CN101004142A - Cmas抗性热障涂层 - Google Patents

Cmas抗性热障涂层 Download PDF

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CN101004142A
CN101004142A CNA2007100040282A CN200710004028A CN101004142A CN 101004142 A CN101004142 A CN 101004142A CN A2007100040282 A CNA2007100040282 A CN A2007100040282A CN 200710004028 A CN200710004028 A CN 200710004028A CN 101004142 A CN101004142 A CN 101004142A
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layer
oxide
yttria
thermal barrier
zirconium oxide
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M·弗雷林
K·W·施利奇廷
M·J·马洛尼
D·A·利顿
J·G·斯梅吉尔
D·B·斯诺
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Raytheon Technologies Corp
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United Technologies Corp
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Abstract

提供一种涡轮发动机构件，其具有衬底和施加在该衬底上的热障涂层。该热障涂层包括氧化钇稳定氧化锆和熔融硅酸盐抗性材料的交替层。熔融硅酸盐抗性外层由至少一种材料的氧化物组成，该材料选自由镧、铈、镨、钕、钷、钐、铕、钆、铽、镝、钬、铒、铥、镱、镥、钪、铟、锆、铪和钛组成的组中，或者可以由氧化钆稳定氧化锆组成。如果需要，可以在衬底和热障涂层系统之间提供金属粘合层。还描述了一种用于形成本发明的热障涂层系统的方法。

