CN105392920A - 功能性梯度热障涂层系统 - Google Patents

功能性梯度热障涂层系统 Download PDF

Info

Publication number
CN105392920A
CN105392920A CN201480039754.6A CN201480039754A CN105392920A CN 105392920 A CN105392920 A CN 105392920A CN 201480039754 A CN201480039754 A CN 201480039754A CN 105392920 A CN105392920 A CN 105392920A
Authority
CN
China
Prior art keywords
layer
bonding coat
coat material
stupalith
coating
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN201480039754.6A
Other languages
English (en)
Inventor
G·J·布鲁克
A·卡梅尔
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Siemens Energy Inc
Original Assignee
Siemens Power Generations Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US13/951,542 external-priority patent/US20150030826A1/en
Application filed by Siemens Power Generations Inc filed Critical Siemens Power Generations Inc
Publication of CN105392920A publication Critical patent/CN105392920A/zh
Pending legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/04—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material
    • C23C28/042—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material including a refractory ceramic layer, e.g. refractory metal oxides, ZrO2, rare earth oxides
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
    • C23C24/103—Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/34—Laser welding for purposes other than joining
    • B23K26/342—Build-up welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/352—Working by laser beam, e.g. welding, cutting or boring for surface treatment
    • B23K26/354—Working by laser beam, e.g. welding, cutting or boring for surface treatment by melting
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
    • C23C24/103—Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides
    • C23C24/106—Coating with metal alloys or metal elements only
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/02—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material
    • C23C28/028—Including graded layers in composition or in physical properties, e.g. density, porosity, grain size
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/32—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer
    • C23C28/321—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer with at least one metal alloy layer
    • C23C28/3215—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer with at least one metal alloy layer at least one MCrAlX layer
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/32—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer
    • C23C28/325—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer with layers graded in composition or in physical properties
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/34—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates
    • C23C28/345—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer
    • C23C28/3455—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer with a refractory ceramic layer, e.g. refractory metal oxide, ZrO2, rare earth oxides or a thermal barrier system comprising at least one refractory oxide layer
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/36—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including layers graded in composition or physical properties
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/288—Protective coatings for blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/90—Coating; Surface treatment
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12014—All metal or with adjacent metals having metal particles
    • Y10T428/12021—All metal or with adjacent metals having metal particles having composition or density gradient or differential porosity

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Metallurgy (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Plasma & Fusion (AREA)
  • Ceramic Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Laminated Bodies (AREA)

Abstract

一种功能性梯度热障涂层(30)，其形成为通过粉末沉积工艺沉积的多个材料层(34，36，44，46)，其中各个层的组成跨涂层的厚度发生变化。由于粘结涂层材料(64)的熔融池(56)内的陶瓷颗粒(62)的浮力，在单层(58)中可以存在组成梯度。粉末沉积工艺包括粉末状焊剂材料(20)，其在沉积过程期间熔融，以形成熔渣(28)的保护层。

