CN101024738A - 耐用的反应性隔热涂层 - Google Patents

耐用的反应性隔热涂层 Download PDF

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CN101024738A
CN101024738A CNA2007100073036A CN200710007303A CN101024738A CN 101024738 A CN101024738 A CN 101024738A CN A2007100073036 A CNA2007100073036 A CN A2007100073036A CN 200710007303 A CN200710007303 A CN 200710007303A CN 101024738 A CN101024738 A CN 101024738A
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oxide compound
turbine engine
substrate
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gadolinium
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D·A·利顿
K·W·施利希廷
M·弗雷林
J·G·斯梅吉尔
D·B·斯诺
M·J·马洛尼
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Raytheon Technologies Corp
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Abstract

本发明提供了一种涡轮发动机部件，其具有衬底和涂敷在衬底上的隔热涂层。这种隔热涂层包括选自锆酸盐、铪酸盐、钛酸盐和其混合物的第一材料层，所述第一材料已经与至少一种氧化物混合，并包含大约25至99重量％的至少一种氧化物。所述至少一种氧化物包括至少一种选自镧、铈、镨、钕、钷、钐、铕、钆、铽、镝、钬、铒、铥、镱、镥、钪、铟和钇的材料的氧化物。如果需要，在衬底和隔热涂层系统之间可存在金属结合涂层。本发明描述了一种用于形成本发明的隔热涂层系统的方法。

Description

耐用的反应性隔热涂层
技术领域
本发明涉及一种隔热涂层材料，其在维护期间与涡轮发动机中的隔热涂层上的沉积物起反应，从而在隔热涂层和沉积物之间的界面处或附近形成几乎不能渗透的阻挡层相，本发明还涉及一种用于形成这种隔热涂层的方法，以及具有这种隔热涂层的涡轮发动机部件。
背景技术
由与沙子相关的隔热涂层的损伤而引起的涡轮翼型的老化对于所有在沙漠环境中使用的涡轮发动机而言都是一项极其重要的考虑因素。这类损伤可能造成发动机不运转而需要进行大量的修理工作。
与沙子相关的损伤是由于流体沙子沉积物穿透到隔热涂层中而造成的，其会导致金属剥落并加速任何裸露金属的氧化。
发明内容
根据本发明，提供了一种隔热涂层系统，其降低了涡轮发动机部件的与沙子相关的损伤。这种隔热涂层系统大致地包括选自锆酸盐、铪酸盐、钛酸盐和其混合物的材料，这种材料已经过混合处理，使得这种材料包含大约25-99重量％的至少一种氧化物。
另外，根据本发明，提供了一种涡轮发动机部件，其大致地包括衬底和隔热涂层，所述隔热涂层包括选自锆酸盐、铪酸盐、钛酸盐和其混合物的材料，所述材料已经掺杂了大约20-100重量％的至少一种氧化物。
另外，根据本发明，提供了一种用于形成涂层系统的方法，这种涂层系统减轻了与沙子相关的损伤。该方法大致地包括，提供衬底的步骤，以及将选自锆酸盐、铪酸盐、钛酸盐和其混合物的材料沉积到衬底上的步骤，所述材料已经掺杂了大约20-100重量％的至少一种氧化物。
在以下详述描述和附图中，将阐述本发明的耐用反应性隔热涂层的其它细节，以及附带的其它目的和优点，其中相似的标号表示相似的元件。
附图说明
图1是带有本发明涂层的涡轮发动机部件的示意图；
图2是带有根据本发明一个备选涂层系统的涡轮发动机部件的示意图。
具体实施方式
已经发现，某些涂层会与流体沙子沉积物起反应，并且反应产物形成了抑制流体沙子穿透到涂层中的阻挡层。反应产物已经被确定为主要包含氧化钇、氧化钙、氧化锆和二氧化硅的氧化磷灰石硅酸盐(silicate oxyapatite)/石榴石。本发明涉及一种用于部件，例如涡轮发动机部件的涂层系统，其利用了这一发现。
根据本发明，现在参看图1，本发明的涂层系统18包括至少一层选自锆酸盐、铪酸盐、钛酸盐和其混合物的材料，该材料已经掺杂了大约25-100重量％的至少一种氧化物。为了形成涂层系统18，将至少一层选自锆酸盐、铪酸盐、钛酸盐和其混合物的材料层10，涂覆到衬底14的表面12上，衬底14例如为涡轮发动机部件，包括但不限于叶片或轮叶。可用于形成各层10的材料包括、但不局限于锆酸钆、锆酸镧、钛酸钕和铪酸钆。各层10中的材料与至少一种金属氧化物混合，并且优选包含大约25至99重量％，优选大约40-70重量％的至少一种金属氧化物，所述金属选自镧、铈、镨、钕、钷、钐、铕、钆、铽、镝、钬、铒、铥、镱、镥、钪、铟和钇。例如，所述至少一种氧化物可以是其中一种前述稀土元素的倍半氧化物。
衬底14可由任何合适的材料形成，例如镍基超合金、钴基合金、钼基合金或钛合金。
可通过例如电子束物理气相沉积(EB-PVD)或空气等离子体喷涂技术来涂覆各层10。其它可用于沉积各层10的方法包括、但不局限于溶胶凝胶技术、浆液(slurry)技术、溅射技术、化学气相沉积技术、HVOF和可紫外线硫化的树脂技术。
用于执行沉积各层10的优选工艺是EB-PVD。当执行这个工艺时，可将衬底14放置在涂覆室中，并加热到1700至2000华氏度范围内的温度。涂覆室可保持在0.05至2.0毫托范围内的压力下。原料进给速度可为0.3至2.0英寸/小时。涂覆时间可在20至120分钟的范围内。
每个沉积的涂层10可具有1.0至50密耳，优选为1.0至15密耳的厚度。
根据本发明的隔热涂层材料大层10将与熔融沙子沉积物起反应，并形成氧化磷灰石硅酸盐和/或石榴石的阻挡层相，以阻挡进一步的穿透。
本发明的涂层系统是一种有利的隔热涂层系统，其阻碍了熔融硅酸盐材料的穿透。这种涂层系统提供了在出现沙子引起的涡轮翼型损伤的环境下的增强的耐用性。
现在参看图2，如果需要，可将金属结合涂层30沉积在衬底14上，以便将衬底14粘合在层10上。金属结合涂层30可以是MCrAlY结合涂层，其中M是镍、钴和铁中的至少一种金属。作为备选，金属结合涂层30可以是铝化物或铝化铂的结合涂层。结合涂层30可具有大约0.5至20密耳，优选为大约0.5至10密耳范围内的厚度。可通过低压等离子体喷涂、HVOF(高速氧气燃料)、阴极电弧工艺、扩散工艺、空气等离子体喷涂工艺或涂镀工艺，以及通过任何能够形成致密均匀金属结构的工艺，来沉积出结合涂层30。

