CN113423855A - 具有脆性且可磨耗组分的致密可磨耗涂层 - Google Patents

具有脆性且可磨耗组分的致密可磨耗涂层 Download PDF

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CN113423855A
CN113423855A CN202080014102.2A CN202080014102A CN113423855A CN 113423855 A CN113423855 A CN 113423855A CN 202080014102 A CN202080014102 A CN 202080014102A CN 113423855 A CN113423855 A CN 113423855A
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abradable
coating
abradable coating
particles
turbine engine
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K·阿南德
E·卡拉
B·达桑
S·S·帕布拉
P·萨克塞纳
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General Electric Co PLC
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    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
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    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
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    • C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
    • C23C4/11—Oxides
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    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D11/00—Preventing or minimising internal leakage of working-fluid, e.g. between stages
    • F01D11/08—Preventing or minimising internal leakage of working-fluid, e.g. between stages for sealing space between rotor blade tips and stator
    • F01D11/12—Preventing or minimising internal leakage of working-fluid, e.g. between stages for sealing space between rotor blade tips and stator using a rubstrip, e.g. erodible. deformable or resiliently-biased part
    • F01D11/122—Preventing or minimising internal leakage of working-fluid, e.g. between stages for sealing space between rotor blade tips and stator using a rubstrip, e.g. erodible. deformable or resiliently-biased part with erodable or abradable material
