CN103879084A - 用于涡轮部件的涂层 - Google Patents

用于涡轮部件的涂层 Download PDF

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CN103879084A
CN103879084A CN201310707883.5A CN201310707883A CN103879084A CN 103879084 A CN103879084 A CN 103879084A CN 201310707883 A CN201310707883 A CN 201310707883A CN 103879084 A CN103879084 A CN 103879084A
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metal matrix
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CN103879084B (zh
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T.维德梅
S.奥里格斯
A.斯坦科维斯基
P-D.格拉斯索
M.梅拉斯
T.鲍曼恩
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General Electric Technology GmbH
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Abstract

本发明涉及用于涡轮部件的涂层。一种方法和涡轮部件，该涡轮部件包括具有基质层的涂层，该基质层包括耐高温疏水聚硅氧烷填料，其中，涂层具有优良的机械强度和耐热性。

Description

用于涡轮部件的涂层
技术领域
本发明涉及涡轮部件的涂层，特别是低压蒸汽涡轮的叶片的涂层，并且涉及用于这样的部件的具有疏水属性的持久涂层。 
背景技术
在以下描述中，用语“涡轮”用于指示旋转发动机，该旋转发动机具有通过流体介质(诸如水或气体)耦合的定子和旋转部件力。本发明特别关注的是轴向涡轮，其包括沿径向布置的固定定子叶片或导叶，该固定定子叶片或导叶与运动的转子叶片的沿径向布置交替。运动一般表现为相对于外壳或壳体的移动。 
在大型蒸汽涡轮中，加压蒸汽典型地横跨涡轮的若干级膨胀，它们分别被称为涡轮的高压级、中压级和低压级。在低压级中，蒸汽膨胀，并且冷却到接近冷凝点，以及排放到冷凝器中。低压级的最后一级处的蒸汽的相对湿度可导致液滴腐蚀和其它潜在的性能损失来源，以及材料由于水滴冲击而产生的退化，从而需要交换附加的备用部件。 
如通过引用而整体地并入在本文中的共同拥有的美国专利No. 6623241中描述的，涡轮蒸汽在低压涡轮中膨胀到冷凝器压力通常导致湿蒸汽的范围。湿的废蒸汽中的冷凝水的质量含量可高达14%。涡轮蒸汽的整个质量流的推动力被保持，这与冷凝水含量无关。然而，在涡轮的旋转元件和固定元件中存在液相可导致耗散损失增加。在所谓的低压涡轮中，大约12-14%的质量流可以以水的形式生成。该水分损失可导致低压涡轮的近似6-7%的效率损失，这对应于整个蒸汽动力装置的近似1-2%的效率损失。在联合循环和非常规动力装置中，相比之下，低压涡轮的功率相对于整个装置功率的贡献略高，以使由水分损失引起的总效率损失总体上可在2-2.3%或3-3.5%之间。 
损失程度大部分取决于水滴的大小。在大多数情况下，在蒸汽相中仅包含在微米范围内的小水滴。根据最新理解，这些水滴保持它们的大小，并且不凝结成较大的水滴，只要它们在蒸汽中漂浮或流动。类似于蒸气，它们与将推动力施加到叶片上的蒸汽流一起流动。只要水滴保持在该小的大小范围内，则它们不对涡轮的操作或性能具有不利影响。然而，在它们流过导叶和旋转叶片时，水滴增大。相信，在与金属表面接触期间，特别是在接触导叶的凹入金属表面时，小冷凝物滴散布在表面上，并且在凹入或凸出的表面上面形成紧密的冷凝物膜，该凝物膜在导叶上流动，该小冷凝物滴遭受蒸汽的剪切力的作用。在导叶的后缘处，流体膜离开表面，其中，流体膜加速，并且被旋转的轮叶轮分开。该分开所生成的水滴比自发冷凝产生的水滴具有更大的直径。 
由于离心力，这些较大的水滴被旋转叶片向外旋转向涡轮壳体。这表示工作介质的推动力的一部分未传递到叶片上，这导致水分损失，该水分损失降低低压涡轮的效率的程度。该现象随着大小和质量而增加，并且因而，水滴的离心力增大。此外，水在低压涡轮的壳体的内表面上的积聚在旋转的导叶末端和导叶盖上引起耗散摩擦损失。最后，直径范围为100-200微米以及速度范围为超过250m/s的扩大水滴由于水滴冲击而引起腐蚀。该腐蚀主要取决于具体材料，由此钛和钛合金的导叶材料尤其易受影响，该钛和该钛合金优选地用于低压涡轮的大叶片。 
