CN106460193A - 钼酸镧耐磨涂层、其形成方法及使用 - Google Patents

钼酸镧耐磨涂层、其形成方法及使用 Download PDF

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CN106460193A
CN106460193A CN201580028241.XA CN201580028241A CN106460193A CN 106460193 A CN106460193 A CN 106460193A CN 201580028241 A CN201580028241 A CN 201580028241A CN 106460193 A CN106460193 A CN 106460193A
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G.H.科尔比
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Abstract

提供了一种涂覆的基底(100)，其可包括限定表面(103)的基底，以及基底的表面(103)上的耐磨涂层(106)。耐磨涂层(106)可包括形成结晶结构的La2‑xAxMo2‑y‑y'WyByO9‑δ，其中A包括Li,Na,K,Rb,Cs,Sc,Y,Ce,Pr,Nd,Pm,Sm,Eu,Gd,Tb,Dy,Ho,Er,Tm,Yb,Lu,Th,Be,Mg,Ca,Sr,Ba,Cu,Bi,Cd,Zn,Ag,Au,Pt,Ir,Rh,Ru,Pd或它们的组合；0＜x≤大约0.2(例如，大约0.1≤x≤大约0.15)；0≤y≤大约1.5(例如，大约0.01≤y≤大约1.5)；B包括Ta,Nb,V,Fe,Cr,Mn,Co,Ni,Sn,Ga,Al,Re,In,S或它们的组合；0≤y'≤大约0.2，其中y和y'的和为大约0.01到大约1.6；以及0≤δ≤大约0.2。

Description

钼酸镧耐磨涂层、其形成方法及使用
技术领域
本发明大体上涉及涡轮。更具体而言，本发明的实施例大体上涉及用于金属护罩的耐磨涂层，特别是燃气涡轮发动机中的那些金属护罩。
相关申请的交叉引用
本申请请求享有2014年5月27日提交的Glen Harold Kirby的标题为"LanthanumMolybdate Abradable Coatings for Metal Shrouds and Their Methods of Formationand Use"的美国临时专利申请序列号62/003180的优先权，其公开通过引用并入本文中。
背景技术
燃气涡轮发动机的涡轮区段包含转子轴，和一个或更多个涡轮级，其均具有安装或另外由轴承载的涡轮盘(或转子)，以及安装于盘的外周并且从其沿径向延伸的涡轮叶片。涡轮组件典型地通过使由燃料的燃烧产生的热压缩气体膨胀来生成旋转轴功率。燃气涡轮轮叶或叶片大体上具有翼型形状，其设计成将流动路径气体的热能和动能转换成转子的机械旋转。
涡轮性能和效率可通过减小涡轮叶片的末端与静止护罩之间的空间，以限制将另外绕过叶片的叶片的顶部之上或周围的空气流来提高。例如，叶片可构造成以使其末端配合成在发动机操作期间接近护罩。因此，生成和保持有效末端空隙出于效率目的是特别期望的。
尽管涡轮叶片可由一定数量的超级合金(例如，镍基超级合金)制成，但陶瓷基质复合物(CMC)由于它们的高温能力和轻重量而为用于涡轮应用的镍基超级合金的有吸引力的备选方案。然而，CMC构件必须以涡轮发动机环境中的环境阻隔涂层(EBC)保护，以避免高温蒸汽存在时的严重氧化和衰退。
因此，在某些构件中，EBC的区域可易受由于与相邻构件的摩擦事件而产生的磨损。例如，对于CMC叶片，叶片末端处的EBC易受抵靠金属护罩构件的摩擦。如果EBC涂层磨掉，则CMC叶片接着对来自高温蒸汽的隐性攻击开启，这将打开CMC叶片末端与金属护罩之间的空隙，由此降低发动机的效率。
