CN101205833A - 隔热涂层 - Google Patents

隔热涂层 Download PDF

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CN101205833A
CN101205833A CNA2007101998710A CN200710199871A CN101205833A CN 101205833 A CN101205833 A CN 101205833A CN A2007101998710 A CNA2007101998710 A CN A2007101998710A CN 200710199871 A CN200710199871 A CN 200710199871A CN 101205833 A CN101205833 A CN 101205833A
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layer
parts
apply
adhesive coatings
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G·H·雷诺
C·W·斯特罗克
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RTX Corp
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Abstract

本发明涉及隔热涂层。在燃气轮机发动机部件基材上施加粘合涂层。在所述粘合涂层上施加阻隔涂层。所述粘合涂层的施加包括：施加具有施加后未经任何处理的第一粗糙度的第一层；和在所述第一层上施加第二层，该第二层具有大于所述第一粗糙度的施加后未经任何处理的第二粗糙度。在所得涂层体系中，所述第一和第二层可具有不同性能(例如第二层具有更大的孔隙度、孔径大小和/或扁平粒子尺寸)。

Description

隔热涂层
                       技术领域
本发明涉及燃气轮机发动机(gas turbine engines)。更具体地，本发明涉及燃气轮机发动机隔热涂层。
                       背景技术
燃气轮机发动机气路部件在不同轮机工作阶段期间暴露在极端热量和温度度下。热-机械应力及产生的疲劳会导致部件失效。在冷却这些部件并提供隔热涂层以改善耐久性方面付出了艰苦的努力。
示例性的隔热涂层体系包括双层隔热涂层体系。示例性体系包括NiCoCrAlY粘合涂层(例如低压等离子体喷涂的(LPPS))和氧化钇稳定的氧化锆(YSZ)隔热涂层(TBC)(例如空气等离子体喷涂的(APS))。当沉积阻隔涂层的时候或在初始加热循环期间，热生长氧化物(thermally grown oxide，TGO)层(例如氧化铝)形成于粘合涂层之上。随着温度时间(time-at-temperature)和循环次数增加，该TGO界面层厚度增加。美国专利4405659和6060177公开了示例性的体系。
示例性的TBC施加到5-40密耳的厚度，能给基底金属提供300以上的温度降抵。这种温度降低转化为部件耐久性提高、轮机工作温度更高和轮机效率提高。
尽管如此，仍需改善部件的耐久性。
                       发明内容
本发明的一个方面涉及涂覆燃气轮机发动机部件的方法。在部件基材上施加粘合涂层。在所述粘合涂层上面施加阻隔涂层。粘合涂层的施加包括：施加具有施加后未经任何处理的第一粗糙度(as-appliedfirst roughness)的第一层；和在所述第一层上面施加第二层，该第二层具有大于所述第一粗糙度的施加后未经任何处理的第二粗糙度。
在各种实施方案中，所述方法可在基线部件(baseline component)的再制造(remanufacturing)或其构造的重新设计(reengineering)中实施。
本发明另一方面涉及包含金属基材的燃气轮机发动机部件。所述基材上存在有涂层。所述涂层包括粘合涂层和在该粘合涂层上面的阻隔涂层。所述粘合涂层包括：底层；和第二层，该第二层在所述底层上面并具有比所述底层更大的特征孔径大小和/或扁平粒子尺寸(splatsize)。
在各种实施方案中，TGO可位于粘合涂层和阻隔涂层之间。所述第二层可具有大于底层的特征孔隙度。
在附图和以下描述中提供了本发明的一个或多个实施方案的细节。本发明的其他特征、目的和优点可从这些描述和附图，以及权利要求中得以显见。
                       附图简述
图1是涂覆的基材的剖面图。
图2是涂覆图1的基材的过程的流程图。
不同附图中的相同参考数字和标记表示相同要素。
                     具体实施方式
图1表示在超级合金基材22上面的涂层体系20。该体系可包括在基材22上面的粘合涂层24和在粘合涂层24上面的TBC 26。该示例性的粘合涂层24包括底层28和中间层30。如下所述，底层28的性能可选择用于粘合到基材22并保护基材22，而中间层的性能可选择用于粘合到TBC 26。示例性的基材是用于诸如涡轮段叶片(turbinesection blades)、涡轮段叶轮(turbine section vanes)、涡轮段叶片外气封件(turbine section blade outer air seals)、燃烧室壳板(combustor shellpieces)、燃烧室隔热板(combustor heat shield pieces)、燃烧室燃料喷嘴和燃烧室燃料喷嘴导向器的热气路部件的镍基或钴基超级合金。