    • 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
    • F01D25/00—Component parts, details, or accessories, not provided for in, or of interest apart from, other groups
    • F01D25/005—Selecting particular materials
    • 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
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    • F05D2240/00—Components
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    • F05D2240/11—Shroud seal segments
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Abstract

各种实施方案包括致密可磨耗涂层、通过向涡轮发动机部件施加致密可磨耗涂层来减少对涡轮发动机部件的摩擦损伤的方法，以及在其上具有可磨耗涂层的涡轮发动机部件。特定实施方案包括致密可磨耗涂层，该致密可磨耗涂层包含无孔金属复合材料、高含铝脆性合金和多个中空可磨耗颗粒。

Description

具有脆性且可磨耗组分的致密可磨耗涂层
技术领域
本公开整体涉及致密可磨耗涂层，通过向涡轮发动机部件施加致密可磨耗涂层来减少对涡轮发动机部件的摩擦损伤的方法，以及在其上具有致密可磨耗涂层的涡轮发动机部件。更具体地，本公开涉及致密可磨耗涂层，该致密可磨耗涂层包含无孔金属复合材料、高含铝脆性合金和多个中空可磨耗颗粒。
背景技术
按照惯例，在旋转电机中的移动部件和静止部件之间使用可磨耗材料，使得部件中的一个部件在可磨耗材料中切出或摩擦出凹槽。在燃气涡轮发动机中，可磨耗材料通常放置在静止壳体(例如，护罩)上，并且旋转叶片在可磨耗材料中切出/摩擦出凹槽。这允许适应由于不圆度、转子下垂、热增长和叶片蠕变引起的机械侵入。然而，与不太先进的非工业用小型燃气涡轮相比，先进的工业燃气涡轮通常以升高的温度(例如，在2000°F至3300°F范围内的烧制温度)运行，并且部件(例如，叶片)具有更大的环形面积，以获得更高的能量输出和更高的效率。常规可磨耗系统通常是高度多孔的，无法承受先进工业燃气涡轮发动机的高温、大气流和易氧化环境，因此在高温(例如，低至1400°F)下的预期寿命有限。
发明内容
本发明公开了致密可磨耗涂层和通过向涡轮发动机部件施加致密可磨耗涂层来减少对涡轮发动机部件的摩擦损伤的方法。在本公开的第一方面，可磨耗涂层包含：金属复合材料，该金属复合材料是无孔的并且包含选自铁(Fe)、镍(Ni)、铝(Al)、铬(Cr)、钛(Ti)、钇(Y)和钴(Co)的两种或更多种金属；脆性合金，该脆性合金包含至少20重量％的铝(Al)和至少一种其它金属；以及多个可磨耗颗粒，该多个可磨耗颗粒包括一种或多种氧化物的中空球体。
在本公开的第二方面，一种减少对涡轮发动机的至少一个部件的摩擦损伤的方法包括：在易于与涡轮发动机的第二部件摩擦的位置将可磨耗涂层施加到涡轮发动机的第一部件，该可磨耗涂层包含金属复合材料、脆性合金和多个可磨耗颗粒，该金属复合材料是无孔的并且包含选自铁(Fe)、镍(Ni)、铝(A1)、铬(Cr)、钛(Ti)、钇(Y)和钴(Co)的两种或更多种金属，该脆性合金包含至少20重量％的铝(A1)和至少一种其它金属，并且该多个可磨耗颗粒包括一种或多种氧化物的中空球体。
