CN114667365A - 包括冷却通道的高温合金飞行器部件 - Google Patents

包括冷却通道的高温合金飞行器部件 Download PDF

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CN114667365A
CN114667365A CN202080076901.2A CN202080076901A CN114667365A CN 114667365 A CN114667365 A CN 114667365A CN 202080076901 A CN202080076901 A CN 202080076901A CN 114667365 A CN114667365 A CN 114667365A
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component
substrate
mass fraction
cavity
elements
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艾玛尔·撒伯恩德吉
杰瑞米·雷姆
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Safran SA
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Abstract

本发明涉及一种部件，该部件包括由镍基高温合金制成的基底，基底具有第一平均质量分数的一种或多种第一元素，一种或多种第一元素选自铪、硅以及铬，基底包括在部件中的至少一个敞开的空腔，并且优选地包括冷却通道，基底进一步包括至少部分地形成空腔的表面层，表面层具有第二平均质量分数的第一元素，第二平均质量分数严格大于第一平均质量分数。

Description

包括冷却通道的高温合金飞行器部件
技术领域
本发明涉及飞行器部件，例如涡轮叶片或分配器叶片。
背景技术
在涡轮喷气发动机中，燃烧腔室产生的废气可以达到高的温度，例如高于1200℃，或者高于1600℃。因此，与这些废气接触的涡轮喷气发动机部件(例如涡轮叶片)在这些高的温度下必须能够保持其机械性能。
为此，已知的惯例是制造一些“高温合金”涡轮部件。高温合金是能够在相对接近其熔融点的温度(通常是金属合金的熔融温度的0.7倍至0.8倍)下使用的高抗性的金属合金的族。
然而，高温合金部件总是有极限使用温度，超过极限使用温度，该部件的蠕变太大而不能使用。
为此，已知的惯例是制造包括一个或多个冷却通道的飞行器部件。流体(例如离开低压压缩机的气体)可以被引入到一个或多个冷却通道中。因此，流体的流通使得部件能够被冷却。
尽管如此，一个或多个冷却通道的壁对环境是敏感的。特别地，这些壁在部件的使用期间可能被氧化和/或腐蚀，这减少了部件的使用时间。
发明内容
本发明的一个目的是提出用于制造涡轮部件的解决方案，该涡轮部件包括与现有技术的冷却通道相比对氧化和/或腐蚀更不敏感的冷却通道。
该目的在本发明的范围内通过一种部件来实现，该部件包括由镍基高温合金制成的基底，基底具有第一平均质量分数的一种或多种第一元素，一种或多种第一元素选自铪、硅以及铬，基底包括在部件中的至少一个敞开的空腔，并且优选地包括冷却通道，基底进一步包括至少部分地形成空腔的表面层，表面层具有第二平均质量分数的一种或多种第一元素，第二平均质量分数严格大于第一平均质量分数。
本发明通过以下特征来有利地完成，这些特征被单独地采用或以其技术上可能的组合中的任意一种组合的方式被采用：
-部件进一步包括覆盖表面层的涂层，涂层具有质量分数大于50％，优选地大于90％的一种或多种第一元素，
-保护涂层的厚度l2至少大于50nm，
-第一元素是铪，并且第二质量分数介于0.4％至4.5％之间，
-第一元素是硅，并且第二质量分数介于4％至10％之间，
-第一元素是铬，并且第二质量分数介于0.2％至5％之间，
-基底包括铼和/或钌，基底的铼和/或钌的平均质量分数大于或等于3％，优选地大于或等于4％，
-该部件是涡轮部件。
本发明的另一个方面是一种飞行器涡轮，该飞行器涡轮包括根据本发明的部件。
本发明的另一个方面是一种飞行器，该飞行器包括根据本发明的部件。
本发明的另一个方面是用于制造根据本发明的飞行器部件的方法，该方法至少包括以下步骤：
