CN109312442A - 热障涂层、涡轮构件及燃气轮机 - Google Patents
热障涂层、涡轮构件及燃气轮机 Download PDFInfo
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- CN109312442A CN109312442A CN201780034914.1A CN201780034914A CN109312442A CN 109312442 A CN109312442 A CN 109312442A CN 201780034914 A CN201780034914 A CN 201780034914A CN 109312442 A CN109312442 A CN 109312442A
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- layer
- barrier coating
- thermal barrier
- compacted zone
- stomata
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- 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
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Abstract
确保热障性及耐锈蚀性,且提高耐腐蚀性。具备:高气孔层(6),其形成于耐热基材(100)上,且由陶瓷构成,并包含气孔;以及致密层(7),其形成于高气孔层(6)上,且由陶瓷构成,致密层(7)的气孔率为高气孔层(6)的气孔率以下且是0.9体积%以下,且层厚度为0.05mm以下,并且维氏硬度为800Hv以上。
Description
技术领域
本发明涉及热障涂层、具备热障涂层的涡轮构件及燃气轮机。
背景技术
例如,在专利文献1中示出了通过一种热障涂层的制造方法而制造出的热障涂层,所述热障涂层的制造方法包括在耐热基材上形成金属结合层的工序和在金属结合层上形成陶瓷层的工序,形成陶瓷层的工序包括通过喷镀而在金属结合层上形成包含气孔的高气孔层的步骤、在高气孔层上形成具有比高气孔层致密的组织的致密层的步骤、以及对致密层的上表面进行研磨以使致密层成为规定厚度的步骤。
例如,在专利文献2中,示出了一种皮膜系部件,该皮膜系部件包括在金属部件上设置的含有化学稳定化氧化锆材料的热障涂层和在热障涂层上设置的喷镀氧化铝系皮膜,氧化铝系皮膜基于其总重量而含有87重量%以上的氧化铝、另外具有对使含有钙-镁-铝-硅混合氧化物系的污染物质的熔点上升而言有效的厚度,而且,喷镀氧化铝系皮膜的平均表面粗糙度小于4.0μm~约0.75μm。
在先技术文献
专利文献
专利文献1:日本专利第5737996号公报
专利文献2:日本专利第5554488号公报
发明内容
发明要解决的课题
在专利文献1中,通常的以往的热障涂层(TBC:Thermal Barrier Coating)成为金属结合层与陶瓷层依次涂覆而成的双层构造,其目的在于,对于该热障涂层而言,确保优异的热障性,且耐锈蚀性高,且形成平滑的表面。于是,在专利文献1中,如上所述,由高气孔层及其层上的致密层构成陶瓷层。
然而,在以石油为燃料的烧油燃气轮机设备中,作为涡轮构件的涡轮动叶及涡轮静叶暴露于包含高温腐蚀性物质(Na2SO4、CaSO4等)的环境中。高温腐蚀性物质浸透于热障涂层内而使热障涂层的寿命降低,因此,热障涂层有可能剥离。
本发明是解决上述的课题的发明,其目的在于提供能够确保热障性及耐锈蚀性且提高耐腐蚀性的热障涂层、涡轮构件及燃气轮机。
用于解决课题的方案
为了达到上述的目的,本发明的一方案的热障涂层具备:高气孔层,其形成于耐热基材上,且由陶瓷构成,并包含气孔;以及致密层,其形成于所述高气孔层上,且由陶瓷构成,所述致密层的气孔率为所述高气孔层的气孔率以下且是0.9体积%以下,且层厚度为0.05mm以下,并且维氏硬度为800Hv以上。