在本公开的第三方面，提供了一种涡轮发动机部件，该涡轮发动机部件在其表面的至少一部分上具有可磨耗涂层，其中该可磨耗涂层包含：金属复合材料，该金属复合材料是无孔的并且包含选自铁(Fe)、镍(Ni)、铝(Al)、铬(Cr)、钛(Ti)、钇(Y)和钴(Co)的两种或更多种金属；脆性合金，该脆性合金包含至少20重量％的铝(Al)和至少一种其它金属；以及多个可磨耗颗粒，该多个可磨耗颗粒包括一种或多种氧化物的中空球体。
附图说明
从结合描绘本公开的各种实施方案的附图的对本公开的各个方面的以下详细描述，将更容易理解本公开的这些和其他特征，其中：
图1是包括紧邻壳体/护罩的叶片/叶片(blade/bucket)的燃气涡轮发动机的一部分的示意性剖视图。
图2示意性地示出了摩擦后的叶片/叶片(blade/bucket)磨损和壳体/护罩切割。
应当注意，本公开的附图未必按比例绘制。附图旨在仅描绘本公开的典型方面，并且因此不应当被视为限制本公开的范围。在附图中，类似的编号表示附图之间的类似的元件。
具体实施方式
本公开整体涉及致密可磨耗涂层，通过向涡轮发动机部件施加致密可磨耗涂层来减少对涡轮发动机部件的摩擦损伤的方法，以及在其上具有致密可磨耗涂层的涡轮发动机部件，并且更具体地涉及致密可磨耗涂层，该致密可磨耗涂层包含无孔金属复合材料、高含铝脆性合金和多个中空可磨耗颗粒。如上所述，常规可磨耗系统通常是高度多孔的，无法承受先进工业燃气涡轮发动机的高温、大气流和易氧化环境，因此在大约1400°F以上的高温下的预期寿命有限。
本公开的各个方面包括可磨耗涂层，该可磨耗涂层包含用于降低孔隙率的无孔金属复合材料组分、用于辅助抗氧化的高含铝脆性合金组分，以及用于提供磨耗性的中空可磨耗颗粒组分，其中每种组分有助于改善在诸如1650°F以上的高温下的预期寿命。本公开的附加方面包括通过向涡轮发动机的一个或多个部件施加可磨耗涂层来减少对该一个或多个部件的摩擦损伤的方法。因此，与常规方法相比，可通过利用本公开的致密、抗氧化、高温稳定且可磨耗的涂层来减少或防止对发动机部件的损伤(例如，摩擦损伤)。此外，可以实现利用本公开的可磨耗涂层的发动机部件的更长预期寿命。
图1示出了燃气涡轮发动机100的截面，该燃气涡轮发动机包括被构造成围绕中心(或主)轴旋转的叶片(或叶片末端)110，以及与叶片110相邻的静止壳体区段120(例如，护罩)。在没有用于适应热增长和叶片蠕变的装置的情况下，可发生叶片磨损和护罩切割中的一者或两者一这示意性地示于图2中。图2所示的左侧图(“摩擦前”)和水平虚线示出了在发生摩擦和叶片磨损/护罩切割之前叶片110和护罩120之间的间隙。右侧图(“摩擦后”)示出了摩擦后的叶片磨损间隙210和护罩切口220。如图2所示，叶片磨损间隙210和护罩切口220显著增加了叶片110和护罩120之间的原始间隙(由水平虚线指示)。这种增大的间隙可导致不需要的间隙和气流泄漏，这可降低发动机100(图1)的总体性能。
可磨耗涂层可用于间隙控制和损伤减少的目的。常规的可磨耗物是构建在多孔涂层架构上的，因此通常具有高水平的孔隙率，这提供所需水平的磨耗性。然而，此类具有高孔隙率的常规研磨制品易于氧化，并且在高于约1400°F的温度下具有有限的预期寿命。
在本公开的各方面，提供了一种可磨耗涂层，该可磨耗涂层可降低孔隙率并增加抗氧化性，同时保持足够的磨耗性，以便减少和/或防止发动机部件之间的摩擦损伤。因此，本公开的可磨耗涂层另外提供了在诸如1650°F以上的高温下改善的预期寿命。
本公开的可磨耗涂层包含金属复合材料、脆性合金和多个可磨耗颗粒。金属复合材料可以具有如此低的孔隙率，以至于被认为是无孔的。可磨耗涂层中的无孔金属复合材料实现了较低孔隙率(即，较致密)的涂层，这有助于在高温(例如，大约1650°F以上)下具有更长的预期寿命，这与在相同高温下使用时的常规较高孔隙率涂层形成对比。
金属复合材料可包含选自铁(Fe)、镍(Ni)、铝(Al)、铬(Cr)、钛(Ti)、钇(Y)和钴(Co)的任何两种或更多种金属。金属复合材料的非限制性示例包括MCrAlY，其中M为Fe、Co和Ni中的至少一种。在M包括Fe、Co和Ni中的两种的情况下，金属复合材料的示例可包括CoNiCrAlY。本公开的可磨耗涂层可包含40重量％至60重量百分比(重量％)的金属复合材料，包括大约50重量％。
