CN109154035A - 具有改进的涂层系统的翼型件及其形成方法 - Google Patents

具有改进的涂层系统的翼型件及其形成方法 Download PDF

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Publication number
CN109154035A
CN109154035A CN201780034110.1A CN201780034110A CN109154035A CN 109154035 A CN109154035 A CN 109154035A CN 201780034110 A CN201780034110 A CN 201780034110A CN 109154035 A CN109154035 A CN 109154035A
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China
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section
weight
content
mcraly
coat system
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CN201780034110.1A
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B.A.纳加拉
M.D.克拉克
S.L.希茨
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General Electric Co
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General Electric Co
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Publication of CN109154035A publication Critical patent/CN109154035A/zh
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    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/01—Layered products comprising a layer of metal all layers being exclusively metallic
    • B32B15/017—Layered products comprising a layer of metal all layers being exclusively metallic one layer being formed of aluminium or an aluminium alloy, another layer being formed of an alloy based on a non ferrous metal other than aluminium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C19/00—Alloys based on nickel or cobalt
    • C22C19/03—Alloys based on nickel or cobalt based on nickel
    • C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
    • C22C19/058—Alloys based on nickel or cobalt based on nickel with chromium without Mo and W
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C5/00—Alloys based on noble metals
    • C22C5/04—Alloys based on a platinum group metal
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/10—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of nickel or cobalt or alloys based thereon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/14—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of noble metals or alloys based thereon