因此，本领域中合乎需要的是提供用于减小在涡轮的操作期间由摩擦事件引起的CMC叶片末端上的EBC磨损的材料和方法。
发明内容
本发明的方面和优点将在以下描述中部分地阐述，或者可从描述为明显的，或者可通过本发明的实践学习。
大体上提供一种涂覆的基底，连同其制造和涂覆方法。在一个实施例中，涂覆的基底包括限定表面的基底，以及基底的表面上的耐磨涂层。耐磨涂层可包括形成结晶结构的La2-xAxMo2-y-y'WyBy'O9-δ，其中A包括Li, Na, K, Rb, Cs, Sc, Y, Ce, Pr, Nd, Pm, Sm,Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Th, Be, Mg, Ca, Sr, Ba, Cu, Bi, Cd, Zn,Ag, Au, Pt, Ir, Rh, Ru, Pd或它们的组合；0＜x≤大约0.2(例如，大约0.1≤x≤大约0.15)；0≤y≤大约1.5(例如，大约0.01≤y≤大约1.5)；B包括Ta, Nb, V, Fe, Cr, Mn,Co, Ni, Sn, Ga, Al, Re, In, S或它们的组合；0≤y'≤大约0.2，其中y和y'的和为大约0.01到大约1.6；以及0≤δ≤大约0.2。
另一个实施例包括一种基底，其具有以下化学式：形成结晶结构的La2-xYxMo2-y-y'WyBy'O9-δ，其中大约0.05≤x≤大约0.15；0≤y≤大约1.5；大约0.01≤y'≤大约0.2；以及0≤δ≤大约0.2。
又一个实施例包括一种基底，其具有以下化学式：形成结晶结构的La2-xYxMo2- yWyO9-δ，其中大约0.05≤x≤大约0.15；0≤y≤大约1.5；大约0.01≤y'≤大约0.2；以及0≤δ≤大约0.2。
还提供了一种燃气涡轮，其包括上文所述的涂覆的基底。例如，涂覆的基底可限定定位在CMC叶片末端附近的金属护罩；并且其中在与CMC叶片末端接触时，耐磨涂层的一部分从金属护罩除去。
本发明的这些及其它的特征、方面和优点将参照以下描述和所附权利要求变得更好理解。并入在本说明书中并且构成本说明书的部分的附图示出了本发明的实施例，并且连同描述用于阐释本发明的原理。
附图说明
看作是本发明的主题在说明书的结束部分中具体指出并且清楚地要求权利。然而，本发明可通过参照连同附图进行的以下描述来最好地理解，在该附图中：
图1示出了根据一个实施例的具有其上的耐磨涂层的示例性涂覆的基底的截面图；
图2示出了示例性涡扇燃气涡轮发动机组件的示意图；以及
图3示出了涡轮内的示例性叶片和护罩的示意图；
图4示出了根据另一个实施例的具有其上的耐磨涂层和热障涂层(TBC)的示例性涂覆的基底的截面图。
具体实施方式
现在将详细参照本发明的实施例，其一个或更多个实例在附图中示出。各个实例经由阐释本发明提供，而不限制本发明。实际上，对本领域技术人员而言将显而易见的是，可在本发明中作出各种改型和变型，而不脱离本发明的范围或精神。例如，示为或描述为一个实施例的部分的特征可与另一个实施例一起使用以产生又一个实施例。因此，意图是，本发明覆盖归入所附权利要求和它们的等同物的范围内的此类改型和变型。
耐磨涂层大体上提供用于基底，特别是定位成紧密接触CMC构件(例如，CMC涡轮叶片)的涡轮中的那些基底。图1示出了涂覆的基底100的截面的图示，涂覆的基底100包括具有表面103上的涂层108的基底102。涂层108大体上包括耐磨涂层106和可选的连结涂层104。基底102和涂层104,106在下面更详细论述。
