CN101024880A - 涡轮机引擎部件上的隔热涂层的局部修补工艺 - Google Patents

涡轮机引擎部件上的隔热涂层的局部修补工艺 Download PDF

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CN101024880A
CN101024880A CNA2007100059931A CN200710005993A CN101024880A CN 101024880 A CN101024880 A CN 101024880A CN A2007100059931 A CNA2007100059931 A CN A2007100059931A CN 200710005993 A CN200710005993 A CN 200710005993A CN 101024880 A CN101024880 A CN 101024880A
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insulating coat
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K·B·波特
J·Z·王
M·拜利
D·布茨
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Abstract

对已经出现局部剥落的涡轮机部件(14)上的隔热涂层系统(10)进行局部修补的工艺包括用水对剥落区域(20)进行局部清洗以从所述剥落区域(20)上去除剥落碎片且在原有隔热涂层(10)中形成渐缩轮廓；并且将粉末混合物局部热喷涂(24)进入所述经过清洗的局部剥落区域(20)内以形成修补的隔热涂层(26)。在此还披露了轮叶涡轮机引擎部件(50)的平台的修补工艺。

Description

涡轮机引擎部件上的隔热涂层的局部修补工艺
技术领域
本发明的披露内容主要针对涡轮机引擎部件。更具体而言，本发明的披露内容针对已出现局部剥落的隔热涂层进行的局部修补过程。
背景技术
隔热涂层系统(TBC)通常用于保护并隔离暴露于高温环境中的燃气轮机引擎上的金属部件。作为一个实例，涡轮叶片和涡轮机引擎的其它部分通常由镍基超合金形成，原因在于它们需要在至少约1,000℃至1,150℃的操作温度下保持其完整性。与合金本身相比，隔热涂层系统在高温环境下提供了更高的耐腐蚀性和耐氧化性。隔热涂层系统通常包括结合涂层和外涂覆层，所述外涂覆层通常由陶瓷材料形成。
当这种保护性涂层受到磨损或发生破损时，其必须被仔细地修补，这是因为下面的基底直接暴露于过高温度中可能最终导致部件失效且对引擎的各个部件产生不利影响。在部件的服役期间通常需要对隔热涂层进行数次修补。对保护性涂层的“大修”通常涉及完全去除涂层，随后施加新的保护性隔热涂层系统。
在许多情况下，保护性涂层的某些部分(即“局部区域”)需要进行修补，而涂层的剩余部分保持完好。作为一个实例，已公知在热气路径(HGP)表面上以局部方式发生剥落。尽管通常在局部区域或补缀区域中发生剥落，但在常规修补方法中却完全去除隔热涂层，根据需要修复或修补结合层表面，且随后重新施加隔热涂层系统的陶瓷部分。用于去除隔热涂层的现有技术工艺包括喷砂或在高温和高压下通过碱性溶液进行化学去除。然而，喷砂是一种速度较慢的劳动集约型工艺且对涂层下面的表面产生了侵蚀。在重复使用的情况下，喷砂工艺最终会毁坏部件。利用碱性溶液去除隔热涂层也不够理想，原因在于该工艺需要使用在高温和高压下操作的高压釜。一旦隔热涂层被完全剥除，随后对表面进行重新涂覆。部件的重新涂覆过程可包括多个电镀步骤、多个堆焊步骤、浆料的使用和类似过程，随后通过机加工提供操作燃气轮机引擎中的部件通常需要的公差。
其它修补技术包括对受损表面进行局部修补。在这些修补工艺中，受损区域首先得到清洗且随后通过补缀或浆料方法进行修补。然而，由于所关心的是涡轮机部件所需的涂层完整性和高度可靠性需求，因此补缀或浆料方法可能不适用于进行局部修补。
此外，修补周期时间和成本相对较为长久和高昂。因此，常规的修补方法是劳动集约型且昂贵的，且可能难以在具有复杂几何形状的部件，如翼面、轮叶和护罩上实施。
考虑到前面所述的情况，在本技术领域中仍然需要改进对已出现局部剥落的隔热涂层进行的修补工艺。
发明内容
这里披露了对已经出现局部剥落的隔热涂层进行局部修补的工艺。在一个实施例中，一种对已经出现局部剥落的涡轮机部件上的隔热涂层系统进行局部修补的方法包括用水对局部剥落区域进行局部清洗以从所述局部剥落区域上去除剥落碎片，其中水被射到所述局部剥落区域上以在现有隔热涂层中形成渐缩轮廓；并且将粉末混合物局部热喷涂进入所述经过清洗的局部剥落区域内。
一种用于修补涡轮机轮叶的平台的工艺包括用水从所述平台区域上选择性地剥除隔热涂层系统并且使设置在所述轮叶的其它部分上的所述隔热涂层系统形成渐缩轮廓；并且将粉末混合物热喷涂到所述平台上并沉积新的隔热涂层系统，其中所述新的隔热涂层系统与所述渐缩轮廓形成一体以形成没有间隙的接缝。