    • 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
    • C23C10/00—Solid state diffusion of only metal elements or silicon into metallic material surfaces
    • C23C10/02—Pretreatment 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
    • C23C10/00—Solid state diffusion of only metal elements or silicon into metallic material surfaces
    • C23C10/28—Solid state diffusion of only metal elements or silicon into metallic material surfaces using solids, e.g. powders, pastes
    • 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
    • C23C10/00—Solid state diffusion of only metal elements or silicon into metallic material surfaces
    • C23C10/28—Solid state diffusion of only metal elements or silicon into metallic material surfaces using solids, e.g. powders, pastes
    • C23C10/34—Embedding in a powder mixture, i.e. pack cementation
    • C23C10/36—Embedding in a powder mixture, i.e. pack cementation only one element being diffused
    • C23C10/48—Aluminising
    • 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
    • C23C10/00—Solid state diffusion of only metal elements or silicon into metallic material surfaces
    • C23C10/60—After-treatment
    • C—CHEMISTRY; METALLURGY
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    • 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
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
    • C23C14/14—Metallic material, boron or silicon
    • C23C14/16—Metallic material, boron or silicon on metallic substrates or on substrates of boron or silicon
    • 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
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
    • C23C14/24—Vacuum evaporation
    • C23C14/32—Vacuum evaporation by explosion; by evaporation and subsequent ionisation of the vapours, e.g. ion-plating
    • C23C14/325—Electric arc evaporation
    • 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
    • C23C28/021—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 including at least one metal alloy layer
    • C23C28/022—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 including at least one metal alloy layer with 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
