US20150240364A1 - Method for coating by thermal spraying with an inclined particle jet - Google Patents

Method for coating by thermal spraying with an inclined particle jet Download PDF

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Publication number
US20150240364A1
US20150240364A1 US14/432,102 US201314432102A US2015240364A1 US 20150240364 A1 US20150240364 A1 US 20150240364A1 US 201314432102 A US201314432102 A US 201314432102A US 2015240364 A1 US2015240364 A1 US 2015240364A1
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Prior art keywords
substrate
structure elements
particle jet
angle
spray angle
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US14/432,102
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Ralph Reiche
Oliver Stier
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Siemens AG
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Siemens AG
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Publication of US20150240364A1 publication Critical patent/US20150240364A1/en
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    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00Coating starting from inorganic powder
    • C23C24/02Coating starting from inorganic powder by application of pressure only
    • C23C24/04Impact or kinetic deposition of particles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00Working by laser beam, e.g. welding, cutting or boring
    • B23K26/352Working by laser beam, e.g. welding, cutting or boring for surface treatment
    • B23K26/355Texturing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00Working by laser beam, e.g. welding, cutting or boring
    • B23K26/352Working by laser beam, e.g. welding, cutting or boring for surface treatment
    • B23K26/3568Modifying rugosity
    • B23K26/3584Increasing rugosity, e.g. roughening
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36Removing material
    • B23K26/362Laser etching
    • B23K26/364Laser etching for making a groove or trench, e.g. for scribing a break initiation groove
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36Removing material
    • B23K26/38Removing material by boring or cutting
    • B23K26/382Removing material by boring or cutting by boring
    • B23K26/389Removing material by boring or cutting by boring of fluid openings, e.g. nozzles, jets
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/02Pretreatment of the material to be coated, e.g. for coating on selected surface areas
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying

Definitions

  • a particle jet is directed onto a substrate to be coated and the particles of the particle jet are deposited onto the substrate.
  • the axis of the particle jet is inclined to the surface normal of the untreated substrate forming a spray angle ⁇ .
  • there is a permissible interval for the spray angle below which the adhesion of the deposited particles reaches maximum values.
  • the zero angle may or may not be included in this interval.
  • the set of all permissible spray angles thus produces a space between two conical surfaces, whose tips meet at the point of incidence of the particle jet. If the zero angle is included in the interval, only one cone oriented in the described manner is required to describe the spray angle interval.
  • Cold gas spraying is a method known per se, in which particles provided for the coating are accelerated by a convergent-divergent nozzle, e.g., to supersonic speeds, in order that these adhere to the surface to be coated by virtue of the kinetic energy imparted to them.
  • the kinetic energy of the particles is used and leads to a plastic deformation of the latter, wherein upon impact the coating particles are melted only at their surface.
  • this method is termed cold gas spraying in comparison with other thermal spraying methods because it is carried out at comparatively low temperatures at which the coating particles remain largely solid.
  • a cold gas spraying apparatus may be used which has a gas heating device for heating a gas.
  • a stagnation chamber is connected to the gas heating device, wherein the outlet of this chamber is connected with the convergent-divergent nozzle, such as a de Laval nozzle.
  • Convergent-divergent nozzles have a convergent part section and a divergent part section which are connected by a nozzle throat.
  • the convergent-divergent nozzle generates, on the outlet side, a powder jet in the form of a gas stream with high-speed—e.g., supersonic—particles therein.
  • the substrate undergoes pretreatment in which the surface is structured.
  • structure elements of the structured surface are produced obliquely on the surface such that the structure elements are oriented towards the inclined axis of the particle jet, that is to say the jet axis.
  • the structure elements are produced obliquely, in other words, so that the finished structure elements do not stand upright, but their principal geometric orientation deviates from the surface normal. If, for example, a structure element is any raised portion, the orientation of the latter would for example be determined taking into account the center line of the structure element.
  • This line is then not oriented parallel to the surface normal but forms an angle of inclination ⁇ thereto, wherein the inclined orientation of the structure elements is such that these are oriented towards the inclined jet axis.
  • the orientation of the named center line of a structure element will be at least similar to that of the jet axis.
  • the spatial extent of the structure elements is smaller, at least in the plane of the spray angle ⁇ , than the average diameter of the particles.
  • the plane of the spray angle ⁇ is to be defined as a plane containing both arms of the spray angle ⁇ . If one considers the spatial extent of the structure elements in this plane, the geometry of the structure elements—as seen in the section of this plane—should be smaller than the size of the particles. It has namely been found that particles which are incident on a surface structured in this manner can, in spite of a spray angle ⁇ , convert a larger proportion of their kinetic energy into deformation than particles which are incident on the unstructured, i.e. smooth, surface at the same spray angle ⁇ .
  • the surface to be coated presents greater adhesion resistance to the incident particles, at least in the direction of the spray angle. This has the advantageous effect that the surface can still be reliably coated at higher spray angles, especially in the direction of the spray angle ⁇ . It is thus for example possible to coat components with undercuts by thermal spraying, because those regions of the component which are hard to reach on account of the undercuts are made accessible for the spray jet.
  • the angle of inclination ⁇ of the oblique orientation of the structure elements largely corresponds to the spray angle ⁇ .