Description

CMAS抗性热障涂层
技术领域
本发明涉及一种热障涂层，其具有可施加于涡轮发动机构件上的氧化钇稳定氧化锆和熔融硅酸盐抗性层的交替层，还涉及一种形成该涂层的方法以及一种具有该涂层的涡轮发动机构件。
背景技术
对所有在沙漠环境中使用的涡轮发动机来说，由于热障涂层的与砂粒相关的损坏而使涡轮叶片老化是一个非常重要的问题。这种类型的损坏需要取出运行的发动机而进行大修。
与砂粒相关的损坏是由于流沙沉积物穿透热障涂层而引起的，这将导致任何暴露的金属剥落并加快氧化。
发明内容
根据本发明，提供一种减小作用在涡轮发动机构件上的与砂粒相关的损坏的涂层系统。该涂层系统广义地包括氧化钇稳定氧化锆和熔融硅酸盐抗性(resistant)材料的交替层。
进一步地根据本发明，提供一种涡轮发动机构件，其广义地包括衬底以及氧化钇稳定氧化锆和熔融硅酸盐抗性材料的交替层。每层熔融硅酸盐抗性材料可由一种材料的氧化物组成，该材料选自由镧、铈、镨、钕、钷、钐、铕、钆、铽、镝、钬、铒、铥、镱、镥、钪、铟、锆、铪和钛组成的组中，或者可替换地由氧化钆稳定氧化锆组成。
仍然进一步地根据本发明，提供一种用于形成减小与砂粒相关的损坏的涂层系统的方法。该方法广义地包括以下步骤：提供衬底，将氧化钇稳定氧化锆材料和熔融硅酸盐抗性材料的交替层沉积到该衬底上。
在随后详细的说明书和附图中阐明了本发明的CMAS抗性热障涂层的其它细节以及其所附有的其它目的和优点，在附图中相同的参考数字表示相同的元件。
附图说明
图1是具有本发明的涂层的涡轮发动机构件的示意性表示；以及
图2是具有根据本发明的可替换涂层系统的涡轮发动机构件的示意性表示。
具体实施方式
已经发现某些涂层会与流沙沉积物反应，且会形成抑制流沙穿透到涂层中的反应产物。已经确定反应产物是主要包含氧化钆、氧化钙、氧化锆和硅石的硅酸氧化磷灰石/石榴石。本发明涉及一种用于构件如涡轮发动机构件的涂层系统，它利用了上述发现。
根据本发明，现在参考图1，本发明的涂层系统18包括氧化钇稳定氧化锆和熔融硅酸盐抗性材料的交替层。为了形成涂层系统18，将氧化钇稳定氧化锆的第一层10施加到衬底14的表面12上，例如施加到包括但不限于叶片或轮叶的涡轮发动机构件上。衬底14可以由任何合适的材料形成，如镍基超合金、钴基合金、钼基合金或钛基合金。氧化钇稳定氧化锆层10例如可以通过电子束物理气相沉积(EB-PVD)或大气电浆喷涂来施加。可以用来沉积氧化钇稳定氧化锆层10的其它方法包括但不限于溶胶凝胶技术、泥浆技术、喷溅技术、化学气相沉积技术和UV固化树脂技术。氧化钇稳定氧化锆层将改进系统的抗腐蚀性。
用于执行沉积氧化钇稳定氧化锆层10的优选处理是EB-PVD。当执行该处理时，将衬底14置于涂层室并加热到其范围在华氏1700至2000的温度。涂层室的压力可以保持在0.1至1.0微米汞柱的范围。供料速率为0.2至1.5英寸/小时。涂层时间的范围是20至120分钟。
沉积的氧化钇稳定氧化锆层10的厚度为0.5至50密耳，优选为1.0至5.0密耳。沉积的层10具有的氧化钇的含量范围为4.0至25重量％，优选为6.0至9.0重量％。沉积的层10由含量为4.0至25重量％的氧化钇和平衡氧化锆组成。在一个更加优选的实施例中，沉积的层10由含量为6.0至9重量％的氧化钇和平衡氧化锆组成。
在沉积氧化钇稳定氧化锆层10之后，在层10上形成由熔融硅酸盐抗性材料组成的层20。该层20可以由至少一种材料的氧化物组成，所述材料选自由镧、铈、镨、钕、钷、钐、铕、钆、铽、镝、钬、铒、铥、镱、镥、钪、铟、锆、铪和钛组成的组中。可替换地，层20可由氧化钆稳定氧化锆组成。可以使用在上文中提到的任何一种沉积技术来沉积形成层20的材料。当层20由氧化钆稳定氧化锆组成时，层20可以包含25至99.9重量％的氧化钆，且其厚度范围为0.5至50密耳。在一个优选的实施例中，氧化钆含量为40至70重量％和/或层20的厚度范围为1.0至5.0密耳。如果需要，层20由包括25至99.9重量％的氧化钆和平衡氧化锆的材料组成。进一步地，如果需要，层20由包括40至70重量％的氧化钆和平衡氧化锆的材料组成。
在将层20沉积到层10上之后，在层20上施加氧化钇稳定氧化锆的第二层22。该氧化钇稳定氧化锆层22可以具有上面论述的任何一种组分，并可以使用这里描述的任何一种技术进行沉积。之后，在该氧化钇稳定氧化锆上沉积熔融硅酸盐抗性材料的第二层24。氧化钇稳定氧化锆和熔融硅酸盐抗性材料层的数量依不同的应用而改变。层的数量是涂层和应用的目标厚度的函数。
本发明的多层涂层系统在氧化钇稳定氧化锆层和熔融硅酸盐抗性材料层之间没有明确的界面。相反，这些层混合在一起从而形成从富含氧化钇稳定氧化锆到富含氧化钆稳定的梯度。
尽管已经在每一层上提供了一定的厚度，但是应该认识到在整个涂层中每种材料层不必具有相同的厚度。
本发明的熔融硅酸盐抗性材料层将与熔融的砂粒沉积物反应并形成氧化磷灰石和/或石榴石的屏障相(barrier phase)，从而抵抗进一步的穿透。氧化钆稳定氧化锆层20具有足够的厚度以形成期望的屏障相。
本发明的涂层系统是一种有利的热障涂层系统，它可抵抗熔融硅酸盐材料的穿透。该涂层系统可在其中涡轮叶片因砂粒诱导而产生损坏的环境中提供增强的耐用性。
现在参考图2，如果需要，可以将金属粘合层30沉积到衬底14上，以将衬底14粘合到氧化钇稳定氧化锆材料的第一层10上。金属粘合层30可以是MCrAlY粘合层，其中M是镍、钴和铁中的至少一种。可替换地，金属粘合层30可以是含铝粘合层或铂铝粘合层。粘合层30的厚度范围为大约0.5至20密耳，优选地为大约0.5至10密耳。可以使用低压等离子喷涂、HVOF(高速氧燃料)、阴极电弧处理、扩散处理、大气等离子喷涂处理、或者电镀处理以及能够形成密集均匀的金属结构的任何处理来沉积粘合层30。

