CN110035983A - 涂覆有热屏障的涡轮机部件和获得它的方法 - Google Patents
涂覆有热屏障的涡轮机部件和获得它的方法 Download PDFInfo
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- CN110035983A CN110035983A CN201780074871.XA CN201780074871A CN110035983A CN 110035983 A CN110035983 A CN 110035983A CN 201780074871 A CN201780074871 A CN 201780074871A CN 110035983 A CN110035983 A CN 110035983A
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- ceramic
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- 230000004888 barrier function Effects 0.000 title claims abstract description 53
- 238000000034 method Methods 0.000 title claims abstract description 23
- 239000000919 ceramic Substances 0.000 claims abstract description 61
- 239000000835 fiber Substances 0.000 claims abstract description 48
- 239000000463 material Substances 0.000 claims abstract description 38
- 229910010293 ceramic material Inorganic materials 0.000 claims abstract description 22
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims abstract description 9
- 239000011777 magnesium Substances 0.000 claims abstract description 9
- 229910052749 magnesium Inorganic materials 0.000 claims abstract description 9
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 claims abstract description 6
- 239000011575 calcium Substances 0.000 claims abstract description 6
- 229910052791 calcium Inorganic materials 0.000 claims abstract description 6
- 238000004519 manufacturing process Methods 0.000 claims abstract description 5
- PNEYBMLMFCGWSK-UHFFFAOYSA-N Alumina Chemical compound [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 25
- 239000000203 mixture Substances 0.000 claims description 14
- 229910001404 rare earth metal oxide Inorganic materials 0.000 claims description 11
- 238000003618 dip coating Methods 0.000 claims description 8
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 claims description 8
- 229910001928 zirconium oxide Inorganic materials 0.000 claims description 8
- 229910052761 rare earth metal Inorganic materials 0.000 claims description 7
- 150000002910 rare earth metals Chemical class 0.000 claims description 7
- 238000001962 electrophoresis Methods 0.000 claims description 5
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 claims description 4
- 229910052726 zirconium Inorganic materials 0.000 claims description 4
- 239000000404 calcium aluminium silicate Substances 0.000 claims description 2
- 235000012215 calcium aluminium silicate Nutrition 0.000 claims description 2
- WNCYAPRTYDMSFP-UHFFFAOYSA-N calcium aluminosilicate Chemical compound [Al+3].[Al+3].[Ca+2].[O-][Si]([O-])=O.[O-][Si]([O-])=O.[O-][Si]([O-])=O.[O-][Si]([O-])=O WNCYAPRTYDMSFP-UHFFFAOYSA-N 0.000 claims description 2
