CA1217433A - Combustion turbine blade with varying coating - Google Patents

Combustion turbine blade with varying coating

Info

Publication number
CA1217433A
CA1217433A CA000460111A CA460111A CA1217433A CA 1217433 A CA1217433 A CA 1217433A CA 000460111 A CA000460111 A CA 000460111A CA 460111 A CA460111 A CA 460111A CA 1217433 A CA1217433 A CA 1217433A
Authority
CA
Canada
Prior art keywords
coating
blade
cooler
temperature
operate
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA000460111A
Other languages
French (fr)
Inventor
Edwin A. Crombie, Iii
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
CBS Corp
Original Assignee
Westinghouse Electric Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Westinghouse Electric Corp filed Critical Westinghouse Electric Corp
Application granted granted Critical
Publication of CA1217433A publication Critical patent/CA1217433A/en
Expired legal-status Critical Current

Links

Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01DNON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12Blades
    • F01D5/28Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01DNON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12Blades
    • F01D5/28Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/288Protective coatings for blades
    • 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
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01DNON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D25/00Component parts, details, or accessories, not provided for in, or of interest apart from, other groups
    • F01D25/005Selecting particular materials

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Coating By Spraying Or Casting (AREA)

Abstract

ABSTRACT OF THE DISCLOSURE
This is a turbine blade for land-based or marine combustion turbines utilizing a hot-end coating, a cooler-end coating, and an intermediate transition zone with a mixture of the two end coatings. The blade has a hot end at least a portion of which is designed to operate at a temperature in excess of 1500°F, a cooler end at least a portion of which is designed to operate at a temperature of less than 1250°F, and an intermediate zone, at least a portion of which is designed to operate at between 1250 and 1500°F. The blade has a hot end coated with a low creep-type coating which is resistant to high temperature corrosion and oxidation, a cooler end coated with a ductile-type coating which is resistant to sulfide corro-sion, and an intermediate portion which is coated with a mixture of the hot end coating and the cooler end coating.

Description

COM~USTION TURBINE BLADE WITH VARYING COATING

BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates to combustion turbine blades for land-based or marine service and in particular to coatings for protecting such blades.
Land based or marine-type combustion turbines present difficulk problems of blade materials. Near the tip of the blades, the temperatures are often 1700F or more. Do~n near the base of the blade (near the shaft), temperatures are much cooler, for example, approximately 1000F. In addition, such turbines are commonly operated - with fuels containing corrosive impurities such as sulfur and vanadium. Further, corrosion-causing compounds such as sea salt or fertilizer are often ingested in with the air drawn in by the turbine compressor. Such problems are significantly worse with land-based and marine combustion turbines as compared to aircraft (aircraft turbines are generally operated with cleaner fuel and significantly less contaminated air).
It has been discovered that not only must the hotter portion be protected against high temperature oxidation type corrosion, but that the coating on this portion of the blade must be creep resistant. Conversely, the cooler temperature~Pof the blade (especially those portions less than about 1250F) must be protected against sulfide-type corrosion and must have high coating ductility to prevent crack propagation. Further, it has been found 3~

that an intermediate zone, which is a mixture of khe two coatings, must be used in order to prevent problems such , às abrupt chemical disco~tinuities in the coating or A stress concentrations~ Preferably,~ the coatings are applied by plasma spraying and the intermediate portion is a graded coating giving a smooth transition from the hot end coating to the cooler end coating.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention can be best understood by refer-ence to the following drawings in which:
Figure 1 is an elevation of a blade showing typical '~p intermediate and base temperatures;
Figure 2 is a blade elevation showing three coating zones;
Figure 3 shows a system for applying the coat-ings of this invention, and Figure 4 is a graph of typical ductilities for coatings and superalloy base materials at various tempera-tures.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The range of temperatures of many gas turbine blades (as used herein, the term "blades" is used to mean turbine components having airfoil portions whether rotat-ing or stationary, e.g., including the stationary parts ~5 which are sometimes called "vanes") generally exceeds the range of effectiveness of any single type of coating.
This is in part due to the chemical/thermal stability of a coating in the various deleterious corrosive environments and partly due to the physical/mechanical properties of the coating itself. This invention enables the use of a multiple composite coating system that enables the designer to maximize coating capabilities without the usual compro-mises ~especially with regard to reduced physical/mechan-ical properties above or below the ductile/brittle transi-tion temperature which are inherent to any given coatingcomposition).