已经尝试向涡轮的导叶叶片提供提高叶片的耐腐性的涂层，从而延长它们的使用寿命。上面引用的No. 6623241专利描述了许多用于蒸汽涡轮的叶片的不同的涂层，其由基底上的耐磨硬材料构成。 
为了增大低压涡轮的大小，特别是对低压涡轮的最后一级安装的叶片的大小，已经提出用诸如基于碳纤维的材料的复合物代替作为基本叶片材料的钢或钛。虽然已经公开了大量的这样的设计，但是这样的复合叶片的现实应用目前局限于高级飞行器发动机的燃气涡轮。 
至今在电功率生产领域中妨碍大规模采用复合叶片的原因之一是复合材料无法抵抗如上所述的腐蚀过程。在被来自水蒸汽的冷凝物不断冲击的情况下，复合材料比目前应用的金属合金腐蚀得更快，并且因而不适合作为大型蒸汽涡轮叶片的翼型件材料。 
对于复合叶片，例如在公开的美国专利申请US 2008/0152506 A1和公开的国际专利申请WO 2011/039075 A1和WO 2010/066648中描述了保护层。 
在公开的美国专利申请No. 2009/0298369 A1中，描述涂层和方法，该方法包括使用并入到聚合物涂层材料中的疏水活性颗粒，其中，涂层用作用以使颗粒结合到下面的基底上的基质。Pg 3 §38可均一地分布。 
考虑到涡轮部件的耐磨涂层的领域中的已知努力，可看成本发明的一个目的的是：提供涂层，以及适合蒸汽涡轮的大型部件(特别是低压涡轮或级内的叶片)的涂覆过程。 
发明内容
根据本发明的一方面，提供具有疏水填料的涂层，可调节该疏水填料的属性，以经受住工作温度。这一般由疏水填料实现，该疏水填料是聚硅氧烷，能够烘烤该聚硅氧烷，以实现所需的耐热性/疏水性平衡。 
一方面提供一种用于在使用中遭受载水的气体的沿轴向旋转的机器部件的涂层，涂层具有金属基质，该金属基质具有聚硅氧烷填料。 
在一方面，涂层是包括镍或其合金的金属基质材料。 
在一方面，聚硅氧烷填料具有如通过激光衍射测得的大小分布：d10=0.37微米、D50=1.07微米和D90=2.31微米。在变型中，填料14包括纤维状、片状、球形或其它颗粒形状。 
在一方面，填料优选地构成涂层的5体积%至50体积%之间，更优选为涂层的25体积%至45体积%之间，以及最优选为涂层的35体积%至45体积%之间。 
在一方面，涂层具有没有填料的耐腐内层，并且其它方面的金属基质形成涂层的外层。 
在一方面，部件是蒸汽涡轮的翼型件。 
在另一方面，部件是燃气涡轮的气体压缩机的翼型件。 
一方面提供一种用于用具有耐腐性和疏水属性的涂层涂覆沿轴向旋转的机器的部件的方法，该方法包括以下步骤： 
提供沿轴向旋转的机器的部件
用包括金属基质的涂层涂覆部件，该金属基质具有由聚合物陶瓷前体制成的疏水材料填料，该疏水材料填料遍及金属基质的厚度均一地分布；以及
在涂覆步骤之前或之后，使填料经受受控制的部分热解步骤，以使填料部分地保持陶瓷属性和聚合物属性两者。
在一方面，涂覆方法包括电解镍镀过程。 
在基底上的可由镍或钛制成的金属基质层的厚度典型地在10-300微米的范围内。而且，涂层施加于其的基底或基部材料可包括碳钢、铬镍钢、钛基材料和复合材料。例如在涡轮的高度可超过1m的静止和旋转的导叶或叶片中使用这些材料。 
从以下详细描述和如下面列出的附图，本发明的这些和另外的方面将是显而易见的。例如，本发明的各种实施例的涂层允许在维修中在腐蚀之后使涂层局部复原，而没有在安装或拆卸状态下的移除，并且从而提供简单且成本有效的解决方案。 
附图说明
现在将参照附图来描述本发明的示例性实施例，其中： 
图1介绍蒸汽涡轮部件的剖视图，其显示本发明的示例性实施例的涂层；
图2是图1的部件和涂层的剖视图，该部件和涂层进一步包括内部和外部涂履层；以及
图3是根据本发明的另一种示例性实施例的蒸汽涡轮部件和涂层的剖视图。
部件列表 
10涂层
12外层/金属基质
14填料
16内层
20机器部件。
具体实施方式
遍及该说明书，以下用语具有以下定义。 
“疏水”限定为在材料的固体表面与水滴之间具有大于90度的如由静态悬滴法测量的接触角的材料。 
硅氧烷限定为有机硅化学中的具有Si-O-Si链的官能团。硅氧烷包括具有公式H3-Si-[O-SiH2]n-O-SiH3的被称为硅酮或聚硅氧烷的聚合氢化物，其中，氢原子可由卤素或有机基代替。 
可通过改变交联和热解/水解程度来改变特定聚硅氧烷的耐热性，其中，连续用氧代替包含端基的碳，以形成SiO2。结果是增加聚硅氧烷的陶瓷(SiO2)-有机物比，这提高耐热性，但是典型地对疏水性具有有害影响。 
