CN102689461B - 防热腐蚀涂层和由其保护的元件 - Google Patents

防热腐蚀涂层和由其保护的元件 Download PDF

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CN102689461B
CN102689461B CN201210087734.9A CN201210087734A CN102689461B CN 102689461 B CN102689461 B CN 102689461B CN 201210087734 A CN201210087734 A CN 201210087734A CN 102689461 B CN102689461 B CN 102689461B
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coat
coating
rare earth
silicon
coat system
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CN102689461A (zh
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P·J·梅施特
R·G·罗维
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General Electric Co PLC
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Abstract

本发明涉及一种防热腐蚀涂层和由其保护的元件。在暴露于高温的物品(10，30)的超合金或含硅基底(12，32)上的涂层系统(14，34)。涂层系统(14，34)包括覆在基底(12，32)上并对熔盐杂质促进的热腐蚀敏感的涂层(16，18，20，22，24，36，38)。腐蚀阻挡涂层(26)覆在涂层(16，18，20，22，24，36，38)上并含有至少一种与熔盐杂质反应形成致密的保护性副产物阻挡层(28)的含有稀土氧化物的化合物。

Description

防热腐蚀涂层和由其保护的元件
发明背景
本发明涉及适合用于保护暴露于高温环境(比如通过燃气涡轮发动机的热气体流路)的元件的涂层系统。更具体地讲，本发明涉及能够保护下面的涂层或基底免于由熔盐引发的热腐蚀的涂层。
持续寻求用于燃气涡轮发动机的较高操作温度以增大发动机效率。已经发现镍基、钴基和铁基超合金在包括航空器和发电产业的各种产业中作为燃气涡轮发动机的元件材料的广泛用途。当操作温度增大时，发动机元件的高温耐久性必须相应地增大。为此，热阻挡涂层(TBC)通常用于元件比如燃烧器、高压涡轮(HPT)叶片(blade)和轮叶(vane)上。TBC的隔热使得由超合金和其它高温材料形成的元件能够幸存于较高的操作温度、增大元件耐久性和提高发动机可靠性。TBC通常包含隔热陶瓷材料，其沉积在环境保护性粘合涂层上以形成所谓的TBC系统。广泛用于TBC系统的粘合涂层材料包括抗氧化覆盖涂层比如MCrAlX(其中M为铁、钴和/或镍，和X为钇、稀土金属和/或另一种反应性金属)和可含有化合物比如铝化物金属间化合物的抗氧化扩散涂层。因为其高温能力、低导热率和相对容易沉积，氧化钇稳定的氧化锆(YSZ)广泛用作TBC系统的隔热陶瓷材料。
为了对于燃气涡轮发动机获得较高的操作温度并因此增大其效率，已提出备选材料替代超合金。具体地说，硅基非氧化物陶瓷，最著名的是碳化硅(SiC)、氮化硅(Si3N4)和/或用作强化相和/或基质相的硅化物，为高温应用比如燃气涡轮发动机的燃烧器衬里、轮叶、护罩、翼面及其它高温段元件的候选材料。然而，当暴露于高温、富含水蒸汽的燃烧气氛中比如在燃气涡轮发动机中时，由于形成挥发性氢氧化硅(Si(OH)4)，由Si-基陶瓷形成的元件失去质量并回退(recede)。在燃气涡轮发动机环境中由于挥发或腐蚀的回退速率(recession rate)足够高，需要环境保护性涂层，通常指的是环境阻挡涂层(EBC)。
