CN100540743C - 层状结构和制造层状结构的方法 - Google Patents

层状结构和制造层状结构的方法 Download PDF

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CN100540743C
CN100540743C CNB2004800188937A CN200480018893A CN100540743C CN 100540743 C CN100540743 C CN 100540743C CN B2004800188937 A CNB2004800188937 A CN B2004800188937A CN 200480018893 A CN200480018893 A CN 200480018893A CN 100540743 C CN100540743 C CN 100540743C
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汉斯-托马斯·博尔姆斯
安德烈亚斯·赫塞尔豪斯
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Abstract

按先有技术的层状结构面对外部的热燃气有一种不那么有效的冷却。按本发明设计的层状结构(1)除一个多孔的层(7)外还在该层(7)的内部至少部分设有涂层(40)。由此改善冷却和防止过多的热量传入层状结构(1)内。

Description

层状结构和制造层状结构的方法
本发明涉及一种按权利要求1的层状结构和涉及一种按权利要求18制造层状结构的方法。
US-PS 3 825 364公开了一种完全设计为多孔的外壁。在此壁与基层之间存在一个空隙。
US-PS 5080557公开了一种层状结构，它由基层、多孔的中间层和一个绝对密实的外层组成。
US-PS 4318666公开了在基层内与US-PS 5080557相比附加的冷却通道，在基层上涂覆一个多孔的中间层和一个密实的外层。
JP 10-231704公开了一种有冷却通道和多孔的中间层的基层。
PCT/EP 02/07029和US 6412541公开了一种在壁内部的多孔结构，其中壁在外面还有一层涂层。壁和涂层有冷却通道。
由G.Cao等人的论文“Pore Narrowing and Formation of UltrathinYttria-Stabilized Zirconia Layers in Ceramic Membranes by Chemical VaporDeposition/Electrochemical Vapor Deposition”(Journal of American CeramicSociety，1993年)已知，在一种多孔的陶瓷内部沉积一种陶瓷。
然而，这些已知的层状结构有时有一种不充分的冷却特性。
因此，本发明的目的是改善对于层状结构的冷却。
为达到此目的，本发明提供一种按权利要求1所述的层状结构和一种按权利要求18所述的层状结构制造方法。
在从属权利要求中记载了按照本发明的层状结构及方法的一些扩展设计方案和其他有利的措施。在从属权利要求中所记载的技术措施可有利地互相组合。
此层状结构在基层内和在基层上的多孔透气层内有冷却通道。该多孔层通过细孔构成，其中，细孔以壁为界。在这些壁上按本发明存在至少一层涂层。
当冷却通道的直径和/或层的细孔尺寸随位置地点改变时，则可以随地点改变冷却功率，以及调整例如沿层状结构的外侧的压力梯度。
按本发明作为外层的隔热层转移到此多孔的层内。因此也取消了外壁。
当不再存在如在先有技术中那样的外部密实壁，就不再需要对它进行冷却，因而可降低冷却功率。
在此隔热层内达到更大的温度梯度，这种隔热层因而防止了基层有过高的温度。
下面借助附图所示实施方式详细描述本发明，附图中：
