CN107022729A - 隔热涂层系统和形成隔热涂层系统的方法 - Google Patents
隔热涂层系统和形成隔热涂层系统的方法 Download PDFInfo
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Abstract
本发明公开一种在基材(102)上形成隔热涂层系统(100)的方法,所述方法制备包含给体粉末、活化剂粉末和粘合剂的浆料。给体粉末包括具有高于铝的熔融温度的金属铝合金,粘合剂包括至少一种有机聚合物凝胶。方法进一步包括施加浆料到基材(102);加热浆料,以形成铝化物粘合涂层(106),铝化物粘合涂层(106)包含添加铝化物层(108)和布置于基材(102)和添加铝化物层(108)之间的铝化物互扩散区域(110);并施加隔热涂层(104)到铝化物粘合涂层(106)。隔热涂层(104)可以为致密的垂直破裂隔热涂层(104),基材(102)可以为燃气涡轮机组件。本发明也公开由这种方法形成的隔热涂层系统(100)。
Description
发明领域
本发明涉及隔热涂层系统和形成隔热涂层系统的方法。更具体地讲,本发明涉及隔热涂层系统和形成结合铝化物粘合涂层的隔热涂层系统的方法。
发明背景
燃气涡轮机包括组件,例如叶片(bucket)(叶片(blade))、喷管(导向叶片(vane))、燃烧器、外壳和其它热气通道组件,它们用隔热涂层涂覆,以保护组件不受燃气涡轮机内存在的极端温度、化学环境和物理条件侵害。粘合涂层可施加到组件和隔热涂层之间,所述粘合涂层提高隔热涂层对组件的粘合强度,并提供附加保护。这些粘合涂层目前可通过高速氧燃料(HVOF)或真空等离子喷涂(VPS)技术施加,这些方法花费大,且进一步导致组件维护费用提高。
发明概述
在一个示例性实施方案中,在基材上形成隔热涂层系统的方法包括制备包含约35至约65%重量给体粉末、约1至约25%重量活化剂粉末和约25至约60%重量粘合剂的浆料。给体粉末包括具有高于铝的熔融温度的金属铝合金,粘合剂包括至少一种有机聚合物凝胶。方法进一步包括施加浆料到基材;加热浆料,以形成铝化物粘合涂层,铝化物粘合涂层包含添加铝化物层和布置于基材和添加铝化物层之间的铝化物互扩散区域;并施加隔热涂层到铝化物粘合涂层。
在另一个示例性实施方案中,在燃气涡轮机组件上形成致密的垂直破裂隔热涂层系统的方法包括提供具有基材的燃气涡轮机组件,并制备包含给体粉末、活化剂粉末和粘合剂的浆料。给体粉末包括具有高于铝的熔融温度的金属铝合金,粘合剂包括至少一种有机聚合物凝胶。方法进一步包括直接施加浆料到基材;加热浆料,以形成铝化物粘合涂层,铝化物粘合涂层包含添加铝化物层和布置于基材和添加铝化物层之间的铝化物互扩散区域;并直接施加致密的垂直破裂隔热涂层到铝化物粘合涂层的添加铝化物层。
在另一个示例性实施方案中,在基材上的隔热涂层系统包括隔热涂层和布置于基材和隔热涂层之间的铝化物粘合涂层,铝化物粘合涂层包含添加铝化物层和布置于基材和添加铝化物层之间的铝化物互扩散区域。
本发明包括以下方面:
方面1. 一种在基材(102)上形成隔热涂层系统(100)的方法,所述方法包括:
制备浆料,所述浆料包含约35至约65%重量给体粉末、约1至约25%重量活化剂粉末和约25至约60%重量粘合剂,给体粉末包括具有高于铝的熔融温度的金属铝合金,且粘合剂包括至少一种有机聚合物凝胶;
向基材(102)施加浆料;
加热浆料,以形成铝化物粘合涂层(106),所述粘合涂层(106)包含添加铝化物层(108)和布置于基材(102)和添加铝化物层(108)之间的铝化物互扩散区域(110);并且