对于旨在保护由Si-基材料形成的燃气涡轮发动机元件的EBC的关键要求包括稳定性、低导热率、与Si-基陶瓷材料相容的热膨胀系数(CTE)、对氧化剂的低渗透性，和与Si-基材料以及通过氧化Si-基材料形成的二氧化硅皮(silica scale)或其可存在以促进EBC粘附于Si-基陶瓷材料的(如以下所讨论的)Si-基保护性粘合涂层的化学相容性。硅酸盐，并且特别是钡锶铝硅酸盐(BSAS；(Ba1xSrx)O-Al2O3-SiO2)及其它碱土铝硅酸盐，鉴于其环境保护性能及低导热率，已被提出作为EBC。例如，Eaton等的美国专利第6254935、6352790、6365288、6387456和6410148号公开了BSAS和碱土铝硅酸盐作为用于Si-基基底的外保护涂层的用途，化学计量的BSAS(摩尔比：075BaO·025SrO·Al2O3·2SiO2，摩尔百分比：18,75BaO·6.25SrO·25Al2O3·50SiO2)通常为优选的碱土铝硅酸盐组成。也已提出使用稀土(RE)硅酸盐比如RE2Si2O7和RE2SiO5作为保护性EBC涂层材料，如在美国专利第6296941、6312763、6645649、6759151和7595114中所报导的那样。作为具体实例，EBC在美国6759151中被公开为包含稀土硅酸盐，该稀土硅酸盐为式RE2SiO5、RE4Si3O12或RE2Si2O7，其中RE为Sc、Dy、Ho、Er、Tm、Yb、Lu、Eu、Tb或其组合。配置在含硅基底及其保护性EBC层之间的中间层(比如莫来石(3Al2O3·2SiO2))和粘合涂层(比如硅)，已被提出以促进EBC粘附于基底、限制层间反应和防止氧化剂渗透进入基底。例如，Wang等的共同受让的美国专利第6299988和6630200号公开了硅和含硅材料作为合适的粘合涂层材料，特别用于含有SiC或氮化硅的基底。如果特殊元件将受到超过约2500°F(约1370℃)的表面温度，EBC可根据Spitsberg等共同受让的美国专利第5985470号用上覆的热阻挡涂层(TBC)而热保护。组合起来，这些层形成所谓的热/环境阻挡涂层(T/EBC)系统。如上所述，用于燃气轮机应用的最常用TBC材料为氧化钇稳定的氧化锆(YSZ)。TBC与下面的EBC之间可提供过渡层，例如YSZ与氧化铝、莫来石和/或碱土金属铝硅酸盐的混合物，如在Wang等共同受让的美国专利第6444335号中教导的那样。
已知发动机环境内的高温可引起燃料中的杂质腐蚀由镍-基、钴-基和铁-基超合金形成的元件，以及使用于保护它们的TBC系统腐蚀和失稳。该现象称为热腐蚀，为由于在元件或其保护性表面氧化物表面形成熔盐沉积物的杂质比如Na2SO4和V2O5的存在造成的加速腐蚀。由熔盐沉积物造成的腐蚀性侵蚀可发生于中等温度范围内。例如，由熔融Na2SO4沉积物引起的I型钠热腐蚀通常发生于约880℃-约1000℃的温度范围，而由熔融V2O5沉积物引起的钒热腐蚀通常发生于约660℃-约1000℃的温度范围。尽管热腐蚀的详细机理随受到侵蚀的材料性质和腐蚀剂性质而不同，在所有情况下结构材料或涂层的降解可为快速的，并且取决于表面温度、熔盐的沉积速率和燃料中有害阳离子(例如钠和/或钒)的浓度，元件可在数十至数千小时内受到严重损害。该类型的腐蚀，不像氧化，已知快速消耗超合金元件并导致灾难性故障。Si-基材料比如SiC和Si3N4由Na2SO4和V2O5杂质的敏感性已经在实验室实验中得到证实。另一方面，EBC材料包括BSAS和RE硅酸盐对来自Na2SO4和V2O5杂质热腐蚀的敏感性(susceptibility)在很大程度上是未知的。
