CN110325666A - 用于燃气涡轮发动机的翼型的涂层和施加涂层的方法 - Google Patents
用于燃气涡轮发动机的翼型的涂层和施加涂层的方法 Download PDFInfo
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Abstract
一种部件(50)以及一种形成涂层系统(100)的方法,部件(50)包括具有涂层系统(100)的镍基合金基底(102),涂层系统(100)包括:覆盖镍基合金基底(102)的CrAl层(104)、覆盖CrAl层(104)的NiCrAlY层(106)以及覆盖NiCrAlY层(106)的氧化钇稳定的氧化锆热障涂层(108),形成涂层系统(100)的方法包括以下步骤:空气等离子喷涂NiCrAlY层(106)、以及空气等离子喷涂氧化钇稳定的氧化锆热障涂层(108)。
Description
技术领域
本发明涉及可用于在燃气涡轮发动机中使用的部件的涂层,并且特别地但不限于,涡轮翼型上的空气等离子喷涂的耐热且耐腐蚀涂层。
背景技术
热障涂层(TBC)系统使用热喷涂的MCrAlY涂层作为部件的金属基底和耐热陶瓷外涂层之间的粘合层。MCrAlY涂层具有提供足够氧化寿命所需的最小厚度。然而,MCrAlY和陶瓷涂层的组合重量意味着:该涂层系统对于某些部件(例如旋转动叶)的寿命来说是至关重要的。对于诸如旋转动叶的某些燃气涡轮部件,该涂层的附加重量可能会导致其寿命周期缩短。
热障涂层还可能因其厚度而影响转子动叶或定子静叶级的空气动力学性能,这可能会减小动叶或静叶之间的可用喉道面积。在TBC经过改装并且转子动叶或定子静叶相对较小的情况下,这一问题尤其严重。
传统TBC基于8wt%的钇稳定氧化锆(YSZ),也称部分稳定YSZ。这些8wt%的YSZ涂层在高于1200℃时开始分解是已知的,并且因此限制了外表面承温能力。此外,腐蚀性物质可以将钇拉出钇稳定氧化锆涂层,并且因此使钇稳定氧化锆涂层不稳定。
改善TBC与镍基合金部件的粘附性的一种已知解决方案是,在部件和TBC之间使用PtAl或扩散铂(Pt)粘合层。虽然在任意镍基合金上使用的PtAl涂层或扩散Pt粘合层均可以提高寿命,但它们仅对低Cr合金(即,Cr小于10wt%的Ni基合金)有效。这两种涂层系统仅对电子束物理气相沉积(EBPVD)TBC系统有效。然而,EBPVD TBC系统在腐蚀性环境中会遇到问题是已知的。
EP2024607B1公开了一种用于燃气涡轮动叶的涂层系统,该涂层系统在动叶上的不同位置中具有不同组分。第一涂层可以包含Cr,这样的第一涂层可以通过应用诸如化学气相沉积的已知方法而被扩散到部件中。实验已经表明:如果第一涂层是5μm至25μm厚和/或包含15wt%至30wt%Cr的层,则可以获得良好的保护性能。第二涂层可以包括MCrAlY,其中M可以是Co或Ni或两者的组合。诸如Re、Si、Hf和/或Y的其它元素也可以包含在涂层中。涂层的优选组分为30wt%至70wt%的Ni、30wt%至50wt%的Co、15wt%至25wt%的Cr、5wt%至15wt%的Al和至多1wt%的Y。可以应用不同的热喷涂技术,例如真空等离子喷涂(VPS)、低压等离子喷涂(LPPS)、高速氧燃料喷涂(HVOF)、冷气喷涂(CGS)或电镀。第一涂层设置在动叶的根部上,并且第二涂层可以被施加至颈部、翼型的外表面和平台的至少一部分中的任意一个。
EP2662529AL公开了一种翼型,包括涂覆表面部,该涂覆表面部被涂覆有铂-铝化物粘合层和热障涂层。
EP2032733A2公开了一种保护部件(尤其是涡轮动叶)免受热腐蚀影响的方法,包括以下步骤:(1)将铬扩散涂层施加到部件上;以及(2)将陶瓷材料涂层施加至铬扩散涂层的一个或多个选定区域。
因此,期望提供一种重量更轻的涂层系统,该涂层系统具有足够的耐热/耐氧化性和抗腐蚀性,并且足以附接至部件且附接至优选具有高Cr含量的部件。另外,期望提供一种与传统涂层相比更薄的涂层系统,该涂层系统在未涂覆的动叶和静叶之间占据更小的喉道面积。