图1表示按本发明的层状结构横截面；
图2表示图1的局部放大；
图3表示一台燃气轮机；
图4表示一个燃烧室；以及
图5表示燃烧室的热屏装置。
图1表示层状结构1，它至少由一个基层4和一个涂覆在该基层4上的至少部分多孔且至少部分透气的层7组成。
基层4例如是尤其燃气轮机100(图3)或汽轮机的一个涡轮构件，例如一个支承结构、一个涡轮叶片120、130、燃烧室内衬155(图4、5)，或其他必须冷却的构件。
基层4例如用一种镍基或钴基的超级高温合金制造。基层4和层7的材料可以不同或可以是同类的(金属、陶瓷)和/或类似的，尤其在层7与基层4共同制造的情况下。
在基层4与层7之间可以存在中间层，例如一粘附层。
层7优选地是金属的以及例如用MCrAlX类型的防腐蚀合金制成，其中，M是铁(Fe)、钴(Co)或镍(Ni)族元素的至少一种。X代表元素钇(Y)和/或至少一种稀土族的元素。
层7可以部分，亦即限于某些区域，有一种较低的或较高的孔隙率。因此，层7无论如何都有细孔10。细孔10以壁37为界(图2)和/或以在层7内透气连通路20(图2)的进/出口为界。在此多孔的层7的内部在壁37上涂覆至少一层涂层40(图2)，它成为壁的内衬。
所述多孔层7例如设计为泡沫状或海绵状并有至少部分敞口的，亦即设计为透气的多孔结构。这种泡沫或海绵状结构可例如通过在基层4上安置泥釉(Schlicker)制成。通过热处理，例如通过气化作用形成气泡，从而制成一种泡沫状结构，与此同时它与基层4结合。
基层4有至少一个冷却通道16，冷却剂如箭头所示可以通过它流动。其中多孔层7设计为透气的，所以冷却剂可以从冷却通道16流入层7，然后通过细孔10和冷却通道19流动。
所述层7在表面43上例如有一些冷却剂可以在这里从层7排出的地点。在这里尤其还可以设计至少一个冷却通道19，尤其是一个冷却穿孔19，亦即不是细孔。冷却通道19可以事后加工在里面。尤其是冷却通道19通过细孔10之间的透气连通路20构成(图2)。
通过冷却剂从层7表面43上的许多孔口，亦即细孔10或冷却通道19排出，造成一种隙透式冷却。
冷却通道16、19例如彼此设置为，使冷却剂尽可能垂直于基层4或层7的表面流过层状结构1。
层7并不一定必须有气膜冷却。也可以存在冷却剂(气体、蒸汽)的一个闭合回路，使得没有冷却剂从层7排出，而是在层7内部例如沿外部热燃气的流动方向25流动。因此，层7例如在表面43的区域内是不透气的，但在此区域下面仍是透气的(未表示)。
尤其是还可以在层7内存在中间壁22(虚线所示)，它防止在沿流动方向25如在燃气轮机100中那样存在压差时，冷却剂在层7的内部沿流动方向25流动。中间壁22可以在层7内形成一个个腔室，如由WO 03/006883已知的那样，它应是本申请公开内容的组成部分。
中间壁22可以通过单独的例如不是多孔的隔壁构成，或通过层7不透气但多孔的区域构成，或通过在这些区域内充填或焊接多孔的中间层7制成密封的中间壁22。因此，中间壁22例如是这样一个区域，它不透气并因此有闭合的细孔结构或没有细孔(不是多孔的)。
细孔10的尺寸例如朝外表面43的方向设计得较小，以防止弄脏层7。
通过设计冷却通道16、19的内径可以调整冷却剂的流量，使流量与冷却功率相配，冷却功率可以设计为与位置地点有关。流量也可以通过在中间层7内取决于地点的细孔尺寸来调整。
图2表示图1中涂覆在基层1上的层7的局部放大。层7是一个多孔的或泡沫状金属层，如已在图1中说明的那样。细孔10以壁37为界，和/或以细孔10之间透气连通路20的进/出口为界。在各细孔10之间的透气连通路20和细孔10意味着是冷却通道19。它们通常不是直线延伸(在图1中示意地表示为直线)。细孔结构设计为，可以从基层4内的冷却通道16的出口到层7的外表面43实现气体流通。
也可以造成闭合的细孔10g，它们从一开始就是闭合的，或通过涂层40成为闭合的。