A gas turbine blade may have an operating tem-perature profile ranging from about 1000F at the base of the gas path surface to nearly 1800F at the outermost tip region. Because the deleterious species and compounds are stable only through certain temperature ranges, applica-tion of a singular coating system has inherent limita-tions. A coating system which is most effective in pre-venting low temperature class II type corrosion in the range of 1000F to 1450F, for example, could be applied through the lower portion of the airfoil and a high tem-perature corrosion resistant composition applied to the upper port~on (away from the center axis) of the airfoil where blade'rtemperatures are highest.
~ , At the hot end of the blade the inherent ductil-ity of most coating systems currently employed for environ-mental protection is generally e~ual to or greater than that of the base alloy to which it is applied. Premature failure of the blade due to brittle coating behavior and crack initiation is therefore not likely. Conse~uently, the coating that exhibits the best environmental protec-- tion may be utilized.
At the cooler end 12 of the blade (generally here the end towards the 1000F temperature), it has been discovered that unusually high ductility for these temper-atures is required in addition to resistance to low temper-ature sulfide-type corrosion. As used herein, the term "ductile-type coating" means coatings which have a ductil-ity of greater than or e~ual to that of the base metal at a given operating temperature. The correlation of coating and base metal ductily can be demonstrated in Figure 4.
Figure 2 shows three zones of coatings, with a hot-end coating 14 at the top and a cooler-end coating 16 at the bottom, with a transition zone 18 in the intermedi-ate portion, the transition zone 18 being coated with a mixture of hot-end coating and cooler-end coating. This transition zone 18 eliminates a sharp transition between the hot end coating and the cooler end coating. As a 7~3 variation in the coating in an abrupt manner would result in poor thermal/mechanical properties and the possibility of uncoated areas resulting from less than perfect align-ment, the transition needs to be gradual. Generally, this transition zone 18 will be at least1~2inch in height.
Preferably, the coating is applied by plasma spray. If pack cementation techniques were used, addi-tional handling would be required and masking would pres-ent difficulties with little or no control over interdif~
fusion between masked areas. It would be very di~ficult, therefore, to control the transition from one coating chemistry to the adjacent coating chemistry.
Although any type of plasma spray could be used, a non-oxidizing plasma spray system is thought to be the most practical. As most such coatings require an inert atmosphere or vacuum, such plasma spraying could, for example, be done with an argon flood or low pressure plasma spray.
Although the transition zone could be formed by applying the coating compositions one at a time (e.g., by applying the hot-end coating with its thickness tapering from full thickness at the top end of the transition zone down to essentially zero thickness at the lower end of the transition zone and then applying the cooler-end coating with a maximum thickness at the lower transition zone and tapering down to near zero at the upper end of the transi-tion zone, preferably followed by appropriate heat treat-ment), the coating is preferably applied by a system such as shown in Figure 3 where the transition zone 18 is 3~ accomplished by spraying a powder premixed by ~he hopper system. Thus, the hot end coating composition (designated "A") and the cooler end coating (designated "B") are loaded into separate hoppers 20, 22. As the plasma gun 24 traverses the blade airfoil (under programmed computive control to maintain coating thickness profile), the feed-ing mechanism of the powder hoppers containing A and B
compositions can be programmed to deliver the proper ~2~ 3~
s powder or powder mixture to the mixing vessel 26 which in turn supplies the gun 24. As the plasma gun 24 moves down the airfoil, the composition is initially 100% A, then an A-rich mixture becoming richer and richer in B, then a B-rich mixture and finally a 100% B coating. Generally all three zones ~14, 18, and 1~) will have a height of at least ~2 inch.
U.S. Patents 3,545,944 issued to Emanuelson et al. on December 8, 1970 and 3,020,182 issued to Daniels on February 6, 1962 describe similar systems being used for different purposes.
It can be seen that a coating system similar to Figure 3 can be used to coat more than three zones. For example, if erosion (or corrosion or coating ductility) were a problem on some particular portion of the blade, a third hopper with a "C" type coating composition could be added to apply an erosion resistant coating (or extended corrosion or lower temperature ductility coating, etc.) in this area (preferably using an additional transition zone).
It should be noted that prior-art single coat-ings can fail mechanically due to insufficient creep strength, but that this problem is generally in the high temperature regions, above the ductile/brittle coating transition temperature. Failures also can be caused by poor ductility below the brittle/ductile transition temp-erature of such a single coating. By using different coatings in the high temperature region and the cooler temperature region, a low temperature corrosion resistant coating with good low temperature ductility can be used on the lower portion of the blade airfoil. A high temperature corrosion resistant coating with good high temperature creep resistance is applie~ to the upper portion of the airfoil. Problems at the interface of the two regions are avoided by using the blended composition in the inter-mediate zone of the airfoil.