- 229940078583 calcium aluminosilicate Drugs 0.000 claims description 2
- 238000005516 engineering process Methods 0.000 claims description 2
- 230000008569 process Effects 0.000 abstract description 6
- 239000000126 substance Substances 0.000 abstract description 2
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- -1 aluminium Calcium magnesium Chemical compound 0.000 description 13
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 10
- 229910000601 superalloy Inorganic materials 0.000 description 10
- 238000000151 deposition Methods 0.000 description 9
- FGZBFIYFJUAETR-UHFFFAOYSA-N calcium;magnesium;silicate Chemical compound [Mg+2].[Ca+2].[O-][Si]([O-])([O-])[O-] FGZBFIYFJUAETR-UHFFFAOYSA-N 0.000 description 8
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- 229910052759 nickel Inorganic materials 0.000 description 5
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 4
- YRKCREAYFQTBPV-UHFFFAOYSA-N acetylacetone Chemical compound CC(=O)CC(C)=O YRKCREAYFQTBPV-UHFFFAOYSA-N 0.000 description 4
- 230000008859 change Effects 0.000 description 4
- 150000001875 compounds Chemical class 0.000 description 4
- 229910052593 corundum Inorganic materials 0.000 description 4
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- 229910052782 aluminium Inorganic materials 0.000 description 3
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 3
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- 229910052727 yttrium Inorganic materials 0.000 description 3
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 description 3
- 229910002080 8 mol% Y2O3 fully stabilized ZrO2 Inorganic materials 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 2
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- SIWVEOZUMHYXCS-UHFFFAOYSA-N oxo(oxoyttriooxy)yttrium Chemical compound O=[Y]O[Y]=O SIWVEOZUMHYXCS-UHFFFAOYSA-N 0.000 description 2
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- NGDQQLAVJWUYSF-UHFFFAOYSA-N 4-methyl-2-phenyl-1,3-thiazole-5-sulfonyl chloride Chemical compound S1C(S(Cl)(=O)=O)=C(C)N=C1C1=CC=CC=C1 NGDQQLAVJWUYSF-UHFFFAOYSA-N 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 206010013786 Dry skin Diseases 0.000 description 1
- 229910052688 Gadolinium Inorganic materials 0.000 description 1
- 229910000943 NiAl Inorganic materials 0.000 description 1
- NPXOKRUENSOPAO-UHFFFAOYSA-N Raney nickel Chemical compound [Al].[Ni] NPXOKRUENSOPAO-UHFFFAOYSA-N 0.000 description 1
- 239000003513 alkali Substances 0.000 description 1