将隔热涂层(104)施加到铝化物粘合涂层(106)。
方面2. 方面1的方法,其中将浆料直接施加到基材(102),将隔热涂层(104)直接施加到铝化物粘合涂层(106)的添加铝化物层(108),且形成不含任何MCrAlY粘合涂层的隔热涂层系统(100)。
方面3. 方面1的方法,其中所述给体粉末包括铬-铝合金。
方面4. 方面1的方法,其中所述给体粉末具有最多100目的粒径。
方面5. 方面1的方法,其中所述活化剂粉末选自氯化铵、氟化铵、溴化铵及其组合。
方面6. 方面1的方法,其中将浆料在基材(102)上加热到约815℃至约1150℃的温度。
方面7. 方面1的方法,其中形成铝化物粘合涂层(106)包括形成铝化物粘合涂层(106)作为外向型涂层。
方面8. 方面1的方法,其中所述基材(102)为燃气涡轮机组件。
方面9. 方面1的方法,其中所述基材(102)包括镍基超合金。
方面10. 方面1的方法,其中施加隔热涂层(104)包括施加致密的垂直破裂隔热涂层(104)。
方面11. 一种在燃气涡轮机组件上形成致密的垂直破裂隔热涂层系统(100)的方法,所述方法包括:
提供具有基材(102)的燃气涡轮机组件;
制备浆料,所述浆料包含给体粉末、活化剂粉末和粘合剂,所述给体粉末包括具有高于铝的熔融温度的金属铝合金,且粘合剂包括至少一种有机聚合物凝胶;
向基材(102)直接施加浆料;
加热浆料,以形成铝化物粘合涂层(106),所述粘合涂层(106)包含添加铝化物层(108)和布置于基材(102)和添加铝化物层(108)之间的铝化物互扩散区域(110);并且
将致密的垂直破裂隔热涂层(104)直接施加到铝化物粘合涂层(106)的添加铝化物层(108)。
方面12. 一种在基材(102)上的隔热涂层系统(100),所述隔热涂层系统(100)包括:
隔热涂层(104);和
布置于基材(102)和隔热涂层(104)之间的铝化物粘合涂层(106),所述铝化物粘合涂层(106)包含添加铝化物层(108)和布置于基材(102)和添加铝化物层(108)之间的铝化物互扩散区域(110)。
方面13. 方面12的隔热涂层系统(100),其中所述铝化物粘合涂层(106)直接接触基材(102),隔热涂层(104)直接接触铝化物粘合涂层(106)的添加铝化物层(108),且隔热涂层系统(100)不含任何MCrAlY粘合涂层。
方面14. 方面12的隔热涂层系统(100),其中所述基材(102)为选自叶片、喷管、外壳、燃烧器、热气通道组件及其组合的燃气涡轮机组件。
本发明还包括以下项目:
项目1. 一种在基材上形成隔热涂层系统的方法,所述方法包括:
制备浆料,所述浆料包含约35至约65%重量给体粉末、约1至约25%重量活化剂粉末和约25至约60%重量粘合剂,给体粉末包括具有高于铝的熔融温度的金属铝合金,且粘合剂包括至少一种有机聚合物凝胶;
向基材施加浆料;
加热浆料,以形成铝化物粘合涂层,所述粘合涂层包含添加铝化物层和布置于基材和添加铝化物层之间的铝化物互扩散区域;并且
将隔热涂层施加到铝化物粘合涂层。
项目2. 项目1的方法,其中将浆料直接施加到基材,将隔热涂层直接施加到铝化物粘合涂层的添加铝化物层,且形成不含任何MCrAlY粘合涂层的隔热涂层系统。
项目3. 项目1的方法,其中所述给体粉末包括铬-铝合金。
项目4. 项目1的方法,其中所述给体粉末具有最多约100目的粒径。