It is felt that current coating systems are compromises in an attempt to perform adequately over a wide range of conditions, and are not optimized for provid-ing either the high temperature corrosion reslstance with high creep strength required in the hot end or the low temperature corrosion high ductility required in the cooler end.
Generally, it is anticipated that the hot end - ~ (designed to operate above about 1500E) can, for example, use MCrAlY coatings (with M being Ni and/or ~). Similar-ly, it is anticipated that the cooler end coatings be similar to the MCrAlY (with M being Fe or FeNi or combina tions thereof).
Figure 4 shows typical ductility variations with temperature for coatings and nickel-based superalloys.
The ductility of coating A is equal to or greater than the base metal alloys at temperature above about 1350F and the ductility of coating B is equal to or greater than the ductility of the base metal alloys above about 1050F.
The corrosion resistance of coating A is greater than that of coating B above about 1400F while below about 1300F
coating B has a corrosion resistance at least as good as that of coating A. Thus, the coating system of this invention provides improved protection against low coating ductility problems (above e.g. 1000F) and against corro-sion problems.
Again, the transition zone which is coated with a mixture of the coatings is to be generally greater than ~ inch in height. The location of the transition zone can vary with various coatings, but at least a portion of this transition zone will be in a portion of the blade which is designed to operate at a temperature of between 1250 and 1500F. Preferably, at least a portion of the transition zone is to be at a part of the blade which is designed to operate at between 1300 and 1450F and most preferably at 1350F.

This invention is not to be construed as limited to the particular forms described herein, especially with regard to coating composition types as it is felt that the invention herein will lead to new types of coatings de-signed especially for this coating system. The inventionis intended to cover all embodiments which do not depart from the spirit and scope of the in~ention as defined in the claims.

Claims (4)

I claim:
1. A turbine blade for land-based or marine combustion turbines, said blade having a hot end at least a portion of which is designed to operate at a temperature in excess of 1500°F, a cooler end at least a portion of which is designed to operate at a temperature of less than 1250°F, and an intermediate portion at least a portion of which is designed to operate at between 1250 and 1500°F, said blade comprising:
(a) a hot end coated with a low creep-type coating which is resistant to high temperature oxidation;
(b) a cooler end coated with a ductile-type coating which is resistant to sulfide corrosion; and (c) an intermediate portion, which is coated with a mixture of said hot end coating and said cooler end coating.
2. The blade of claim 1, wherein a mixture of said hot end coating is applied over at least ? inch of blade height.
3. The blade of claim 2, wherein said cooler end coating is chosen from the group consisting of MCrAlY
where M is Fe or FeNi.
4. The blade of claim 2, wherein said coatings are applied by plasma spray.
CA000460111A 1983-08-29 1984-07-31 Combustion turbine blade with varying coating Expired CA1217433A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US52760683A 1983-08-29 1983-08-29
US527,606 1983-08-29

Publications (1)

Publication Number Publication Date
CA1217433A true CA1217433A (en) 1987-02-03

Family

ID=24102176

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000460111A Expired CA1217433A (en) 1983-08-29 1984-07-31 Combustion turbine blade with varying coating

Country Status (7)

Country Link
EP (1) EP0139396B1 (en)
JP (1) JPS6062603A (en)
KR (1) KR850001950A (en)
CA (1) CA1217433A (en)
DE (1) DE3472698D1 (en)
IE (1) IE55513B1 (en)
MX (1) MX159535A (en)