图2为具有中心旋转轴线12的示例性涡扇发动机组件10的示意图。在示例性实施例中，涡扇发动机组件10包括进气侧14和排气侧16。涡扇发动机组件10还包括芯部燃气涡轮发动机18，其包括高压压缩机20、燃烧器22和高压涡轮24。此外，涡扇发动机组件10包括设置在芯部燃气涡轮发动机18轴向下游的低压涡轮26，以及设置在芯部燃气涡轮发动机22轴向上游的风扇组件28。风扇组件28包括从转子毂32沿径向向外延伸的风扇叶片30的阵列。此外，涡扇发动机组件10包括设置在风扇组件28与低压涡轮26之间的第一转子轴34，以及设置在高压压缩机20与高压涡轮24之间的第二转子轴36，使得风扇组件28、高压压缩机20、高压涡轮24和低压涡轮26串流连通并且关于涡扇发动机组件10的中心旋转轴线12同轴对准。
在操作期间，空气进入穿过进气侧14，并且流动穿过风扇组件28至高压压缩机20。压缩空气输送至燃烧器22。在通过排气侧16离开涡扇发动机组件10之前，来自燃烧器22的空气流驱动高压涡轮24和低压涡轮26。
高压压缩机20、燃烧器22、高压涡轮24和低压涡轮26均包括至少一个转子组件。旋转或转子组件大体上取决于涡扇发动机组件10内的它们的相对轴向位置经受不同的温度。例如，在示例性实施例中，涡扇发动机组件10具有朝前风扇组件28的大体上较冷的操作温度，以及朝后高压压缩机20的较热的操作温度。就此而言，高压压缩机20内的转子构件大体上由相比于用于风扇组件28的转子构件的制造材料能够耐受较高温度的材料制造。
如图3中所示，涡轮组件10包括多个转子叶片40和绕着转子叶片40同心地设置的外护罩42。转子叶片40包括内根部46、翼型件48和外末端44。如图3中最佳所示，外护罩42与叶片末端44间隔开，以便限定其间的空隙间隙43。如以上背景技术节段中大体上所论述，涡轮的性能和效率由空隙间隙43关键地影响。穿过空隙间隙43的泄漏流的量越大，涡轮10就越低效，因为泄漏流并未将原动力施加在叶片表面上，并且因此不提供功。因此，叶片末端44定位成与静止护罩42紧密工作邻近，使得摩擦或冲击事件在涡轮10的操作期间是可能的。
尽管本文中关于涡轮组件10描述本发明，但本发明不限于在涡轮组件10中实践。本发明可关于许多其它构造实施和使用。因此，应当理解的是，涡轮组件10为本发明可在其中实施和使用的示例性组件。
在一个特定实施例中，涂覆的涂层100形成护罩42，使得耐磨涂层106(如图1中所示)面对叶片末端44。例如，耐磨涂层106可在涡轮的金属护罩上，该金属护罩紧密操作邻近涡轮叶片的叶片末端。在叶片末端44(例如，EBC涂覆的CMC叶片末端)与涂覆的基底100(例如，涂覆的金属护罩42)之间的摩擦事件中，耐磨涂层106构造成比EBC涂层更软，使得耐磨涂层从基底102除去，替代EBC从叶片末端除去。耐磨涂层相对致密，并且大体上机械地抵抗涡轮发动机环境中的剥落。如在下面更详细所论述，耐磨涂层大体上包括钼酸镧基材料。
尽管在下文中关于金属护罩论述，但涂覆有耐磨涂层的基底可为涡轮内的任何构件，特别是金属构件。当基底100为金属构件如金属护罩时，在特定实施例中，过渡层104定位在金属基底100与耐磨涂层106之间。例如，过渡层104可为在基底材料(例如，金属合金自身或沉积在基底上的连结涂层)热氧化时形成的被动的基于氧化铝的比例层。过渡层104可为连结涂层，例如，扩散涂层。例如，适合的连结涂层将包括铝化镍、铝化铂、铝和氧化铝，或它们的组合。此外，可使用具有化学式MCrAlY的连结涂层；其中M为Ni、Co、Fe或它们的混合物。
如所陈述，耐磨涂层106大体上包括钼酸镧基材料。钼酸镧基材料在提供将在摩擦或冲击事件时退让的表面方面提供了护罩涂层的功能性。例如，当施加在金属护罩上时，钼酸镧基材料提供用于与CMC叶片末端的摩擦或冲击事件的耐磨功能性，而不对CMC叶片末端上的EBC涂层强加严重的磨损。
当在金属护罩上时，该钼酸镧基材料的高温立方相是优选形式，因为其具有非常类似于镍基和钴基超级合金的热膨胀的热膨胀。立方相可在宽范围的钼酸镧基成分(其中镧和/或钼由另一元素替换)内稳定至室温或以下(即，使得在操作温度范围期间不存在相变)。
