22 150 295 0.016 0.04 0.08 0.22 Test Example 23 150 295 0 0.04 0.09 0.23 Test Example 24 165 280 0 0.02 0.11 0.21 Test Example 25 165 285 0 0.03 0.07 0.25 Test Example 26 155 280 0 0.02 0.06 0.22 Test Example 27 155 295 0.014 0.05 0.06 0.25 Test Example 28 150 290 0.014 0.02 0.08 0.22 Test Example 29 160 285 0.015 0.02 0.06 0.24 Test Example 30 160 280 0.01 0.02 0.07 0.21 Comparative Example 1 150 250 0.02 0.08 0.28 0.8 Comparative Example 2 150 255 0.03 0.07 0.27 0.8 Comparative Example 3 155 250 0.02 0.06 0.27 0.8 Comparative Example 4 120 210 0.03 0.05 0.17 0.4 Comparative Example 5 145 235 0.03 0.05 0.17 0.4 Comparative Example 6 145 245 0.04 0.05 0.14 0.4 Comparative Example 7 135 250 0.03 0.75 0.15 0.5 Comparative Example 8 140 245 0.02 0.06 0.16 0.65 Comparative Example 9 150 245 0.02 0.06 0.15 0.85 Comparative Example 10 155 250 0.03 0.08 0.27 0.85 Comparative Example 11 140 245 0.04 0.09 0.25 0.9 Comparative Example 12 135 245 0.04 0.09 0.25 0.85 Comparative Example 13 10 15 2.1 4.2 8.9 10.9

[0174] It can be seen that by depositing composite bonding layer, composite ceramic layer, reflecting layer, catadioptric layer, insulating layer and carbon foam layer on the magnesium alloy, the service temperature of the magnesium alloy can be increased to 100-500° C. higher than the original melting point. The corrosion resistance can be greatly improved as well. In addition, by controlling the thickness of each coating layer within the range provided by the present disclosure, the effects of the prepared ultralimit magnesium alloy can be optimized. Compared with the ultralimit magnesium alloy provided by the present disclosure, the traditional magnesium alloy with parameters beyond the range provided in the test examples of the present embodiment has a much lower maximum service temperature and poorer corrosion resistance.

Embodiment 2 (Ultralimit Aluminum Alloy)

[0175] In this embodiment, the ultralimit alloy is an ultralimit aluminum alloy, that is, the alloy matrix is an aluminium alloy matrix.

[0176] The present disclosure will be described in more detail by using the embodiments below:

[0177] The reference signs in FIG. 1A include: aluminum alloy matrix 1, composite bonding layer 2, bonding layer 21, precious metal layer 22, composite ceramic layer 3, ceramic A layer 31, ceramic B layer 32, reflecting layer 4, catadioptric layer 5, insulating layer 6, and carbon foam layer 7.

[0178] As shown in FIG. 1A, the present disclosure provides an ultralimit aluminum alloy. The ultralimit aluminum alloy includes a aluminum alloy matrix 1. The surface of the magnesium alloy matrix 1 is successively deposited with a composite bonding layer 2 with a thickness of 100-200 μm, a composite ceramic layer 3 with a thickness of 150-500 μm, a reflecting layer 4 with a thickness of 10-30 μm, a catadioptric layer 5 with a thickness of 10-30 μm, an insulating layer 6 with a thickness of 10-200 μm, and a carbon foam layer 7 with a thickness of 20-200 μm. The composite bonding layer 2 includes a bonding layer 21 deposited on the surface of the aluminum alloy matrix 1 and a precious metal layer 22 deposited on the surface of the bonding layer 21. The composition of the bonding layer 21 is one or more of MCrAlY, NiAl, NiCr—Al and Mo; MCrAlY is NiCrCoAlY, NiCoCrAlY, CoNiCrAlY or CoCrAlY. The composition of the precious metal layer 22 is one of or an alloy of more of Au, Pt, Ru, Rh, Pd, and Ir. The composite ceramic layer 3 includes a ceramic A layer 31 and a ceramic B layer 32. The ceramic A layer 31 is close to the precious metal layer 22, or, the ceramic B layer 32 is close to the precious metal layer 22. The composition of the ceramic A layer 31 is YSZ or rare earth zirconate (RE.sub.2Zr.sub.2O.sub.7, RE=Y, Nd, Eu, Gd, Dy or Sm). The composition of the ceramic B layer 32 is ZrO.sub.2-RETaO.sub.4; the ZrO.sub.2-RETaO.sub.4 is spherical in shape and has a particle size of 10-70 μm; the chemical formula of ZrO.sub.2-RETaO.sub.4 is RE.sub.1-x(Ta/Nb).sub.1-x(Zr/Ce/Ti).sub.2xO.sub.4, RE=Y, Nd, Eu, Gd, Dy, Er, Yb, Lu or Sm. The composition of the reflecting layer 4 is one or more of REVO.sub.4, RETaO.sub.4 and Y.sub.2O.sub.3, and RE=Y, Nd, Eu, Gd, Dy, Er, Yb, Lu or Sm. The composition of the catadioptric layer 5 is one or two of graphene and boron carbide, and the spatial distribution of the graphene and boron carbide are in a disorderly arranged state. The composition of the insulating layer 6 is one or more of epoxy resin, phenolic resin, and ABS resin.

[0179] The present disclosure uses ZrO.sub.2-RETaO.sub.4 as the ceramic B layer, which has the effects of low thermal conductivity and high expansion rate, and can reduce heat conduction; The method for preparing ZrO.sub.2-RETaO.sub.4 is the same as that of Embodiment 1, and the ZrO.sub.2-RETaO.sub.4 can meet the requirements of APS spraying technology.

[0180] Based on extensive experiments, the inventors concludes that within the parameter scope of the present disclosure, the prepared ultralimit aluminum alloys have the largest increase in service temperature, and small increase in weight of the aluminum alloy. In the present disclosure, 30 of them are listed for description.

[0181] The parameters of Test Examples 1-30 of an ultralimit aluminum alloy and its preparation method according to the present disclosure are shown in Table 2-1, Table 2-2, and Table 2-3 (thickness unit: μm):

TABLE-US-00006 TABLE 2-1 Composition and thickness of each coating layer in Test Examples 1-10 of an ultralimit aluminum alloy and its preparation method Test Example 1 2 3 4 5 6 7 8 9 10 Composite Thickness of NiCrCoAlY 50 60 40 50 50 — — — — — bonding bonding layer CoCrAlY — — — — — — — — — — layer NiCoCrAlY — — — — — — — — — — CoNiCrAlY — — — — — — — — — — NiAl — — — — — 70 70 60 80 60 NiCr—Al — — — — — — — — — — Mo — — — — — — — — — — Thickness of Au 50 — — — — — 40 — — — precious metal Pt — 40 — — — — — 60 — — layer Ru — — 60 — — — — — 50 — Rh — — — 60 — — — — — 70 Pd — — — — 50 — — — — — Ir — — — — — 30 — — — — PT—Rh alloy — — — — — — — — — — Pd—Rh alloy — — — — — — — — — — Ru—Rh alloy — — — — — — — — — — Composite Thickness of YSZ 70 60 80 50 65 90 — — — — ceramic ceramic A layer Y.sub.2Zr.sub.2O.sub.7 — — — — — — 100 — — — layer Gd.sub.2Zr.sub.2O.sub.7 — — — — — — — 90 — — Nd.sub.2Zr.sub.2O.sub.7 — — — — — — — — 90 — Sm.sub.2Zr.sub.2O.sub.7 — — — — — — — — — 120 Eu.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Dy.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Sm.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Eu.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Nd.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Thickness of ZrO.sub.2—YTaO.sub.4 80 90 — 100 — — 90 — — — ceramic B layer ZrO.sub.2—GdTaO.sub.4 — — 70 — 85 60 — 80 — — ZrO.sub.2—NdTaO.sub.4 — — — — — — — — 100 — ZrO.sub.2—SmTaO.sub.4 — — — — — — — — — 70 ZrO.sub.2—EuTaO.sub.4 — — — — — — — — — — ZrO.sub.2—DyTaO.sub.4 — — — — — — — — — — ZrO.sub.2—ErTaO.sub.4 — — — — — — — — — — ZrO.sub.2—YbTaO.sub.4 — — — — — — — — — — ZrO.sub.2—LuTaO.sub.4 — — — — — — — — — — Thickness of Y.sub.2O.sub.3 10 10 — — — — — — — — reflecting layer YVO.sub.4 — — — — 30 — — — — — NdVO.sub.4 — — — 20 — — — — — — SmVO.sub.4 — — 20 — — — — — — — EuVO.sub.4 — — — — — 10 — — — — GdVO.sub.4 — — — — — — 15 — — — DyVO.sub.4 — — — — — — — — — 10 ErVO.sub.4 — — — — — — — — 20 — YbVO.sub.4 — — — — — — — 10 — — LuVO.sub.4 — — — — — — — — — — YTaO.sub.4 —- — —- — — — — — — — NdTaO.sub.4 — — — — — — — — — — SmTaO.sub.4 — — — — — — — — — — EuTaO.sub.4 — — — — — — — — — — GdTaO.sub.4 — — — — — — — — — — DyTaO.sub.4 — — — — — — — — — — ErTaO.sub.4 — — — — — — — — — — YbTaO.sub.4 — — — — — — — — — — LuTaO.sub.4 — — — — — — — — — — Y.sub.2O.sub.3 and EuVO.sub.4 — — — — — — — — — — YVO.sub.4 and EuTaO.sub.4 — — — — — — — — — — YVO.sub.4 and LuTaO.sub.4 — — — — — — — — — — Thickness of Graphene 10 10 20 20 20 10 — — — — catadioptric layer Boron carbide — — — — — — 30 15 25 20 Thickness of Epoxy resin 15 10 — — — — 20 — — 10 insulating layer Phenolic resin — — 20 20 — — — — 15 — ABS resin — — — — 50 100 — 10 — — Thickness of carbon foam layer 20 20 20 20 100 200 30 25 20 35

TABLE-US-00007 TABLE 2-2 Composition and thickness of each coating layer in Test Examples 11-20 of an ultralimit aluminum alloy and its preparation method Test Example 11 12 13 14 15 16 17 18 19 20 Composite Thickness of NiCrCoAlY — — — — — — — — — — bonding bonding layer CoCrAlY 70 — — — — — — — — — layer NiCoCrAlY — 100 — — — — — — — — CoNiCrAlY — — 75 — — 65 — — — 55 NiAl — — — — 100 — — — — — NiCr—Al — — — 80 — — — 80 — — Mo — — — — — — 105 — 95 — Thickness of Au — — — — — — 75 — — — precious metal Pt — — — — — 105 — — 75 — layer Ru — — — — — — — 100 — — Rh — — — — — — — — — 125 Pd — — — — — — — — — — Ir — — — — — — — — — — PT—Rh alloy 90 — — — 60 — — — — — Pd—Rh alloy — 60 — 95 — — — — — — Ru—Rh alloy — — 90 — — — — — — — Composite Thickness of YSZ — — — — — 80 — — — — ceramic ceramic A layer Y.sub.2Zr.sub.2O.sub.7 — — — — — — 140 — — — layer Gd.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Nd.sub.2Zr.sub.2O.sub.7 — — — — — — — 100 — — Sm.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Eu.sub.2Zr.sub.2O.sub.7 50 — — — — — — — 110 — Dy.sub.2Zr.sub.2O.sub.7 — 70 — — — — — — — — YSZ and Sm.sub.2Zr.sub.2O.sub.7 — — 90 — — — — — — 180 YSZ and Eu.sub.2Zr.sub.2O.sub.7 — — — 60 — — — — — — YSZ and Nd.sub.2Zr.sub.2O.sub.7 — — — — 100 — — — — — Thickness of ZrO.sub.2—YTaO.sub.4 — — — — — 120 — — — — ceramic B layer ZrO.sub.2—GdTaO.sub.4 — — — — — — — 50 — — ZrO.sub.2—NdTaO.sub.4 — — — — — — 60 — — — ZrO.sub.2—SmTaO.sub.4 — — — — — — — — 70 — ZrO.sub.2—EuTaO.sub.4 130 — — — — — — — — 100 ZrO.sub.2—DyTaO.sub.4 — 90 — — — — — — — — ZrO.sub.2—ErTaO.sub.4 — — 70 — — — — — — — ZrO.sub.2—YbTaO.sub.4 — — — 90 — — — — — — ZrO.sub.2—LuTaO.sub.4 — — — — 60 — — — — — Thickness of Y.sub.2O.sub.3 — — — — — — — — — — reflecting layer YVO.sub.4 — — — — — — — — — — NdVO.sub.4 — — — — — — — — — — SmVO.sub.4 — — — — — — — — — — EuVO.sub.4 — — — — — — — — — — GdVO.sub.4 — — — — — — — — — — DyVO.sub.4 — — — — — — — — — — ErVO.sub.4 — — — — — — — — — — YbVO.sub.4 — — — — — — — — — — LuVO.sub.4 — — — — — — — 20 — — YTaO.sub.4 — — — — — — — — — 18 NdTaO.sub.4 — — — — — — — — 25 — SmTaO.sub.4 — — — — — — — — — — EuTaO.sub.4 — — — — — — — — — — GdTaO.sub.4 — — — — — — — — — — DyTaO.sub.4 — — — — — — — — — — ErTaO.sub.4 — — — — — — 15 — — — YbTaO.sub.4 — — — — — 10 — — — — LuTaO.sub.4 — — — — 20 — — — — — Y.sub.2O.sub.3 and EuVO.sub.4 15 — — — — — — — — — YVO.sub.4 and EuTaO.sub.4 — 20 — — — — — — — — Y.sub.2O.sub.3 and LuTaO.sub.4 — — 10 — — — — — — — YVO.sub.4 and LuTaO.sub.4 — — — 15 — — — — — — Thickness of Graphene 15 30 — — 25 — 20 — — 23 catadioptric layer Boron carbide — — 15 20 — 25 — 30 23 — Thickness of Epoxy resin 15 — — 15 — — 25 30 — 35 insulating layer Phenolic resin — 10 — — — — — — 200 — ABS resin — — 20 — 10 20 — — — — Thickness of carbon foam layer 30 40 45 50 70 50 60 80 100 200

TABLE-US-00008 TABLE 2-3 Composition and thickness of each coating layer in Test Examples 21-30 of an ultralimit aluminum alloy and its preparation method Test Example 21 22 23 24 25 26 27 28 29 30 Composite Thickness of NiCrCoAlY 65 — 40 — — — — — — 45 bonding bonding layer CoCrAlY — 50 — — — — — — — — layer NiCoCrAlY — — — — — 20 — — — — CoNiCrAlY — — — — 60 — — — — — NiAl — — — 30 — — — — — — NiCr—Al — — — — — — 80 100 — — Mo — — — — — — — — 65 — Thickness of Au 55 — — — — — — — — 65 precious metal Pt — 70 — — — — — — — — layer Ru — — 60 — 40 — — — 65 — Rh — — — 70 — — — — — — Pd — — — — — 80 — — — — Ir — — — — — — 80 — — — PT—Rh alloy — — — — — — — 100 — — Pd—Rh alloy — — — — — — — — — — Ru—Rh alloy — — — — — — — — — — Composite Thickness of YSZ 90 — — — — — — — — 70 ceramic ceramic A layer Y.sub.2Zr.sub.2O.sub.7 — 50 — — — — — 90 — — layer Gd.sub.2Zr.sub.2O.sub.7 — — — — — 80 — — — — Nd.sub.2Zr.sub.2O.sub.7 — — 150 — — — 300 — 85 — Sm.sub.2Zr.sub.2O.sub.7 — — — 100 80 — — — — — Eu.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Dy.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Sm.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Eu.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Nd.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Thickness of ZrO.sub.2—YTaO.sub.4 — — — — — — — — — 100 ceramic B layer ZrO.sub.2—GdTaO.sub.4 — — — — — — — — — — ZrO.sub.2—NdTaO.sub.4 — — — — — — — — 75 — ZrO.sub.2—SmTaO.sub.4 — — — — — — — — — — ZrO.sub.2—EuTaO.sub.4 — — — — — — — — — — ZrO.sub.2—DyTaO.sub.4 80 — — — — — — 100 — — ZrO.sub.2—ErTaO.sub.4 — — — — 90 — 200 — — — ZrO.sub.2—YbTaO.sub.4 — 150 — — — 100 — — — — ZrO.sub.2—LuTaO.sub.4 — — 50 70 — — — — — — Thickness of Y.sub.2O.sub.3 — — — — — — — — — 20 reflecting layer YVO.sub.4 — — — — — — — — — — NdVO.sub.4 — — — — — — — — — — SmVO.sub.4 — — — — — — — — — — EuVO.sub.4 — — — — — — — — — — GdVO.sub.4 — — — — — — — — — — DyVO.sub.4 — — — 22 — — — — — — ErVO.sub.4 — — — — — 10 — — — — YbVO.sub.4 — — — — — — — — — — LuVO.sub.4 — — — — — — — — — — YTaO.sub.4 — — — — — — — — — — NdTaO.sub.4 — — — — — — — — — — SmTaO.sub.4 18 — — — — — — — — — EuTaO.sub.4 — — 12 — — — — — — — GdTaO.sub.4 — — — — 15 — — — — — DyTaO.sub.4 — 12 — — — — — — — — ErTaO.sub.4 — — — — — — — 30 — — YbTaO.sub.4 — — — — — — 28 — — — LuTaO.sub.4 — — — — — — — — 30 — Y.sub.2O.sub.3 and EuVO.sub.4 — — — — — — — — — — YVO.sub.4 and EuTaO.sub.4 — — — — — — — — — — Y.sub.2O.sub.3 and LuTaO.sub.4 — — — — — — — — — — YVO.sub.4 and LuTaO.sub.4 — — — — — — — — — — Thickness of Graphene 15 28 — 18 — 13 10 10 — 20 catadioptric layer Boron carbide — — 18 — 13 — — — 15 — Thickness of Epoxy resin — 10 — — — 180 — 160 — 15 insulating layer Phenolic resin 30 — — 80 100 — — — — — ABS resin — — 60 — — — 150 — 170 — Thickness of carbon foam layer 130 150 160 170 175 180 185 190 200 30

[0182] Take Test Example 1 of Embodiment 2 as an example to illustrate another technical solution of the present disclosure, that is, a method for preparing an ultralimit aluminum alloy. A method for preparing an ultralimit aluminum alloy, including the following operations:

[0183] Operation 1: basically the same as operation 1 of preparing ultralimit magnesium alloy in Embodiment 1, except that 7072 aluminum alloy serves as the alloy matrix in this test example.

[0184] Operation 2: same as that in Embodiment 1.

[0185] Operation 3: a layer of YSZ is sprayed on the surface of the bonding layer as a ceramic A layer by the APS method. Then, a layer of ZrO.sub.2—YTaO.sub.4 is sprayed on the ceramic A layer as a ceramic B layer by the APS method, such that a composite ceramic layer is formed. The thickness of the ceramic A layer is 70 μm, and the thickness of the ceramic B layer is 80 μm.

[0186] Operation 4: same as that in Embodiment 1.

[0187] Operation 5: same as that in Embodiment 1.

[0188] Operation 6: a layer of epoxy resin is brushed on the surface of the catadioptric layer as an insulating layer, and the thickness of the insulating layer is 15 μm.

[0189] Operation 7: a layer of carbon foam layer is brushed on the insulating layer. The thickness of the carbon foam layer is 20 μm. The ultralimit aluminum alloy is obtained.

[0190] The only difference between Test Examples 2-29 and Test Example 1 is that the parameters as shown in Table 2-1 are different. The difference between Test Example 30 and Test Example 1 is that the spraying sequence of the ceramic A layer and the ceramic B layer in operation 3 is different.

[0191] Experiments:

[0192] 13 groups of Comparative Examples are provided to perform comparative experiments with Test Examples 1-30. The parameters of Comparative Examples 1-12 are shown in Table 2-4 (thickness unit: μm):

TABLE-US-00009 TABLE 2-4 Composition and thickness of each coating layer in Comparative Examples 1-12 Comparative Example 1 2 3 4 5 6 7 8 9 10 11 12 Composite Thickness of NiCrCoAlY 45 — — — 50 — — — — — — — bonding layer bonding layer NiAl — 60 — — — 70 50 — — — — — NiCr—Al — — 40 — — — — 30 — — — — Mo — — — 20 — — — — — 90 — 45 Thickness of Au — 30 — — — — — 60 — — — — precious Pt — — 40 — — — — — 50 — — — metal layer Ru — — — 60 — — — — — — — — Rh — — — — 50 — — — — — — — Pd — — — — — 30 — — — — — — Ir — — — — — — 60 — — — — — Composite Thickness of YSZ — — 60 55 — — — — — — — — ceramic layer ceramic A layer Y.sub.2Zr.sub.2O.sub.7 50 — — — 35 — — — — — — — Gd.sub.2Zr.sub.2O.sub.7 — 45 — — — — — — — — — — Nd.sub.2Zr.sub.2O.sub.7 — — — — — 100 — — — — — — Sm.sub.2Zr.sub.2O.sub.7 — — — — — — 150 — — — — — Eu.sub.2Zr.sub.2O.sub.7 — — — — — — — 150 — — — — Dy.sub.2Zr.sub.2O.sub.7 — — — — — — — — 80 — — — Thickness of ZrO.sub.2—YTaO.sub.4 40 — — — — — — — — — — — ceramic B layer ZrO.sub.2—GdTaO.sub.4 — — — 30 — — — — — — — — ZrO.sub.2—NdTaO.sub.4 — 50 — — — — — — — — — — ZrO.sub.2—SmTaO.sub.4 — — — — — — — 100 — — — — ZrO.sub.2—EuTaO.sub.4 — — 20 — — — — — — — — — ZrO.sub.2—DyTaO.sub.4 — — — — — 150 — — — — — — ZrO.sub.2—ErTaO.sub.4 — — — — 30 — — — — — — — ZrO.sub.2—YbTaO.sub.4 — — — — — — 80 — — — — — ZrO.sub.2—LuTaO.sub.4 — — — — — — — — 100 — — — Thickness of Y.sub.2O.sub.3 5 — — — — — — — — 20 — — reflecting layer YVO.sub.4 — 8 — — — — — — 35 — — — GdVO.sub.4 — — 5 — — — 38 — — — — 20 YTaO.sub.4 — — — 35 — — — 8 — — — — GdTaO.sub.4 — — — — 8 35 — — — — — — Thickness of Graphene 5 — 9 — 35 38 — 45 50 20 20 20 catadioptric layer Boron carbide — 8 — 6 — — 40 — — — — — Thickness of Epoxy resin 5 — — — 25 — 30 — — 15 15 15 insulating layer Phenolic resin — 9 — — — — — — 40 — — ABS resin — — 8 5 — 28 — 35 — — — — Thickness of carbon foam layer 15 10 18 5 250 220 230 260 280 10 10 —

[0193] The only difference between Comparative Examples 1-12 and Test Example 1 is that the parameters as shown in Table 2-3 are different; the Comparative Example 13 uses 7072 aluminum alloy.

[0194] The following experiments are performed using the aluminum alloys provided in Test Examples 1-30 and Comparative Examples 1-13:

[0195] High Temperature Creep Test:

[0196] The aluminum alloys provided in Test Examples 1-30 and Comparative Examples 1-13 are processed into columnar test pieces with a length of 187 mm and a diameter of 16 mm. The procedure of the high temperature creep test is the same as that in Embodiment 1. Take Test Example 1 and Comparative Example 13 as examples, the experimental results are shown in FIG. 2B (in FIG. 2B, (A) represents Comparative Example 13, and (B) represents Test Example 1). The specific experimental results of Test Examples 1-30 and Comparative Examples 1-13 are shown in Table 2-5.

[0197] It can be observed from FIG. 2B that there are three stages of creep in both test pieces (A) and (B). However, when the temperature exceeds the melting point of 7072 aluminum alloy, the creep rupture of test piece (A) occurs within a very short period of time. Therefore, it can be concluded that 7072 aluminum alloy can hardly carry loads at a temperature higher than its melting point. Compared with test piece (A), the creep resistance of test piece (B) is significantly improved. The steady-state creep time of the test piece (B) is longer. It can be observed that after a long steady-state creep stage, the creep curve enters an accelerated creep stage, and the creep rupture occurs. Therefore, it can be concluded that, compared with the original 7072 aluminum alloy, the ultralimit aluminum alloy provided by the present disclosure maintains good mechanical properties without rupturing at a temperature exceeding the melting point of 7072 aluminum alloy, and has excellent high-temperature resistance.

[0198] Salt-Spray Corrosion Test:

[0199] The aluminum alloys provided in Test Examples 1-30 and Comparative Examples 1-13 are processed into test pieces of 50 mm×25 mm×2 mm, and the subsequent operations and experimental conditions are the same as those of Embodiment 1. The weight loss of the test pieces is shown in FIG. 3B (in FIG. 3B, (A) represents Comparative Example 13, and (B) represents Test Example 1). The specific experimental results of Test Examples 1-30 and Comparative Examples 1-13 are shown in Table 2-5.

[0200] It can be concluded from FIG. 3B that test pieces (A) and (B) have obviously different corrosion patterns. For test piece (A) (7072 aluminum alloy), the corrosion weight loss value tends to increase as the corrosion time extends. In the early stage of corrosion (8-24 h), there is an oxidation film on the surface of the test piece, which prevents the aluminum alloy matrix from contacting the solution; the corrosion rate is low. In the middle stage of corrosion (24-48 h), the in the solution has penetrated the oxidation film, and a large amount of is adsorbed on the matrix, which increases the corrosion pit points and deepens the original corrosion pit points; the corrosion rate is obviously accelerated. After 48 hours of continuous spraying, the corrosion products are evenly distributed and the thickness increases, covering almost the entire surface of the test piece. Cl.sup.− needs to pass through the corrosion products to contact the aluminum alloy matrix, which reduces the amount of Cl.sup.− adsorbed on the matrix surface and reduces the corrosion rate. In general, the corrosion loss weight of test piece (A) is much higher than that of test piece (B). Basically, the test piece (B) has no corrosion due to the existence of the coating layers, and the mass of the test piece (B) has hardly changed. Therefore, the ultralimit aluminum alloy provided by the present disclosure has good corrosion resistance.