- 150000001398 aluminium Chemical class 0.000 description 1
- 229910000323 aluminium silicate Inorganic materials 0.000 description 1
- 239000002585 base Substances 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 229910000420 cerium oxide Inorganic materials 0.000 description 1
- VLOFLNGRXXADOF-UHFFFAOYSA-N cerium(3+) oxygen(2-) yttrium(3+) Chemical compound [Y+3].[O-2].[Ce+3].[O-2].[O-2] VLOFLNGRXXADOF-UHFFFAOYSA-N 0.000 description 1
- 238000003426 chemical strengthening reaction Methods 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 238000013034 coating degradation Methods 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 125000004122 cyclic group Chemical group 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 1
- 239000002270 dispersing agent Substances 0.000 description 1
- 238000004090 dissolution Methods 0.000 description 1
- 239000012153 distilled water Substances 0.000 description 1
- 230000003628 erosive effect Effects 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 238000005187 foaming Methods 0.000 description 1
- 239000004088 foaming agent Substances 0.000 description 1
- UIWYJDYFSGRHKR-UHFFFAOYSA-N gadolinium atom Chemical compound [Gd] UIWYJDYFSGRHKR-UHFFFAOYSA-N 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 239000010931 gold Substances 0.000 description 1
- 238000007654 immersion Methods 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000000391 magnesium silicate Substances 0.000 description 1
- 235000019792 magnesium silicate Nutrition 0.000 description 1
- 229910052919 magnesium silicate Inorganic materials 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- BMMGVYCKOGBVEV-UHFFFAOYSA-N oxo(oxoceriooxy)cerium Chemical compound [Ce]=O.O=[Ce]=O BMMGVYCKOGBVEV-UHFFFAOYSA-N 0.000 description 1
- 238000007750 plasma spraying Methods 0.000 description 1
- 229910052697 platinum Inorganic materials 0.000 description 1
- 229910052573 porcelain Inorganic materials 0.000 description 1
- 239000002243 precursor Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000001226 reprecipitation Methods 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 238000004062 sedimentation Methods 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 229910021332 silicide Inorganic materials 0.000 description 1
- FVBUAEGBCNSCDD-UHFFFAOYSA-N silicide(4-) Chemical compound [Si-4] FVBUAEGBCNSCDD-UHFFFAOYSA-N 0.000 description 1
- 229910052709 silver Inorganic materials 0.000 description 1
- 239000004332 silver Substances 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
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- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