发明内容
为了解决已知涂层系统的问题,提供了一种用于燃气涡轮发动机的部件,包括具有涂层系统的镍基合金基底,该涂层系统包括覆盖镍基合金基底的CrAl层、覆盖CrAl层的NiCrAlY层,以及氧化钇稳定的氧化锆热障涂层。
本涂层系统的另一方面是制造部件的方法,该部件包括具有涂层系统的镍基合金基底。涂层系统包括覆盖镍基合金基底的CrAl层、覆盖CrAl层的NiCrAlY层以及氧化钇稳定的氧化锆热障涂层,该方法包括以下步骤:空气等离子喷涂NiCrAlY层,以及空气等离子喷涂氧化钇稳定的氧化锆热障涂层。
CrAl层的厚度可以在50μm至90μm之间并且包括50μm和90μm。
NiCrAlY层可以包含21wt%至23wt%的Cr、9wt%至11wt%的Al、0.8wt%至1.2wt%的Y,余量为Ni。
NiCrAlY层可以具有35μm的最大厚度。
NiCrAlY层可以包括大于10μm Ra的表面粗糙度。
氧化钇稳定的氧化锆热障涂层的厚度为50μm至500μm。
氧化钇稳定的氧化锆热障涂层包括10%至15%的孔隙率。
涂层系统可以小于部件的总重量的7%,并且优选约为部件的总重量的6%。
部件可以是转子动叶,该转子动叶是多个转子动叶的一个环形阵列中的一个,其中喉道面积被限定在没有涂层的相邻转子动叶之间,并且其中喉道面积小于1000mm2。
涂层系统可以占据的小于2.5%的喉道面积,优选占据约1.5%的喉道面积。
制造部件的方法可以包括化学气相沉积CrAl层的步骤。
形成CrAl层的方法步骤可以包括:化学气相沉积Cr层和化学气相沉积Al层的步骤。
该方法可以包括:使部件和涂层系统在1080℃至1120℃的范围中的温度下扩散并持续1至4小时的步骤。
附图说明
通过参考下面结合附图对本发明实施例的描述,本发明的上述属性及其它特征和优势及其实现方式将变得更加明显,并且将更好地理解本发明本身,其中,
图1以截面图示出涡轮发动机的一部分,并且其中包含本发明的过渡管,
图2示出具有根据所要求保护技术方案的涂层系统的涡轮动叶的立体视图,
图3是涂层系统的一个实施例的示意性截面,
图4是涂层系统的另一实施例的示意性截面。
具体实施方式
图1以截面图示出燃气涡轮发动机10的示例。燃气涡轮发动机10按流动顺序包括入口12、压气机部14、燃烧装置部16及涡轮部18,这些部件总体上按流动顺序,并且总体上围绕纵向轴线或旋转轴线20并沿纵向轴线或旋转轴线20的方向而被布置。燃气涡轮发动机10进一步包括轴22,轴22可以围绕旋转轴线20旋转并且纵向延伸穿过燃气涡轮发动机10。轴22驱动地将涡轮部18连接至压气机部14。
在燃气涡轮发动机10运行时,通过进气口12吸入的空气24由压气机部14压缩并被输送至燃烧部或燃烧器部16。燃烧器部16包括:燃烧器增压室26、一个或多个燃烧室28以及被固定至每个燃烧室28的至少一个燃烧器30。燃烧室28和燃烧器30位于燃烧器增压室26的内部。穿过压气机14的压缩空气进入散流器32并从散流器32排出到燃烧器增压室26中,部分空气从燃烧器增压室26进入燃烧器30并与气态燃料或液体燃料混合。之后,空气/燃料混合物燃烧,并且来自燃烧的燃烧气体34或工作气体经由过渡管17穿过燃烧室28而被引导至涡轮部18。
该示例性燃气涡轮发动机10具有管状燃烧装置部布置16,其由燃烧装置罐19的环状阵列构成,每个燃烧装置罐19具有燃烧器30和燃烧室28,过渡管17具有与燃烧室28交界的大体圆形入口及环形段形式的出口。过渡管出口的环形阵列形成用于将燃烧气体引导至涡轮18的环。
涡轮部18包括附接至轴22的多个动叶承载盘36。在该示例中,两个盘36分别承载涡轮动叶38的环形阵列。然而,动叶承载盘的数目可以不同,即,仅有一个盘或多于两个盘。此外,被固定至燃气涡轮发动机10的定子42的导流静叶40被设置在涡轮动叶38的环形阵列的级之间。导流静叶44被设置在在燃烧室28的出口与前涡轮动叶38的入口之间,并且导流静叶44将工作气体流转向至涡轮动叶38上。