示例性的涂覆过程100包括102制备基材(例如通过清洗和表面处理)。104施加粘合涂层底层24的前体。示例性的104施加是MCrAlY层，更具体地是NiCoCrAlY材料。对底层24有益的高温保护性能可能伴随有不利于粘合到TBC 26的性能。例如，对保护有益的高密度和低孔隙度可伴随有比TBC粘合所需要的表面粗糙度低的表面粗糙度。底层28的示例性的施加后未经任何处理的粗糙度低于300微英寸Ra(例如200±40微英寸Ra或更低)。一种示例性的施加是通过从小于45μm粒度的粉末源喷涂来实现所述粗糙度。一种示例性的施加是借助高速氧燃料(high-velocity oxy-fuel，HVOF)工艺。一种示例性的施加可达到0.003-0.010英寸厚度。可使用LPPS、VPS、EBPVD、冷喷涂(cold spray)和任何其他合适的方法来提供致密的、低氧化物的底层28，其中该底层28提供良好的氧化和腐蚀抗性。
在施加104后，106该前体可扩散。一种示例性的扩散是借助于在真空或非活性(例如氩气)气氛下加热(例如加热到至少1900达至少4小时)实现。这种示例性的扩散106可有效在底层和基材间形成冶金接合(metallurgical bond)。所述扩散还可减少保护氧化物形成物种的扩散路径长度。作为选择，扩散步骤可在施加中间层和/或TBC后进行，如果需要的话。
在施加104和非必需的扩散106后，108可施加中间层30。示例性的中间层可以是与底层前体基本相同的材料，并可以通过类似技术施加。然而，优选中间层的施加产生有益的与TBC的粘合。中间层30可具有可大于底层28表面粗糙度的表面粗糙度。示例性的施加后未经任何处理的粗糙度是300-800微英寸Ra，更具体是500±100微英寸Ra。它可以是底层28的施加后未经任何处理的粗糙度的150-300％(或更高)。这种粗糙度可通过使用更粗的原料粉末(例如底层原料粉末特征粒度的至少150+％)和/或改变施加参数实现。示例性的粉末粒度是45-70μm。其他性能可以与底层不同(例如，如下文所述)。
在典型粗糙度的升序排列中，用于施加108的可选方法包括：EBPVD、冷喷涂、HVOF和LPPS、APS、丝电弧法(wire arc)和丝火焰法(wire flame)。其他选择包括浆料法，其中用任选的粘合剂和粉末制备浆料，然后通过喷涂、浸涂、刷涂等施加在底层上。然后烘干粘合剂并将金属粒子(metallics)烧结用于粘合。所述浆料具有产生所述粗糙度的大颗粒。所述浆料可包含在烧结温度以下熔化的微细颗粒和/或元素或合金，以通过烧结和/或钎焊(brazing)促进中间层与底层的烧结和粘合。
中间层30的示例性厚度小于底层28的厚度(例如为后者的10-50％)。例如，可选择绝对厚度和相对厚度以使抗氧化和腐蚀的底层尽可能厚，以使这些性能的效果最大化。所述粗糙的中间层仅需要足以提供期望的TBC粘合改善的厚度。示例性的中间层厚度是至少0.001英寸，更具体地可能需要0.002-0.004英寸。
在施加108之后，110可施加TBC 26。示例性的施加110是钇稳定的氧化锆(例如6-8％重量钇，标称7YSZ)。然后112可施加环境阻隔涂层(“外涂层”-未示出，如果有的话)。示例性的外涂层是不被钙-镁-铝-硅酸盐(CMAS)或吸入的灰尘或砂砾润湿，也不与它们反应的外涂层。
一般而言，为了获得良好的抗氧化和腐蚀性能，底层28相对于中间层28应具有以下部分或全部特征：粗糙度更低、密度更大、孔更小、孔隙度(体积分数)更低、氧化物颗粒更小、氧化物含量(质量分数)更低、扁平粒子(splats)更小和氧化物狭带(oxide stringers)更小。这些不同的性能可通过金相学(例如通过使用蚀刻剂)观察。在可测量的程度内，残余表面粗糙度可具有与施加后未经任何处理的表面粗糙度相同的差异方式。
所述扁平粒子结构(splat structure)源自喷涂微滴的冲击。随着扁平粒子的进一步堆积，微滴变平并固化，在涂层内留下单个扁平粒子结构的痕迹。中间层30的示例性特征扁平粒子尺寸可至少为底层28特征扁平粒子尺寸的两倍。这种特征可以是中值、均值或最常见的值(modal value)，可以基于扁平粒子大小加权或不加权。这可作为垂直于涂层表面的截面中的截面面积测量。
在研发过程中，通过在喷涂物中加入标记组分可以容易地观察扁平粒子。所述标记组分然后可突出扁平粒子界面。然而，工艺参数一旦确定，标记组分就可省去。在不存在标记组分的情况下，可在施加涂层后在涂层中渗入染料。示例性染料是铑-B荧光染料。
在某些重新设计或再制造情况下，上述教导可用于减小总粘合涂层厚度，同时改善或保持TBC粘合和/或抗氧化性。还可实现这些益处的其他组合。在从基线粘合涂层(baseline bond coat)的重新设计中，所述基线(baseline)可具有上述段落中的处于底层28和中间层30的性能之间的性能。性能(例如抗散裂性)可通过观察或直接测试来测量。示例性的观察包括具有差分加热和冷却(differential heating andcooling)的热循环(加热涂层某一部分，同时冷却该部件另一部分)。可在足够的循环次数后观察散裂。
已描述了本发明的一个或几个实施方案。然而，可以理解可在本发明的精神和范围内进行各种变动。例如，而且如已有部件的重新设计那样实施，已有部件的细节可影响或规定任何特定实施方式的细节。因此，其他实施方案也在以下权利要求范围内。