项目5. 项目1的方法,其中所述活化剂粉末选自氯化铵、氟化铵、溴化铵及其组合。
项目6. 项目1的方法,其中施加浆料涂层包括施加约25mm最大厚度的浆料涂层。
项目7. 项目1的方法,其中将浆料在基材上加热到约815℃至约1150℃的温度。
项目8. 项目1的方法,其中形成铝化物粘合涂层包括形成铝化物粘合涂层作为外向型涂层。
项目9. 项目1的方法,其中所述基材为燃气涡轮机组件。
项目10. 项目9的方法,其中燃气涡轮机组件选自叶片、喷管、外壳、燃烧器、热气通道组件及其组合。
项目11. 项目1的方法,其中所述基材包括镍基超合金。
项目12. 项目1的方法,其中加热浆料形成残余物,所述残余物通过选自以下的技术去除:在铝化物粘合涂层引导强制气流、对铝化物粘合涂层喷砂处理及其组合。
项目13. 项目1的方法,其中施加浆料到基材形成具有最小厚度为约0.25mm和最大厚度为约6mm或更大的不均匀厚度的浆料涂层,且铝化物粘合涂层具有以约0.01mm或更小变动的厚度,因此,基本独立于浆料涂层厚度。
项目14. 项目1的方法,其中施加隔热涂层包括施加致密的垂直破裂隔热涂层。
项目15. 一种在燃气涡轮机组件上形成致密的垂直破裂隔热涂层系统的方法,所述方法包括:
提供具有基材的燃气涡轮机组件;
制备浆料,所述浆料包含给体粉末、活化剂粉末和粘合剂,所述给体粉末包括具有高于铝的熔融温度的金属铝合金,且粘合剂包括至少一种有机聚合物凝胶;
向基材直接施加浆料;
加热浆料,以形成铝化物粘合涂层,所述粘合涂层包含添加铝化物层和布置于基材和添加铝化物层之间的铝化物互扩散区域;并且
将致密的垂直破裂隔热涂层直接施加到铝化物粘合涂层的添加铝化物层。
项目16. 一种在基材上的隔热涂层系统,所述隔热涂层系统包括:
隔热涂层;和
布置于基材和隔热涂层之间的铝化物粘合涂层,所述铝化物粘合涂层包含添加铝化物层和布置于基材和添加铝化物层之间的铝化物互扩散区域。
项目17. 项目16的隔热涂层系统,其中所述铝化物粘合涂层直接接触基材,隔热涂层直接接触铝化物粘合涂层的添加铝化物层,且隔热涂层系统不含任何MCrAlY粘合涂层。
项目18. 项目16的隔热涂层系统,其中所述铝化物粘合涂层为外向型涂层。
项目19. 项目16的隔热涂层系统,其中所述基材为选自叶片、喷管、外壳、燃烧器、热气通道组件及其组合的燃气涡轮机组件。
项目20. 项目16的隔热涂层系统,其中所述基材包括镍基超合金。
通过以下优选实施方案的更详细描述并结合附图,本发明的其它特征和优点将显而易见,这些附图举例说明本发明的原理。
附图说明
图1为本公开的一个实施方案的隔热涂层系统的横截面图。
只要可能,在整个图中相同的附图标记表示相同的部件。
发明详述
在此提供示例性隔热涂层系统和形成隔热涂层系统的方法。与不利用一个或多个本文所公开特征的方法比较,本公开的实施方案提高效率,减小应用成本,减小维护成本或其组合。
参考图1,在一个实施方案中,在基材102上的隔热涂层系统100包括隔热涂层104和布置于基材102和隔热涂层104之间的铝化物粘合涂层106,铝化物粘合涂层106包含添加铝化物层108和布置于基材102和添加铝化物层108之间的铝化物互扩散区域110。在另一个实施方案中,铝化物粘合涂层106为外向型涂层。
在一个实施方案中,铝化物粘合涂层106直接接触基材102,隔热涂层104直接接触铝化物粘合涂层106的添加铝化物层108,且隔热涂层系统100不含任何MCrAlY粘合涂层。本文所用“不含任何MCrAlY粘合涂层”表示MCrAlY粘合涂层的层不结合到基材102上的隔热涂层系统100,且基材102不包括接触隔热涂层系统100的MCrAlY粘合涂层。