来自燃烧室28的燃烧气体进入涡轮部18并且驱动涡轮动叶38,涡轮动叶38进而使轴22旋转。导流静叶40、44用于优化燃烧或工作气体在涡轮动叶38上的角度。
涡轮部18驱动压气机部14。压气机部14包括轴向串联的静叶级46和转子动叶级48。转子动叶级48包括转子盘,用于支撑动叶的环形阵列。压气机部14还包括壳体50,壳体50包围转子级并支撑静叶级46。导流静叶级包括径向延伸静叶的环形阵列,径向延伸静叶被安装至壳体50。这些静叶被设置为在给定发动机操作点以最优角度向动叶提供气流。一些导流静叶级具有可变静叶,其中这些静叶围绕其自身纵向轴线的角度可以根据在不同发动机运行条件下可能发生的气流特征来调整。
壳体50限定压气机14的通路56的径向外表面52。通路56的径向内表面54至少部分由转子的转子鼓53限定,转子鼓53部分地由动叶48的环形阵列限定。
本发明结合上述具有单个轴或线轴的示例性涡轮发动机而被描述,该轴或线轴连接单个多级压气机以及单个一级或多级涡轮。然而,应当理解的是,本发明同样适用于两轴发动机或三轴发动机,并且可以被用于工业、航空或海洋应用。
除非另有说明,否则术语“上游”和“下游”是指流经发动机的气流和/或工作气体的流方向。术语“向前”和“向后”是指流经发动机的总气体流。术语“轴向”、“径向”和“周向”是相对于发动机的旋转轴线20而言。
图2示出涡轮动叶80,涡轮动叶80被涂覆有本发明的涂层系统100。涡轮动叶80与上面描述的动叶38、48类似,并且可以在燃气涡轮发动机10中实施。涡轮动叶80具有根部84,根部84包括根部固定装置86和颈部88。颈部88在其它动叶上可以是可选的。根部固定装置86是枞树形的根构造,但是在其它实施例中,其它公知的固定装置也可以被实施。根部固定装置86与由一个或多个转子盘形成的互补固定装置接合。颈部88融入平台60中,平台60具有径向内表面64和径向外表面62或气洗表面62。从平台60延伸的翼型66包括前缘68和后缘70。总体上凹形的压力表面72和总体上凸形的吸入表面74分别在前缘68和后缘70之间延伸。翼型66的压力表面72和吸入表面74还沿径向方向从平台60延伸至翼型66的顶端76。这里示出的动叶80是无罩动叶,但在其它示例中,动叶80可以是带护罩动叶或具有本领域已知的一个或多个小翼的动叶。
图3是涂层系统100的实施例的示意性截面。涂层系统100涂覆在涡轮动叶80的表面之上。涡轮动叶80被铸造而成,但也可以由增材制造方法制成。涡轮动叶80包括镍基合金,并且这种镍基合金组分在本领域中是公知的。术语“基底”用于表示涡轮动叶材料。涂层系统100被施加至动叶80上的所有气洗表面,并且类似地施加在诸如静叶的其它部件上。气洗表面包括翼型的压力表面72和吸入表面74、平台的表面62以及甚至顶端76的表面。其中在静叶中存在小翼或护罩或甚至其它平台的情况下,也可以涂覆其它平台的气洗表面。“气洗”表面旨在表示与流经发动机的热工作气流接触的表面或表面的一部分。因此,基底(用102表示)可以是施加涂层系统100的部件壁的一部分。部件可以是动叶、静叶、燃烧装置的衬套、过渡管或甚至排气喷嘴中的任意一个。
被施加至镍基合金基底102的涂层系统100是覆盖镍基合金基底102的铬-铝(CrAl)层104,然后是覆盖CrAl层的镍-铬-铝-氧化钇(NiCrAlY)层106,并且然后是NiCrAlY层106之上的氧化钇稳定的氧化锆(YSZ)热障涂层108。重要的是,在形成涂层系统100的方法中,NiCrAlY层106和氧化钇稳定的氧化锆热障涂层108分别通过单独的空气等离子喷涂步骤来施加。使用化学气相沉积技术来施加CrAl层104。
在涂层系统100的另一实施例中并且如图4所示,形成涂层系统的方法涉及通过两个步骤过程来形成CrAl层104,其中通过化学气相沉积步骤沉积Cr层110,并且继而通过化学气相沉积步骤沉积Al层。Cr容易扩散到Ni合金基底中,并且继而一旦Al被施加,就形成具有有限Cr溶解度的NiAl相。因此,可以形成同时包括铬和铝的单个层。
