CN103827352A - 形成具有经设计的表面粗糙度的热障涂层系统的方法 - Google Patents

形成具有经设计的表面粗糙度的热障涂层系统的方法 Download PDF

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CN103827352A
CN103827352A CN201280042401.2A CN201280042401A CN103827352A CN 103827352 A CN103827352 A CN 103827352A CN 201280042401 A CN201280042401 A CN 201280042401A CN 103827352 A CN103827352 A CN 103827352A
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安德鲁·J·布恩斯
加里·B·梅里尔
约翰·R·保卢斯
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Mikro Systems Inc
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Abstract

一种制造具有陶瓷热障涂层（28，32）的基底（16）的方法。所述涂层的层之间的界面包括经设计的表面粗糙度（12，24）以提高其间的接合的机械完整性。将表面粗糙度形成于模具（10，20）的表面中并通过随后的材料浇铸层（16，28）引入。在应用所述涂层之前可将所述基底部分烧结（76），并可共同烧结经涂覆的基底和涂层以形成完全一致的无应变的间层。

Description

形成具有经设计的表面粗糙度的热障涂层系统的方法
本申请为2011年8月30日提交的共同待决申请第13/221077号的部分继续申请（代理人案号2010P13124US），其通过引用将其全部内容并入本文。
技术领域
本发明一般性涉及陶瓷涂覆的金属部件以及应用这种涂层的方法。
背景技术
已知使用陶瓷热障涂层以保护在燃气涡轮发动机中暴露于热的燃烧气体的金属零件。美国专利申请公开US2009/0110954A1描述了已知的热障涂层系统，其通常包括陶瓷热障涂层与底层金属基底之间沉积的粘合涂层材料。还已知，改进的热障涂层粘附可通过在粘合涂层材料上提供粗糙化的表面来实现，例如通过控制用来沉积粘合涂层材料的工艺参数。一种这样的技术描述于美国专利申请公开US2010/0092662A1中。
附图说明
参照附图在以下描述中解释本发明，附图示出：
图1至图5举例说明根据本发明的实施方案的方法中的步骤。
图6为根据本发明的实施方案的燃气涡轮机部件的横截面图。
图7举例说明了根据本发明的实施方案的方法中的步骤。
发明详述
本发明人已经认识到需要进一步改进用于提高陶瓷热障涂层的粘附的技术。例如，尽管已知通过控制借此沉积材料的喷涂参数来影响粘合涂层材料的表面粗糙度，但是本发明人已经发现这样的喷涂工艺控制可能由于经历工艺的多个应用而在热障涂层系统中的层之间的机械界面结构中的可变性而不适于一些先进的燃气涡轮发动机应用。
图1至图6举例说明了根据本发明的实施方案的方法的步骤。在图1中，使模具10（基底模具）形成为在内表面14上具有第一经设计的表面粗糙度12。表面粗糙度12不是例如可通过喷砂法或喷射法实现的随机得到的形貌，而是特定设计成具有期望表面特征几何和大小的经设计的表面。可通过如美国专利7141812描述的切割光刻法（tomo-lithographicprocess）或通过任意其他已知工艺形成这样的经设计的表面形貌。将这种基底模具用于浇铸如图2所示的生坯16，从而将经设计的表面粗糙度12复制到生坯16的外表面18上。例如，可从陶瓷或金属粉末浆料浇铸生坯16，并且生坯16可以是燃气涡轮发动机部件的基底的形状。
使另一个模具20（粘合层模具）形成为在如图3举例说明的内表面24上具有另一个经设计的表面粗糙度22。这里，同样地，表面粗糙度22不是随机得到的形貌，而是特定设计成具有期望表面特征几何和大小的经设计的表面。将生坯16从模具10移除并且用小的控制的空间26将生坯表面18与第二模具表面24分离的方式放置于模具20内。空间26呈现出待连接至生坯16的粘合涂层材料的期望厚度。
之后，如图4举例说明的，将浆料形式的粘合涂层材料28浇铸至空间26中并使其凝固。浆料与生坯16的外表面18上的表面粗糙度12协作以形成生坯16与粘合涂层材料28之间的期望机械互连。另外，将模具20的内表面24上的表面粗糙度22转移至粘合涂层材料28，使得当将具有涂层28的生坯16从模具20中移除时，其外表面30可用于接收热障涂层材料32，以形成如图5所示的热绝缘部件34。热障涂层材料32可通过已知的喷涂方法应用或其可通过使用又一种模具36（涂层模具）浇铸。