本公开的可磨耗涂层的脆性合金组分可包括高含铝合金。脆性合金可包含20重量％或更多的铝(Al)。当金属复合材料在氧化期间经历β相耗尽时，脆性合金中这种高含量的Al可向金属复合材料提供铝供应。因此，本公开的可磨耗涂层中所存在的高含铝脆性合金可增强本公开的可磨耗涂层的抗氧化性。
脆性合金包含如上所述的铝以及至少一种其它金属，以便构成合金。脆性合金的非铝组分可为选自钛(Ti)、镍(Ni)、钴(Co)、镁(Mg)、铁(Fe)、钨(W)、锌(Zn)、锰(Mn)、硅(Si)、铬(Cr)、碳(C)和铍(Be)的一种或多种金属。脆性合金的非限制性示例包括NiAl合金。当脆性合金为NiAl合金时，NiAl合金可包含20重量％的Al，并且其余为Ni。本公开的可磨耗涂层可包含20重量％至30重量％的脆性合金，在特定情况下为20重量％。
本公开的可磨耗涂层的可磨耗颗粒组分有助于整个涂层的磨耗性，这最终有助于减少/防止摩擦损伤，并因此有助于利用该涂层的发动机部件的更长预期寿命。可磨耗颗粒可具有在100纳米(nm)至100微米(μm)范围内的粒度。本公开的涂层的可磨耗颗粒可包括一种或多种氧化物的中空球体(颗粒)。氧化物可选自氧化锌、氧化硅、氧化铝、氧化锆、氧化铈、飞灰(来自煤燃烧)和羟基磷灰石。中空氧化物的非限制性示例包括氧化锌(ZnO)。本公开的可磨耗涂层可包含20重量％至30重量％的多个可磨耗颗粒，包括大约30重量％。一种或多种氧化物的中空球体可占多个可磨耗颗粒的一部分或全部。
在本公开的其它方面，可磨耗涂层可具有在120密耳至200密耳(1密耳＝1/1000英寸)范围内的厚度。本公开的可磨耗涂层的这种厚度可有助于减少/防止对发动机部件的摩擦损伤。另外，在不经历涂层厚度的基于逐渐氧化的损失的情况下，本公开的可磨耗涂层可用于在大约1650°F或更高的温度下的扩展操作中，这可进一步有助于减少/防止对发动机部件的摩擦损伤。
在本公开的其它方面，提供了一种用于减少对涡轮发动机的至少一个部件的摩擦损伤的方法。本公开的方法包括在易于与涡轮发动机的第二部件(例如，叶片)摩擦的位置将上述可磨耗涂层施加到涡轮发动机的第一部件(例如，壳体)。可使用一种或多种已知的涂层施加技术来施加可磨耗涂层，只要所选择的技术能够保持本公开的可磨耗涂层的低孔隙率(致密)性质即可。
能够施加本公开的致密可磨耗涂层同时在施加完成时保持涂层的致密性质的技术包括但不限于超音速氧气火焰喷涂(HVOF)涂布工艺、低压等离子喷涂(LPPS)涂布工艺、超音速等离子喷涂(HVPS)涂布工艺、超音速空气火焰喷涂(HVAF)涂布工艺和悬浮热喷涂超音速空气火焰喷涂(STS-HVAF)涂布工艺中。可使用这些涂布工艺中的任何一种或多种。当通过诸如基于HVOF、HVAF或HVPS涂布工艺的高动能工艺来施加本公开的可磨耗涂层时，可磨耗涂层可具有8000磅/平方英寸(psi)或更高的粘结强度(发动机部件上施加有涂层)。此外，所选择的涂覆工艺可用于将涂层作为致密单片或作为图案施加，例如具有突出脊的图案，这些突出脊还可有助于摩擦期间的叶片末端损失。
如上所述，当施加到发动机部件时，本公开的可磨耗涂层可有助于减少/防止摩擦损伤。重新参考图2的右侧示意图(“摩擦后”)，叶片磨损间隙210和壳体切口220在摩擦后存在，并且可显著增加叶片110与壳体120之间的初始间隙(由水平虚线指示)。然而，在本公开的方法的发动机第一部件具有施加到其上的可磨耗涂层(例如，壳体120)并抵靠发动机第二部件(例如，叶片110)摩擦的情况下，可减少对至少第二部件的摩擦损伤。更具体地，对第二部件的摩擦损伤可小于(两个部件的)总侵入深度的25％。总侵入深度计算为第二部件的磨损深度(即，叶片磨损间隙210)加上可磨耗涂覆的第一部件的磨损深度(即，壳体切口220)的总和。
因此，本公开的可磨耗涂层不仅可在摩擦的情况下提供小于总侵入深度的25％的摩擦损伤/损失，而且可磨耗涂层还能够在高温下(例如，大约1650°F以上)扩展操作，并且不会因氧化而经历逐渐的涂层厚度损失。