    • C23C28/02—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
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    • 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
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    • 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
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    • 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
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    • 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
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    • 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
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    • 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
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    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
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    • C25D3/02—Electroplating: Baths therefor from solutions
    • C25D3/50—Electroplating: Baths therefor from solutions of platinum group metals
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    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
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    • C25D5/48—After-treatment of electroplated surfaces
    • C25D5/50—After-treatment of electroplated surfaces by heat-treatment
    • C—CHEMISTRY; METALLURGY
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    • C—CHEMISTRY; METALLURGY
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • 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
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    • F05D2230/30—Manufacture with deposition of material
    • F05D2230/31—Layer deposition
    • F05D2230/312—Layer deposition by plasma spraying
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Abstract

提供了一种用于超合金部件表面的涂层系统。该涂层系统在超合金部件的表面上包括MCrAlY涂层，其中M是Ni、Fe、Co或其组合。MCrAlY涂层总体上具有比超合金部件更高的铬含量。MCrAlY涂层还包括铂族金属铝化物扩散层。MCrAlY涂层包括Re、Ta或其混合物。还提供了用于在超合金部件的表面上形成涂层系统的方法。

Description

具有改进的涂层系统的翼型件及其形成方法
发明领域
本发明总体上涉及部件上的保护涂层，更具体地，涉及具有翼型件的燃气涡轮部件上的MCrAlY和铂族金属铝化物涂层。
发明背景
