CN116904905A - 在表面上形成涂布系统的方法和修复现有涂布系统的方法 - Google Patents
在表面上形成涂布系统的方法和修复现有涂布系统的方法 Download PDFInfo
- Publication number
- CN116904905A CN116904905A CN202310885007.5A CN202310885007A CN116904905A CN 116904905 A CN116904905 A CN 116904905A CN 202310885007 A CN202310885007 A CN 202310885007A CN 116904905 A CN116904905 A CN 116904905A
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- China
- Prior art keywords
- nicocraly
- layer
- coating
- superalloy component
- group metal
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
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- 238000000576 coating method Methods 0.000 title claims abstract description 170
- 239000011248 coating agent Substances 0.000 title claims abstract description 156
- 238000000034 method Methods 0.000 title claims abstract description 91
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical group [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 claims abstract description 113
- 229910052751 metal Inorganic materials 0.000 claims abstract description 65
- 239000002184 metal Substances 0.000 claims abstract description 65
- 229910000601 superalloy Inorganic materials 0.000 claims abstract description 56
- 229910000951 Aluminide Inorganic materials 0.000 claims abstract description 50
- 239000011651 chromium Substances 0.000 claims abstract description 22
- 229910052804 chromium Inorganic materials 0.000 claims abstract description 19
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims abstract description 13
- 239000011148 porous material Substances 0.000 claims abstract description 7
- 238000012545 processing Methods 0.000 claims abstract description 6
- 229910052782 aluminium Inorganic materials 0.000 claims description 22
- 230000008569 process Effects 0.000 claims description 22
- 238000010438 heat treatment Methods 0.000 claims description 21
- 239000012720 thermal barrier coating Substances 0.000 claims description 18
- 230000008021 deposition Effects 0.000 claims description 15
- 238000011282 treatment Methods 0.000 claims description 15
- 229910052735 hafnium Inorganic materials 0.000 claims description 7
- 229910052727 yttrium Inorganic materials 0.000 claims description 7
- 239000010410 layer Substances 0.000 description 113
- PXHVJJICTQNCMI-UHFFFAOYSA-N nickel Substances [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 35
- 239000007789 gas Substances 0.000 description 26
- 229910052697 platinum Inorganic materials 0.000 description 25
- 238000000151 deposition Methods 0.000 description 20
- 239000000243 solution Substances 0.000 description 17
- 239000000203 mixture Substances 0.000 description 16
- 238000009792 diffusion process Methods 0.000 description 15
- 239000010408 film Substances 0.000 description 14
- 238000005260 corrosion Methods 0.000 description 13
- 230000007797 corrosion Effects 0.000 description 13
- 229910052759 nickel Inorganic materials 0.000 description 13
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 12
- 238000001816 cooling Methods 0.000 description 12
- 239000000463 material Substances 0.000 description 10
- 229910017052 cobalt Inorganic materials 0.000 description 9
- 239000010941 cobalt Substances 0.000 description 9
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 9
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 7
- 230000007613 environmental effect Effects 0.000 description 7
- 230000003647 oxidation Effects 0.000 description 7
- 238000007254 oxidation reaction Methods 0.000 description 7
- 238000005328 electron beam physical vapour deposition Methods 0.000 description 6
