CN104507602A - 由具有低表面粗糙度的材料制成的耐磨涂层 - Google Patents

由具有低表面粗糙度的材料制成的耐磨涂层 Download PDF

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CN104507602A
CN104507602A CN201380040094.9A CN201380040094A CN104507602A CN 104507602 A CN104507602 A CN 104507602A CN 201380040094 A CN201380040094 A CN 201380040094A CN 104507602 A CN104507602 A CN 104507602A
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迈克尔·波多哥斯基
飞利浦·查尔斯·阿兰·勒比兹
卢多维克·埃德蒙·卡米尔·莫里克斯
瑟奇·塞莱斯纳
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    • F01D11/00—Preventing or minimising internal leakage of working-fluid, e.g. between stages
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    • F01D11/00—Preventing or minimising internal leakage of working-fluid, e.g. between stages
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    • F01D11/122—Preventing or minimising internal leakage of working-fluid, e.g. between stages for sealing space between rotor blade tips and stator using a rubstrip, e.g. erodible. deformable or resiliently-biased part with erodable or abradable material
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
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Abstract

本发明涉及一种涡轮发动机部件的耐磨涂层，其特征在于，所述涂层包括由耐磨材料制成的层，该层的表面粗糙处填充有热粘合陶瓷颗粒，形成具有低粗糙度的平滑、自由表面。

Description

由具有低表面粗糙度的材料制成的耐磨涂层
技术领域
本发明涉及涡轮发动机的领域并涉及一种由耐磨材料制成的涂层，该涂层在涡轮发动机定子和转子部件之间形成密封元件。这特别地涉及具有低表面粗糙度的类型的涂层。
背景技术
涡轮发动机是一种旋转机械，其中能量转移可以发生在流体和被刚性地连接到转子的叶片系统之间，例如形成诸如燃气涡轮发动机的涡轮轴发动机一部分的压缩机或涡轮。带有用于飞机的燃气轮机的涡轮轴发动机，如多流式涡轮喷气发动机在气流方向，也就是说从上游到下游，通常包括风扇、一个或多个压缩机级、燃烧室、一个或多个涡轮级和排气管。
由耐磨材料制成的涂层—参考以这种方式，由于它们能够被磨损损坏—设置在定子部件的内表面上，例如外壳，在该外壳内侧或面对该外壳旋转部件移动，如压缩机或涡轮转子的叶片系统或形成刀刃密封的迷宫式密封的叶片。为了减少在由旋转部件的端部和定子部件的涂层所形成的密封两侧上的气体泄漏，在它们之间提供尽可能小的间隙。然而，在涡轮发动机的操作循环中，该间隙可能会减少甚至消除。为了防止对移动部件的损坏，在操作阶段中允许密封的静态元件变形或通过所述旋转部件的端部被加工，其中发生了维度变化引起彼此接触的部件的交互作用。相对于所述旋转部件的所述端部结构和所述定子元件的所述内表面，以这种方式使该接触的不利影响最小化。
耐磨材料必须具有以下性质：它必须明显地具有良好的耐磨性；它还必须承受其工作中的环境温度(500℃到1200℃，例如在飞机发动机外壳内侧)，它还必须承受耐磨粒子(在上述接触中被分离)的重复碰撞产生的侵蚀；其制造和装配成本也必须尽可能小。
一种已知的耐磨材料由MCrAIY类型的合金产生，M选自镍，钴，NiCo或CoNi。例如MCrAIY基合金和致孔剂(芳香族聚酯)的混合物以商标Metco 2043熟知。根据将粉末热喷涂到基底上的技术所获得的这种材料将适合于在压缩机的或面对其转子叶片的涡轮外壳的内侧形成涂层；它还承受部件在操作中所受到的高达1200℃的温度。然而，对于该材料，在通过消除致孔剂形成气孔所必需的热解步骤后，获得了相对粗糙的表面光洁度，例如Ra+12μm。由于限制层内气流的增加，这导致了空气动力学性能的显著减少，因而从涡轮发动机的效率角度看这种表面粗糙度是不利的。对于发动机，可用材料的粗糙度从而对其单位消耗量具有影响。
发明内容
本发明的主要目的是产生一种由耐磨材料制成的涂层，其表面光洁度对涡轮发动机效率以及发动机的单位消耗量不产生负面影响。
本发明的目的因此是产生一种由耐磨材料制成的多孔结构的涂层，其表面具有小于6μm的表面粗糙度(Ra<6μm)。
本发明的另一目的是一种由耐磨材料制成的涂层，其能够承受高达1200℃的温度。该温度对应于支撑涂层的基底所能够承受的温度。