有利地，根据本发明的实施方案的热绝缘部件具有基底与粘合涂层之间的由形成于基底上之第一经设计的表面粗糙度限定的第一期望的机械互连，以及粘合涂层与上覆陶瓷热障涂层之间的由形成于粘合涂层材料上的第二经设计的表面粗糙度限定的第二期望的机械互连。第一机械互连和第二机械互连因设计者可能期望的而可具有不同的物理参数。例如，可将粗糙度特征的尺寸设计成两个机械互连之间不同，该不同对应于两种不同的用于浇铸生坯16和粘合涂层材料28的浆料的物理参数的差异。另外，第一机械互连和/或第二机械互连的物理参数以及粘合涂层材料的厚度可从部件的一个区域到另一个区域变化。例如，在燃气涡轮发动机运行期间，翼片部件的前缘可比翼片的其余部分经受更严重的冲击损害。根据本发明制造的翼片可在前缘区具有较厚的粘合涂层材料层和/或其可在前缘区具有提供两个材料层之间更多表面区域接触（即较多侵入性表面粗糙度图案）的机械互连。
图6为根据本发明的实施方案的一个这样的热绝缘部件40的说明。部件40包括受热障涂层44保护的基底42，热障涂层44在部件的一个区域到另一个区域之间变化。热障涂层44包括粘合涂层材料46层和陶瓷隔热材料48的顶层。在部件40的第一区域50中，例如翼片的吸入侧或燃烧器过渡件的笔直区域，可通过接近具有相对长周期的正弦波形的基底表面的粗糙度来产生基底42与粘合涂层材料46之间的机械互连52；而在部件40的第二区域54中，例如翼片前缘或燃烧器过渡件的弯曲区域，可通过接近具有相对较短周期的正弦波形的基底表面的粗糙度来产生基底42与粘合涂层材料46之间的机械互连56。相对较短的正弦波形提供了每单位表面面积较多的接触面积的更加侵入性的互连。另外，可通过特征为锯齿状64的粘合涂层表面的粗糙度来产生第一区域50中粘合涂层材料46与陶瓷隔热材料48之间的机械互连58；而可通过包括突出底切形（protruding undercut shape）60的粘合涂层表面的粗糙度来产生第二区域54中粘合涂层材料46与陶瓷隔热材料48之间的机械互连62。突出底切形60提供了比锯齿形64更加侵入性的互连。另外，与在区域50中的粘合涂层材料46的平均厚度相比，在区域54中的粘合涂层材料46的平均厚度可更厚。可通过上述和图1至图5中举例说明的模制和浇铸技术利用反复应用的精度来产生这样的特征。因此，本发明提供了在设计热障涂层系统中现有技术不可达到的柔性程度和控制精度。
用于在现有技术陶瓷热障系统中利用粘合涂层的主要目的是在形成金属-陶瓷界面的表面中提供期望的粗糙度，这是因为如果不存在粘合涂层，则浇铸金属基底表面不会提供与陶瓷隔热层的界面的期望机械程度。另外，传统的MCrAlY粘合涂层材料也提供了铝源，当部件暴露于高温时，用于形成保护性氧化铝层。在本发明的一个实施方案中，使用具有期望的适合于直接应用陶瓷热障涂层材料32而没有任何介入粘合涂层的经设计的表面粗糙度12的形成氧化铝的基底材料来浇铸图2的生坯16。在这些实施方案中，表面粗糙度12可相当于或优于利用传统热喷粘合涂层材料实现的表面粗糙度。因此，在一些实施方案中，本发明提供了在基底的表面上有效确保适当的金属-陶瓷界面而不需要粘合涂层的期望粗糙度。
本发明有利地利用这样的工艺实施，其中选择金属和陶瓷材料并将其加工以协同匹配烧结收缩和热膨胀性能二者。在图7中举例说明了一个这样的工艺70，其包括以下步骤：72-选择CTE可相容的金属和陶瓷材料；74-由金属材料的粉末形成基底；76-将基底部分烧结；78-由包含一定数量的有效抑制材料烧结温度的纳米颗粒的陶瓷材料的粉末在基底上形成层；以及79-将基底和陶瓷材料的层共同烧结至最终密度。将基底部分烧结的步骤76可确保在共烧结步骤期间基底和层的收缩是大致相同的，以及包含一定数量的纳米颗粒的步骤78可确保基底和层的烧结温度是大致相同的以实现共烧结步骤79。
应理解，为了实现层之间的期望机械界面，形成基底的步骤76可根据相应于图1和2的上述模制工艺完成，以及将层形成于基底上的步骤78可根据相应于图3和4的上述模制工艺完成。结果是这样的层化材料系统，其具有完全一致的无应变的间层，由两个构件沿着界面的散置元件组成，并且由经设计的表面粗糙度形貌限定。所得共加工系统是密集的和尺寸上稳定的，并且可用于侵入性的抗冲击的高温燃气涡轮机应用的先进模块化插件。在各个实施方案中，本文中公开的方法允许施用氧化铝、稳定化氧化锆和/或钇铝石榴石粉末的双模粒径分布将基于铬、钼、铌、钽、钨和/或铁的低膨胀合金难熔金属系统与烧结活性陶瓷粉末热障覆层组合物共加工。
与之前在没有使用用于应力释放的陶瓷层中的经设计的槽（slot）和/或柔性中间层的情况下可能在金属基底上实现的陶瓷层相比，本文中所描述的工艺和材料使得能够在金属基底上实现厚得多的陶瓷层。在整个广泛的工作温度范围（例如在一些实施方案中为0至1000℃或0至1500℃）在供使用的超合金基底上，本发明可生产超过1.0mm厚（包括超过2.0mm厚，例如在一些实施方案中高达3.0mm厚）的耐久性一体的（monolithic）陶瓷层，而在该温度范围中现有的一体的陶瓷层限于约0.3mm厚。本文中，“一体的”意指没有用于应力释放的柔性中间层或经设计的槽的层。
尽管本文中示出并描述了本发明的多个实施方案，但是明显地是仅通过示例的方式提供这些实施方案。在不背离本发明的情况下可进行多种变化、改变和替代。因此，本发明旨在仅受所附权利要求书的精神和范围的限制。