- 239000012071 phase Substances 0.000 description 6
- 239000013535 sea water Substances 0.000 description 6
- 239000007921 spray Substances 0.000 description 6
- 239000000126 substance Substances 0.000 description 6
- -1 but not limited to Inorganic materials 0.000 description 5
- 230000003746 surface roughness Effects 0.000 description 5
- 239000010409 thin film Substances 0.000 description 5
- 239000002253 acid Substances 0.000 description 4
- 230000008901 benefit Effects 0.000 description 4
- 238000009713 electroplating Methods 0.000 description 4
- 150000002500 ions Chemical class 0.000 description 4
- 238000012986 modification Methods 0.000 description 4
- 230000004048 modification Effects 0.000 description 4
- 230000008439 repair process Effects 0.000 description 4
- 238000005266 casting Methods 0.000 description 3
- 239000000567 combustion gas Substances 0.000 description 3
- 238000010276 construction Methods 0.000 description 3
- 238000010286 high velocity air fuel Methods 0.000 description 3
- 229910052763 palladium Inorganic materials 0.000 description 3
- 238000007747 plating Methods 0.000 description 3
- 239000011253 protective coating Substances 0.000 description 3
- 229910052703 rhodium Inorganic materials 0.000 description 3
- 239000010948 rhodium Substances 0.000 description 3
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 description 3
- 239000000758 substrate Substances 0.000 description 3
- 238000010290 vacuum plasma spraying Methods 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 229910000629 Rh alloy Inorganic materials 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- 238000005269 aluminizing Methods 0.000 description 2
- 238000005219 brazing Methods 0.000 description 2
- 239000003518 caustics Substances 0.000 description 2
- 238000005229 chemical vapour deposition Methods 0.000 description 2
- 238000005137 deposition process Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 238000004070 electrodeposition Methods 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 239000000446 fuel Substances 0.000 description 2
- 238000007749 high velocity oxygen fuel spraying Methods 0.000 description 2
- 238000005240 physical vapour deposition Methods 0.000 description 2
- 238000007750 plasma spraying Methods 0.000 description 2
- 238000000623 plasma-assisted chemical vapour deposition Methods 0.000 description 2
- 239000011241 protective layer Substances 0.000 description 2
- 238000009718 spray deposition Methods 0.000 description 2
- 238000007740 vapor deposition Methods 0.000 description 2
- 239000012808 vapor phase Substances 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- 229910002515 CoAl Inorganic materials 0.000 description 1
- KRHYYFGTRYWZRS-UHFFFAOYSA-N Fluorane Chemical compound F KRHYYFGTRYWZRS-UHFFFAOYSA-N 0.000 description 1
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- 229910000943 NiAl Inorganic materials 0.000 description 1
- 229910001252 Pd alloy Inorganic materials 0.000 description 1
- NPXOKRUENSOPAO-UHFFFAOYSA-N Raney nickel Chemical compound [Al].[Ni] NPXOKRUENSOPAO-UHFFFAOYSA-N 0.000 description 1
- KJTLSVCANCCWHF-UHFFFAOYSA-N Ruthenium Chemical compound [Ru] KJTLSVCANCCWHF-UHFFFAOYSA-N 0.000 description 1
- PMZURENOXWZQFD-UHFFFAOYSA-L Sodium Sulfate Chemical compound [Na+].[Na+].[O-]S([O-])(=O)=O PMZURENOXWZQFD-UHFFFAOYSA-L 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 239000003513 alkali Substances 0.000 description 1
- 238000005275 alloying Methods 0.000 description 1