重要的是,无论通过哪种方法形成CrAl层104,其厚度均在50μm至90μm之间并且包括50μm和90μm。NiCrAlY层106的厚度约为22μm,但其厚度可以在5μm至35μm之间。氧化钇稳定的氧化锆热障涂层108的厚度约为200μm,但其厚度可以在50μm至500μm之间。通常,涂层系统100的重量可以比传统涂层轻约25%,并且可以轻20%至30%。
NiCrAlY层106包含16wt%至23wt%的Cr、9wt%至11wt%的Al、0.8wt%至1.2wt%的Y,余量为Ni。NiCrAlY层106具有5μm至35μm的厚度。NiCrAlY层106包括大于10μm且小于35μm Ra的表面粗糙度。该粗糙度由空气等离子喷涂中使用的喷涂粉末的粒度控制,不过,其它因素也会影响表面粗糙度。NiCrAlY层106通过空气等离子喷涂而被施加。
氧化钇稳定的氧化锆热障涂层108包括10%-15%的孔隙率。氧化钇稳定的氧化锆热障涂层108通过空气等离子喷涂而被施加。空气等离子喷涂TBC的寿命取决于喷涂参数,例如粉末颗粒有多热以及孔隙率。一般而言,如果涂层过密,则会在界面处产生显著应力并导致涂层剥落,并且如果涂层具有太多孔,则容易被侵蚀损坏或容易在孔之间产生连接裂缝。已经发现孔隙率在10%至15%之间是优选的。
为了完成涂层系统100的制造,在施加完涂层系统的所有层之后,部件50和涂层系统100在1080℃至1120℃的温度下一起扩散1-4小时。确切的温度和确切的时间取决于所使用的镍基超合金的组分。
本发明的涂层系统100尤其适用于相对较小的旋转燃气涡轮动叶,在这种较小的旋转燃气涡轮动叶中,涂层系统的重量是显著的。在燃气涡轮发动机的涡轮中,动叶高速旋转并因此产生高离心力。在动叶中引起的这些高离心力和“机械应力”是限制动叶的寿命的因素之一。对于相对较小的动叶,传统的“厚”涂层系统可能会显著增加动叶的总重量、并且由于机械应力增加而降低动叶的寿命。有利地,涂层系统100小于动叶的总重量的7%。在一个示例中,涂层系统是每个动叶的总重量的6%。在同一相对较小的动叶上,传统涂层系统通常是动叶的总重量的至少8%。对于在寿命方面至关重要的动叶而言,如此小的重量减少就可以使得动叶的寿命显著增加。
除相对较轻的重量外,本发明的涂层系统还比传统的TBC系统更薄。这可以是有利的,因为涂层系统100不会减小转子的周向相邻的动叶之间的喉道面积。喉道面积是工作气体流经的相邻的动叶或静叶之间的最小面积。施加至转子部件的相对较小动叶的相对厚TBC可能会对转子组件的效率具有小但显著的影响。因此,对于具有相对较小的动叶并且两个相邻的动叶之间的喉道面积小于1000mm2的转子组件来说,本涂层系统100是特别合适的。有利地,当被施加至相对较小动叶和静叶时,涂层系统100可以小于未涂覆动叶的喉道面积的2.5%。在一个示例中,转子动叶级具有约为700mm2的平均喉道面积,并且涂层系统100的施加占据喉道面积的大约1.5%。传统涂层通常占喉道面积的约3.5%。因此,应当理解的是,本涂层系统100可以提供优于传统涂层系统的显著效率改进。
Claims (14)
1.一种用于一个燃气涡轮发动机(10)的部件(50),包括具有一个涂层系统(100)的一个镍基合金基底(102),所述涂层系统(100)包括:
覆盖所述镍基合金基底(102)的一层CrAl层(104),
覆盖所述CrAl层的一层NiCrAlY层(106),以及
一层氧化钇稳定的氧化锆热障涂层(108)。
2.根据权利要求1所述的部件(50),其中,
所述CrAl层(104)的厚度在50μm至90μm之间并且包括50μm和90μm。
3.根据权利要求1至2中任一项所述的部件(50),其中,
所述NiCrAlY层(106)包括21wt%至23wt%的Cr、9wt%至11wt%的Al、0.8wt%至1.2wt%的Y,余量为Ni。
4.根据权利要求1至3中任一项所述的部件(50),其中,
所述NiCrAlY层(106)具有在5μm至35μm之间的厚度。
5.根据权利要求1至4中任一项所述的部件(50),其中,
所述NiCrAlY层(106)包括10μm Ra的最小表面粗糙度。