  • the angle of inclination of the oblique orientation of the structure elements is determined so as to achieve an optimal improvement of the spray angle ⁇ . From a manufacturing aspect, it is particularly advantageous in that context if the entire hard-to-reach region of the component is provided with structure elements which have at least largely the same orientation. For the purpose of coating this region, the particle jet is then also oriented such that when coating the region the jet is displaced at least essentially parallel.
  • the jet-generating device for example the spray nozzle of an apparatus for cold gas spraying
  • the jet-generating device is at a large distance from the substrate with respect to the region to be coated and, for the purpose of coating this region, is pivoted by for example plus/minus 5°.
  • the resulting angular offsets are then relatively small.
  • the structuring of the surface of the substrate to produce the structure elements can also be termed a microscopic striation.
  • the binding mechanism of the particles on the surface can also be described more simply in that, when the particles are incident on the “peaks” of the striation, the latter pierce the former and thus improve adhesion.
  • This can be compared with the function of a metal file, which also has a striation.
  • This striation usually has the effect that the file must be guided over the workpiece in a specific direction in order to guarantee optimal chip removal. This is only possible if the striation has an angle of inclination of the oblique orientation of the individual structure elements. This analogy clarifies the function of the microscopic striation.
  • Microscopic hereinbelow means that the extent of the structure elements, as already explained, must be smaller than that of the particles so that the particles can act like the workpiece under the file, so to speak.
  • the surface normal of the substrate is defined by the surface of the untreated substrate. This means that, after treating the substrate by generating the structure elements, other local surface normals can result. However, of relevance are the surface normals which are to be determined on account of the superordinate structure of the substrate. The structuring, which is small in comparison, thus generates a surface which is much more finely structured, such that after structuring the substrate the surface normal could only be determined by averaging over multiple structure elements.
  • trenches are produced as structure element.
  • these trenches are particularly easy to create in manufacturing terms. They may be created for example by a laser, by moving the latter over the surface of the workpiece. The trenches can then run parallel to one another in order to make best use of the available surface area of the substrate. Depending on the geometry of the substrate to be coated, the trenches can be either straight or curved. The latter is also important for optimizing the angle ⁇ .
  • the structure elements are produced as holes.
  • holes can also be produced simply. These can for example be produced by punctiform laser shots to the surface of the substrate to be coated.
  • these holes have axes of symmetry which are oriented obliquely during production such that they are oriented towards the inclined axes of the particle jet during the thermal spraying.
  • the axes of symmetry of the holes thus simultaneously represent the center lines of the holes, wherein, when using a laser, these can in particular be directly influenced by the orientation of the latter.
  • this also holds for the production of trenches by the laser.
  • the uprights remaining between the holes also constitute oriented structures which, as structure elements, participate in the improvement of adhesion of the surface.
  • cold gas spraying is used as thermal spraying.
  • This is advantageously well-suited to the relatively cost-effective production of relatively thick coats.
  • the coat is produced in multilayer fashion, i.e. coating by alternating multiple times between production of structure elements and production of layers of the desired coating, it is possible to produce relatively thick coats.
  • the deposited layers in turn serve for the production of the next layer, wherein in the case of hard-to-reach regions of the substrate, of course, the layer must always once again be structured as a surface to be coated. Otherwise, subsequent layers would not adhere to the preceding layers.
  • the substrate is produced in the regions which are inaccessible to the particle jet while observing the maximum permissible spray angle in the case of the untreated substrate, such that an increase, connected thereto, of the permissible spray angle ⁇ results in the region being able to be coated with the thermal spraying method. This is the case if the maximum permissible spray angle ⁇ increases specifically in that direction whence the particle jet is incident on account of the geometric specifications of the substrate to be coated.
  • the structure elements may advantageously be generated with a laser beam, by an erosion method, by chip removal, by a shaping method or chemically, depending on which method is best suited to the relevant substrate.
  • the structure is copied by an erosion electrode onto the surface to be coated. To that end, it is necessary to provide the electrode with the desired structure prior to copying.
  • the surface to be coated of the substrate can then be structured using one or more electrodes. If multiple electrodes are used, these can have different configurations in order to be able to treat different regions of the surface of the substrate at an optimum distance.
  • a particularly versatile erosion electrode is for example in the form of an elongate ellipsoid of revolution (similar to a cigar or a cylinder) whose surface is knurled circumferentially along the longitudinal extent of the electrode.
  • These striation grooves can then be formed by bringing the workpiece surface close to the erosion tool, wherein the longitudinal axis of the erosion tool is oriented parallel to the direction of the smallest curvature of the workpiece surface at the point of contact with the erosion tool.
  • the erosion tool can then be guided over the surface of the substrate, perpendicular to the longitudinal axis. A relatively effective structuring of the surface is thus possible.
  • the laser can be guided taking into account the accessibility of the workpiece and its geometric configuration. This is in particular possible using CAD data of the substrate.
  • a laser has the advantage that it has an axis, similar to the particle jet, such that it can be guided in the same manner as the particle jet will be subsequently. That is to say that, if both the jet-generating device (for example a cold gas spray nozzle) and the laser are moved according to the same movement pattern, then the spray angle ⁇ always largely matches the angle of inclination ⁇ of the oblique orientation of the structure elements, making it possible to achieve an optimum coating result.