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- C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
- C04B41/81—Coating or impregnation
- C04B41/85—Coating or impregnation with inorganic materials
- C04B41/87—Ceramics
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- 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
- 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
- C23C28/32—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer
- 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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- B64—AIRCRAFT; AVIATION; COSMONAUTICS
- B64C—AEROPLANES; HELICOPTERS
- B64C11/00—Propellers, e.g. of ducted type; Features common to propellers and rotors for rotorcraft
- B64C11/16—Blades
- B64C11/20—Constructional features
- B64C11/205—Constructional features for protecting blades, e.g. coating
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/71—Ceramic products containing macroscopic reinforcing agents
- C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
- C04B35/80—Fibres, filaments, whiskers, platelets, or the like
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- C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
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- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
- C04B41/5025—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials with ceramic materials
- C04B41/5042—Zirconium oxides or zirconates; Hafnium oxides or hafnates
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- C04B41/52—Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
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- C04B41/81—Coating or impregnation
- C04B41/89—Coating or impregnation for obtaining at least two superposed coatings having different compositions
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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
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- C23C14/083—Oxides of refractory metals or yttrium
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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
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- C23C18/12—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition characterised by the deposition of inorganic material other than metallic material
- C23C18/1225—Deposition of multilayers of inorganic material
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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