在一个实施方案中,基材102为燃气涡轮机组件。燃气涡轮机组件可以为任何适合燃气涡轮机组件,包括但不限于热气通道组件、叶片(bucket)(叶片(blade))、喷管(导向叶片(vane))、外壳、燃烧器或其组合。
在一个实施方案中,基材102包括铁基超合金、镍基超合金、钴基超合金或其组合。
隔热涂层104可以为任何适合隔热涂层104,包括但不限于氧化钇稳定化的氧化锆。在一个实施方案中,隔热涂层104为致密的垂直破裂隔热涂层104。
在一个实施方案中,根据基材102材料,添加铝化物层108包括耐环境金属间相MAl,其中M为铁、镍或钴。添加铝化物层108的化学组成可通过加入元素改变,例如铬、硅、铂、铑、铪、钇、锆或其组合。这些改变可改变添加铝化物层108的环境和物理性质。在一个实施方案中,添加铝化物层108包括高达约50μm厚度,或者高达约75μm,或者高达约100μm,或者在约25μm至约75μm之间,或者在约50μm至约100μm之间。
在一个实施方案中,铝化物互扩散区域110包括高达约25μm厚度,或者高达约50μm,或者高达约75μm,或者在约10μm至约40μm之间,或者在约20μm至约50μm之间,或者在约30μm至约60μm之间。铝化物互扩散区域110可包括在用隔热涂层系统100涂覆基材102期间形成的不同金属间相和亚稳相100。不受理论限制,相信不同金属间相和亚稳相由于扩散梯度而形成,并且改变在基材102局部区域内的元素溶解度。不同金属间相和亚稳相在基材102材料的基质中分布。
在一个实施方案中,在基材102上形成隔热涂层系统100的方法包括制备包含给体粉末、活化剂粉末和粘合剂的浆料,给体粉末包括具有高于铝的熔融温度的金属铝合金,且粘合剂包括至少一种有机聚合物凝胶。施加浆料到基材,并加热,以形成铝化物粘合涂层106。将隔热涂层104施加到铝化物粘合涂层106。在基材102和铝化物粘合涂层106的添加铝化物层108之间形成铝化物互扩散区域110。在另一个实施方案中,将浆料直接施加到基材102,将隔热涂层104直接施加到铝化物粘合涂层106的添加铝化物层108,且形成不含任何MCrAlY粘合涂层的隔热涂层系统100。
浆料可在基材上加热到约815℃至约1150℃的温度。在一个实施方案中,在浆料施加到基材102后,立即将基材102放入涂覆室,以进行扩散过程。将涂覆室抽空,并且可用惰性或还原气氛(例如,分别用氩或氢)反填。使涂覆室内的温度升高到足以烧尽粘合剂的温度(例如,约150℃至约200℃),并进一步进行加热,以达到所需的扩散温度,在此期间使活化剂挥发,形成卤化铝,并在基材102上沉积铝。根据添加铝化物层108和铝化物扩散区域110所需的最终厚度,基材102可保持在扩散温度约1至约8小时的持续时间。加热浆料可形成残余物。残余物可通过任何适合技术去除,包括但不限于在铝化物粘合涂层106引导强制气流,对铝化物粘合涂层106喷砂处理,或其组合。
在一个实施方案中,浆料包含约35至约65%重量给体粉末、约1至约25%重量活化剂粉末和约25至约60%重量粘合剂。在另一个实施方案中,浆料涂层包括具有约0.25mm最小厚度和约6mm或更大最大厚度的不均匀厚度,铝化物粘合涂层106具有以约0.01mm或更小变动的厚度,因此,基本独立于浆料涂层厚度。浆料涂层可包括约25mm最大厚度。