Claims (22)

1.一种涡轮发动机部件，包括：
衬底；和
隔热涂层系统，其包括至少一层选自锆酸盐、铪酸盐、钛酸盐及其混合物的材料，所述材料已经与至少一种氧化物混合，使得每一所述层包含大约25至99重量％的所述至少一种氧化物。
2.根据权利要求1所述的涡轮发动机部件，其特征在于，每一所述层包含大约40至70重量％的所述至少一种氧化物。
3.根据权利要求1所述的涡轮发动机部件，其特征在于，所述材料选自锆酸钆、锆酸镧、钛酸钕和铪酸钆。
4.根据权利要求1所述的涡轮发动机部件，其特征在于，所述至少一种氧化物包括至少一种选自镧、铈、镨、钕、钷、钐、铕、钆、铽、镝、钬、铒、铥、镱、镥、钪、铟和钇的材料的氧化物。
5.根据权利要求1所述的涡轮发动机部件，其特征在于，每一所述层具有1.0至50密耳范围内的厚度。
6.根据权利要求1所述的涡轮发动机部件，其特征在于，每一所述层具有1.0至15密耳范围内的厚度。
7.根据权利要求1所述的涡轮发动机部件，其特征在于，所述衬底由选自镍基合金、钴基合金和钼基合金的材料形成，并且，所述涡轮发动机部件还包括位于所述衬底和所述隔热涂层之间的金属结合涂层。
8.根据权利要求7所述的涡轮发动机部件，其特征在于，所述结合涂层具有大约0.5至20密耳范围内的厚度。
9.根据权利要求7所述的涡轮发动机部件，其特征在于，所述结合涂层具有大约0.5至10密耳范围内的厚度。
10.一种用于为部件提供保护以免受到与沙子相关的损伤的方法，所述方法包括如下步骤：
提供衬底；
通过沉积出至少一层选自锆酸盐、铪酸盐、钛酸盐和其混合物的第一材料来形成隔热涂层系统，所述第一材料已经与至少一种氧化物混合，使得每一所述层包含大约25至99重量％的所述至少一种氧化物。
11.根据权利要求10所述的方法，其特征在于，所述沉积步骤包括沉积出所述第一材料的至少一层，所述第一材料已经掺杂了大约40重量％至70重量％的所述至少一种氧化物。
12.根据权利要求10所述的方法，其特征在于，所述沉积步骤包括，沉积选自锆酸钆、锆酸镧、钛酸钕和铪酸钆的材料。
13.根据权利要求10所述的方法，其特征在于，所述沉积步骤还包括，从至少一种材料的氧化物中选择所述至少一种氧化物，并将所述第一材料与所述至少一种所选择的氧化物混合起来，所述这种材料选自镧、铈、镨、钕、钷、钐、铕、钆、铽、镝、钬、铒、铥、镱、镥、钪、铟和钇。
14.根据权利要求10所述的方法，其特征在于，所述沉积步骤包括，将每一所述层沉积出大约1.0至50密耳范围内的厚度。
15.根据权利要求10所述的方法，其特征在于，所述沉积步骤包括，将每一所述层沉积出大约1.0至15密耳范围内的厚度。
16.根据权利要求10所述的方法，其特征在于，所述提供衬底的步骤包括，提供由选自镍基合金、钴基合金和钼基合金的材料所形成的衬底。
17.根据权利要求10所述的方法，其特征在于，还包括：
将所述衬底放置到涂覆室中；
在所述涂覆室中将所述衬底加热到1700至2000华氏度范围内的温度；
将所述涂覆室中的压力保持在0.05至2.0毫托范围内的压力下；和
执行所述沉积步骤。
18.根据权利要求10所述的方法，其特征在于，还包括在所述衬底和所述隔热涂层系统之间沉积金属结合涂层。
19.一种用于部件的涂层系统，包括至少一层选自锆酸盐、铪酸盐、钛酸盐和其混合物的第一材料，所述第一材料已经与至少一种氧化物混合，使得每一所述层包含大约25至99重量％的所述至少一种氧化物。
20.根据权利要求19所述的涂层系统，其特征在于，每一所述层包含大约40重量％至70重量％的所述至少一种氧化物。
21.根据权利要求19所述的涂层系统，其特征在于，所述材料选自锆酸钆、锆酸镧、钛酸钕和铪酸钆。
22.根据权利要求19所述的涂层，其特征在于，所述至少一种氧化物包括至少一种选自镧、铈、镨、钕、钷、钐、铕、钆、铽、镝、钬、铒、铥、镱、镥、钪、铟和钇的材料的氧化物。
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