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- C23C18/12—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition characterised by the deposition of inorganic material other than metallic material
- C23C18/1229—Composition of the substrate
- C23C18/1241—Metallic substrates
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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
- C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
- C23C18/02—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition
- C23C18/12—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition characterised by the deposition of inorganic material other than metallic material
- C23C18/125—Process of deposition of the inorganic material
- C23C18/1254—Sol or sol-gel processing
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Abstract
本发明涉及一种涂覆有至少一层第一热屏障层(33)的涡轮机部件(30)，该至少一层第一热屏障层(33)包括陶瓷材料和分散在所述第一层中的第一陶瓷纤维(34)。第一层可在热屏障材料以及用于保护抵抗铝硅酸钙镁的材料之间包括化学组分的梯度，该梯度的含量在第一层的外部区域上较大，和/或第一层可以是多孔的并且具有孔隙率梯度，使得第一层的外部部分具有减小的孔隙率。本发明还追求一种用于制造这种部件的方法，该方法经由湿法在部件上形成第一层。
Description
技术领域
本发明涉及用于在高温环境中使部件热绝缘的热屏障涂层的总体领域。本发明更具体地应用于用于保护航空燃气涡轮机中的由超级合金或陶瓷基质复合材料制成的部件的热屏障。
背景技术
在荒漠环境中或高污染外界中运行的航空涡轮机的热部分中存在的部件，由于来自在由发动机吸入的空气中存在的砂和碱化合物的损害被迅速降解。这些化合物，称为铝硅酸钙镁(CMAS)(具体包括钙、镁、铝和硅的氧化物)，能使提供热屏障并覆盖涡轮机的热部分中的某些部件的涂层降解。
在热屏障被CMAS化合物降解的机制中，注意到CMAS化合物在液态时渗入到热屏障中，以及热屏障(传统上由基于用氧化钇稳定氧化锆YSZ的陶瓷构成)的溶解和再沉淀，从而形成贫氧化钇的氧化锆的分离结节。这两种机制降低了热屏障的机械性能，并可能导致其在发动机的冷却阶段期间破裂。此外，固体颗粒的吸入导致热屏障侵蚀现象，该屏障随后脱落并离开暴露下面的基板，从而降低了部件的寿命。
因此，需要一种涂覆有热屏障的涡轮机部件，该热屏障具有抗CMAS特性和改善的使用寿命。还需要一种制造这种部件的方法，该方法具有降低的实施成本。
发明内容
本发明的主要目的因此是通过提出一种涂覆有至少第一陶瓷层的涡轮机部件以克服这些缺点，该至少第一陶瓷层形成热屏障并且包括分散在所述第一层中的具有第一陶瓷纤维的陶瓷材料。
在根据本发明的部件的第一热屏障层中存在第一陶瓷纤维用作增加热屏障的机械强度及其对CMAS化合物的耐受能力。这些陶瓷纤维用作增强热屏障并减少裂缝的传播，在涡轮机的运行期间和当它被CMAS化合物的攻击时，裂缝的传播可以与屏障的循环氧化同时产生。总之，陶瓷纤维在第一热屏障层中用作强化物，以改善该层的固有机械性能。陶瓷纤维还可以呈现抵挡CMAS材料的性能。
在一实施例中，第一层中第一陶瓷纤维的质量含量可以在30％至90％的范围内。例如，第一层中第一陶瓷纤维的质量含量可以在50％至90％的范围内或甚至在70％至90％的范围内。通常，第一陶瓷层中第一陶瓷纤维的含量足以执行机械增强功能。
在一实施例中，第一陶瓷纤维的平均长度可小于或等于50微米(μm)。术语“平均长度”是指纤维的D50长度。
在一实施例中，第一热屏障层的平均厚度在100μm至200μm的范围内。
在一实施例中，第一层的陶瓷材料可以是由稀土氧化物稳定的氧化锆，例如，由氧化钇稳定的或部分稳定的氧化锆(YSZ或8YSZ)。
在一实施例中，第一陶瓷纤维可以由选自以下的材料组成：稀土氧化物稳定的氧化锆、稀土氧化物、烧绿石结构、稀土锆酸盐、氧化铝Al2O3及其混合物。在一实施例中，第一陶瓷纤维可以包括用于提供保护抵抗铝硅酸钙镁的材料，以进一步增强抵抗CMAS化合物的热屏障层。例如，该纤维可包括氧化铝和至少一种稀土锆酸盐的混合物，以化学强化抵抗CMAS化合物的第一热屏障层，特别是当该层包括氧化钇部分稳定的氧化锆时。
在一实施例中，第一陶瓷纤维可以由与第一热屏障层的材料相同的材料构成。
在一实施例中，第一层的材料的热膨胀系数与第一陶瓷纤维的材料的热膨胀系数之间的差异可以小于或等于4×10-6K-1(每开尔文)，或甚至小于或等于在2×10-6K-1。
在一实施例中，涂覆的部件还可包括布置在基板和第一热屏障层之间的连结底层。具体地，当基板是超级合金(例如，基于铁、钴或镍的超级合金)时，底层可包括简单的镀铝(aluminiure)或改性的镀铝(例如，用于镍基超级合金基板的NiAl或NiCrAlY)。在变型中，当基板是由陶瓷基质复合(CMC)材料制成时，连结底层可以包括例如由硅或金属硅化物的形成的硅。
在一实施例中，部件可以还可涂覆有包括陶瓷材料的第二陶瓷层，以提供保护抵抗铝硅酸钙镁，第二层位于第一层上，并且还包括分散在所述第二层中的第二陶瓷纤维。第二陶瓷纤维的存在用作改善第二层机械强度及其耐受CMAS化合物攻击的能力。第二层还用作阻塞在第一层的表面中存在的孔，以便更好地保护它抵抗CMAS化合物的渗透。