大体上，钼酸镧基材料基于以下化学式的母结构：La2Mo2O9。该母结构具有低温单斜结构，并且因此由各种其它元素替换来形成宽范围的温度(低于室温至1350℃或更高)内的立方材料。就此而言，耐磨涂层包括形成结晶结构的La2-xAxMo2-y-y'WyBy'O9-δ，其中A包括Li, Na, K, Rb, Cs, Sc, Y, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb,Lu, Th, Be, Mg, Ca, Sr, Ba, Cu, Bi, Cd, Zn, Ag, Au, Pt, Ir, Rh, Ru, Pd或它们的组合；0＜x≤大约0.2(即，x大于零到大约0.20)；0≤y≤大约1.5(即，y为零到大约1.5)；B包括Ta, Nb, V, Fe, Cr, Mn, Co, Ni, Sn, Ga, Al, Re, In, S或它们的组合；0≤y'≤大约0.2(即，y'为零到大约0.2)，其中y和y'的和为大约0.01到大约1.6；以及0≤δ≤大约0.2(即，δ为零到大约0.2)。在特定实施例中，x为大约0.1到大约0.15(即，大约0.1≤x≤大约0.15)。
如所陈述，A大体上包括稀土元素或稀土元素的混合物，以在结晶结构的类似地点与La组合。在特定实施例中，A可包括Y, Gd, Ce, Ca, Sr, Ba或它们的组合。例如，在一个特定实施例中，A为Y，使得耐磨涂层包括形成结晶结构的La2-xYxMo2-y-y'WyFey'O9-δ，其中大约0.05≤x≤大约0.15(即，x为大约0.05到大约0.15)；0≤y≤大约1.5(即，y为零到大约1.5)；大约0.01≤y'≤大约0.2(即，y'为大约0.01到大约0.2)；以及0≤δ≤大约0.2(即，δ为零到大约0.2)。
当存在时，钨(W)可用于使耐磨涂层中的晶体结构的β相稳定，并且/或者使立方相稳定至较低温度。在某些实施例中，y为大约0.01到大约1.5(即，大约0.01≤y≤大约1.5)，使得一些量的W存在于耐磨涂层的晶体结构中。在此类实施例中，y'可为0，使得没有B元素存在于耐磨涂层的晶体结构中。作为备选，y'可为大于零到大约0.15(即，0＜y'≤大约0.15)，使得W和至少一个B元素存在于耐磨涂层的晶体结构中。W的水平有助于调整耐磨涂层的柔软度。
如所陈述，B包括Ta, Nb, V, Fe, Cr, Mn, Co, Ni, Sn, Ga, Al, Re, In, S或它们的组合。B可存在，而W(如上文所陈述)存在或不存在于耐磨涂层的晶体结构中(即，y为0)。在某些实施例中，B可有助于使立方相稳定至低温，特别是在B包括Ta, Nb, V或它们的组合时。此外，B可有助于通过抑制Mo改变其氧化状态(例如，减少)来使耐磨涂层的晶体结构中的Mo稳定，降低材料的处理温度，并且/或者减少材料与金属基底或连结涂层的相互作用。此类性质可特别是在B包括Fe, Cr, Mn, Co, Ni, Sn, Ga, Al, In或它们的组合时实现。
在任何情况下，那些钼酸镧材料的结晶材料的立方相提供具有与基底(特别是金属基底)失配的非常低热膨胀的耐磨涂层，并且因此可沉积为致密的未开裂的层，其在发动机中的热循环性能方面为稳健的，但对摩擦而言足够软，而在其中CMC叶片末端接触立方相的这些钼酸镧材料的侵入事件的情况下不从叶片快速除去EBC涂层。