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical group [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 238000005422 blasting Methods 0.000 description 1
- 230000000903 blocking effect Effects 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 229910052729 chemical element Inorganic materials 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 239000003245 coal Substances 0.000 description 1
- 239000008199 coating composition Substances 0.000 description 1
- GUBSQCSIIDQXLB-UHFFFAOYSA-N cobalt platinum Chemical compound [Co].[Pt].[Pt].[Pt] GUBSQCSIIDQXLB-UHFFFAOYSA-N 0.000 description 1
- 238000010288 cold spraying Methods 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 230000008878 coupling Effects 0.000 description 1
- 238000010168 coupling process Methods 0.000 description 1
- 238000005859 coupling reaction Methods 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000004090 dissolution Methods 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 150000004820 halides Chemical class 0.000 description 1
- 239000001307 helium Substances 0.000 description 1
- 229910052734 helium Inorganic materials 0.000 description 1
- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium atom Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 229910000041 hydrogen chloride Inorganic materials 0.000 description 1
- IXCSERBJSXMMFS-UHFFFAOYSA-N hydrogen chloride Substances Cl.Cl IXCSERBJSXMMFS-UHFFFAOYSA-N 0.000 description 1
- 229910000040 hydrogen fluoride Inorganic materials 0.000 description 1
- 229910000039 hydrogen halide Inorganic materials 0.000 description 1
- 239000012433 hydrogen halide Substances 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 229910052741 iridium Inorganic materials 0.000 description 1
- GKOZUEZYRPOHIO-UHFFFAOYSA-N iridium atom Chemical compound [Ir] GKOZUEZYRPOHIO-UHFFFAOYSA-N 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 238000000608 laser ablation Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 230000000873 masking effect Effects 0.000 description 1
- 229910001092 metal group alloy Inorganic materials 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 229910052762 osmium Inorganic materials 0.000 description 1
- SYQBFIAQOQZEGI-UHFFFAOYSA-N osmium atom Chemical compound [Os] SYQBFIAQOQZEGI-UHFFFAOYSA-N 0.000 description 1
- 238000013021 overheating Methods 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 230000000737 periodic effect Effects 0.000 description 1
- PXXKQOPKNFECSZ-UHFFFAOYSA-N platinum rhodium Chemical compound [Rh].[Pt] PXXKQOPKNFECSZ-UHFFFAOYSA-N 0.000 description 1
- 238000004321 preservation Methods 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 229910052707 ruthenium Inorganic materials 0.000 description 1
- 229910052938 sodium sulfate Inorganic materials 0.000 description 1
- 235000011152 sodium sulphate Nutrition 0.000 description 1
- 238000004544 sputter deposition Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- 229910001233 yttria-stabilized zirconia Inorganic materials 0.000 description 1
Classifications
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C30/00—Alloys containing less than 50% by weight of each constituent
-
- 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
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
- C23C4/073—Metallic material containing MCrAl or MCrAlY alloys, where M is nickel, cobalt or iron, with or without non-metal elements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P6/00—Restoring or reconditioning objects
- B23P6/04—Repairing fractures or cracked metal parts or products, e.g. castings