在一实施例中，第二层的材料的热膨胀系数与第二陶瓷纤维的材料的热膨胀系数之间的差异可以小于或等于4×10-6K-1，或甚至小于或等于2×10-6K-1。
在一实施例中，第一层和第二层可以是多孔的，第一层呈现第一孔隙率，并且第二层呈现严格小于第一孔隙率的第二孔隙率。
在一实施例中，第二陶瓷纤维可以由选自以下的材料组成：稀土氧化物稳定的氧化锆、稀土氧化物、烧绿石结构、稀土锆酸盐、氧化铝Al2O3及其混合物。
在一实施例中，第二陶瓷纤维可以由与第二陶瓷层相同的材料组成。
在一实施例中，第二层中第二陶瓷纤维的质量含量可以在30％至90％的范围内。例如，第二层中第二陶瓷纤维的质量含量可以在50％至90％的范围内或甚至在70％至90％的范围内。
在本发明的第一替代方案中，第一层包括用于提供热屏障的第一陶瓷材料和用于提供保护抵抗铝硅酸钙镁的第二陶瓷材料的混合物，第一和第二陶瓷材料是不同的，所述第一层呈现在其厚度的一部分上方延伸的第一区域并且呈现第二材料的第一质量含量，并且，第二区域在其厚度的一部分上方延伸并且覆盖所述第一区域，第二区域呈现严格大于第一质量含量的第二材料的第二质量含量。该规定用作获得涂覆在该部件上的、呈现性能梯度的热屏障涂层，从第一区域主要用作基板的热屏障，并且第二区域提供对第一区域的保护，更具体地保护抵抗CMAS化合物。当在第一层上存在包含用于提供保护抵抗铝硅酸钙镁的陶瓷材料的第二层时，该组合物梯度用作在第一层和第二层之间提供良好的热机械相容性。
在一实施例中，用于提供保护抵抗硅铝酸钙和镁的陶瓷材料可以从下列中选择：稀土氧化物、稀土氧化物稳定的氧化锆、烧绿石结构、稀土锆酸盐、氧化铝Al2O3及其混合物。例如，用于提供抵抗CMAS的陶瓷材料可以是氧化钇Y2O3、氧化铈Ce0,5Y0,5O1,8(铈钇氧化物)、钇锆酸盐Y2ZrO7、钆锆酸盐GdZr2O7、氧化铝Al2O3与稀土锆酸盐混合等。
在与本发明的第一替代方案可选地组合的本发明的第二替代方案中，第一层是多孔的并且包括第一部分和第二部分，第一部分在其厚度的一部分上方延伸并呈现第一孔隙度，第二部分在其厚度的一部分上方延伸并覆盖第一部分，第二部分呈现严格小于第一孔隙率的第二孔隙率。通过这种结构，第一层包括呈现有限孔隙率的第二部分，以使有效保护抵抗CMAS化合物渗透。该第二部分位于呈现较高的孔隙率的第一层的第一部分上。更多孔的第一部分用作改善热屏障经受由CMAS化合物的任何渗透所施加的应力的能力。
最后，本发明提供一种制造如上所述的部件的方法，该方法包括通过湿法在部件上形成第一层的至少一个步骤。术语“湿法”用于意指溶胶-凝胶、浸涂(“dip coating”)或电泳类型的沉积方法。在一实施方案中，第一层可以通过溶胶-凝胶工艺、浸涂或电泳形成。
附图说明
本发明的其它特征和优点从以下参考附图的描述中显现，附图示出了没有限制字符的实施例。在附图中：
-图1至图4是示出了本发明的不同实施例中涂覆的涡轮机部件的表面的示意性剖视图；
-图5是示出了本发明的一实施例的方法的各步骤的流程图；
-图6是通过扫描电子显微镜获得的照片，示出了通过本发明的方法获得的涂覆的部件的表面的截面。
具体实施方式
图1示出涡轮机部件10的表面的放大剖视图，其包括基板11，基板11被连结底层12和第一热屏障层13顺序覆盖。在该示例中，连结底层12直接与基板11和第一层13接触。在该示例中，第一层13形成部件10的外层。借助于示例，涡轮机部件10可以是在涡轮机的热部分(诸如透平机)中存在的部件，并且借助于示例，它可以组成透平机叶片、透平机环的一部分等等。
借助于示例，基板11可以包括金属超级合金，例如镍基超级合金、或CMC材料。本身已知的连结底层12用作使第一热屏障涂层13良好地粘附在基板11上。更一般地，这种连结底层12用作在第一热屏障层13和基板11之间提供良好的机械相容性，特别是用作补偿在基板11和第一层13的材料之间可能存在的任何差异热膨胀。
当基板11包括金属超级合金时，连结底层12例如可以包括简单的镀铝或改性的镀铝(例如用于镍基超级合金基板的NiCrAlY)，其可被部分氧化以形成氧化物层(也称为“热生长氧化物”TGO)。当基板11包括陶瓷基质复合材料时，连结底层12可以包括硅或金属硅化物。通常，连结底层12的材料将根据形成基板11和第一热屏障层13的材料进行改适。
以已知的方式，第一热屏障层13可包括氧化钇稳定氧化锆(YSZ)或氧化钇部分稳定氧化锆(8YSZ)，其通常呈现柱状结构。
第一热屏障层13包含分散在其中的陶瓷纤维14。纤维14可以由与第一层13相同的陶瓷材料制成，或者在变型中由不同材料制成。在所有情况下，可以保证在第一层13与纤维14的材料之间的热膨胀系数中的任何差异小于或等于4×10-6K-1，或甚至小于或等于2×10-6K-1，以提高其热机械兼容性。
图2示出了另一个涡轮机部件20。以与上面描述的部件10类似的方式，部件20包括覆盖在连结底层22中的基板21，在该连结底层22上存在填充有第一陶瓷纤维24的第一热屏障层23，在该示例中，第一热屏障层23被第二陶瓷层25覆盖，第二陶瓷层25包括提供保护抵抗CMAS化合物的材料。在该示例中，连结底层22直接与基板21和第一层23接触。类似地，第一层23与第二层25直接接触。在该示例中，第二层25构成部件20的外层。
类似第一层23，第二陶瓷层25包括分散在其中的陶瓷纤维26(第二陶瓷纤维)。第一陶瓷纤维24和第二陶瓷纤维26可以是相同的，或者在变型中可以由不同的陶瓷材料制成。类似第一陶瓷纤维24，第二陶瓷纤维可以由与第二层25的材料相同的材料制成。在变型中，第二陶瓷纤维26可以由与第二层25的材料不同的材料制成，例如同时注意第二纤维26的材料和第二层25的材料之间的热膨胀系数差异小于或等于4×10-6K-1，或甚至小于或等于2×10-6K-1，以提高其热机械兼容性。
图3示出了根据本发明第一变型实施例的涡轮机部件30。以与先前的实施例类似的方式，部件30包括被连结底层32覆盖的基板31，在该连结底层32上存在填充有第一陶瓷纤维34的第一热屏障层33。在该示例中，连结底层32直接与基板31和第一层33接触。在该示例中，第一层33构成部件30的外层。