在燃气涡轮发动机中，空气被吸入发动机的前部，由轴装压缩机压缩，并与燃料混合。混合物燃烧，且产生的热燃烧气体通过安装在同一轴上的涡轮。气流通过接触涡轮桨叶(turbine blade)的翼型件部分来转动涡轮，涡轮桨叶的翼型件部分转动轴并向压缩机提供动力。涡轮气体越热，发动机的工作效率越高。因此，存在提高涡轮工作温度的动机。然而，涡轮气体的最高温度通常受到用于制造涡轮的涡轮叶片(turbine vane)和涡轮桨叶的材料的限制。
保护层被施加于充当基材的涡轮桨叶或涡轮叶片部件的翼型件。目前已知的扩散保护层包括铝化物和铂铝化物层。保护层保护基材免受来自热的高腐蚀性燃烧气体的环境损害。该保护层没有覆盖的陶瓷层，可用于中温应用。对于更高温度的应用，可以施加陶瓷热障涂层覆盖保护层，以形成热障涂层(TBC)系统。陶瓷热障涂层使部件与废气隔离，允许废气比起利用基材的该特定材料和制造工艺另外可能的更热。
即使使用这些保护技术，在某些工作服务条件下仍然存在要克服的问题，特别是在暴露于与工作环境的盐度相关的苛刻条件的船用涡轮发动机中。
发明简述
本发明的目的和优点将部分地在以下描述中阐述，或者可以从描述中显而易见，或者可以通过实践本发明来学习。
总体上提供用于超合金部件的表面的涂层系统。在一个实施方案中，涂层系统包括在超合金部件表面上的MCrAlY涂层，其中M是Ni、Fe、Co或其组合。MCrAlY涂层通常具有比超合金部件更高的铬含量。MCrAlY涂层还包括铂族金属铝化物扩散层。在一个特定实施方案中，MCrAlY涂层包括Re、Ta或其混合物。
还总体上提供用于在超合金部件的表面上形成涂层系统的方法。在一个实施方案中，该方法包括：在超合金部件的表面上形成MCrAlY层，其中MCrAlY层的铬含量高于超合金部件，并且其中M是Ni、Fe、Co或其组合；在MCrAlY层上形成铂族金属层；将铂族金属层加热至约900℃至约1200℃的处理温度；和在铂族金属层上形成铝化物涂层。
下面更详细地讨论本发明的其他特征和方面。
附图简述
通过参考以下描述并结合附图，可以最好地理解本发明，在附图中：
图1A是部件(例如燃气涡轮发动机的涡轮桨叶)的透视图；
图1B是另一个部件(例如燃气涡轮发动机的喷嘴段)的透视图；
图2是热处理前，部件(例如图1A或图1B的翼型件)表面上的示例性MCrAlY涂层的横截面图；
图3是在热处理和形成TBC之后，包括MCrAlY涂层的示例性涂层系统的横截面图；
图4是在翼型件表面上形成涂层的示例性方法的框图；和
图5是修复翼型件表面上的涂层的示例性方法的框图。
在本说明书和附图中重复使用附图标记旨在表示本发明的相同或类似的特征或元件。
发明详述
现在将参考本发明的实施方案，其一个或多个实例在下面阐述。提供每个实例作为对本发明的解释，而不是作为对本发明的限制。事实上，对于本领域技术人员显而易见的是，在不脱离本发明的范围或精神的情况下，可以在本发明中进行各种修改和变化。例如，作为一个实施方案示出或描述的特征可以用在另一个实施方案上，以产生又一个实施方案。因此，本发明旨在覆盖落入所附权利要求及其等同物的范围内的这些修改和变化。本领域普通技术人员应理解，本讨论仅是示例性实施方案的描述，并不意图限制本发明的更广泛的方面，该更广泛的方面体现为示例性构造。
总体上提供用于涡轮发动机的热气路径部件(例如，翼型件)的涂层系统，及其形成方法。特别地，涂层系统可用于船用涡轮发动机的超合金部件，其暴露于特别腐蚀性的工作环境。涂层系统具有多层构造化学，其至少包括MCrAlY涂层，其中M是Ni、Fe、Co或其组合。在一个特定的实施方案中，MCrAlY涂层通过扩散涂覆工艺由MCrAlY层和铂族金属铝化物涂层形成。在其沉积组成和其处理后的组成两者中，MCrAlY层的铬含量都高于超合金部件。另外，在大多数实施方案中，MCrAlY层在其组成中包含增强组分(例如，Re、Ta、Hf、Zr、Si或其混合物)。例如，刚沉积的MCrAlY层(例如，在Pt镀覆和Al沉积之前)可以包括按重量计约5%至约7%的Ta和/或约1%至约3%的Re。热障涂层任选地置于MCrAlY涂层上与部件反向的其表面上。
涂层系统可以降低燃气涡轮部件对性能退化(例如低周疲劳失效)的敏感性，同时保持与施加到部件上的保护涂层相关的益处。本方法可以作为正常生产操作的一部分来完成，而无需大的修改。另外，在部件表面与MCrAlY涂层之间和/或MCrAlY涂层的构造内(例如，在MCrAlY层与铂族金属铝化物涂层之间)任何额外的粘合涂层或其他层的使用可以在特定实施方案中避免。也就是说，在该实施方案中，MCrAlY层直接在部件的表面上，和/或铂族金属铝化物涂层直接在MCrAlY层上，以形成MCrAlY涂层。当存在热障涂层时，涂层系统在MCrAlY涂层(例如，MCrAlY涂层的铂族金属铝化物涂层)与热障涂层之间没有粘合涂层(例如，热障涂层直接在MCrAlY涂层的铂族金属铝化物涂层上)。
参考附图，图1A描绘了燃气涡轮发动机的示例性部件5，示出为燃气涡轮桨叶。涡轮桨叶5包括：翼型件6，横向延伸的平台7，呈燕尾形式以将燃气涡轮桨叶5附接到涡轮盘(未示出)的附件8。在一些部件中，多个冷却通道延伸穿过翼型件6的内部，终止于翼型件6的表面中的开口9。在特定实施方案中，开口9可以是膜孔。