尽管有以上问题和不确定性，在工业中要求使用燃气涡轮发动机以采用更便宜的低等级燃料，其燃料因此含有较高浓度的盐杂质并因此加剧热腐蚀问题。减轻热腐蚀的最常见方法包括仅指定含有低的和相对无害浓度的腐蚀性元素(例如，少于1ppm钠和少于0.5ppm V)的燃料，在燃烧之前水洗燃料以除去可溶性Na种类，和注入经测量量的合适化合物，该化合物含有反应性元素(例如镁)以与燃料中的钒反应并形成高熔化温度、相对惰性化合物(比如Mg3V2O8)。在燃油价格逐步上升的时代，高度有利的是基于更便宜的含有相对高水平的腐蚀性种类(例如超过10ppm的Na2SO4和/或V2O5)的燃料运行涡轮发动机。除了使用反应性元素和洗涤燃料，允许使用这种燃料的另外措施将是合乎需要的。
发明简述
本发明主要提供用于超合金和含Si材料的涂层系统，特别是用于暴露于高温、包括用于航空器和发电产业的燃气涡轮发动机的恶劣热环境的元件的涂层系统。这样的材料的实例包括金属组合物比如镍-基、钴-基和铁-基超合金，和含Si材料比如硅、碳化硅、氮化硅、金属硅化物合金比如铌和钼硅化物等。含Si材料的更具体实例包括具有碳化硅、氮化硅、金属硅化物和/或硅颗粒分散体作为金属或非金属基质中的强化材料的那些含Si材料，以及具有碳化硅、氮化硅、金属硅化物和/或含硅基质的那些材料，并且特别是采用碳化硅、氮化硅、金属硅化物和/或硅作为强化材料和基质材料两者的复合材料(例如SiC/SiC陶瓷基质复合材料(CMC))。
根据本发明的第一个方面，涂层系统覆在由超合金或含硅材料形成的基底上。涂层系统的至少一个涂层和/或基底对由熔盐杂质促进的热腐蚀敏感。涂层系统进一步包括腐蚀阻挡涂层，其覆在涂层系统上并含有至少一种含有稀土氧化物的化合物，该化合物与熔盐杂质反应形成致密的保护性阻挡层，该保护性阻挡层优选地限定涂层系统的连续最外表面层。
根据本发明的第二个方面，提供燃气涡轮发动机元件，其包括由超合金或含硅材料形成的基底和基底上的涂层系统。基底或涂层系统的至少一个涂层对由熔盐杂质促进的热腐蚀敏感。腐蚀阻挡涂层覆在涂层系统上并含有至少一种含有稀土氧化物的化合物，该化合物与熔盐杂质反应形成致密的保护性阻挡层，该保护性阻挡层优选地限定涂层系统的连续最外表面层。
本发明的技术效果为，通过与由于杂质例如Na2SO4或V2O5而形成的熔盐沉积物反应，腐蚀阻挡涂层的含有稀土氧化物的化合物能够形成副产物阻挡层，其化学性质通过防止或至少延迟进一步的熔盐杂质渗透而防止下面的基底和/或涂层系统例如热阻挡涂层或环境阻挡涂层(TBC和EBC)失稳。像这样，腐蚀阻挡涂层能够大大提高下面的基底和/或涂层系统对盐腐蚀(热腐蚀)的抗性。含有稀土氧化物的腐蚀阻挡涂层的另外的有利条件包括在富含水蒸气的燃料燃烧气氛中对挥发的抗性，和基本上与要保护的超合金或含Si基底匹配的热膨胀系数，因此促进对有害裂缝或散裂的抗性。本发明适用于与用于热阻挡和环境阻挡涂层系统的已知涂层材料一起使用，并且腐蚀阻挡涂层可使用本领域通常已知的各种方法得到沉积。
本发明的其它方面和有利条件将由以下详细描述得到更好的理解。
附图简述
图1示意性描绘由含Si材料形成和用热/环境阻挡涂层系统保护并进一步提供本发明的腐蚀阻挡涂层的燃气涡轮发动机元件的剖视图。
图2示意性描绘由超合金材料形成和用热阻挡涂层(TBC)系统保护并进一步提供本发明的腐蚀阻挡涂层的燃气涡轮发动机元件的剖视图。
附图标记
10 元件
12 基底
14 系统
16 层
18 涂层
20 层
22 层
24 层
26 涂层
28 层
30 元件
32 基底
34 系统
36 粘合涂层
38 外涂层
发明详述