  • the coating apparatus and the device for generating the structure elements can be used in alternation or simultaneously. Simultaneous use advantageously shortens production times but is possible only if the region of the substrate is sufficiently accessible. Alternating use results in longer production times but harder-to-reach regions of the substrate can be optimally provided with a coating. In order to optimize the production method for a certain component, both simultaneous and alternating production of the structure elements and of the coating can be chosen, such that the production times for each substrate can be optimized.
  • One example for which the method according to the invention can be used is coating what are termed blade drillings for gas turbines. These have three blades which are produced together. This results in hard-to-reach regions between the blades, which can advantageously be coated with the method according to the invention.
  • FIG. 1 is a schematic view of an exemplary embodiment of the method with a three-dimensional view of the substrate, showing the angles ⁇ and ⁇ ,
  • FIG. 2 is a perspective view of the substrate in FIG. 1 , showing the angles ⁇ and ⁇ ,
  • FIG. 3 is partial perspective view of an alternative substrate, as an exemplary embodiment with holes,
  • FIG. 4 has multiple cross sections in a schematic view illustrating an exemplary embodiment of the method, in which a blade drilling is coated
  • FIG. 5 is a partial cross section illustrating an exemplary embodiment of the method, in which a multilayer coat is deposited and
  • FIG. 6 is a three-dimensional graphic representation of the spray angle interval in the form of a modified cone.
  • the surface 14 is subjected to a structuring process using a laser beam 16 .
  • the trenches 17 and the resulting ridges 18 between the trenches are oriented obliquely. That is to say that they do not project vertically upwards in line with the surface normal 15 but the trenches have a plane of symmetry 19 which is inclined by the angle of inclination ⁇ , in line with the orientation of the laser beam 16 .
  • FIG. 1 indicates schematically the manner in which the particle 12 is deformed when it hits the structured surface 14 , such that the structure elements formed as trenches 17 and ridges 18 therebetween pierce the surface of the particle. This increases the surface area for adhesion such that the subsequent further plastic deformation (not shown in FIG. 1 ) of the particle 12 leads to an effective interlocking between the particle 12 and the substrate 11 .
  • FIG. 2 shows another detail of the substrate. This is chosen such that the trenches 17 run diagonally.
  • the angle of inclination ⁇ and the spray angle ⁇ are also marked in FIG. 2 .
  • the particle jet 13 and the surface normal 15 at the point of incidence of the particle jet, give the arms of the spray angle ⁇ , wherein these two arms define a plane 20 which stands vertically on the surface 14 of the substrate 11 .
  • the figure further shows a plane 21 at right angles to the trenches 17 and through which a surface normal 15 also passes. Marked in this plane is the angle of inclination ⁇ , whose two arms lie in this plane 21 (even if the inclination in the trenches 17 cannot be seen in FIG. 2 ).
  • the background for a deviation ⁇ between the planes 20 , 21 being permitted is that real components have a more complex geometry than the substrates shown in FIGS. 1 and 2 .
  • FIG. 3 shows a three-dimensional representation of a substrate which, instead of the trenches 17 , has holes 22 which can for example be shot with a laser beam (not shown in more detail) into the surface 14 of the substrate 11 .
  • This also results in an angle of inclination ⁇ as a consequence of the orientation of the laser, wherein the arms of this angle are the surface normal 15 and the axis of symmetry 23 of the holes 22 .
  • a grid 24 which is also inclined by the angle of inclination ⁇ and which is also part of the adhesion-improving structuring of the surface 14 .
  • FIG. 4 shows a blade drilling 25 as the substrate. This is cast as a one-piece component, as represented, and is then assembled with other blade drillings to give a blade ring for a gas turbine.
  • the position with respect to one another of turbine blades 26 of the blade drilling has the effect that problems would arise when coating, for example by cold gas spraying with the particle jet 13 under conditions according to the known art.
  • the spray angle interval according to the known art is represented at two points in the form of a cone 27 . Taking into account the maximum permissible spray angle, which according to the known art must lie within the cone, it is possible that a region 28 in the middle of the turbine blade is not coated. This is where the measure comes into play.
  • Shown not to scale on the middle turbine blade are the ridges 18 and trenches 17 which run substantially perpendicular to the principal blade curvature of the turbine blade 26 and thus also to the plane of the drawing. These make it possible for the depicted particle jets 13 to be directed past the adjacent turbine blade and into the region 28 , since the spray angle interval is increased thereby (cf. also FIG. 6 ). Complete coating of the turbine blades 26 is thus possible.
  • a method of erosion is indicated on one of the blades, which method could serve to produce the surface structuring on the blades.
  • it is a roller which in FIG. 4 is seen only from the end side.
  • the roller is namely arranged perpendicular to the plane of the drawing, according to the trenches 17 and ridges 18 to be produced, and hence to the principal curvature of the turbine blades.
  • the roller has a profile which matches the trenches 17 and ridges 18 to be produced. This profile is comparable to a sawtooth profile 29 .
  • FIG. 5 shows a method in which a coat 30 to be generated has three layers 31 a , 31 b , 31 c .
  • the individual stages of coating the substrate 11 are separated from one another with break lines 32 and the stages are denoted with Roman numerals. These are briefly explained below.
  • FIG. 6 shows how the measure of a surface treatment prior to coating influences the spray angle interval.