- B23P6/045—Repairing fractures or cracked metal parts or products, e.g. castings of turbine components, e.g. moving or stationary blades, rotors, etc.
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C19/00—Alloys based on nickel or cobalt
- C22C19/03—Alloys based on nickel or cobalt based on nickel
- C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
- C22C19/058—Alloys based on nickel or cobalt based on nickel with chromium without Mo and W
-
- 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
- C23C10/00—Solid state diffusion of only metal elements or silicon into metallic material surfaces
- C23C10/04—Diffusion into selected surface areas, e.g. using masks
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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
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/02—Pretreatment of the material to be coated
-
- 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
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
- C23C14/14—Metallic material, boron or silicon
- C23C14/16—Metallic material, boron or silicon on metallic substrates or on substrates of boron or silicon
-
- 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
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
- C23C14/221—Ion beam deposition
-
- 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
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/58—After-treatment
- C23C14/5806—Thermal treatment
-
- 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
- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/06—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of metallic material
-
- 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
- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/44—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
- C23C16/50—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating using electric discharges
-
- 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
- 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
- C23C28/02—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 only coatings only including layers of metallic material
- C23C28/021—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 only coatings only including layers of metallic material including at least one metal alloy layer
- C23C28/022—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 only coatings only including layers of metallic material including at least one metal alloy layer with at least one MCrAlX layer
-
- 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
- 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
- C23C28/02—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 only coatings only including layers of metallic material
- C23C28/028—Including graded layers in composition or in physical properties, e.g. density, porosity, grain size
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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
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/134—Plasma spraying
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Abstract
本申请提供一种在其中限定有薄膜孔的超合金部件的表面上形成涂布系统的方法。所述方法包括:在所述薄膜孔保持开放时,在所述超合金部件的所述表面上涂覆NiCoCrAlY以形成NiCoCrAlY层(例如,其中所述NiCoCrAlY层具有高于所述超合金部件的铬含量),接着将所述NiCoCrAlY层加热到约900℃到约1200℃的处理温度,接着在所述NiCoCrAlY层上形成铂族金属层,且接着在铂族金属层上方形成铝化物涂层。所述NiCoCrAlY可以被涂覆到所述超合金部件的所述表面上的现有涂布系统上,其中所述现有涂布系统是大体上不含Ni的Co基涂布系统。
Description
技术领域
本申请大体上涉及部件上的保护涂层,且更具体地涉及具有翼型的燃气涡轮部件上的NiCoCrAlY和铂族金属铝化物涂层。
背景技术
在燃气涡轮发动机中,空气被抽吸到发动机的前部、由轴安装式压缩机压缩,并与燃料混合。点燃混合物,且所得热燃烧气体穿过安装在同一轴上的涡轮。气流通过接触涡轮叶片的翼型部来转动涡轮,这会转动轴并向压缩机提供动力。涡轮气体越热,发动机的运作越高效。因此,有必要升高涡轮运作温度。然而,涡轮气体的最大温度通常受限于用于制造涡轮的涡轮轮叶和涡轮叶片的材料。