在该示例中，第一热屏障层33包括第一热屏障陶瓷材料和不同于第一材料的、提供保护抵抗化合物CMAS的第二陶瓷材料的混合物。更具体地，第一层33包括第一区域33a，第一区域33a在其厚度的一部分上延伸，其位于基板31的侧部并呈现第二材料的非零第一质量含量。在该示例中，第一区域33a直接与连结底层32接触。第一层33还包括位于第一区域33a上并直接与其接触的第二区域33b，第二区域33b呈现严格大于第一含量的第二材料的第二含量。在该示例中，第一热屏障层33由一个堆叠在另一个之上的两个连续的区域33a、33b组成。因此，第一层33在第一区域33a和第二区域33b之间呈现组分梯度，以改善热屏障对CMAS化合物的抵抗性而不降低其性能。在第一层33上存在由提供保护抵抗CMAS化合物的材料制成的第二层的情况下，该组合物梯度还用作改善第一层33和第二层之间的相容性。应观察到，第一层33可呈现大于两个的多个区域，同时继续注意保持第一层33中的组分梯度。
图4示出了根据本发明第二变型实施例的涡轮机部件40。以与以上实施例类似的方式，部件40包括被连结底层42覆盖的基板41，在该连结底层42上存在填充有第一陶瓷纤维44的第一热屏障层43。在该示例中，连结底层42直接与基板41和第一层43接触。在该示例中，第一层43构成部件40的外层。
在该示例中，第一热屏障层43是多孔的并且包括各自在第一层43的厚度的一部分上方延伸的第一部分43a和第二部分43b。第一部分43a位于基板41的侧部，并且在该示例中，它与连结底层42直接接触。第二部分43b覆盖第一部分43a，并且在该示例中直接与其接触。在该示例中，第一部分43a呈现第一非零孔隙率，并且第二部分43b呈现严格小于第一孔隙率的第二非零孔隙率。因此，第一热屏障层43在第一部分43a和第二部分43b之间呈现减小的孔隙率梯度。该布置用作减少CMAS化合物渗透到第二部分43b中，以改善第一部分43a的应力耐受能力，并且在第一层43上呈现其它层的情况下，以改善这些层之间的热机械兼容性。
现在将参照图5的流程图描述制造涂覆的部件10的方法。
传统的先前步骤首先包括例如通过等离子喷涂在基板11上沉积连结底层12。
然后在步骤E1中，通过湿法在连结底层12上形成第一热屏障层13。湿沉积方法具体包括浸涂和电泳。当通过电泳形成第一层13时，在连结底层12上沉积导电层(例如金、银或铂)可能是有利的。为了获得填充有第一陶瓷纤维14的第一层13，用于沉积的浴体可包括悬浮的第一陶瓷纤维14，其将与第一层13的材料一起沉积在部件10上。
为了获得呈现受控的孔隙率的第一层，能够将稍后将被除去的例如碳颗粒的发泡剂放入浴体中。在变型中，为了获得受控的孔隙率，能够在浴体中使用呈现特定形态的粉末，其可以使沉积层具有受控的孔隙率。为了获得呈现组分梯度或孔隙率梯度的第一层，即具有不同组分或孔隙率的区域或部分，能够进行多次连续沉积操作，同时改变它们每次使用的浴体的组分。
应当观察到，在沉积第一热屏障层13之前，有利的是沉积由未用陶瓷纤维填充的陶瓷材料制成的中间底层，以改善在连结底层12上的第一热屏障层13上的粘附性。该底层也可以通过湿法沉积。
如果合适的话，能够在第一热屏障层23上形成第二陶瓷层25，该第二陶瓷层25包括提供保护抵抗CMAS化合物的材料并且其填充有第二陶瓷纤维26。该第二层25也类似地可以以已知的方式通过湿法形成。
最后，在步骤E2中，可以使以此方式涂覆的部件10经受热处理。在该步骤期间，完成第一层13的形成，并且在适当的情况下，除去它包含的发泡剂以释放第一层中的孔隙。当在部件上形成多层时，能够在每层沉积之后进行热处理，或者在变型中，在沉积所有层之后进行热处理。
示例
已经在由覆盖有NiPtAl型连结底层的镍基超级合金(AM1型)制成的涡轮机部件上执行了一种方法。在该示例中，目标是获得包含氧化钇稳定氧化锆基质的第一热屏障层，该基质具有其中分散有由氧化钇稳定氧化锆制成的第一陶瓷纤维。
以已知的方式，第一浴体首先被制备以获得YSZ的溶胶，该溶胶包括7.08mL(毫升)的1-丙醇、0.88mL的乙酰丙酮、4.93mL的丙醇锆和2.36mL的硝酸钇。
然后，制备第二浴体，用于随后浸涂具有填充有陶瓷纤维的第一热屏障的部件。第二浴体包括1-丙醇和1％的PVP 3500类型的分散剂，将以名称东曹(Tosoh)TZ6Y销售的商用YSZ粉末和由供应商泽卡泽康尼(Zircar Zirconia)销售的YSZ陶瓷纤维添加到其中。在第二浴体的固体部分中，YSZ粉末的质量含量在该示例中等于40摩尔％m(mol％)。仍然在第二浴体的固体部分中，YSZ陶瓷纤维的填充质量在该示例中等于60mol％。在该示例中，陶瓷纤维呈现的尺寸小于或等于50μm。浴体中YSZ的总质量含量约为40mol％。在超声波下搅动并添加蒸馏水之后，将第一浴体的一部分添加到第二浴体中。最后，再次搅动以此方式制备的第二浴体。
然后，在该部件上沉积中间YSZ溶胶底层，以便改进将由纤维填充的YSZ制成的第一热屏障层在部件上的连结。为此，使用预先制备的第一浴体来浸涂一层，然后在烘箱中以50℃干燥5分钟。
然后从先前制备的第二浴体中沉积填充有由YSZ制成的第一陶瓷纤维的第一YSZ层。为此，从第一浴体来浸涂用于第一层的前体(précurseur)层，然后在烘箱中以50℃干燥5分钟。重复该操作直到获得期望的厚度。为了获得在150μm至200μm之间的厚度，通常需要进行至少20次浸入。
最后，使具有在其上制成的先前沉积物的部件在露天的烘箱中经受热处理，初始以600℃处理1小时，然后以在1100℃和1250℃之间的温度处理2小时，在每个阶段(chaquepalier)之间以50℃/h改变温度。
在该步骤之后，获得涂覆的部件，具有以图6中的、如利用扫描电子显微镜所见的剖面示出的表面。第一层13呈现在AM1超级合金基板11上。在图6的照片中不可见的中间YSZ溶胶底层呈现在基板11和第一层13之间。第一层13呈现约180μm的平均厚度。照片清楚地显示在第一层13中存在陶瓷纤维14。第一热屏障层13中的平均孔隙率在该示例中小于20％。第一热屏障层13没有呈现任何分层或裂缝，这反映了热机械应力被良好适应。