  • the spray angle interval is formed by the cone 27 .
  • the permissible spray angles, or the particle jet which is not shown in more detail in FIG. 6 lie within the cone.
  • FIG. 6 shows the cone 27 in part by dashed lines.
  • This form of the cone results, according to the known art, in the case of an untreated surface.
  • the modified cone is not conical but deviates from the conical configuration which is depicted by the dashed line.
  • the angle of inclination

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)
  • Plasma & Fusion (AREA)
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  • Coating By Spraying Or Casting (AREA)

Abstract

A substrate is coated by cold-gas spraying in which a particle jet is oriented at an inclination to the surface of a substrate thus forming a spraying angle. To increase the possible spraying angle compared to the known art, the surface is applied with a directional patterning, for example trenches and ridges. The orientation of this patterning has an angle of inclination in the direction of the spraying angle. As a result, the adhesion of striking particles is improved and it is possible to achieve larger spraying angles.

Description

    CROSS REFERENCE TO RELATED APPLICATIONS
  • This application is the U.S. national stage of International Application No. PCT/EP2013/069218, filed Sep. 17, 2013 and claims the benefit thereof. The International Application claims the benefit of German Application No. 102012217685.3 filed on Sep. 28, 2012, both applications are incorporated by reference herein in their entirety.
  • BACKGROUND
  • Described below is a method for coating by thermal spraying. Herein, a particle jet is directed onto a substrate to be coated and the particles of the particle jet are deposited onto the substrate. In that context, the axis of the particle jet is inclined to the surface normal of the untreated substrate forming a spray angle α.
  • EP 1 534 877 B1 discloses that the deposition of particles during thermal spraying can be improved by a laser being guided along therewith on the workpiece surface which is to be coated. This laser can warm the substrate at the point of incidence of the particle jet, whereby the incident particles adhere better to the substrate. However, this improvement in adhesion works only in the case of a particle jet which is oriented approximately perpendicular to the surface of the substrate to be coated. In the case of such a particle jet, the spray angle is approximately 0°. The spray angle is defined by a non-oriented angle between the axis of symmetry of the particle jet (in the following denoted simply as the jet axis) and the surface normal at the point of incidence of the particle jet. In the following, the spray angle will be denoted as α.
  • The particle jet is normally set with a spray angle α=0°. Any orientation of the jet axis which deviates therefrom results in a positive value of the spray angle α. Depending on the basic conditions such as processed particles, surface material and spray parameters, there is a permissible interval for the spray angle, below which the adhesion of the deposited particles reaches maximum values. The zero angle may or may not be included in this interval. The set of all permissible spray angles thus produces a space between two conical surfaces, whose tips meet at the point of incidence of the particle jet. If the zero angle is included in the interval, only one cone oriented in the described manner is required to describe the spray angle interval.
  • In particular in the case of cold gas spraying, optimum results can be obtained only in a comparatively small spray angle interval since, as the spray angle α increases, the component of the kinetic energy of the particles in the direction of the surface normal is ever-decreasing. It is thus possible, in the case of components having complex shapes, for certain regions of the component to not be coated by the thermal spraying, in particular cold gas spraying since, for geometric reasons, taking into account the spray angle interval, no particle jet can be oriented onto the surface.
  • Cold gas spraying is a method known per se, in which particles provided for the coating are accelerated by a convergent-divergent nozzle, e.g., to supersonic speeds, in order that these adhere to the surface to be coated by virtue of the kinetic energy imparted to them. In this process, the kinetic energy of the particles is used and leads to a plastic deformation of the latter, wherein upon impact the coating particles are melted only at their surface. For that reason, this method is termed cold gas spraying in comparison with other thermal spraying methods because it is carried out at comparatively low temperatures at which the coating particles remain largely solid. For cold gas spraying, which is also termed kinetic spraying, a cold gas spraying apparatus may be used which has a gas heating device for heating a gas. A stagnation chamber is connected to the gas heating device, wherein the outlet of this chamber is connected with the convergent-divergent nozzle, such as a de Laval nozzle. Convergent-divergent nozzles have a convergent part section and a divergent part section which are connected by a nozzle throat. The convergent-divergent nozzle generates, on the outlet side, a powder jet in the form of a gas stream with high-speed—e.g., supersonic—particles therein.
  • SUMMARY
  • Described below is a method for coating by thermal spraying, in particular a method for cold gas spraying, by which it is possible to coat even hard-to-reach regions of a component, with a satisfactory coat result.
  • This is achieved with the method mentioned in the introduction in that, prior to the thermal spraying, the substrate undergoes pretreatment in which the surface is structured. In that context, structure elements of the structured surface are produced obliquely on the surface such that the structure elements are oriented towards the inclined axis of the particle jet, that is to say the jet axis. The structure elements are produced obliquely, in other words, so that the finished structure elements do not stand upright, but their principal geometric orientation deviates from the surface normal. If, for example, a structure element is any raised portion, the orientation of the latter would for example be determined taking into account the center line of the structure element. This line is then not oriented parallel to the surface normal but forms an angle of inclination β thereto, wherein the inclined orientation of the structure elements is such that these are oriented towards the inclined jet axis. In other words, the orientation of the named center line of a structure element will be at least similar to that of the jet axis.