[0201] The experimental results are shown in Table 2-5: (A. the steady creep time of the test pieces under 50 Mpa and 900° C. (min); B. the time when creep rupture of the test pieces happens under 50 Mpa and 900° C. (min); C. the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 8 hours; D. the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 24 hours; E. the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 48 hours; F. the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 72 hours))

TABLE-US-00010 TABLE 2-5 Experimental results of high temperature creep test and salt-spray test A B C D E F Test Example 1 170 300 0 0.01 0.07 0.11 Test Example 2 165 290 0 0.05 0.09 0.17 Test Example 3 165 290 0 0.04 0.09 0.17 Test Example 4 160 290 0 0.03 0.09 0.18 Test Example 5 160 295 0 0.03 0.08 0.13 Test Example 6 150 295 0 0.03 0.09 0.13 Test Example 7 150 280 0.005 0.02 0.09 0.12 Test Example 8 165 290 0 0.05 0.09 0.13 Test Example 9 165 290 0.006 0.04 0.09 0.15 Test Example 10 160 295 0 0.04 0.08 0.11 Test Example 11 160 295 0 0.05 0.08 0.11 Test Example 12 150 290 0.004 0.03 0.08 0.12 Test Example 13 150 285 0 0.03 0.09 0.13 Test Example 14 160 280 0 0.05 0.09 0.14 Test Example 15 160 280 0 0.05 0.09 0.13 Test Example 16 150 285 0 0.03 0.09 0.12 Test Example 17 150 290 0.005 0.02 0.09 0.11 Test Example 18 165 295 0.006 0.02 0.08 0.11 Test Example 19 160 290 0.006 0.03 0.08 0.11 Test Example 20 155 290 0 0.04 0.09 0.12 Test Example 21 155 290 0 0.05 0.09 0.12 Test Example 22 150 295 0.006 0.04 0.09 0.12 Test Example 23 150 295 0 0.04 0.09 0.13 Test Example 24 165 280 0 0.02 0.09 0.11 Test Example 25 165 285 0 0.03 0.09 0.15 Test Example 26 155 280 0 0.02 0.08 0.12 Test Example 27 155 295 0.004 0.05 0.08 0.15 Test Example 28 150 290 0.004 0.02 0.08 0.12 Test Example 29 160 285 0.005 0.02 0.08 0.14 Test Example 30 160 280 0 0.02 0.08 0.11 Comparative Example 1 150 250 0.07 0.08 0.18 0.85 Comparative Example 2 150 255 0.07 0.05 0.18 0.95 Comparative Example 3 155 250 0.06 0.05 0.17 0.8 Comparative Example 4 120 210 0.05 0.06 0.17 0.6 Comparative Example 5 145 235 0.05 0.07 0.17 0.7 Comparative Example 6 145 245 0.05 0.08 0.17 0.6 Comparative Example 7 135 250 0.05 0.08 0.17 0.7 Comparative Example 8 140 245 0.05 0.09 0.16 0.65 Comparative Example 9 150 245 0.03 0.09 0.15 0.85 Comparative Example 10 155 250 0.03 0.07 0.17 0.85 Comparative Example 11 140 245 0.02 0.08 0.18 0.9 Comparative Example 12 135 245 0.02 0.06 0.18 0.75 Comparative Example 13 20 45 2.1 4.2 8.6 11.1

[0202] It can be seen that by depositing composite bonding layer, composite ceramic layer, reflecting layer, catadioptric layer, insulating layer and carbon foam layer on the aluminum alloy, the service temperature of the aluminum alloy can be increased to 100-500° C. higher than the original melting point. The corrosion resistance can be greatly improved as well. In addition, by controlling the thickness of each coating layer within the range provided by the present disclosure, the best effects of the prepared ultralimit aluminum alloy can be achieved. Compared with the ultralimit aluminum alloy provided by the present disclosure, the aluminum alloy with parameters beyond the range provided in the test examples of the present embodiment has a much lower maximum service temperature and poorer corrosion resistance.

Embodiment 3 (Ultralimit Nickel Alloy)

[0203] In this embodiment, the ultralimit alloy is an ultralimit nickel alloy, that is, the alloy matrix is a nickel alloy.

[0204] The reference signs in FIG. 1A include: nickel alloy matrix 1, composite bonding layer 2, bonding layer 21, precious metal layer 22, composite ceramic layer 3, ceramic A layer 31, ceramic B layer 32, reflecting layer 4, catadioptric layer 5, insulating layer 6, and carbon foam layer 7.

[0205] As shown in FIG. 1A, the present disclosure provides an ultralimit nickel alloy. The ultralimit nickel alloy includes a nickel alloy matrix 1. The surface of the nickel alloy matrix 1 is successively deposited with a composite bonding layer 2 with a thickness of 80-100 μm, a composite ceramic layer 3 with a thickness of 150-500 μm, a reflecting layer 4 with a thickness of 10-30 μm, a catadioptric layer 5 with a thickness of 10-30 μm, an insulating layer 6 with a thickness of 10-200 μm, and a carbon foam layer 7 with a thickness of 20-200 μm. The composite bonding layer 2 includes a bonding layer 21 deposited on the surface of the nickel alloy matrix 1 and a precious metal layer 22 deposited on the surface of the bonding layer 21. The composition of the bonding layer 21 is one or more of MCrAlY, NiAl, NiCr—Al and Mo; MCrAlY is NiCrCoAlY, CoCrAlY, NiCoCrAlY or CoNiCrAlY. The composition of the precious metal layer 22 is one of or an alloy of more of Au, Pt, Ru, Rh, Pd, and Ir. The composite ceramic layer 3 includes a ceramic A layer 31 and a ceramic B layer 32. The ceramic A layer 31 is close to the precious metal layer 22, or, the ceramic B layer 32 is close to the precious metal layer 22. The composition of the ceramic A layer 31 is YSZ or rare earth zirconate (RE.sub.2Zr.sub.2O.sub.7, RE=Y, Nd, Eu, Gd, Dy or Sm). The composition of the ceramic B layer 32 is ZrO.sub.2-RETaO.sub.4; the ZrO.sub.2-RETaO.sub.4 is spherical in shape and has a particle size of 10-70 μm; the chemical formula of ZrO.sub.2-RETaO.sub.4 is RE.sub.1-x(Ta/Nb).sub.1-x(Zr/Ce/Ti).sub.2xO.sub.4, RE=Y, Nd, Eu, Gd, Dy, Er, Yb, Lu or Sm. The composition of the reflecting layer 4 is one or more of REVO.sub.4, RETaO.sub.4 and Y.sub.2O.sub.3, and RE=Y, Nd, Eu, Gd, Dy, Er, Yb, Lu or Sm. The composition of the catadioptric layer 5 is one or two of graphene and boron carbide, and the spatial distribution of the graphene and boron carbide are in a disorderly arranged state. The composition of the insulating layer 6 is one or more of epoxy resin, phenolic resin, and ABS resin.

[0206] The present disclosure uses ZrO.sub.2-RETaO.sub.4 as the ceramic B layer, which has the effects of low thermal conductivity and high expansion rate, and can reduce heat conduction; The method for preparing ZrO.sub.2-RETaO.sub.4 is the same as that of Embodiment 1, and the ZrO.sub.2-RETaO.sub.4 can meet the requirements of APS spraying technology.

[0207] Based on extensive experiments, the inventors conclude that within the parameter scope of the present disclosure, the prepared ultralimit nickel alloys have the largest increase in service temperature, and small increase in weight of the nickel alloy. In the present disclosure, 30 of them are listed for description.

[0208] The parameters of Test Examples 1-30 of an ultralimit nickel alloy and its preparation method according to the present disclosure are shown in Table 3-1, Table 3-2, and Table 3-3 (thickness unit: μm):

TABLE-US-00011 TABLE 3-1 Composition and thickness of each coating layer in Test Examples 1-10 of an ultralimit nickel alloy and its preparation method Test Example 1 2 3 4 5 6 7 8 9 10 Composite Thickness of NiCrCoAlY 45 60 40 20 50 — — — — — bonding layer bonding layer CoCrAlY — — — — — — — — — — NiCoCrAlY — — — — — — — — — — CoNiCrAlY — — — — — — — — — — NiAl — — — — — 70 50 30 40 20 NiCr—Al — — — — — — — — — — Mo — — — — — — — — — — Thickness of Au 45 — — — — — 40 — — — precious Pt — 30 — — — — — 60 — — metal layer Ru — — 40 — — — — — 50 — Rh — — — 60 — — — — — 70 Pd — — — — 50 — — — — — Ir — — — — — 30 — — — — PT-Rh alloy — — — — — — — — — — Pd—Rh alloy — — — — — — — — — — Ru—Rh alloy — — — — — — — — — — Composite Thickness of YSZ 70 60 80 50 65 90 — — — — ceramic layer ceramic A layer Y.sub.2Zr.sub.2O.sub.7 — — — — — — 100 — — — Gd.sub.2Zr.sub.2O.sub.7 — — — — — — — 90 — — Nd.sub.2Zr.sub.2O.sub.7 — — — — — — — — 90 — Sm.sub.2Zr.sub.2O.sub.7 — — — — — — — — — 120 Eu.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Dy.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Sm.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Eu.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Nd.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Thickness of ZrO.sub.2—YTaO.sub.4 80 90 — 100 — — 90 — — — ceramic B layer ZrO.sub.2—GdTaO.sub.4 — — 70 — 85 60 — 80 — — ZrO.sub.2—NdTaO.sub.4 — — — — — — — — 100 — ZrO.sub.2—SmTaO.sub.4 — — — — — — — — — 70 ZrO.sub.2—EuTaO.sub.4 — — — — — — — — — — ZrO.sub.2—DyTaO.sub.4 — — — — — — — — — — ZrO.sub.2—ErTaO.sub.4 — — — — — — — — — — ZrO.sub.2—YbTaO.sub.4 — — — — — — — — — — ZrO.sub.2—LuTaO.sub.4 — — — — — — — — — — Thickness of Y.sub.2O.sub.3 10 10 — — — — — — — — reflecting layer YVO.sub.4 — — — — 30 — — — — — NdVO.sub.4 — — — 20 — — — — — — SmVO.sub.4 — — 20 — — — — — — — EuVO.sub.4 — — — — — 10 — — — — GdVO.sub.4 — — — — — — 15 — — — DyVO.sub.4 — — — — — — — — — 10 ErVO.sub.4 — — — — — — — — 20 — YbVO.sub.4 — — — — — — — 10 — — LuVO.sub.4 — — — — — — — — — — YTaO.sub.4 — — — — — — — — — — NdTaO.sub.4 — — — — — — — — — — SmTaO.sub.4 — — — — — — — — — — EuTaO.sub.4 — — — — — — — — — — GdTaO.sub.4 — — — — — — — — — — DyTaO.sub.4 — — — — — — — — — — ErTaO.sub.4 — — — — — — — — — — YbTaO.sub.4 — — — — — — — — — — LuTaO.sub.4 — — — — — — — — — — Y.sub.2O.sub.3 and EuVO.sub.4 — — — — — — — — — — YVO.sub.4 and EuTaO.sub.4 — — — — — — — — — — Y.sub.2O.sub.3 and LuTaO.sub.4 — — — — — — — — — — YVO.sub.4 and LuTaO.sub.4 — — — — — — — — — — Thickness of Graphene 10 10 20 20 20 10 — — — — catadioptric layer Boron carbide — — — — — — 30 15 25 20 Thickness of Epoxy resin 15 10 — — — — 20 — — 10 insulating layer Phenolic resin — — 20 20 — — — — 15 — ABS resin — — — — 50 100 — 10 — — Thickness of carbon foam layer 20 20 20 20 100 200 30 25 20 35

TABLE-US-00012 TABLE 3-2 Composition and thickness of each coating layer in Test Examples 21-20 of an ultralimit nickel alloy and its preparation method Test Example 11 12 13 14 15 16 17 18 19 20 Composite Thickness of NiCrCoAlY — — — — — — — — — — bonding layer bonding layer CoCrAlY 70 — — — — — — — — — NiCoCrAlY — 20 — — — — — — — — CoNiCrAlY — — 55 — — 35 — — — 55 NiAl — — — — 60 — — — — — NiCr—Al — — — 30 — — — 20 — — Mo — — — — — — 45 — 35 — Thickness of Au — — — — — — 35 — — — precious Pt — — — — — 55 — — — — metal layer Ru — — — — — — — 60 — — Rh — — — — — — — — — 25 Pd — — — — — — — — 50 — Ir — — — — — — — — — — PT-Rh alloy 20 — — — 20 — — — — — Pd—Rh alloy — 60 — 55 — — — — — — Ru—Rh alloy — — 40 — — — — — — — Composite Thickness of YSZ — — — — — 80 — — — — ceramic layer ceramic A layer Y.sub.2Zr.sub.2O.sub.7 — — — — — — 140 — — — Gd.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Nd.sub.2Zr.sub.2O.sub.7 — — — — — — — 100 — — Sm.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Eu.sub.2Zr.sub.2O.sub.7 50 — — — — — — — 110 — Dy.sub.2Zr.sub.2O.sub.7 — 70 — — — — — — — — YSZ and Sm.sub.2Zr.sub.2O.sub.7 — — 90 — — — — — — 180 YSZ and Eu.sub.2Zr.sub.2O.sub.7 — — — 60 — — — — — — YSZ and Nd.sub.2Zr.sub.2O.sub.7 — — — — 100 — — — — — Thickness of ZrO.sub.2—YTaO.sub.4 — — — — — 120 — — — — ceramic B layer ZrO.sub.2—GdTaO.sub.4 — — — — — — — 50 — — ZrO.sub.2—NdTaO.sub.4 — — — — — — 60 — — — ZrO.sub.2—SmTaO.sub.4 — — — — — — — — 70 — ZrO.sub.2—EuTaO.sub.4 130 — — — — — — — — 100 ZrO.sub.2—DyTaO.sub.4 — 90 — — — — — — — — ZrO.sub.2—ErTaO.sub.4 — — 70 — — — — — — — ZrO.sub.2—YbTaO.sub.4 — — — 90 — — — — — — ZrO.sub.2—LuTaO.sub.4 — — — — 60 — — — — — Thickness of Y.sub.2O.sub.3 — — — — — — — — — — reflecting layer YVO.sub.4 — — — — — — — — — — NdVO.sub.4 — — — — — — — — — — SmVO.sub.4 — — — — — — — — — — EuVO.sub.4 — — — — — — — — — — GdVO.sub.4 — — — — — — — — — — DyVO.sub.4 — — — — — — — — — — ErVO.sub.4 — — — — — — — — — — YbVO.sub.4 — — — — — — — — — — LuVO.sub.4 — — — — — — — 20 — — YTaO.sub.4 — — — — — — — — — 18 NdTaO.sub.4 — — — — — — — — 25 — SmTaO.sub.4 — — — — — — — — — — EuTaO.sub.4 — — — — — — — — — — GdTaO.sub.4 — — — — — — — — — — DyTaO.sub.4 — — — — — — — — — — ErTaO.sub.4 — — — — — — 15 — — — YbTaO.sub.4 — — — — — 10 — — — — LuTaO.sub.4 — — — — 20 — — — — — Y.sub.2O.sub.3 and EuVO.sub.4 15 — — — — — — — — — YVO.sub.4 and EuTaO.sub.4 — 20 — — — — — — — — Y.sub.2O.sub.3 and LuTaO.sub.4 — — 10 — — — — — — — YVO.sub.4 and LuTaO.sub.4 — — — 15 — — — — — — Thickness of Graphene 15 30 — — 25 — 20 — — 23 catadioptric layer Boron carbide — — 15 20 — 25 — 30 23 — Thickness of Epoxy resin 15 — — 15 — — 25 30 — 35 insulating layer Phenolic resin — 10 — — — — — — 200 — ABS resin — — 20 — 10 20 — — — — Thickness of carbon foam layer 30 40 45 50 70 50 60 80 100 200

TABLE-US-00013 TABLE 3-3 Composition and thickness of each coating layer in Test Examples 21-30 of an ultralimit nickel alloy and its preparation method Test Example 21 22 23 24 25 26 27 28 29 30 Composite Thickness of NiCrCoAlY 35 — 40 — — — — — — 45 bonding layer bonding layer CoCrAlY — 50 — — — — — — — — NiCoCrAlY — — — — — 20 — — — — CoNiCrAlY — — — — 60 — — — — — NiAl — — — 30 — — — — — — NiCr—Al — — — — — — 80 45 — — Mo — — — — — — — — 65 — Thickness of Au 55 — — — — — — — — 45 precious Pt — 30 — — — — — — — — metal layer Ru — — 60 — 40 — — — 35 — Rh — — — 70 — — — — — — Pd — — — — — 80 — 55 — — Ir — — — — — — 20 — — — PT-Rh alloy — — — — — — — — — — Pd—Rh alloy — — — — — — — — — — Ru—Rh alloy — — — — — — — — — — Composite Thickness of YSZ 90 — — — — — — — — 70 ceramic layer ceramic A layer Y.sub.2Zr.sub.2O.sub.7 — 50 — — — — — 90 — — Gd.sub.2Zr.sub.2O.sub.7 — — — — — 80 — — — — Nd.sub.2Zr.sub.2O.sub.7 — — 150 — — — 300 — 85 — Sm.sub.2Zr.sub.2O.sub.7 — — — 100 80 — — — — — Eu.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Dy.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Sm.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Eu.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Nd.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Thickness of ZrO.sub.2—YTaO.sub.4 — — — — — — — — — 100 ceramic B layer ZrO.sub.2—GdTaO.sub.4 — — — — — — — — — — ZrO.sub.2—NdTaO.sub.4 — — — — — — — — 75 — ZrO.sub.2—SmTaO.sub.4 — — — — — — — — — — ZrO.sub.2—EuTaO.sub.4 — — — — — — — — — — ZrO.sub.2—DyTaO.sub.4 80 — — — — — — 100 — — ZrO.sub.2—ErTaO.sub.4 — — — — 90 — 200 — — — ZrO.sub.2—YbTaO.sub.4 — 150 — — — 100 — — — — ZrO.sub.2—LuTaO.sub.4 — — 50 70 — — — — — — Thickness of Y.sub.2O.sub.3 — — — — — — — — — 20 reflecting layer YVO.sub.4 — — — — — — — — — — NdVO.sub.4 — — — — — — — — — — SmVO.sub.4 — — — — — — — — — — EuVO.sub.4 — — — — — — — — — — GdVO.sub.4 — — — — — — — — — — DyVO.sub.4 — — — 22 — — — — — — ErVO.sub.4 — — — — — 10 — — — — YbVO.sub.4 — — — — — — — — — — LuVO.sub.4 — — — — — — — — — — YTaO.sub.4 — — — — — — — — — — NdTaO.sub.4 — — — — — — — — — — SmTaO.sub.4 18 — — — — — — — — — EuTaO.sub.4 — — 12 — — — — — — — GdTaO.sub.4 — — — — 15 — — — — — DyTaO.sub.4 — 12 — — — — — — — — ErTaO.sub.4 — — — — — — — 30 — — YbTaO.sub.4 — — — — — — 28 — — — LuTaO.sub.4 — — — — — — — — 30 — Y.sub.2O.sub.3 and EuVO.sub.4 — — — — — — — — — — YVO.sub.4 and EuTaO.sub.4 — — — — — — — — — — Y.sub.2O.sub.3 and LuTaO.sub.4 — — — — — — — — — — YVO.sub.4 and LuTaO.sub.4 — — — — — — — — — — Thickness of Graphene 15 28 — 18 — 13 10 10 — 20 catadioptric layer Boron carbide — — 18 — 13 — — — 15 — Thickness of Epoxy resin — 10 — — — 180 — 160 — 15 insulating layer Phenolic resin 30 — — 80 100 — — — — — ABS resin — — 60 — — — 150 — 170 — Thickness of carbon foam layer 130 150 160 170 175 180 185 190 200 30

[0209] Take Test Example 1 of Embodiment 3 as an example to illustrate another technical solution of the present disclosure, that is, a method for preparing an ultralimit nickel alloy. A method for preparing an ultralimit nickel alloy, including the following operations:

[0210] Operation 1: basically the same as operation 1 of preparing ultralimit magnesium alloy in Embodiment 1, except that GH4099 nickel alloy serves as the alloy matrix in this test example.

[0211] Operation 2: basically the same as that in Embodiment 1, except that the thickness of the deposited bonding layer is 45 μm, and the thickness of the precious metal layer is 45 μm.

[0212] Operation 3: a layer of YSZ is sprayed on the surface of the bonding layer as a ceramic A layer by the HVOF method. Then, a layer of YTaO.sub.4 is sprayed on the ceramic A layer as a ceramic B layer by the HVOF method, such that a composite ceramic layer is formed. The thickness of the ceramic A layer is 70 μm, and the thickness of the ceramic B layer is 80 μm.

[0213] Operation 4: same as that in Embodiment 1.

[0214] Operation 5: same as that in Embodiment 1.

[0215] Operation 6: a layer of epoxy resin is brushed on the surface of the catadioptric layer as an insulating layer, and the thickness of the insulating layer is 15 μm.

[0216] Operation 7: a layer of carbon foam layer is brushed on the insulating layer. The thickness of the carbon foam layer is 20 μm. The ultralimit nickel alloy is obtained.

[0217] The only difference between Test Examples 2-29 and Test Example 1 is that the parameters are different as shown in Table 3-1. The difference between Test Example 30 and Test Example 1 is that the spraying sequence of the ceramic A layer and the ceramic B layer in operation 3 is different.

[0218] Experiments:

[0219] 13 groups of Comparative Examples are provided to perform comparative experiments with Test Examples 1-30. The parameters of Comparative Examples 1-12 are shown in Table 3-4 (thickness unit: μm):

TABLE-US-00014 TABLE 3-4 Composition and thickness of each coating layer in Comparative Examples 1-12 Comparative Example 1 2 3 4 5 6 7 8 9 10 11 12 Composite Thickness of NiCrCoAlY 45 50 30 20 40 — — — — 45 45 50 bonding layer bonding layer MCrAlY — — — — — 40 — 30 40 — — — NiAl — — — — — — — — — — — — NiCr—Al — — — — — — — — — — — — Mo 30 — — — — — 50 — — 90 50 45 Thickness of Au — 20 — — — — — 60 — — — — precious Pt — — 40 — — — — — 50 — — — metal layer Ru — — — 40 — — — — — — — — Rh — — — — 30 — — — — — — — Pd — — — — — 30 — — — — — — Ir — — — — — — 60 — — — — — Composite Thickness of YSZ — — 60 55 — — — — — — — — ceramic layer ceramic A layer Y.sub.2Zr.sub.2O.sub.7 50 — — — 35 — — — — — — — Gd.sub.2Zr.sub.2O.sub.7 45 — — — — — — — — — — Nd.sub.2Zr.sub.2O.sub.7 — — — — — 300 — — — — — — Sm.sub.2Zr.sub.2O.sub.7 — — — — — — — 200 — — — — Eu.sub.2Zr.sub.2O.sub.7 — — — — — — — — 250 — — — Dy.sub.2Zr.sub.2O.sub.7 — — — — — — 350 — — — — — Thickness of ZrO.sub.2—YTaO.sub.4 40 — — — — — — — — — — — ceramic B layer ZrO.sub.2—GdTaO.sub.4 — — — 30 — — — — — — — — ZrO.sub.2—NdTaO.sub.4 — 50 — — — — — — — — — — ZrO.sub.2—SmTaO.sub.4 — — — — — — — 450 — — — — ZrO.sub.2—EuTaO.sub.4 — — 20 — — — — — — — — — ZrO.sub.2—DyTaO.sub.4 — — — — — 350 — — — — — — ZrO.sub.2—ErTaO.sub.4 — — — — 30 — — — — — — — ZrO.sub.2—YbTaO.sub.4 — — — — — — 250 — — — — — ZrO.sub.2—LuTaO.sub.4 — — — — — — — — 300 — — — Thickness of Y.sub.2O.sub.3 5 — — — — — — — — 20 — — reflecting layer YVO.sub.4 — 8 — — — — — — 35 — — — GdVO.sub.4 — — 5 — — — 38 — — — — 20 YTaO.sub.4 — — — 35 — — — 8 — — — — GdTaO.sub.4 — — — — 8 35 — — — — — — Thickness of Graphene 5 — 9 — 35 38 — 45 50 20 20 20 catadioptric layer Boron carbide — 8 — 6 — — 40 — — — — — Thickness of Epoxy resin 5 — — — 25 — 30 — — 15 15 15 insulating layer Phenolic resin — 9 — — — — — — 40 — — ABS resin — — 8 5 — 28 — 35 — — — — Thickness of carbon foam layer 15 10 18 5 250 220 230 260 280 10 10 —

[0220] The only difference between Comparative Examples 1-12 and Test Example 1 is that the parameters as shown in Table 3-3 are different; the Comparative Example 13 uses GH4099 nickel alloy.