图1B表示喷嘴段10，喷嘴段10是多个喷嘴段中的一个，所述多个喷嘴段当连接在一起时形成燃气涡轮发动机的环形喷嘴组件。段10由多个叶片12构成，每个叶片12均限定翼型件并且在外平台(带)14和内平台(带)16之间延伸。叶片12与平台14和16可以单独形成然后组装，例如通过将每个叶片12的端部钎焊在平台14和16中限定的开口内。或者，整个段10可以作为整体铸件而形成。叶片12通常具有前缘22、后缘24、压力面26(即凹面)和吸力面28(即凸面)。前缘22有时被描述为由翼型件12的最前点(鼻部)限定。
当喷嘴段10与其他喷嘴段组装在一起以形成喷嘴组件时，这些段各自的内平台和外平台形成连续的内带和外带，叶片12在所述内带和外带之间沿周向间隔开并径向延伸。由于通常采用的冷却方案的复杂性，具有单独喷嘴段的喷嘴组件的构造通常是有利的。图1B中描绘的喷嘴段10被称为二联体(doublet)，因为两个叶片12与每个段10相关联。喷嘴段可配备有多于两个的叶片，例如三个叶片(称为三联体(triplet))、四个叶片、六个叶片，或具有单个叶片以形成被称为单联体(singlet)的物体。如本领域已知，单联体和二联体铸件之间的设计选择考虑了与它们的不同构造和工艺相关的优点。单联体喷嘴构造的显著优点是在叶片12周围具有优异的涂层厚度分布的能力，其除了促进抗氧化性和耐腐蚀性之外还促进了喷嘴之间的喉部区域的控制和不同级的叶片之间的均匀性。另一方面，双联体铸件避免了高温钎焊操作的必要性，尽管对涂层厚度的控制较少。
在一个实施方案中，图1A的涡轮桨叶5的翼型件6和图1B的喷嘴段10的叶片12位于发动机的涡轮部分中，并经受来自发动机燃烧器的热燃烧气体。除了强制空气冷却技术(例如，通过膜孔15)之外，这些部件的表面由它们各自的表面上的涂层系统18保护。
图1A的涡轮桨叶5的翼型件6和图1B的喷嘴段10的叶片12可由能够形成为所需形状并且能够在将安装该段的燃气涡轮区域的预期工作温度下承受必要的工作负荷的材料形成。这种材料的实例包括金属合金，其包括但不限于钛基、铝基、钴基、镍基和钢基合金。在一个特定实施方案中，图1A的翼型件6和/或图1B的叶片12由超合金金属材料形成，例如镍基超合金、钴基超合金或铁基超合金。在典型的实施方案中，超合金部件具有微细γ-(M)(面心立方)和β-(M)Al(体心立方)的二相结构。β-(M)Al相是铝(Al)储库。在服务期间，表面附近的铝可通过扩散到TBC界面而耗尽，在扩散涂覆的基底的表面上形成α-Al2O3热生长氧化物。
尽管在上文和图1A和1B中对于涡轮桨叶5和喷嘴段10进行了描述，涂层系统可以与燃气涡轮发动机的任何部件一起使用。
参见图2，示出在热处理之前包括MCrAlY涂层22的涂层系统18，其显示由超合金部件19(例如，翼型件12)的表面上的MCrAlY层20、铂族金属层30和铝化物涂层34形成的MCrAlY涂层22。
在形成铂族金属层之前，以某一组成沉积MCrAlY层20，其具有以下组成：按重量计包含至多约25%的Cr(例如，约10%至约25%的Cr)，约6%至约7%的Al，至多约1%的Hf(例如，约0.1%至约1%的Hf)，至多约0.5%的Y(例如，约0.1%至约0.5%的Y)，约8%至约12%Co，约5%至约7%Ta，约1%至约3%Re，约0.5%至约1.5%Si，至多约0.5%Zr(例如，约0.0001%至约0.5%Zr)，和余量Ni。MCrAlY层20在表面13上形成为约10μm至约100μm(例如，约15μm至约50μm)的厚度。通过保持MCrAlY层20相对薄(即，小于100μm)，即使不使用掩模或其他沉积阻挡方法，在表面内限定的任何膜孔也可保持打开。
由此，根据任何合适的施加工艺，在部件的表面上形成MCrAlY层20。非限制性示例包括等离子体沉积(例如，离子等离子体沉积、真空等离子体喷涂(VPS)、低压等离子体喷涂(LPPS)和等离子体增强化学气相沉积(PECVD))、高速氧燃料(HVOF)技术、高速空气燃料(HVAF)技术、物理气相沉积(PVD)、电子束物理气相沉积(EBPVD)、化学气相沉积(CVD)、空气等离子体喷涂(APS)、冷喷涂和激光烧蚀。在一个实施方案中，MCrAlY层20通过热喷涂技术(例如，VPS、LPPS、HVOF、HVAF、APS和/或冷喷涂)施加。在一个特定实施方案中，MCrAlY层20通过离子等离子体沉积形成。
铂族金属层30沉积在MCrAlY层20上。铂族金属层30通常包括铂、铑、钯、钌、锇、铱或其混合物。这些元素具有相似的物理和化学性质，并且倾向于在相同的矿床中一起出现。在一个实施方案中，钯族铂族金属(即铂、铑、钯或其混合物)包含在铂族金属层30中。在一个特定实施方案中，铂族金属层30通常包括铂，但也可包括其他元素(例如，钯和/或铑)。例如，铂族金属层30可包括铂-钯合金、铂-铑合金或铂-钯-铑合金。在一个实施方案中，铂族金属层30包括至少50重量%(例如，约75重量%至100重量%)的铂。
在大多数实施方案中，铂族金属层30的合适厚度为约1μm至约10μm(例如，约3μm至约7μm)。在所示的实施方案中，由于铂族金属层的这种相对薄的性质，铂族金属层30直接形成在表面13上。因此，没有其他层(例如，粘合涂层)置于表面13和铂族金属层30之间。