为了另外的耐用性，如图4中所示，可选的TBC110可定位在连结涂层104与耐磨涂层106之间。该TBC提供附加的耐侵蚀，并且用作附加的相对硬的层来减轻在摩擦事件或延长的侵蚀之后使裸露的基底暴露的风险。例如，用于TBC110的选择将包括稀土的锆酸盐和铪酸盐，如，锆酸钪、锆酸钇、锆酸镧、锆酸铈、锆酸镨、锆酸钕、锆酸钷、锆酸钐、锆酸铕、锆酸钆、锆酸铽、锆酸镝、锆酸钬、锆酸铒、锆酸铥、锆酸镱和锆酸镥，以及铪酸钪、铪酸钇、铪酸镧、铪酸铈、铪酸镨、铪酸钕、铪酸钷、铪酸钐、铪酸铕、铪酸钆、铪酸铽、铪酸镝、铪酸钬、铪酸铒、铪酸铥、铪酸镱和铪酸镥，具有立方相或正方晶相的稀土掺杂的氧化锆、具有立方相或正方晶相的稀土掺杂的二氧化铪、具有立方相或正方晶相的碱土掺杂的氧化锆、具有立方相或正方晶相的碱土掺杂的二氧化铪、单斜二氧化铪，或它们的组合。TBC110的施加方法和厚度将在从大约0.003英寸到大约0.030英寸的范围内，并且可基于构件的特定需要而较高。TBC的其它描述在2014年10月28日提交的标题为"Thermal and EnvironmentalBarrier Coating Compositions and Methods of Deposition"的美国临时专利申请序列号62/069346和2014年6月30日提交的标题为"Thermal and Environmental BarrierCoating Compositions and Methods of Deposition"的美国临时专利申请序列号62/018983中找到，它们的公开通过引用并入本文中。
尽管按照一个或更多个特定实施例描述了本发明，但显而易见的是，其它形式可由本领域的技术人员采用。将理解的是，连同本文中特别地描述的涂层成分的"包括"的使用公开并且包括了其中涂层成分"基本上由指定的组分构成"(即，包含指定的组分并且不包含显著不利地影响公开的基本且新颖的特征的其它组分)的实施例，以及其中涂层成分"由指定的组分构成"(即，除自然且不可避免地存在于指定的组分中的各个中的污染物外，仅包含指定的组分)的实施例。
该书面的描述使用实例以公开本发明(包括最佳模式)，并且还使本领域技术人员能够实践本发明(包括制造和使用任何装置或系统并且执行任何并入的方法)。本发明的可专利范围由权利要求限定，并且可包括本领域技术人员想到的其它实例。如果这些其它实例包括不与权利要求的字面语言不同的结构元件，或者如果这些其它实例包括与权利要求的字面语言无显著差别的等同结构元件，则这些其它实例意图在权利要求的范围内。

Claims (26)

1.一种涂覆的基底(100)，其包括限定表面(103)的基底和具有以下化学式的所述基底的所述表面(103)上的耐磨涂层(106)：形成结晶结构的La2-xAxMo2-y-y'WyBy'O9-δ，其中：
A包括Li, Na, K, Rb, Cs, Sc, Y, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho,Er, Tm, Yb, Lu, Th, Be, Mg, Ca, Sr, Ba, Cu, Bi, Cd, Zn, Ag, Au, Pt, Ir, Rh,Ru, Pd或它们的组合；
0＜x≤大约0.2；
0≤y≤大约1.5；
B包括Ta, Nb, V, Fe, Cr, Mn, Co, Ni, Sn, Ga, Al, Re, In, S或它们的组合；
0≤y'≤大约0.2，其中y和y'的和为大约0.01到大约1.6；以及
0≤δ≤大约0.2。
2. 根据权利要求1所述的涂覆的基底(100)，其特征在于，所述耐磨涂层(106)包括选自由Y, Yb, Gd, Ce, Ca, Sr, Ba和它们的组合构成的组的A。
3.根据权利要求1所述的涂覆的基底(100)，其特征在于，所述耐磨涂层(106)包括选自由Y和Yb和它们的组合构成的组的A。
4.根据权利要求1所述的涂覆的基底(100)，其特征在于，所述耐磨涂层(106)包括为0的y。
5.根据权利要求1所述的涂覆的基底(100)，其特征在于，所述耐磨涂层(106)包括为0的y'。
6.根据权利要求1所述的涂覆的基底(100)，其特征在于，所述耐磨涂层(106)包括0＜y'≤大约0.15。
7.根据权利要求1所述的涂覆的基底(100)，其特征在于，所述耐磨涂层(106)包括选自由Ta,Nb,V或它们的组合构成的组的B。