结合下面对所披露内容及其中包括的实例的多个特征进行的详细描述可更易于理解所披露的内容。
附图说明
下面参见附图，其中相似的元件具有相似的附图标记：
图1是示出沉积到涡轮机部件上的典型隔热涂层系统的剖视图，图中所示出的隔热涂层系统包括局部剥落区域；
图2是示出在进行局部清洗且剥除局部剥落区域后的隔热涂层系统的剖视图，图中所述清洗工艺为现有隔热涂层提供了渐缩轮廓；
图3是示出了利用热喷涂工艺局部重新涂覆隔热涂层的剖视图；和
图4示出了轮叶涡轮机引擎部件的透视图。
具体实施方式
在此披露了一种对已经出现局部剥落的隔热涂层系统进行局部修补的工艺，所述工艺具有可编程的机加工工艺如水射流工艺以对剥落区域进行局部清洗和剥除，随后通过可编程的热喷涂工艺如空气等离子体喷涂(APS)或高速氧燃料喷涂工艺(HVOF)对表面进行重新涂覆。有利地，该工艺大大减少了修补周期时间和成本同时为涡轮机部件提供了涂层完整性和高度可靠性。被去除的区域被设计成渐缩进入原有隔热涂层内以防止在原有涂层与新施加的涂层之间形成薄弱接缝。此外，该工艺使部件的其它部分的热暴露最小化。例如，可在翼面顶部不暴露于该工艺的情况下利用该工艺修补轮叶平台。
现在参见图1，图中示出了通常由附图标记10表示的一种典型的隔热涂层系统，所述隔热涂层系统具有局部剥落区域20。所述系统通常包括沉积在涡轮机引擎部件14的表面上的结合涂层12以及设置在其上的陶瓷层16。涡轮机引擎部件的形式在燃烧室衬里、燃烧室穹顶、护罩、轮叶或叶片、喷嘴或导叶的范围内。该部件最典型地为翼面，所述翼面包括固定翼面如喷嘴或导叶，和包括叶片和轮叶的旋转翼面。叶片和轮叶这里可互换地使用；叶片通常是飞行器涡轮机引擎的旋转翼面，且轮叶是基于地面的发电涡轮机引擎的旋转翼面。对于叶片或轮叶的情况而言，典型地进行修补的区域是由于与周围护罩产生摩擦接触而产生磨损和在高温环境中受到氧化的顶部区域。对于喷嘴或导叶的情况而言，典型地进行修补的区域是前缘，所述前缘由于在高温下暴露于引擎的高速气体中而产生磨损。所述部件可由镍、钴或铁基超合金或类似材料形成。所述合金可以是铸造或锻造超合金。这些基底的实例是GTD-111、GTD-222、Ren80、Ren41、Ren125、Ren77、Ren N4、Ren N5、Ren N6、第四代单晶超合金MX-4、哈斯特合金X、钴基HS-188和MAR-M509。
有时也被称作外涂层的陶瓷层(外涂层)16被沉积在结合涂层12的表面上。结合涂层12通常以覆盖涂层如MCrAlX(其中M是铁、钴和/或镍，且X是钇或另一种稀土元素)或扩散铝化涂层的形式存在。结合涂层12保护下面的部件14不被氧化且使得陶瓷层16能够更有效地附着到部件14上。在沉积陶瓷外涂覆层且随后暴露于高温的过程中，如在引擎操作过程中，这些结合涂层形成了将外涂层附着到结合涂层上的氧化皮18，如紧密附着的氧化铝(Al2O3)层。
陶瓷层16的优选材料是氧化钇稳定的氧化锆(锆的氧化物)(YSZ)，所述材料的优选成分为重量百分比约4％至8％的氧化钇，但可使用其它陶瓷材料如氧化钇、未稳定的氧化锆、或由氧化镁(MgO)、氧化铈(CeO2)、氧化钪(Sc2O3)和/或其它氧化物稳定的氧化锆。陶瓷层16被沉积达到足以为部件14提供所需热保护的厚度，对于绝大多数涡轮机而言，所述厚度通常介于约50微米与1500微米之间。更优选地，陶瓷层是在下文被限定为致密垂直开裂(dense verticallycracked)隔热涂层的DVC-TBC，所述隔热涂层具有近似于电子束物理气相沉积(EB-PVD)涂层的准柱状的微观结构。
在运行的涡轮机中，部件14的表面受到热燃烧气体的作用，且因此受到氧化、腐蚀和侵蚀的侵袭。因此，必须通过隔热涂层系统10保持部件14处于免受该不利操作环境作用的状态。陶瓷层以及可能结合涂层12由于热疲劳带来的剥落而产生的损失可能导致部件14过早且通常迅速地产生劣化。陶瓷层16的局部剥落区域20如图1所示。
在修补工艺过程中，首先从涡轮机上取出部件14且包括局部剥落区域20的表面被清洗和剥除以便去除疏松的氧化物和污染物如油脂、油和烟垢。尽管可使用多种技术，但一个实施例包括从剥落区域20上去除疏松材料且利用水射流工艺用水清洗表面。对水射流工艺进行编程从而以剥落区域20为特定目标且如图2所示使限定出特定隔热涂层系统10的多个层形成渐缩轮廓。可选择性地实施该步骤以确保未对周围的未受损隔热涂层实施该过程。在进行清洗后，利用热喷涂工艺对剥落区域20进行局部重新涂覆。
热喷涂工艺组包括高速氧燃料沉积(HVOF)及其变型如高速空气燃料喷涂、等离子体喷涂、火焰喷涂和金属丝电弧喷涂。在绝大多数热涂覆工艺中，以粉末、金属丝或棒的形式存在的材料(例如金属)被加热至接近或某种程度上高于其熔点的温度以使得材料液滴在气体流中得到加速。液滴被导向要进行涂覆的基底表面，在所述表面处所述液滴进行附着且流动成为被称作层片(splat)的薄层状颗粒。
