CN105612270B - 热喷涂方法和热喷涂制品 - Google Patents
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F13/00—Arrangements for modifying heat-transfer, e.g. increasing, decreasing
- F28F13/18—Arrangements for modifying heat-transfer, e.g. increasing, decreasing by applying coatings, e.g. radiation-absorbing, radiation-reflecting; by surface treatment, e.g. polishing
-
- 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
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/18—After-treatment
-
- 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
-
- 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
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/01—Selective coating, e.g. pattern coating, without pre-treatment of the material to be coated
-
- 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
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Inorganic Chemistry (AREA)
- Thermal Sciences (AREA)
- General Engineering & Computer Science (AREA)
- Coating By Spraying Or Casting (AREA)
- Turbine Rotor Nozzle Sealing (AREA)
- Application Of Or Painting With Fluid Materials (AREA)
Abstract
公开了热喷涂方法和热喷涂制品。所述热喷涂方法包括将覆盖物安放在部件的冷却通道上，和将原料热喷射到所述覆盖物上。所述覆盖物阻止所述原料进入部件中的冷却通道且不从部件除去。在另一个实施方案中，所述热喷涂方法包括提供包含基材材料的部件，提供部件表面上的冷却通道，将覆盖物安放在所述冷却通道上，和将原料热喷射到所述部件和所述覆盖物上，所述原料包含粘合涂布材料。所述覆盖物阻止所述粘合涂布材料进入所述冷却通道。所述热喷涂制品包括部件、冷却通道、所述冷却通道上的覆盖物和所述部件和所述覆盖物上的热喷射涂层。
Description
发明领域
本发明涉及涂布方法和涂布制品。更具体而言，本发明涉及热喷涂方法和热喷涂制品。
发明背景
各种设备中的部件，例如机翼、冷却翅片和拨爪常常经受越来越高的温度。这些高温通常会需要冷却机构来降低部件温度并避免部件损害。
一种已知的冷却机构包括位于接近部件的热表面例如热气路径的冷却通道。在一种机构中，该冷却通道可以在其中具有冷却介质，例如气体或液体。该冷却介质将热从部件的一个区域输送走以提供冷却。
除了冷却通道之外，部件还常常用环境涂层热喷射以对付高温。施加环境涂层会导致原料填充冷却通道。填充冷却通道会限制或停止冷却介质流动，由此降低或消除通过冷却机构提供的冷却。
不经受一个或多个上述缺点的涂布方法和涂布制品在本领域将是合乎需要的。
发明概述
在一个例示性实施方案中，热喷涂方法包括将覆盖物安放在部件的冷却通道上，和将原料热喷射到所述覆盖物上。所述覆盖物阻止所述原料进入部件中的冷却通道且不从部件除去。
在另一个例示性实施方案中，热喷涂方法包括提供包含基材材料的部件，在部件表面上提供冷却通道，将覆盖物安放在所述冷却通道上，和将原料热喷射到所述部件和所述覆盖物上，所述原料包含粘合涂布材料。所述覆盖物阻止所述原料进入所述冷却通道。
在又一个例示性实施方案中，热喷涂制品包括部件、部件表面上的冷却通道、冷却通道上的覆盖物和部件上的热喷射涂层。
本发明的其他特点和优点将结合附图从优选实施方案的以下更详细描述中显而易见，所述附图通过示例阐述本发明的原理。
发明概述
图1显示根据本公开的一个实施方案的热喷涂方法。
图2显示根据本公开的一个实施方案的网状覆盖物。
图3显示通过根据本公开的一个实施方案的热喷涂方法涂布的制品的透视图。
图4显示对应图3的制品的横截面图。
只要有可能，将在整个附图中使用相同的引用数字来表示相同的部件。
发明详述
提供了例示性热喷涂方法和热喷涂制品。与不采用一个或多个文中公开的特点的方法相比，本公开的实施方案提高了热冷却通道的有效性，提高了冷却介质通过热冷却通道的流动，提高了热喷射效率，降低了热冷却通道上的涂层厚度，降低了在热喷射期间热冷却通道的污染，或其组合。