图1显示示例性实施例的涂层10，涂层10至少部分地涂覆遭受水滴冲击的沿轴向旋转的机器部件20，其中，涂层10包括金属基质12，金属基质12具有分布有聚硅氧烷的填料14。这样的装置包括蒸汽涡轮装置，以及为燃气涡轮装置(特别是在压缩机上游构造有喷水器件的燃气涡轮装置)的一部分的轴向流压缩机。涂层10对轴向旋转机器的适用性是由于涂层10的耐腐性、耐热性和耐pH值性。由于该原因，示例性实施例特别适合在蒸汽涡轮或压缩机中使用。然而，本发明不受限于这些机器，而是可以可选地用于任何高温潮湿环境，其中，需要涂层10来通过硬度提供腐蚀保护，以及通过并入疏水填料颗粒提供耐热性和疏水属性。 
填料14均匀地分布在涂层10中的作用在于，这确保在涂层不可避免地腐蚀(这出现在其中存在水分的区域中的蒸汽涡轮和压缩机的侵蚀性环境中，不管材料如何，诸如像钛和镍合金)期间，腐蚀问题仍存在。 
在不同的示例性实施例中，填料14可为纤维状的，具有片状、球形或其它形状。在每种情况下，如通过激光衍射测得的大小分布优选为d10=0.37微米、D50=1.07微米和D90=2.31微米。金属基质12的加载在5 vol%至50 vol%的范围内，优选为在25 vol%至45 vol %的范围内，最优选为在35 vol%至45 vol %的范围内。 
在示例性实施例中，涂层包括不止一种类型的填料14，其中，类型的定义包括形状、大小、材料和交联/热解/水解程度。 
图2中显示的示例性实施例的涂层10包括耐腐蚀内层16和外层12，其中，内层16夹在外层12与机器部件20中间。内层16的目的是在外层12被腐蚀的情况下保护机器部件20。 
在图3中显示的示例性实施例中，颗粒可为球形颗粒、薄片状颗粒、球形和薄片状颗粒的组合。 
在示例性实施例中，可使用电解镍-磷涂覆方法，使用改编自例如在“Chemisches Vernickeln”，作者：N. Kanani，E.G. Leuze Verlag 2007(ISBN 978-3-87480-229-1)第510-513页中描述的已知电解Ni-P-PTFE涂覆方法的方法，来将涂层10施加于机器部件20，或可选地施加于内层16。方法包括使镍在还原剂中化学还原的处理步骤，其中，在润湿剂的协助下，填料14颗粒均匀地悬浮。以该方式，在填料14颗粒淀积在机器部件20上时，填料14颗粒均一地分布在镍涂层10内。 
在另一个示例性实施例中，借助于如本领域中已知的化学无电镍镀来施加涂层10。 
在又一个示例性实施例中，使用多层原理来施加涂层10，在该多层原理中，用不同的方法施加层，例如化学无电镍镀和电解镍涂层。 
在可施加包含聚硅氧烷填料14的涂层的示例性方法中，使用受控制的烘烤来改变填料耐热性/疏水属性。所需的实际烘烤温度是不均匀的，而是相反地考虑到催化物质(诸如影响交联/热解/水解程度以及聚硅氧烷的实际组成和形式的酸、锡和钛化合物)的存在，需要与所需的涂层最终用途匹配。改变聚硅氧烷与可选的聚合物疏水填料14相比的特别的优点在于，改变使得可以产生具有适合其中温度超过400℃或者甚至500℃的应用的聚合物疏水填料颗粒的涂层。该方法需要烘烤具有包含聚硅氧烷颗粒的填料的涂层的构件，使得填料的耐热性提高。在示例性实施例中，这在填料14嵌入到金属基质12中之后完成，例如，在对机器部件20进行热处理的期间，执行热处理例如是为了改进涂层与机器部件20的粘合属性。在另一个示例性实施例中，在将填料14嵌入到金属基质12中之前，完成烘烤步骤。这可例如在烘烤步骤显著地改变填料14的密度时完成。以该方式，填料14的任何收缩在其嵌入在金属基质12中之前由于热解而出现。 
这样的涂层和方法可在蒸汽涡轮涂层中，特别是在低压蒸汽涡轮中，有利地用作除雾涂层，以便降低/避免蒸汽冷凝引起的损失。 
上面仅经由实例描述本发明，其中，可在本发明的范围内进行修改。本发明还可包括本文中描述或隐含的或者图中显示或隐含的任何单独的特征，或者任何这样的特征的任何组合或任何这样的特征或组合的任何概括，这延及它们的等效物。例如，虽然疏水填料的描述的示例性实施例排外地包括聚硅氧烷颗粒，但是聚硅氧烷颗粒可与其它疏水颗粒结合起来使用，该其它疏水颗粒包括例如基于CFx的这些疏水颗粒。因而，本发明的宽度和范围不应当由以上描述的示例性实施例中的任何一个限制。用于相同、相等或相似的目的的可选特征可代替说明书(包括附图)中公开的每个特征，除非另有清楚的说明。 
除非本文中另有清楚的说明，否则遍及说明书的对现有技术的任何讨论不承认这种现有技术是广为人知的，或者形成本领域中的公知常识的一部分。 