Claims (37)

1.一种涡轮发动机构件，包括：
衬底；和
热障涂层系统，其包括施加在所述衬底上的氧化钇稳定氧化锆材料和熔融硅酸盐抗性材料的交替层。
2.根据权利要求1的涡轮发动机构件，其中所述熔融硅酸盐抗性材料包括至少一种材料的氧化物，所述材料选自由镧、铈、镨、钕、钷、钐、铕、钆、铽、镝、钬、铒、铥、镱、镥、钪、铟、锆、铪和钛组成的组中。
3.根据权利要求1的涡轮发动机构件，其中熔融硅酸盐抗性材料包括氧化钆稳定氧化锆。
4.根据权利要求3的涡轮发动机构件，其中所述氧化钆稳定氧化锆由25至99.9重量％的氧化钆和平衡氧化锆组成。
5.根据权利要求1的涡轮发动机构件，其中每一所述熔融硅酸盐抗性材料层的厚度范围为0.5至50密耳。
6.根据权利要求1的涡轮发动机构件，其中至少一层所述氧化钇稳定氧化锆由4.0至25重量％的氧化钇和平衡氧化锆组成。
7.根据权利要求1的涡轮发动机构件，其中至少一层所述氧化钇稳定氧化锆由6.0至9.0重量％的氧化钇和平衡氧化锆组成。
8.根据权利要求1的涡轮发动机构件，其中每一所述氧化钇稳定氧化锆层的厚度范围为1.0至50密耳。
9.根据权利要求1的涡轮发动机构件，其中所述衬底由一种材料组成，该材料选自由镍基合金、钴基合金和钼基合金组成的组中。
10.根据权利要求1的涡轮发动机构件，还包括在所述衬底和所述热障涂层之间的金属粘合层。
11.一种热障涂层系统，包括：
氧化钇稳定氧化锆的第一层；
沉积在所述氧化钇稳定氧化锆的第一层之上的熔融硅酸盐抗性材料的第一层；
沉积在所述熔融硅酸盐抗性材料的所述第一层之上的氧化钇稳定氧化锆的第二层；和
沉积在所述钇稳定材料的所述第二层之上的熔融硅酸盐抗性材料的第二层。
12.根据权利要求11的热障涂层系统，还包括至少一个氧化钇稳定氧化锆的附加层和至少一个所述熔融硅酸盐抗性材料的附加层。
13.根据权利要求11的热障涂层系统，其中所述熔融硅酸盐抗性材料由至少一种材料的氧化物组成，所述材料选自由镧、铈、镨、钕、钷、钐、铕、钆、铽、镝、钬、铒、铥、镱、镥、钪、铟、锆、铪和钛组成的组中。
14.根据权利要求11的热障涂层系统，其中熔融硅酸盐抗性材料由氧化钆稳定氧化锆组成。
15.根据权利要求14的热障涂层系统，其中所述氧化钆稳定氧化锆由25至99.9重量％的氧化钆和平衡氧化锆组成。
16.根据权利要求14的热障涂层系统，其中所述氧化钆稳定氧化锆由40至70重量％的氧化钆和平衡氧化锆组成。
17.根据权利要求11的热障涂层系统，其中每一所述熔融硅酸盐抗性材料层的厚度范围为0.5至50密耳。
18.根据权利要求11的热障涂层系统，其中至少一层所述氧化钇稳定氧化锆由4.0至25重量％的氧化钇和平衡氧化锆组成。
19.根据权利要求11的热障涂层系统，其中至少一层所述氧化钇稳定氧化锆由6.0至9.0重量％的氧化钇和平衡氧化锆组成。
20.根据权利要求11的热障涂层系统，其中每一所述氧化钇稳定氧化锆层的厚度范围为0.5至50密耳。