在高速氧燃料喷涂和相关涂覆工艺中，利用氧、空气或另一种氧源使燃料如氢、丙烷、丙烯、乙炔或煤油在燃烧室中燃烧且气体燃烧产物允许通过喷嘴产生膨胀。气体速度可以是超音速的。粉末状涂层材料被注入喷嘴内且被加热至接近或高于其熔点的温度并被加速至相对较高的速度如对于一些涂层系统而言达约600m/sec。可通过改变进入喷枪内的气体或液体的成分和流速而控制通过喷嘴的气体流且最终控制粉末颗粒的温度和速度。熔化的颗粒撞击在要进行涂覆的表面上且流动成为良好地结合在基底上且彼此结合的排列相当致密的层片。
在等离子体喷涂工艺中，当气体围绕钨阴极流动且通过相对较短的聚敛发散喷嘴时，通过电弧使所述气体部分离子化。等离子体芯部的温度可能超过30,000K且气体速度可以是超音速的。通常以粉末形式存在的涂层材料被注入气体等离子体内且被加热至接近或高于其熔点的温度且被加速至可达到约600m/sec的速度。向涂层材料传热的速度和涂层材料的最终温度是气体等离子体的流速和成分以及焰炬设计和粉末注射技术的函数。熔化的颗粒被射到要进行涂覆的表面上形成附着的层片。
在火焰喷涂工艺中，氧和燃料如乙炔在焰炬中燃烧。粉末、金属丝或棒被注入火焰内，且在所述火焰中被熔化和加速。颗粒速度可达约300m/sec。气体且最终涂层材料的最高温度是所使用的气体的流速和成分以及焰炬设计的函数。熔化的颗粒同样被射到要进行涂覆的表面上形成附着的层片。
热喷涂工艺通常包括将粉末状混合物(即颗粒)引导至燃烧室、喷射流和/或诸如此类(取决于特定喷涂工艺)，且对混合物进行充分加热以使得颗粒能够在部件上扁平化并附着到部件上。例如，可采用HVOF工艺，其中氧和燃料在部件上清洁的局部剥落区域20处进行燃烧并推动粉末状混合物。为了控制当混合物在部件处被推动时喷射物中氧化物和/或碳化物的产生过程，可控制喷涂条件。可控制喷涂以使得在部件处被推动的颗粒(如涂层材料)的温度处于足以使颗粒软化以使得它们附着到部件上且温度低于导致涂层材料产生氧化的温度，且具体温度取决于涂层材料和结构增强件的类型。例如，涂层温度可低于或等于约1,500℃，或更具体而言，低于或等于约1,200℃，或甚至更具体而言，约750℃至约1,100℃。
用于形成隔热涂层系统的涂层材料可包括镍(Ni)、钴(Co)、铁(Fe)、铬(Cr)、铝(Al)、钇(Y)、包括至少一种前述元素的合金以及包括至少一种前述物质的组合物，例如涂层可包括MCrAlY(其中M包括镍、钴、铁和包括至少一种前述元素的组合物)。MCrAlY涂层可进一步包括元素如硅(Si)、钌(Ru)、铱(Ir)、锇(Os)、金(Au)、银(Ag)、钽(Ta)、钯(Pd)、铼(Re)、铪(Hf)、铂(Pt)、铑(Rh)、钨(W)、包括至少一种前述元素的合金、以及包括至少一种前述物质的组合物。
图3示意性地示出了典型的局部修补隔热涂层系统，在清洗局部剥落区域20以提供渐缩轮廓之后，掩模22与热喷涂工艺结合使用。通过利用掩模22，热喷涂24以受损区域为特定目标且对所述区域进行重新涂覆。通过仔细选择热喷涂工艺中使用的粉末，可基本上重新产生修补的隔热涂层区域26以使其与围绕剥落区域20的原有隔热涂层的涂层成分相匹配。通过这种方式，重新涂覆的隔热涂层26可被热沉积以使得结合涂层12不会交叠到外涂层16上。此外，通过利用渐缩轮廓，消除了间隙和/或使间隙显著地最小化，由此为修补区域提供与原有隔热涂层相似的涂层性质。
图4示出了通常由附图标记50表示的轮叶涡轮机引擎部件。轮叶50包括翼面部分52和燕尾榫部分54。翼面部分52位于平台56上。所有表面都涂覆有隔热涂层系统，已经结合图1示出了所述隔热系统的一个实例。在重复操作过程中，平台56可如前所述出现剥落情况。有利地，上面提到的修补工艺可用于修补平台。由于修补工艺是在局部进行的，因此所述工艺使得翼面未暴露于热喷涂过程中采用的热条件从而实现修补。正如本领域中已公知地，在操作过程中，翼面周围的隔热涂层系统可能由于在操作过程中施加到翼面上的应力而产生开裂。尽管可能出现开裂，但裂纹的存在通常无法保证立即得到修补。现有技术中的喷涂工艺需要从所有表面上剥除所有隔热涂层系统，原因在于热暴露会导致翼面上的开裂涂层受到附加损伤如腐蚀、氧化和类似损伤。
该描述利用实例披露出包括最佳模式的本发明，并且还使得本领域的技术人员能够制造和利用本发明。本发明的可获得专利的范围由权利要求限定，且可包括本领域的技术人员易于想到的其它实例。这种其它实例旨在位于权利要求的范围内，如果它们具有与权利要求的字面语言相同的结构元件或如果它们包括与权利要求的字面语言没有实质区别的等效结构元件的话。
零件表
10隔热涂层系统
12结合涂层
14涡轮机引擎部件
16陶瓷层
18氧化皮
20局部剥落区域
22掩模
24热喷涂
26修补的隔热涂层区域
50轮叶涡轮机引擎部件
52翼面部分
54燕尾榫部分
56平台