根据该热障涂层,能够在高气孔层中确保针对耐热基材的热障性。另外,通过在形成于高气孔层上的致密层的气孔率及维氏硬度方面具有致密的硬质膜,能够确保耐锈蚀性。而且,通过在致密层的气孔率方面具有致密性,能够防止腐蚀性成分的浸透而提高耐腐蚀性。其结果是,能够提高高温腐蚀环境中的热障涂层的耐久性。
为了达到上述的目的,本发明的一方案的热障涂层具备:金属结合层,其形成于耐热基材上;高气孔层,其形成于所述金属结合层上,且由陶瓷构成,并包含气孔;以及致密层,其形成于所述高气孔层上,且由陶瓷构成,所述致密层的气孔率为所述高气孔层的气孔率以下且是0.9体积%以下,且层厚度为0.05mm以下,并且维氏硬度为800Hv以上。
根据该热障涂层,能够在通过金属结合层而结合于耐热基材的高气孔层中确保针对耐热基材的热障性。另外,通过在形成于高气孔层上的致密层的气孔率及维氏硬度方面具有致密的硬质膜,能够确保耐锈蚀性。而且,通过在致密层的气孔率方面具有致密性,能够防止腐蚀性成分的浸透而提高耐腐蚀性。其结果是,能够提高高温腐蚀环境中的热障涂层的耐久性。
另外,在本发明的一方案的热障涂层中,优选的是,在所述致密层上还具备使所述致密层熔融而成的熔融层。
根据该热障涂层,使气孔率0.9体积%以下的致密层的表层熔融得到的熔融层通过熔融而使致密层的表面进一步致密化。因此,能够进一步提高使耐腐蚀性增强的效果。其结果是,能够进一步提高高温腐蚀环境中的热障涂层的耐久性。
另外,在本发明的一方案的热障涂层中,优选的是,所述熔融层下的所述致密层的层厚度为0.01mm以上。
根据该热障涂层,熔融层有可能因高的致密化而强度降低,但通过将熔融层下的致密层的层厚度确保为0.01mm以上,能够抑制强度降低。
另外,在本发明的一方案的热障涂层中,优选的是,所述高气孔层或所述致密层中的任一方由氧化钇稳定化氧化锆材料构成,且任意另一方由氧化镱稳定化氧化锆材料构成。
根据该热障涂层,通过高气孔层或致密层中的任一方由氧化钇稳定化氧化锆材料构成,且任意另一方由氧化镱稳定化氧化锆材料构成,能够显著地得到在高气孔层中确保针对耐热基材的热障性的效果。另外,能够显著地得到在致密层中确保耐锈蚀性且提高耐腐蚀性的效果。其结果是,能够提高高温腐蚀环境中的热障涂层的耐久性。
另外,在本发明的一方案的热障涂层中,优选的是,所述高气孔层及所述致密层由氧化镱稳定化氧化锆材料构成。
根据该热障涂层,通过高气孔层及致密层由氧化镱稳定化氧化锆材料构成,能够具有高的热障功能、耐久功能及耐腐蚀功能。
为了达到上述的目的,本发明的一方案的涡轮构件在表面具备上述的任一热障涂层。
根据该涡轮构件,上述的任一热障涂层兼具备高的热障性、耐锈蚀性及耐腐蚀性,因此例如能够适用于1600℃级别的燃气轮机构件等。
为了达到上述的目的,本发明的一方案的燃气轮机具备上述的涡轮构件。
根据该燃气轮机,通过配备有兼具备上述的高的热障性、耐锈蚀性及耐腐蚀性的燃气轮机构件,能够提高耐久性。
发明效果
根据本发明,能够确保热障性及耐锈蚀性,且提高耐腐蚀性。
附图说明
图1是本发明的实施方式的燃气轮机的简要结构图。
图2是本发明的实施方式的热障涂层的简要剖视图。
图3是本发明的实施方式的热障涂层的另一例的简要剖视图。
具体实施方式
以下,基于附图来详细地说明本发明的实施方式。需要说明的是,本发明不被本实施方式限定。另外,下述实施方式中的构成要素包括本领域技术人员能够且容易置换的构成要素、或者实质相同的构成要素。
图1是本实施方式的燃气轮机的简要结构图。
在本实施方式中,以图1所示的产业用的燃气轮机10为一例,但此外包括航空用燃气轮机等燃气轮机。
如图1所示,燃气轮机10具备压缩机1、燃烧器2及涡轮3。该燃气轮机10在压缩机1、燃烧器2及涡轮3的中心部贯穿配置有作为旋转轴的涡轮轴4。压缩机1、燃烧器2及涡轮3沿着涡轮轴4的轴心R从空气的流动的前侧朝向后侧依次并列设置。需要说明的是,在以下的说明中,轴向是指与轴心R平行的方向,周向是指以轴心R为中心的环绕方向,径向是指与轴心R正交的方向。
压缩机1是将空气压缩而形成压缩空气的部件。压缩机1在具有导入空气的空气导入口11的压缩机壳体12内设置有压缩机静叶13及压缩机动叶14。压缩机静叶13安装于压缩机壳体12侧并沿着周向并列设置有多个。另外,压缩机动叶14安装于涡轮轴4侧并沿着周向并列设置有多个。这些压缩机静叶13与压缩机动叶14沿着轴向交替地设置。