[0221] The following experiments are performed using the nickel alloys provided in Test Examples 1-30 and Comparative Examples 1-13:

[0222] High Temperature Creep Test:

[0223] The nickel alloys provided in Test Examples 1-30 and Comparative Examples 1-13 are processed into columnar test pieces with a length of 187 mm and a diameter of 16 mm. The procedure of the high temperature creep test is basically the same as that in Embodiment 1, except that when the temperature of the test machine reaches 1800° C., the stress of the test machine is adjusted to 50 MPa, and the high temperature creep test is carried out. Take Test Example 1 and Comparative Example 13 as examples, the experimental results are shown in FIG. 2C (in FIG. 2C, (A) represents Comparative Example 13, and (B) represents Test Example 1). The specific experimental results of Test Examples 1-30 and Comparative Examples 1-13 are shown in Table 3-5.

[0224] It can be observed from FIG. 2C that there are three stages of creep in both test pieces (A) and (B). However, when the temperature exceeds the melting point of GH4099 nickel alloy, the creep rupture of test piece (A) occurs within a very short period of time. Therefore, it can be concluded that GH4099 nickel alloy can hardly carry loads at a temperature higher than its melting point. Compared with test piece (A), the creep resistance of test piece (B) is significantly improved. The steady-state creep time of the test piece (B) is longer. It can be observed that after a long steady-state creep stage, the creep curve enters an accelerated creep stage, and the creep rupture occurs. Therefore, it can be concluded that, compared with the original GH4099 nickel alloy, the ultralimit nickel alloy provided by the present disclosure maintains good mechanical properties without rupturing at a temperature exceeding the melting point of GH4099 nickel alloy, and has excellent high-temperature resistance.

[0225] Salt-Spray Corrosion Test:

[0226] The nickel alloy provided in Test Examples 1-30 and Comparative Examples 1-13 are processed into test pieces of 50 mm×25 mm×2 mm, and the subsequent operations and experimental conditions are the same as those of Embodiment 1. The weight loss of the test pieces is shown in FIG. 3C (in FIG. 3C, (A) represents Comparative Example 13, and (B) represents Test Example 1). The specific experimental results of Test Examples 1-30 and Comparative Examples 1-13 are shown in Table 3-5.

[0227] It can be concluded from FIG. 3C that test pieces (A) and (B) have obviously different corrosion patterns. For test piece (A), the corrosion weight loss value tends to increase as the corrosion time extends. In the early stage of corrosion (8-24 h), there is an oxidation film on the surface of the test piece, which prevents the nickel alloy matrix from contacting the solution; the corrosion rate is low. In the middle stage of corrosion (24-48 h), the Cl.sup.− in the solution has penetrated the oxidation film, and a large amount of Cl.sup.− is adsorbed on the matrix, which increases the corrosion pit points and deepens the original corrosion pit points; the corrosion rate is obviously accelerated. After 48 hours of continuous spraying, the corrosion products are evenly distributed and the thickness increases, covering almost the entire surface of the test piece. Cl.sup.− needs to pass through the corrosion products to contact the nickel alloy matrix, which reduces the amount of Cl.sup.− adsorbed on the matrix surface and reduces the corrosion rate. In general, the corrosion loss weight of test piece (A) is much higher than that of test piece (B). Basically, the test piece (B) has no corrosion due to the existence of the coating layers, and the mass of the test piece (B) has hardly changed. Therefore, the ultralimit nickel alloy provided by the present disclosure has good corrosion resistance.

[0228] The experimental results are shown in Table 3-5: (A. the steady creep time of the test pieces under 50 Mpa and 1800° C. (min); B. the time when creep rupture of the test pieces happens under 50 Mpa and 1800° C. (min); C. the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 8 hours; D. the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 24 hours; E. the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 48 hours; F. the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 72 hours))

TABLE-US-00015 TABLE 3-5 Experimental results of high temperature creep test and salt-spray test A B C D E F Test Example 1 180 330 0 0.01 0.02 0.1 Test Example 2 165 320 0 0.01 0.025 0.15 Test Example 3 165 315 0 0.015 0.027 0.13 Test Example 4 170 315 0.005 0.015 0.027 0.15 Test Example 5 170 320 0.004 0.017 0.027 0.16 Test Example 6 165 320 0.005 0.018 0.028 0.13 Test Example 7 170 325 0 0.018 0.03 0.13 Test Example 8 165 320 0 0.018 0.03 0.14 Test Example 9 165 320 0.006 0.018 0.028 0.15 Test Example 10 165 335 0.006 0.017 0.028 0.15 Test Example 11 160 315 0.005 0.017 0.028 0.14 Test Example 12 160 315 0.005 0.018 0.029 0.14 Test Example 13 160 315 0.004 0.018 0.028 0.14 Test Example 14 165 315 0 0.019 0.029 0.15 Test Example 15 165 320 0 0.018 0.028 0.15 Test Example 16 170 320 0.005 0.019 0.029 0.15 Test Example 17 160 325 0.005 0.018 0.028 0.14 Test Example 18 170 315 0.005 0.019 0.03 0.14 Test Example 19 165 315 0 0.019 0.029 0.15 Test Example 20 165 320 0 0.019 0.03 0.15 Test Example 21 160 320 0 0.018 0.028 0.13 Test Example 22 165 325 0.005 0.019 0.028 0.13 Test Example 23 165 325 0.003 0.018 0.029 0.15 Test Example 24 160 320 0.004 0.019 0.028 0.14 Test Example 25 165 320 0.003 0.018 0.029 0.15 Test Example 26 160 315 0.004 0.018 0.03 0.14 Test Example 27 160 315 0.003 0.018 0.03 0.17 Test Example 28 160 320 0.004 0.019 0.028 0.18 Test Example 29 165 320 0 0.019 0.029 0.16 Test Example 30 165 315 0.002 0.018 0.029 0.15 Comparative Example 1 145 285 0.03 0.025 0.038 0.25 Comparative Example 2 145 285 0.01 0.025 0.041 0.25 Comparative Example 3 140 275 0.01 0.025 0.041 0.21 Comparative Example 4 150 275 0.009 0.023 0.035 0.21 Comparative Example 5 155 285 0.009 0.021 0.035 0.21 Comparative Example 6 150 290 0.008 0.021 0.036 0.22 Comparative Example 7 150 285 0.01 0.023 0.038 0.21 Comparative Example 8 150 385 0.01 0.022 0.036 0.22 Comparative Example 9 150 285 0.009 0.021 0.036 0.22 Comparative Example 10 140 265 0.02 0.021 0.041 0.26 Comparative Example 11 135 275 0.02 0.025 0.042 0.27 Comparative Example 12 145 265 0.02 0.025 0.041 0.25

[0229] In summary, the ultralimit nickel alloy prepared by the ultralimit nickel alloy preparation method of the present disclosure has a wide service temperature range and strong corrosion resistance; the effects of Test Example 1 are the best. Compared with the ultralimit nickel alloy provided by the present disclosure, the nickel alloy with parameters beyond the range provided in the test examples of the present embodiment has a much lower maximum service temperature and poorer corrosion resistance.

Embodiment 4 (Ultralimit Titanium Alloy)

[0230] In this embodiment, the ultralimit alloy is an ultralimit titanium alloy, that is, the alloy matrix is a titanium alloy matrix.

[0231] The reference signs in FIG. 1B include: titanium alloy matrix 1, bonding layer 2, precious metal layer 3, ceramic A layer 4, ceramic B layer 5, reflecting layer 6, catadioptric layer 7, insulating layer 8, and carbon foam layer 9.

[0232] As shown in FIG. 1B, the present disclosure provides an ultralimit titanium alloy, including an titanium alloy matrix 1. The surface of the titanium alloy matrix 1 is successively deposited with a composite bonding layer, a composite ceramic layer with a thickness of 100-150 μm, a reflecting layer 6 with a thickness of 10-30 μm, a catadioptric layer 7 with a thickness of 20-30 μm, an insulating layer 8 with a thickness of 100-200 μm and a carbon foam layer 9 with a thickness of 20-200 μm. The composite bonding layer includes a bonding layer 2 deposited on the surface of the titanium alloy matrix 1 and a precious metal layer 3 deposited on the surface of the bonding layer 2. The thickness of the bonding layer 2 is 20-30 μm, and the thickness of the precious metal layer is 40-60 μm. The composition of the bonding layer 2 is one or more of MCrAlY, NiAl, NiCr—Al and Mo; MCrAlY is NiCrCoAlY, NiCoCrAlY, CoNiCrAlY or CoCrAlY. The composition of the precious metal layer 3 is one of or an alloy of more of Au, Pt, Ru, Rh, Pd, and Ir. The composite ceramic layer includes a ceramic A layer 4 and a ceramic B layer 5. The composition of the ceramic A layer 4 is YSZ or rare earth zirconate (RE.sub.2Zr.sub.2O.sub.7, RE=Y, Gd, Nd, Sm, Eu or Dy). The composition of the ceramic B layer 5 is ZrO.sub.2-RETaO.sub.4 (RE=Y, Gd, Nd, Sm, Eu, Dy, Er, Yb or Lu). The reflecting layer 6 is one or more of REVO.sub.4, RETaO.sub.4 and Y.sub.2O.sub.3, and RE=Y, Nd, Sm, Eu, Gd, Dy, Er, Yb or Lu. The composition of the catadioptric layer 7 is one or two of graphene and boron carbide, and the spatial distribution of the graphene and boron carbide are in a disorderly arranged state. The composition of the insulating layer 8 is one or more of epoxy resin, phenolic resin, and ABS resin.

[0233] The present disclosure uses ZrO.sub.2-RETaO.sub.4 as the ceramic B layer, which has the effects of low thermal conductivity and high expansion rate, and can reduce heat conduction; The method for preparing ZrO.sub.2-RETaO.sub.4 is the same as that of Embodiment 1, and the ZrO.sub.2-RETaO.sub.4 can meet the requirements of APS spraying technology on powder particle size and shape. Based on extensive experiments, the inventors obtain ultralimit titanium alloys with the largest increase in service temperature, small increase in weight of the titanium alloy and the best composition and thickness of the coating layers within the parameter scope of the present disclosure. In the present disclosure, 30 of them are listed for description.

[0234] The parameters of Test Examples 1-30 of an ultralimit titanium alloy and its preparation method according to the present disclosure are shown in Table 4-1, Table 4-2, and Table 4-3 (thickness unit: μm):

TABLE-US-00016 TABLE 4-1 Composition and thickness of each coating layer in Test Examples 1-10 of an ultralimit titanium alloy and its preparation method Test Example 1 2 3 4 5 6 7 8 9 10 Composite Composition and NiCrCoAlY 20 30 20 25 30 — — — — — bonding layer thickness of CoCrAlY — — — — — — — — — — bonding layer NiCoCrAlY — — — — — — — — — — CoNiCrAlY — — — — — — — — — — NiAl — — — — — 30 20 25 20 25 NiCr—Al — — — — — — — — — — Mo alloy — — — — — — — — — — Composition and Au 50 — — — — — 45 — — — thickness of Pt — 40 — — — — — 60 — — precious layer Ru — — 60 — — — — — 50 — Rh — — — 50 — — — — — 50 Pd — — — — 40 — — — — — Ir — — — — — 50 — — — — PT-Rh alloy — — — — — — — — — — Pd—Rh alloy — — — — — — — — — — Ru—Rh alloy — — — — — — — — — — Composite Composition and YSZ 70 60 80 90 110 50 — — — — ceramic layer thickness of Y.sub.2Zr.sub.2O.sub.7 — — — — — — 40 — — — ceramic A layer Gd.sub.2Zr.sub.2O.sub.7 — — — — — — — 80 — — Nd.sub.2Zr.sub.2O.sub.7 — — — — — — — — 60 — Sm.sub.2Zr.sub.2O.sub.7 — — — — — — — — — 60 Eu.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Dy.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Sm.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Eu.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Nd.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Composition and ZrO.sub.2—YTaO.sub.4 80 90 — 50 — — 70 — — — thickness of ZrO.sub.2—GdTaO.sub.4 — — 70 — 40 50 — 50 — — ceramic B layer ZrO.sub.2—NdTaO.sub.4 — — — — — — — — 60 — ZrO.sub.2—SmTaO.sub.4 — — — — — — — — — 70 ZrO.sub.2—EuTaO.sub.4 — — — — — — — — — — ZrO.sub.2—DyTaO.sub.4 — — — — — — — — — — ZrO.sub.2—ErTaO.sub.4 — — — — — — — — — — ZrO.sub.2—YbTaO.sub.4 — — — — — — — — — — ZrO.sub.2—LuTaO.sub.4 — — — — — — — — — — Composition and Y.sub.2O.sub.3 10 10 — — — — 15 — — — thickness of YVO.sub.4 — — 20 — 30 10 — — — — reflecting layer NdVO.sub.4 — — — — — — — — — — SmVO.sub.4 — — — — — — — — — — EuVO.sub.4 — — — — — — — — — — GdVO.sub.4 — — — — — — — — — 10 DyVO.sub.4 — — — — — — — — — — ErVO.sub.4 — — — — — — — — — — YbVO.sub.4 — — — — — — — — — — LuVO.sub.4 — — — — — — — — — — YTaO.sub.4 — — — 20 — — — 10 20 — NdTaO.sub.4 — — — — — — — — — — SmTaO.sub.4 — — — — — — — — — — EuTaO.sub.4 — — — — — — — — — — GdTaO.sub.4 — — — — — — — — — — DyTaO.sub.4 — — — — — — — — — — ErTaO.sub.4 — — — — — — — — — — YbTaO.sub.4 — — — — — — — — — — LuTaO.sub.4 — — — — — — — — — — Y.sub.2O.sub.3 and EuVO.sub.4 — — — — — — — — — — YVO.sub.4 and EuTaO.sub.4 — — — — — — — — — — Y.sub.2O.sub.3 and LuTaO.sub.4 — — — — — — — — — — YVO.sub.4 and LuTaO.sub.4 — — — — — — — — — — Composition and Graphene 20 20 20 20 30 20 — — — — thickness of Boron carbide — — — — — — 30 25 25 20 catadioptric layer Composition and Epoxy resin 150 100 — — — — 200 — — 100 thickness of Phenolic resin — — 200 200 — — — — 150 — insulating layer ABS resin — — — — 150 100 — 100 — — Thickness of carbon foam layer 20 20 20 20 100 200 30 25 20 35

TABLE-US-00017 TABLE 4-2 Composition and thickness of each coating layer in Test Examples 11-20 of an ultralimit titanium alloy and its preparation method Test Example 11 12 13 14 15 16 17 18 19 20 Composite Composition and NiCrCoAlY — — — — — — — — — — bonding layer thickness of CoCrAlY 20 — — — — — — — — — bonding layer NiCoCrAlY — 25 — — — — — — — — CoNiCrAlY — — 25 — — 30 — — — 30 NiAl — — — — 30 — — — — — NiCr—Al — — — 25 — — — 25 — — Mo alloy — — — — — — 30 — 25 — Composition and Au — — — — — — 50 — — — thickness of Pt — — — — — 50 — — — — precious layer Ru — — — — — — — 60 — — Rh — — — — — — — — — 50 Pd — — — — — — — — 45 — Ir — — — — — — — — — — PT-Rh alloy 40 — — — 50 — — — — — Pd—Rh alloy — 40 — 50 — — — — — — Ru—Rh alloy — — 60 — — — — — — — Composite Composition and YSZ — — — — — 80 — — — — ceramic layer thickness of Y.sub.2Zr.sub.2O.sub.7 — — — — — — 70 — — — ceramic A layer Gd.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Nd.sub.2Zr.sub.2O.sub.7 — — — — — — — 100 — — Sm.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Eu.sub.2Zr.sub.2O.sub.7 50 — — — — — — — 80 — Dy.sub.2Zr.sub.2O.sub.7 — 40 — — — — — — — — YSZ and Sm.sub.2Zr.sub.2O.sub.7 — — 60 — — — — — — 50 YSZ and Eu.sub.2Zr.sub.2O.sub.7 — — — 60 — — — — — — YSZ and Nd.sub.2Zr.sub.2O.sub.7 — — — — 80 — — — — — Composition and ZrO.sub.2—YTaO.sub.4 — — — — — 60 — — — — thickness of ZrO.sub.2—GdTaO.sub.4 — — — — — — — 50 — — ceramic B layer ZrO.sub.2—NdTaO.sub.4 — — — — — — 60 — — — ZrO.sub.2—SmTaO.sub.4 — — — — — — — — 70 — ZrO.sub.2—EuTaO.sub.4 100 — — — — — — — — 100 ZrO.sub.2—DyTaO.sub.4 — 110 — — — — — — — — ZrO.sub.2—ErTaO.sub.4 — — 80 — — — — — — — ZrO.sub.2—YbTaO.sub.4 — — — 90 — — — — — — ZrO.sub.2—LuTaO.sub.4 — — — — 50 — — — — — Composition and Y.sub.2O.sub.3 — — — — — — — — — — thickness of YVO.sub.4 — — — — — — — — — — reflecting layer NdVO.sub.4 — — — — — — — — — — SmVO.sub.4 — — — — — — — — — — EuVO.sub.4 — — — — — — — 20 — — GdVO.sub.4 — — — — — — — — DyVO.sub.4 — — — — — — — — — — ErVO.sub.4 — — — — — — — — — 18 YbVO.sub.4 — — — — — — — — — — LuVO.sub.4 — — — — — — — — — — YTaO.sub.4 — — — — — — — — — — NdTaO.sub.4 — — — — — — — — — — SmTaO.sub.4 — — — — — — — — — — EuTaO.sub.4 — — — — — — — — 25 — GdTaO.sub.4 — — — — — — — — — — DyTaO.sub.4 — — — — — — — — — — ErTaO.sub.4 — — — — — — — — — — YbTaO.sub.4 — — — — — — — — — — LuTaO.sub.4 — — — — — — — — — — Y.sub.2O.sub.3 and EuVO.sub.4 15 — — — — 10 — — — — YVO.sub.4 and EuTaO.sub.4 — 20 — — — — 15 — — — Y.sub.2O.sub.3 and LuTaO.sub.4 — — 10 — 20 — — — — — YVO.sub.4 and LuTaO.sub.4 — — — 15 — — — — — — Composition and Graphene 25 30 — — 25 — 20 — — 23 thickness of Boron carbide — — 25 20 — 25 — 30 23 — catadioptric layer Composition and Epoxy resin 150 — — 150 — — 250 200 — 135 thickness of Phenolic resin — 100 — — — — — — 150 — insulating layer ABS resin — — 200 — 110 200 — — — — Thickness of carbon foam layer 30 40 45 50 70 50 60 80 100 120

TABLE-US-00018 TABLE 4-3 Composition and thickness of each coating layer in Test Examples 21-30 of an ultralimit titanium alloy and its preparation method Test Example 21 22 23 24 25 26 27 28 29 30 Composite Composition and NiCrCoAlY 20 — 30 — — — — — — 95 bonding layer thickness of CoCrAlY — 20 — — — — — — — — bonding layer NiCoCrAlY — — — — — 25 — — — — CoNiCrAlY — — — — 25 — — — — — NiAl — — — 30 — — — — — — NiCr—Al — — — — — — 20 20 — — Mo alloy — — — — — — — — 30 — Composition and Au 40 — — — — — — — — 45 thickness of Pt — 60 — — — — — — — — precious layer Ru — — 60 — 50 — — — 55 — Rh — — — 50 — — — — — — Pd — — — — — 40 — 55 — — Ir — — — — — — 40 — — — PT-Rh alloy — — — — — — — — — — Pd—Rh alloy — — — — — — — — — — Ru—Rh alloy — — — — — — — — — — Composite Composition and YSZ 90 — — — — — — — — 70 ceramic layer thickness of Y.sub.2Zr.sub.2O.sub.7 — 50 — — — — — 90 — — ceramic A layer Gd.sub.2Zr.sub.2O.sub.7 — — — — — 80 — — — — Nd.sub.2Zr.sub.2O.sub.7 — — 100 — — — 70 — 75 — Sm.sub.2Zr.sub.2O.sub.7 — — — 100 80 — — — — — Eu.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Dy.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Sm.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Eu.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Nd.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Composition and ZrO.sub.2—YTaO.sub.4 — — — — — — — — — 80 thickness of ZrO.sub.2—GdTaO.sub.4 — — — — — — — — — — ceramic B layer ZrO.sub.2—NdTaO.sub.4 — — — — — — — — 75 — ZrO.sub.2—SmTaO.sub.4 — — — — — — — — — — ZrO.sub.2—EuTaO.sub.4 — — — — — — — — — — ZrO.sub.2—DyTaO.sub.4 80 — — — — — — 60 — — ZrO.sub.2—ErTaO.sub.4 — — — — 90 — 80 — — — ZrO.sub.2—YbTaO.sub.4 — 100 — — — 60 — — — — ZrO.sub.2—LuTaO.sub.4 — — 50 40 — — — — — — Composition and Y.sub.2O.sub.3 — — — — — — — — — 20 thickness of YVO.sub.4 — — — — — — — — — — reflecting layer NdVO.sub.4 — 12 — — — — — — — — SmVO.sub.4 — — — — — — — — — — EuVO.sub.4 — — — — — — — — — — GdVO.sub.4 — — — — — — — — — — DyVO.sub.4 — — — 22 — — — — — — ErVO.sub.4 — — — — — 10 — — — — YbVO.sub.4 — — — — — 18 — — — — LuVO.sub.4 — — — — — — — 30 — — YTaO.sub.4 — — — — — — — — — — NdTaO.sub.4 — — 12 — — — — — — — SmTaO.sub.4 — — — — — — — — — — EuTaO.sub.4 — — — — — — — — — — GdTaO.sub.4 — — — — — — — — — — DyTaO.sub.4 — — — — 12 — — — — — ErTaO.sub.4 18 — — — — — — — — — YbTaO.sub.4 — — — — 10 — 28 — — — LuTaO.sub.4 — — — — — — — — 30 — Y.sub.2O.sub.3 and EuVO.sub.4 — — — — — — — — — — YVO.sub.4 and EuTaO.sub.4 — — — — — — — — — — Y.sub.2O.sub.3 and LuTaO.sub.4 — — — — — — — — — — YVO.sub.4 and LuTaO.sub.4 — — — — — — — — — — Composition and Graphene 25 28 28 28 23 23 20 20 25 20 thickness of Boron carbide — — — — — — — — — — catadioptric layer Composition and Epoxy resin — — — — — 180 — 160 — 150 thickness of Phenolic resin 130 — — 180 100 — — — — — insulating layer ABS resin — 130 160 — — — 150 — 170 — Thickness of carbon foam layer 130 150 160 170 175 180 185 190 200 30

[0235] Take Test Example 1 of Embodiment 4 as an example to illustrate another technical solution of the present disclosure, that is, a method for preparing an ultralimit titanium alloy. A method for preparing an ultralimit titanium alloy, including the following operations:

[0236] Operation 1: the oil stains and impurities on the surface of titanium alloy matrix are removed by a soaking method. In this test example, TC4 titanium alloy serves as the material of the titanium alloy matrix. The titanium alloy matrix is soaked in a solvent for 0.5-1.5 h; the main components of the solvent are ethanol and surfactant. After the oil stains and impurities are cleaned up, the titanium alloy matrix is taken out and then rinsed with deionized water and dried. The surface of the titanium alloy matrix is shot peened by a shot peening machine. The shot peening machine used is a JCK-SS500-6A automatic transmission shot peening machine. The shot peening material used is any one of iron sand, glass shot and ceramic shot. In this test example, iron sand is used, and the particle size of the iron sand may be 0.3-0.8 mm; the particle size of the iron sand in this test example is 0.5 mm. The surface roughness of the titanium alloy matrix after shot peening is 60-100 μm. In this test example, the surface roughness of the titanium alloy matrix is 80 μm, which facilitates the bonding of the coating layer to the titanium alloy matrix.

[0237] Operation 2: a composite bonding layer is deposited on the surface of the titanium alloy after the shot peening. First, a layer of NiCrCoAlY is sprayed on the surface of the titanium alloy matrix as a bonding layer by a high velocity oxygen fuel (HVOF) method or supersonic arc spraying method. In this test example, the HVOF method is used. The process parameters of the HVOF method are as follows: the powder particle size is 25-65 μm, the oxygen flow rate is 2000SCFH, the kerosene flow rate is 18.17 LPH, the carrier gas is 12.2SCFH, the powder feed rate is 5 RPM, the barrel length is 5 in, and the spraying distance is 254 mm.

[0238] Then, a layer of Au is deposited on the NiCrCoAlY bonding layer as a precious metal layer by an electron beam physical vapor deposition (EB-PVD) method, such that a composite bonding layer is formed. The gas pressure when depositing Au is less than 0.01 Pa. The process parameters of EB-PVD method are as follows: the gas pressure is 0.008 Pa, the deposition rate is 6 μm/min, and the ratio of the temperature of the titanium alloy matrix to the melting point of the titanium alloy matrix is less than 0.3. The thickness of the deposited bonding layer is 20 μm, and the thickness of the precious metal layer is 50 μm.

[0239] Operation 3: a layer of YSZ is sprayed on the surface of the composite bonding layer as a ceramic A layer by the HVOF method. Then, a layer of 2-YTaO.sub.4 is sprayed on the YSZ ceramic A layer as a ceramic B layer by the HVOF method, such that a composite ceramic layer is formed. The thickness of the ceramic A layer is 70 μm, and the thickness of the ceramic B layer is 80 μm.

[0240] Operation 4: a layer of Y.sub.2O.sub.3 transparent ceramic material is sprayed on the surface of the composite ceramic layer as a reflecting layer by the HVOF method. The thickness of the sprayed reflecting layer is 10 μm.

[0241] Operation 5: a layer of graphene is brushed on the surface of the Y.sub.2O.sub.3 reflecting layer as a catadioptric layer by a brushing method, and the thickness of the catadioptric layer is 20 μm.