保护层被涂覆到充当基板的涡轮叶片的翼型部或涡轮叶片部件。铝化物和铂铝化物层在目前已知的扩散保护层当中。保护层保护基板免受来自高度腐蚀性热燃烧气体的环境侵害。此保护涂层大约为38μm到76μm(即,大约0.0015到0.0030英寸)厚,且提供针对海水热腐蚀的保护等级。扩散涂层的大约一半厚度是原始叶片厚度的部分,且扩散铂铝化物涂层能在涂布工艺之后有效地维持冷却孔开放。即使在使用这些保护性技术的情况下,在某些运作服务条件下,尤其在暴露于相关于运作环境的盐度的恶劣条件的船用涡轮发动机内仍存在要克服的问题。
广泛用于船用燃气涡轮应用中的更有效替代涂层大约为254μm(即,约0.010英寸),其具有厚度范围介于约177.8μm到约330μm(即,约0.007英寸到约0.013英寸)的“上覆”MCrAlX涂层,其中M是Co和/或Ni,X是例如Y、Hf的反应元素,且涂层具有20%到28%的铬浓度。上覆涂层通常由等离子体喷射过程沉积,且涂层的组成可以被调适成减轻海水热腐蚀。
然而,涡轮气体的最大温度通常受限于用于制造涡轮的涡轮轮叶和涡轮叶片的材料。先进涡轮叶片通过来自压缩机排放口的冷却空气来进行冷却,以减少叶片温度并实现更高气体温度以用于增大效率。因此,重要的是保持冷却孔开放以防止叶片过热。
对于海水环境中的燃气涡轮运作,涂层必需能抵抗来自环境腐蚀剂的腐蚀性攻击。含有硫酸钠的沉积物已被辨识为对船用翼型件尤其具腐蚀性。
已成功地利用具有20%到25%范围内的铬含量、9%到11%范围内的铝的钴类CoCrAlHf涂层来抵抗海水腐蚀。所述涂层较厚(相对于先进涡轮叶片的冷却孔的大小),通常处于177.8μm到约356μm(即,约0.07英寸到约0.014英寸)的范围内,且由热喷射过程沉积。此类涂层在钻取孔之前沉积在新叶片上,这是因为涂层在其涂覆期间可以部分或完全地封闭孔。
当现场返回叶片准备进行修复时,用适当酸剥除掉任何和所有剩余CoCrAlHf涂层。一些制造商需要用强酸或碱混合物进行化学清洗,以在剥除之前去除现场服务残渣和/或热腐蚀产物。其它制造商允许进行砂粒喷砂处理以实现相同目的。叶片中的复杂冷却通路会在服务时积聚灰尘或其它残渣,可能需要在高压釜中以高压用热苛性碱去除这些灰尘或残渣。
通常通过用各种简单或复杂的酸混合物选择性溶解涂层相来实现对涂层的完全去除。大部分程序取决于β(NiAl或CoAl)相的选择性攻击。如果涂层耗尽了β相,那么选择性涂层溶解可能难以进行或不可能进行,且接着必须通过物理方法(例如,砂带磨削)来去除残余涂层。
通常通过保持冷却孔开放的扩散铝化物或铂铝化物过程(上文所描述)来实现对具有冷却孔的修复叶片的再涂布。铂铝化物是扩散涂层,铂铝化物涂层的组成和性质部分取决于底层合金或涂层的化学性质。有必要去除所有原始CoCrAlHf涂层,这是因为任何底层CoCrAlHf涂层的铂铝化物涂层将带来不合需要的脆性钴铂铝化物。由于扩散铂铝化物涂层相对薄且具有镍丰富但铬和钴不足的组成,因此铂铝化物涂层的耐海水热腐蚀性差于较厚CoCrAlHf涂层所提供的耐腐蚀性。
因此,大体上需要修复此类涂层的改进方法,尤其对于在海水环境中使用的燃气涡轮部件。
发明内容
本申请的目标和优势将部分在以下描述中阐述,或可以从所述描述显而易见,或可以通过本申请的实践而得知。
大体上提供一种在其中界定有薄膜孔的超合金部件的表面上形成涂布系统的方法。在一个实施例中,所述方法包括:在所述薄膜孔保持开放时,在所述超合金部件的所述表面上涂覆NiCoCrAlY以形成NiCoCrAlY层(例如,其中所述NiCoCrAlY层具有高于所述超合金部件的铬含量),接着将所述NiCoCrAlY层加热到约900℃到约1200℃的处理温度,接着在所述NiCoCrAlY层上形成铂族金属层,且接着在铂族金属层上方形成铝化物涂层。
在一个特定实施例中,所述NiCoCrAlY被涂覆到所述超合金部件的所述表面上的现有涂布系统上,其中所述现有涂布系统是大体上不含Ni的Co基(Co-based)涂布系统。
技术方案1.一种在超合金部件的表面上形成涂布系统的方法,于所述超合金部件中限定有薄膜孔,所述方法包括:
在所述薄膜孔保持开放时,在所述超合金部件的表面上涂覆NiCoCrAlY以形成NiCoCrAlY层,其中所述NiCoCrAlY层具有高于所述超合金部件的铬含量;
将所述NiCoCrAlY层加热到约900℃到约1200℃的处理温度;
在所述NiCoCrAlY层上形成铂族金属层;以及
在所述铂族金属层上方形成铝化物涂层。
技术方案2.根据技术方案1所述的方法,所述NiCoCrAlY层被加热到约1000℃到约1100℃的处理温度。
技术方案3.根据技术方案1所述的方法,所述NiCoCrAlY层是在约30分钟到约5小时内被加热到所述处理温度。
技术方案4.根据技术方案1所述的方法,所述NiCoCrAlY层的至多约30%的厚度扩散到所述超合金部件的所述表面中。
技术方案5.根据技术方案4所述的方法,所述NiCoCrAlY层的约5%到约25%的厚度扩散到所述超合金部件的所述表面中。
技术方案6.根据技术方案4所述的方法,在热处理之后,所述NiCoCrAlY层具有从所述表面延伸约10μm到约100μm的厚度,同时限定在所述超合金部件的所述表面内的所述薄膜孔保持开放。
技术方案7.根据技术方案4所述的方法,在热处理之后,所述NiCoCrAlY层具有从所述表面延伸约25μm到约50μm的厚度,同时限定在所述超合金部件的所述表面内的所述薄膜孔保持开放。
技术方案8.根据技术方案1所述的方法,在形成所述铂族金属层之前,所述NiCoCrAlY层按重量百分比计包括约16%到约20%的Cr,约9%到约11%的Al,约19%到约24%的Co,约0.05%到约0.2%的Y,至多0.5%的Hf,至多1%的Si和其余部分Ni。
技术方案9.根据技术方案1所述的方法,在形成所述铂族金属层之前,所述NiCoCrAlY层按重量百分比计包括约17%到约19%的Cr,约9.5%到约10.5%的Al,约21%到约23%的Co,约0.07%到约0.15%的Y,约0.05%到约0.3%的Hf,约0.5%到约0.9%的Si,和其余部分Ni。
技术方案10.根据技术方案1所述的方法,进一步包括:
在形成所述铂族金属层之后,将所述铂族金属层加热到约900℃到约1200℃的第二热处理温度。
技术方案11.根据技术方案1所述的方法,进一步包括:
在形成所述铂族金属层之后,将所述铂族金属层加热到约1000℃到约1100℃的第二热处理温度。
技术方案12.根据技术方案1所述的方法,所述超合金部件的所述表面中限定有多个薄膜孔,且所述薄膜孔在将NiCoCrAlY涂覆到所述超合金部件的所述表面上以形成NiCoCrAlY层之后保持开放。
技术方案13.根据技术方案1所述的方法,将所述铝化物涂层沉积到约25μm到约100μm的厚度。
技术方案14.根据技术方案1所述的方法,进一步包括:
在形成所述铝化物涂层之后,在粘结涂层上方形成热屏障涂层。
技术方案15.根据技术方案1所述的方法,所述NiCoCrAlY层是经由离子等离子体沉积形成在所述超合金部件的所述表面上。
技术方案16.根据技术方案1所述的方法,进一步包括:
在将所述NiCoCrAlY涂覆到所述表面上之前,去除所述超合金部件的所述表面上的现有涂布系统的至少一部分。
技术方案17.根据技术方案1所述的方法,所述NiCoCrAlY被涂覆到所述超合金部件的所述表面上的现有涂布系统上。
技术方案18.根据技术方案17所述的方法,所述现有涂布系统是大体上不含Ni的Co基涂布系统。
技术方案19.一种修复超合金部件的表面上的现有涂布系统的方法,其中现有涂层包括CoCrAlHf,所述方法包括:
从所述超合金部件的表面去除所述现有涂层的至少一部分,其中所述超合金部件的表面中限定有薄膜孔;
在所述薄膜孔保持开放时在所述超合金部件的表面上形成NiCoCrAlY层,其中所述NiCoCrAlY层具有高于所述超合金部件的铬含量;
在所述NiCoCrAlY层上形成铂族金属层;
将所述铂族金属层加热到约900℃到约1200℃的处理温度;以及
在铂族金属层上方形成铝化物涂层。
技术方案20.根据技术方案19所述的方法,所述NiCoCrAlY被涂覆到所述超合金部件的表面上的现有涂布系统上,且所述现有涂布系统是大体上不含Ni的Co基涂布系统。