8. 根据权利要求1所述的涂覆的基底(100)，其特征在于，所述耐磨涂层(106)包括选自由Fe, Cr, Mn, Co, Ni, Sn, Ga, Al, In或它们的组合构成的组的B。
9.根据权利要求1所述的涂覆的基底(100)，其特征在于，所述耐磨涂层(106)包括为Fe的B。
10. 一种涂覆的基底(100)，其包括限定表面(103)的基底和具有以下化学式的所述基底的所述表面(103)上的耐磨涂层(106)：形成结晶结构的La2-xYxMo2-y-y'WyB y'O9-δ，其中：
大约0.05≤x≤大约0.15；
0≤y≤大约1.5；
大约0.01≤y'≤大约0.2；以及
0≤δ≤大约0.2。
11.根据权利要求10所述的涂覆的基底(100)，其特征在于，所述耐磨涂层(106)包括为0的y，以及可选地大约0.05＜y’＜大约0.2。
12.一种涂覆的基底(100)，其包括限定表面(103)的基底和具有以下化学式的所述基底的所述表面(103)上的耐磨涂层(106)：形成结晶结构的La2-xYxMo2-yWyO9-δ，其中：
大约0.05≤x≤大约0.15；
0≤y≤大约1.5；
大约0.01≤y'≤大约0.2；以及
0≤δ≤大约0.2。
13.根据权利要求12所述的涂覆的基底(100)，其特征在于，所述耐磨涂层(106)包括为0的y，以及可选地大约0.05≤y'≤大约0.2。
14.根据权利要求1所述的涂覆的基底(100)，其特征在于，所述结晶结构可具有单相结构，其具有体积不大于大约10%的二次相。
15.根据权利要求14所述的涂覆的基底(100)，其特征在于，所述单相结构为立方相结晶结构。
16.根据权利要求1所述的涂覆的基底(100)，其特征在于，所述耐磨涂层(106)厚度为大约0.005英寸或更大。
17.根据权利要求1所述的涂覆的基底(100)，其特征在于，所述基底为具有选自由Ni、Cr和Co或它们的组合构成的组的基础金属的超级合金。
18.根据权利要求1所述的涂覆的基底(100)，其特征在于，所述涂覆的基底(100)还包括定位在所述基底与所述耐磨涂层之间的连结涂层(104)。
19.根据权利要求18所述的涂覆的基底(100)，其特征在于，所述连结涂层(104)为选自由铝化镍、铝化铂、铝和氧化铝或它们的组合构成的组的扩散涂层。
20.根据权利要求18所述的涂覆的基底(100)，其特征在于，所述连结涂层(104)具有化学式MCrAlY；其中M为Ni、Co、Fe或它们的混合物。
21.根据权利要求18所述的涂覆的基底(100)，其特征在于，所述涂覆的基底(100)还包括定位在所述连结涂层与所述耐磨涂层之间的TBC(110)。
22.根据权利要求21所述的涂覆的基底(100)，其特征在于，所述TBC(110)为选自由锆酸钪、锆酸钇、锆酸镧、锆酸铈、锆酸镨、锆酸钕、锆酸钷、锆酸钐、锆酸铕、锆酸钆、锆酸铽、锆酸镝、锆酸钬、锆酸铒、锆酸铥、锆酸镱和锆酸镥或它们的组合构成的组的锆酸盐。
23.根据权利要求21所述的涂覆的基底(100)，其特征在于，所述TBC(110)为选自由铪酸钪、铪酸钇、铪酸镧、铪酸铈、铪酸镨、铪酸钕、铪酸钷、铪酸钐、铪酸铕、铪酸钆、铪酸铽、铪酸镝、铪酸钬、铪酸铒、铪酸铥、铪酸镱和铪酸镥或它们的组合构成的组的铪酸盐。
24.一种燃气涡轮，其包括根据权利要求1所述的涂覆的基底(100)，其中所述涂覆的基底限定定位在叶片末端(44)附近的护罩(42)，并且其中在与叶片末端(44)接触时，所述耐磨涂层的一部分从所述护罩除去。
25.根据权利要求24所述的燃气涡轮(10)，其特征在于，所述叶片末端(44)为CMC。
26.根据权利要求25所述的燃气涡轮(10)，其特征在于，所述叶片末端还包括EBC，其中所述耐磨涂层从所述护罩(42)除去的速率低于EBC从所述叶片末端(44)除去的速率。
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