  • Also, the spatial extent of the structure elements is smaller, at least in the plane of the spray angle α, than the average diameter of the particles. The plane of the spray angle α is to be defined as a plane containing both arms of the spray angle α. If one considers the spatial extent of the structure elements in this plane, the geometry of the structure elements—as seen in the section of this plane—should be smaller than the size of the particles. It has namely been found that particles which are incident on a surface structured in this manner can, in spite of a spray angle α, convert a larger proportion of their kinetic energy into deformation than particles which are incident on the unstructured, i.e. smooth, surface at the same spray angle α. In other words, on account of the geometry of the structure elements, the surface to be coated presents greater adhesion resistance to the incident particles, at least in the direction of the spray angle. This has the advantageous effect that the surface can still be reliably coated at higher spray angles, especially in the direction of the spray angle α. It is thus for example possible to coat components with undercuts by thermal spraying, because those regions of the component which are hard to reach on account of the undercuts are made accessible for the spray jet.
  • It is provided according to one advantageous embodiment that the angle of inclination β of the oblique orientation of the structure elements largely corresponds to the spray angle α. In other words, the angle of inclination of the oblique orientation of the structure elements is determined so as to achieve an optimal improvement of the spray angle α. From a manufacturing aspect, it is particularly advantageous in that context if the entire hard-to-reach region of the component is provided with structure elements which have at least largely the same orientation. For the purpose of coating this region, the particle jet is then also oriented such that when coating the region the jet is displaced at least essentially parallel. This can also be achieved if the jet-generating device (for example the spray nozzle of an apparatus for cold gas spraying) is at a large distance from the substrate with respect to the region to be coated and, for the purpose of coating this region, is pivoted by for example plus/minus 5°. The resulting angular offsets are then relatively small.
  • The structuring of the surface of the substrate to produce the structure elements, can also be termed a microscopic striation. The binding mechanism of the particles on the surface can also be described more simply in that, when the particles are incident on the “peaks” of the striation, the latter pierce the former and thus improve adhesion. This can be compared with the function of a metal file, which also has a striation. This striation usually has the effect that the file must be guided over the workpiece in a specific direction in order to guarantee optimal chip removal. This is only possible if the striation has an angle of inclination of the oblique orientation of the individual structure elements. This analogy clarifies the function of the microscopic striation. Microscopic hereinbelow means that the extent of the structure elements, as already explained, must be smaller than that of the particles so that the particles can act like the workpiece under the file, so to speak.
  • The surface normal of the substrate is defined by the surface of the untreated substrate. This means that, after treating the substrate by generating the structure elements, other local surface normals can result. However, of relevance are the surface normals which are to be determined on account of the superordinate structure of the substrate. The structuring, which is small in comparison, thus generates a surface which is much more finely structured, such that after structuring the substrate the surface normal could only be determined by averaging over multiple structure elements.
  • One further configuration provides that the plane of the spray angle α and the plane of the angle of inclination β of the oblique orientations of the structure elements are at an angle γ of at most 25° to one another. In this context, manufacturing considerations play a role. On one hand, there are production-induced tolerances when producing the structure elements. In addition, the geometry of the substrate to be coated can be designed such that an ideal orientation of the structure elements, i.e. an orientation with an angle γ of 0°, would lead to more complex production. In this case, it is possible to choose an orientation of the structure elements which, in parts of the hard-to-coat regions of the component, deviates to a greater or lesser extent—but never by more than 25°—from the ideal orientation. It is also possible to establish an upper limit of 15° or 10° for the angle γ. This is then advantageous if, on account of the processed particles, the chosen thermal coating method or the substrate material, a tighter tolerance for the angle γ is required in order to still achieve the required coating results.
  • It is of particular advantage if trenches are produced as structure element. Advantageously, these trenches are particularly easy to create in manufacturing terms. They may be created for example by a laser, by moving the latter over the surface of the workpiece. The trenches can then run parallel to one another in order to make best use of the available surface area of the substrate. Depending on the geometry of the substrate to be coated, the trenches can be either straight or curved. The latter is also important for optimizing the angle γ.
  • Particularly advantageously, the trenches have, at least locally, planes of symmetry which are oriented during production such that they are oriented towards the inclined axis of the particle jet during the thermal spraying. This produces, so to speak, the required orientation to the particle jet. It is to be noted in this context that not only the trenches but in particular the ridges remaining between the trenches are responsible for the resulting effect of an improvement in adhesion. The structuring of the surface is thus influenced not only by the trenches produced but also by the structure elements in the form of ridges therebetween.
  • Another advantageous possibility provides that the structure elements are produced as holes. Advantageously, holes can also be produced simply. These can for example be produced by punctiform laser shots to the surface of the substrate to be coated. Advantageously, these holes have axes of symmetry which are oriented obliquely during production such that they are oriented towards the inclined axes of the particle jet during the thermal spraying. The axes of symmetry of the holes thus simultaneously represent the center lines of the holes, wherein, when using a laser, these can in particular be directly influenced by the orientation of the latter. Moreover, this also holds for the production of trenches by the laser. In the case of producing holes, it is also worth mentioning that the uprights remaining between the holes also constitute oriented structures which, as structure elements, participate in the improvement of adhesion of the surface.