燃烧器2对由压缩机1压缩得到的压缩空气供给燃料,由此生成高温高压的燃烧气体。燃烧器2作为燃烧筒而具有使压缩空气与燃料混合并燃烧的内筒21、从内筒21将燃烧气体向涡轮3引导的尾筒22、以及覆盖内筒21的外周且形成将来自压缩机1的压缩空气向内筒21引导的空气通路25的外筒23。该燃烧器2相对于燃烧器壳体24沿着周向并列设置有多个(例如16个)。
涡轮3是由燃烧器2燃烧得到的燃烧气体而产生旋转动力的部件。涡轮3在涡轮壳体31内设置有涡轮静叶32及涡轮动叶33。涡轮静叶32安装于涡轮壳体31侧并沿着周向并列设置有多个。另外,涡轮动叶33安装于涡轮轴4侧并沿着周向并列设置有多个。这些涡轮静叶32与涡轮动叶33沿着轴向交替地设置。另外,在涡轮壳体31的后侧设置有排气室34,该排气室34具有与涡轮3连续的排气扩散器34a。
涡轮轴4的压缩机1侧的端部由轴承部41支承、且涡轮轴4的排气室34侧的端部由轴承部42支承,从而涡轮轴4设置为以轴心R为中心旋转自如。并且,虽然未在图中明示,涡轮轴4在压缩机1侧的端部连结有发电机的驱动轴。
在这样的燃气轮机10中,从压缩机1的空气导入口11导入的空气通过多个压缩机静叶13和压缩机动叶14而被压缩,由此成为高温高压的压缩空气。针对该压缩空气而在燃烧器2中混合燃料并使之燃烧,由此生成高温高压的燃烧气体。并且,使该燃烧气体通过涡轮3的涡轮静叶32和涡轮动叶33而驱动涡轮轴4旋转,并对与该涡轮轴4连结的发电机赋予旋转动力,由此进行发电。并且,驱动涡轮轴4旋转之后的废气经由排气室34的排气扩散器34a而作为废气向大气放出。
图2是本实施方式的热障涂层的简要剖视图。
本实施方式的热障涂层适用于上述的燃气轮机10等。具体而言,如图2所示,热障涂层施加于耐热基材100的表面100a。耐热基材100作为涡轮构件而例如存在适用于上述的燃气轮机10的涡轮动叶、涡轮静叶等。
图2所示的热障涂层在耐热基材100的表面100a上从表面100a向上方而依次具备金属结合层5、高气孔层6及致密层7。
金属结合层5采用MCrAlY合金(M表示Ni、Co、Fe等金属元素或它们中的两种类以上的组合)等。金属结合层5能够通过施加喷镀(低压等离子体喷镀法(LPPS:Low PressurePlasma Spraying)、高速火焰喷镀法(HVOF:High Velocity Oxygen Fuel)、大气等离子体喷镀法(APS:Atmospheric Plasma Spraying))施加于耐热基材100的表面100a。通过将MCrAlY合金作为金属结合层5层叠于耐热基材100的表面100a上,由此具有对耐热基材100的耐腐蚀功能及作为高气孔层6的结合剂的功能。
高气孔层6由陶瓷构成,采用YbSZ(氧化镱稳定化氧化锆、Yb2O3的添加比例为0.01重量%以上且17.00重量%以下)、或YSZ(氧化钇稳定化氧化锆)等。高气孔层6能够使用具有如下粒度分布的YbSZ粉末或YSZ粉末并通过大气等离子体喷镀法而施加于金属结合层5的表面5a,所述粒度分布是指累计粒度10%粒径为30μm以上且150μm以下的粒度分布。高气孔层6作为皮膜组织而采用含有多的气孔6a且热障性优异的多孔组织。此处所述的“含有多的”是指与致密层7进行比较而气孔率(体积%)高。高气孔层6的气孔率为1体积%以上且30体积%以下(优选为10体积%以上且15体积%以下)。高气孔层6的层厚度A为0.3mm以上且1.0mm以下。高气孔层6的维氏硬度(依据JIS Z 2244维氏硬度试验-试验方法)为800Hv以上(优选为1000Hv以上)。另外,高气孔层6在其表面6b具有耐久性优异的纵向裂纹组织。纵向裂纹组织在高气孔层6的厚度方向上在高气孔层6的层厚度A的5%以上且100%以下的范围内具有纵向裂纹,且高气孔层6的截面中的每单位长度(1mm)的纵向裂纹的数量为1条以上且10条以下。因此,通过设置高气孔层6,从而具有热障功能及耐久功能。