[0242] Operation 6: a layer of epoxy resin is brushed on the surface of the graphene catadioptric layer as an insulating layer by a brushing method, and the thickness of the insulating layer is 150 μm.

[0243] Operation 7: a layer of carbon foam layer is brushed on the epoxy resin insulating layer by a brushing method, and the thickness of the carbon foam layer is 20 μm. The ultralimit titanium alloy is obtained.

[0244] The preparation process of Test Examples 2-29 is the same as that of Test Example 1, except that the composition and thickness of the coating layers as shown in Table 4-1 are different. The difference between Test Example 30 and Test Example 1 is that the spraying sequence of the ceramic A layer and the ceramic B layer in operation 3 is different.

[0245] 13 groups of Comparative Examples are provided to perform comparative experiments with Test Examples 1-30. The parameters of Comparative Examples 1-12 are shown in Table 4-4 (thickness unit: μm):

TABLE-US-00019 TABLE 4-4 Composition and thickness of each coating layer in Comparative Examples 1-12 Comparative Example 1 2 3 4 5 6 7 8 9 10 11 12 Composite Composition and NiCrCoAlY 45 60 40 20 50 — — — — 45 45 45 bonding thickness of MCrAlY — — — — — 70 50 30 40 — — — layer bonding NiAl — — — — — — — — — — — — layer NiCr—Al — — — — — — — — — — — — Mo 45 — — — — — 40 — — 45 45 45 Composition and Au — 30 — — — — — 60 — — — — thickness of Pt — — 40 — — — — — 50 — — — precious Ru — — — 60 — — — — — — — — layer Rh — — — — 50 — — — — — — — Pd — — — — — 30 — — — — — — Ir — — — — — — — — — — — — Composite Composition and YSZ — — — — — — — — — 60 40 — ceramic thickness of RE.sub.2Zr.sub.2O.sub.7 50 45 60 55 35 100 100 50 80 — — — layer ceramic — — — — — — — — — — — — A layer Composition and ZrO.sub.2—YTaO.sub.4 40 — — — — — — — — — — — thickness of ZrO.sub.2—GdTaO.sub.4 — — — 30 — — — — — — — — ceramic ZrO.sub.2—NdTaO.sub.4 — 50 — — — — — — — — — — B layer ZrO.sub.2—SmTaO.sub.4 — — — — — — — 60 — — — — ZrO.sub.2—EuTaO.sub.4 — — 20 — — — — — — — — — ZrO.sub.2—DyTaO.sub.4 — — — — — 10 — — — — — — ZrO.sub.2—ErTaO.sub.4 — — — — 30 — — — — — — — ZrO.sub.2—YbTaO.sub.4 — — — — — — 20 — — — — — ZrO.sub.2—LuTaO.sub.4 — — — — — — — — 20 — — — Composition and Y.sub.2O.sub.3 5 — — — — — — — — 20 — — thickness of YVO.sub.4 — 8 — — — — — — 35 — — — reflecting layer GdVO.sub.4 — — 5 — — — 38 — — — — 20 YTaO.sub.4 — — — 35 — — — 8 — — — — GdTaO.sub.4 — — — — 8 35 — — — — — — Composition and Graphene 5 — 9 — 35 38 — 45 50 20 20 20 thickness of Boron carbide — 8 — 6 — — 40 — — — — — catadioptric layer Composition and Epoxy resin 50 — — — 250 — 300 — — 150 150 150 thickness of Phenolic resin — 90 — — — — — — 400 — — insulating layer ABS resin — — 80 50 — 280 — 350 — — — — Thickness of carbon foam layer 15 10 18 5 250 220 230 260 280 30 30 —

[0246] The preparation method of Comparative Examples 1-12 is the same as that of Test Example 1, except that the composition and thickness of the coating layers as shown in Table 4-3 are different. Comparative Example 13 is a TC4 titanium alloy matrix without deposited coating layers.

[0247] The following experiments are performed using the titanium alloys provided in Test Examples 1-30 and Comparative Examples 1-13:

[0248] High Temperature Creep Test:

[0249] The titanium alloys prepared in Test Examples 1-30 and Comparative Examples 1-13 are processed into tensile test pieces. The high temperature creep test is carried out with an electronic high temperature creep rupture strength test machine (model: RMT-D5). The maximum test load is 50 KN, the test load control accuracy is within ±5%, the deformation measuring range is 0-10 mm, the speed adjustment range is 0-50 mm/min−1, the deformation resolution is 0.001 mm, the temperature control range of high temperature furnace is 200-2000° C., and the uniform temperature zone length is 150 mm.

[0250] The test pieces of Test Examples 1-30 and Comparative Examples 1-13 are placed into the electronic high temperature creep rupture strength test machine, and the test pieces are in a stress-free state (in a stress-free state, the test pieces can expand freely; the high-temperature creep means that the deformation increases with time under the combined action of temperature and stress, therefore, the heating rate has no influence on the creep). The test machine is adjusted to a stress of 50 MPa and a temperature of 1300° C., and the following data are recorded. As shown in Table 4-5, a represents the steady creep time (min) of the test pieces; b represents the time when creep rupture of the test pieces happens (min).

[0251] Take Test Example 1 and Comparative Example 13 as examples. FIG. 2D shows the high temperature creep test curves of Test Example 1 and Comparative Example 13. In FIG. 2D, (A) represents the TC4 titanium alloy matrix material without deposited coating layers in Comparative Example 13, and (B) represents the material prepared in Test Example 1.

[0252] It can be seen from FIG. 2D that under a stress of 50 MPa and a temperature of 1900° C., there are three stages of creep in test pieces (A) and (B): the first stage is short, and the creep rate is high, which quickly transitions to the second stage of creep; the creep rate of the second stage reaches a minimum value, and the second stage is long and is basically in a steady-state creep process; in the third stage, the creep rate increases rapidly, and the creep deformation develops rapidly until the material is broken and the creep rupture occurs. Meanwhile, it can be found that under a stress of 50 MPa and a temperature of 1900° C., the test piece (A) ruptures in a very short time, indicating that the titanium alloy can hardly bear the load at the temperature higher than the melting point, while the test piece (B) can maintain good mechanical properties under the condition of 1900° C. without rupturing for a long time and has excellent high-temperature resistance.

[0253] Salt-Spray Corrosion Test:

[0254] The titanium alloy provided in Test Examples 1-30 and Comparative Examples 1-13 are processed into test pieces of 50 mm×25 mm×2 mm, and the subsequent operations are the same as those of Embodiment 1. The weight loss of the test pieces is shown in FIG. 3D (in FIG. 3D, (A) represents the TC4 titanium alloy matrix material without deposited coating layers in Comparative Example 13, and (B) represents Test Example 1). The specific experimental results of Test Examples 1-30 and Comparative Examples 1-13 are shown in Table 4-5.

[0255] It can be seen from FIG. 3D that the two titanium alloys have obviously different corrosion patterns. For test piece (A) (TC4 titanium alloy test piece), the corrosion weight loss value tends to increase as the corrosion time extends. In the early stage of corrosion (8-24 h), there is an oxidation film on the surface of the test piece, which prevents the titanium alloy matrix from contacting the solution; the corrosion rate is low. In the middle stage of corrosion (24-48 h), the Cl.sup.− (chloridion) in the solution has penetrated the oxidation film, and a large amount of Cl.sup.− is adsorbed on the matrix, which increases the corrosion pit points and deepens the original corrosion pit points; the corrosion rate is obviously accelerated. After 48 hours of continuous spraying, the corrosion products are evenly distributed and the thickness increases, covering almost the entire surface of the test piece. Cl.sup.− needs to pass through the corrosion products to contact the titanium alloy matrix, which reduces the amount of Cl.sup.− adsorbed on the matrix surface and reduces the corrosion rate. In general, the corrosion loss weight of TC4 titanium alloy is much higher than that of the titanium matrix surface composite material. Basically, the titanium matrix surface composite material has no corrosion due to the existence of the coating layers, and the mass of the titanium matrix surface composite material has hardly changed.

[0256] The experimental results are shown in Table 4-5: a represents the steady creep time (min) of the test pieces;

[0257] b represents the time when creep rupture of the test pieces happens (min);

[0258] c represents the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 8 hours;

[0259] d represents the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 24 hours;

[0260] e represents the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 48 hours;

[0261] f represents the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 72 hours.

TABLE-US-00020 TABLE 4-5 Experimental results of high temperature creep test and salt-spray test a b c d e f Test Example 1 245 360 0 0.01 0.02 0.08 Test Example 2 235 350 0 0.01 0.02 0.08 Test Example 3 237 355 0 0.01 0.02 0.08 Test Example 4 238 355 0 0.02 0.03 0.12 Test Example 5 235 354 0 0.03 0.05 0.13 Test Example 6 235 354 0 0.03 0.05 0.13 Test Example 7 235 354 0.005 0.02 0.03 0.12 Test Example 8 237 356 0 0.01 0.02 0.08 Test Example 9 240 358 0.006 0.02 0.03 0.12 Test Example 10 240 358 0 0.02 0.03 0.12 Test Example 11 240 358 0 0.01 0.02 0.08 Test Example 12 242 359 0.004 0.02 0.03 0.11 Test Example 13 242 359 0 0.02 0.03 0.11 Test Example 14 242 359 0 0.02 0.03 0.11 Test Example 15 243 359 0 0.01 0.03 0.11 Test Example 16 243 359 0 0.03 0.05 0.13 Test Example 17 242 359 0.005 0.02 0.03 0.11 Test Example 18 239 352 0.006 0.02 0.03 0.12 Test Example 19 240 357 0.006 0.03 0.05 0.13 Test Example 20 242 359 0 0.01 0.02 0.08 Test Example 21 242 359 0 0.01 0.02 0.08 Test Example 22 242 356 0.006 0.02 0.03 0.11 Test Example 23 242 357 0 0.02 0.03 0.11 Test Example 24 242 359 0 0.02 0.03 0.11 Test Example 25 245 359 0 0.03 0.05 0.13 Test Example 26 238 352 0 0.02 0.04 0.13 Test Example 27 238 353 0.004 0.01 0.02 0.09 Test Example 28 238 352 0.004 0.02 0.04 0.14 Test Example 29 244 359 0.005 0.02 0.04 0.14 Test Example 30 243 358 0 0.02 0.03 0.11 Comparative Example 1 90 185 0.07 0.13 0.25 0.55 Comparative Example 2 95 190 0.07 0.13 0.25 0.5 Comparative Example 3 125 220 0.06 0.12 0.24 0.51 Comparative Example 4 130 230 0.05 0.11 0.22 0.52 Comparative Example 5 120 220 0.05 0.11 0.22 0.52 Comparative Example 6 100 205 0.05 0.11 0.22 0.53 Comparative Example 7 110 220 0.05 0.11 0.22 0.56 Comparative Example 8 110 220 0.05 0.11 0.22 0.53 Comparative Example 9 95 195 0.03 0.09 0.21 0.52 Comparative Example 10 130 235 0.03 0.09 0.19 0.58 Comparative Example 11 115 225 0.02 0.07 0.18 0.56 Comparative Example 12 120 230 0.02 0.06 0.14 0.52 Comparative Example 13 40 50 1.1 2.2 4.1 8.1

[0262] As can be seen from Table 4-5, the titanium alloy obtained by the comparative examples beyond the parameter range of the present disclosure has a significant decrease in stability at high temperature; the rupture occurs in a short period of time, and the corrosion resistance is poor.

[0263] In summary, by depositing composite bonding layer, composite ceramic layer, reflecting layer, catadioptric layer, insulating layer and carbon foam layer on the titanium alloy, the service temperature of the titanium alloy can be increased to 100-500° C. higher than the original melting point. The corrosion resistance can be greatly improved as well. The ultralimit titanium alloy prepared by the ultralimit titanium alloy preparation method of the present disclosure has a wide service temperature range and strong corrosion resistance; the effects of Test Example 1 are the best.

Embodiment 5 (Ultralimit Iron Alloy)

[0264] In this embodiment, the ultralimit alloy is an ultralimit iron alloy, that is, the alloy matrix is an iron alloy matrix.

[0265] The reference signs in FIG. 1B include: iron alloy matrix 1, bonding layer 2, precious metal layer 3, ceramic A layer 4, ceramic B layer 5, reflecting layer 6, catadioptric layer 7, insulating layer 8, and carbon foam layer 9.

[0266] As shown in FIG. 1B, the present disclosure provides an ultralimit iron alloy, including an iron alloy matrix 1. The surface of the iron alloy matrix 1 is successively deposited with a composite bonding layer with a thickness of 100-200 μm, a composite ceramic layer with a thickness of 150-500 μm, a reflecting layer 6 with a thickness of 10-30 μm, a catadioptric layer 7 with a thickness of 10-30 μm, an insulating layer 8 with a thickness of 10-200 μm, and a carbon foam layer 9 with a thickness of 20-200 μm. The composite bonding layer includes a bonding layer 2 deposited on the surface of the titanium alloy matrix 1 and a precious metal layer 3 deposited on the surface of the bonding layer 2. The composition of the bonding layer 2 is one or more of MCrAlY, NiAl, NiCr—Al and Mo; MCrAlY is NiCrCoAlY, NiCoCrAlY, CoNiCrAlY or CoCrAlY. The composition of the precious metal layer 3 is one of or an alloy of more of Au, Pt, Ru, Rh, Pd, and Ir. The composite ceramic layer includes a ceramic A layer 4 and a ceramic B layer 5. The composition of the ceramic A layer 4 is YSZ or rare earth zirconate (RE.sub.2Zr.sub.2O.sub.7, RE=Y, Gd, Nd, Sm, Eu or Dy). The composition of the ceramic B layer 5 is ZrO.sub.2-RETaO.sub.4 (RE=Y, Gd, Nd, Sm, Eu, Dy, Er, Yb or Lu). The reflecting layer 6 is one or more of REVO.sub.4, RETaO.sub.4 and Y.sub.2O.sub.3, and RE=Y, Nd, Sm, Eu, Gd, Dy, Er, Yb or Lu. The composition of the catadioptric layer 7 is one or two of graphene and boron carbide, and the spatial distribution of the graphene and boron carbide are in a disorderly arranged state. The composition of the insulating layer 8 is one or more of epoxy resin, phenolic resin, and ABS resin.

[0267] The present disclosure uses ZrO.sub.2-RETaO.sub.4 as the ceramic B layer, which has the effects of low thermal conductivity and high expansion rate, and can reduce heat conduction; the method for preparing ZrO.sub.2-RETaO.sub.4 is consistent with that of Embodiment 1, and the ZrO.sub.2-RETaO.sub.4 can meet the requirements of APS spraying technology on powder particle size and shape.

[0268] Based on extensive experiments, the inventors obtain ultralimit iron alloys with the largest increase in service temperature, small increase in weight of the iron alloy and the best composition and thickness of the coating layers within the parameter scope of the present disclosure. In the present disclosure, 30 of them are listed for description.

[0269] The parameters of Test Examples 1-30 of an ultralimit iron alloy and its preparation method according to the present disclosure are shown in Table 5-1, Table 5-2, and Table 5-3

[0270] (Thickness unit: μm):

TABLE-US-00021 TABLE 5-1 Composition and thickness of each coating layer in Test Examples 1-10 of an ultralimit iron alloy and its preparation method Test Example 1 2 3 4 5 6 7 8 9 10 Composite Composition and NiCrCoAlY 50 60 40 60 70 — — — — — bonding thickness of CoCrAlY — — — — — — — — — — layer bonding NiCoCrAlY — — — — — — — — — — layer CoNiCrAlY — — — — — — — — — — NiAl — — — — — 70 50 60 70 60 NiCr—Al — — — — — — — — — — Mo alloy — — — — — — — — — — Composition and Au 50 — — — — — 150 — — — thickness of Pt — 40 — — — — — 60 — — precious Ru — — 60 — — — — — 50 — layer Rh — — — 60 — — — — — 70 Pd — — — — 50 — — — — — Ir — — — — — 100 — — — — PT-Rh alloy — — — — — — — — — — Pd—Rh alloy — — — — — — — — — — Ru—Rh alloy — — — — — — — — — — Composite Composition and YSZ 70 60 80 90 110 180 — — — — ceramic thickness of Y.sub.2Zr.sub.2O.sub.7 — — — — — — 200 — — — layer ceramic Gd.sub.2Zr.sub.2O.sub.7 — — — — — — — 80 — — A layer Nd.sub.2Zr.sub.2O.sub.7 — — — — — — — — 90 — Sm.sub.2Zr.sub.2O.sub.7 — — — — — — — — — 120 Eu.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Dy.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Sm.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Eu.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Nd.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Composition and ZrO.sub.2—YTaO.sub.4 80 90 — 100 — — 300 — — — thickness of ZrO.sub.2—GdTaO.sub.4 — — 70 — 85 150 — 80 — — ceramic ZrO.sub.2—NdTaO.sub.4 — — — — — — — — 100 — B layer ZrO.sub.2—SmTaO.sub.4 — — — — — — — — — 70 ZrO.sub.2—EuTaO.sub.4 — — — — — — — — — — ZrO.sub.2—DyTaO.sub.4 — — — — — — — — — — ZrO.sub.2—ErTaO.sub.4 — — — — — — — — — — ZrO.sub.2—YbTaO.sub.4 — — — — — — — — — — ZrO.sub.2—LuTaO.sub.4 — — — — — — — — — — Composition and Y.sub.2O.sub.3 10 10 — — — — 15 — — — thickness of YVO.sub.4 — — 20 — 30 10 — — — — reflecting NdVO.sub.4 — — — — — — — — — — layer SmVO.sub.4 — — — — — — — — — — EuVO.sub.4 — — — — — — — — — — GdVO.sub.4 — — — — — — — — — 10 DyVO.sub.4 — — — — — — — — — — ErVO.sub.4 — — — — — — — — — — YbVO.sub.4 — — — — — — — — — — LuVO.sub.4 — — — — — — — — — — YTaO.sub.4 — — — 20 — — — 10 20 — NdTaO.sub.4 — — — — — — — — — — SmTaO.sub.4 — — — — — — — — — — EuTaO.sub.4 — — — — — — — — — — GdTaO.sub.4 — — — — — — — — — — DyTaO.sub.4 — — — — — — — — — — ErTaO.sub.4 — — — — — — — — — — YbTaO.sub.4 — — — — — — — — — — LuTaO.sub.4 — — — — — — — — — — Y.sub.2O.sub.3 and EuVO.sub.4 — — — — — — — — — — YVO.sub.4 and EuTaO.sub.4 — — — — — — — — — — Y.sub.2O.sub.3 and LuTaO.sub.4 — — — — — — — — — — YVO.sub.4 and LuTaO.sub.4 — — — — — — — — — — Composition and Graphene 10 10 20 20 30 10 — — — — thickness of Boron carbide — — — — — — 30 15 25 20 catadioptric layer Composition and Epoxy resin 15 10 — — — — 20 — — 10 thickness of Phenolic resin — — 20 20 — — — — 15 — insulating ABS resin — — — — 50 100 — 10 — — layer Thickness of carbon foam layer 20 20 20 20 100 200 30 25 20 35

TABLE-US-00022 TABLE 5-2 Composition and thickness of each coating layer in Test Examples 11-20 of an ultralimit iron alloy and its preparation method Test Example 11 12 13 14 15 16 17 18 19 20 Composite Composition and NiCrCoAlY — — — — — — — — — — bonding thickness of CoCrAlY 70 — — — — — — — — — layer bonding layer NiCoCrAlY — 80 — — — — — — — — CoNiCrAlY — — 55 — — 75 — — — 55 NiAl — — — — 80 — — — — — NiCr—Al — — — 80 — — — 100 — — Mo alloy — — — — — — 95 — 35 — Composition and Au — — — — — — 105 — — — thickness of Pt — — — — — 85 — — — — precious layer Ru — — — — — — — 60 — — Rh — — — — — — — — — 70 Pd — — — — — — — — 110 — Ir — — — — — — — — — — PT-Rh alloy 70 — — — 70 — — — — — Pd—Rh alloy — 60 — 55 — — — — — — Ru—Rh alloy — — 100 — — — — — — — Composite Composition and YSZ — — — — — 80 — — — — ceramic thickness of Y.sub.2Zr.sub.2O.sub.7 — — — — — — 140 — — — layer ceramic A layer Gd.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Nd.sub.2Zr.sub.2O.sub.7 — — — — — — — 100 — — Sm.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Eu.sub.2Zr.sub.2O.sub.7 50 — — — — — — — 110 — Dy.sub.2Zr.sub.2O.sub.7 — 70 — — — — — — — — YSZ and Sm.sub.2Zr.sub.2O.sub.7 — — 60 — — — — — — 180 YSZ and Eu.sub.2Zr.sub.2O.sub.7 — — — 60 — — — — — — YSZ and Nd.sub.2Zr.sub.2O.sub.7 — — — — 100 — — — — — Composition and ZrO.sub.2—YTaO.sub.4 — — — — — 120 — — — — thickness of ZrO.sub.2—GdTaO.sub.4 — — — — — — — 50 — — ceramic B layer ZrO.sub.2—NdTaO.sub.4 — — — — — — 60 — — — ZrO.sub.2—SmTaO.sub.4 — — — — — — — — 70 — ZrO.sub.2—EuTaO.sub.4 130 — — — — — — — — 100 ZrO.sub.2—DyTaO.sub.4 — 160 — — — — — — — — ZrO.sub.2—ErTaO.sub.4 — — 170 — — — — — — — ZrO.sub.2—YbTaO.sub.4 — — — 190 — — — — — — ZrO.sub.2—LuTaO.sub.4 — — — — 140 — — — — — Composition and Y.sub.2O.sub.3 — — — — — — — — — — thickness of YVO.sub.4 — — — — — — — — — — reflecting layer NdVO.sub.4 — — — — — — — — — — SmVO.sub.4 — — — — — — — — — — EuVO.sub.4 — — — — — — — 20 — — GdVO.sub.4 — — — — — — — — — — DyVO.sub.4 — — — — — — — — — — ErVO.sub.4 — — — — — — — — — 18 YbVO.sub.4 — — — — — — — — — — LuVO.sub.4 — — — — — — — — — — YTaO.sub.4 — — — — — — — — — — NdTaO.sub.4 — — — — — — — — — — SmTaO.sub.4 — — — — — — — — — — EuTaO.sub.4 — — — — — — — — 25 — GdTaO.sub.4 — — — — — — — — — — DyTaO.sub.4 — — — — — — — — — — ErTaO.sub.4 — — — — — — — — — — YbTaO.sub.4 — — — — — — — — — — LuTaO.sub.4 — — — — — — — — — — Y.sub.2O.sub.3 and EuVO.sub.4 15 — — — — 10 — — — — YVO.sub.4 and EuTaO.sub.4 — 20 — — — — 15 — — — Y.sub.2O.sub.3 and LuTaO.sub.4 — — 10 — 20 — — — — — YVO.sub.4 and LuTaO.sub.4 — — — 15 — — — — — — Composition and Graphene 15 30 — — 25 — 20 — — 23 thickness of Boron carbide — — 15 20 — 25 — 30 23 — catadioptric layer Composition and Epoxy resin 15 — — 15 — — 25 30 — 35 thickness of Phenolic resin — 10 — — — — — — 40 — insulating layer ABS resin — — 20 — 110 200 — — — — Thickness of carbon foam layer 30 40 45 50 70 50 60 80 100 120

TABLE-US-00023 TABLE 5-3 Composition and thickness of each coating layer in Test Examples 21-30 of an ultralimit iron alloy and its preparation method Test Example 21 22 23 24 25 26 27 28 29 30 Composite Composition and NiCrCoAlY 75 — 40 — — — — — — 95 bonding layer thickness of CoCrAlY — 50 — — — — — — — — bonding layer NiCoCrAlY — — — — — 40 — — — — CoNiCrAlY — — — — 60 — — — — — NiAl — — — 30 — — — — — — NiCr—Al — — — — — — 80 95 — — Mo alloy — — — — — — — — 65 — Composition and Au 55 — — — — — — — — 45 thickness of Pt — 60 — — — — — — — — precious layer Ru — — 60 — 40 — — — 55 — Rh — — — 70 — — — — — — Pd — — — — — 80 — 55 — — Ir — — — — — — 70 — — — PT-Rh alloy — — — — — — — — — — Pd—Rh alloy — — — — — — — — — — Ru—Rh alloy — — — — — — — — — — Composite Composition and YSZ 90 — — — — — — — — 70 ceramic layer thickness of Y.sub.2Zr.sub.2O.sub.7 — 50 — — — — — 90 — — ceramic A layer Gd.sub.2Zr.sub.2O.sub.7 — — — — — 80 — — — — Nd.sub.2Zr.sub.2O.sub.7 — — 150 — — — 300 — 85 — Sm.sub.2Zr.sub.2O.sub.7 — — — 100 180 — — — — — Eu.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Dy.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Sm.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Eu.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Nd.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Composition and ZrO.sub.2—YTaO.sub.4 — — — — — — — — — 150 thickness of ZrO.sub.2—GdTaO.sub.4 — — — — — — — — — — ceramic B layer ZrO.sub.2—NdTaO.sub.4 — — — — — — — — 75 — ZrO.sub.2—SmTaO.sub.4 — — — — — — — — — — ZrO.sub.2—EuTaO.sub.4 — — — — — — — — — — ZrO.sub.2—DyTaO.sub.4 80 — — — — — — 100 — — ZrO.sub.2—ErTaO.sub.4 — — — — 90 — 130 — — — ZrO.sub.2—YbTaO.sub.4 — 150 — — — 100 — — — — ZrO.sub.2—LuTaO.sub.4 — — 50 70 — — — — — — Composition and Y.sub.2O.sub.3 — — — — — — — — — 20 thickness of YVO.sub.4 — — — — — — — — — — reflecting layer NdVO.sub.4 — 12 — — — — — — — — SmVO.sub.4 — — — — — — — — — — EuVO.sub.4 — — — — — — — — — — GdVO.sub.4 — — — — — — — — — — DyVO.sub.4 — — — 22 — — — — — — ErVO.sub.4 — — — — — 10 — — — — YbVO.sub.4 — — — — — 18 — — — — LuVO.sub.4 — — — — — — — 30 — — YTaO.sub.4 — — — — — — — — — — NdTaO.sub.4 — — 12 — — — — — — — SmTaO.sub.4 — — — — — — — — — — EuTaO.sub.4 — — — — — — — — — — GdTaO.sub.4 — — — — — — — — — — DyTaO.sub.4 — — — — 12 — — — — — ErTaO.sub.4 18 — — — — — — — — — YbTaO.sub.4 — — — — 10 — 28 — — — LuTaO.sub.4 — — — — — — — — 30 — Y.sub.2O.sub.3 and EuVO.sub.4 — — — — — — — — — — YVO.sub.4 and EuTaO.sub.4 — — — — — — — — — — Y.sub.2O.sub.3 and LuTaO.sub.4 — — — — — — — — — — YVO.sub.4 and LuTaO.sub.4 — — — — — — — — — — Composition and Graphene 15 28 18 18 13 13 10 10 15 20 thickness of Boron carbide — — — — — — — — — — catadioptric layer Composition and Epoxy resin — — — — — 180 — 160 — 15 thickness of Phenolic resin 30 — — 80 100 — — — — — insulating layer ABS resin — 30 60 — — — 150 — 170 — Thickness of 130 150 160 170 175 180 185 190 200 30 carbon foam layer

[0271] Take Test Example 1 of Embodiment 5 as an example to illustrate another technical solution of the present disclosure, that is, a method for preparing an ultralimit iron alloy. A method for preparing an ultralimit iron alloy, including the following operations:

[0272] Operation 1: basically the same as operation 1 of preparing ultralimit titanium alloy in Embodiment 4, except that Q235 iron alloy serves as the alloy matrix in this test example.