-提供部件，该部件包括由镍基高温合金制成的基底，基底包括在部件中的至少一个敞开的空腔，
-在空腔的至少一部分上沉积一种或多种第一元素的至少一个层，一种或多种第一元素选自铪、硅以及铬，
-对基底和层进行热处理，使得层的一种或多种第一元素扩散到基底中。
本发明通过以下特征来有利地完成，这些特征被单独地采用或以其技术上可能的组合中的任意一种组合的方式被采用：
-热处理在真空的腔室中或在包括一种或多种惰性气体的腔室中进行，优选地，惰性气体为选自氩气和氦气的至少一种气体，
-所述热处理步骤温度被设置在700℃至1300℃之间，优选地被设置在900℃至1250℃之间的腔室中进行了一小时至八小时的时间段。
本发明的另一个方面是用于冷却飞行器部件的方法，其中，该部件按照本发明，该方法包括在空腔中注入冷却流体的步骤。
附图说明
本发明的其它特征、目的以及优点将通过以下描述而显现，以下描述完全是说明性的且非限制性的，并且应该参照附图来阅读，在附图中：
[图1]-图1示意性地示出了包括冷却通道的飞行器部件(例如涡轮叶片或者分配器叶片)的截面，
[图2]-图2示意性地示出了根据本发明的一个实施例的用于制造部件的方法，
[图3]-图3示意性地示出了在制造根据本发明的一个实施例的部件期间的冷却通道的壁。
[图4]-图4示意性地示出了在制造根据本发明的一个实施例的部件期间的冷却通道的壁。
[图5]-图5示意性地示出了根据本发明的一个实施例的部件的冷却通道的壁。
[图6]-图6是在制造根据本发明的一个实施例的部件期间的冷却通道的壁的显微照片。
[图7]-图7是根据本发明的一个实施例的部件的冷却通道的壁的显微照片。
在该组附图中，相似的元件具有相同的附图标记。
具体实施方式
定义
术语“高温合金”是指在高温高压下具有非常好的抗氧化性、抗腐蚀性、抗蠕变性以及抗循环约束(特别是机械的或热的)性的合金。高温合金在制造航空用部件(例如涡轮叶片)方面具有特别的应用，因为高温合金包括能够在相对接近其熔融点的温度(通常是金属合金的熔融温度的0.7被至0.8倍)下工作的高抗性的金属合金的族。
高温合金可以具有包括第一相(被称为“γ相”)和第二相(被称为“γ’相”)的两相微结构，第一相形成基质，第二相形成在基质中硬化的析出相。这两个相的共存由短语“γ-γ’相”表示。
高温合金的“基体”是指基质的主要金属成分。在大部分情况下，高温合金包括铁基体、钴基体或镍基体，但有时也包括钛基体或铝基体。优选地，高温合金基体是镍基体。
“镍基高温合金”的优点是在抗氧化性、抗高温断裂性以及重量之间提供了良好的折中，这证明了在涡轮喷气发动机的最热的部分中使用镍基高温合金是合理的。
镍基高温合金包括：γ-Ni面心立方奥氏体类型的γ相(或基质)，该γ相固溶体中可能包含具有α取代的添加剂(Co、Cr、W、Mo)；以及γ’-Ni3X类型的γ’相(或析出相)，其中，X＝Al、Ti或者Ta。γ’相具有来源于面心立方结构的、与基质一致的(即具有与基质非常相似的原子网格)有序的L12结构。
由于γ’的良好有序的性质，γ’相具有非凡性能：机械抗性随着温度(高达约800℃)而增大。γ相和γ’相之间非常强的一致性使镍基高温合金具有非常高的热机械抗性，这本身取决于γ/γ’比和硬化析出相的尺寸。
优选地，高温合金富含铼和/或钌，也就是说，高温合金的铼和钌的平均质量分数大于或等于3％，优选地大于或等于4％，与不含铼的高温合金相比，这使得能够增加高温合金部件的抗蠕变性。
优选地，高温合金通常包含较少的铬，也就是说，在整个高温合金中的铬的平均质量分数小于5％，优选地小于3％。实际上，在高温合金的铼和/或钌的富集期间，铬的耗尽使得能够保持稳定的同素异形结构，特别地使得能够保持γ/γ’相。
术语“质量分数”是指元素或元素的组的质量与总质量的比。
“保护涂层”是指覆盖基底并且使得基底能够被化学地保护和/或被机械地保护的层。优选地，保护涂层防止基底的腐蚀和/或氧化。优选地，保护涂层可以是基底和热保护层之间的粘结层。
部件的“敞开的空腔”是指连接到部件外部的空腔。
“二级真空”是指环境被设置在介于10-7毫巴至10-3毫巴(不包括10-3毫巴)之间的压力下的真空。
“初级真空”是指环境被设置在介于10-3毫巴至1毫巴之间的压力下的真空。
本发明的详细描述
基底2
