CN101479398B - 保护部件不热腐蚀的方法以及通过所述方法保护的部件 - Google Patents
保护部件不热腐蚀的方法以及通过所述方法保护的部件 Download PDFInfo
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- 238000000034 method Methods 0.000 title claims abstract description 30
- 238000005260 corrosion Methods 0.000 title abstract 2
- 230000007797 corrosion Effects 0.000 title abstract 2
- 230000001681 protective effect Effects 0.000 title 1
- 239000011248 coating agent Substances 0.000 claims abstract description 63
- 238000000576 coating method Methods 0.000 claims abstract description 63
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims abstract description 55
- 239000011651 chromium Substances 0.000 claims abstract description 55
- 229910052804 chromium Inorganic materials 0.000 claims abstract description 55
- 238000009792 diffusion process Methods 0.000 claims abstract description 43
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 25
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 25
- 239000004411 aluminium Substances 0.000 claims abstract description 24
- 229910044991 metal oxide Inorganic materials 0.000 claims abstract description 10
- 150000004706 metal oxides Chemical class 0.000 claims abstract description 10
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims abstract description 5
- 229910052719 titanium Inorganic materials 0.000 claims abstract description 5
- 239000010936 titanium Substances 0.000 claims abstract description 5
- 239000000463 material Substances 0.000 claims description 22
- 238000005530 etching Methods 0.000 claims description 9
- 229910000951 Aluminide Inorganic materials 0.000 claims description 5
- 238000007746 phosphate conversion coating Methods 0.000 claims description 5
- 238000007669 thermal treatment Methods 0.000 claims description 5
- 229910010293 ceramic material Inorganic materials 0.000 abstract 3
- 239000011230 binding agent Substances 0.000 abstract 1
- 238000005255 carburizing Methods 0.000 description 4
- 239000000758 substrate Substances 0.000 description 4
- 239000000919 ceramic Substances 0.000 description 3
- 238000005229 chemical vapour deposition Methods 0.000 description 3
- 244000050510 Cunninghamia lanceolata Species 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 229910001011 CMSX-4 Inorganic materials 0.000 description 1
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 1