来看图1，在一个实施方案中，热喷涂方法包括将覆盖物102安放在部件101中的一个或多个冷却通道105上，和将原料104热喷射到部件101和覆盖物102上。覆盖物102阻止原料104进入部件101中的冷却通道105。在一个实施方案中，原料104包含粘合涂布材料。
合适的覆盖物102包括但不限于网、箔或其组合。覆盖物102的合适形式包括但不限于平面、弧形、模制、波状外形、复合体、条、片或其组合。例如，在一个实施方案中，将覆盖物102切割成条并施加到部件101的表面上，该条限制于覆盖冷却通道105(图1)。在另一个实施例中，将覆盖物102施加到部件101的整个表面上(图4)。
如文中所用，术语“网”是指由交织纤维203(图2)、机器交织箔或其组合的图案形成的配置。交织纤维203的合适图案包括但不限于平纹编织、斜织、平纹荷兰编织、斜纹荷兰织、双斜纹荷兰织(twill dutch double)、绞合或其组合。如文中所用，术语“箔”是指由任何合适材料制备的可变形的片。合适的箔构型包括但不限于具有开口204、不具有开口204的那些或其组合。箔具有弹性且对来自热喷射嘴103的变形具有抵抗力。网是柔韧的，例如能够绕约30密耳的半径延伸而不具有结构损坏。在一个实施方案中，选择网或箔作为覆盖物102，且热喷射嘴103对应于所选择的材料安放以降低或消除覆盖物102的变形。
在一个实施方案中，覆盖物102例如通过放电加工(EDM)、金属注射成型、薄片加工或其组合形成。覆盖物102为预成形或后成形的。预成形包括在将覆盖物102安放在部件101上之前形成覆盖物102。后成形包括在部件101的位置形成覆盖物102。在一个实施方案中，将覆盖物102临时或长期固定到部件101。将覆盖物102固定到部件101的合适技术包括但不限于点焊、镀覆、烧结、钎焊或其组合。
覆盖物102的合适组分包括基材材料、粘合涂布材料或其组合。在一个实施方案中，基材材料包括但不限于钴、铬、钨、碳、镍、铁、硅、钼、锰、其合金、镍基合金、钴基合金、超合金、金属间化物(TiAl和/或NiAl)、陶瓷基质复合材料或其组合。在一个实施方案中，粘合涂布材料包括但不限于Ba1-xSrxAl2Si2O8(BSAS)、陶瓷氧化物、(Yb，Y)2Si2O7、具有BSAS的莫来石、硅和/或单硅酸钇和/或二硅酸钇或其组合。
用作基材材料的合适镍基合金以重量计包含约14％铬、约9.5％钴、约3.8％钨、约1.5％钼、约4.9％钛、约3.0％铝、约0.1％碳、约0.01％硼、约2.8％钽以及余量的镍和偶见杂质。
另一种合适的镍基合金以重量计包含约7.5％钴、约9.75％铬、约4.20％铝、约3.5％钛、约1.5％钼、约4.8％钽、约6.0％钨、约0.5％钶(铌)、约0.05％碳、约0.15％铪、约0.004％硼以及余量的镍和偶见杂质。
用作基材材料的另一种合适的镍基合金以重量计包含约0.07％-约0.10％碳、约8.0％-约8.7％铬、约9.0％-约10.0％钴、约0.4％-约0.6％钼、约9.3％-约9.7％钨、约2.5％-约3.3％钽、约0.6％-约0.9％钛、约5.25％-约5.75％铝、约0.01％-约0.02％硼、约1.3％-约1.7％铪、至多约0.1％锰、至多约0.06％硅、至多约0.01％磷、至多约0.004％硫、约0.005％-约0.02％锆、至多约0.1％铌、至多约0.1％钒、至多约0.1％铜、至多约0.2％铁、至多约0.003％镁、至多约0.002％氧、至多约0.002％氮，余量的镍和偶见杂质。
来看图2，在一个实施方案中，覆盖物102中的开口204具有第一尺寸例如第一宽度201和第二尺寸例如第二宽度202。第一宽度201和第二宽度202至少部分限定预定区域。覆盖物102中的开口204的预定区域小于最小尺寸例如原料104的最小宽度，使得原料104无法经过开口204。将原料104通过热喷射嘴103引导到并喷射到部件101上。覆盖物102中的开口204的较小区域避免原料104经过覆盖物102。在一个实施方案中，网中的交织纤维203的图案在覆盖物102中形成开口204。在另一个实施方案中，覆盖物102中的开口204通过覆盖物102的机械加工形成。
开口204的合适尺寸对应于原料104的粒径。在一个实施方案中，该尺寸例如为小于50μm、约3μm-约50μm、约3μm-约5μm、约45μm-约55μm或其任何组合、子组合、范围或子范围。
热喷射使原料104熔融并形成具有预定尺寸的熔融液滴。使熔融液滴加速向部件101并与其接触。与部件101接触后熔融液滴变平。原料104的合适预定尺寸包括但不限于约2μm-约50μm、约5μm-约45μm、约15μm-约35μm、约2μm-约30μm、约2μm-约10μm、约5μm-约15μm、约10μm-约20μm、约20μm-约30μm、约30μm-约40μm、约40μm-约50μm或其任何组合、子组合、范围或子范围。
来看图3，原料104的热喷射在部件101上形成涂层304。在一个实施方案中，覆盖物102在部件101和涂层304之间形成连续层401(图4)，如图4的A-A截面所示。在一个实施方案中，覆盖物102在部件101和涂层304之间形成非连续层，如图1中所示。将覆盖物102熔融、分解、氧化、微结构改性、通过热喷射破坏、保持完整或其其他合适的组合。覆盖物102可以不再作为部件101和涂层304之间的限定层存在，可以保持为部件101和涂层304之间的单独层或其任何合适的组合。