本发明的另一目的是一种由耐磨材料制成的涂层，其也不会在其上产生磨损或易碎行为。
申请人已经开发了一种由多孔耐磨材料制成的涂层，其具有带有平滑表面的额外层。该涂层是专利申请FR 1157729提交的发明主题。通过研磨沉积在多孔耐磨材料上的薄层获得了该额外层的平滑特性。特别地通过热喷涂实施该层。
申请人已经开发了一种由耐磨材料制成的新涂层。
根据本发明用于涡轮发动机部件的由耐磨材料制成的涂层，其特征在于，它包括耐磨材料层，该层的表面不规则处(irregularity)由热粘合陶瓷颗粒填充，耐磨材料层的自由表面具有低粗糙度。
特别地，陶瓷颗粒通过局部烧结被粘合并且带有低粗糙度的平滑自由表面具有小于6μm的粗糙度(Ra<6μm)。通过使用基于具有有低粒度(granulometry)的颗粒的填充材料，例如粒度(granulometry)为0.3μm的颗粒，获得了实现本发明目的的结果而不必加工该涂层。
填充表面不规则处的材料包括任何类型的陶瓷材料：氧化物、碳化物、氮化物、碳氧化物、碳氮化物等。由于在氧化环境中氧化物陶瓷具有稳定性，因此优选地为氧化物陶瓷。有利地，它是以下材料之一：氧化铝，氧化锆，氧化钇稳定的氧化锆，莫来石或氧化钇。优选地选择具有与初始耐磨材料的热膨胀系数接近的热膨胀系数的材料。此外，在低温下烧结的能力是必要的。
本发明涉及一种耐磨涂层，其耐磨材料层是多孔的并包括例如具有组分MCrAlY的合金，M选自Ni，Co，NiCo或CoNi、氧化锆或镍-石墨化合物。
根据另一特征，形成填充材料的陶瓷颗粒穿入耐磨材料的深度为50到1000μm之间。
本发明还涉及一种用于施加耐磨涂层到基底的方法，包括，在所述基底上产生耐磨层后，施加由陶瓷材料组成的粉末到所述层以填充表面不规则处，然后热处理涂层以粘合该粉末的步骤。
特别地选择陶瓷粉末的粒度(granulometry)，使得其小于形成耐磨材料的不规则处的孔的尺寸。特别地当孔由热处理产生时，在处理后施加粉末以产生气孔。
有利地，粉末以泥浆形式被施加到耐磨材料，该泥浆包括可选地与诸如硝酸的分散剂、以及可选地同样有机粘结剂一起的粉末在水中的悬浮液。
在低于1200℃的温度下进行局部烧结热处理。说烧结是局部的，由于所获得的材料不是密致材料。在热处理过程中不施加压力。此外，密致材料在没有施加压力的这些温度下不能经由短热处理产生。仅在颗粒之间的接触点存在扩散现象。
也可通过局部施加适合功率的激光束或提供局部加热的任何其他方式进行粘合热处理，特别地在直径不超过1000μm的表面区域上。
附图说明
参考附图，在阅读本发明的非限制性实施方式的详细描述后，其他特征和优点将显而易见，其中：
图1示出了具有第一放大率的本发明涂层的剖面的照相视图；
图2示出了具有更大放大率的图1的详细视图。
具体实施方式
以下示例涉及燃气涡轮发动机的高压径向压缩机；由诸如被命名为INCO909的钢制成的轮罩，在其内表面上覆盖有超过1毫米厚度的耐磨涂层。通过热喷涂与致孔剂相一起的CoNiCrAlY合金产生涂层，致孔剂为诸如芳香族聚酯、以商标名METCO 2043售卖。耐磨材料的产生包括热解致孔剂的步骤，其中在材料内形成气孔。
在材料的表面上，气孔形成必须填充的不规则处。根据本发明，陶瓷材料的粉末沉积在耐磨材料的表面上，以填充表面孔。
在此，该材料是氧化铝，其在涡轮发动机的工作温度下稳定以及因为是氧化物因此不对氧化现象敏感的优点。
优选地以水泥浆(aqueous slip)的形式提供氧化铝粉末，其粘度参数和负载因子被特别地确定，从而可以优化地覆盖材料和控制穿入的深度在50到1000μm之间。
根据在耐磨材料内待填充的气孔尺寸选择粉末的粒度。粉末的粒度在0.1至15μm之间，例如小于1μm。
小于1μm的陶瓷颗粒尺寸可在与耐磨材料基底可承受的兼容的温度下影响颗粒粘结处理。
然而，如果基底可接受的最大温度小于耐磨材料所接受的，然后有利地形成基底的局部冷却，例如通过冷却线圈。
经由陶瓷材料平滑的过程如下：
在诸如硝酸的分散剂、以及可选地诸如PVA(聚乙烯醇)的有机粘结剂的存在下，通过将例如0.3μm的适当粒度的氧化铝粉末与水混合而制备泥浆；
泥浆沉积在耐磨材料的表面上；
通过刮除表面移除过量的泥浆；
如果孔被封闭，则仅填充表面的孔，
如果孔是打开的，穿入深度由通道的数量管理；寻求大于最大接触深度的穿入深度，从而即使在触摸情况下保持低粗糙度；
在户外或在烤箱内干燥；
在600℃下热处理4小时以在必要时消除PVA，以及将陶瓷颗粒粘合在一起。进行局部烧结以粘结在微孔氧化铝相内的颗粒，其既不太脆弱，以免在涡轮发动机的操作中在任何接触之前损失其内聚力，也不太强，以防止不再耐磨但磨损的行为。
本发明的解决方案可以获得具有Ra<1μm的平滑表面的涂层。与现有技术的12μm粗糙度相比的这种粗糙度，在单位消耗量内的颗粒被估计为在0.4％。
在图1和图2中，以剖面示出了本发明的涂层，可以看到以亮的印制图片示出的耐磨材料CoNiCrAlY与以暗的印制图片示出的的被填充的气孔P，并且氧化铝Al2O3在表面上也是可见的，平滑了由表面气孔形成的不规则处。用与图1相比更大的放大率形成的图2示出了在氧化铝颗粒之间的内聚力。
本发明并不局限于在压缩机外壳上形成平滑耐磨涂层，但当这存在优点或意义时，适用于任何部件。
氧化铝可被任何其他陶瓷材料取代，只要其为足够活性的粉末的形式，以能够根据基底的耐热性在相对低的温度下进行局部烧结。氧化物是优选的。
在示例中提到的耐磨材料是Metco 2043：本发明并不局限于此。也可以使用镍石墨75/25、Metco 2460、Metco 310或Metco 314。应该指出的是，材料镍石墨75/25、Metco 310和Metco 314不包含被热解以产生孔的任何聚酯。孔直接来自沉淀耐磨材料的过程。