- WGLPBDUCMAPZCE-UHFFFAOYSA-N Trioxochromium Chemical compound O=[Cr](=O)=O WGLPBDUCMAPZCE-UHFFFAOYSA-N 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 230000000903 blocking effect Effects 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- ZCDOYSPFYFSLEW-UHFFFAOYSA-N chromate(2-) Chemical compound [O-][Cr]([O-])(=O)=O ZCDOYSPFYFSLEW-UHFFFAOYSA-N 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 239000012809 cooling fluid Substances 0.000 description 1
- 238000000151 deposition Methods 0.000 description 1
- 230000008021 deposition Effects 0.000 description 1
- 238000007598 dipping method Methods 0.000 description 1
- 230000006353 environmental stress Effects 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 230000035882 stress Effects 0.000 description 1
- 229910000601 superalloy Inorganic materials 0.000 description 1
- 238000001029 thermal curing Methods 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
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Abstract
一种保护特别是涡轮叶片的部件不受到热腐蚀影响的方法，包括如下步骤：(1)将铬扩散覆层施加在部件上；以及(2)将陶瓷材料的覆层施加在铬扩散覆层的一个或多个所选区域上，所述一个或多个所选区域是在部件的随后使用过程中受到低于第一预定温度的温度的区域。陶瓷材料最好包括与金属氧化物结合的结合材料。在优选实施例中，涡轮叶片在整个内表面和外表面上被覆铬扩散覆层。接着经由掩模将铝扩散覆层施加在翼面表面以及叶片的内表面上。掩模被去除，并且陶瓷材料作为覆盖层在平台和叶片根部之间的区域内施加在铬扩散覆层上。
Description
技术领域
本发明涉及保护部件不热腐蚀的方法，并且在该方法中部件是燃气涡轮发动机的转子叶片。
背景技术
所谓的类型I和类型II的热腐蚀可以经由公知为铬化处理的工艺通过将铬添加在部件表面上来控制。这在部件衬底上形成了扩散的铬阻挡层。2001年9月4日公开的US专利申请6283715描述这种扩散铬层在涡轮叶片表面上、特别是在作为的平台之下以及平台之上的翼面部件上的叶片部分上的使用。
虽然扩散铬层的使用本身提供抵抗类型II腐蚀的良好保护，对于较高温度类型I腐蚀的保护通常需要另外的扩散铝，在衬底表面上形成造成铬调节铝化物覆层。这种构造同样在US6283715中描述，铝扩散层在平台之上的翼面区域内施加在铬扩散层上。此专利还描述了陶瓷覆层形式的覆盖层，以用作热阻挡层来隔离下面的层。这种覆盖层只施加在叶片的翼面部分上。
2001年8月7日公开的US6270318描述一种涡轮叶片，其中平台和根部之间的区域被覆陶瓷覆盖层。2001年10月2日公开的US6296447披露一种涡轮叶片，其具有被覆可以是扩散铝层的第一层的上平台表面，随后是第二陶瓷层。类似的覆层配置用于所述的叶片的翼面的压力侧上。
发明内容
按照本发明的第一方面，提供一种保护部件不热腐蚀的方法，包括如下步骤：
(1)将铬扩散覆层施加在部件上；以及
(2)将陶瓷材料的覆层施加在铬扩散覆层的一个或多个所选区域上，所述一个或多个所选区域是在部件的随后使用过程中受到低于第一预定温度的温度的区域。
陶瓷材料最好在结合材料中包括一种或多种金属氧化物。金属氧化物可以从包括铝、钛和铬氧化物的组中选择，同时结合材料可以是铬酸盐-磷酸盐材料。
第一预定温度可以是大约800℃。
步骤(1)可以使其形成厚度在5和25μm之间的铬覆层。还可以形成包括15和30wt％之间的铬的铬扩散覆层。
步骤(1)可包括将铬扩散覆层施加在整个部件上，并且步骤(2)可包括如下步骤：
(2a)至少掩蔽所选区域；
(2b)将铝扩散覆层施加在未掩蔽的区域；
(2c)去除掩模；以及
(2d)在大致室温下将陶瓷材料的覆层施加在一个或多个所选区域上。
该方法还分别在步骤(2b)和(2c)之间以及在步骤(2d)之后包括如下步骤：
(2b’)在第二预定温度下热处理部件，由此保持所需机械性能，以及
(2d’)在第三预定温度下热处理陶瓷覆层。
第二和第三预定温度可以在各自范围850-1150℃以及100-600℃之间。
步骤(2b)可以使其形成铬调整的铝化物覆层，具有15和30wt％之间的铝以及5和15wt％之间的铬的β相微型结构。
该部件可具有内表面，并且步骤(1)和(2b)可分别包括将铬扩散覆层和铝扩散覆层施加在内表面上。
该部件可以是涡轮叶片，在这种情况下施加陶瓷的所选区域可包括涡轮叶片的平台部分和根部部分之间的区域。
步骤(2a)可包括掩藏所选区域和根部部分。
在本发明的第二方面下，部件具有保护而不热腐蚀的覆层，覆层包括布置在部件的表面上的铬扩散覆层以及布置在铬扩散覆层上的一个或多个所选区域上的陶瓷材料，一个或多个所选区域是在部件随后使用过程中受到低于预定温度的温度的区域。
部件可以是涡轮叶片，在这种情况下，陶瓷覆层可在其平台部分和根部部分之间布置在叶片的一部分上。
平台部分之上的叶片的一部分可设置与铬扩散覆层相互扩散的铝扩散层。
涡轮叶片可包括内部通道，并且内部通道可设置与铬扩散覆层相互扩散的铝扩散覆层。
相互扩散的铝和铬覆层可具有15和30wt％之间的铝以及5和15wt％之间的铬的β相微型结构。