  • It is particularly advantageous if cold gas spraying is used as thermal spraying. This is advantageously well-suited to the relatively cost-effective production of relatively thick coats. Particularly if the coat is produced in multilayer fashion, i.e. coating by alternating multiple times between production of structure elements and production of layers of the desired coating, it is possible to produce relatively thick coats. In each case, the deposited layers in turn serve for the production of the next layer, wherein in the case of hard-to-reach regions of the substrate, of course, the layer must always once again be structured as a surface to be coated. Otherwise, subsequent layers would not adhere to the preceding layers.
  • In order to be able to coat workpieces with hard-to-reach regions, it is advantageous if the substrate is produced in the regions which are inaccessible to the particle jet while observing the maximum permissible spray angle in the case of the untreated substrate, such that an increase, connected thereto, of the permissible spray angle α results in the region being able to be coated with the thermal spraying method. This is the case if the maximum permissible spray angle α increases specifically in that direction whence the particle jet is incident on account of the geometric specifications of the substrate to be coated.
  • The structure elements may advantageously be generated with a laser beam, by an erosion method, by chip removal, by a shaping method or chemically, depending on which method is best suited to the relevant substrate.
  • If, for example, the surface structuring is carried out by an erosion process, the structure is copied by an erosion electrode onto the surface to be coated. To that end, it is necessary to provide the electrode with the desired structure prior to copying. The surface to be coated of the substrate can then be structured using one or more electrodes. If multiple electrodes are used, these can have different configurations in order to be able to treat different regions of the surface of the substrate at an optimum distance.
  • A particularly versatile erosion electrode is for example in the form of an elongate ellipsoid of revolution (similar to a cigar or a cylinder) whose surface is knurled circumferentially along the longitudinal extent of the electrode. These striation grooves can then be formed by bringing the workpiece surface close to the erosion tool, wherein the longitudinal axis of the erosion tool is oriented parallel to the direction of the smallest curvature of the workpiece surface at the point of contact with the erosion tool. The erosion tool can then be guided over the surface of the substrate, perpendicular to the longitudinal axis. A relatively effective structuring of the surface is thus possible.
  • If a laser machining process is chosen for structuring, the laser can be guided taking into account the accessibility of the workpiece and its geometric configuration. This is in particular possible using CAD data of the substrate. Using a laser has the advantage that it has an axis, similar to the particle jet, such that it can be guided in the same manner as the particle jet will be subsequently. That is to say that, if both the jet-generating device (for example a cold gas spray nozzle) and the laser are moved according to the same movement pattern, then the spray angle α always largely matches the angle of inclination β of the oblique orientation of the structure elements, making it possible to achieve an optimum coating result.
  • Accordingly, the coating apparatus and the device for generating the structure elements can be used in alternation or simultaneously. Simultaneous use advantageously shortens production times but is possible only if the region of the substrate is sufficiently accessible. Alternating use results in longer production times but harder-to-reach regions of the substrate can be optimally provided with a coating. In order to optimize the production method for a certain component, both simultaneous and alternating production of the structure elements and of the coating can be chosen, such that the production times for each substrate can be optimized.
  • One example for which the method according to the invention can be used is coating what are termed blade drillings for gas turbines. These have three blades which are produced together. This results in hard-to-reach regions between the blades, which can advantageously be coated with the method according to the invention.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • These and other aspects and advantages will become more apparent and more readily appreciated from the following description of the exemplary embodiments, taken in conjunction with the accompanying drawings of which:
  • FIG. 1 is a schematic view of an exemplary embodiment of the method with a three-dimensional view of the substrate, showing the angles α and β,
  • FIG. 2 is a perspective view of the substrate in FIG. 1, showing the angles α and γ,
  • FIG. 3 is partial perspective view of an alternative substrate, as an exemplary embodiment with holes,
  • FIG. 4 has multiple cross sections in a schematic view illustrating an exemplary embodiment of the method, in which a blade drilling is coated,
  • FIG. 5 is a partial cross section illustrating an exemplary embodiment of the method, in which a multilayer coat is deposited and
  • FIG. 6 is a three-dimensional graphic representation of the spray angle interval in the form of a modified cone.
  • DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
  • Reference will now be made in detail to the preferred embodiments, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout.
  • FIG. 1 shows a substrate 11 which is to be coated with particles 12 by cold gas spraying. To that end, a particle jet 13 is directed onto the surface 14 of the substrate 11. However, the particle jet 13 is inclined with respect to the surface normal 15 by an angle α. This angle α is named the spray angle.
  • In addition, to improve an adhesion of the incident particles 12, the surface 14 is subjected to a structuring process using a laser beam 16. This involves generating trenches 17 by laser ablation, wherein the laser beam 16 is incident on the surface 14 of the substrate 11 at an angle of inclination β. This means that the trenches 17 and the resulting ridges 18 between the trenches are oriented obliquely. That is to say that they do not project vertically upwards in line with the surface normal 15 but the trenches have a plane of symmetry 19 which is inclined by the angle of inclination β, in line with the orientation of the laser beam 16. In FIG. 1, in the represented detail of the substrate 11, the spray angle α exactly matches the angle of inclination β. Under these geometric conditions, it is possible, for spray angles α>0, to achieve an optimum adhesion result of the particles 12 on the surface 14. FIG. 1 indicates schematically the manner in which the particle 12 is deformed when it hits the structured surface 14, such that the structure elements formed as trenches 17 and ridges 18 therebetween pierce the surface of the particle. This increases the surface area for adhesion such that the subsequent further plastic deformation (not shown in FIG. 1) of the particle 12 leads to an effective interlocking between the particle 12 and the substrate 11.