Description

功能性梯度热障涂层系统
本申请是2013年7月26日提交的共同未决的美国专利申请号13/951542的部分继续申请(代理人案号2013P03164US)，其以引用的方式并入本文。
技术领域
本发明一般涉及材料技术领域，并且更具体地涉及可以在燃气涡轮发动机应用中使用的隔热金属合金，并且涉及将热障涂层施加到金属合金的方法。
背景技术
陶瓷热障涂层系统被用于燃气涡轮发动机的热气体通路部件，以保护下层金属合金基底免受超过合金安全操作温度的燃烧气体温度的影响。典型的热障涂层系统可包括被沉积在基底合金上的粘结涂层，诸如MCrAlY材料，和沉积在粘结涂层上的陶瓷顶涂层，例如氧化钇稳定的氧化锆。粘结涂层和陶瓷材料通常是通过热喷涂工艺，诸如高速氧燃烧(HVOF)或空气等离子喷涂(APS)沉积。
功能性梯度材料的特征在于在体积内组成的梯度变化。这样的材料避免了有时与突然的材料变化，例如热障涂层系统中在材料界面处材料性质的明显改变相关的缺点。金属-陶瓷梯度材料在美国专利号6322897中被描述为通过烧结粉末填充床形成，该粉末填充床具有横跨床的梯度组成。
附图说明
本发明在以下说明中结合附图被说明，所述附图示出：
图1示出了通过粉末沉积工艺使用激光以熔融在焊剂材料床下方的合金颗粒来将涂层沉积到基底上。
图2示出了功能性梯度热障涂层系统，其被沉积为具有不同组成的多个材料层。
图3示出了粉末沉积工艺，其形成具有陶瓷材料的梯度浓度的粘结涂层。
具体实施方式
图1是具有基底12的气体涡轮机部件10的局部剖视图，期望增加保护涂层到基底12。粉末层14被沉积到基底12的表面16上。粉末层14包括金属合金18的颗粒，诸如MCrAlY粘结涂层材料，和焊剂材料20的颗粒。焊剂材料20被施加，以在随后的熔融步骤期间提供清洁和大气保护功能。金属合金18的颗粒可以被焊剂材料20的颗粒覆盖，如图所示。在其他实施例中，金属合金的颗粒和焊剂材料的颗粒可被混合在一起，并预先放置为单层，或者它们可通过在熔融步骤期间朝向表面引导颗粒的喷雾被施加。还有一个附加替代方案是焊剂和金属材料可被提供为复合颗粒，被预先放置或进给。粉末14被暴露于能量束22，例如激光束，以形成熔体24。熔体24将会隔离和固化成金属合金26的涂层26，该金属合金的涂层被表面16上的熔渣28层覆盖。熔渣28然后可以被除去以露出基底12上的粘结涂层材料26的涂层。
本发明人已使用上述方法利用在2-5mm的熔剂粉末厚度下方的1-4mm的合金粉末厚度成功地沉积了CoNiCrAlY粘结涂层材料，从而形成从0.7-3mm厚度的无裂缝沉积。高达1mm厚的粘结涂层材料粉末层可以优选覆盖有至少3mm厚的焊剂材料层，并且1-4mm厚的粘结涂层材料粉末层可以优选覆盖有至少5mm厚的焊剂材料层。各种激光类型可以被使用，包括镱纤维、平板、二极管、钕YAG和二氧化碳。来自埋弧焊、焊剂芯电弧焊、电渣焊和屏蔽金属电弧焊材料或其变体的广阔家族的氧化物、氟化物和碳酸盐的焊剂可以被利用。功率水平通常可以是2千瓦，但也可以根据待处理区域、处理速度、沉积深度和相关变量变化。