本文使用的术语仅用于描述特定实施方案的目的并且不旨在限制本公开。如本文所用，单数形式“一个”、“一种”和“该”旨在也包括复数形式，除非上下文另有明确地说明。将进一步理解，当在说明书中使用时，术语“包括(comprises)”和/或“包括(comprising)”指定存在陈述特征、整数、步骤、操作、元件和/或组件，但是不排除存在或添加一个或多个其他特征、整数、步骤、操作、元件、组件和/或它们的组。
如在整个说明书和权利要求书中使用的，近似语言可以用于修改可以允许变化的任何定量表示，而不会导致与其相关的基本功能的变化。因此，由一个或多个术语(诸如“约”、“大约”和“基本上”)修饰的值不限于指定的精确值。在至少一些情况下，近似语言可以对应于用于测量值的仪器的精度。在此和整个说明书和权利要求书中，范围限制可以组合和/或互换，此类范围被识别并且包括其中包含的所有子范围，除非上下文或语言另有指示。应用于范围的特定值的“大约”适用于两个值，除非另外依赖于测量值的仪器的精度，否则可以指示所述值的+/-10％。“基本上”大多数情况下主要是指提供本公开的相同技术益处的完全指定的或任何轻微的偏差。
以下权利要求书中的所有装置或步骤加功能元件的对应结构、材料、动作和等同物旨在包括用于结合具体要求保护的其他要求保护的元件执行功能的任何结构、材料或动作。已经出于说明和描述的目的给出了对本公开的描述，但其并不旨在穷举或将本公开限制于所公开的形式。在不脱离本公开的范围和实质的情况下，许多修改和变化对于本领域普通技术人员将是显而易见的。选择和描述了实施方案以便最好地解释本公开的原理和实际应用，并且使得本领域的其他技术人员能够理解具有适合于预期的特定用途的各种修改的本公开的各种实施方案。

Claims (20)

1.一种可磨耗涂层，所述可磨耗涂层包含：
金属复合材料，所述金属复合材料是无孔的并且包含选自以下的两种或更多种金属：铁(Fe)、镍(Ni)、铝(A1)、铬(Cr)、钛(Ti)、钇(Y)和钴(Co)；
脆性合金，所述脆性合金包含至少20重量％的铝(A1)和至少一种其它金属；和
多个可磨耗颗粒，所述多个可磨耗颗粒包括一种或多种氧化物的中空球体。
2.根据权利要求1所述的可磨耗涂层，其中所述金属复合材料包括MCrAlY，其中M为铁(Fe)、镍(Ni)和钴(Co)中的至少两种。
3.根据权利要求1所述的可磨耗涂层，其中所述金属复合材料占所述可磨耗涂层的40重量％至60重量％并且包括CoNiCrAlY。
4.根据权利要求1所述的可磨耗涂层，其中所述脆性合金的所述至少一种其它金属选自钛(Ti)、镍(Ni)、钴(Co)、镁(Mg)、铁(Fe)、钨(W)、锌(Zn)、锰(Mn)、硅(Si)、铬(Cr)、碳(C)和铍(Be)。
5.根据权利要求1所述的可磨耗涂层，其中所述脆性合金占所述可磨耗涂层的20重量％至30重量％并且包含镍(Ni)。
6.根据权利要求1所述的可磨耗涂层，其中所述多个可磨耗颗粒的所述一种或多种氧化物选自氧化锌、氧化硅、氧化铝、氧化锆、氧化铈、飞灰和羟基磷灰石。
7.根据权利要求1所述的可磨耗涂层，其中所述多个可磨耗颗粒占所述可磨耗涂层的20重量％至30重量％，并且具有在100纳米(nm)至100微米(um)范围内的粒度。
8.根据权利要求1所述的可磨耗涂层，所述可磨耗涂层包含：
约50重量％的CoNiCrAlY作为所述金属复合材料，
约20重量％的NiAl20％作为所述脆性合金，以及
约30重量％的中空ZnO颗粒作为所述多个可磨耗颗粒。
9.根据权利要求1所述的可磨耗涂层，其中所述涂层的厚度在120密耳至200密耳的范围内。
10.根据权利要求1所述的可磨耗涂层，其中所述涂层是单片的或图案化的。
11.一种减少对涡轮发动机的至少一个部件的摩擦损伤的方法，所述方法包括：
在易于与涡轮发动机的第二部件摩擦的位置将可磨耗涂层施加到所述涡轮发动机的第一部件，所述可磨耗涂层包含金属复合材料、脆性合金和多个可磨耗颗粒，