Claims (14)

1. 一种用于在使用中遭受载水的气体的沿轴向旋转的机器部件的涂层，所述涂层具有金属基质，所述金属基质包括遍及所述涂层的厚度分布的聚硅氧烷填料。
2. 根据权利要求1所述的涂层，其特征在于，颗粒遍及所述涂层的厚度均一地分布。
3. 根据权利要求1所述的涂层，其特征在于，所述金属基质包括镍或其合金。
4. 根据权利要求1所述的涂层，其特征在于，所述填料具有颗粒的形式。
5. 根据权利要求6所述的涂层，其特征在于，所述颗粒具有如通过激光衍射测得的大小分布：d10=0.37微米、D50=1.07微米和D90=2.31微米。
6. 根据权利要求1所述的涂层，其特征在于，所述填料构成所述涂层的5体积%至50体积%之间。
7. 根据权利要求1所述的涂层，其特征在于，所述填料构成所述涂层的25体积%至45体积%之间，更优选为所述涂层的35体积%至45体积%之间。
8. 根据权利要求1所述的涂层，其特征在于，包括没有所述填料的耐腐性内层，并且所述金属基质形成所述涂层的外层。
9. 根据权利要求1所述的涂层，其特征在于，所述部件是蒸汽涡轮的翼型件。
10. 根据权利要求1所述的涂层，其特征在于，所述部件是燃气涡轮的气体压缩机的翼型件。
11. 一种用于用耐腐性涂层涂覆用于沿轴向旋转的机器的部件的方法，所述方法包括以下步骤：
提供沿轴向旋转的机器的部件；
用包括金属基质的涂层涂覆所述部件，所述金属基质具有遍及所述金属基质的厚度分布的聚硅氧烷填料；以及
烘烤所述填料，以便改变所述聚硅氧烷填料的耐热性。
12. 根据权利要求11所述的方法，其特征在于，所述烘烤在涂覆所述部件的步骤之前。
13. 根据权利要求11所述的方法，其特征在于，在所述涂覆步骤之后实行所述烘烤步骤。
14. 根据权利要求11所述的方法，其特征在于，所述涂覆方法包括电解镍镀和/或无电化学涂覆。
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