在除去熔渣28层之后，另一材料层可以通过图1中所示的步骤被施加，以便在多个层中建立沉积涂层到期望的厚度。一种这样的工艺示于图2中，其中热障涂层30以多个层34、36、38、40、42、44、46被沉积在超合金基底32上。当沉积各个层时，不同材料类型的颗粒可以被使用，在层之间材料类型比率改变，以在涂层30中产生功能性梯度。图2还包括显示在每个相应层中超合金颗粒、粘结涂层颗粒和陶瓷颗粒的相对比例的表。标题为“焊剂”的列表示每层使用参照图1所描述的粉末沉积工艺，诸如激光熔融或激光烧结被沉积。
层34包含100％的超合金颗粒。这种类型的层对于修补基底32中的裂缝或不平整是有用的。
层36包括超合金材料和粘结涂层材料，但具有比粘结涂层材料更高的超合金材料含量(即贫粘结涂层，富超合金)。
层38也包括超合金和粘结涂层材料，但它包含比超合金材料相对更多的粘结涂层材料(即富粘结涂层)，和比层36更多的粘结涂层材料。
层40仅包括粘结涂层材料。
层42包括粘结涂层材料和较少量的陶瓷绝缘材料。
层44包括粘结涂层材料和陶瓷材料，但具有比层42中更多的陶瓷材料。
层46仅包括陶瓷绝缘材料。
层34、36、38、40、42、44、46是由多个材料层的粉末沉积形成的功能性梯度热障涂层系统的示例，其具有跨涂层的厚度变化的层的组成。这些层的不同组合或其它类型的层可以被包括在其他实施例中。例如，在一个实施例中，涂层可以缺乏层32和/或层40。更逐渐改变组成比率的多个步骤可以在其他实施例中被使用。一些层可以包括超合金、粘结涂层和陶瓷材料。层可以具有相同或不同的厚度。超合金、粘结涂层和/或陶瓷材料的多个组合物可以在单个涂层系统中被使用。
因为在本文描述的粉末沉积工艺中使用的焊剂材料提供了对裂化的改进保护，可以沉积高达3mm或更多的粘结涂层材料层。当使用包括在粉末层中的某一浓度的陶瓷颗粒形成这样的层时，在熔融粘结涂层材料内的陶瓷材料的固有浮力将趋于驱动陶瓷颗粒朝向熔体的向上表面。通过控制工艺参数，现在可以在粘结涂层中产生陶瓷颗粒的功能性梯度浓度。一种这样的工艺示于图3，其中基底50覆盖有一层粉末52，该层粉末包括粘结涂层材料、陶瓷材料和焊剂材料的混合物。能量束54在粉末52之上作光栅化扫描，以形成分离成涂层58和熔渣60的覆层的熔体56。涂层58包括包在粘结涂层材料64的基质内的陶瓷材料62的颗粒。由于陶瓷材料通常具有小于金属合金(例如大于8g/cm3)的密度(例如小于6g/cm3)，熔体56内的陶瓷颗粒的自然浮力将有效地提供通过涂层58的厚度的陶瓷材料62的梯度浓度。涂层58可以包括接近纯陶瓷的顶部区域和接近纯粘结涂层的底部区域。这样的梯度层58可形成为热障涂层系统的多个不同层的一个，例如沉积在粘结涂层材料层之上和/或陶瓷材料层之下，或者其可以在该容量单独发挥作用。在一些实施例中，这样的梯度层58还可以包括超合金材料。
虽然本发明的各种实施例已经被示出和描述，但显然，这些实施例仅通过示例的方式被提供。许多变化、改变和替换可以被作出而不脱离本发明。因此，本发明旨在仅由所附权利要求的精神和范围限定。术语基底包括具有供在其上施加涂层的表面的任何材料，并且它可以包括超合金组分，或者这种组分已经具有一层或多层任意涂层材料，其将随后接收另一涂层。因此，本发明旨在仅由所附权利要求的精神和范围限定。