[0273] Operation 2: the experimental procedures and parameters are consistent with that in Embodiment 4, except that the thickness of the deposited bonding layer is 45 μm, and the thickness of the precious metal layer is 45 μm.

[0274] Operation 3: the experimental procedures and parameters are consistent with that in Embodiment 4, except that the thickness of the ceramic A layer is 70 μm, and the thickness of the ceramic B layer is 50 μm.

[0275] Operation 4: a layer of Y.sub.2O.sub.3 transparent ceramic material is sprayed on the surface of the composite ceramic layer as a reflecting layer by the HVOF method. The thickness of the sprayed reflecting layer is 20 μm.

[0276] Operation 5: a layer of graphene is brushed on the surface of the Y.sub.2O.sub.3 reflecting layer as a catadioptric layer by a brushing method, and the thickness of the catadioptric layer is 10 μm.

[0277] Operation 6: a layer of epoxy resin is brushed on the surface of the catadioptric layer as an insulating layer, and the thickness of the insulating layer is 15 μm.

[0278] Operation 7: a layer of carbon foam layer is brushed on the insulating layer. The thickness of the carbon foam layer is 20 μm. The ultralimit iron alloy is obtained.

[0279] The only difference between Test Examples 2-29 and Test Example 1 is that the parameters are different as shown in Table 5-1. The difference between Test Example 30 and Test Example 1 is that the spraying sequence of the ceramic A layer and the ceramic B layer in operation 3 is different.

[0280] Experiments:

[0281] 13 groups of Comparative Examples are provided to perform comparative experiments with Test Examples 1-30. The parameters of Comparative Examples 1-12 are shown in Table 5-4 (thickness unit: μm):

TABLE-US-00024 TABLE 5-4 Composition and thickness of each coating layer in Comparative Examples 1-12 Comparative Example 1 2 3 4 5 6 7 8 9 10 11 12 Composite Composition and NiCrCoAlY 45 60 40 20 50 — — — — 45 45 45 bonding layer thickness of MCrAlY — — — — — 70 50 30 40 — — — bonding layer NiAl — — — — — — — — — — — — NiCr—Al — — — — — — — — — — — — Mo 45 — — — — — 40 — — 45 45 45 Composition and Au — 30 — — — — — 60 — — — — thickness of Pt — — 40 — — — — — 50 — — — precious layer Ru — — — 60 — — — — — — — — Rh — — — — 50 — — — — — — — Pd — — — — — 30 — — — — — — Ir — — — — — — — — — — — — Composite Composition and YSZ — — — — — — — — — 60 40 — ceramic layer thickness of RE.sub.2Zr.sub.2O.sub.7 50 45 60 55 35 100 100 50 80 — — — ceramic A layer Composition and ZrO.sub.2—YTaO.sub.4 40 — — — — — — — — — — — thickness of ZrO.sub.2—GdTaO.sub.4 — — — 30 — — — — — — — — ceramic B layer ZrO.sub.2—NdTaO.sub.4 — 50 — — — — — — — — — — ZrO.sub.2—SmTaO.sub.4 — — — — — — — 60 — — — — ZrO.sub.2—EuTaO.sub.4 — — 20 — — — — — — — — — ZrO.sub.2—DyTaO.sub.4 — — — — — 10 — — — — — — ZrO.sub.2—ErTaO.sub.4 — — — — 30 — — — — — — — ZrO.sub.2—YbTaO.sub.4 — — — — — — 20 — — — — — ZrO.sub.2—LuTaO.sub.4 — — — — — — — — 20 — — — Composition and Y.sub.2O.sub.3 5 — — — — — — — — 20 — — thickness of YVO.sub.4 — 8 — — — — — — 35 — — — reflecting layer GdVO.sub.4 — — 5 — — — 38 — — — — 20 YTaO.sub.4 — — — 35 — — — 8 — — — — GdTaO.sub.4 — — — — 8 35 — — — — — — Composition and Graphene 5 — 9 — 35 38 — 45 50 20 20 20 thickness of Boron carbide — 8 — 6 — — 40 — — — — — catadioptric layer Composition and Epoxy resin 5 — — — 25 — 30 — — 15 15 15 thickness of Phenolic resin — 9 — — — — — — 40 — — — insulating layer ABS resin — — 8 5 — 28 — 35 — — — — Thickness of carbon foam layer 15 10 18 5 250 220 230 260 280 30 30 —

[0282] The preparation method of Comparative Examples 1-12 is the same as that of Test Example 1, except that the composition and thickness of the coating layers as shown in Table 5-3 are different. Comparative Example 13 is a Q235 iron alloy matrix without deposited coating layers.

[0283] The following experiments are performed using the iron alloys provided in Test Examples 1-30 and Comparative Examples 1-13:

[0284] 1. High Temperature Creep Test:

[0285] The iron alloys prepared in Test Examples 1-30 and Comparative Examples 1-13 are processed into tensile test pieces. The experimental procedures and parameters are the same as those in Embodiment 4. The data are recorded. As shown in Table 5-5, a represents the steady creep time (min) of the test pieces; b represents the time when creep rupture of the test pieces happens (min).

[0286] Take Test Example 1 and Comparative Example 13 as examples. FIG. 2E shows the high temperature creep test curves of Test Example 1 and Comparative Example 13. In FIG. 2E, (A) represents the Q235 iron alloy matrix material without deposited coating layers in Comparative Example 13, and (B) represents the material prepared in Test Example 1.

[0287] It can be seen from FIG. 2E that under a stress of 50 MPa and a temperature of 1900° C., there are three stages of creep in test pieces (A) and (B): the first stage is short and has a high creep rate, which quickly transitions to the second stage of creep; the creep rate of the second stage reaches a minimum value, and the second stage is long and is basically in a steady-state creep process; in the third stage, the creep rate increases rapidly, and the creep deformation develops rapidly until the material is broken and the creep rupture occurs. It can be found that under a stress of 50 MPa and a temperature of 1900° C., the test piece (A) ruptures in a very short time, indicating that the iron alloy can hardly bear the load at the temperature higher than the melting point, while the test piece (B) can maintain good mechanical properties under the condition of 1900° C. without rupturing for a long time and has excellent high-temperature resistance.

[0288] 2. Salt-Spray Corrosion Test:

[0289] The iron alloy provided in Test Examples 1-30 and Comparative Examples 1-13 are processed into test pieces of 50 mm×25 mm×2 mm, and the subsequent operations are the same as those of Embodiment 1. FIG. 3E shows the relationship curves between salt-spray corrosion weight loss and corrosion time of Test Example 1 and Comparative Example 13. In FIG. 3E, (A) represents the Q235 iron alloy matrix material without deposited coating layers in Comparative Example 13, and (B) represents the material prepared in Test Example 1. The specific experimental results of Test Examples 1-30 and Comparative Examples 1-13 are shown in Table 5-5.

[0290] It can be seen from FIG. 3E that the two iron alloys have obviously different corrosion patterns. For test piece (A) (Q235 iron alloy test piece), the corrosion weight loss value tends to increase as the corrosion time extends. In the early stage of corrosion (8-24 h), there is an oxidation film on the surface of the test piece, which prevents the iron alloy matrix from contacting the solution; the corrosion rate is low. In the middle stage of corrosion (24-48 h), the Cl.sup.− (chloridion) in the solution has penetrated the oxidation film, and a large amount of Cl.sup.− is adsorbed on the matrix, which increases the corrosion pit points and deepens the original corrosion pit points; the corrosion rate is obviously accelerated. After 48 hours of continuous spraying, the corrosion products are evenly distributed and the thickness increases, covering almost the entire surface of the test piece. Cl.sup.− needs to pass through the corrosion products to contact the iron alloy matrix, which reduces the amount of Cl.sup.− adsorbed on the matrix surface and reduces the corrosion rate. In general, the corrosion loss weight of Q235 iron alloy is much higher than that of the iron matrix surface composite material. Basically, the iron matrix surface composite material has no corrosion due to the existence of the coating layers, and the mass of the iron matrix surface composite material has hardly changed.

[0291] The experimental results are shown in Table 5-5: a represents the steady creep time (min) of the test pieces;

[0292] b represents the time when creep rupture of the test pieces happens (min);

[0293] c represents the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 8 hours;

[0294] d represents the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 24 hours;

[0295] e represents the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 48 hours;

[0296] f represents the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 72 hours.

TABLE-US-00025 TABLE 5-5 Experimental results of high temperature creep test and salt-spray test a b c d e f Test Example 1 170 280 0 0.01 0.07 0.11 Test Example 2 165 279 0 0.02 0.08 0.14 Test Example 3 160 273 0 0.04 0.09 0.13 Test Example 4 159 277 0 0.03 0.07 0.16 Test Example 5 161 278 0 0.03 0.08 0.13 Test Example 6 167 278 0 0.03 0.09 0.13 Test Example 7 163 275 0.005 0.02 0.09 0.12 Test Example 8 163 275 0 0.05 0.06 0.13 Test Example 9 164 275 0.006 0.04 0.09 0.15 Test Example 10 164 272 0 0.04 0.08 0.11 Test Example 11 166 260 0 0.05 0.08 0.11 Test Example 12 169 270 0.004 0.03 0.08 0.12 Test Example 13 168 275 0 0.03 0.07 0.13 Test Example 14 168 275 0 0.05 0.09 0.14 Test Example 15 168 275 0 0.05 0.09 0.13 Test Example 16 168 275 0 0.03 0.07 0.12 Test Example 17 164 272 0.005 0.02 0.09 0.11 Test Example 18 164 273 0.006 0.02 0.08 0.11 Test Example 19 164 271 0.006 0.03 0.08 0.11 Test Example 20 164 278 0 0.04 0.09 0.12 Test Example 21 164 278 0 0.05 0.09 0.12 Test Example 22 162 278 0.006 0.04 0.09 0.12 Test Example 23 162 270 0 0.04 0.07 0.13 Test Example 24 161 270 0 0.02 0.09 0.11 Test Example 25 165 270 0 0.03 0.09 0.15 Test Example 26 165 275 0 0.02 0.08 0.12 Test Example 27 165 275 0.004 0.05 0.08 0.15 Test Example 28 165 275 0.004 0.02 0.06 0.12 Test Example 29 165 274 0.005 0.02 0.08 0.14 Test Example 30 167 279 0 0.02 0.08 0.11 Comparative Example 1 72 125 0.07 0.13 0.27 0.63 Comparative Example 2 77 120 0.07 0.15 0.31 0.65 Comparative Example 3 70 124 0.06 0.13 0.29 0.63 Comparative Example 4 75 125 0.05 0.1 0.27 0.59 Comparative Example 5 68 120 0.05 0.11 0.27 0.58 Comparative Example 6 75 129 0.05 0.11 0.27 0.58 Comparative Example 7 75 125 0.05 0.13 0.29 0.61 Comparative Example 8 75 112 0.05 0.13 0.29 0.61 Comparative Example 9 75 113 0.03 0.1 0.26 0.6 Comparative Example 10 69 118 0.03 0.1 0.26 0.6 Comparative Example 11 68 119 0.02 0.08 0.2 0.55 Comparative Example 12 65 110 0.02 0.09 0.21 0.57 Comparative Example 13 10 30 2.1 5.1 8.5 16

[0297] As can be seen from Table 5-5, the iron alloy obtained by the comparative examples beyond the parameter range of the present disclosure has a significant decrease in stability at high temperature; the rupture occurs in a relatively short period of time, and the corrosion resistance is poor.

[0298] In summary, by depositing composite bonding layer, composite ceramic layer, reflecting layer, catadioptric layer, insulating layer and carbon foam layer on the iron alloy, the service temperature of the iron alloy can be increased to 100-500° C. higher than the original melting point. The corrosion resistance can be greatly improved as well. The ultralimit iron alloy prepared by the ultralimit iron alloy preparation method of the present disclosure has a wide service temperature range and strong corrosion resistance; the effects of Test Example 1 are the best.

Embodiment 6 (Ultralimit Copper Alloy)

[0299] In this embodiment, the ultralimit alloy is an ultralimit copper alloy, that is, the alloy matrix is a copper alloy.

[0300] The reference signs in FIG. 1B include: copper alloy matrix 1, bonding layer 2, precious metal layer 3, ceramic A layer 4, ceramic B layer 5, reflecting layer 6, catadioptric layer 7, insulating layer 8, and carbon foam layer 9.

[0301] As shown in FIG. 1B, the present disclosure provides an ultralimit copper alloy, including an copper alloy matrix 1. The surface of the copper alloy matrix 1 is successively deposited with a composite bonding layer with a thickness of 100-200 μm, a composite ceramic layer with a thickness of 150-500 μm, a reflecting layer 6 with a thickness of 10-30 μm, a catadioptric layer 7 with a thickness of 10-30 μm, an insulating layer 8 with a thickness of 10-200 μm and a carbon foam layer 9 with a thickness of 20-200 μm. The composite bonding layer includes a bonding layer 2 deposited on the surface of the copper alloy matrix 1 and a precious metal layer 3 deposited on the surface of the bonding layer 2. The composition of the bonding layer 2 is one or more of MCrAlY, NiAl, NiCr—Al and Mo; MCrAlY is NiCrCoAlY, NiCoCrAlY, CoNiCrAlY or CoCrAlY. The composition of the precious metal layer 3 is one of or an alloy of more of Au, Pt, Ru, Rh, Pd, and Ir. The composite ceramic layer includes a ceramic A layer 4 and a ceramic B layer 5. The composition of the ceramic A layer 4 is YSZ or rare earth zirconate (RE.sub.2Zr.sub.2O.sub.7, RE=Y, Gd, Nd, Sm, Eu or Dy). The composition of the ceramic B layer 5 is ZrO.sub.2-RETaO.sub.4 (RE=Y, Gd, Nd, Sm, Eu, Dy, Er, Yb or Lu). The reflecting layer 6 is one or more of REVO.sub.4, RETaO.sub.4 and Y.sub.2O.sub.3, and RE=Y, Nd, Sm, Eu, Gd, Dy, Er, Yb or Lu. The composition of the catadioptric layer 7 is one or two of graphene and boron carbide, and the spatial distribution of the graphene and boron carbide are in a disorderly arranged state. The composition of the insulating layer 8 is one or more of epoxy resin, phenolic resin, and ABS resin.

[0302] The present disclosure uses ZrO.sub.2-RETaO.sub.4 as the ceramic B layer, which has the effects of low thermal conductivity and high expansion rate, and can reduce heat conduction; The method for preparing ZrO.sub.2-RETaO.sub.4 is the same as that of Embodiment 1, and the ZrO.sub.2-RETaO.sub.4 can meet the requirements of APS spraying technology on powder particle size and morphology.

[0303] Based on extensive experiments, the inventors obtain ultralimit copper alloys with the largest increase in service temperature, small increase in weight of the copper alloy and the best composition and thickness of the coating layers within the parameter scope of the present disclosure. In the present disclosure, 30 of them are listed for description.

[0304] The parameters of Test Examples 1-30 of an ultralimit copper alloy and its preparation method according to the present disclosure are shown in Table 6-1, Table 6-2, and Table 6-3 (thickness unit: μm):

TABLE-US-00026 TABLE 6-1 Composition and thickness of each coating layer in Test Examples 1-10 of an ultralimit copper alloy and its preparation method Test Example 1 2 3 4 5 6 7 8 9 10 Composite Composition and NiCrCoAlY 50 60 40 60 70 — — — — — bonding layer thickness of CoCrAlY — — — — — — — — — — bonding layer NiCoCrAlY — — — — — — — — — — CoNiCrAlY — — — — — — — — — — NiAl — — — — — 70 50 60 70 60 NiCr—Al — — — — — — — — — — Mo alloy — — — — — — — — — — Composition and Au 50 — — — — — 150 — — — thickness of Pt — 40 — — — — — 60 — — precious layer Ru — — 60 — — — — — 50 — Rh — — — 60 — — — — — 70 Pd — — — — 50 — — — — — Ir — — — — — 100 — — — — PT-Rh alloy — — — — — — — — — — Pd—Rh alloy — — — — — — — — — — Ru—Rh alloy — — — — — — — — — — Composite Composition and YSZ 70 60 80 90 110 180 — — — — ceramic layer thickness of Y.sub.2Zr.sub.2O.sub.7 — — — — — — 200 — — — ceramic A layer Gd.sub.2Zr.sub.2O.sub.7 — — — — — — — 80 — — Nd.sub.2Zr.sub.2O.sub.7 — — — — — — — — 90 — Sm.sub.2Zr.sub.2O.sub.7 — — — — — — — — — 120 Eu.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Dy.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Sm.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Eu.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Nd.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Composition and ZrO.sub.2—YTaO.sub.4 80 90 — 100 — — 300 — — — thickness of ZrO.sub.2—GdTaO.sub.4 — — 70 — 85 150 — 80 — — ceramic B layer ZrO.sub.2—NdTaO.sub.4 — — — — — — — — 100 — ZrO.sub.2—SmTaO.sub.4 — — — — — — — — — 70 ZrO.sub.2—EuTaO.sub.4 — — — — — — — — — — ZrO.sub.2—DyTaO.sub.4 — — — — — — — — — — ZrO.sub.2—ErTaO.sub.4 — — — — — — — — — — ZrO.sub.2—YbTaO.sub.4 — — — — — — — — — — ZrO.sub.2—LuTaO.sub.4 — — — — — — — — — — Composition and Y.sub.2O.sub.3 10 10 — — — — 15 — — — thickness of YVO.sub.4 — — 20 — 30 10 — — — — reflecting layer NdVO.sub.4 — — — — — — — — — — SmVO.sub.4 — — — — — — — — — — EuVO.sub.4 — — — — — — — — — — GdVO.sub.4 — — — — — — — — — 10 DyVO.sub.4 — — — — — — — — — — ErVO.sub.4 — — — — — — — — — — YbVO.sub.4 — — — — — — — — — — LuVO.sub.4 — — — — — — — — — — YTaO.sub.4 — — — 20 — — — 10 20 — NdTaO.sub.4 — — — — — — — — — — SmTaO.sub.4 — — — — — — — — — — EuTaO.sub.4 — — — — — — — — — — GdTaO.sub.4 — — — — — — — — — — DyTaO.sub.4 — — — — — — — — — — ErTaO.sub.4 — — — — — — — — — — YbTaO.sub.4 — — — — — — — — — — LuTaO.sub.4 — — — — — — — — — — Y.sub.2O.sub.3 and EuVO.sub.4 — — — — — — — — — — YVO.sub.4 and EuTaO.sub.4 — — — — — — — — — — Y.sub.2O.sub.3 and LuTaO.sub.4 — — — — — — — — — — YVO.sub.4 and LuTaO.sub.4 — — — — — — — — — — Composition and Graphene 10 10 20 20 30 10 — — — — thickness of Boron carbide — — — — — — 30 15 25 20 catadioptric layer Composition and Epoxy resin 15 10 — — — — 20 — — 10 thickness of Phenolic resin — — 20 20 — — — — 15 — insulating layer ABS resin — — — — 50 100 — 10 — — Thickness of carbon foam layer 20 20 20 20 100 200 30 25 20 35

TABLE-US-00027 TABLE 6-2 Composition and thickness of each coating layer in Test Examples 11-20 of an ultralimit copper alloy and its preparation method Test Example 11 12 13 14 15 16 17 18 19 20 Composite Composition and NiCrCoAlY — — — — — — — — — — bonding layer thickness of CoCrAlY 70 — — — — — — — — — bonding layer NiCoCrAlY — 80 — — — — — — — — CoNiCrAlY — — 55 — — 75 — — — 55 NiAl — — — — 80 — — — — — NiCr—Al — — — 80 — — — 100 — — Mo alloy — — — — — — 95 — 35 — Composition and Au — — — — — — 105 — — — thickness of Pt — — — — — 85 — — — — precious layer Ru — — — — — — — 60 — — Rh — — — — — — — — — 70 Pd — — — — — — — — 110 — Ir — — — — — — — — — — PT-Rh alloy 70 — — — 70 — — — — — Pd—Rh alloy — 60 — 55 — — — — — — Ru—Rh alloy — — 100 — — — — — — — Composite Composition and YSZ — — — — — 80 — — — — ceramic layer thickness of Y.sub.2Zr.sub.2O.sub.7 — — — — — — 140 — — — ceramic A layer Gd.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Nd.sub.2Zr.sub.2O.sub.7 — — — — — — — 100 — — Sm.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Eu.sub.2Zr.sub.2O.sub.7 50 — — — — — — — 110 — Dy.sub.2Zr.sub.2O.sub.7 — 70 — — — — — — — — YSZ and Sm.sub.2Zr.sub.2O.sub.7 — — 60 — — — — — — 180 YSZ and Eu.sub.2Zr.sub.2O.sub.7 — — — 60 — — — — — — YSZ and Nd.sub.2Zr.sub.2O.sub.7 — — — — 100 — — — — — Composition and ZrO.sub.2—YTaO.sub.4 — — — — — 120 — — — — thickness of ZrO.sub.2—GdTaO.sub.4 — — — — — — — 50 — — ceramic B layer ZrO.sub.2—NdTaO.sub.4 — — — — — — 60 — — — ZrO.sub.2—SmTaO.sub.4 — — — — — — — — 70 — ZrO.sub.2—EuTaO.sub.4 130 — — — — — — — — 100 ZrO.sub.2—DyTaO.sub.4 — 160 — — — — — — — — ZrO.sub.2—ErTaO.sub.4 — — 170 — — — — — — — ZrO.sub.2—YbTaO.sub.4 — — — 190 — — — — — — ZrO.sub.2—LuTaO.sub.4 — — — — 140 — — — — — Composition and Y.sub.2O.sub.3 — — — — — — — — — — thickness of YVO.sub.4 — — — — — — — — — — reflecting layer NdVO.sub.4 — — — — — — — — — — SmVO.sub.4 — — — — — — — — — — EuVO.sub.4 — — — — — — — 20 — — GdVO.sub.4 — — — — — — — — DyVO.sub.4 — — — — — — — — — — ErVO.sub.4 — — — — — — — — — 18 YbVO.sub.4 — — — — — — — — — — LuVO.sub.4 — — — — — — — — — — YTaO.sub.4 — — — — — — — — — — NdTaO.sub.4 — — — — — — — — — — SmTaO.sub.4 — — — — — — — — — — EuTaO.sub.4 — — — — — — — — 25 — GdTaO.sub.4 — — — — — — — — — — DyTaO.sub.4 — — — — — — — — — — ErTaO.sub.4 — — — — — — — — — — YbTaO.sub.4 — — — — — — — — — — LuTaO.sub.4 — — — — — — — — — — Y.sub.2O.sub.3 and EuVO.sub.4 15 — — — — 10 — — — — YVO.sub.4 and EuTaO.sub.4 — 20 — — — — 15 — — — Y.sub.2O.sub.3 and LuTaO.sub.4 — — 10 — 20 — — — — — YVO.sub.4 and LuTaO.sub.4 — — — 15 — — — — — — Composition and Graphene 15 30 — — 25 — 20 — — 23 thickness of Boron carbide — — 15 20 — 25 — 30 23 — catadioptric layer Composition and Epoxy resin 15 — — 15 — — 25 30 — 35 thickness of Phenolic resin — 10 — — — — — — 40 — insulating layer ABS resin — — 20 — 110 200 — — — — Thickness of carbon foam layer 30 40 45 50 70 50 60 80 100 120