  • FIG. 1 shows how the pretreatment by the laser beam 16 and the coating by the particle jet 13 are effected simultaneously. However, this means that the laser beam 16 and the particle jet 13 act simultaneously but at different points of the surface 14. Alternatively, it is of course also possible for the structuring of the surface to take place in a special production step as a pretreatment prior to coating.
  • FIG. 2 shows another detail of the substrate. This is chosen such that the trenches 17 run diagonally. The angle of inclination β and the spray angle α are also marked in FIG. 2. It can also be seen in FIG. 2 that the particle jet 13 and the surface normal 15, at the point of incidence of the particle jet, give the arms of the spray angle α, wherein these two arms define a plane 20 which stands vertically on the surface 14 of the substrate 11. The figure further shows a plane 21 at right angles to the trenches 17 and through which a surface normal 15 also passes. Marked in this plane is the angle of inclination β, whose two arms lie in this plane 21 (even if the inclination in the trenches 17 cannot be seen in FIG. 2).
  • The difference which appears in the case of the cold spraying method according to FIG. 1 and according to FIG. 2 is that, in FIG. 2, the spray angle α and the angle of inclination β do not lie in one plane (the plane of the drawing in FIG. 1). Instead, the planes 20, 21 of the angles α and β lie rotated with respect to one another by an angle γ. Since both planes 20, 21 stand vertically on the surface 14, the angle γ can be measured in the aspect on the surface 14, i.e. looking towards the surface normal 15. The maximum possible angle γ of 25° defines in this context the maximum permissible deviation from the state represented in FIG. 1, in which the spray angle α and the angle of inclination β lie in one and the same plane. In spite of the deviation γ, the structured surface 14 can still be advantageous for the coating result, since the effective interlocking mechanism of the incident particle 12, as shown in FIG. 1, is still effective.
  • The background for a deviation γ between the planes 20, 21 being permitted is that real components have a more complex geometry than the substrates shown in FIGS. 1 and 2. Here, for example for reasons of accessibility (cf. FIG. 4), it is necessary to deviate from the ideal geometric proportions according to FIG. 1 in the permissible range of the angle γ.
  • FIG. 3 shows a three-dimensional representation of a substrate which, instead of the trenches 17, has holes 22 which can for example be shot with a laser beam (not shown in more detail) into the surface 14 of the substrate 11. This also results in an angle of inclination β as a consequence of the orientation of the laser, wherein the arms of this angle are the surface normal 15 and the axis of symmetry 23 of the holes 22. Between the holes 22 there results a grid 24 which is also inclined by the angle of inclination β and which is also part of the adhesion-improving structuring of the surface 14.
  • FIG. 4 shows a blade drilling 25 as the substrate. This is cast as a one-piece component, as represented, and is then assembled with other blade drillings to give a blade ring for a gas turbine. The position with respect to one another of turbine blades 26 of the blade drilling has the effect that problems would arise when coating, for example by cold gas spraying with the particle jet 13 under conditions according to the known art. In order to illustrate this, the spray angle interval according to the known art is represented at two points in the form of a cone 27. Taking into account the maximum permissible spray angle, which according to the known art must lie within the cone, it is possible that a region 28 in the middle of the turbine blade is not coated. This is where the measure comes into play. Shown not to scale on the middle turbine blade are the ridges 18 and trenches 17 which run substantially perpendicular to the principal blade curvature of the turbine blade 26 and thus also to the plane of the drawing. These make it possible for the depicted particle jets 13 to be directed past the adjacent turbine blade and into the region 28, since the spray angle interval is increased thereby (cf. also FIG. 6). Complete coating of the turbine blades 26 is thus possible.
  • Moreover, a method of erosion is indicated on one of the blades, which method could serve to produce the surface structuring on the blades. In this case it is a roller which in FIG. 4 is seen only from the end side. The roller is namely arranged perpendicular to the plane of the drawing, according to the trenches 17 and ridges 18 to be produced, and hence to the principal curvature of the turbine blades. The roller has a profile which matches the trenches 17 and ridges 18 to be produced. This profile is comparable to a sawtooth profile 29.
  • FIG. 5 shows a method in which a coat 30 to be generated has three layers 31 a, 31 b, 31 c. The individual stages of coating the substrate 11 are separated from one another with break lines 32 and the stages are denoted with Roman numerals. These are briefly explained below.
    • I The substrate 11 is made available.
    • II The surface 14 of the substrate 11 is structured. Trenches 17 and ridges 18 as shown in FIG. 1 are produced. This is also the case for the following structuring in IV and VI.
    • III The first layer 31 a is produced and makes the surface 14 a available for the subsequent coating. It can also be seen that, in this context, the structuring of the surface 14 changes, wherein in this context an interlocking of the sprayed particles (no longer visible in FIG. 5) with the surface 14 takes place simultaneously. This is also the case for V and VII.
    • IV The surface 14 a again undergoes surface structuring (in the same manner as in II).
    • V The next layer 31 b is applied. This can be the same coat material as applied in III or a multilayer coat is produced in which another coat material is applied.