铂族金属层30可以通过任何合适的工艺形成。例如，在一个特定实施方案中，铂族金属层30通过电沉积工艺沉积(例如，电镀)，尽管溅射、刷镀等也可以备选使用。镀覆可以在室温(例如，约20℃至约25℃)下进行。在一个实施方案中，通过将含铂族金属的溶液(例如，含铂溶液)放入沉积槽中并将铂族金属从溶液沉积到表面13上来完成电沉积过程。例如，当沉积铂时，含铂的水溶液可以包括Pt(NH3)4HPO4，并且电压/电流源可以在每平方英尺面对的制品表面约1/2-10安培下操作。在沉积中，铂族金属层30沉积在表面13的未掩蔽部分(即后缘24)上。
根据需要，可以对铂族金属层30进行热处理。例如，铂族金属层30可以在约900℃至约1200℃的处理温度下进行热处理。在一个实施方案中，铂族金属层30在真空中(例如，在约10托或更低的处理压力下，例如在约1托或更低的处理压力下)进行热处理。
将抗氧化涂层施加到翼型件12的表面13上以进一步促进抗氧化性。在一个特定实施方案中，抗氧化涂层是扩散铝化物涂层34，其可包括铝金属间化合物、γ相、γ'相等。铝化物涂层34沉积覆盖铂族金属层30。铝化物涂层34可以通过任何合适的方法形成为约2μm至约100μm的厚度(例如，约25μm至约100μm，例如约35μm至约75μm)。例如，铝化物涂层34可以通过任何可操作的方法沉积，例如通过包埋渗( pack cementation)或其他工艺(包括气相铝化)进行铝化。
在一个实施方案中，铝化物涂层34通过气相铝化沉积。例如，使卤化氢气体如氯化氢或氟化氢与铝金属或铝合金接触以形成相应的卤化铝气体。如果需要，可以将其他元素从相应的气体掺杂到铝层中。卤化铝气体与表面13接触，在其上沉积铝。在循环时间(例如，4至20小时循环)期间，沉积在升高的温度(例如约900℃至约1125℃)下发生。铝化物涂层34优选为约12至约125微米厚(例如约25μm至约100μm，例如约35μm至约75μm)。沉积技术允许成合金元素从卤化物气体(如果需要)共沉积到铝化物涂层34中。
因为铝的沉积在升高的温度下进行，所以沉积的铝原子与铂族金属层30(或相互扩散的铂/基底区域)和/或表面13的材料相互扩散，形成扩散区。
在图2所示的实施方案中，铝化物涂层34沉积在整个表面13上，在表面13中存在的任何空腔和任何膜孔内，以及在铂族金属层30上。在过程期间，铝化物涂层与铂族金属层30反应形成铂族金属铝化物涂层31。该铂族金属铝化物涂层31包含铂族金属和铝，例如铂改性的铝化物(PtAl)，但可以含有另外的组分(例如铂改性的镍铝化物)。因此，铂族金属镀覆之后扩散铝化物，得到“铂铝化物层”，其中它的涂层的外层具有铂族金属(例如铂)，以及扩散铝化物。。
在对图2中所示的MCrAlY层20、铂族金属层30和铝化物涂层34进行热处理之后，形成MCrAlY涂层22以在其整个厚度上具有组成梯度，如内部部分21、中间部分31和外部部分35所限定，如图3所示。在一个实施方案中，热处理在真空中在约975℃至约1125℃的处理温度下进行(例如，处理时间为约1至约4小时)。
通常，所得到的经热处理的MCrAlY涂层22在其整个厚度上具有组成梯度，并且包括内部部分21、中间部分31和外部部分35。内部部分21通常与部件相邻，而外部部分35与部件反向并且与TBC36相邻。内部部分21、中间部分31和外部部分35中的每一个限定MCrAlY涂层22的厚度的三分之一(即1/3)。例如，如果MCrAlY涂层22具有约60μm至约100μm(例如，约75μm至约85μm)的厚度，则内部部分21、中间部分31和外部部分35各自限定约20μm至约33.3μm的厚度(例如，约25μm至约28.3μm)。
在一个实施方案中，MCrAlY涂层22具有组成梯度，并且与中间部分31的组成相比时，外部部分35具有相对低浓度的Cr和相对高浓度的Pt和Al。因此，外部部分35具有良好的氧化品质和对TBC(或其上的其他层)的粘附性。然而，中间部分31和/或内部部分21中Cr浓度的增加可以允许提高耐腐蚀性，这在船舶和工业发动机应用中特别有用。
在一个特定实施方案中，内部部分21的铬(Cr)含量以重量百分比计低于中间部分31的铬含量。类似地，外部部分35的铬含量以重量百分比计低于中间部分31的铬含量。因此，中间部分31的铬含量以重量百分比计大于内部部分21和/或外部部分35。在某些实施方案中，例如，外部部分35的铬含量为约3%至约7.5%重量；中间部分31的铬含量为约8%至约20%重量；且内部部分21的铬含量为约5%至12%重量。
在一个特定实施方案中，外部部分35的铼(Re)含量以重量百分比计低于中间部分31的铼含量。类似地，中间部分31的铼含量以重量百分比计低于内部部分21的铼含量。在某些实施方案中，例如，外部部分35的铼含量为0%至约0.1%重量；中间部分31的铼含量为约0.1%至约4%重量；且内部部分21的铼含量大于约3%重量。