TABLE-US-00028 TABLE 6-3 Composition and thickness of each coating layer in Test Examples 21-30 of an ultralimit copper alloy and its preparation method Test Example 21 22 23 24 25 26 27 28 29 30 Composite Composition and NiCrCoAlY 75 — 40 — — — — — — 95 bonding layer thickness of CoCrAlY — 50 — — — — — — — — bonding layer NiCoCrAlY — — — — — 40 — — — — CoNiCrAlY — — — — 60 — — — — — NiAl — — — 30 — — — — — — NiCr—Al — — — — — — 80 95 — — Mo alloy — — — — — — — — 65 — Composition and Au 55 — — — — — — — — 45 thickness of Pt — 60 — — — — — — — — precious layer Ru — — 60 — 40 — — — 55 — Rh — — — 70 — — — — — — Pd — — — — — 80 — 55 — — Ir — — — — — — 70 — — — PT-Rh alloy — — — — — — — — — — Pd—Rh alloy — — — — — — — — — — Ru—Rh alloy — — — — — — — — — — Composite Composition and YSZ 90 — — — — — — — — 70 ceramic layer thickness of Y.sub.2Zr.sub.2O.sub.7 — 50 — — — — — 90 — — ceramic A layer Gd.sub.2Zr.sub.2O.sub.7 — — — — — 80 — — — — Nd.sub.2Zr.sub.2O.sub.7 — — 150 — — — 300 — 85 — SmZr.sub.2O.sub.7 — — — 100 180 — — — — — Eu.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Dy.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Sm.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Eu.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — YSZ and Nd.sub.2Zr.sub.2O.sub.7 — — — — — — — — — — Composition and ZrO.sub.2—YTaO.sub.4 — — — — — — — — — 150 thickness of ZrO.sub.2—GdTaO.sub.4 — — — — — — — — — — ceramic B layer ZrO.sub.2—NdTaO.sub.4 — — — — — — — — 75 — ZrO.sub.2—SmTaO.sub.4 — — — — — — — — — — ZrO.sub.2—EuTaO.sub.4 — — — — — — — — — — ZrO.sub.2—DyTaO.sub.4 80 — — — — — — 100 — — ZrO.sub.2—ErTaO.sub.4 — — — — 90 — 130 — — — ZrO.sub.2—YbTaO.sub.4 — 150 — — — 100 — — — — ZrO.sub.2—LuTaO.sub.4 — — 50 70 — — — — — — Composition and Y.sub.2O.sub.3 — — — — — — — — — 20 thickness of YVO.sub.4 — — — — — — — — — — reflecting layer NdVO.sub.4 — 12 — — — — — — — — SmVO.sub.4 — — — — — — — — — — EuVO.sub.4 — — — — — — — — — — GdVO.sub.4 — — — — — — — — — — DyVO.sub.4 — — — 22 — — — — — — ErVO.sub.4 — — — — — 10 — — — — YbVO.sub.4 — — — — — 18 — — — — LuVO.sub.4 — — — — — — — 30 — — YTaO.sub.4 — — — — — — — — — — NdTaO.sub.4 — — 12 — — — — — — — SmTaO.sub.4 — — — — — — — — — — EuTaO.sub.4 — — — — — — — — — — GdTaO.sub.4 — — — — — — — — — — DyTaO.sub.4 — — — — 12 — — — — — ErTaO.sub.4 18 — — — — — — — — — YbTaO.sub.4 — — — — 10 — 28 — — — LuTaO.sub.4 — — — — — — — — 30 — Y.sub.2O.sub.3 and EuVO.sub.4 — — — — — — — — — — YVO.sub.4 and EuTaO.sub.4 — — — — — — — — — — Y.sub.2O.sub.3 and LuTaO.sub.4 — — — — — — — — — — YVO.sub.4 and LuTaO.sub.4 — — — — — — — — — — Composition and Graphene 15 28 18 18 13 13 10 10 15 20 thickness of Boron carbide — — — — — — — — — — catadioptric layer Composition and Epoxy resin — — — — — 180 — 160 — 15 thickness of Phenolic resin 30 — — 80 100 — — — — — insulating layer ABS resin — 30 60 — — — 150 — 170 — Thickness of carbon foam layer 130 150 160 170 175 180 185 190 200 30

[0305] Now, take Test Example 1 of Embodiment 6 as an example to illustrate another technical solution of the present disclosure, that is, a method for preparing an ultralimit copper alloy. A method for preparing an ultralimit copper alloy, including the following operations:

[0306] Operation 1: basically the same as the operation 1 of preparing ultralimit titanium alloy in Embodiment 4, except that C86100 copper alloy serves as the alloy matrix in this test example.

[0307] Operation 2: basically the same as the operation 2 of preparing ultralimit titanium alloy in Embodiment 4, except that the thickness of the deposited bonding layer is 45 μm, and the thickness of the precious metal layer is 45 μm.

[0308] Operation 3: basically the same as the operation 3 of preparing ultralimit titanium alloy in Embodiment 4, except that the thickness of the ceramic A layer is 70 μm, and the thickness of the ceramic B layer is 50 μm.

[0309] Operation 4: a layer of Y.sub.2O.sub.3 transparent ceramic material is sprayed on the surface of the composite ceramic layer as a reflecting layer by the HVOF method. The thickness of the sprayed reflecting layer is 20 μm.

[0310] Operation 5: a layer of graphene is brushed on the surface of the Y.sub.2O.sub.3 reflecting layer as a catadioptric layer by a brushing method, and the thickness of the catadioptric layer is 10 μm.

[0311] Operation 6: a layer of epoxy resin is brushed on the surface of the graphene catadioptric layer as an insulating layer by a brushing method, and the thickness of the insulating layer is 15 μm.

[0312] Operation 7: a layer of carbon foam layer is brushed on the epoxy resin insulating layer by a brushing method, and the thickness of the carbon foam layer is 20 μm. The ultralimit copper alloy is obtained.

[0313] The preparation process of Test Examples 2-29 is the same as that of Test Examples 1, except that the composition and thickness of the coating layers as shown in Table 6-1 are different. The difference between Test Example 30 and Test Example 1 is that the spraying sequence of the ceramic A layer and the ceramic B layer in operation 3 is different.

[0314] 13 groups of Comparative Examples are provided to perform comparative experiments with Test Examples 1-30. The parameters of Comparative Examples 1-12 are shown in Table 6-4 (thickness unit: μm):

[0315] Table 6-4 Composition and thickness of each coating layer in Comparative Examples 1-12

TABLE-US-00029 Comparative Example 1 2 3 4 5 6 7 8 9 10 11 12 Composite Composition and NiCrCoAlY 45 60 40 20 50 — — — — 45 45 45 bonding thickness of MCrAlY — — — — — 70 50 30 40 — — — layer bonding layer NiAl — — — — — — — — — — — — NiCr—Al — — — — — — — — — — — — Mo alloy 45 — — — — — 40 — — 45 45 45 Composition and Au — 30 — — — — — 60 — — — — thickness of Pt — — 40 — — — — — 50 — — — precious layer Ru — — — 60 — — — — — — — — Rh — — — — 50 — — — — — — — Pd — — — — — 30 — — — — — — Ir — — — — — — — — — — — — Composite Composition and YSZ — — — — — — — — — 60 40 — ceramic thickness of RE.sub.2Zr.sub.2O.sub.7 50 45 60 55 35 100 100 50 80 — — — layer ceramic A layer Composition and ZrO2—YTaO.sub.4 40 — — — — — — — — — — — thickness of ZrO.sub.2—GdTaO.sub.4 — — — 30 — — — — — — — — ceramic B layer ZrO.sub.2—NdTaO.sub.4 — 50 — — — — — — — — — — ZrO.sub.2—SmTaO.sub.4 — — — — — — — 60 — — — — ZrO.sub.2—EuTaO.sub.4 — — 20 — — — — — — — — — ZrO.sub.2—DyTaO.sub.4 — — — — — 10 — — — — — — ZrO.sub.2—ErTaO.sub.4 — — — — 30 — — — — — — — ZrO.sub.2—YbTaO.sub.4 — — — — — — 20 — — — — — ZrO.sub.2—LuTaO.sub.4 — — — — — — — — 20 — — — Composition and Y.sub.2O.sub.3 5 — — — — — — — — 20 — — thickness of YVO.sub.4 — 8 — — — — — — 35 — — — reflecting layer GdVO.sub.4 — — 5 — — — 38 — — — — 20 YTaO.sub.4 — — — 35 — — — 8 — — — — GdTaO.sub.4 — — — — 8 35 — — — — — — Composition and Graphene 5 — 9 — 35 38 — 45 50 20 20 20 thickness of Boron carbide — 8 — 6 — — 40 — — — — — catadioptric layer Composition and Epoxy resin 5 — — — 25 — 30 — — 15 15 15 thickness of Phenolic resin — 9 — — — — — — 40 — — — insulating layer ABS resin — — 8 5 — 28 — 35 — — — — Thickness of carbon foam layer 15 10 18 5 250 220 230 260 280 30 30 —

[0316] The preparation method of Comparative Examples 1-12 is the same as that of Test Example 1, except that the composition and thickness of the coating layers as shown in Table 6-3 are different. Comparative Example 13 is a C86100 copper alloy matrix without deposited coating layers.

[0317] The following experiments are performed using the copper alloys provided in Test Examples 1-30 and Comparative Examples 1-13:

[0318] 1. High Temperature Creep Test:

[0319] The copper alloys prepared by Test Examples 1-30 and Comparative Examples 1-13 are processed into tensile test pieces and placed into an electronic high temperature creep rupture strength test machine. The experimental conditions are the same as in Embodiment 4. The test machine is adjusted to a stress of 50 MPa and a temperature of 1300° C., and the following data are recorded. As shown in Table 6-5, a represents the steady creep time (min) of the test pieces; b represents the time when creep rupture of the test pieces happens (min).

[0320] Take Test Example 1 and Comparative Example 13 as examples. FIG. 2F shows the high temperature creep test curves of Test Example 1 and Comparative Example 13. In FIG. 2F, (A) represents the C86100 copper alloy matrix material without deposited coating layers in Comparative Example 13, and (B) represents the material prepared in Test Example 1.

[0321] It can be seen from FIG. 2F that under a stress of 50 MPa and a temperature of 1300° C., there are three stages of creep in test pieces (A) and (B): the first stage is short and has a high creep rate, which quickly transitions to the second stage of creep; the creep rate of the second stage reaches a minimum value, and the second stage is long and is basically in a steady-state creep process; in the third stage, the creep rate increases rapidly, and the creep deformation develops rapidly until the material is broken and the creep rupture occurs. It can be found that under a stress of 50 MPa and a temperature of 1300° C., the test piece (A) ruptures in a very short time, indicating that the copper alloy can hardly bear the load at the temperature higher than the melting point, while the test piece (B) can maintain good mechanical properties under the condition of 1300° C. without rupturing for a long time and has excellent high-temperature resistance.

[0322] Salt-Spray Corrosion Test:

[0323] The copper alloy provided in Test Examples 1-30 and Comparative Examples 1-13 are processed into test pieces of 50 mm×25 mm×2 mm, and the subsequent operations are the same as those of Embodiment 1. The weight loss of the test pieces is shown in FIG. 3F (in FIG. 3F, (A) represents the C86100 copper alloy matrix material without deposited coating layers in Comparative Example 13, and (B) represents Test Example 1). The specific experimental results of Test Examples 1-30 and Comparative Examples 1-13 are shown in Table 6-5.

[0324] It can be seen from FIG. 3F that the two copper alloys have obviously different corrosion patterns. For test piece (A) (C86100 copper alloy test piece), the corrosion weight loss value tends to increase as the corrosion time extends. In the early stage of corrosion (8-24 h), there is an oxidation film on the surface of the test piece, which prevents the copper alloy matrix from contacting the solution; the corrosion rate is low. In the middle stage of corrosion (24-48 h), the Cl.sup.− (chloridion) in the solution has penetrated the oxidation film, and a large amount of Cl.sup.− is adsorbed on the matrix, which increases the corrosion pit points and deepens the original corrosion pit points; the corrosion rate is obviously accelerated. After 48 hours of continuous spraying, the corrosion products are evenly distributed and the thickness increases, covering almost the entire surface of the test piece. Cl.sup.− needs to pass through the corrosion products to contact the copper alloy matrix, which reduces the amount of Cl.sup.− adsorbed on the matrix surface and reduces the corrosion rate. In general, the corrosion loss weight of C86100 copper alloy is much higher than that of the copper matrix surface composite material. Basically, the copper matrix surface composite material has no corrosion due to the existence of the coating layers, and the mass of the copper matrix surface composite material has hardly changed.

[0325] In Table 6-5, a represents the steady creep time (min) of the test pieces;

[0326] b represents the time when creep rupture of the test pieces happens (min);

[0327] c represents the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 8 hours;

[0328] d represents the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 24 hours;

[0329] e represents the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 48 hours;

[0330] f represents the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 72 hours.

TABLE-US-00030 TABLE 6-5 Experimental results of high temperature creep test and salt-spray test a b c d e f Test Example 1 160 270 0 0.01 0.07 0.11 Test Example 2 155 269 0 0.05 0.08 0.17 Test Example 3 160 263 0 0.04 0.08 0.17 Test Example 4 159 267 0 0.03 0.07 0.18 Test Example 5 161 268 0 0.03 0.07 0.13 Test Example 6 155 268 0 0.03 0.07 0.13 Test Example 7 157 265 0.005 0.02 0.06 0.12 Test Example 8 157 265 0 0.05 0.09 0.13 Test Example 9 152 265 0.006 0.04 0.07 0.15 Test Example 10 156 262 0 0.04 0.07 0.11 Test Example 11 158 260 0 0.05 0.09 0.11 Test Example 12 159 260 0.004 0.03 0.06 0.12 Test Example 13 159 265 0 0.03 0.06 0.13 Test Example 14 155 265 0 0.05 0.09 0.14 Test Example 15 154 265 0 0.05 0.09 0.13 Test Example 16 159 265 0 0.03 0.06 0.12 Test Example 17 159 262 0.005 0.02 0.05 0.11 Test Example 18 156 263 0.006 0.02 0.05 0.11 Test Example 19 153 261 0.006 0.03 0.06 0.11 Test Example 20 152 268 0 0.04 0.09 0.12 Test Example 21 157 268 0 0.05 0.09 0.12 Test Example 22 155 268 0.006 0.04 0.09 0.12 Test Example 23 154 270 0 0.04 0.09 0.13 Test Example 24 161 270 0 0.02 0.05 0.11 Test Example 25 155 270 0 0.03 0.05 0.15 Test Example 26 152 265 0 0.02 0.05 0.12 Test Example 27 156 265 0.004 0.05 0.09 0.15 Test Example 28 155 265 0.004 0.02 0.06 0.12 Test Example 29 154 264 0.005 0.02 0.06 0.14 Test Example 30 153 269 0 0.02 0.06 0.11 Comparative Example 1 52 115 0.07 0.08 0.23 0.55 Comparative Example 2 60 110 0.07 0.05 0.19 0.5 Comparative Example 3 57 114 0.06 0.05 0.19 0.51 Comparative Example 4 58 115 0.05 0.06 0.2 0.52 Comparative Example 5 52 110 0.05 0.07 0.21 0.52 Comparative Example 6 56 109 0.05 0.08 0.22 0.53 Comparative Example 7 55 105 0.05 0.08 0.25 0.56 Comparative Example 8 55 112 0.05 0.09 0.22 0.53 Comparative Example 9 52 113 0.03 0.09 0.21 0.52 Comparative Example 10 59 108 0.03 0.07 0.24 0.58 Comparative Example 11 59 109 0.02 0.08 0.23 0.56 Comparative Example 12 51 110 0.02 0.06 0.21 0.52 Comparative Example 13 30 45 1.1 2.1 4.2 6.4

[0331] As can be seen from Table 6-5, the copper alloy obtained by the comparative examples beyond the parameter range of the present disclosure has a significant decrease in stability at high temperature; the rupture occurs in a relatively short period of time, and the corrosion resistance is poor.

[0332] In summary, by depositing composite bonding layer, composite ceramic layer, reflecting layer, catadioptric layer, insulating layer and carbon foam layer on the copper alloy, the service temperature of the copper alloy can be increased to 100-500° C. higher than the original melting point. The corrosion resistance can be greatly improved as well. The ultralimit copper alloy prepared by the ultralimit copper alloy preparation method of the present disclosure has a wide service temperature range and strong corrosion resistance; the effects of Test Example 1 are the best.

Embodiment 7 (Ultralimit Zirconium Alloy)

[0333] In this embodiment, the ultralimit alloy is an ultralimit zirconium alloy, that is, the alloy matrix is a zirconium alloy matrix.

[0334] The reference signs in FIG. 4 include: zirconium alloy matrix 1, bonding layer 2, precious metal layer 3, ceramic A layer 4, ceramic B layer 5, seal coating layer 6, reflecting layer 7, catadioptric layer 8, and electrically insulating layer 9.

[0335] As shown in FIG. 4, the present disclosure provides an ultralimit zirconium alloy, including an zirconium alloy matrix 1. The surface of the zirconium alloy matrix 1 is successively deposited with a bonding layer 2 with a thickness of 50-150 μm, a precious metal layer 3 with a thickness of 10-20 μm, a ceramic A layer 4 with a thickness of 50-80 μm, a ceramic B layer 5 with a thickness of 50-80 μm, a seal coating layer 6 with a thickness of 5-10 μm, a reflecting layer 7 with a thickness of 10-15 μm, a catadioptric layer 8 with a thickness of 10-15 μm, and an electrically insulating layer 9 with a thickness of 15-20 μm; the zirconium alloy matrix 1 is a zirconium alloy added with one or more elements of zinc, aluminum, copper, tin, niobium, iron, chromium, and nickel. The composition of the bonding layer 2 is MCrAlY, and the MCrAlY is CoCrAlY, NiCoCrAlY or CoNiCrAlY. The composition of the precious metal layer 3 is one of or an alloy of more of Pt, Ru, Rh, Pd, Ir, and Os. The composition of the ceramic A layer 4 is one or more of Y.sub.2O.sub.3—ZrO.sub.2, Y.sub.2O.sub.3—CeO.sub.2, Y.sub.2O.sub.3—TiO.sub.2, Y.sub.2O.sub.3—CeO.sub.2, Y.sub.2O.sub.3—Yb.sub.2O.sub.3, Y.sub.2O.sub.3—Er.sub.2O.sub.3, Y.sub.2O.sub.3—Dy.sub.2O.sub.3, and Y.sub.2O.sub.3—HfO.sub.2. The composition of the ceramic B layer 5 is RETaO.sub.4 (RE=Y, Nd, Eu, Gd, Dy, Er or Yb), and RETaO.sub.4 is spherical in shape and has a particle size of 10-70 μm. The composition of the seal coating layer 6 is one or more of REVO.sub.4, REPO.sub.4 (RE=Nd, Eu, Gd, Dy, Er, Y or Yb) and BN. The composition of the reflecting layer 7 is one or more of REVO.sub.4, RETaO.sub.4 and Y.sub.2O.sub.3, and RE=Y, Nd, Eu, Gd, Dy, Er or Yb. The composition of the catadioptric layer 8 is graphene, and the spatial distribution of the graphene is in a disorderly arranged state. The composition of the electrically insulating layer 9 is one or more of polytetrafluoroethylene, polyimide, polyphenyl ether, polyphenylene sulfide, polyether ether ketone, bismaleimide, furan resin, cyanate ester resin and polyarylacetylene.

[0336] The present disclosure uses RETaO.sub.4 as the ceramic B layer, which has the effects of low thermal conductivity and high expansion rate, and can reduce heat conduction. The RETaO.sub.4 prepared by the following method can meet the requirements of APS spraying technology.

[0337] RETaO.sub.4 is prepared by the following method, including the following operations:

[0338] Operation (1): pre-drying rare earth oxide (RE.sub.2O.sub.3) powder and tantalum pentoxide (Ta.sub.2O.sub.5) powder, the pre-drying temperature is 600° C., and the pre-drying time is 8 hours; weighing the pre-dried rare earth oxide powder (RE.sub.2O.sub.3) and tantalum oxide (Ta.sub.2O.sub.5) powder according to a molar ratio of 1:1; adding the pre-dried powders into the ethanol solvent to obtain a mixed solution, so that the molar ratio of RE:Ta in the mixed solution is 1:1; ball-milling the mixed solution using a ball mill for 10 hours, and the speed of the ball mill is 300 r/min;

[0339] drying the slurry obtained after ball milling using a rotary evaporator (model: N-1200B), the drying temperature is 60° C., and the drying time is 2 hours; sieving the dried powder through a 300-mesh sieve to obtain powder A.

[0340] Operation (2): preparing powder B with a composition of RETaO.sub.4 from the powder A obtained in operation (1) by a high-temperature solid-phase reaction method, the reaction temperature is 1700° C. and the reaction time is 10 hours; sieving the powder B with a 300-mesh sieve;

[0341] Operation (3): mixing the powder B sieved in operation (2) with deionized water solvent and an organic bonding agent to obtain slurry C, the mass percentage of powder B in slurry C is 25%, the mass percentage of organic bonding agent in slurry C is 2%, and the rest is the solvent; the organic bonding agent is polyvinyl alcohol or gum arabic; drying the slurry C by the centrifugal atomization method to obtain dried granules D, the temperature during drying is 600° C., and the centrifugal speed is 8500 r/min;

[0342] Operation (4): sintering the granules D obtained in operation (3) at 1200° C. for 8 hours, sieving the sintered granules D with a 300-mesh sieve to obtain RETaO.sub.4 ceramic powder having a particle size of 10-70 μm and a spherical shape.

[0343] Based on extensive experiments, the inventors conclude that the ultralimit zirconium alloys prepared based on parameters within the scope of the present disclosure have high service temperature and good corrosion resistance. In the present disclosure, 20 of them are listed for description.

[0344] The parameters of Test Examples 1-20 of an ultralimit zirconium alloy and its preparation method according to the present disclosure are shown in Table 7-1 and Table 7-2 (thickness unit: μm):

TABLE-US-00031 TABLE 7-1 Composition and thickness of each coating layer in Test Examples 1-10 of an ultralimit zirconium alloy and its preparation method Test Example 1 2 3 4 5 6 7 8 9 10 Composition and CoCrAlY 75 — — 70 — — — 110 — — thickness of NiCoCrAlY — 93 — — 90 — — — 80 75 bonding layer CoNiCrAlY — — 90 — — 100 120 — — — Composition and Pt 10 — — — — — — — — — thickness of Ru — — — — — — — — 15 — precious layer Rh — 10 — — — — — — — — Pd — — 10 — — — — — — — Ir — — — — 20 — — — — — Os — — — 15 — — — — — — PtRh alloy — — — — — 10 — — — — PdRh alloy — — — — — — — — — 10 PtRu alloy — — — — — — — 15 — — Composition and YSZ — 50 50 — — — — — — — thickness of Y.sub.2O.sub.3—ZrO.sub.2 — — — 60 — — — — — — ceramic A layer Y.sub.2O.sub.3—CeO.sub.2 — — — — 65 — — — — — Y.sub.2O.sub.3—TiO.sub.2 — — — — — 80 — — — — Y.sub.2O.sub.3—CeO.sub.2 — — — — — — 70 — — — Y.sub.2O.sub.3—Yb.sub.2O.sub.3 50 — — — — — — 75 — — Y.sub.2O.sub.3—Er.sub.2O.sub.3 — — — — — — — — 60 — Y.sub.2O.sub.3—Dy.sub.2O.sub.3 — — — — — — — — — 55 Y.sub.2O.sub.3—HfO.sub.2 — — — — — — — — — — Composition and YTaO.sub.4 50 — — — — — — — — — thickness of YbTaO.sub.4 — 50 50 — — — — — — — ceramic B layer EuTaO.sub.4 — — — — — — — 50 — — DyTaO.sub.4 — — — — 60 — — — — 60 ErTaO.sub.4 — — — — — 80 — — — — NdTaO.sub.4 — — — 70 — — — — 70 — GdTaO.sub.4 — — — — — — 80 — — — Composition and Ti.sub.3SiC 5 — 6 — — — — — — — thickness of BN — 5 — — — — — — — — seal coating layer NdPO.sub.4 — — — 5 — — — — — — EuPO.sub.4 — — — — 8 — — — — — GdPO.sub.4 — — — — — 7 — — — — DyPO4 — — — — — — 6 — — — ErPO.sub.4 — — — — — — — 5 — — YbPO.sub.4 — — — — — — — — 9 — YPO.sub.4 — — — — — — — — — 10 Ti.sub.3SiC and BN — — — — — — — — — — Ti.sub.3SiC and YPO.sub.4 — — — — — — — — — — Ti.sub.3SiC and GdPO.sub.4 — — — — — — — — — — BN and NdPO.sub.4 — — — — — — — — — — BN and DyPO.sub.4 — — — — — — — — — — Composition Y.sub.2O.sub.3 — — — 10 — — — — — — and thickness REVO.sub.4 YVO.sub.4 10 — — — — — — — — — of reflecting NdVO.sub.4 — — — — — 15 — — — — layer EuVO.sub.4 — — — — 10 — — — — — GdVO.sub.4 — — 10 — — — — — — — DyVO.sub.4 — 10 — — — — — — — — ErVO.sub.4 — — — — — — — 15 — — YbVO.sub.4 — — — — — — 10 — — — RETaO.sub.4 NdTaO.sub.4 — — — — — — — — 10 — EuTaO.sub.4 — — — — — — — — — 15 GdTaO.sub.4 — — — — — — — — — — DyTaO.sub.4 — — — — — — — — — — ErTaO.sub.4 — — — — — — — — — — YbTaO.sub.4 — — — — — — — — — — YTaO.sub.4 — — — — — — — — — — Y.sub.2O.sub.3 and DyVO.sub.4 — — — — — — — — — — Y.sub.2O.sub.3 and EuTaO.sub.4 — — — — — — — — — — YVO.sub.4 and GdTaO.sub.4 — — — — — — — — — — EuVO.sub.4 and NdTaO.sub.4 — — — — — — — — — — Y.sub.2O.sub.3, YVO.sub.4 and YTaO.sub.4 — — — — — — — — — — Thickness of Graphene 13 10 15 15 10 12 15 12 13 10 catadioptric layer Composition and Polytetrafluoroethylene — 15 — 18 — — — — — — thickness of Polyimide — — 20 — — 20 — — — — electrically Polyphenyl ether 15 — — — 15 — — — — — insulating layer Polyphenylene sulfide — — — — — — — 17 — — Polyether ether ketone — — — — — — — — — 15 Bismaleimide — — — — — — — — — — Furan resin — — — — — — — — — — Cyanate ester resin — — — — — — 18 — — — Polyarylacetylene — — — — — — — — 20 —