Claims (20)

1.一种方法，包括：
将包括粘结涂层材料颗粒和焊剂材料颗粒的粉末沉积到基底上；
使用能量束熔融所述粉末以形成由所述基底上的熔渣层覆盖的熔融粘结涂层材料层；
使所述熔融粘结涂层材料在所述熔渣层下冷却并固化以在所述基底上形成涂层；和
除去所述熔渣层。
2.根据权利要求1所述的方法，还包括将所述粉末沉积为所述基底上的粘结涂层材料颗粒层和在所述粘结涂层材料颗粒层上的焊剂材料颗粒层。
3.根据权利要求2所述的方法，还包括将所述粘结涂层材料颗粒层沉积为不超过1mm厚，并将所述焊剂材料颗粒层沉积为至少3mm厚。
4.根据权利要求2所述的方法，还包括将所述粘结涂层材料颗粒层沉积为1-4mm厚，并且将所述焊剂材料颗粒层沉积为至少5mm厚。
5.根据权利要求1所述的方法，还包括：
多次重复权利要求1所述的步骤，以在多个层中构建所述涂层到期望厚度；
在所述粉末中包括用于所述涂层的至少一些层的附加材料颗粒；和
改变至少一些层之间所述附加材料颗粒与所述粘结涂层材料颗粒的比率，以在所述涂层中产生功能性梯度。
6.根据权利要求5所述的方法，其中所述附加材料包括超合金材料，并且所述超合金材料颗粒与所述粘结涂层材料颗粒的比率从所述层中的一个到随后层减小。
7.根据权利要求5所述的方法，其中所述附加材料包括陶瓷材料，并且所述陶瓷材料颗粒与所述粘结涂层材料颗粒的比率从所述层中的一个到随后层增大。
8.根据权利要求1所述的方法，还包括：
多次重复根据权利要求1所述的步骤，以在多个层中将所述涂层构建到期望厚度；
在所述粉末中包括用于所述涂层的至少一层的陶瓷材料颗粒；和
沉积所述至少一层以具有一定厚度，其中在所述熔融粘结涂层材料内陶瓷材料的浮力有效以产生通过所述至少一层的厚度的陶瓷材料的浓度的功能性梯度。
9.一种装置，包括：
超合金基底；
设置在所述基底上的热障涂层，所述热障涂层还包括：
相对更接近所述基底的第一区域，所述第一区域包括粘结涂层材料，但不包括陶瓷材料；和
相对更远离所述基底的第二区域，所述第二区域包括所述粘结涂层材料和陶瓷材料的梯度浓度，其中所述陶瓷材料相对于所述粘结涂层材料的梯度浓度在远离所述基底的厚度方向上增加。
10.根据权利要求9所述的装置，其中所述第一区域还包括超合金材料的梯度浓度和所述粘结涂层材料，并且其中所述超合金材料相对于所述粘结涂层材料的梯度浓度在远离所述基底的厚度方向上减小。
11.根据权利要求10所述的装置，其中所述第一区域包括仅粘结涂层材料而没有陶瓷材料并且没有超合金材料的层。
12.根据权利要求10所述的装置，其中所述第一区域不包括仅粘结涂层材料的层。
13.根据权利要求9所述的装置，其中所述第二区域中的梯度浓度是在通过粉末沉积工艺沉积所述第二区域期间，由熔融粘结涂层材料内的陶瓷材料颗粒的浮力形成的。
14.根据权利要求9所述的装置，其中所述热障涂层还包括通过粉末沉积工艺的连续重复沉积的多个材料层，其中在连续层内沉积的粉末具有材料类型的不同比例，以产生所述第一区域和所述第二区域。
15.根据权利要求14所述的装置，其中所述热障涂层还包括：
包括粘结涂层材料加上陶瓷材料的层；和
仅包括陶瓷材料的层。
16.根据权利要求15所述的装置，其中所述热障涂层还包括包含粘结涂层材料和超合金材料的层。
17.根据权利要求15所述的装置，其中所述热障涂层包括仅包括粘结涂层材料的层。
18.一种装置，包括：
超合金基底；
设置在所述基底上的涂层；
所述涂层包括多个材料层，所述层的超合金材料与粘结涂层材料的比例从在第一层内超合金材料的相对较高浓度变化到在比所述第一层远离所述基底的第二层内粘结涂层材料的相对较高的浓度。
19.根据权利要求18所述的装置，还包括所述层的粘结涂层材料与陶瓷材料的比例从在第三层内粘结涂层材料的相对较高浓度变化到在比所述第三层远离所述基底的第四层内陶瓷材料的相对较高的浓度。
20.根据权利要求19所述的装置，还包括设置在所述第二层和所述第三层之间仅包括粘结涂层材料的层。
CN201480039754.6A 2013-07-26 2014-06-30 功能性梯度热障涂层系统 Pending CN105392920A (zh)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
US13/951,542 2013-07-26
US13/951,542 US20150030826A1 (en) 2013-07-26 2013-07-26 Method for creating a textured bond coat surface
US14/016,501 2013-09-03
US14/016,501 US20150030871A1 (en) 2013-07-26 2013-09-03 Functionally graded thermal barrier coating system
PCT/US2014/044816 WO2015013005A2 (en) 2013-07-26 2014-06-30 Functionally graded thermal barrier coating system

Publications (1)

Publication Number Publication Date
CN105392920A true CN105392920A (zh) 2016-03-09

Family

ID=51213038

Family Applications (1)

Application Number Title Priority Date Filing Date
CN201480039754.6A Pending CN105392920A (zh) 2013-07-26 2014-06-30 功能性梯度热障涂层系统

Country Status (5)