参照图1，飞行器的部件1包括由单晶高温合金制成的基底2。优选地，飞行器部件是涡轮部件。优选地，单晶高温合金是例如通过等轴铸造法或定向凝固法获得的镍基高温合金，也可以是例如通过等轴铸造法或定向凝固法获得的钴基高温合金。优选地，基底2主要具有γ-γ’相。基底2还可以包括铼和/或钌，铼和/或钌的平均质量分数大于或等于3％，优选地大于或等于4％，与不含铼和/或钌的高温合金部件相比，这使得能够增加高温合金部件的抗蠕变性。
优选地，基底2在整个基底中的铬的第一平均质量分数较低，即小于5％。因此，该基底与铬的第一平均质量分数大于5％的基底相比，在高温下表现出更优的抗蠕变的机械性能。表1通过在整个基底2中每种元素的平均质量分数来给出了基底2的组成的示例。
表1
Figure BDA0003627095430000051
Figure BDA0003627095430000061
参照图1，基底2在部件1中形成至少一个空腔12。优选地，空腔12是部件1的冷却通道13。冷却通道13可以具有冷却流体入口和冷却流体出口。因此，可以在部件的冷却通道中引入冷却流体(例如从低压压缩机喷射的气体)，以在其使用期间降低部件的温度。
用于制造部件1和保护空腔12的方法
参照图2，本发明的一个方面是用于制造飞行器部件的方法。这种方法包括提供部件的步骤201，该部件包括基底2(例如之前所描述的基底)。这种基底2已经经受了溶解-形成共晶体和淬火的步骤。
参照图3和图4，该方法包括步骤202：在空腔12的至少一部分上沉积选自铪、硅以及铬的第一元素的至少一个处理层14。参照图3，可以在空腔12的至少一部分上沉积多个层14，每个层14包括选自铪、硅以及铬的不同元素。
在步骤102期间沉积的层14的厚度l1可以介于10nm至10μm之间。当第一元素是铪时，优选地，被沉积的层14的厚度l1介于50nm至500nm之间。当第一元素是硅时，优选地，被沉积的层14的厚度l1介于100nm至500nm之间。当第一元素是铬时，优选地，被沉积的层14的厚度l1介于0.5微米至3微米之间。
在空腔12上沉积一个或多个层14可以通过气相化学沉积(CVD)(例如PECVD、LPCVD、UHVCVD、APCVD、ALCVD、UHVCVD)来进行。
参照图2、图5、图6以及图7，该方法包括对基底2和层14进行热处理的步骤203，以使层14的一种或多种第一元素扩散到基底2中。因此，层14的一种或多种第一元素在基底2中扩散，从而在基底2中形成表面层C1。表面层C1中的一种或多种第一元素的第二平均质量分数严格大于基底2中的第一元素的第一平均质量分数。因此，能够保护空腔12并且优选地保护一个或多个冷却通道13免受氧化和/或腐蚀，同时在基底2中保持足够低的铬、铪和/或硅的平均质量分数。
参照图7，在步骤203之后，基底2包括表面层C1，并且被涂层C2覆盖，该涂层由在热处理步骤203之前沉积的层14产生。涂层C2可以仅包括一种或多种第一元素。
然而，在热处理步骤203期间，基底2的一些元素可能引入到层14中。因此，涂层C2的一种或多种第一元素的质量分数大于50％，优选地大于90％。表面层C1的厚度l2大于50nm，即为一种或多种第一元素的扩散的长度特征。特别地，厚度l2可以大于100nm，优选地介于100nm至100μm之间。涂层C2具有介于50mn至100μm之间的厚度l3。
优选地，表面层C1具有第二质量分数的第一元素，第二质量分数的第一元素适于通过第一元素的氧化形成保护涂层。当第一元素为铪时，优选地，第二质量分数可以介于0.4％至4.5％之间。当第一元素为硅时，优选地，第二质量分数可以介于4％至10％之间。当第一元素为铬时，优选地，第二质量分数可以介于0.2％至5％之间。
在步骤202期间获得的基底2和一个或多个层14可以例如被布置在腔室中，以执行热处理步骤203。在热处理步骤203期间，腔室可以被放置在真空中，或者填充有一种或多种惰性气体，例如氩气和/或氦气。优选地，可以在腔室内部保持二级真空。优选地，可以在腔室内部设置初级真空，初级真空由选自氩、氦和氢的至少一种元素组成。因此，能够在热处理步骤203期间避免基底2的表面的氧化。优选地，热处理步骤203包括温度上升的子步骤，在该子步骤中，腔室中的温度被设置成以每分钟5℃至100℃的速度上升。优选地，热处理步骤进行一小时至八小时，在热处理步骤中腔室中的温度被设置在700℃至1300℃之间，优选地被设置在900℃至1250℃之间。在700℃以上，优选地在900℃以上，一种或多种第一元素扩散到基底2中。温度被设置在1300℃以下，优选地被设置在1250℃以下，以防止高温合金劣化。