在一个特定实施方案中，外部部分35的钽(Ta)含量以重量百分比计低于中间部分31的钽含量。在某些实施方案中，例如，外部部分35的钽含量为约0.1%至约2.25%重量；中间部分31的钽含量为约2.5%至约7.5%重量。在这样的实施方案中，内部部分21可具有约3%至约7.5%重量的钽含量。
在一个特定实施方案中，外部部分35的钨(W)含量以重量百分比计低于中间部分31的钨含量。在某些实施方案中，例如，外部部分35的钨含量为0%至约0.015%重量；中间部分31的钨含量为约0.1%至约1%重量；且内部部分21的钨含量为约1.5%至约6%。
类似地，在一个特定实施方案中，内部部分21的铪(Hf)含量以重量百分比计低于中间部分31的铪含量。类似地，外部部分35的铪含量以重量百分比计低于中间部分31的铪含量。因此，中间部分31的铪含量以重量百分比计大于内部部分21和/或外部部分35。在某些实施方案中，例如，外部部分35的铪含量为0%至约0.1%重量；中间部分31的铪含量为约0.1%至约0.5%重量；且内部部分21的铪含量为0%至约0.1%重量。
在一个特定实施方案中，外部部分35的镍(Ni)含量以重量百分比计高于中间部分31的镍含量。类似地，内部部分21的镍含量以重量百分比计高于中间部分31的镍含量。因此，中间部分31的镍含量以重量百分比计低于内部部分21和/或外部部分35。在某些实施方案中，例如，外部部分35的镍含量为约40%至约50%重量；中间部分31的镍含量为约30%至约40%重量；且内部部分21的镍含量为大于约40%重量(例如，大于约50%重量)。
沉积并加工MCrAlY涂层22以具有光滑的表面光洁度，例如约3μm或更小的表面粗糙度(Ra)，以促进喷嘴组件的空气动力学。在一个实施方案中，MCrAlY涂层22优选具有小于约3μm(例如，约0.75μm至约2.75μm，例如约1.25μm至约2.25μm)的表面粗糙度(Ra)。
图3还示出了在MCrAlY涂层22上的环境涂层36(例如，热障涂层(TBC))，如果需要进一步的保护(例如，要在非常高的温度下使用的翼型件12的表面上)，则其特别有用。在特定实施方案中，环境涂层36也可沉积在内带和外带的表面上。例如，热障涂层36可以完全由一种或多种陶瓷组分构成。环境涂层36可以通过任何可操作的技术施加，其中电子束物理气相沉积(EB-PVD)优选用于优选的氧化钇稳定的氧化锆涂层。 EB-PVD工艺之前和/或之后可以是可影响粘合涂层中元素分布的高温过程。EB-PVD工艺本身通常在升高的温度下进行。其他涂层、涂层组成和涂层厚度也在本发明的范围内。
将热障涂层36沉积并加工成具有非常光滑的表面光洁度，例如约1.5μm Ra或更小，以促进喷嘴组件的空气动力学。在一个实施方案中，热障涂层36优选地具有小于约3μm的刚沉积的表面粗糙度(Ra)。此后，环境涂层36的表面优选经过加工，优选喷丸(peening)然后滚光(tumbling)，以改善环境涂层36的表面光洁度。在喷丸和滚光之后，环境涂层36优选具有不高于约2.0μm Ra的表面粗糙度，同时在叶片的凹面和前缘上具有约1.3μm至约1.8μm Ra的典型范围，且在叶片的凸面上具有约0.5μm至1.0μm Ra。
在图2和图3中示出的实施方案中，涂层系统基本上没有任何粘合涂层。也就是说，涂层系统在MCrAlY涂层22和超合金部件19的表面13之间没有粘合涂层，并且涂层系统18在MCrAlY涂层22和热障涂层36之间没有粘合涂层。例如，MCrAlY涂层22可以直接在部件19的表面13上，和/或热障涂层36可以直接在MCrAlY涂层22上。
如上所述，喷嘴段可具有任何数量的翼型件(例如，一个(单联体)、两个(二联体)、四个、六个等)。取决于喷嘴段中的翼型件的数目，可以使用不同的加工方法。在大多数实施方案中，可以在形成任何涂层之前形成(例如，钻)膜孔，并且如果需要，可以对要施加的任何后续涂层掩蔽膜孔。
本发明通常可适用于在表征为相对高温的环境中工作的部件，特别是可适用于图1B中所示类型的喷嘴段，并因此经受严重的氧化性和腐蚀性工作环境。应当注意，附图是为了在结合以下描述观看时清楚的目的而绘制的，因此不意图按照规定比例。
还总体上提供了用于在部件(例如，翼型件)的表面上形成涂层和用于修复翼型件表面上的涂层的方法。参考图5，总体上示出了用于在部件的表面上形成涂层的示例性方法500的图。在502，MCrAlY层沉积在部件的表面上。在504，在MCrAlY层上沉积铂族金属(PGM)层，例如上述电镀工艺。在506，对PGM层进行热处理，例如通过加热至约900℃至约1200℃的处理温度。在508，可以在所有表面上形成铝化物涂层，例如气相沉积。在510，可以对沉积的层进行热处理以形成MCrAlY涂层。在512，可以在MCrAlY涂层上形成热障涂层(TBC)，例如通过等离子体喷涂沉积工艺。
参考图6，总体上示出了用于修复部件(例如，翼型件)的表面上的涂层的示例性方法600的图。在601，可以从翼型件的服务中剥离任何和所有涂层，例如化学剥离工艺(例如，酸剥离等)。在602，MCrAlY层沉积在部件的表面上。在604，在MCrAlY层上沉积铂族金属(PGM)层，例如上述电镀工艺。在606，对PGM层进行热处理，例如通过加热至约900℃至约1200℃的处理温度。在608，可以在所有表面上形成铝化物涂层，例如气相沉积。在610，可以对沉积的层进行热处理以形成MCrAlY涂层。在612，可以在MCrAlY涂层上形成热障涂层(TBC)，例如通过等离子体喷涂沉积工艺。通过这种修复工艺，可以通过包含铂族金属来改善涂层。