6.根据权利要求1至5中任一项所述的部件(50),其中,
所述氧化钇稳定的氧化锆热障涂层(108)的厚度为50μm至500μm。
7.根据权利要求1至5中任一项所述的部件(50),其中,
所述氧化钇稳定的氧化锆热障涂层(108)包括10%至15%的孔隙率。
8.根据权利要求1至6中任一项所述的部件(50),其中,
所述涂层系统(100)小于所述部件(50)的总重量的7%,并且优选约为所述部件(50)的总重量的6%。
9.根据权利要求1至8中任一项所述的部件(50),其中,
所述部件(50)是一个转子动叶(50),所述转子动叶(50)是多个转子动叶的一个环形阵列中的一个,
其中喉道面积被限定在没有涂层的相邻的多个转子动叶(50)之间,并且
其中所述喉道面积小于1000mm2。
10.根据权利要求9所述的部件(50),其中,
所述涂层系统(100)占据小于2.5%的所述喉道面积,优选占据约1.5%的喉道面积。
11.一种制造一个部件(50)的方法,所述部件(50)包括具有一个涂层系统(100)的一个镍基合金基底(102),所述涂层系统(100)包括覆盖所述镍基合金基底(102)的一层CrAl层(104)、覆盖所述CrAl层(104)的一层NiCrAlY层(106)以及一层氧化钇稳定的氧化锆热障涂层(108),所述方法包括以下多个步骤:
空气等离子喷涂所述NiCrAlY层(106),以及
空气等离子喷涂所述氧化钇稳定的氧化锆热障涂层(108)。
12.根据权利要求11所述的制造一个部件(50)的方法,所述方法包括以下步骤:
化学气相沉积所述CrAl层(104)。
13.根据权利要求11所述的制造一个部件(50)的方法,其中所述CrAl层(104)由包括下述多个步骤的方法形成:
化学气相沉积一层Cr层(110),以及
化学气相沉积一层Al层(112)。
14.根据权利要求11至13所述的制造一个部件(50)的方法,所述方法包括以下步骤:
使所述部件(50)和所述涂层系统(100)在1080℃至1120℃的范围中的一个温度下扩散并且持续1至4个小时。
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EP1790825A1 (en) * | 2005-11-29 | 2007-05-30 | General Electric Company | Method for applying a bond coat and a thermal barrier coating over an aluminided surface |
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CN113088967A (zh) * | 2021-04-02 | 2021-07-09 | 东北大学 | 一种具有sn/aps复合结构双粘结层的热障涂层及其制备方法 |
CN115198270A (zh) * | 2022-06-02 | 2022-10-18 | 广东羚光新材料股份有限公司 | 耐高温镍基熔射复合网及其制备方法和应用 |
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RU2019126176A (ru) | 2021-03-23 |
WO2018153558A1 (en) | 2018-08-30 |
GB201702763D0 (en) | 2017-04-05 |
CA3050170A1 (en) | 2018-08-30 |
US20190368050A1 (en) | 2019-12-05 |
RU2019126176A3 (zh) | 2021-03-23 |
GB2559806A (en) | 2018-08-22 |
EP3585925A1 (en) | 2020-01-01 |
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