TABLE-US-00032 TABLE 7-2 Composition and thickness of each coating layer in Test Examples 21-20 of an ultralimit zirconium alloy and its preparation method Test Example 11 12 13 14 15 16 17 18 19 20 Composition and CoCrAlY 130 — — — — 85 — — 120 — thickness of NiCoCrAlY — 120 130 — 70 — — 110 — — bonding layer CoNiCrAlY — — — 125 — — 95 — — 100 Composition and Pt 15 — — — — — — — — — thickness of Ru — 20 — — — — — — 10 — precious layer Rh — — 10 — — — — — — — Pd — — — — — 10 — — — — Ir — — — — 10 — — — — — Os — — — 15 — — — — — — PtRh alloy — — — — — — 15 — — — PdRh alloy — — — — — — — — — 10 PtRu alloy — — — — — — — 15 — — Composition and Y.sub.2O.sub.3—ZrO.sub.2 — — — — 65 — — — — — thickness of Y.sub.2O.sub.3—CeO.sub.2 — — — — — 60 — — — — ceramic A layer Y.sub.2O.sub.3—TiO.sub.2 — — — — — — — 70 — — Y.sub.2O.sub.3—CeO.sub.2 — — — 50 — — 80 — — — Y.sub.2O.sub.3—Yb.sub.2O.sub.3 — — — — — — — — 50 — Y.sub.2O.sub.3—Er.sub.2O.sub.3 — — 60 — — — — — — — Y.sub.2O.sub.3—Dy.sub.2O.sub.3 — 75 — — — — — — — — Y.sub.2O.sub.3—HfO.sub.2 80 — — — — — — — — 60 Composition and YTaO.sub.4 — — 50 — — — — — — — thickness of YbTaO.sub.4 — 70 — — — — — — 60 — ceramic B layer EuTaO.sub.4 — — — — — 55 — — — — DyTaO.sub.4 75 — — — 65 — — — — — ErTaO.sub.4 — — — — — — — — — 80 NdTaO.sub.4 — — — 60 — — — 75 — — GdTaO.sub.4 — — — — — — 65 — — — Composition and Ti.sub.3SiC — — — — — — — — — — thickness of BN — — — — — — — — — — seal coating layer NdPO.sub.4 — — — — — — — — — — EuPO.sub.4 — — — — — — 10 — — — GdPO.sub.4 — — — — — — — — — — DyPO.sub.4 — — — — — — — — — — ErPO.sub.4 — — — — — — — — 10 — YbPO.sub.4 — — — — — — — 5 — — YPO.sub.4 — — — — — — — — — 10 Ti.sub.3SiC and BN — 5 — — — — — — — — Ti.sub.3SiC and YPO.sub.4 — — — — 10 — — — — — Ti.sub.3SiC and GdPO.sub.4 10 — 8 — — — — — — — BN and NdPO.sub.4 — — — — — 10 — — — — BN and DyPO.sub.4 — — — 5 — — — — — — Composition and Y.sub.2O.sub.3 — — — — — — — — — — thickness of REVO.sub.4 YVO.sub.4 — — — — — — — — — — reflecting layer NdVO.sub.4 — — — — — — — — — — EuVO.sub.4 — — — — — — — — — — GdVO.sub.4 — — — — — — — — — — DyVO.sub.4 — — — — — — — — — — ErVO.sub.4 — — — — — — — — — — YbVO.sub.4 — — — — — — — — — — RETaO.sub.4 NdTaO.sub.4 — — — — — — — — — — EuTaO.sub.4 — — — — — — — — — — GdTaO.sub.4 15 — — — — — — — — — DyTaO.sub.4 — 10 — — — — — — — — ErTaO.sub.4 — — 13 — — — — — — — YbTaO.sub.4 — — — 12 — — — — — — YTaO.sub.4 — — — — 15 — — — — — Y.sub.2O.sub.3 and DyVO.sub.4 — — — — — 10 — — — — Y.sub.2O.sub.3 and EuTaO.sub.4 — — — — — — 13 — — — YVO.sub.4 and GdTaO.sub.4 — — — — — — — 10 — — EuVO.sub.4 and NdTaO.sub.4 — — — — — — — — 12 — Y.sub.2O.sub.3, YVO.sub.4 and YTaO.sub.4 — — — — — — — — — 13 Thickness of Graphene 15 10 15 12 13 5 13 10 13 10 catadioptric layer Composition and Polytetrafluoroet hylene — — — 18 — — — — — — thickness of Polyimide — — — — — 20 — — — — electrically Polyphenyl ether — — — — 17 — — — — — insulating layer Polyphenylene sulfide — — — — — — — 18 — — Polyether ether ketone — 17 — — — — — — — 15 Bismaleimide 20 — — — — — — — — — Furan resin — — 15 — — — — — — — Cyanate ester resin — — — — — — 15 — — — Polyarylacetylene — — — — — — — — 20 —

[0345] Take Test Example 1 of Embodiment 7 as an example to illustrate another technical solution of the present disclosure, that is, a method for preparing an ultralimit zirconium alloy. A method for preparing an ultralimit zirconium alloy, including the following operations:

[0346] Operation 1: in this test example, Zr-1Nb zirconium alloy serves as the zirconium alloy matrix, and the oil stains and impurities on the surface of zirconium alloy matrix are removed by a soaking method. First, the zirconium alloy matrix is soaked in an alkali solution or an emulsified detergent; the main components of the emulsified detergent are ethanol and surfactant, and the main components of the alkali solution are sodium hydroxide, trisodium phosphate, sodium carbonate and sodium silicate; in this test example, the zirconium alloy matrix is soaked in the alkali solution. The pH value of the alkali solution is adjusted to between 10-11, and then the zirconium alloy matrix is soaked in the alkali solution for 0.5-1.5 h and then taken out. In this test example, the soaking time is 1 hour. Then, the zirconium alloy matrix is rinsed with clean water and dried. The surface of the zirconium alloy matrix is sandblasted by a sand-blasting machine. The sand-blasting machine used is a JCK-SS500-6A automatic transmission sand-blasting machine. The sandblasting material used is 23-mesh quartz sand. The surface roughness of the zirconium alloy matrix after sand blasting is 60-100 μm. In this test example, the surface roughness of the zirconium alloy matrix is 80 μm, which facilitates the bonding of the coating layer to the zirconium alloy matrix.

[0347] Operation 2: a bonding layer is deposited on the surface of the sandblasted Zr-1Nb zirconium alloy. First, a layer of CoCrAlY with a thickness of 75 μm is sprayed on the surface of the zirconium alloy matrix as a bonding layer by a high velocity oxygen fuel (HVOF) method. The process parameters of the HVOF method during spraying are as follows: the pressure of oxygen is 0.4 MPa, and the flow rate of oxygen is 250 L/min; the pressure and flow rate of C2H.sub.4 are 0.4 MPa and 55 L/min, respectively; the nozzle of the spray gun has a length of 100 mm, and the spraying distance is 100 mm.

[0348] Operation 3: a layer of Pt with a thickness of 10 μm is deposited on the CoCrAlY as a precious metal layer by the HVOF method, and the process parameters of the HVOF method during spraying are the same as those in operation 1.

[0349] Operation 4: a layer of Y.sub.2O.sub.3—Yb.sub.2O.sub.3 with a thickness of 50 μm is sprayed on the surface of the precious metal layer as a ceramic A layer by a plasma-spraying technology. The process parameters of ion spraying technology during spraying are as follows: the flow rate of argon is 40 L/min; the flow rate of hydrogen is 5 L/min, the power is 30 kW, the powder feed rate is 20 g/min, and the spraying distance is 100 mm.

[0350] Operation 5: a layer of YTaO.sub.4 with a thickness of 50 μm is sprayed on the surface of the ceramic A layer as a ceramic B layer by a plasma-spraying technology. The spraying process parameters are the same as those in operation 4.

[0351] Operation 6: a layer of Ti.sub.3SiC with a thickness of 5 μm is sprayed on the surface of the ceramic B layer as a seal coating layer by an electron beam physical vapor deposition (EB-PVD) technology. The parameters of the electron beam physical vapor deposition technology during spraying are as follows: the argon pressure is 0.2 Mpa, the power is 2 kW, and the matrix temperature is 250° C.

[0352] Operation 7: a layer of REVO.sub.4 reflecting layer with a thickness of 10 μm is sprayed on the seal coating layer by the electron beam physical vapor deposition (EB-PVD) technology, and the spraying process parameters are the same as those in operation 6.

[0353] Operation 8: graphene and micron-sized carbon powder material are uniformly mixed with each other, and then the mixed powder is introduced into a solution for ultrasonic vibration mixing. In this test example, the solution is an ethanol solution with 1% dispersant. The micron-sized carbon powder is separated from the mixed solution by a filter paper. The solution mixed with graphene is brushed on the surface of the reflecting layer as a catadioptric layer. Then, the zirconium alloy brushed with the graphene catadioptric layer is placed in a drying oven and dried at 60° C. for 2 hours. The thickness of the brushed catadioptric layer is 13 μm.

[0354] Operation 9: the polyphenyl ether is adhered to wool or sponge. In this test example, sponge is used. The sponge adhered with the polyphenyl ether is attached to the catadioptric layer. The sponge is vibrated and rubbed at high speed by a vibrating polishing machine so that the polyphenyl ether is permeated into the surface of the catadioptric layer, to form an electrically insulating layer with a thickness of 15 μm.

[0355] Operation 10: the zirconium alloy sprayed with the bonding layer, precious metal layer, ceramic A layer, ceramic B layer, seal coating layer, reflecting layer, catadioptric layer, and electrically insulating layer is subjected to aging treatment for 5-10 h at 50-80° C. In this test example, the temperature is 60° C., and the time is 8 h, so as to release the internal stress of the coating layers to improve the bonding performance of the coating layers, and to finally obtain the ultralimit zirconium alloy. The only difference between Test Examples 2-20 and Test Example 1 is that the parameters as shown in Table 7-1 are different.

[0356] Experiments:

[0357] 9 groups of Comparative Examples are provided to perform comparative experiments with Test Examples 1-20. The parameters of Comparative Examples 1-9 are shown in Table 7-3 (thickness unit: μm):

TABLE-US-00033 TABLE 7-3 Composition and thickness of each coating layer in Comparative Examples 1-9 Comparative Example 1 2 3 4 5 6 7 8 9 Composition and CoCrAlY 35 — — 45 35 — — 160 — thickness of NiCoCrAlY — 30 — — — 40 — — 180 bonding layer CoNiCrAlY — — 40 — — — 170 — — Composition and Pt 8 — — — — — — — — thickness of Ru — — — — — — — — 30 precious layer Rh — 5 — — — — — — — Pd — — 5 — — — — — — Ir — — — — 25 — — — — Os — — — 7 — — — — — PtRh alloy — — — — — 30 — — — PdRh alloy — — — — — — 28 — — PtRu alloy — — — — — — — 25 — Composition and YSZ — — 50 — — — — — — thickness of Y.sub.2O.sub.3—ZrO.sub.2 — — — 60 — — — — — ceramic A layer Y.sub.2O.sub.3—CeO.sub.2 — — — — 65 — — — — Y.sub.2O.sub.3—TiO.sub.2 — — — — — 80 — — — Y.sub.2O.sub.3—CeO.sub.2 — — — — — — 70 — — Y.sub.2O.sub.3—Yb.sub.2O.sub.3 — — — — — — — 75 — Y.sub.2O.sub.3—Er.sub.2O.sub.3 — — — — — — — — 60 Composition and YTaO.sub.4 — — — — — — — — 90 thickness of YbTaO.sub.4 — — 30 — — — — — — ceramic B layer EuTaO.sub.4 — — — — — — — 95 — DyTaO.sub.4 — — — — 35 — — — — ErTaO.sub.4 — — — — — 85 — — — NdTaO.sub.4 — — — 25 — — — — — GdTaO.sub.4 — — — — — — 85 — — Composition and Ti.sub.3SiC 3 — 3 — — — — — — thickness of BN — 2 — — — — — — — seal coating layer GdPO.sub.4 — — — 13 15 — — — — YPO.sub.4 — — — — — 18 — — — Ti.sub.3SiC and BN — — — — — — — — — Ti.sub.3SiC and YPO.sub.4 — — — — — — — — — Ti.sub.3SiC and GdPO.sub.4 — — — — — — — — — Y.sub.2O.sub.3 5 — — — — — — — — Composition and REVO.sub.4 YVO.sub.4 — 7 — — — — — — — thickness of GdVO.sub.4 — — 5 — — — — — — reflecting layer YbTaO.sub.4 — — — 25 — — — — — YTaO.sub.4 — — — — 28 — — — — GdTaO.sub.4 — — — — — — — — — Y.sub.2O.sub.3 and YVO.sub.4 — — — — — 30 — — — YVO.sub.4 and GdTaO.sub.4 — — — — — — 25 — — Y.sub.2O.sub.3, YVO.sub.4 and YTaO.sub.4 — — — — — — — 5 — Thickness of Graphene 8 5 7 8 18 30 2 17 23 catadioptric layer Composition and Polytetrafluoro ethylene — 10 — 8 — — — — — thickness of Polyimide — — 8 — — 25 — — — electrically Polyphenyl ether 10 — — — 25 — — — — insulating layer Polyphenylene sulfide — — — — — — — 10 — Polyether ether ketone — — — — — — — — — Bismaleimide — — — — — — — — — Furan resin — — — — — — — — — Cyanate ester resin — — — — — — 10 — — Polyarylacetyl ene — — — — — — — — 25

[0358] The only difference between Comparative Examples 1-9 and Test Example 1 is that the parameters as shown in Table 7-3 are different; the Comparative Example 10 is Zr-1Nb zirconium alloy.

[0359] The following experiments are performed using the zirconium alloys provided in Test Examples 1-20 and Comparative Examples 1-10:

[0360] High Temperature Creep Test:

[0361] The zirconium alloys provided in Test Examples 1-20 and Comparative Examples 1-10 are processed into columnar test pieces with a length of 187 mm and a diameter of 16 mm. The high temperature creep test is carried out with an electronic high temperature creep rupture strength test machine (model: RMT-D5).

[0362] The test pieces of Test Examples 1-20 and Comparative Examples 1-10 are placed into the electronic high temperature creep rupture strength test machine, and the test machine is started to heat up the test machine. During the heating process, the test pieces are in a stress-free state (in a stress-free state, the test pieces can expand freely; the high-temperature creep is that the deformation increases with time under the combined action of temperature and stress, therefore, the heating rate has no influence on the creep). When the temperature of the test machine reaches 2000° C., the stress of the test machine is adjusted to 50 MPa, and the high temperature creep test is carried out. Take Test Example 1 and Comparative Example 10 as examples, the experimental results are shown in FIG. 5 (in FIG. 5, (A) represents Comparative Example 10, and (B) represents Test Example 1). The specific experimental results of Test Examples 1-20 and Comparative Examples 1-10 are shown in Table 7-4.

[0363] It can be observed from FIG. 5 that there are three stages of creep in both test pieces (A) and (B). However, when the temperature exceeds the melting point of ZR-1NB zirconium alloy, the creep rupture of test piece (A) occurs within a very short period of time. Therefore, it can be concluded that ZR-1NB zirconium alloy can hardly carry loads at a temperature higher than its melting point. Compared with test piece (A), the creep resistance of test piece (B) is significantly improved. The steady-state creep time of the test piece (B) is longer. It can be observed that after a long steady-state creep stage, the creep curve enters an accelerated creep stage, and the creep rupture occurs. Therefore, it can be concluded that, compared with the original ZR-1NB zirconium alloy, the ultralimit zirconium alloy provided by the present disclosure maintains good mechanical properties without rupturing at a temperature exceeding the melting point of ZR-1NB zirconium alloy, and has excellent high-temperature resistance.

[0364] Salt-Spray Corrosion Test:

[0365] The zirconium alloys provided in Test Examples 1-20 and Comparative Examples 1-10 are processed into test pieces of 50 mm×25 mm×2 mm, and then subjected to degreasing, rust removal, cleaning and drying. YWX/Q-250B salt-spray corrosion tester serves as the test equipment, and an atmospheric corrosive environment of GB/T2967.3-2008 is simulated. The test pieces provided by Test Examples 1-20 and Comparative Examples 1-10 are hung in the test equipment, the test equipment is adjusted to a temperature of 50±1° C. and pH of 3.0-3.1, and then the test pieces are continuously sprayed with NaCl solution with a concentration of 5±0.5%. Taking Test Example 1 and Comparative Example 10 as examples, after continuously spraying a 5±0.5% NaCl solution on the test pieces for 8 h, 24 h, 48 h and 72 h, the weight loss of the test pieces is shown in FIG. 6 (in FIG. 6, (A) represents Comparative Example 10, and (B) represents Test Example 1). The specific experimental results of Test Examples 1-20 and Comparative Examples 1-10 are shown in Table 7-4.

[0366] It can be concluded from FIG. 6 that test pieces (A) and (B) have obviously different corrosion patterns. For test piece (A), the corrosion weight loss value tends to increase as the corrosion time extends. In the early stage of corrosion (8-24 h), there is an oxidation film on the surface of the test piece, which prevents the zirconium alloy matrix from contacting the solution; the corrosion rate is low. In the middle stage of corrosion (24-48 h), the Cl.sup.− in the solution has penetrated the oxidation film, and a large amount of Cl.sup.− is adsorbed on the matrix, which increases the corrosion pit points and deepens the original corrosion pit points; the corrosion rate is obviously accelerated. After 48 hours of continuous spraying, the corrosion products are evenly distributed and the thickness increases, covering almost the entire surface of the test piece. Cl.sup.− needs to pass through the corrosion products to contact the zirconium alloy matrix, which reduces the amount of Cl.sup.− adsorbed on the matrix surface and reduces the corrosion rate. In general, the corrosion loss weight of test piece (A) is much higher than that of test piece (B). Basically, the test piece (B) has no corrosion due to the existence of the coating layers, and the mass of the test piece (B) has hardly changed. Therefore, the ultralimit zirconium alloy provided by the present disclosure has good corrosion resistance.

[0367] The experimental results are shown in Table 7-4: (A. the steady creep time of the test pieces under 50 Mpa and 2000° C. (min); B. the time when creep rupture of the test pieces happens under 50 Mpa and 2000° C. (min); C. the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 8 hours; D. the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 24 hours; E. the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 48 hours; F. the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 72 hours)

TABLE-US-00034 TABLE 7-4 Experimental results of high temperature creep test and salt-spray test A B C D E F Test Example 1 170 360 0 0.05 0.06 0.1 Test Example 2 165 355 0 0.06 0.08 0.11 Test Example 3 150 350 0 0.06 0.08 0.11 Test Example 4 160 355 0 0.07 0.09 0.11 Test Example 5 145 345 0 0.06 0.09 0.12 Test Example 6 140 330 0.002 0.06 0.08 0.1 Test Example 7 165 345 0 0.07 0.09 0.11 Test Example 8 165 345 0 0.06 0.09 0.13 Test Example 9 160 350 0.001 0.07 0.08 0.13 Test Example 10 160 355 0.002 0.08 0.08 0.12 Test Example 11 165 355 0.001 0.08 0.09 0.12 Test Example 12 145 345 0 0.07 0.09 0.11 Test Example 13 155 350 0 0.06 0.08 0.12 Test Example 14 150 350 0 0.07 0.09 0.12 Test Example 15 160 340 0 0.07 0.08 0.12 Test Example 16 160 340 0 0.07 0.09 0.13 Test Example 17 165 340 0 0.08 0.08 0.13 Test Example 18 165 350 0 0.07 0.09 0.12 Test Example 19 150 345 0 0.07 0.09 0.13 Test Example 20 155 345 0 0.07 0.08 0.13 Comparative Example 1 120 305 0.01 0.15 0.25 0.28 Comparative Example 2 120 315 0.01 0.15 0.24 0.31 Comparative Example 3 135 325 0.002 0.08 0.19 0.28 Comparative Example 4 135 320 0.003 0.12 0.2 0.26 Comparative Example 5 140 320 0.003 0.11 0.22 0.27 Comparative Example 6 145 325 0.002 0.11 0.2 0.26 Comparative Example 7 130 315 0.005 0.13 0.21 0.25 Comparative Example 8 130 315 0.005 0.14 0.18 0.25 Comparative Example 9 125 310 0.006 0.15 0.18 0.27 Comparative Example 10 20 50 1 2.1 5.50 8.1

[0368] In summary, the ultralimit zirconium alloy prepared by the ultralimit zirconium alloy preparation method of the present disclosure has a wide service temperature range and strong corrosion resistance; the effects of Test Example 1 are the best. Compared with the ultralimit zirconium alloy provided by the present disclosure, the zirconium alloy with parameters beyond the range provided in the test examples of the present embodiment has a much lower maximum service temperature and poorer corrosion resistance.

Embodiment 8 (Ultralimit Tin Alloy)

[0369] In this embodiment, the ultralimit alloy is an ultralimit tin alloy, that is, the alloy matrix is a tin alloy matrix.

[0370] The reference signs in FIG. 7 include: tin alloy matrix 1, bonding layer 2, ceramic layer 3, seal coating layer 4, reflecting layer 5, catadioptric layer 6, insulating layer 7, welding parent material 8, and weld 9.

[0371] As shown in FIG. 7, the present disclosure provides an ultralimit tin alloy, including an tin alloy matrix 1. The surface of the tin alloy matrix 1 is successively deposited with a bonding layer 2 with a thickness of 50-180 μm, a ceramic layer 3 with a thickness of 50-80 μm, a seal coating layer 4 with a thickness of 5-15 μm, a reflecting layer 5 with a thickness of 5-15 μm, a catadioptric layer 6 with a thickness of 5-15 μm, and an insulating layer 7 with a thickness of 10-25 μm.

[0372] The composition of the bonding layer 2 is one of or an alloy of more of platinum (Pt), palladium (Pd), rhodium (Rh), ruthenium (Ru), iridium (Ir), and osmium (Os). The composition of the ceramic layer 3 is RETaO.sub.4 (RE=Nd, Eu, Gd, Dy, Er, Y or Yb). The composition of the seal coating layer 4 is one or more of Ti.sub.3SiC, REPO.sub.4 (RE=Nd, Eu, Gd, Dy, Er, Y or Yb) and boron nitride (BN). The composition of the reflecting layer 5 is one or more of REVO.sub.4, RETaO.sub.4 and Y.sub.2O.sub.3, and RE=Nd, Eu, Gd, Dy, Er, Y or Yb. The catadioptric layer 6 is one or two of graphene and boron carbide, and the spatial distribution of the graphene and boron carbide are in a disorderly arranged state. The insulating layer 7 is an organic coating layer including one or more of polytetrafluoroethylene, polyimide (PI), polyphenyl ether (PPO/PPE), polyphenylene sulfide (PPS), polyether ether ketone (PEEK), bismaleimide (BMI), furan resin, cyanate ester (CE) resin and polyarylacetylene (PAA).

[0373] RETaO.sub.4 powder is prepared by the following method, including the following operations:

[0374] Operation (1): pre-drying rare earth oxide (RE.sub.2O.sub.3) powder and tantalum pentoxide (Ta.sub.2O.sub.5) powder, the pre-drying temperature is 600° C., and the pre-drying time is 8 hours; weighing the pre-dried rare earth oxide powder (RE.sub.2O.sub.3) and tantalum oxide (Ta.sub.2O.sub.5) powder according to the molar ratio of RETaO.sub.4; adding the pre-dried powders into the ethanol solvent to obtain a mixed solution, so that the molar ratio of RE:Ta in the mixed solution is 1:1; ball-milling the mixed solution using a ball mill for 10 hours, and the speed of the ball mill is 300 r/min;

[0375] drying the slurry obtained after ball milling using a rotary evaporator (model: N-1200B), the drying temperature is 60° C., and the drying time is 2 hours; sieving the dried powder through a 300-mesh sieve to obtain powder A;

[0376] Operation (2): preparing powder B with a composition of RETaO.sub.4 from the powder A obtained in operation (1) by a high-temperature solid-phase reaction method, the reaction temperature is 1700° C. and the reaction time is 10 hours; sieving the powder B with a 300-mesh sieve;

[0377] Operation (3): mixing the powder B sieved in operation (2) with deionized water solvent and an organic bonding agent to obtain slurry C, the mass percentage of powder B in slurry C is 25%, the mass percentage of organic bonding agent in slurry C is 2%, and the rest is the solvent; the organic bonding agent is polyvinyl alcohol or gum arabic; drying the slurry C by a high-temperature spray pyrolysis method to obtain dried granules D, the temperature during drying is 1000° C., and the drying time is 60 min;

[0378] Operation (4): sintering the granules D obtained in operation (3) at 1200° C. for 8 hours, sieving the sintered granules D with a 300-mesh sieve to obtain RETaO.sub.4 ceramic powder having a particle size of 10-50 μm and a spherical morphology.