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US5077090A (en) * 1990-03-02 1991-12-31 General Electric Company Method of forming dual alloy disks
WO1993005194A1 (en) * 1991-09-05 1993-03-18 Technalum Research, Inc. Method for the production of compositionally graded coatings
DE19615549B8 (en) * 1996-04-19 2005-07-07 Alstom Device for thermal protection of a rotor of a high-pressure compressor
US6095755A (en) * 1996-11-26 2000-08-01 United Technologies Corporation Gas turbine engine airfoils having increased fatigue strength
SE508860C2 (en) * 1997-03-18 1998-11-09 Abb Stal Ab Device on a guide rail arranged in a rotor machine and a rotatable turbine rail
DE59907046D1 (en) 1998-10-22 2003-10-23 Siemens Ag PRODUCT WITH A HEAT INSULATION LAYER AND METHOD FOR PRODUCING A HEAT INSULATION LAYER
GR1003298B (en) * 1999-01-08 2000-01-18 Interceramic S.E. �.�. Method of selective priming of lamina with metal ceramic materials and construction of special features parts using them in a single production stage
DE19934418A1 (en) * 1999-07-22 2001-01-25 Abb Alstom Power Ch Ag Process for coating a locally differently stressed component
DE19955789A1 (en) * 1999-11-19 2001-05-23 Basf Ag Process for combinatorial production of a library of materials
DE10001516B4 (en) 2000-01-15 2014-05-08 Alstom Technology Ltd. Non-destructive method for determining the layer thickness of a metallic protective layer on a metallic base material
US6670046B1 (en) * 2000-08-31 2003-12-30 Siemens Westinghouse Power Corporation Thermal barrier coating system for turbine components
US6592947B1 (en) * 2002-04-12 2003-07-15 Ford Global Technologies, Llc Method for selective control of corrosion using kinetic spraying
JP4058294B2 (en) * 2002-04-30 2008-03-05 株式会社荏原製作所 Wear-resistant surface treatment method for rotating member, impeller, and fluid machine having the impeller
DE502006003548D1 (en) 2006-08-23 2009-06-04 Siemens Ag Coated turbine blade
DE102006051813A1 (en) * 2006-11-03 2008-05-08 Mtu Aero Engines Gmbh Blade for a compressor or turbine of an aircraft engine, aircraft engine with such a blade and method for coating a blade of an aircraft engine
US20080113163A1 (en) * 2006-11-14 2008-05-15 United Technologies Corporation Thermal barrier coating for combustor panels
US20110116912A1 (en) * 2009-11-13 2011-05-19 Mccall Thomas Zoned discontinuous coating for high pressure turbine component
EP2354454A1 (en) * 2010-02-02 2011-08-10 Siemens Aktiengesellschaft Turbine blade with variable oxidation resistance coating
US10309018B2 (en) * 2011-05-31 2019-06-04 United Technologies Corporation Composite article having layer with co-continuous material regions
US9353948B2 (en) * 2011-12-22 2016-05-31 General Electric Company Gas turbine combustor including a coating having reflective characteristics for radiation heat and method for improved combustor temperature uniformity
DE102012108919A1 (en) * 2012-09-21 2014-05-15 Reinhausen Plasma Gmbh Device and method for producing a layer system
EP2938926A1 (en) * 2013-02-05 2015-11-04 Siemens Aktiengesellschaft Fuel lances having thermally insulating coating
US11261742B2 (en) 2013-11-19 2022-03-01 Raytheon Technologies Corporation Article having variable composition coating
US9896585B2 (en) * 2014-10-08 2018-02-20 General Electric Company Coating, coating system, and coating method
DE102017213553A1 (en) 2017-08-04 2019-02-07 MTU Aero Engines AG VESSEL FOR FLOW MACHINE WITH VARIOUS DIFFUSION PROTECTION LAYERS AND METHOD OF MANUFACTURING THEREOF

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GB616432A (en) * 1946-08-30 1949-01-21 Power Jets Res & Dev Ltd Improvements relating to turbine rotors and the like bladed structures
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Also Published As

Publication number Publication date
JPS6062603A (en) 1985-04-10
EP0139396B1 (en) 1988-07-13
IE842094L (en) 1985-02-28
JPH02521B2 (en) 1990-01-08
KR850001950A (en) 1985-04-10
DE3472698D1 (en) 1988-08-18
IE55513B1 (en) 1990-10-10
EP0139396A1 (en) 1985-05-02
MX159535A (en) 1989-06-28

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