至少在层7多孔结构的细孔10内壁37上至少涂覆一层涂层40。在连通路20和冷却通道16内也可以涂覆至少一层涂层40。多孔层7的壁37上的涂层40，可沿层7的整个厚度一直延伸到基层4，或可以只处于层7的一个表面区域13内。
下面是在层7或层状结构1内的分层顺序的一些具体实施例。
基层4：超级高温合金
层7：MCrAlX
涂层40：陶瓷
基层4：超级高温合金
中间层：铂
层7：MCrAlX
涂层40：陶瓷
基层4：超级高温合金
层7：超级高温合金
第一涂层40：MCrAlX
第二涂层40：陶瓷(涂覆在第一涂层上)
基层4：超级高温合金
层7：MCrAlX
第一涂层40：MCrAlX，与层7的不同
第二涂层40：陶瓷(涂覆在第一涂层上)
其他的基层、中间层、涂层的材料组合和分层顺序也是可能的。重要的是在多孔层7内部的一涂层40。
涂层40例如是一个陶瓷层，它例如可以起隔热层的作用。它例如是氧化铝或钇稳定的锆氧化物。尤其可以采用在金属的中间层7上不需要连接层的陶瓷涂层40。外部的涂层40可以通过浸入法、涂敷泥釉(Schlickerauftrag)、等离子喷镀或其他方法涂覆。
多孔的层7可以预制并例如通过钎焊、粘结、熔焊或其他固定措施尤其直接涂覆在基层4上。多孔的层7也可以与基层4共同制成，尤其共同浇铸。
在制造涂层40时可例如采取如下过程。
多孔层7喷洒陶瓷泥釉或浸没在相应的液体中(浸入法)，所以在多孔的层7的壁37上沉积一个绿层(Grünschicht)。它还可以变密。变密可以通过烧结或激光辐射法进行。
分层系统1可以使用在新制的构件上，或也可以应用在重新加工的构件上。
对于重新加工的构件，构件，尤其涡轮叶片120、130(图3)和燃烧室零件(图4、5)，在使用后重新加工(Refurbishment-修复)，为此去除外层以及其他腐蚀或氧化层。在这时同样检查构件的裂纹，必要时对它们进行修理。然后，构件可以重新涂覆防护层7、40，以构成分层系统1。
图3表示燃气轮机100局部纵剖面。燃气轮机100在内部有一个可绕旋转轴线102旋转地支承的转子103，它也称为涡轮转子。沿转子103彼此相继地是进气机匣104、压气机105、有多个同轴排列的燃烧器107的例如花托状燃烧室110尤其环形燃烧室106、涡轮108和排气机匣109。环形燃烧室106与例如环形的热燃气通道111连通。在热燃气通道111中例如四个前后串联的涡轮级112构成涡轮108。每个涡轮级112由两个叶片环构成。沿工质113的流动方向看在热燃气通道111内依次是一个导向叶片排115、一个由工作叶片120组成的叶排125。
导向叶片130固定在定子143的内机匣138上，叶排125的工作叶片120则例如借助涡轮盘133装在转子103上。在转子103上连接一台发电机或工作机械(未表示)。
燃气轮机100运行时由压气机105通过进气机匣104吸入空气135并进行压缩。压气机105在涡轮一侧的末端制备好的压缩空气供给燃烧器107并在那里与燃料混合。混合物在燃烧室110内燃烧形成工质113。工质113从那里起沿热燃气通道111流过导向叶片130和工作叶片120。工质113在工作叶片120上传输动量地膨胀，所以工作叶片120推动转子103以及转子103带动与之连接的工作机械。
在燃气轮机100运行期间遭遇热工质113的构件承受热负荷。沿工质113流向看的第一个涡轮级112的导向叶片130和工作叶片120，除环形燃烧室106内衬的热屏块外热负荷最大。为了能耐受在那里存在的温度，它们借助冷却剂冷却并例如有按图1、2的层7。热负荷很大的构件可以由一些基层构成，它们有一种定向结构，亦即是单晶体(SX结构)或只有纵向方向的晶粒(DS结构)。作为材料尤其采用铁、镍或钴基的超级高温合金。同样，叶片120、130可以有一些防腐蚀的涂层(MCrAlX：M是铁(Fe)、钴(Co)、镍(Ni)族元素中的至少一种，X代表钇(Y)和/或至少一种稀土元素)和通过隔热层隔热。隔热层例如由ZrO2、Y2O4-ZrO2组成，也就是说，它不、部分或完全通过氧化钇和/或氧化钙和/或氧化镁稳定化。采用恰当的涂层方法，例如电子束蒸发(EB-PVD)，在隔热层内生成杆状晶粒。