致密层7采用YbSZ(氧化镱稳定化氧化锆、Yb2O3的添加比例为0.01重量%以上且17.00重量%以下)、或者YSZ(氧化钇稳定化氧化锆)等。致密层7可以使用具有平均粒径为20μm以下的粒度分布的YbSZ粉末或YSZ粉末,并通过大气等离子体喷镀法以近距离喷镀(100mm以下)的方式施加于高气孔层6的表面6b。另外,致密层7也可以通过无需高温地烧结陶瓷微粒而在常温下就能够固化、致密化的公知的方法(例如冷喷涂法、气溶胶沉积法)而施加于高气孔层6的表面6b。致密层7作为皮膜组织而采用气孔7a少的多孔组织。此处所述的“少”是指与高气孔层6相比气孔率(体积%)低。致密层7的气孔率采用0.9体积%以下(优选为小于0.5体积%)的气孔率。致密层7的层厚度B为0.05mm以下。致密层7的维氏硬度(依据JIS Z 2244维氏硬度试验-试验方法)为800Hv以上(优选为1000Hv以上)。因此,通过设置致密层7,从而能够在表层具备致密性,由此,浸透防止性能提高且具有耐腐蚀功能。
这样,本实施方式的热障涂层具备:金属结合层5,其形成于耐热基材100上;高气孔层6,其形成于金属结合层5上且由陶瓷构成,且包含气孔6a;以及致密层7,其形成于高气孔层6上且由陶瓷构成,致密层7的气孔率为高气孔层6的气孔率以下且是0.9体积%以下,层厚度为0.05mm以下,维氏硬度为800Hv以上。
根据该热障涂层,能够在通过金属结合层5而结合于耐热基材100的高气孔层6中确保针对耐热基材100的热障性。另外,通过在形成于高气孔层6上的致密层7的气孔率及维氏硬度方面具有致密的硬质膜,由此能够确保耐锈蚀性。而且,在致密层7的气孔率方面具有致密性,由此能够防止腐蚀性成分的浸透而提高耐腐蚀性。其结果是,能够提高高温腐蚀环境中的热障涂层的耐久性。
另外,在本实施方式的热障涂层中,优选的是,高气孔层6和致密层7中的任一方由YbSZ(氧化镱稳定化氧化锆)材料构成,且任意另一方由YSZ(氧化钇稳定化氧化锆)材料构成。通过任意另一方由YSZ材料构成,与YbSZ材料相比能够减少材料成本。YSZ材料与YbSZ材料相比存在耐剥离性降低的倾向,但作为耐腐蚀功能的浸透防止性能大致同等。
在图2所示的结构中,在使高气孔层6由YbSZ材料构成且使致密层7由YSZ材料构成的情况下,针对附着于致密层7的表面7b的腐蚀性成分(Na2SO4),在920℃的高温环境下使腐蚀成分熔融并利用电子射线微量分析器(EPMA:Electron Probe Micro Analyzer)来评价了向热障涂层的浸透状况的高温腐蚀试验中,没有确认到腐蚀性成分的浸透。需要说明的是,在不具有致密层7的结构的热障涂层中,确认到了腐蚀性成分的浸透。另外,对高温腐蚀试验后的热障涂层进行激光热循环试验,并评价了耐剥离性,其结果是,显现了与不具有致密层7的结构的热障涂层同等的耐剥离性。
根据该热障涂层,高气孔层6或致密层7中的任一方由YSZ材料构成,任意另一方由YbSZ材料构成,由此能够显著地得到在高气孔层6中确保针对耐热基材100的热障性的效果。另外,能够显著地得到在致密层7中确保耐锈蚀性且提高耐腐蚀性的效果。其结果是,能够进一步提高高温腐蚀环境中的热障涂层的耐久性。
另外,在本实施方式的热障涂层中,优选的是,高气孔层6和致密层7彼此由YbSZ(氧化镱稳定化氧化锆)材料构成。通过双方由YbSZ材料构成,能够具有高的热障功能、耐久功能及耐腐蚀功能。
在图2所示的结构中,在使高气孔层6及致密层7由YbSZ材料构成的情况下,针对附着于致密层7的表面7b的腐蚀性成分(Na2SO4),在920℃的高温环境下使腐蚀成分熔融并利用电子射线微量分析器(EPMA:Electron Probe Micro Analyzer)评价了向热障涂层的浸透状况的高温腐蚀试验中,没有确认到腐蚀性成分的浸透。需要说明的是,在不具有致密层7的结构的热障涂层中,确认到了腐蚀性成分的浸透。另外,对高温腐蚀试验后的热障涂层进行激光热循环试验,并评价了耐剥离性,其结果是,显现了与不具有致密层7的结构的热障涂层同等的耐剥离性。
根据该热障涂层,通过高气孔层6及致密层7由YbSZ材料构成,能够更显著地得到在高气孔层6中确保针对耐热基材100的热障性的效果。另外,能够更显著地得到在致密层7中确保耐锈蚀性且提高耐腐蚀性的效果。其结果是,能够进一步提高高温腐蚀环境中的热障涂层的耐久性。
图3是本实施方式的热障涂层的另一例的简要剖视图。
图3所示的热障涂层在耐热基材100的表面100a上从表面100a向上方而依次具备金属结合层5、高气孔层6、致密层7及熔融层8。