Country Link
US (1) US20150030871A1 (zh)
KR (1) KR20160036572A (zh)
CN (1) CN105392920A (zh)
DE (1) DE112014003451T5 (zh)
WO (1) WO2015013005A2 (zh)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108251832A (zh) * 2016-12-29 2018-07-06 通用汽车环球科技运作有限责任公司 沉积微球的一个或多个层以形成热障涂层的方法
CN111246965A (zh) * 2017-10-25 2020-06-05 株式会社尼康 加工装置、涂料、加工方法、及移动体的制造方法

Families Citing this family (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3071732B1 (en) * 2013-11-19 2019-11-13 United Technologies Corporation Article having variable composition coating
US20150360322A1 (en) * 2014-06-12 2015-12-17 Siemens Energy, Inc. Laser deposition of iron-based austenitic alloy with flux
US20160201200A1 (en) * 2015-01-14 2016-07-14 Siemens Energy, Inc. Adhesion of coatings using adhesive bonding compositions
EP3075954A1 (en) * 2015-04-01 2016-10-05 Siemens Aktiengesellschaft Vane segment for a gas turbine
GB201508703D0 (en) 2015-05-21 2015-07-01 Rolls Royce Plc Additive layer repair of a metallic component
US9683901B2 (en) 2015-07-16 2017-06-20 Siemens Energy, Inc. Acoustic measurement system incorporating a temperature controlled waveguide
US10031032B2 (en) 2015-07-16 2018-07-24 Siemens Energy, Inc. Acoustic measurement system incorporating a hybrid waveguide providing thermal isolation
US20170167277A1 (en) * 2015-12-10 2017-06-15 General Electric Company Methods for modifying components
US20170167288A1 (en) * 2015-12-10 2017-06-15 General Electric Company Methods for modifying components
US20170216971A1 (en) * 2016-01-28 2017-08-03 Lawrence Livermore National Security, Llc Use of variable wavelength laser energy for custom additive manufacturing
US10859033B2 (en) * 2016-05-19 2020-12-08 Tenneco Inc. Piston having an undercrown surface with insulating coating and method of manufacture thereof
US20180156064A1 (en) * 2016-12-06 2018-06-07 GM Global Technology Operations LLC Turbocharger heat shield thermal barrier coatings
WO2018193036A1 (en) * 2017-04-21 2018-10-25 Oerlikon Surface Solutions Ag, Pfäffikon Superalloy sputtering target
CN107142479B (zh) * 2017-05-09 2019-06-18 江苏晨日环保科技有限公司 一种用于环保设备的涂层的形成方法
CN108179417B (zh) * 2018-01-17 2019-12-06 河南省煤科院耐磨技术有限公司 一种大尺寸双金属耐磨耐蚀复合板的制造方法

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1295970A1 (en) * 2001-09-22 2003-03-26 ALSTOM (Switzerland) Ltd MCrAlY type alloy coating
US20050268998A1 (en) * 2002-09-17 2005-12-08 Georg Bostanjoglo Method for producing a three-dimensional moulded body
CN101748402A (zh) * 2009-12-10 2010-06-23 南昌航空大学 激光感应复合熔覆梯度功能热障涂层的方法
CN102441672A (zh) * 2011-11-09 2012-05-09 铜陵学院 一种激光熔覆纳米陶瓷颗粒增强的金属基梯度涂层制备方法
US20130136868A1 (en) * 2011-01-13 2013-05-30 Gerald J. Bruck Selective laser melting / sintering using powdered flux

Family Cites Families (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS62156938A (ja) * 1985-12-28 1987-07-11 航空宇宙技術研究所 傾斜機能材料の製造方法
JP2002502462A (ja) 1997-05-28 2002-01-22 シーメンス アクチエンゲゼルシヤフト 金属とセラミックスの勾配材料、その製品及び金属とセラミックスの勾配材料の製造方法
US5912087A (en) * 1997-08-04 1999-06-15 General Electric Company Graded bond coat for a thermal barrier coating system
US6287644B1 (en) * 1999-07-02 2001-09-11 General Electric Company Continuously-graded bond coat and method of manufacture
EP1396556A1 (en) * 2002-09-06 2004-03-10 ALSTOM (Switzerland) Ltd Method for controlling the microstructure of a laser metal formed hard layer
US8349396B2 (en) * 2005-04-14 2013-01-08 United Technologies Corporation Method and system for creating functionally graded materials using cold spray