图4表示燃气轮机100的燃烧室110。燃烧室110例如设计为所谓环形燃烧室，其中多个沿周向围绕涡轮轴103排列的燃烧器102通入一个公共的燃烧室腔内。为此，燃烧室110在其总体上设计成环形结构，它围绕着涡轮轴103定位。
为了达到比较高的效率，燃烧室110针对比较高的工质M的温度约1000℃至1600℃来设计。为了即使在这些对材料不利的运行参数下仍能具有比较长的工作寿命，燃烧室壁153在其面朝工质M那一侧设一个由热屏元件155构成的内衬。每个热屏元件155在工质一侧配备有特别耐热的保护层或用耐高温的材料制成。此外，由于燃烧室110内部高的温度，为热屏元件155或为它们的固定元件设冷却系统。这些热屏元件155可以有按图1、2的层状结构1。
燃烧室壁及其涂层的材料按本发明可以类似于涡轮叶片120、130。
图5表示热屏装置160，其中在支承结构163上覆盖表面地并列布置热屏元件155。通常例如作为一个较大的热燃气腔，例如一个燃烧室110的内衬，在支承结构163上彼此邻接地排列许多行热屏元件155。热屏装置160可例如作为燃烧室110的和/或燃气轮机100的燃烧室110与涡轮叶片112之间过渡区的内衬，防止燃气轮机100运行期间损坏支承结构163。
为了减小热负荷，例如规定热屏元件155总是在其背对燃烧室110的那一面借助冷却空气冷却。
至少两个相邻的热屏元件155a、155b在支承结构163与热屏元件155a、155b背对热燃气113的那一面之间形成一个冷却空气通道166。以此方式使所述的两个相邻热屏元件155a、155b例如通过冷却空气流L连通，冷却空气流L直接从相邻的一个到另一个流入由相邻者构成的总的冷却空气通道166内。
图5中作为举例表示了四个热屏元件155，它们构成一个共同的冷却空气通道166。然而还可以考虑数量更多的热屏元件，它们也可以排成许多行。
通过孔169、16(图1)供入冷却空气通道166内的冷却空气L，例如借助冲击式冷却方式冷却热屏元件155背面，在这里，冷却空气L实际上垂直于热屏元件155背对热燃气的面与之相撞，并由此可吸收并带走热能。此外，热屏元件155的冷却也可以通过对流冷却实现，在这种情况下冷却空气L基本上平行于热屏元件155的表面沿其后侧掠过，并由此同样可以吸收并带走热能。在图5中冷却空气L作为冷却气流绝大部分从右向左在由热屏元件155共同构成的冷却空气通道166内运动，以及可以供给例如处于燃烧室110内的燃烧器107，以便利用于燃烧。
热屏元件155有例如按图1的按本发明的层状结构1。采用层状结构1也可以免去冷却通道166，为此将具有层状结构1的热屏元件155例如直接涂覆在支承结构163、4上。

Claims (27)

1.一种层状结构(1)，至少包括一个基层(4)和一个在该基层(4)上的至少部分多孔的、至少部分透气的层(7)，其中，该基层(4)中有冷却通道(16)，冷却剂可以经冷却通道(16)穿过基层(4)进入多孔层(7)内，其特征为：所述多孔层(7)中有一些细孔(10)，它们以壁(37)为界，其中，在所述壁(37)上至少部分存在至少一层涂层(40)。
2.按照权利要求1所述的层状结构，其特征为：所述层(7)是金属或陶瓷的。
3.按照权利要求1所述的层状结构，其特征为：所述基层(4)是金属或陶瓷的。
4.按照权利要求1或2所述的层状结构，其特征为：所述层(7)设计为泡沫或海绵状。
5.按照权利要求1所述的层状结构，其特征为：所述涂层(40)是一个陶瓷层。
6.按照权利要求5所述的层状结构，其特征为：所述涂层(40)是一个隔热层。