金属结合层5、高气孔层6及致密层7为上述的结构,对其省略说明。不过,致密层7通过使用具有平均粒径为20μm以下的粒度分布的YbSZ粉末或YSZ粉末,并采用大气等离子体喷镀法以近距离喷镀(100mm以下)的方式施加于高气孔层6的表面6b。
熔融层8通过高速激光扫描熔融上述那样通过喷镀而施加的致密层7的表层来形成。此时,使在高气孔层6的表面6b施加的致密层7残留。熔融层8下的致密层7的层厚度D为了不损害上述的效果而优选为0.01mm以上。因此,由于致密层7的层厚度B为0.05mm以下,从而熔融层8的层厚度C留出熔融层8下的致密层7的层厚度D且为0.04mm以下(优选为0.03mm以下)。
使由YSZ材料或YbSZ材料构成的气孔率为0.9体积%以下(优选小于0.5体积%)的致密层7的表层熔融得到的熔融层8通过熔融而使致密层7的表面7b进一步致密化。因此,能够进一步提高使耐腐蚀性增强的效果。其结果是,能够进一步提高高温腐蚀环境中的热障涂层的耐久性。
熔融层8有可能因高的致密化而强度降低,但通过将熔融层8下的致密层7的层厚度D确保为0.01mm以上,能够抑制强度降低。
需要说明的是,在上述的实施方式中,将金属结合层5施加于耐热基材100上来使高气孔层6结合在耐热基材100上,但根据耐热基材100的材质的不同,能够不施加金属结合层5地将高气孔层6结合于耐热基材100的表面100a。因此,也可以是在图2及图3所示的结构中不施加金属结合层5的结构,能够得到与图2及图3所示的结构同等的效果。
附图标记说明
1 压缩机
11 空气导入口
12 压缩机壳体
13 压缩机静叶
14 压缩机动叶
2 燃烧器
21 内筒
22 尾筒
23 外筒
24 燃烧器壳体
25 空气通路
3 涡轮
31 涡轮壳体
32 涡轮静叶
33 涡轮动叶
34 排气室
34a 排气扩散器
4 涡轮轴
41、42 轴承部
5 金属结合层
5a 表面
6 高气孔层
6a 气孔
6b 表面
7 致密层
7a 气孔
7b 表面
8 熔融层
10 燃气轮机
100 耐热基材
R 轴心。
Claims (8)
1.一种热障涂层,其中,
所述热障涂层具备:
高气孔层,其形成于耐热基材上,且由陶瓷构成,并包含气孔;以及
致密层,其形成于所述高气孔层上,且由陶瓷构成,所述致密层的气孔率为所述高气孔层的气孔率以下且是0.9体积%以下,且层厚度为0.05mm以下,并且维氏硬度为800Hv以上。
2.一种热障涂层,其中,
所述热障涂层具备:
金属结合层,其形成于耐热基材上;
高气孔层,其形成于所述金属结合层上,且由陶瓷构成,并包含气孔;以及
致密层,其形成于所述高气孔层上,且由陶瓷构成,所述致密层的气孔率为所述高气孔层的气孔率以下且是0.9体积%以下,且层厚度为0.05mm以下,并且维氏硬度为800Hv以上。
3.根据权利要求1或2所述的热障涂层,其中,
在所述致密层上还具备使所述致密层熔融而成的熔融层。
4.根据权利要求3所述的热障涂层,其中,
所述熔融层下的所述致密层的层厚度为0.01mm以上。
5.根据权利要求1至4中任一项所述的热障涂层,其中,
所述高气孔层或所述致密层的任一方由氧化钇稳定化氧化锆材料构成,任意另一方由氧化镱稳定化氧化锆材料构成。
6.根据权利要求1至4中任一项所述的热障涂层,其中,
所述高气孔层及所述致密层由氧化镱稳定化氧化锆材料构成。
7.一种涡轮构件,其中,
所述涡轮构件在表面具备权利要求1至6中任一项所述的热障涂层。
8.一种燃气轮机,其中,
所述燃气轮机具备权利要求7所述的涡轮构件。
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US20190119804A1 (en) | 2019-04-25 |
US10808308B2 (en) | 2020-10-20 |
JP6908973B2 (ja) | 2021-07-28 |
DE112017002907T5 (de) | 2019-03-07 |
JP2017218635A (ja) | 2017-12-14 |
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