下文更详细地论述本申请的其它特征和方面。
附图说明
可参考以下结合附图做出的描述最佳地理解本申请,在附图中:
图1A是例如燃气涡轮发动机的涡轮叶片的部件的透视图;
图1B是例如燃气涡轮发动机的喷嘴段的另一部件的透视图;
图2是例如图1A或图1B的翼型件的部件的表面上的示例性NiCoCrAlY层在热处理之前的横截面图;
图3是包括热处理之后的NiCoCrAlY层且在其上形成铂铝化物涂层的示例性涂布系统的横截面图;
图4是其上具有TBC涂层的图3的示例性涂布系统的横截面图;
图5是在部件的表面上形成涂层的示例性方法的框图;且
图6是在部件的表面上修复涂层的示例性方法的框图。
在本说明书和附图中参考标号的重复使用意图表示本申请的相同或相似特征或元件。
具体实施方式
现将参考本申请的实施例,下文阐述本申请的实施例的一个或多个实例。每一实例是为了解释本申请而非限制本申请而提供。实际上,所属领域的技术人员将清楚,在不脱离本申请的范围或精神的情况下,可在本申请中进行各种修改和变化。举例来说,说明或描述为一个实施例的特征可与另一实施例一起使用以产生又一实施例。因此,希望本申请涵盖此类属于所附权利要求书和其等效物的范围内的修改和变化。所属领域的一般技术人员应理解,本申请论述仅为示例性实施例的描述,且不打算为限制本申请的更广方面,所述更广方面体现在示例性构造中。
在本申请中使用例如通常在元素周期表上发现的常见化学名称缩写来论述化学元素。举例来说,氢由其常见化学名称缩写H表示;氦由其常见化学名称缩写He表示;等等。
涂布系统连同其形成方法大体上供用于涡轮发动机的热气路径部件(例如,翼型件)。具体来说,涂布系统可用于尤其暴露于腐蚀性运作环境的船用涡轮发动机的超合金部件。所述方法和涂布系统尤其可用于已使用且在使用期间因碰撞事件或腐蚀而受损的部件的修复期间。本说明书所描述的方法的实施例通过在保持冷却孔开放时并入铬和钴而增强现有涂层的耐腐蚀性。在一个实施例中,本说明书所描述的方法通过添加NiCoCrAlY材料来允许保留所使用翼型件的表面上(或新翼型件的表面上)的现有船用Co基涂布系统(例如,大体上不含Ni的CoCrAlHf型涂层)。上面具有铂铝化物涂层的所得涂层可能更厚、较不脆性,且可能具有更高铝量,从而导致相比钴类材料上的铂铝化物更具抗氧化性,这是由于钴类材料中的铝和铂的相对扩散较低。
涂布系统具有多层构造化学性质,其包括至少一NiCoCrAlY层,所述层可以具有高于底层超合金的铬(Cr)含量。在一个特定实施例中,涂布系统是通过扩散涂布过程由NiCoCrAlY层和铂族金属铝化物涂层形成,从而带来包括NiCoCrAlY、Pt和Al的涂布系统。NiCoCrAlY层在其沉积组成和处理之后的组成中都具有高于超合金部件的铬含量。
涂布系统可以减少燃气涡轮部件对例如低循环疲劳失效的性能下降的易感性,同时能保持与涂覆到部件的保护涂层相关联的益处。本申请方法可以实现为正常生产操作的部分,而无需进行重大修改。另外,在特定实施例中,可以避免在部件的表面与涂布系统之间和/或涂布系统的构造内(例如,NiCoCrAlY层与铂族金属铝化物涂层之间)使用任何额外粘结涂层或其它层。也就是说,在此实施例中,NiCoCrAlY层直接在部件的表面上,和/或铂族金属铝化物涂层直接在NiCoCrAlY层上以形成涂布系统。当存在热屏障涂层时,涂布系统在NiCoCrAlY层(例如,涂布系统的铂族金属铝化物涂层)与热屏障涂层之间不含粘结涂层(例如,热屏障涂层直接在涂布系统的铂族金属铝化物涂层上)。
现参考附图,图1A示出了燃气涡轮叶片的燃气涡轮发动机的示例性部件5。涡轮叶片5包括翼型件6、侧向延伸平台7、呈楔形榫头形式以将燃气涡轮叶片5联接到涡轮盘(未示出)的联接件8。在一些部件中,数个冷却通道延伸穿过翼型件6的内部,从而在翼型件6的表面中的开口15中终止。在特定实施例中,开口15可以是薄膜孔。
例如图1A中示出的在高温和高压下运作且承载负载的高压燃气涡轮叶片对机械性质具有要求。为满足这些要求,先进的高压叶片由镍基(nickel-based)超合金制成,所述镍基超合金的耐热腐蚀性并不理想。叶片尖端并不承载相同负载,且并不具有相同的机械性质要求。在修复期间且在新制造叶片中,船用燃气涡轮叶片尖端由例如HS188的耐腐蚀钴类材料制成,所述材料含有高铬浓度。虽然此Co基尖端材料上的单独铂铝化物涂层会带来脆性涂层,但目前提供的涂布系统(包括NiCoCrAlY、Pt和Al)能为尖端涂层提供抗氧化性、耐腐蚀性和机械性质的优良组合。
图1B表示为数个喷嘴段中的一个的喷嘴段10,当所述喷嘴段连接在一起时,形成燃气涡轮发动机的环状喷嘴总成。段10由多个轮叶12组成,每一轮叶限定翼型件且延伸于外平台(带)14与内平台16之间。轮叶12以及平台14和16可以单独地形成,且接着例如通过将每一轮叶12的末端钎焊到平台14和16中限定的开口内而进行组装。替代地,整个段10可以形成为一体式铸件。轮叶12通常具有前边缘18、后边缘、压力侧(即,凹面侧)和抽吸侧(即,凸面侧)。前边缘18有时被描述为由翼型件12的最前点(前缘)限定。
当喷嘴段10与其它喷嘴段组装在一起以形成喷嘴总成时,段的相应内、外平台形成连续内、外带,轮叶12在所述带之间周向地间隔且径向地延伸。由于通常利用的冷却方案的复杂度,具有个别喷嘴段的喷嘴总成的构造通常是有优势的。图1B示出的喷嘴段10被称为双联体(doublet),这是因为两个轮叶12与每一段10相关联。喷嘴段可以装备有多于两个轮叶,例如三个轮叶(被称为三联体(triple))、四个轮叶、六个轮叶或具有单个轮叶以形成被称为单联体(singlet)的结构。如所属领域中已知,在单联体与双联体铸件之间进行设计选择要考虑与其不同构造和处理相关联的优势。单联体喷嘴构造的重要优势在于围绕轮叶12的极好涂层厚度分布能力,这除了能促进氧化和耐腐蚀性之外,还能促进控制喷嘴之间的喉部面积和不同轮叶级之间的一致性。另一方面,双联体铸件避免了必需进行高温铜焊操作,但不能很好地控制涂层厚度。
在一个实施例中,图1A的涡轮叶片5的翼型件6和图1B的喷嘴段10的轮叶12位于发动机的涡轮区段中,且经受来自发动机燃烧室的热燃烧气体。除了强制空气冷却技术(例如,经由薄膜孔15)之外,通过其相应表面上的涂布系统22来保护这些部件的表面。
图1A的涡轮叶片5的翼型件6和图1B的喷嘴段10的轮叶12可以由如下材料形成,所述材料可以形成为所要形状,且耐受在燃气涡轮的将安装所述段的区域的预期操作温度下的必要操作负载。此类材料的实例包括金属合金,包括但不限于钛基、铝基、钴基、镍基和钢基合金。在一个特定实施例中,图1A的翼型件6和/或图1B的轮叶12由超合金金属材料形成,例如镍基超合金、钴基超合金或铁基超合金。在典型实施例中,超合金组分具有2相结构:细γ-(M)(面心立方)和β-(M)Al(体心立方)。β-(M)Al相是铝(Al)储集器。靠近表面的铝可以在服务期间通过扩散到TBC界面而耗尽,所述TBC界面在扩散涂布基板的表面上形成热生长氧化物α-Al2O3。
尽管上文以及图1A和1B中相对于涡轮叶片5和喷嘴段10进行描述,但涂布系统可以与燃气涡轮发动机的任何部件一起使用。
参考图2,在热处理之前,NiCoCrAlY层20示出沉积在超合金部件5(例如,翼型件12,如图1A和1B中所示出)的表面13上。如所示出,部件5限定穿过其中的薄膜孔15。如所示出,NiCoCrAlY层20形成为并不封闭薄膜孔15的厚度。在某些实施例中,NiCoCrAlY层20可以延伸到部件5内限定薄膜孔15的内表面42中。举例来说,可以在并不制造薄膜孔15的情况下经由离子等离子体沉积(ionplasmadeposition)来形成NiCoCrAlY层20。然而,任何合适的涂覆方法可用以形成NiCoCrAlY层20,在需要时可以在具有或不具有遮蔽技术的情况下利用所述方法。非限制性实例包括等离子体沉积(例如,离子等离子体沉积、真空等离子体喷射(vacuumplasmaspraying,VPS)、低压等离子体喷射(lowpressure plasmaspray,LPPS)和等离子体增强化学气相沉积(plasma-enhanced chemical-vapordeposition,PECVD))、高速氧气燃料(highvelocity oxygenfuel,HVOF)技术、高速空气燃料(high-velocityair-fuel,HVAF)技术、物理气相沉积(physicalvapordeposition,PVD)、电子束物理气相沉积(electronbeamphysicalvapordeposition,EBPVD)、化学气相沉积(chemicalvapordeposition,CVD)、空气等离子体喷射(air plasmaspray,APS)、冷喷射和激光烧蚀。在一个实施例中,MCrAlY层20是通过热喷射技术(例如,VPS、LPPS、HVOF、HVAF、APS和/或冷喷射)涂覆。