7.按照权利要求1、2或3所述的层状结构(1)，其特征为：所述基层(4)和层(7)的材料不同。
8.按照权利要求1所述的层状结构(1)，其特征为：所述层(7)中有冷却通道(19)。
9.按照权利要求8所述的层状结构(1)，其特征为：所述冷却通道(19)通过层(7)的细孔(10)之间的透气连通路(20)和细孔(10)构成。
10.按照权利要求1、8或9所述的层状结构(1)，其特征为：所述冷却通道(16、19)有用于确定冷却剂通过它们的流量的不同的内部横截面。
11.按照权利要求1所述的层状结构(1)，其特征为：所述层(7)的细孔尺寸随位置地点不同。
12.按照权利要求11所述的层状结构(1)，其特征为：靠近层(7)外表面(43)的细孔尺寸比靠近基层(4)的小。
13.按照权利要求1或2所述的层状结构(1)，其特征为：所述层(7)有化合物MCrAlX，其中，M是铁、钴或镍族元素中的至少一种，以及X代表元素钇和/或至少一种稀土元素。
14.按照权利要求1或3所述的层状结构(1)，其特征为：所述基层(4)是一种镍基或钴基超级高温合金。
15.按照权利要求1、2或3所述的层状结构(1)，其特征为：所述基层(4)和层(7)的材料相同。
16.按照权利要求1或5所述的层状结构(1)，其特征为：仅仅在所述层(7)的一个表面区域(13)内设有所述至少一层涂层(40)。
17.按照权利要求1所述的层状结构(1)，其特征为：所述层状结构(1)是燃气轮机(100)涡轮构件上的至少一部分。
18.按照权利要求17所述的层状结构(1)，其特征为：所述层状结构(1)是涡轮叶片(120、130)或燃气轮机(100)的燃烧室的内衬(155)。
19.按照权利要求1所述的层状结构(1)，其特征为：所述层状结构(1)可通过隙透冷却方式冷却，其中，冷却剂可以从多孔层(7)的表面(43)中排出。
20.一种制造按照权利要求1至19中一项或多项所述层状结构(1)的方法，按此方法，将一个至少部分多孔的且至少部分透气的层(7)涂覆在基层(4)上，其中，多孔层(7)中有以壁(37)为界的多个细孔(10)，然后在至少部分壁(37)上涂覆至少一层涂层(40)。
21.按照权利要求20所述的方法，其特征为：先单独制造出所述多孔层(7)，然后将其与基层(4)结合。
22.按照权利要求20或21所述的方法，其特征为：所述多孔层(7)与基层(4)钎焊、熔焊、粘结或通过固定装置固定在基层(4)上。
23.按照权利要求20所述的方法，其特征为：所述多孔层(7)与基层(4)被一起制造出。
24.按照权利要求20或23所述的方法，其特征为：所述多孔层(7)与基层(4)被一起浇铸出。
25.按照权利要求20所述的方法，其特征为：所述涂层(40)通过浸入法、涂镀或等离子喷镀涂覆。
26.按照权利要求20所述的方法，其特征为：所述层状结构(1)涂覆在一个新制的构件上。
27.按照权利要求20所述的方法，其特征为：所述层状结构(1)涂覆在一个重新加工后的构件上。
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EP1641959A1 (de) 2006-04-05
ES2287758T3 (es) 2007-12-16
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PL1641959T3 (pl) 2007-10-31
US20060153685A1 (en) 2006-07-13
US7402335B2 (en) 2008-07-22
WO2005005688A1 (de) 2005-01-20
EP1496140A1 (de) 2005-01-12
EP1641959B1 (de) 2007-06-13

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