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1295970A1 (en) * 2001-09-22 2003-03-26 ALSTOM (Switzerland) Ltd MCrAlY type alloy coating
US20050268998A1 (en) * 2002-09-17 2005-12-08 Georg Bostanjoglo Method for producing a three-dimensional moulded body
CN101748402A (zh) * 2009-12-10 2010-06-23 南昌航空大学 激光感应复合熔覆梯度功能热障涂层的方法
US20130136868A1 (en) * 2011-01-13 2013-05-30 Gerald J. Bruck Selective laser melting / sintering using powdered flux
CN102441672A (zh) * 2011-11-09 2012-05-09 铜陵学院 一种激光熔覆纳米陶瓷颗粒增强的金属基梯度涂层制备方法

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108251832A (zh) * 2016-12-29 2018-07-06 通用汽车环球科技运作有限责任公司 沉积微球的一个或多个层以形成热障涂层的方法
CN108251832B (zh) * 2016-12-29 2020-05-19 通用汽车环球科技运作有限责任公司 沉积微球的一个或多个层以形成热障涂层的方法
CN111246965A (zh) * 2017-10-25 2020-06-05 株式会社尼康 加工装置、涂料、加工方法、及移动体的制造方法

Also Published As

Publication number Publication date
WO2015013005A3 (en) 2015-05-14
KR20160036572A (ko) 2016-04-04
US20150030871A1 (en) 2015-01-29
DE112014003451T5 (de) 2016-05-19
WO2015013005A2 (en) 2015-01-29

Similar Documents

Publication Publication Date Title
CN105392920A (zh) 功能性梯度热障涂层系统
KR102026354B1 (ko) 일체화된 시스템들로서 형성되는 다재료들을 포함하는 3 차원 컴포넌트들의 레이저 적층 가공
US20150033561A1 (en) Laser melt particle injection hardfacing
US20160214176A1 (en) Method of inducing porous structures in laser-deposited coatings
US6264766B1 (en) Roughened bond coats for a thermal barrier coating system and method for producing
JP3983323B2 (ja) 熱溶射したセラミック断熱層のための金属付着層を金属部材に被覆する方法および金属付着層
EP2543748B1 (en) Method of improving a superalloy component
US10005127B2 (en) Powder improvement for additive manufacturing
US6368727B1 (en) Roughened bond coat for a thermal barrier coating system and method for producing
US6242050B1 (en) Method for producing a roughened bond coat using a slurry
JP7097668B2 (ja) 改質された遮熱複合コーティング
EP2881216B1 (en) Laser cladding system and method using metal-filled wires
KR19990030016A (ko) 열차단 피복 시스템을 위한 결합 피복층의 침착방법
US10131969B2 (en) Method to form oxide dispersion strengthended (ODS) alloys
KR101869523B1 (ko) 분말 및 포일을 이용한 재료 용착
CN101838807A (zh) 一种发动机进、排气门用激光熔覆涂层材料及其涂层
CN105378147A (zh) 用于创建纹理粘结涂层表面的方法
US10293434B2 (en) Method to form dispersion strengthened alloys
US20150224603A1 (en) Filler cloth for laser cladding
EP3137653A1 (en) Laser glazing using hollow objects for shrinkage compliance
KR20150105351A (ko) 적층 용접시 재용융
US20110076414A1 (en) Process for Applying a Bonding Primer Layer
US7144602B2 (en) Process for obtaining a flexible/adaptive thermal barrier
CN113438997A (zh) 具有通过脆弱区域的分离的增材制造方法

Legal Events

Date Code Title Description
C06 Publication
PB01 Publication
C10 Entry into substantive examination
SE01 Entry into force of request for substantive examination
RJ01 Rejection of invention patent application after publication

Application publication date: 20160309

RJ01 Rejection of invention patent application after publication