所述金属复合材料是无孔的并且包含选自以下的两种或更多种金属：铁(Fe)、镍(Ni)、铝(Al)、铬(Cr)、钛(Ti)、钇(Y)和钴(Co)，
所述脆性合金包含至少20重量％的铝(Al)和至少一种其它金属，并且
所述多个可磨耗颗粒包括一种或多种氧化物的中空球体。
12.根据权利要求11所述的方法，其中所述可磨耗涂层的施加包括超音速氧气火焰喷涂(HVOF)涂布工艺、低压等离子喷涂(LPPS)涂布工艺、超音速等离子喷涂(HVPS)涂布工艺、超音速空气火焰喷涂(HVAF)涂布工艺和悬浮热喷涂超音速空气火焰喷涂(STS-HVAF)涂布工艺中的至少一种。
13.根据权利要求11所述的方法，其中
所述金属复合材料包括MCrAlY，其中M为铁(Fe)、镍(Ni)和钴(Co)中的至少两种；
所述脆性合金的所述至少一种其它金属选自钛(Ti)、镍(Ni)、钴(Co)、镁(Mg)、铁(Fe)、钨(W)、锌(Zn)、锰(Mn)、硅(Si)、铬(Cr)、碳(C)和铍(Be)；并且
所述多个可磨耗颗粒的所述一种或多种氧化物选自氧化锌、氧化硅、氧化铝、氧化锆、氧化铈、飞灰和羟基磷灰石。
14.根据权利要求11所述的方法，其中所述多个可磨耗颗粒具有在100纳米(nm)至100微米(μm)范围内的粒度。
15.根据权利要求11所述的方法，其中所述可磨耗涂层包含：
40重量％至60重量％的MCrAlY作为所述金属复合材料，其中M为铁(Fe)、镍(Ni)和钴(Co)中的至少两种；
20重量％至30重量％的NiAl作为所述脆性合金，其中NiAl包含至少20重量％的铝(Al)；和
20重量％至30重量％的所述多个可磨耗颗粒，其中中空氧化锌为所述一种或多种氧化物中的一种氧化物。
16.根据权利要求11所述的方法，其中所述可磨耗涂层以120密耳至200密耳范围内的厚度和8000磅/平方英寸(psi)或更大的粘结强度施加。
17.根据权利要求11所述的方法，其中对涡轮发动机的所述第二部件的所述摩擦损伤小于总侵入深度的25％，所述总侵入深度是所述第二部件的磨损深度和可磨耗涂覆的第一部件的磨损深度的总和。
18.一种涡轮发动机部件，所述涡轮发动机部件在其表面的至少一部分上具有可磨耗涂层，所述可磨耗涂层包含：
金属复合材料，所述金属复合材料是无孔的并且包含选自以下的两种或更多种金属：铁(Fe)、镍(Ni)、铝(Al)、铬(Cr)、钛(Ti)、钇(Y)和钴(Co)；
脆性合金，所述脆性合金包含至少20重量％的铝(Al)和至少一种其它金属；和
多个可磨耗颗粒，所述多个可磨耗颗粒包括一种或多种氧化物的中空球体。
19.根据权利要求18所述的涡轮发动机部件，其中所述可磨耗涂层包含：
40重量％至60重量％的MCrAlY作为所述金属复合材料，其中M为铁(Fe)、镍(Ni)和钴(Co)中的至少两种；
20重量％至30重量％的NiAl作为所述脆性合金，其中NiAl包含至少20重量％的铝(Al)；和
20重量％至30重量％的所述多个可磨耗颗粒，其中所述多个可磨耗颗粒具有在100纳米(nm)至100微米(μm)范围内的粒度，并且其中中空氧化锌为所述多个可磨耗颗粒的所述一种或多种氧化物中的一种氧化物。
20.根据权利要求18所述的涡轮发动机部件，其中所述可磨耗涂层的厚度在120密耳至200密耳的范围内，并且与所述涡轮发动机部件的粘结强度为8000磅/平方英寸(psi)或更大。
CN202080014102.2A 2019-02-20 2020-02-12 具有脆性且可磨耗组分的致密可磨耗涂层 Pending CN113423855A (zh)

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US20200263307A1 (en) 2020-08-20
WO2020172016A1 (en) 2020-08-27
EP3927863B1 (en) 2023-09-20
EP3927863A1 (en) 2021-12-29

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