Claims (14)

1.一种部件(1)，所述部件包括由镍基高温合金制成的基底(2)，所述基底(2)具有第一平均质量分数的一种或多种第一元素，所述一种或多种第一元素选自铪、硅以及铬，所述基底(2)包括在所述部件(1)中的至少一个敞开的空腔(12)，并且优选地包括冷却通道(13)，所述部件的特征在于，所述基底包括至少部分地形成所述空腔的表面层(C1)，所述表面层(C1)具有第二平均质量分数的所述一种或多种第一元素，所述第二平均质量分数严格大于所述第一平均质量分数。
2.根据权利要求1所述的部件，所述部件进一步包括覆盖所述表面层(C1)的涂层(C2)，所述涂层(C2)具有质量分数大于50％，优选地大于90％的所述一种或多种第一元素。
3.根据权利要求1或2所述的部件(1)，其中，保护涂层的厚度l2至少大于50nm。
4.根据权利要求1至3中任一项所述的部件(1)，其中，所述第一元素是铪，并且其中，所述第二质量分数介于0.4％至4.5％之间。
5.根据权利要求1至4中任一项所述的部件(1)，其中，所述第一元素是硅，并且其中，所述第二质量分数介于4％至10％之间。
6.根据权利要求1至5中任一项所述的部件(1)，其中，所述第一元素是铬，并且其中，所述第二质量分数介于0.2％至5％之间。
7.根据权利要求1至6中任一项所述的部件(1)，其中，所述基底(2)包括铼和/或钌，所述基底的铼和/或钌的平均质量分数大于或等于3％，优选地大于或等于4％。
8.根据权利要求1至7中任一项所述的部件(1)，其中，所述部件是涡轮部件。
9.一种飞行器涡轮，所述飞行器涡轮包括根据前述权利要求中任一项所述的部件。
10.一种飞行器，所述飞行器包括根据权利要求1至5中任一项所述的部件。
11.用于制造根据权利要求1至7中任一项所述的飞行器部件(1)的方法，所述方法至少包括以下步骤：
-提供部件，所述部件包括由镍基高温合金制成的基底(2)，所述基底(2)包括在所述部件(1)中的至少一个敞开的空腔，
-在所述空腔的至少一部分上沉积一种或多种第一元素的至少一个层(14)，所述一种或多种第一元素选自铪、硅以及铬，
-对所述基底(2)和所述层(14)进行热处理，使得所述层(14)的一种或多种第一元素扩散到所述基底中。
12.根据权利要求11所述的方法，其中，所述热处理在真空的腔室中或在包括一种或多种惰性气体的腔室中进行，优选地，所述惰性气体为选自氩气和氦气的至少一种气体。
13.根据权利要求11至12中任一项所述的方法，其中，所述热处理步骤在温度被设置在700℃至1300℃之间，优选地被设置在900℃至1250℃之间的腔室中进行了一小时至八小时的时间段。
14.用于冷却飞行器部件(1)的方法，其中，所述部件(1)符合权利要求1至8中的任一项，所述方法包括在所述空腔中注入冷却流体的步骤。
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