通常,NiCoCrAlY层具有以镍(Ni)计(按重量计)的组成,这能提供用于后续PtAl沉积的良好表面。钴(Co)存在于NiCoCrAlY层中以与来自先前涂层的在表面上剩余的Co相互作用并粘结,所述剩余Co可能仍存在于所述表面上或可能已扩散到表面中。在一个特定实施例中,NiCoCrAlY层具有如下沉积组成(即,在热处理之前且在上面形成额外层之前),按重量百分比计包括约16%到约20%的Cr(例如,约17%到约19%的Cr)、约9%到约11%的Al(例如,约9.5%到约10.5%的Al)、约19%到约24%的Co(例如,约21%到约23%的Co)、约0.05%到约0.2%的Y(例如,约0.07%到约0.15%的Y)、至多约0.5%的Hf(例如,约0.05%到约0.3%的Hf,例如约0.05%到约0.2%的Hf)、至多约1%的Si(例如,约0.5%到约0.9%的Si,例如约0.6%到约0.8%的Si)和其余部分Ni。
在沉积之后,加热NiCoCrAlY层20,以将NiCoCrAlY层20粘结到部件5的表面13上。在一个实施例中,NiCoCrAlY层20的一部分扩散到部件5中以形成扩散部分44。在一个实施例中,将NiCoCrAlY层20加热到约900℃到约1200℃(例如,约1000℃到约1100℃)的处理温度。可以在足以将NiCoCrAlY层20粘结到表面13上的时间内将NiCoCrAlY层20加热到处理温度,例如在约30分钟到约5小时内。
如前所述,NiCoCrAlY层20由于热处理可能扩散到部件5中,以形成扩散部分44。在一个实施例中,NiCoCrAlY层20的约30%或更小的沉积厚度扩散到部件5的表面13中,例如约5%到约25%的沉积厚度可以扩散到部件5中。在热处理之后,NiCoCrAlY层20具有从表面13延伸的厚度,即约10μm到约100μm(例如,约25μm到约50μm)。通过使NiCoCrAlY层20相对薄(即,小于100μm),甚至可以在不使用遮罩或其它沉积阻断方法时使限定在表面内的任何薄膜孔保持开放。
可以用于沉积NiCoCrAlY层而不会封闭冷却孔且带来平滑涂层(例如,具有约100μm或更小的表面粗糙度)的沉积过程的实例包括离子等离子体沉积过程、复合电镀过程、冷喷射过程、高速空气等离子体喷射过程。
在热处理之后,铂族金属层30和铝化物涂层34可以形成到NiCoCrAlY层20上,如图3中所示出。首先,将铂族金属层30沉积在NiCoCrAlY层20上。铂族金属层30大体上包括铂、铑、钯、钌、锇、铱或其混合物。这些元素具有类似的物理和化学性质,且往往会一起出现于相同矿物质沉积物中。在一个实施例中,钯族铂族金属(即,铂、铑、钯或其混合物)包括在铂族金属层30中。在一个特定实施例中,铂族金属层30大体上包括铂,但也可以包括其它元素(例如,钯和/或铑)。举例来说,铂族金属层30可以包括铂钯合金、铂铑合金或铂钯铑合金。在一个实施例中,铂族金属层30按重量计包括至少50%的铂(例如,按重量计约75%到100%)。
在大部分实施例中,铂族金属层30的合适厚度为约1μm到约10μm(例如,约3μm到约7μm)。在所示出的实施例中,由于铂族金属层的此相对薄本质,铂族金属层30直接形成在NiCoCrAlY层20上。因而,无其它层(例如,粘结涂层)定位于NiCoCrAlY层20与铂族金属层30之间。
铂族金属层30可以经由任何合适的过程形成。举例来说,在一个特定实施例中,通过电沉积过程(例如,电镀)沉积铂族金属层30,但可以替代地使用溅镀、毛刷电镀等。电镀可以在室温(例如,约20℃到约25℃)下执行。在一个实施例中,通过将含铂族金属溶液(例如,含铂溶液)放置到沉积槽中,并将铂族金属从溶液沉积到NiCoCrAlY层20上来实现电沉积过程。举例来说,在沉积铂时,含铂水溶液可以包括Pt(NH3)4HPO4,且电压/电流源可以在每平方英尺面向制品表面约1/2-10安培下操作。在沉积中,铂族金属层30被沉积到表面13的未遮蔽部分(即,后边缘24)上。
可以按需要对铂族金属层30进行热处理。举例来说,可以在约900℃到约1200℃的处理温度下对铂族金属层30进行热处理。在一个实施例中,在真空中对铂族金属层30进行热处理(例如,在约10托或更小的处理压力,例如约1托或更小的处理压力下)。
抗氧化涂层被涂覆到翼型件12的表面13,以进一步促进抗氧化性。在一个特定实施例中,抗氧化涂层是扩散铝化物涂层34,其可以包括铝金属间化合物、γ相、γ'相等。铝化物涂层34沉积为上覆铂族金属层30。铝化物涂层34可以通过任何合适的方法形成为约2μm到约100μm(例如,约25μm到约100μm,例如约35μm到约75μm)的厚度。举例来说,铝化物涂层34可以通过任何可操作方法沉积成,例如通过包埋渗铝化物化或包括气相铝化物化的其它过程。
在一个实施例中,铝化物涂层34是经由气相铝化物化沉积成。举例来说,将例如氯化氢或氟化氢的卤化氢气体与铝金属或铝合金接触,以形成对应卤化铝气体。在需要时,可以将其它元素从对应气体掺杂到铝层中。卤化铝气体接触表面13,从而将铝沉积到表面上。所述沉积在循环时间(例如,4到20小时循环)期间以例如从约900℃到约1125℃的高温进行。铝化物涂层34的厚度优选为从约12到约125微米(例如约25μm到约100μm,例如约35μm到约75μm)。在需要时,沉积技术允许将合金化元素从卤化物气体共沉积到铝化物涂层34中。
因为铝的沉积是在高温下执行,所以所沉积铝原子与铂族金属层30(或相互扩散的铂/基板区)和/或NiCoCrAlY层20的材料相互扩散,从而在部件5的表面13上形成涂布系统22。
在图3示出的实施例中,铝化物涂层34沉积在整个表面13上,表面13中存在的任何空腔和任何薄膜孔内,且在铂族金属层30上方。在处理期间,铝化物涂层与铂族金属层30反应,以形成铂族金属铝化物涂层31。此铂族金属铝化物涂层31包括铂族金属和铝,例如铂改性铝化物(PtAl),但可以含有额外组分(例如,铂改性镍铝化物)。因此,铂族金属电镀继而扩散铝化物会带来“铂铝化物层”,其中除了扩散铝化物之外,所述涂层的外层具有铂族金属(例如,铂)。在一个实施例中,在真空中以约975℃到约1125℃的处理温度(例如,在约1到约4小时的处理周期内)执行第二热处理。
在对图3中示出的铂族金属层30和铝化物涂层34进行热处理之后,涂布系统22在其整个厚度中可以具有组成梯度。举例来说,所得的经热处理涂布系统22可以包括邻近于部件的内部部分、中间部分和与部件相对的外部部分,其中内部部分、中间部分和外部部分中的每一个限定涂布系统22的厚度的三分之一(即,1/3)。在一个实施例中,涂布系统22具有如下组成梯度:当相比于中间部分和内部部分的组成时,外部部分具有相对低的Cr浓度和相对高的Pt和Al浓度。因而,外部部分具有良好的氧化品质且粘附到TBC(如果上面存在)。然而,中间部分31和/或内部部分21中的增大Cr浓度可以允许耐腐蚀性增大,这在船用和工业发动机应用中尤其有用。
在一个特定实施例中,外部部分具有就重量百分比来说,比中间部分31的镍(Ni)含量高的镍含量。类似地,内部部分具有就重量百分比来说比中间部分的镍含量高的镍含量。因而,中间部分具有就重量百分比来说比内部部分和/或外部部分小的镍含量。在某些实施例中,举例来说,外部部分按重量计具有约40%到约50%的镍含量;中间部分按重量计具有约30%到约40%的镍含量;且内部部分按重量计具有大于约40%(例如,大于约50%)的镍含量。
涂布系统22被沉积且处理成具有平滑表面光洁度,例如约3μm或更小的表面粗糙度(Ra),以便促进喷嘴总成的空气动力学。在一个实施例中,涂布系统22优选地具有小于约3μm(例如,约0.75μm到约2.75μm,例如约1.25μm到约2.25μm)的表面粗糙度(Ra)。