本发明提供含有稀土(RE)氧化物的涂层，该涂层适合于保护超合金元件和含硅元件及其保护性TBC和EBC系统(包括热/环境阻挡涂层(T/EBC)系统)，使它们免于熔盐比如由于存在于低等级燃料中的杂质而形成的熔盐的侵蚀和失稳化。这样的盐的显著实例包括(但不限于)自Na2SO4和/或V2O5形成的那些盐。由TBC和EBC系统保护的超合金元件和含硅元件的实例包括燃烧器元件、涡轮叶片和轮叶以及用于包括航空器和发电产业的各种产业的燃气涡轮发动机热气体流路中的其它元件。超合金材料的实例包括镍-基、钴-基和铁-基合金，并且含硅材料的实例包括具有碳化硅、氮化硅、金属硅化物(比如铌和钼硅化物)和/或硅强化材料在金属或非金属基质中的分散体的那些材料，以及具有碳化硅、氮化硅和/或含硅基质的那些材料，并且特别是采用碳化硅、氮化硅、金属硅化物(比如铌和钼硅化物)和/或硅作为强化材料和基质材料两者的复合材料(比如陶瓷基质复合材料(CMC))。尽管本发明的有利条件将参照燃气涡轮发动机元件得到描述，本发明的教导通常可用于其基底和/或涂层系统受到熔盐侵蚀的任何元件。
多层热/环境阻挡涂层T/EBC系统14在图1中得到示意性描绘。如在图1中显示的那样，含硅元件10的基底12用涂层系统14保护，涂层系统14任选地包括热阻挡涂层(TBC)18。涂层系统14对元件10的在下面的基底12提供环境保护，同时任选的TBC 18减低元件10和涂层系统14的内部层16、20、22和24的操作温度，从而使得比起否则可能的幸存温度，元件10能够幸存于更高的温度环境。尽管涂层系统14在图1中描绘为含有层16、18、20、22和24中的每一个，从以下讨论变为显而易见的是，这些层中的一个或更多个可自涂层系统14省略。像这样，图1的涂层系统14表示本发明范围内多种不同涂层系统中的一种。
在图1中描绘的涂层系统14的内部层22称为环境阻挡层22，其通过直接涂布于基底12的粘合涂层16粘附于基底12。在图1中显示的其它层包括过渡或中间层20和过渡层24。根据本发明的优选方面，涂层系统14进一步包括腐蚀阻挡涂层26，其作为元件10的最外层而沉积。如在以下更详细讨论的那样，腐蚀阻挡涂层26通过抑制熔盐渗透来防止或至少抑制内部层16、20、22、24和18特别是环境阻挡层22的腐蚀性侵蚀。
碳化硅(以及硅和其它硅化合物)在腐蚀性环境中降解的主要机理为形成挥发性氢氧化硅(Si(OH)4)产物。因为氧化剂在通常适合用作TBC 18的材料中的扩散性通常很高，尤其是在TBC 18具有由于PVD沉积造成的柱状晶粒结构的情况下，单独的和优选与涂层系统14的其它层组合的阻挡层22对氧化剂比如水蒸气呈现低扩散性，抑制在粘合涂层16和/或基底12内形成有害的晶体氧化物产物。用于阻挡层22的优选组成也为与基底12化学和物理相容的，以保持在苛刻的热条件下附着于区域12。按照美国专利第5496644、5869146、6254935、6352790、6365288、6387456和6410148号中的教导，其相关内容通过引用结合到本文中，用于阻挡层22的合适材料包括碱土金属铝硅酸盐，其显著实例包括铝硅酸钙、铝硅酸钡、铝硅酸锶并且尤其是BSAS(如上所述)。备选地或另外地，例如根据美国专利第6296941、6312763、6645649和6759151号，阻挡层22可含有稀土硅酸盐。BSAS(并且特别是化学计量的BSAS)及用于阻挡层22的其它优选组成给含Si基底12以及在下面的层16和20提供环境保护，如以上所讨论的那样。结果，当元件10暴露于燃气涡轮发动机的氧化燃烧环境时，阻挡层22能够抑制在基底12处有害结晶二氧化硅层的生长。另外，阻挡层22的优选组成由于低导热率而呈现良好的热阻挡性能，物理顺应于含有SiC的基底比如基底12，并在CTE方面与含有Si的基底12相对相容。用于阻挡层22的合适厚度范围为约50-约250微米。