Claims (10)

1.用于涡轮发动机部件的耐磨涂层，其特征在于，该耐磨涂层包括耐磨材料层，该耐磨材料层的表面不规则处由热粘合陶瓷颗粒填充，该耐磨材料层的自由表面具有低粗糙度。
2.根据权利要求1所述的耐磨涂层，其中，平滑自由表面的粗糙度小于6μm，特别地小于1微米。
3.根据前述权利要求任一所述的耐磨涂层，其中，表层包括至少以下材料之一：氧化铝，氧化锆，氧化钇稳定的氧化锆，莫来石或氧化钇。
4.根据前述权利要求任一所述的耐磨涂层，其中，耐磨材料层是多孔的并包括MCrAlY成分的合金，M选自Ni、Co、NiCo或CoNi、氧化锆或镍-石墨复合物。
5.根据前述权利要求任一所述的耐磨涂层，其中，陶瓷穿入耐磨材料的深度为50到1000μm之间。
6.用于施加根据前述权利要求任一所述的耐磨涂层的方法，该方法包括，在基底上产生耐磨层后，施加陶瓷材料粉末以及然后热处理该涂层以粘结粉末的步骤。
7.根据前一权利要求所述的方法，其中，陶瓷粉末的粒度在0.1和15μm之间，并且小于耐磨材料气孔的尺寸。
8.根据权利要求6或7所述的方法，其中，所述粉末以泥浆形式施加，该泥浆包括可选地与分散剂和粘结剂一起在水中悬浮的粉末。
9.根据权利要求6到8任一所述的方法，其中，在小于1200℃的温度下进行烧结。
10.根据权利要求6到8任一所述的方法，其中，通过施加激光束或提供局部加热的其他手段进行烧结。
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