图4还示出在涂布系统22上方的环境涂层36(例如,热屏障涂层(TBC)),在需要进一步保护的情况下(例如,在待用于极高温下的翼型件12的表面上)所述涂层尤其有用。在特定实施例中,环境涂层36也可以沉积在内带和外带的表面上。举例来说,热屏障涂层36可以完全由一个或多个陶瓷组合物组成。环境涂层36可以通过任何可操作技术来涂覆,其中电子束物理气相沉积(EB-PVD)优选用于优选的氧化钇稳定的氧化锆涂层。EB-PVD处理可以在高温过程之前和/或后跟着高温过程,所述高温过程可能会影响粘结涂层中的元素分布。EB-PVD过程自身通常是在高温下进行。其它涂层、涂层组成和涂层厚度也在本申请的范围内。
热屏障涂层36被沉积且处理成具有极平滑的表面光洁度,例如约1.5μmRa或更小,以便促进喷嘴总成的空气动力学。在一个实施例中,热屏障涂层36优选地具有小于约3μm的沉积后表面粗糙度(Ra)。此后,环境涂层36的表面优选地经历处理,优选为进行硬化且接着进行滚揉,以改进环境涂层36的表面光洁度。在硬化和滚揉之后,环境涂层36优选地具有不高于约2.0μmRa的表面粗糙度,其中在轮叶的凹面表面和前边缘上的典型范围为约1.3μm到约1.8μmRa,且在轮叶的凸面表面上的典型范围为约0.5μm到1.0μmRa。
在图2和3中示出的实施例中,涂布系统大体上不含任何粘结涂层。也就是说,涂布系统在NiCoCrAlY层20与超合金部件5的表面13之间不含粘结涂层,且涂布系统22在涂布系统22与热屏障涂层36之间不含粘结涂层。
如前所述,喷嘴段可以具有任何数目个翼型件(例如,一个(单联体)、两个(双联体)、四个、六个等)。取决于喷嘴段中的翼型件数目,可以利用不同的处理方法。在大部分实施例中,薄膜孔可以在形成任何涂层之前形成(例如,钻取),且在需要时可以被遮蔽以用于待涂覆的任何后续涂层。
本申请大体上适用于在表征为相对高温度的环境内操作,且因此经受恶劣氧化和腐蚀性操作环境的部件,且尤其适用于图1B中所表示类型的喷嘴段。应注意,在与以下描述组合查看时,图式是为清楚起见而绘制,且因此并不意图为按比例的。
还大体上提供用于在部件(例如,翼型件)的表面上形成涂层,并修复翼型件的表面上的涂层的方法。参考图5,大体上示出用于在部件的表面上形成涂层的示例性方法500。在502处,将NiCoCrAlY层沉积在部件的表面上。在504处热处理NiCoCrAlY层,例如经由加热到约900℃到约1200℃的处理温度。在506处,将铂族金属(PGM)层沉积在NiCoCrAlY层上,例如上文所描述的电镀过程。在508处热处理PGM层,例如经由加热到约900℃到约1200℃的处理温度。在510处可以将铝化物涂层形成在所有表面上,例如气相沉积。在512处,可以对所沉积层进行热处理以形成涂布系统。可选择地,在514处,可以将热屏障涂层(TBC)形成在涂布系统上方,例如通过等离子体喷射沉积过程。
参考图6,大体上示出用于修复部件(例如,翼型件)的表面上的涂层的示例性方法600。在602处,可以从翼型件的服务设施剥除任何和所有涂层,例如化学剥除过程(例如,酸性剥除等)。在604处,将NiCoCrAlY层沉积在部件的表面上,并在606处进行热处理。在608处,将铂族金属(PGM)层沉积在MCrAlY层上,例如上文所描述的电镀过程。在610处热处理PGM层,例如经由加热到约900℃到约1200℃的处理温度。在612处可以将铝化物涂层形成在所有表面上,例如气相沉积。在614处,可以对所沉积层进行热处理以形成涂布系统。在616处,可以将热屏障涂层(TBC)可选择地形成在涂布系统上方,例如通过等离子体喷射沉积过程。通过此修复过程,可以通过包括铂族金属来改进所述涂层。
所属领域的一般技术人员可以在不脱离本申请的精神和范围的情况下,实践对本申请的这些和其它修改和变化,所附权利要求书中更具体地阐述本申请的精神和范围。另外,应理解,各种实施例的方面可以完全或部分地互换。此外,所属领域的一般技术人员将了解,前述描述仅作为实例,且并不意图限制在所附权利要求书中如此进一步描述的本申请。
Claims (17)
1.一种在超合金部件的表面上形成涂布系统的方法,所述超合金部件的表面在其中限定有薄膜孔,所述方法包括:
在所述薄膜孔保持开放时,在所述超合金部件的表面上涂覆NiCoCrAlY以形成NiCoCrAlY层,其中所述NiCoCrAlY层具有高于所述超合金部件的铬含量;
将所述NiCoCrAlY层加热到900℃到1200℃的处理温度,使得所述NiCoCrAlY层的一部分扩散到所述超合金部件中以形成扩散部分;
在所述NiCoCrAlY层上形成铂族金属层;以及
在所述铂族金属层上方形成铝化物涂层;
其中,所述NiCoCrAlY层的5%到25%的厚度扩散到所述超合金部件的所述表面中。
2.根据权利要求1所述的方法,其特征在于:所述NiCoCrAlY层被加热到1000℃到1100℃的处理温度。
3.根据权利要求1所述的方法,其特征在于:所述NiCoCrAlY层是在30分钟到5小时内被加热到所述处理温度。
4.根据权利要求1所述的方法,其特征在于:在热处理之后,所述NiCoCrAlY层具有从所述表面延伸25μm到50μm的厚度,同时限定在所述超合金部件的所述表面内的所述薄膜孔保持开放。
5.根据权利要求1所述的方法,其特征在于:在形成所述铂族金属层之前,所述NiCoCrAlY层按重量百分比计包括16%到20%的Cr,9%到11%的Al,19%到24%的Co,0.05%到0.2%的Y,至多0.5%的Hf,至多1%的Si和其余部分Ni。
6.根据权利要求1所述的方法,其特征在于:在形成所述铂族金属层之前,所述NiCoCrAlY层按重量百分比计包括17%到19%的Cr,9.5%到10.5%的Al,21%到23%的Co,0.07%到0.15%的Y,0.05%到0.3%的Hf,0.5%到0.9%的Si,和其余部分Ni。
7.根据权利要求1所述的方法,其特征在于,进一步包括:
在形成所述铂族金属层之后,将所述铂族金属层加热到900℃到1200℃的第二热处理温度。
8.根据权利要求1所述的方法,其特征在于,进一步包括:
在形成所述铂族金属层之后,将所述铂族金属层加热到1000℃到1100℃的第二热处理温度。
9.根据权利要求1所述的方法,其特征在于:所述超合金部件的所述表面在其中限定多个薄膜孔,且其中,所述薄膜孔在将NiCoCrAlY涂覆到所述超合金部件的所述表面上以形成NiCoCrAlY层之后保持开放。
10.根据权利要求1所述的方法,其特征在于:将所述铝化物涂层沉积到25μm到100μm的厚度。
11.根据权利要求1所述的方法,其特征在于,进一步包括:
在形成所述铝化物涂层之后,在粘结涂层上方形成热屏障涂层。
12.根据权利要求1所述的方法,其特征在于:所述NiCoCrAlY层是经由离子等离子体沉积形成在所述超合金部件的所述表面上。
13.根据权利要求1所述的方法,其特征在于,进一步包括:
在将所述NiCoCrAlY涂覆到所述表面上之前,去除所述超合金部件的所述表面上的现有涂布系统的至少一部分。
14.根据权利要求1所述的方法,其特征在于:所述NiCoCrAlY被涂覆到所述超合金部件的所述表面上的现有涂布系统上。
15.根据权利要求14所述的方法,其特征在于:所述现有涂布系统是大体上不含Ni的Co基涂布系统。
16.一种修复超合金部件的表面上的现有涂布系统的方法,其中现有涂层包括CoCrAlHf,所述方法包括:
从所述超合金部件的表面去除所述现有涂层的至少一部分,其中,所述超合金部件的表面在其中限定有薄膜孔;
在所述薄膜孔保持开放时在所述超合金部件的表面上形成NiCoCrAlY层,其中所述NiCoCrAlY层具有高于所述超合金部件的铬含量;
将所述NiCoCrAlY层加热到900℃到1200℃的处理温度,使得所述NiCoCrAlY层的一部分扩散到所述超合金部件中以形成扩散部分;
在所述NiCoCrAlY层上形成铂族金属层;
将所述铂族金属层加热到900℃到1200℃的处理温度;以及
在铂族金属层上方形成铝化物涂层;
其中,所述NiCoCrAlY层的5%到25%的厚度扩散到所述超合金部件的所述表面中。
17.根据权利要求16所述的方法,其特征在于:所述NiCoCrAlY被涂覆到所述超合金部件的表面上的现有涂布系统上,且其中,所述现有涂布系统是大体上不含Ni的Co基涂布系统。
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