部件101为任何合适的制品或制品的一部分，例如机翼、冷却翅片、拨爪、热气路径元件或其组合。热气路径元件为暴露到燃烧过程和/或从燃烧反应放出的热气的燃气涡轮元件。合适的热气路径元件包括但不限于燃烧衬里、端盖、燃料喷嘴组件、联焰管、过渡连接件、涡轮喷嘴、涡轮固定护罩、涡轮叶片(turbine bucket)(静叶)、涡轮盘、涡轮密封物或其组合。在一个实施方案中，部件101能够经受严酷条件，例如约1500°F-约2600°F、约1500°F-约2100°F、约2100°F-约2600°F、约1800°F-约2300°F、约2000°F-约2400°F或其任何合适范围、子范围、组合或子组合的温度。
为了避免部件101的热损坏，在一个实施方案中，在部件101的表面107上提供冷却通道105。在另一个实施方案中，冷却通道105包括冷却流体，例如但不限于气体、液体、制冷剂或其组合。冷却通道105的合适实施方案包括但不限于半圆形、矩形、三角形、线形、弧形、复合体、交叉、平行或其组合。覆盖物102阻止原料104在热喷射期间进入冷却通道105，使涂层304在冷却通道105和覆盖物102上形成。冷却通道105上的涂层304阻止冷却流体从冷却通道105逃逸。
冷却通道105上的涂层304的厚度控制冷却介质的传热速率。涂层304的厚度降低提高冷却通道105的冷却速率。涂层304的合适厚度包括但不限于约150μm-约4000μm、约300μm-约1000μm、约200μm-约800μm、约150μm-约250μm、约500μm-约1,500μm或其任何组合、子组合、范围或子范围。
虽然参考优选实施方案描述本发明，但是本领域技术人员应当理解，在不偏离本发明的范围的情况下，可以进行各种改变且等价物可以取代其要素。另外，在不偏离其基本范围的情况下，可以进行许多修改以使具体的情形或材料适应本发明的教导。因此，本发明旨在不受限于作为被考虑用于实施本发明的最佳模式公开的具体实施方案，而是本发明将包括所有落入随附权利要求的范围内的实施方案。
Claims (20)
1. 热喷涂方法，所述方法包括：
1）将覆盖物安放在部件的冷却通道上，所述覆盖物具有若干开口；和
2）将原料热喷射到所述覆盖物上；
其中所述覆盖物阻止所述原料进入部件中的冷却通道且不从部件除去；
其中，所述若干开口尺寸小于50µm。
2.权利要求1的方法，其还包括将涂层施加到所述覆盖物和基材上。
3.权利要求2的方法，其还包括通过所述冷却通道输送冷却介质。
4.权利要求3的方法，其中所述冷却介质不从所述涂层逃逸。
5.权利要求1的方法，其还包括将所述覆盖物固定到所述部件。
6.权利要求1的方法，其还包括将所述覆盖物点焊到所述部件。
7.权利要求1的方法，其还包括在安放所述覆盖物之前，形成所述覆盖物。
8.权利要求1的方法，还包括在安放所述覆盖物之后形成所述覆盖物。
9.权利要求1的方法，还包括由放电加工形成所述覆盖物。
10.权利要求1的方法，还包括由金属注射成型形成所述覆盖物。
11.权利要求1的方法，还包括通过所述热喷射使所述覆盖物熔融。
12.权利要求1的方法，其中所述覆盖物为网。
13.权利要求1的方法，其中所述覆盖物为箔。
14.权利要求1的方法，其中所述部件选自机翼、冷却翅片、拨爪、燃烧衬里、端盖、燃料喷嘴组件、联焰管、过渡连接件、涡轮喷嘴、涡轮固定护罩、涡轮叶片或其组合。
15.权利要求1的方法，其中原料的热喷射将所述原料施加到部件的一部分。
16.权利要求1的方法，其中原料的热喷射只将所述原料施加到所述覆盖物。
17.热喷涂方法，所述方法包括：
1）提供包含基材材料的部件；
2）在部件表面上提供冷却通道；
3）将覆盖物安放在所述冷却通道上，所述覆盖物具有若干开口；和
4）将原料热喷射到所述部件和所述覆盖物上，所述原料包含粘合涂布材料；
其中所述覆盖物阻止所述原料进入所述冷却通道；
其中，所述若干开口尺寸小于50µm。
18.权利要求17的方法，其中所述覆盖物包含基材材料。
19.权利要求17的方法，其中所述覆盖物包含粘合涂布材料。
20.热喷涂制品，其包括：
部件；
部件表面上的冷却通道；
冷却通道上的覆盖物，所述覆盖物具有若干开口；和
所述部件和所述覆盖物上的热喷射涂层；
其中所述覆盖物阻止热喷射涂层的原料进入冷却通道，并且所述热喷射涂层阻止冷却通道中的冷却流体从冷却通道逃逸；
其中，所述若干开口尺寸小于50µm。
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| US14/013,194 US10775115B2 (en) | 2013-08-29 | 2013-08-29 | Thermal spray coating method and thermal spray coated article |
| PCT/US2014/050497 WO2015031034A2 (en) | 2013-08-29 | 2014-08-11 | Thermal spray coating method and thermal spray coated article |
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| KR102030407B1 (ko) | 2018-05-31 | 2019-10-10 | (주)에스에이치팩 | Cfrp 표면 코팅방법 및 이 방법에 의해 코팅되는 구성품을 포함하는 유압실린더 |
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