给体粉末可包括具有高于铝的熔融温度(熔点约660℃)的金属铝合金。在一个实施方案中,给体粉末包括与铬、铁、另一种铝成合金剂成合金的金属铝,或其组合,条件为成合金剂在扩散铝化过程期间不沉积,而是作为给体材料的铝的惰性载体。在另一个实施方案中,给体粉末包括铬-铝合金,例如但不限于44%重量铝、余量铬和伴随杂质。在另一个实施方案中,给体粉末具有达到100目(149µm)的粒径,或达到200目(74µm)的粒径。不受理论限制,相信给体粉末为细粉末减小给体粉末留存或残留在基材102内的可能性。
活化剂粉末可包括任何适合材料,包括但不限于氯化铵、氟化铵、溴化铵、另一种卤化活化剂或其组合。用于活化剂粉末的适合材料与铝在给体材料内反应形成挥发性卤化铝,例如但不限于AlCl3或AlF3,它在基材102反应以沉积铝,铝扩散进入基材102,形成具有添加铝化物层108和铝化物互扩散区域110的铝化物粘合涂层106。
粘合剂可包括至少一种有机聚合物凝胶。适合的粘合剂包括但不限于以商品名Vitta Braz-Binder Gel购自Vitta Corporation的聚合物凝胶和低分子量聚醇(例如,聚乙烯醇)。在一个实施方案中,粘合剂还包括固化催化剂和加速剂或二者,例如但不限于次磷酸钠。
在一个实施方案中,浆料不含惰性填料和无机粘合剂。不存在惰性填料和无机粘合剂防止这些物质烧结和变得残留在基材102内。
隔热涂层可通过任何适合技术施加,包括但不限于空气等离子喷涂、低压等离子喷涂、HVOF、电子束物理气相沉积或其组合。
虽然已关于优选的实施方案描述了本发明,但本领域的技术人员应理解,可在不脱离本发明的范围下进行各种变化,并可用等效物代替其要素。另外,可在不脱离本发明的基本范围下作出很多修改,以使具体情况或材料适应本发明的教导。因此,预期本发明不限于预期作为实施本发明的最佳方式而公开的具体实施方案,但本发明应包括落在所附权利要求范围内的所有实施方案。
Claims (10)
1.一种在基材(102)上形成隔热涂层系统(100)的方法,所述方法包括:
制备浆料,所述浆料包含约35至约65%重量给体粉末、约1至约25%重量活化剂粉末和约25至约60%重量粘合剂,给体粉末包括具有高于铝的熔融温度的金属铝合金,且粘合剂包括至少一种有机聚合物凝胶;
向基材(102)施加浆料;
加热浆料,以形成铝化物粘合涂层(106),所述粘合涂层(106)包含添加铝化物层(108)和布置于基材(102)和添加铝化物层(108)之间的铝化物互扩散区域(110);并且
将隔热涂层(104)施加到铝化物粘合涂层(106)。
2.权利要求1的方法,其中将浆料直接施加到基材(102),将隔热涂层(104)直接施加到铝化物粘合涂层(106)的添加铝化物层(108),且形成不含任何MCrAlY粘合涂层的隔热涂层系统(100)。
3.权利要求1的方法,其中所述给体粉末包括铬-铝合金。
4.权利要求1的方法,其中所述给体粉末具有最多100目的粒径。
5.权利要求1的方法,其中所述活化剂粉末选自氯化铵、氟化铵、溴化铵及其组合。
6.权利要求1的方法,其中将浆料在基材(102)上加热到约815℃至约1150℃的温度。
7.权利要求1的方法,其中形成铝化物粘合涂层(106)包括形成铝化物粘合涂层(106)作为外向型涂层。
8.权利要求1的方法,其中所述基材(102)为燃气涡轮机组件。
9.权利要求1的方法,其中所述基材(102)包括镍基超合金。
10.权利要求1的方法,其中施加隔热涂层(104)包括施加致密的垂直破裂隔热涂层(104)。
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