叶片的根部部分可设置铬扩散覆层。
陶瓷材料最好在结合材料中包括一种或多种金属氧化物。金属氧化物可以从包括铝、钛和铬氧化物的组中选择，而结合材料可以是铬酸盐-磷酸盐的材料。
铬扩散覆层可以具有5和25μm之间的厚度。还可以包括15和30wt％之间的铬。
附图说明
现在参考附图，只通过实例，描述本发明的实施例，附图中：
图1是按照本发明的部件的透视图；
图2是图1所示的部件的侧视图。
具体实施方式
图1和2所示的部件是涡轮叶片。叶片包括位于翼面部分12的上端处的台肩部分10。翼面部分的下端通向平台部分14，平台部分继而通向根部部分16。根部部分具有公知的“杉树”形状，以便可靠地锚固在围绕其周边并排承载多个这种叶片的盘件(未示出)中。
在典型的叶片中根部16和平台14之间的区域包括与内部通道20(虚线所示)的一端连通的开口18。通道在翼面部分12内在其本身上折叠，并在在其另一端终止于台肩10处的开口22。通道具有将冷却流体引导进入和离开翼面部分的功能。
在所示的优选实施例中，使用传统和直接固化(包括单晶)铸造的方法叶片由镍基超合金制成。可以采用的典型的合金是MarM247、IN6203、CM186DC LC和CMSX-4。
现在将描述保护这种叶片不受到热腐蚀影响的优选方法。
在第一阶段，所有表面(外表面和内表面)被铬化。在此过程中，铬通过适当装置扩散到部件表面内。这可以例如通过扩散渗碳处理、扩散渗碳处理之上或者通过CVD(化学气相沉积)来实现。此阶段实现了富含铬的表面层。该层通常包括15和30wt％之间的铬，并通常具有5和25μm之间的厚度。
在第二阶段，叶片通过适当介质掩藏，以便防止随后施加的铝化物覆层沉积在被覆陶瓷覆层(同样随后描述)的叶片的那些表面上。这种表面将此后称为“所选区域”。在优选实施例中，所选区域是平台14和根部16之间的区域。在这种情况下，不仅是所选区域被掩藏，而且根部16也被掩藏，即使它不设置陶瓷覆盖层。
第三，该部件在其外表面和内表面上铝化。在此过程中，类似于所述的铬化阶段，铝通过任何适当的装置扩散到铬化表面内。这可以例如通过扩散渗碳处理、扩散渗碳处理之上或者通过CVD来实现。这造成铬调整的铝化物覆层，在覆层中具有15-30wt％的铝以及5-15wt％的铬的β相微型结构。覆层中具有的其它元素将取决于组成部件衬底的材料。
在第四阶段，掩模被去除，并且部件被热处理，以确保衬底保持最佳机械性能。这种热处理可涉及850℃-1150℃范围内的温度。
第五，部件的“所选区域”在大约室温下设置陶瓷覆盖覆层。这种覆层可通过任何浸渍、通过施加器(例如刷子或拖把等)上漆或者喷涂来施加。适当的陶瓷材料是含有包括在适当结合材料内的一种或多种金属氧化物的材料。适当的氧化物是氧化铝、氧化钛和氧化铬。结合材料最好采取铬酸盐-磷酸盐类型的材料的形式。
在最后第六阶段，陶瓷覆层在适当升高的温度下被热处理或固化。此温度最好在100-600℃的范围内。
将结合材料添加在组成陶瓷的氧化物材料中的优点在于它使得覆层延展。考虑到叶片在服务过程中加热而出现膨胀，这很重要。没有使用结合材料，覆层容易变得脆性并裂开，继而使得叶片受到不希望的环境应力。
所述的结合材料在大约800℃的温度以上的情况下退化。因此，这种陶瓷覆层用于部件(在此情况下是涡轮叶片)受到低于此温度的温度的部分。虽然这通常排除了叶片的翼面部分，陶瓷在大多数操作情况下会安全施加在平台之下的区域。另外，虽然陶瓷还可施加在杉树形根部16以及平台和根部之间的区域上，实际上最好不这样作。这是由于根部和盘件内的相应凹槽之间的间隙在大多数情况下小于陶瓷覆层的厚度。另外，杉树根部的侧面(水平接触部分)在操作过程中受到高接触应力，在长时间之后在金属内产生裂纹。这会将陶瓷覆层研磨成粉末，继而用作楔形件，使其在服务之后极度难以从盘件上拆卸叶片。因此在优选实施例中，陶瓷覆层只在附图中施加在虚线A和B之间的区域。
为了总结在最终状态下位于叶片上的覆层，根部部分16只具有铬扩散覆层；平台和根部之间区域的外表面(虚线A和B之间的区域)具有铬扩散层加上陶瓷覆层，如上所述；外部翼面表面具有铬-铝化扩散覆层，并且叶片的内表面具有铬-铝化扩散覆层。
虽然假设被覆陶瓷层的区域是平台和根部之间的区域，任何其它区域可被类似地覆层，只要它不受到高于所述结合材料可以忍受的温度的温度即可。
同样，虽然结合涡轮叶片来描述和说明本发明，它还可适用于受到热腐蚀的其它部件。
Claims (26)
1.一种保护部件不热腐蚀的方法，包括如下步骤：
(1)将铬扩散覆层施加在部件上；以及
(2)将陶瓷材料的覆层施加在铬扩散覆层的一个或多个所选区域上，所述一个或多个所选区域是在部件的随后使用过程中受到低于第一预定温度的温度的区域。
2.如权利要求1所述的方法，其特征在于，在陶瓷材料中添加结合材料，所述陶瓷材料包括一种或多种金属氧化物。
3.如权利要求2所述的方法，其特征在于，金属氧化物从包括铝、钛和铬氧化物的组中选择。
4.如权利要求2或3所述的方法，其特征在于，结合材料是铬酸盐-磷酸盐材料。
5.如权利要求4所述的方法，其特征在于，第一预定温度是大约800℃。
6.如权利要求1至3中任一项所述的方法，其特征在于，步骤(1)形成厚度在5和25μm之间的铬覆层。
7.如权利要求1至3中任一项所述的方法，其特征在于，步骤(1)形成包括15和30wt％之间的铬的铬扩散覆层。
8.如权利要求1至3中任一项所述的方法，其特征在于，步骤(1)包括将铬扩散覆层施加在整个部件上，并且步骤(2)包括如下步骤：
(2a)至少掩蔽所选区域；
(2b)将铝扩散覆层施加在未掩蔽的区域；
(2c)去除掩模；以及
(2d)在大致室温下将陶瓷材料的覆层施加在一个或多个所选区域上。
9.如权利要求8所述的方法，其特征在于，该方法还分别在步骤(2b)和(2c)之间以及在步骤(2d)之后包括如下步骤：
(2b’)在第二预定温度下热处理部件，由此保持所需机械性能，以及
(2d’)在第三预定温度下热处理陶瓷覆层。