Claims (9)
1.一种涂覆有至少一层第一热屏障层(33；43)的涡轮机部件(30；40)，所述至少一层第一热屏障层(33；43)包括陶瓷材料和分散在所述第一层中的第一陶瓷纤维(34；44)，所述部件的特征在于：
-所述第一层包括用于提供热屏障的第一陶瓷材料和用于提供保护抵抗铝硅酸钙镁的第二陶瓷材料的混合物，所述第一陶瓷材料和所述第二陶瓷材料不同，所述第一层呈现第一区域(33a)和第二区域(33b)，所述第一区域(33a)在其厚度的一部分上方延伸并呈现第二材料的第一质量含量，所述第二区域(33b)在其厚度的一部分上方延伸并且覆盖所述第一区域，所述第二区域呈现严格大于所述第一质量含量的所述第二材料的第二质量含量；和/或
-所述第一层是多孔的并且包括第一部分(43a)和第二部分(43b)，所述第一部分(43a)在其厚度的一部分上方延伸并呈现第一孔隙度，所述第二部分(43b)在其厚度的一部分上方延伸并且覆盖所述第一部分，所述第二部分呈现严格低于所述第一孔隙率的第二孔隙率。
2.根据权利要求1所述的部件，其特征在于，所述第一层(33；43)中的所述第一陶瓷纤维(34；44)的质量含量在30％至90％的范围内。
3.根据权利要求2所述的部件，其特征在于，所述第一层(33；43)中的所述第一陶瓷纤维(34；44)的质量含量在50％至90％的范围内。
4.根据权利要求1至3中任一项所述的部件，其特征在于，所述第一陶瓷纤维(34；44)的平均长度小于或等于50μm。
5.根据权利要求1至4中任一项所述的部件，其特征在于，所述第一陶瓷纤维(34；44)是由选自以下的材料组成：稀土氧化物稳定的氧化锆；稀土氧化物；烧绿石结构；稀土锆酸盐；氧化铝及它们的混合物。
6.根据权利要求1至5中的任一项所述的部件，其特征在于，所述部件(20)还涂覆有包括陶瓷材料的第二陶瓷层(25)，所述第二陶瓷层(25)用于提供保护抵抗铝硅酸钙镁，所述第二层位于所述第一层(23)上，并且还包括分散在所述第二层中的第二陶瓷纤维(26)。
7.根据权利要求1至6中任一项所述的部件，其特征在于，用于提供保护抵抗铝硅酸钙镁的所述陶瓷材料选自以下：稀土氧化物；稀土氧化物稳定的氧化锆；烧绿石结构；稀土锆酸盐；氧化铝及它们的混合物。
8.一种制造根据权利要求1至7中任一项所述的部件的方法，其特征在于，包括通过湿法在所述部件(30；40)上形成所述第一层(33；43)的至少一个步骤。
9.根据权利要求8所述的方法，其特征在于，所述第一层(33；43)通过溶胶-凝胶工艺、浸涂、或电泳形成。
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| FR2940278B1 (fr) * | 2008-12-24 | 2011-05-06 | Snecma Propulsion Solide | Barriere environnementale pour substrat refractaire contenant du silicium |
| RU88389U1 (ru) * | 2009-07-06 | 2009-11-10 | Закрытое акционерное общество научно-производственный центр "Трибоника" | Лопатка турбины газотурбинного двигателя с жаростойким покрытием |
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- 2017-10-31 CN CN201780074871.XA patent/CN110035983A/zh active Pending
- 2017-10-31 WO PCT/FR2017/052996 patent/WO2018087452A1/fr unknown
- 2017-10-31 EP EP17804614.0A patent/EP3538500B1/fr active Active
- 2017-10-31 CA CA3043107A patent/CA3043107A1/fr active Pending
- 2017-10-31 US US16/348,369 patent/US11466370B2/en active Active
- 2017-10-31 RU RU2019117737A patent/RU2741491C2/ru active
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Also Published As
| Publication number | Publication date |
|---|---|
| BR112019009410A2 (pt) | 2019-07-30 |
| EP3538500A1 (fr) | 2019-09-18 |
| US11466370B2 (en) | 2022-10-11 |
| WO2018087452A1 (fr) | 2018-05-17 |
| RU2019117737A (ru) | 2020-12-10 |
| CA3043107A1 (fr) | 2018-05-17 |
| FR3058469B1 (fr) | 2020-08-21 |
| FR3058469A1 (fr) | 2018-05-11 |
| US20190256983A1 (en) | 2019-08-22 |
| RU2741491C2 (ru) | 2021-01-26 |
| EP3538500B1 (fr) | 2024-01-24 |
| RU2019117737A3 (zh) | 2020-12-10 |
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