Claims (9)

1、一种对已经出现局部剥落的涡轮机部件(14)上的隔热涂层系统(10)进行局部修补的方法，所述方法包括：
用水对剥落区域(20)进行局部清洗以从所述剥落区域(20)上去除剥落碎片且在原有隔热涂层(10)中形成渐缩轮廓；并且
将粉末混合物局部热喷涂(24)进入所述经过清洗的局部剥落区域(20)内以形成修补的隔热涂层(26)。
2、根据权利要求1所述的方法，其中所述涡轮机部件(14)包括选自包括镍基超合金、钴基超合金和铁基超合金的组群中的材料。
3、根据前述权利要求中任一项所述的方法，其中所述涡轮机部件(14)被设置在燃气轮机引擎内。
4、根据前述权利要求中任一项所述的方法，其中所述修补的隔热涂层(26)和所述隔热涂层系统(10)包括与所述部件(14)接触的结合涂层(12)；在所述结合涂层(12)上形成的氧化皮(18)；和设置在所述氧化皮(18)上的外涂覆层(16)。
5、根据权利要求4所述的方法，其中所述外涂覆层(16)是陶瓷。
6、根据前述权利要求中任一项所述的方法，其中所述修补的隔热涂层(26)不与所述原有隔热涂层(10)交叠。
7、根据前述权利要求中任一项所述的方法，其中局部热喷涂所述粉末混合物的过程包括高速氧燃料热喷涂工艺。
8、根据前述权利要求中任一项所述的方法，其中局部热喷涂所述粉末混合物的过程包括空气等离子体喷涂工艺。
9、根据前述权利要求中任一项所述的方法，其中用水对所述剥落区域(20)进行局部清洗的过程包括将水射流引导到所述剥落区域(20)。
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CN102534613A (zh) * 2011-12-19 2012-07-04 北京矿冶研究总院 一种新型复合结构涂层及其制备方法
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