Claims (11)

1.一种形成热绝缘部件的方法，所述方法包括：
形成第一模具，所述第一模具包括表现第一表面粗糙度特征的经设计的表面；
将第一粉末和粘合剂的混合物浇铸在所述第一模具中以形成生坯，所述生坯包括具有所述第一表面粗糙度特征的第一表面；
将所述生坯从所述第一模具中移除；
形成第二模具，所述第二模具包括表现第二表面粗糙度特征的经设计的表面；
将所述生坯插入所述第二模具中；
将第二粉末和粘合剂的混合物浇铸在所述生坯与所述第二模具之间的空间中以形成具有第二涂层的生坯，所述第二涂层包括具有所述第二表面粗糙度特征的第二表面；
将具有所述第二涂层的所述生坯从所述第二模具移除；以及
将陶瓷隔热材料层应用至所述第二表面上。
2.根据权利要求1所述的方法，还包括形成所述第一模具和所述第二模具，使得所述第一表面粗糙度特征和所述第二表面粗糙度特征不同。
3.根据权利要求1所述的方法，还包括：
选择所述第一粉末以包含金属合金；和
选择所述第二粉末以包含粘合涂层材料。
4.根据权利要求1所述的方法，还包括形成所述第一模具以沿着第一区域表现所述第一表面粗糙度特征以及沿着第二区域表现第三表面粗糙度特征。
5.通过根据权利要求1所述的方法形成的装置。
6.一种形成热绝缘部件的方法，所述方法包括：
形成基底模具，所述基底模具包括表现第一表面粗糙度特征的经设计的表面；
将包含粉末和粘合剂的第一混合物浇铸在所述基底模具中以形成基底，所述基底包括具有所述第一表面粗糙度特征的第一表面；
将所述基底从所述基底模具移除；
部分烧结所述基底；
形成涂层模具；
将部分烧结的基底插入所述涂层模具中；
将包含粉末和粘合剂的第二混合物浇铸在所述部分烧结的基底与所述涂层模具之间的空间中以在所述基底上形成层；
将具有层的所述基底从所述涂层模具移除；以及
将层和所述基底共同烧结至最终密度。
7.根据权利要求6所述的方法，还包括在所述第二混合物中引入能有效降低所述层的烧结温度以实现所述共烧结步骤的一部分纳米颗粒。
8.根据权利要求6所述的方法，其中所述第一混合物包含金属粉末，所述第二混合物包含陶瓷粉末，并且所述方法还包括：
通过以下步骤在所述基底与所述层之间形成粘合涂层：
形成粘合涂层模具，所述粘合涂层模具包括表现第二表面粗糙度特征的经设计的表面；
在将所述层形成在所述基底上之前将所述部分烧结的基底插入所述粘合涂层模具中；
将粘合材料浇铸在所述部分烧结的基底与所述粘合涂层模具之间的空间中以将粘合涂层形成在所述基底上；
之后使用具有粘合涂层的所述基底进行将所述层形成于所述基底上的步骤。
9.根据权利要求6所述的方法，还包括形成所述基底和所述粘合涂层模具，使得所述第一表面粗糙度特征不同于所述第二表面粗糙度特征。
10.根据权利要求6所述的方法，还包括控制所述部分烧结的基底与所述涂层模具之间的所述空间，使得所述基底上的所述层超过1.0mm厚。
11.通过根据权利要求6所述的方法形成的装置。
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