在不脱离本发明的精神和范围的情况下，本领域普通技术人员可以实行对本发明的这些和其他修改和变化，本发明的精神和范围在所附权利要求中更具体地阐述。另外，应该理解的是，各种实施方案的那些方面可以整体或部分地互换。此外，本领域普通技术人员将理解，前面的描述仅是为了示例，并不意图限制在所附权利要求中进一步描述的本发明。

Claims (20)

1.一种在超合金部件表面上的涂层系统，所述涂层系统包含：
在超合金部件表面上的MCrAlY涂层，其中M是Ni、Fe、Co或其组合，其中MCrAlY涂层具有比超合金部件更高的铬含量，并且其中MCrAlY涂层包含铂族金属铝化物扩散层，此外其中MCrAlY涂层包含Re、Ta或其混合物。
2.如权利要求1所述的涂层系统，其中所述MCrAlY涂层包括与所述超合金部件相邻的内部部分、在所述内部部分上的中间部分和在所述中间部分上的外部部分，并且其中所述中间部分的铬含量以重量百分比计大于内部部分和外部部分。
3.如权利要求2所述的涂层系统，其中所述外部部分具有约3重量%至约7.5重量%的铬含量，并且其中所述中间部分具有约8重量%至约20重量%的铬含量，此外其中内部部分具有约5%重量至约12%重量的铬含量。
4.如权利要求1所述的涂层系统，其中所述MCrAlY涂层包括与所述超合金部件相邻的内部部分、在所述内部部分上的中间部分和在所述中间部分上的外部部分，并且其中所述外部部分的铼含量以重量百分比计低于中间部分的铼含量，此外其中中间部分的铼含量以重量百分比计低于内部部分的铼含量。
5.如权利要求4所述的涂层系统，其中所述外部部分具有0%重量至约0.1%重量的铼含量，并且其中所述中间部分具有约0.1%重量至约4%重量的铼含量，并且其中所述内部部分具有大于约3重量%的铼含量。
6.如权利要求1所述的涂层系统，其中所述MCrAlY涂层包括与所述超合金部件相邻的内部部分、在所述内部部分上的中间部分和在所述中间部分上的外部部分，并且其中所述外部部分的钽含量以重量百分比计低于中间部分的钽含量。
7.如权利要求6所述的涂层系统，其中所述外部部分具有约0.1%重量至约2.25%重量的钽含量，并且其中所述中间部分具有约2.5%重量至约7.5%重量的钽含量。
8.如权利要求6所述的涂层系统，其中所述内部部分可具有约3重量%至约7.5重量%的钽含量。
9.如权利要求1所述的涂层系统，其中所述MCrAlY涂层的厚度为约10μm至约100μm。
10.如权利要求9所述的涂层系统，其中所述超合金部件在所述表面内限定膜孔。
11.如权利要求5所述的涂层系统，其中所述MCrAlY涂层限定外表面，所述外表面具有约0.75μm至约2.75μm的表面粗糙度(Ra)。
12.如权利要求1所述的涂层系统，所述MCrAlY涂层包含一起扩散的MCrAlY层和铂族金属铝化物层，并且其中所述铂族金属铝化物层包含选自铂、铑、钯或其混合物的铂族金属。
13.如权利要求1所述的涂层系统，其中所述MCrAlY涂层直接在所述部件的表面上，并且其中所述涂层系统还包含直接在所述MCrAlY涂层上的热障涂层。
14.如权利要求1所述的涂层系统，其中所述MCrAlY涂层包括与所述超合金部件相邻的内部部分、在所述内部部分上的中间部分和在所述中间部分上的外部部分，并且其中所述内部部分的铪含量以重量百分比计低于中间部分的铪含量，此外其中外部部分的铪含量以重量百分比计低于中间部分的铪含量。
15.一种在超合金部件表面上形成涂层系统的方法，所述方法包括：
在超合金部件的表面上形成MCrAlY层，其中MCrAlY层的铬含量高于所述超合金部件，并且其中M是Ni、Fe、Co或其组合；
在MCrAlY层上形成铂族金属层；
将铂族金属层加热至约900℃至约1200℃的处理温度；和
在铂族金属层上形成铝化物涂层。
16.如权利要求15所述的方法，还包括：
加热涂层系统，从MCrAlY层、铂族金属层和铝化物涂层形成MCrAlY涂层。
17.如权利要求16所述的方法，其中所述超合金部件的表面在其中限定多个膜孔，并且其中所述MCrAlY涂层被沉积至约10μm至约100μm的厚度，同时使在超合金部件的表面内限定的膜孔保持打开。
18.如权利要求15所述的方法，其中在形成所述铂族金属层之前，所述MCrAlY层具有以下组成：包含至多约25%Cr、约6至约7%Al、至多约1%Hf、至多约0.5%Y、约8%至约12%Co、约5%至约7%Ta、约1%至约3%Re、约0.5至约1.5%Si、至多约0.5%Zr和余量的Ni。
19.如权利要求15所述的方法，其中将所述铝化物涂层沉积至约25μm至约100μm的厚度。
20.如权利要求15所述的方法，还包括：
在形成铝化物涂层之后，在粘合涂层上形成热障涂层。
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