10.如权利要求9所述的方法，其特征在于，第二和第三预定温度在各自范围850-1150℃以及100-600℃之间。
11.如权利要求8所述的方法，其特征在于，步骤(2b)形成铬调整的铝化物覆层，具有15和30wt％之间的铝以及5和15wt％之间的铬的β相微型结构。
12.如权利要求8所述的方法，其特征在于，该部件具有内表面，并且步骤(1)和(2b)分别包括将铬扩散覆层和铝扩散覆层施加在内表面上。
13.如权利要求1至3中任一项所述的方法，其特征在于，该部件是涡轮叶片。
14.如权利要求13所述的方法，其特征在于，所选区域包括涡轮叶片的平台部分和根部部分之间的区域。
15.如权利要求8所述的方法，其特征在于，步骤(2a)包括掩藏所选区域和根部部分。
16.一种具有保护而不热腐蚀的覆层的部件，覆层包括：
布置在部件的表面上的铬扩散覆层，以及
布置在铬扩散覆层上的一个或多个所选区域上的陶瓷材料，一个或多个所选区域是在部件随后使用过程中受到低于预定温度的温度的区域。
17.如权利要求16所述的部件，其特征在于，部件是涡轮叶片，并且陶瓷覆层在其平台部分和根部部分之间布置在叶片的一部分上。
18.如权利要求17所述的部件，其特征在于，平台部分之上的叶片的一部分设置与铬扩散覆层相互扩散的铝扩散层。
19.如权利要求18所述的部件，其特征在于，涡轮叶片包括内部通道，并且内部通道设置与铬扩散覆层相互扩散的铝扩散覆层。
20.如权利要求18或19所述的部件，其特征在于，相互扩散的铝和铬覆层具有15和30wt％之间的铝以及5和15wt％之间的铬的β相微型结构。
21.如权利要求18或19所述的部件，其特征在于，叶片的根部部分设置铬扩散覆层。
22.如权利要求16至19中任一项所述的部件，其特征在于，在陶瓷材料中添加结合材料，所述陶瓷材料包括一种或多种金属氧化物。
23.如权利要求22所述的部件，其特征在于，金属氧化物从包括铝、钛和铬氧化物的组中选择。
24.如权利要求22或23所述的部件，其特征在于，结合材料是铬酸盐-磷酸盐的材料。
25.如权利要求16至19中任一项所述的部件，其特征在于，铬扩散覆层具有5和25μm之间的厚度。
26.如权利要求16至19中任一项所述的部件，其特征在于，铬扩散覆层包括15和30wt％之间的铬。
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| PCT/EP2007/055296 WO2007147708A2 (en) | 2006-06-24 | 2007-05-31 | Method of protecting a component against hot corrosion and a component protected by said method |
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| US10077494B2 (en) | 2016-09-13 | 2018-09-18 | General Electric Company | Process for forming diffusion coating on substrate |
| US10711361B2 (en) * | 2017-05-25 | 2020-07-14 | Raytheon Technologies Corporation | Coating for internal surfaces of an airfoil and method of manufacture thereof |
| DE102017213553A1 (de) | 2017-08-04 | 2019-02-07 | MTU Aero Engines AG | Schaufel für strömungsmaschine mit verschiedenen diffusionsschutzschichten und verfahren zur herstellung |
| US11535560B2 (en) | 2019-05-08 | 2022-12-27 | Praxair S.T. Technology, Inc. | Chromate-free ceramic coating compositions for hot corrosion protection of superalloy substrates |
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| CN110923621B (zh) * | 2019-10-31 | 2022-01-04 | 中国航发南方工业有限公司 | 铝铬共渗的防护涂料及其制备方法和应用 |
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| IN2014DN06653A (zh) | 2015-07-10 |
| RU2442846C2 (ru) | 2012-02-20 |
| US20090185912A1 (en) | 2009-07-23 |
| EP2032733A2 (en) | 2009-03-11 |
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| GB2439313B (en) | 2011-11-23 |
| CN101479398A (zh) | 2009-07-08 |
| GB0612576D0 (en) | 2006-08-02 |
| US8596985B2 (en) | 2013-12-03 |
| RU2009102212A (ru) | 2010-08-10 |
| WO2007147708A3 (en) | 2008-03-27 |
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