21.一种用于为构件提供保护以抵抗与砂粒相关的损坏的方法，其包括以下步骤：
提供衬底；
通过将氧化钇稳定氧化锆材料和熔融硅酸盐抗性材料的交替层沉积到该衬底上，形成热障涂层系统。
22.根据权利要求21的方法，其中所述沉积交替层的步骤包括沉积由至少一种材料的氧化物组成的熔融硅酸盐抗性材料层，所述材料选自由镧、铈、镨、钕、钷、钐、铕、钆、铽、镝、钬、铒、铥、镱、镥、钪、铟、锆、铪和钛组成的组中。
23.根据权利要求21的方法，其中所述沉积交替层的步骤包括沉积至少一层氧化钆稳定氧化锆。
24.根据权利要求23的方法，其中所述氧化钆稳定氧化锆的沉积步骤包括沉积由25至99.9重量％的氧化钆和平衡氧化锆组成的材料。
25.根据权利要求23的方法，其中所述氧化钆稳定氧化锆的沉积步骤包括沉积由40至70重量％的氧化钆和平衡氧化锆组成的材料。
26.根据权利要求21的方法，其中所述熔融硅酸盐抗性材料沉积步骤包括在每一相应氧化钇稳定氧化锆材料层上沉积厚度范围为0.5至50密耳的层。
27.根据权利要求21的方法，其中所述熔融硅酸盐抗性材料沉积步骤包括在每一相应氧化钇稳定氧化锆材料层上沉积厚度范围为1.0至5.0密耳的层。
28.根据权利要求21的方法，其中所述氧化钇稳定氧化锆层沉积步骤包括沉积由4.0至25重量％的氧化钇和平衡氧化锆组成的材料。
29.根据权利要求21的方法，其中所述氧化钇稳定氧化锆层沉积步骤包括沉积由6.0至9.0重量％的氧化钇和平衡氧化锆组成的材料。
30.根据权利要求21的方法，其中所述氧化钇稳定氧化锆层沉积步骤包括形成厚度范围为0.5至50密耳的每一所述层。
31.根据权利要求21的方法，其中所述氧化钇稳定氧化锆层沉积步骤包括形成厚度范围为1.0至5.0密耳的层。
32.根据权利要求21的方法，其中所述衬底提供步骤包括提供由一种材料组成的衬底，所述材料选自由镍基合金、钴基合金和钼基合金组成的组中。
33.根据权利要求21的方法，还包括：
将所述衬底放置到涂层室中；
将所述涂层室中的所述衬底加热到其范围在华氏1700至2000的温度；
使所述涂层室中的压力保持在0.1至1.0微米汞柱的压力范围；和
随后形成所述氧化钇稳定氧化锆层和所述熔融硅酸盐抗性材料层。
34.根据权利要求21的方法，还包括在所述衬底和所述热障涂层系统之间沉积金属粘合层。
35.一种用于构件的涂层系统，包括氧化钇稳定氧化锆材料和熔融硅酸盐抗性材料的交替层，且每一所述熔融硅酸盐抗性材料层具有氧化磷灰石和石榴石中至少一种的屏障相，从而抵抗熔融硅酸盐材料的穿透。
36.根据权利要求35的涂层系统，其中所述熔融硅酸盐抗性材料由至少一种材料的氧化物组成，所述材料选自由镧、铈、镨、钕、钷、钐、铕、钆、铽、镝、钬、铒、铥、镱、镥、钪、铟、锆、铪和钛组成的组中。
37.根据权利要求35的涂层系统，其中所述熔融的抗性材料由氧化钆稳定氧化锆组成。
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