如上所述，涂层系统14的粘合涂层16用于使环境阻挡层22(并且因此使其余层18、20、24和26)粘附于基底12。用于粘合涂层16的优选组成含有硅。例如，粘合涂层16可含有以下成分或由其组成：元素硅，具有一种或更多种另外的金属、金属间化合物或陶瓷相(例如碳化硅和/或氮化硅)的硅，和/或一种或更多种硅合金(例如硅铝、硅铬、硅镁、硅钙、硅钼/或硅钛合金)。根据Wang等共同受让的美国专利第6299988和6630200号，在层16中包含硅有益于改善基底12的抗氧化性和提高其它层18、20、22、24和26对基底12的粘合，特别是在区域12含有SiC或氮化硅的情况下。对于层16的合适厚度为约50-约125微米。
中间层20可用于某些应用以促进阻挡层22粘附于粘合涂层16和元件10在下面的基底12。用于中间层20的值得注意的材料包括莫来石和莫来石与碱土铝硅酸盐的混合物例如BSAS，或式RE2Si2O7的稀土硅酸盐。对于中间层20的合适厚度范围，取决于具体应用，为约25-约75微米。
TBC 18用于保护其覆盖的在下面的阻挡层22和元件10免于高操作温度。燃烧液体燃料的涡轮发动机中的热气路元件比如叶片桶、喷嘴和护罩通常用热阻挡涂层(TBC)保护。用于TBC 18的合适材料包括单独的YSZ或适当加入能够减少TBC 18的CTE的其它掺杂氧化物的YSZ。用于TBC 18的备选材料包括本领域已知和提出用于热阻挡涂层的其它陶瓷材料，比如锆酸盐和钙钛矿材料。对于TBC 18的合适厚度范围取决于具体应用，为约25-约750微米。
过渡层24为涂层系统14的任选层，其如果存在，可用于减轻在TBC 18和阻挡层22之间的CTE失配，和/或抑制TBC 18和阻挡层22之间的反应，例如在TBC 18含有YSZ和阻挡层22含有化学计量的BSAS的情况下。如果TBC 18含有YSZ和阻挡层22含有BSAS，用于过渡层24的特别合适的材料包括YSZ与氧化铝、莫来石和/或碱土金属铝硅酸盐的混合物，如在Wang等共同受让的美国专利第6444335号中教导的那样。过去已经提出的过渡层材料也包括式RE2Si2O7的稀土硅酸盐。对于过渡层24的合适厚度将取决于具体应用，尽管在至高达约100微米范围内的厚度通常为适当的。
在导致本发明的研究期间，评价了未涂布的含Si基底和用EBC系统保护的含Si基底在中等温度范围内对熔盐沉积物造成的热腐蚀性侵蚀的敏感性。如先前讨论的那样，I型钠热腐蚀由熔融Na2SO4沉积物引起，钒热腐蚀由熔融V2O5沉积物引起。引发腐蚀性侵蚀的腐蚀剂可作为燃气涡轮发动机燃烧的燃料中的杂质存在。热腐蚀的详细机理随受侵蚀材料的性质和腐蚀剂的性质、暴露的温度和时间、熔盐沉积速率和燃料中有害阳离子(例如钠和/或钒)的浓度而不同。未涂布的含Si基底和用EBC系统保护的含Si基底两者均显示对腐蚀性侵蚀非常敏感。研究确定，CMC未给予超过它们用于燃烧含有成盐杂质的低等级燃料涡轮机的超合金替代品的本质有利条件。因为TBC 18以及涂层系统14的其它层16、20和22可含有Si和/或复合铝硅酸盐，它们对热腐蚀敏感并且需要进一步的保护措施。
根据本发明的优选方面，为了保护涂层系统14的下面的层16、18、20、22和24免于热腐蚀，所沉积涂层系统14的最外表面由腐蚀阻挡涂层26形成，并且腐蚀阻挡涂层26含有至少一种含有稀土(RE)氧化物的化合物，该化合物能够在升高的温度下与一种或更多种熔盐，例如由杂质比如Na2SO4、V2O5、K2SO4和PbSO4在约600℃-约1000℃的范围内形成的液态盐腐蚀剂反应。另外，在含有稀土氧化物的化合物与熔盐之间的反应必须在腐蚀阻挡涂层26的表面形成致密的保护性副产物阻挡层28。副产物阻挡层28具有比熔盐本身更高的熔化温度(例如约1200℃或者更高)并且防止或延迟进一步的熔盐向下面结构的渗透。