    • VI The surface 14 b resulting from V again undergoes surface structuring.
    • VII The last layer 31 c of the coat 30 is applied and forms the final surface 14 c of the coated component.
  • FIG. 6 shows how the measure of a surface treatment prior to coating influences the spray angle interval. As already explained in relation to FIG. 4, the spray angle interval is formed by the cone 27. The permissible spray angles, or the particle jet which is not shown in more detail in FIG. 6, lie within the cone.
  • FIG. 6 shows the cone 27 in part by dashed lines. This form of the cone results, according to the known art, in the case of an untreated surface. However, it can also be seen in FIG. 6 that the modified cone is not conical but deviates from the conical configuration which is depicted by the dashed line. Namely, on account of the angle of inclination β (cf. FIG. 1, not shown in FIG. 6), there is a related orientation for the spray angle interval. In the direction of the angle of inclination, there results a nose-like protuberance. This means that, in this direction, much greater spray angles α (cf. FIG. 1, not shown in FIG. 6) are possible. Conversely, however, this leads to a flattening 34 of the cone since in this direction only smaller spray angles are possible. The representation according to FIG. 6 thus makes clear that, depending on the desired spray geometry, the structuring must be applied to the surface 14 in a targeted manner. It is also clear that, in the case of a deviation from the related orientation by the angle γ (cf. FIG. 2), an increased spray angle interval can still be of advantage, although the effect is not as pronounced.
  • A description has been provided with particular reference to preferred embodiments thereof and examples, but it will be understood that variations and modifications can be effected within the spirit and scope of the claims which may include the phrase “at least one of A, B and C” as an alternative expression that means one or more of A, B and C may be used, contrary to the holding in Superguide v. DIRECTV, 358 F3d 870, 69 USPQ2d 1865 (Fed. Cir. 2004).

Claims (21)

1-12. (canceled)
13. A method for coating a substrate by thermal spraying, comprising:
producing a structured surface of the substrate by pretreating the substrate, the structured surface having structure elements that are obliquely produced; and
depositing particles of a particle jet onto the substrate by directing the particle jet onto the structured surface of the substrate at a spray angle between an axis of the particle jet and a surface normal of the substrate when the substrate is untreated, the structure elements being oriented towards the axis of the particle jet during the thermal spraying and having a spatial extent that is smaller, at least in a spray angle plane in which the spray angle lies, than an average diameter of the particles.
14. The method as claimed in claim 13, wherein the structure elements have an inclination angle substantially corresponding to the spray angle.
15. The method as claimed in claim 14, wherein the spray angle plane and an inclination plane in which the inclination angle of the structure elements form an angle of at most 25°.
16. The method as claimed in claim 16, wherein the structure elements include trenches with symmetry planes oriented obliquely during production such that the symmetry planes are oriented towards the axis of the particle jet during the thermal spraying.
17. The method as claimed in claim 15, wherein the structure elements are holes with symmetry axes oriented towards the axis of the particle jet during the thermal spraying.
18. The method as claimed in claim 15, wherein the thermal spraying is cold gas spraying.
19. The method as claimed in claim 18, wherein the substrate, prior to said pretreating, has a region inaccessible to the particle jet while observing a maximum permissible spray angle, and
wherein said pretreating produces the structure elements in the region that enable the particle jet at the maximum permissible spray angle to coat the region with the particles.
20. The method as claimed in claim 19, wherein said pretreating produces the structure elements using at least one of a laser beam, an erosion method, chip removal, a shaping method, and application of a chemical.
21. The method as claimed in claim 20, further comprising repeating said pretreating and said depositing, thereby producing layers of the particles until a desired coating is produced.
22. The method as claimed in claim 21, wherein the substrate with the desired coating is a blade drilling of a gas turbine.
23. The method as claimed in claim 13, wherein the spray angle plane and an inclination plane in which the inclination angle of the structure elements form an angle of at most 25°.
24. The method as claimed in claim 13, wherein the structure elements include trenches.
25. The method as claimed in claim 24, wherein the trenches have symmetry planes oriented obliquely during production such that the symmetry planes are oriented towards the axis of the particle jet during the thermal spraying.
26. The method as claimed in claim 13, wherein the structure elements are holes.
27. The method as claimed in claim 26, wherein the holes have symmetry axes oriented towards the axis of the particle jet during the thermal spraying.
28. The method as claimed in claim 13, wherein the thermal spraying is cold gas spraying.
29. The method as claimed in claim 13, wherein the substrate, prior to said pretreating, has a region inaccessible to the particle jet while observing a maximum permissible spray angle, and
wherein said pretreating produces the structure elements in the region that enable the particle jet at the maximum permissible spray angle to coat the region with the particles.
30. The method as claimed in claim 13, wherein said pretreating produces the structure elements using at least one of a laser beam, an erosion method, chip removal, a shaping method, and application of a chemical.
31. The method as claimed in claim 13, further comprising repeating said pretreating and said depositing, thereby producing layers of the particles until a desired coating is produced.
32. The method as claimed in claim 13, wherein the substrate after the coating is a blade drilling of a gas turbine.
US14/432,102 2012-09-28 2013-09-17 Method for coating by thermal spraying with an inclined particle jet Abandoned US20150240364A1 (en)

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