[0379] The present disclosure uses RETaO.sub.4 as the ceramic B layer, which has the effects of low thermal conductivity and high expansion rate, and can reduce heat conduction; The RETaO.sub.4 prepared by the above method can meet the requirements of APS spraying technology on particle size and shape of the powder.

[0380] Based on extensive experiments, the inventors obtain ultralimit tin alloy weld materials with the largest increase in service temperature, small increase in weight of the ultralimit tin alloy weld material and the best composition and thickness of the coating layers within the parameter scope of the present disclosure. In the present disclosure, 20 of them are listed for description.

[0381] The parameters of Test Examples 1-20 of an ultralimit tin alloy and its preparation method according to the present disclosure are shown in Table 8-1 and Table 8-2 (thickness unit: μm):

TABLE-US-00035 TABLE 8-1 Composition and thickness of each coating layer in Test Examples 1-10 of an ultralimit tin alloy and its preparation method Test Example 1 2 3 4 5 6 7 8 9 10 Composition and PtRh alloy 75 — — — — — — — — — thickness of PdRh alloy — 110 — — — — — — 60 — bonding layer PtRu alloy — — 125 — — — — — — — Pd — — — — — 150 — — — — Composition and Ir — — — — 165 — — — — — thickness of Os — — — 170 — — — — — — ceramic layer Ru — — — — — — 175 — — — Rh — — — — — — — — — 50 Pt — — — — — — — 180 — — YTaO.sub.4 50 — — — — — — 50 — — YbTaO.sub.4 — 50 — — — — — — — — EuTaO.sub.4 — — 50 — — — — — — — DyTaO.sub.4 — — — — 60 — — — — 60 ErTaO.sub.4 — — — — — 80 — — — — NdTaO.sub.4 — — — 70 — — — — 70 — GdTaO.sub.4 — — — — — — 80 — — — Composition and Ti.sub.3SiC — — 10 — — — — — — — thickness of BN — 15 — — — — — — — — seal coating layer NdPO.sub.4 10 — — — — — — — — — EuPO.sub.4 — — — — — — 15 — — — GdPO.sub.4 — — — — — — — — — — DyPO.sub.4 — — — — — — — — — — ErPO.sub.4 — — — — — — — — 10 — YbPO.sub.4 — — — — — — — 5 — — YPO.sub.4 — — — — — — — — — 15 Ti.sub.3SiC and BN — — — — — — — — — — Ti.sub.3SiC and YPO.sub.4 — — — — 10 — — — — — Ti.sub.3SiC and GdPO.sub.4 — — — — — — — — — — BN and NdPO.sub.4 — — — — — 15 — — — — BN and DyPO.sub.4 — — — 5 — — — — — — Thickness of Y.sub.2O.sub.3 — — — 10 — — — — — — reflecting layer REVO.sub.4 YVO.sub.4 10 — — — — — — — — — NdVO.sub.4 — — — — — — — — — 10 EuVO.sub.4 — — — — 10 — — — — — GdVO.sub.4 — — 10 — — — — — — — DyVO.sub.4 — 15 — — — — — — — — ErVO.sub.4 — — — — — — — — — — YbVO.sub.4 — — — — — — 10 — — — RETaO.sub.4 NdTaO.sub.4 — — — — — — — — — — EuTaO.sub.4 — — — — — — — — — — GdTaO.sub.4 — — — — — — — — — — DyTaO.sub.4 — — — — — 5 — — — — ErTaO.sub.4 — — — — — — — 10 — — YbTaO.sub.4 — — — — — — — — — — YTaO.sub.4 — — — — — — — — 15 — Y.sub.2O.sub.3 and DyVO.sub.4 — — — — — — — — — — Y.sub.2O.sub.3 and EuTaO.sub.4 — — — — — — — — — — YVO.sub.4 and GdTaO.sub.4 — — — — — — — — — — EuVO.sub.4 and NdTaO.sub.4 — — — — — — — — — — Y.sub.2O.sub.3, YVO.sub.4 and YTaO.sub.4 — — — — — — — — — — Composition and Graphene 15 10 15 5 10 — — — — — thickness of Boron carbide — — — — — 5 15 15 15 10 catadioptric layer Composition and Polytetrafluoroethylene — — — 10 — — — — — — thickness of Polyimide — — — — — 20 — — — — insulating Polyphenyl ether — — — — 15 — — — — — layer Polyphenylene sulfide — — — — — — — 12 — — Polyether ether ketone — 12 — — — — — — — 15 Bismaleimide 22 — — — — — — — — — Furan resin — — 23 — — — — — — — Cyanate ester resin — — — — — — 10 — — — Polyarylacetylene — — — — — — — — 25 —

TABLE-US-00036 TABLE 8-2 Composition and thickness of each coating layer in Test Examples 11-20 of an ultralimit tin alloy and its preparation method Test Example 11 12 13 14 15 16 17 18 19 20 Composition and PtRh alloy 75 — — — — — — — — — thickness of PdRh alloy — 110 — — — — — — 60 — bonding layer PtRu alloy — — 125 — — — — — — — Pd — — — — — 150 — — — — Ir — — — — 165 — — — — — Os — — — 170 — — — — — — Ru — — — — — — 175 — — — Rh — — — — — — — — — 50 Pt — — — — — — — 180 — — Composition and YTaO.sub.4 50 — — — — — — 50 — — thickness of YbTaO.sub.4 — 50 — — — — — — — — ceramic layer EuTaO.sub.4 — — 50 — — — — — — — DyTaO.sub.4 — — — — 60 — — — — 60 ErTaO.sub.4 — — — — — 80 — — — — NdTaO.sub.4 — — — 70 — — — — 70 — GdTaO.sub.4 — — — — — — 80 — — — Composition and Ti.sub.3SiC — — — — — — — — — — thickness of BN — — — — — — — — — — seal coating layer NdPO.sub.4 — — — — — — — — — — EuPO.sub.4 — — — — — — 15 — — — GdPO.sub.4 10 — — — — — — — — — DyPO.sub.4 — 15 — — — — — — — — ErPO.sub.4 — — — — — — — — 10 — YbPO.sub.4 — — — 5 — — — — — — YPO.sub.4 — — — — — — — — — 15 Ti.sub.3SiC and BN — — 10 — — — — — — — Ti.sub.3SiC and YPO.sub.4 — — — — 10 — — — — — Ti.sub.3SiC and GdPO.sub.4 — — — — — — — 10 — — BN and NdPO.sub.4 — — — — — 15 — — — — BN and DyPO.sub.4 — — — 5 — — — — — — Composition and Y.sub.2O.sub.3 — — — 10 — — — — — — thickness of REVO.sub.4 YVO.sub.4 — — — — — — — — — — reflecting layer NdVO.sub.4 — — — — — — — — — — EuVO.sub.4 — — — — — — — — — — GdVO.sub.4 — — — — — — — — — — DyVO.sub.4 — — — — — — — — — — ErVO.sub.4 10 — — — — — — — — — YbVO.sub.4 — — — — — — — — — — RETaO.sub.4 NdTaO.sub.4 — 15 — — — — — — — — EuTaO.sub.4 — — — — 10 — — — — — GdTaO.sub.4 — — — 10 — — — — — — DyTaO.sub.4 — — — — — — — — — — ErTaO.sub.4 — — — — — — — — — — YbTaO.sub.4 — — — — — — — — 10 — YTaO.sub.4 — — — — — — — — — — Y.sub.2O.sub.3 and DyVO.sub.4 — — 5 — — — — — — — Y.sub.2O.sub.3 and EuTaO.sub.4 — — — — — 12 — — — — YVO.sub.4 and GdTaO.sub.4 — — — — — — 10 — — — EuVO.sub.4 and NdTaO.sub.4 — — — — — — — 10 — — Y.sub.2O.sub.3, YVO.sub.4 and YTaO.sub.4 — — — — — — — — — 15 Composition and Graphene 15 10 15 5 10 — — — — — thickness of Boron carbide — — — — — 5 15 15 15 10 catadioptric layer Composition and Polytetrafluoroethylene — — — 10 — — — — — — thickness of Polyimide — — — — — 20 — — — — insulating Polyphenyl ether — — — — 15 — — — — — layer Polyphenylene sulfide — — — — — — — 12 — — Polyether ether ketone — 12 — — — — — — — 15 Bismaleimide 22 — — — — — — — — — Furan resin — — 23 — — — — — — — Cyanate ester resin — — — — — — 10 — — — Polyarylacetylene and — — — — — — — — 25 —

[0382] Take Test Example 1 of Embodiment 8 as an example to illustrate another technical solution of the present disclosure, that is, a method for preparing an ultralimit tin alloy. A method for preparing an ultralimit tin alloy, including the following operations:

[0383] Operation 1: a tin alloy matrix is prepared. Two pieces of Q235 steel plate are selected as the welding parent materials. An S221 tin alloy welding wire is selected to weld the two parent material, and the diameter of the welding wire is 2.5 mm. The welding equipments are MZ-1000 automatic submerged-arc welding machine and MZ-1000 time submerged-arc welding power source. The parameters of the welding process are as follows: the voltage is 30V, the current is 530-570A, and the welding speed is 55 m/h. The tin alloy matrix is prepared by using the welding equipments.

[0384] Operation 2: the surface of the tin alloy matrix obtained in operation 1 is sandblasted by a sand-blasting machine. The sand-blasting machine used is a JCK-SS500-6A automatic transmission sand-blasting machine. The sandblasting material used is 15-20 mesh quartz sand. In this test example, the quartz sand is 20-mesh. After sandblasting, the dust on the surface of the tin alloy matrix is removed by an air compressor.

[0385] Operation 3: a Pt—Rh bonding layer is sprayed on a surface of the tin alloy matrix subjected to the surface treatment in operation 2 by a high velocity oxygen fuel (HVOF) method, and the thickness of the bonding layer is 75 μm. The process parameters of the high velocity oxygen fuel method are as follows: the pressure and flow rate of oxygen are 0.4 MPa and 250 L/min, respectively; the pressure and flow rate of C.sub.2H.sub.4 are 0.4 MPa and 55 L/min, respectively; the nozzle of the spray gun has a length of 100 mm, and the spraying distance is 100 mm.

[0386] Operation 4: a layer of ceramic layer with a composition of YTaO.sub.4 is prepared on the surface of the Pt—Rh bonding layer obtained in operation 3 by an air plasma-spraying technology. The thickness of the YTaO.sub.4 ceramic layer is 50 μm. The process parameters of the air plasma-spraying technology are as follows: the flow rate of argon is 40 L/min; the flow rate of hydrogen is 5 L/min, the power is 30 kW, the powder feed rate is 20 g/min, and the spraying distance is 100 mm.

[0387] Operation 5: a layer of seal coating layer with a composition of NdPO.sub.4 is prepared on the surface of the YTaO.sub.4 ceramic layer obtained in operation 4 by the electron beam physical vapor deposition (EB-PVD) technology. The thickness of the NdPO.sub.4 seal coating layer is 10 μm. The process parameters of the electron beam physical vapor deposition technology are as follows: the argon pressure is 0.22 Mpa, the power is 2 kW, and the matrix temperature is 400° C.

[0388] Operation 6: a reflecting layer with a composition of YVO.sub.4 is prepared on the surface of the NdPO.sub.4 seal coating layer obtained in operation 5 by the electron beam physical vapor deposition (EB-PVD) technology. The thickness of the YVO.sub.4 reflecting layer is 10 μm. The process parameters of the electron beam physical vapor deposition technology are as follows: the argon pressure is 0.22 Mpa, the power is 2 kW, and the matrix temperature is 400° C.

[0389] Operation 7: a layer of graphene catadioptric layer is prepared on the surface of the YVO.sub.4 reflecting layer obtained in operation 6 by a brushing method, and the thickness of the graphene catadioptric layer is 15 μm. Graphene has a high specific surface area and is extremely difficult to be dissolved in solution. Therefore, ultrasonic dispersion and solid-liquid separation of graphene are required before coating. That is, first, graphene and micron-sized carbon powder material are uniformly mixed with each other, and then the mixed powder is introduced into a solution for ultrasonic vibration mixing. In this test example, the solution is an ethanol solution with 1% dispersant. The micron-sized carbon powder is separated from the mixed solution by a filter paper. The solution mixed with graphene is coated on the surface of the reflecting layer. Then, the tin alloy weld material coated with the graphene catadioptric layer is placed in a drying oven and dried at 60° C. for 2 hours.

[0390] In addition, after the graphene is ultrasonically dispersed, the spatial distribution of the graphene is rearranged in all directions, so that the spatial distribution of the graphene is in a disorderly arranged state. In this way, even though graphene has a high refractive index, when the incident light is irradiated on the graphene catadioptric layer, the disorderly arranged graphene can enhance the refraction of the light in all directions, so as to avoid the incident light from being refracted in the same direction and achieve the effect of dispersed refraction. In this way, the intensity of incident light entering into the coating layers can be reduced.

[0391] Operation 8: an insulating layer with a composition of bismaleimide is prepared on the surface of the graphene catadioptric layer obtained in operation 7 by a sealing glaze treatment, and the thickness of the insulating layer is 22 μm.

[0392] Sealing glaze treatment is a technical means for preparing an electrically insulating layer. In the sealing glaze treatment, soft wool or sponge is vibrated and rubbed at high speed by a vibrating polishing machine, so that the bismaleimide molecule is strongly permeated into the surface of the graphene coating layer utilizing the unique permeability and adhesion of the graphene coating layer.

[0393] Operation 9: the tin alloy weld material prepared by operations 1-8 is allowed to stand for 5-10 hours at 50-80° C. for the aging treatment. In this test example, the aging temperature is 60° C., and the aging time is 8 hours.

[0394] The only difference between the preparation methods of Test Examples 2-20 and that of Test Example 1 is that the parameters as shown in Table 8-1 are different.

[0395] 11 groups of Comparative Examples are provided to perform comparative experiments with Test Examples 1-20, as shown in Table 8-3 (thickness unit: μm):

TABLE-US-00037 TABLE 8-3 Composition and thickness of each coating layer in Comparative Examples 1-10 Comparative Example 1 2 3 4 5 6 7 8 9 10 Composition and PtRh alloy 20 — — — — — — — — — thickness of PdRh alloy — 25 — — — — — — 190 — bonding layer PtRu alloy — — 30 — — — — — — — Pd — — — — — 190 — — — — Ir — — — — 40 — — — — — Os — — — 185 — — — — — — Ru — — — — — — 188 — — — Rh — — — — — — — — — 195 Pt — — — — — — — 45 — — Composition and YTaO.sub.4 20 — — — — — — 10 — — thickness of YbTaO.sub.4 — 20 — — — — — — — — ceramic layer EuTaO.sub.4 — — 30 — — — — — — — DyTaO.sub.4 — — — — 35 — — — — 10 ErTaO.sub.4 — — — — — 95 — — — — NdTaO.sub.4 — — — 100 — — — — 15 — GdTaO.sub.4 — — — — — — 95 — — — Composition and Ti.sub.3SiC — — 3 — — — — — — — thickness of BN — 1 — — — — — — — — seal coating layer NdPO.sub.4 2 — — — — — — — — — EuPO.sub.4 — — — — 25 — 2 — — — ErPO.sub.4 — — — — — — — — 1 — YbPO.sub.4 — — — — — — — 22 — — YPO.sub.4 — — — — — — — — — 1 Ti.sub.3SiC and BN — — — — — 30 — — — — Composition and Y.sub.2O.sub.3 — — — 1 — — — — — — thickness of REVO.sub.4 YVO.sub.4 2 — — — — — — — — — reflecting layer EuVO.sub.4 — — — — 3 — — — — — ErVO.sub.4 — — 28 — — — — — — — YbVO.sub.4 — — — — — — 30 — — — RETaO.sub.4 NdTaO.sub.4 — 25 — — — — — — — — DyTaO.sub.4 — — — — — 2 — — — — ErTaO.sub.4 — — — — — — — 10 — — YTaO.sub.4 — — — — — — — — 15 — Y.sub.2O.sub.3 and EuTaO.sub.4 — — — — — — — — — 1 Composition and Graphene 2 2 3 20 4 — — — — — thickness of Boron carbide — — — — — 3 3 2 25 2 catadioptric layer Composition and Polytetrafluoroethylene — — — 6 — — — — — — thickness of Polyimide — — — — — 35 — — — — insulating Polyphenyl ether — — — — 30 — — — — — Polyphenylene sulfide — — — — — — — 7 — — layer Polyether ether ketone — 5 — — — — — — — 5 Bismaleimide 2 — — — — — — — — — Furan resin — — 3 — — — — — — — Cyanate ester resin — — — — — — 2 — — — Polyarylacetylene — — — — — — — — 5 —

[0396] The only difference between the preparation methods of Comparative Examples 1-10 and that of Test Example 1 is that the parameters as shown in Table 8-3 are different. The Comparative Example 11 uses the tin alloy weld material prepared in operation 1, that is, no coating layer is deposited on the surface of the tin alloy matrix.

[0397] The following experiments are performed using the tin alloy welds provided in Test Examples 1-20 and Comparative Examples 1-11:

[0398] 1 High-Temperature Bonding Strength Test of Tin Alloy Welds:

[0399] 1.1 Preparation of Tin Alloy Weld Materials

[0400] As shown in FIG. 8, tensile test pieces are prepared. Two pieces of welding parent materials 8 are welded together using a welding equipment to form a tin alloy matrix 9. The coating layers are prepared on the surface of the tin alloy matrix 9 using the parameters provided in Test Examples 1-20 and Comparative Examples 1-10. Comparative Example 11 uses a tin alloy matrix without deposited coating layers.

[0401] The tensile test pieces are subjected to high temperature creep test by an electronic high temperature creep rupture strength test machine (model: RMT-D5). The maximum test load of the RMT-D5 electronic high temperature creep rupture strength test machine is 50 KN, the test load control accuracy is within ±5%, the deformation measuring range is 0-10 mm, the speed adjustment range is 0-50 mm/min-1, the deformation resolution is 0.001 mm, the temperature control range of high temperature furnace is 900-1200° C., and the uniform temperature zone length is 150 mm.

[0402] 2.2 High-Temperature Tensile Strength Testing of Tin Alloy Welds

[0403] The tin alloy weld material test pieces prepared in test Examples 1-20 and Comparative Examples 1-11 are placed into the above test machine, and the test pieces are in a stress-free state (in a stress-free state, the test pieces can expand freely; the high-temperature creep means that the deformation increases with time under the combined action of temperature and stress, therefore, the heating rate has no influence on the creep). The test machine is adjusted to a temperature of 350° C., each test piece is tested for 5 times, and the tensile strength obtained each time is recorded, as shown in Table 8-4. In Table 8-4, a represents the average tensile strength (Mpa) of the test piece.

[0404] Take the tin alloy weld material test pieces prepared in Test Example 1 and Comparative Example 11 as examples. FIG. 9 shows the tensile strength curves of the tin alloy weld materials of Test Example 1 and Comparative Example 11. In FIG. 9, (A) represents the tin alloy matrix without deposited coating layers in Comparative Example 11, and (B) represents the tin alloy weld material with composite coating layers deposited on the surface using the parameters in Test Example 1. Mechanical performances of tin alloy weld materials under extreme temperature conditions are tested. Based on relevant literatures, the melting point temperature of S221 tin alloy is 220° C. Therefore, the test temperature is set to 350° C. The test results are as follows:

[0405] It can be seen from FIG. 9 that under the condition of 350° C., test piece (A) has very low tensile strength, and the tin alloy matrix without the coating layers deposited can hardly bear the load; the rupture of tin alloy matrix occurs when the load is less than 40 MPa. As for test piece (B), test piece (B) can maintain good mechanical properties under the condition of 350° C. and has excellent high-temperature resistance.

[0406] 2. Salt-Spray Corrosion Test:

[0407] The tin alloy weld material test pieces prepared in Test Examples 1-20 and Comparative Examples 1-11 are processed into test pieces of 50 mm×25 mm×2 mm, and then subjected to degreasing, rust removal, cleaning and drying. YWX/Q-250B salt-spray corrosion tester serves as the test equipment, and an atmospheric corrosive environment of GB/T2967.3-2008 is simulated.

[0408] The test pieces provided by Test Examples 1-20 and Comparative Examples 1-11 are hung in the test equipment, the test equipment is adjusted to a temperature of 50±1° C. and pH of 3.0-3.1, and then the test pieces are continuously sprayed with NaCl solution with a concentration of 5±0.5%. The weight loss rate of the test pieces is recorded in Table 8-4 after a certain period of time (8, 24, 48, 72 h).

[0409] FIG. 10 shows the relationship curves between salt-spray corrosion weight loss and corrosion time of Test Example 1 and Comparative Example 11. In FIG. 10, (A) represents the tin alloy matrix without deposited coating layers in Comparative Example 11, and (B) represents the tin alloy weld material with deposited composite coating layers using the parameters in Test Example 1.

[0410] It can be seen from FIG. 3 that the two tin alloy weld materials have obviously different corrosion patterns. For test piece (A), the corrosion weight loss value tends to increase as the corrosion time extends. In the early stage of corrosion (8-24 h), there is an oxidation film on the surface of the test piece, which prevents the tin alloy weld material from contacting the solution; the corrosion rate is low. In the middle stage of corrosion (24-48 h), the Cl.sup.− (chloridion) in the solution has penetrated the oxidation film, and a large amount of Cl.sup.− is adsorbed on the matrix, which increases the corrosion pit points and deepens the original corrosion pit points; the corrosion rate is obviously accelerated. After 48 hours of continuous spraying, the corrosion products are evenly distributed and the thickness increases, covering almost the entire surface of the test piece. Cl.sup.− needs to pass through the corrosion products to contact the tin alloy weld material, which reduces the amount of Cl.sup.− adsorbed on the matrix surface and reduces the corrosion rate. Generally speaking, the corrosion weight loss of tin alloy matrix without deposited coating layers is much higher than that of tin alloy weld material with coating layers deposited on the surface. Basically, the tin alloy weld material has no corrosion due to the existence of the coating layers, and the mass of the tin alloy weld material has hardly changed.

[0411] In Table 8-4, a represents the average tensile strength (MPa) of the test piece;

[0412] b represents the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 8 hours;

[0413] c represents the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 24 hours; d represents the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 48 hours; e represents the weight loss (v/mg.Math.cm.sup.2) of the test pieces after continuously spraying NaCl solution on the test pieces for 72 hours.

TABLE-US-00038 TABLE 8-4 Experimental results of high-temperature tensile strength test and salt-spray test a b c d e Test Example 1 155 0.01 0.03 0.06 0.1 Test Example 2 152 0.01 0.03 0.06 0.1 Test Example 3 150 0.01 0.03 0.06 0.1 Test Example 4 142 0.02 0.032 0.064 0.12 Test Example 5 148 0.01 0.03 0.06 0.1 Test Example 6 150 0.01 0.03 0.06 0.1 Test Example 7 153 0.01 0.03 0.06 0.1 Test Example 8 154 0.01 0.03 0.06 0.1 Test Example 9 150 0.01 0.03 0.06 0.1 Test Example 10 155 0.01 0.03 0.06 0.1 Test Example 11 155 0.01 0.03 0.06 0.1 Test Example 12 149 0.01 0.03 0.06 0.1 Test Example 13 149 0.01 0.03 0.06 0.1 Test Example 14 145 0.01 0.03 0.06 0.1 Test Example 15 145 0.01 0.03 0.06 0.1 Test Example 16 153 0.01 0.03 0.06 0.1 Test Example 17 154 0.01 0.03 0.06 0.1 Test Example 18 153 0.01 0.03 0.06 0.1 Test Example 19 152 0.01 0.03 0.06 0.1 Test Example 20 149 0.01 0.03 0.06 0.1 Comparative Example 1 77 0.2 0.9 1.9 3.6 Comparative Example 2 70 0.3 1 2 4.1 Comparative Example 3 78 0.2 0.9 1.89 3.59 Comparative Example 4 62 0.44 1.15 2.3 4.7 Comparative Example 5 52 0.47 1.19 2.32 4.75 Comparative Example 6 65 0.4 1.02 2.1 4.5 Comparative Example 7 63 0.44 1.15 2.3 4.7 Comparative Example 8 50 0.5 1.2 2.4 4.8 Comparative Example 9 70 0.3 1 2 4.1 Comparative Example 10 65 0.4 1.02 2.1 4.5 Comparative Example 11 26 1.1 2.4 4.6 8.4

[0414] It can be seen from Table 8-4 that the tin alloy weld material obtained by the comparative examples beyond the parameter range of the present disclosure has a significant decrease in average tensile strength and has poor corrosion resistance.

[0415] In summary, by depositing a bonding layer, a ceramic layer, a seal coating layer, a reflecting layer, a catadioptric layer and an insulating layer on the tin alloy matrix, the service temperature of the tin alloy weld material can be increased to 100-500° C. higher than the original melting point. The corrosion resistance can be greatly improved as well. The ultralimit tin alloy weld material prepared by the ultralimit tin alloy preparation method of the present disclosure has a wide service temperature range and strong corrosion resistance; the effects of Test Example 1 are the best.

[0416] The descriptions above are merely embodiments of the present disclosure, and common knowledge such as specific structures and features that are well-known in the schemes will not be described in detail herein. It should be noted that for those skilled in the art, variations and improvements may be made without departing from the structure of the present disclosure, these variations and improvements are within the scope of the present disclosure, and will not affect the implementation effect or practicality of the present disclosure. The protection scope of the present disclosure is subject to the protection scope defined in claims. The specific embodiments of the present disclosure may be used to interpret the content of the claims.

ULTRALIMIT ALLOY AND PREPARATION METHOD THEREFOR

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