特别合适的含有稀土氧化物的化合物包括(但不限于)稀土氧化物(RE2O3)、稀土磷酸盐(REPO4)、稀土锆酸盐(RE2Zr2O7)、稀土铪酸盐(RE2Hf2O7)和/或含有稀土氧化物的其它化合物，其非限定性实例包括稀土单硅酸盐(RE2SiO5)和稀土二硅酸盐(RE2Si2O7)。在本发明的优选实施方案中，稀土(RE)元素为Sc、Y、La、Ce、Pr、Nd、Pm、Sm、Eu、Gd、Tb、Dy、Ho、Er、Tm、Yb和/或Lu中的一种或更多种。一种或更多种含有稀土氧化物的化合物以足以形成副产物阻挡层28的量存在于腐蚀阻挡涂层26中，副产物阻挡层28在图1中作为涂层系统14和元件10的连续和最外层描绘。为此，一种或更多种含有稀土氧化物的化合物以重量计应构成腐蚀阻挡涂层26的至少15％，例如约30％-约100％，并且更优选地为约50％-约100％。除了含有稀土氧化物的化合物，腐蚀阻挡涂层26可进一步含有常规TBC材料，包括经稳定的氧化锆并且特别是氧化钇稳定的氧化锆(YSZ)和/或其它已知的TBC材料，例如其它陶瓷材料比如锆酸盐和钙钛矿材料。对于腐蚀阻挡涂层26的合适厚度为至少50微米，例如约50微米-约200微米，并且更优选地为约75微米-约125微米，优选的厚度取决于具体应用。
如先前所指出的那样，在腐蚀阻挡涂层26中存在一种或更多种含有稀土氧化物的化合物旨在促进在升高的温度下与熔盐的反应，并且特别是与由于可在燃气涡轮发动机中燃烧的低等级燃料中的杂质而可形成的那些盐的反应。用于通过腐蚀阻挡涂层26形成的副产物阻挡层28的合适组成包括REVO4、RE2V2O7和/或Na-RE-Si-O化合物，其中RE为腐蚀阻挡涂层26的稀土氧化物的稀土金属。例如，含有至少15重量％的稀土氧化物比如Y2O3(氧化钇)作为含有稀土氧化物的化合物的腐蚀阻挡涂层26能够与V2O5反应形成YVO4反应产物，该产物具有约1810℃的熔化温度并形成副产物阻挡层28，其然后抑制另外的V2O5渗透进入涂层系统14的内部层16、20、22、24和18。还相信氧化钇与含有Na2O的熔盐比如Na2SO4反应形成Na-Y-Si-O化合物，其熔化温度可高达约1365℃。像这样，含有足够量氧化钇和/或一种或更多种类似的含有稀土氧化物的化合物的腐蚀阻挡涂层26应能够保护或至少显著延长在高温下暴露于熔盐的燃气轮机元件的寿命。
为了促进其对裂缝或散碎和下面的基底12与涂层16、20、22、24和18暴露于熔盐的抗性，可调节腐蚀阻挡涂层26中的一种或更多种含有稀土氧化物的化合物的含量，以增大其顺应性和/或促进更接近地匹配其保护的基底的热膨胀系数(CTE)。例如，腐蚀阻挡涂层26可含有相对大量的Y2Si2O7，其CTE为约5ppm/℃，并与典型CMC相容。备选地或另外地，一种或更多种含有稀土氧化物的化合物可基于具有更接近地匹配腐蚀阻挡涂层26其余部分的CTE来进行选择。例如，纯RE2O3化合物和REPO4化合物的CTE通常与YSZ的CTE相容。
腐蚀阻挡涂层26可单独使用或与用于保护涂层系统14及其在下面的基底12免于热腐蚀的其它方法组合使用。例如，腐蚀阻挡涂层26可与一种或更多种加入到含有钒的液体燃料以产生惰性高熔点产物比如Mg3V2O8的Mg化合物组合使用。已知这些产物固定钒-基杂质以抑制钒-诱导的热腐蚀。
如同现有技术的粘合涂层和环境涂层，涂层系统14的层16、18、20、22和24以及腐蚀阻挡涂层26可经热喷涂工艺例如空气和真空等离子喷涂(分别为APS和VPS)单独沉积，尽管可预见沉积可经其它已知技术比如化学气相沉积(CVD)和高速氧-燃料(high velocity oxy-fuel，HVOF)工艺实施。腐蚀阻挡涂层26也可经已知技术比如浆料涂布和PVD技术沉积，可实施后者以在单个的层16、18、20、22、24和26中的一层或更多层中得到柱状晶粒结构。可在沉积单个的层16、18、20、22、24和/或26之后实施热处理，以减轻从升高的沉积温度冷却期间产生的残留应力。