Claims (22)

1.一种燃气轮机发动机部件，包括：
金属基材；
在所述基材上的涂层，包含：
粘合涂层；和
在所述粘合涂层上的阻隔涂层，
其中所述粘合涂层包含：
底层；和
在所述底层上面的第二层，所述第二层具有以下至少之一：大于所述底层的特征孔径大小和大于所述底层的特征扁平粒子尺寸。
2.用作燃气轮机发动机部件的权利要求1的部件，选自：
涡轮段叶片；
涡轮段叶轮；
涡轮段叶片外气封件；
燃烧室壳板；
燃烧室隔热板；
燃烧室燃料喷嘴；和
燃烧室燃料喷嘴导向器。
3.权利要求1的部件，其中：
所述底层的厚度是所述第二层的2-10倍。
4.权利要求1的部件，其中
所述底层和所述第二层基本上由相同的化学组成组成。
5.权利要求1的部件，还包括
所述底层与所述基材部分扩散。
6.权利要求1的部件，其中：
所述阻隔涂层含有至少50％重量的基于稀土的经稳定的氧化锆。
7.权利要求1的部件，其中：
所述粘合底层和第二层各含有至少50％重量的NiCoCrAlY材料。
8.权利要求1的部件，其中：
所述基材基本上由铸造镍基超级合金组成。
9.权利要求1的部件，其中：
所述第二层具有大于所述底层的孔隙度。
10.权利要求1的部件，其中：
所述第二层具有大于所述底层的特征扁平粒子尺寸。
11.权利要求1的部件，其中：
所述第二层具有大于所述底层的特征孔径大小。
12.涂覆燃气轮机发动机部件的方法，该方法包括：
在所述部件的基材上施加粘合涂层；和
在所述粘合涂层上施加阻隔涂层，
其中所述粘合涂层的施加包括：
施加具有施加后未经任何处理的第一粗糙度的第一层；和
在所述第一层上施加第二层，该第二层具有大于所述第一粗糙度的施加后未经任何处理的第二粗糙度。
13.权利要求12的方法，其中：
所述第二粗糙度为300-800微英寸Ra，且为所述第一粗糙度的至少150％。
14.权利要求12的方法，其中：
所述第一层的施加包括喷涂具有特征第一粒度的第一粉末；和
所述第二层的施加包括喷涂具有大于所述第一粒度的特征第二粒度的第二粉末。
15.权利要求14的方法，其中：
所述第一和第二粉末基本上由相同的化学组成组成。
16.权利要求14的方法，其中：
所述第一和第二粉末基本上由NiCoCrAlY材料组成。
17.权利要求14的方法，其中：
所述第一和第二粉末基本上由相同化学组成的NiCoCrAlY材料组成。
18.权利要求14的方法，其中：
所述第一层的施加厚度大于所述第二层。
19.权利要求12的方法，还包括：
除去具有比所述粘合涂层厚的整体粘合涂层的基线涂层。
20.设计用于燃气轮机发动机部件的涂层的方法，该方法包括：
在基材上施加试验涂层，该施加包括：
在基材上施加粘合涂层，包括具有不同施加后未经任何处理的粗糙度的第一和第二层；和
在所述粘合涂层上施加阻隔涂层；
测量所述试验涂层对氧化和散裂至少之一的抗性；和
对于所述第一和第二层的不同相对性能重复所述施加和测量，直至确定期望的抗性。
21.权利要求20的方法，其中：
所述测量包括循环进行差分加热；和
观察涂层状况。
22.权利要求20的方法，是基线涂层的重新设计形式，其中：
所述重新设计的涂层的总粘合涂层厚度小于基线涂层的粘合涂层厚度。
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