如先前所指出的那样，本发明的腐蚀阻挡涂层26也适用于在对熔盐腐蚀(热腐蚀)敏感的超合金元件上使用。图2描绘这样的元件30为，其具有用热阻挡涂层(TBC)系统34保护的超合金基底32。也如在图2中显示的那样，TBC系统34包括金属粘合涂层36和陶瓷外涂层38。粘合涂层36旨在给元件30的在下面的基底32提供环境保护，而外涂层38(任选地与元件30的内部冷却组合)减低元件30的操作温度，从而使得比起否则可能的幸存温度，元件30能够在更高的温度环境内幸存。多种材料可用于外涂层38，包括氧化钇稳定的氧化锆(YSZ)组合物，它们由于其高温能力、低导热率和相对容易沉积已经得到广泛使用。用于粘合涂层36的合适材料包括抗氧化覆盖涂层比如MCrAlX(其中M为铁、钴和/或镍，和X为钇、稀土金属和/或反应性金属)，和可含有化合物比如铝化物金属间化合物的抗氧化扩散涂层。腐蚀阻挡涂层26及其形成的副产物阻挡层28可如参照图1所描述的那样。
尽管本发明已经根据优选的实施方案得到描述，显而易见的是其它形式可由本领域技术人员采用。因此，本发明的范围仅通过所附权利要求限定。

Claims (11)

1.在物品(10，30)的基底(12，32)上的涂层系统(14，34)，该涂层系统(14，34)包含覆在基底(12，32)上的至少一个涂层(16，18，20，22，24，36，38)，该涂层(16，18，20，22，24，36，38)具有对熔盐杂质促进的热腐蚀敏感的组成，其特征在于：
腐蚀阻挡涂层(26)，其覆在涂层(16，18，20，22，24，36，38)上并含有至少一种与熔盐杂质反应以在腐蚀阻挡涂层(26)的表面形成致密的保护性副产物阻挡层(28)的含有稀土氧化物的化合物，该至少一种含有稀土氧化物的化合物以至少15重量％的量存在于腐蚀阻挡涂层(26)中并且选自稀土氧化物(RE2O3)、稀土磷酸盐(REPO4)、稀土锆酸盐(RE2Zr2O7)、稀土铪酸盐(RE2Hf2O7)。
2.权利要求1的涂层系统(14)，其特征在于基底(12)由选自以下的含硅材料形成：金属硅化物合金；用碳化硅、氮化硅、硅化物和/或硅强化的金属基质复合材料；具有碳化硅、氮化硅、硅化物和/或硅基质的复合材料；以及具有用碳化硅、氮化硅、硅化物和/或硅强化的碳化硅、氮化硅、硅化物和/或硅基质的复合材料。
3.权利要求2的涂层系统(14)，其进一步特征在于在基底(12)与涂层(18，20，22，24)之间的至少一个粘合涂层(16)，粘合涂层(16)由元素硅、硅合金和具有一种或更多种另外的陶瓷相的硅中的至少一种形成。
4.权利要求2或3的涂层系统(14)，其特征在于涂层(22)为包含硅酸盐、碱土金属铝硅酸盐和/或稀土金属硅酸盐的环境阻挡层(22)。
5.权利要求1的涂层系统(34)，其特征在于基底(32)由选自镍-基、钴-基和铁-基超合金的金属材料形成。
6.权利要求5的涂层系统(34)，其进一步特征在于在基底(32)与涂层(38)之间的至少一个粘合涂层(36)，粘合涂层(36)由MCrAlX覆盖涂层或扩散铝化物形成，其中M为铁、钴和/或镍，X为稀土金属和/或反应性金属。
7.权利要求6的涂层系统(34)，其特征在于X为钇。
8.权利要求5-7中任何一项的的涂层系统(34)，其进一步特征在于在涂层(36)与腐蚀阻挡涂层(26)之间的至少一个热阻挡层(38)。
9.权利要求1的涂层系统(14，34)，其特征在于腐蚀阻挡涂层(26)的至少一种含有稀土氧化物的化合物含有选自Sc、Y、La、Ce、Pr、Nd、Pm、Sm、Eu、Gd、Tb、Dy、Ho、Er、Tm、Yb和Lu的元素的氧化物。
10.权利要求1的涂层系统(14，34)，其进一步特征在于在腐蚀阻挡涂层(26)表面上的副产物阻挡层(28)，副产物阻挡层(28)限定涂层系统(14，34)的最外表面层并且选自REVO4、RE2V2O7和Na-RE-Si-O化合物。
11.权利要求1的涂层系统(14)，其特征在于物品(10)为燃气涡轮发动机的元件。
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