CN1180126C - 高温部件的磨蚀/腐蚀防护涂层 - Google Patents

高温部件的磨蚀/腐蚀防护涂层 Download PDF

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CN1180126C
CN1180126C CNB961940425A CN96194042A CN1180126C CN 1180126 C CN1180126 C CN 1180126C CN B961940425 A CNB961940425 A CN B961940425A CN 96194042 A CN96194042 A CN 96194042A CN 1180126 C CN1180126 C CN 1180126C
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�ֶ���ԡ�����ķ
沃尔弗拉姆·比利
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Abstract

一种在高温环境下遭受磨蚀和腐蚀侵蚀的制品，由镍或钴基高温合金基体(1)以及位于该基体上的硅化物保护涂层(6)构成。一个陶瓷隔热层(2)可以位于该高温合金基体和该硅化物涂层之间，以及一个MCrAlY层(4)可以位于该陶瓷层和该高温合金基体之间。该硅化物层(6)优选的是MoSi2。

Description

高温部件的磨蚀/ 腐蚀防护涂层
本发明涉及一种制品以及涉及一种防护该制品免受磨蚀和腐蚀侵蚀的方法，所述侵蚀包括在高温下的颗粒冲击损伤。
US4,055,705(授于Stecura等人)，4,321,310(授于Ulion等人)和4,321,311(授于Strangman)中公开了用于镍基或钴基高温合金制的气轮机部件的涂层体系。上述专利中所公开的涂层体系包括位于粘合层或粘合涂层上的陶瓷隔热层，该隔热层具有柱状晶粒的组织结构。所述粘合层或粘合涂层依次位于基体上并将该隔热层粘合于该基体上。该粘合层或粘合涂层是由MCrAlY型合金制成，即含铬、铝和稀土金属(如钆)的、以铁、钴和镍中至少一种元素为基的合金。其它元素也可含在MCrAlY合金中，下面给出例子。该粘合层的一个重要特征是在MCrAlY合金表面形成薄的氧化铝层来粘结该隔热层。
授予Duderstadt等人的US5,238,752公开了一种用于汽轮机部件的涂层体系，它也包括陶瓷隔热层和将该隔热层粘合于该基体上的粘合层或粘合涂层。该粘合层由金属间铝化物组成，特别是镍铝化物或铂铝化物。界面层也具有用于粘结隔热层的薄氧化铝层。
授于Ulion等人的US5,262,245公开了一种通过省去粘合层而试图简化包括隔热层的用于汽轮机部件的涂层体系的研究结果。为此，公开了一种高温合金的成分，它可用于制造汽轮机部件基体并且通过合适的处理能在其外表面形成氧化铝层。该氧化铝层用于直接将陶瓷隔热层粘结在该基体上，省去了需要将特定的粘合层插入于基体和隔热层之间。
授予Giggins等人的US5,087,477公开了一种通过物理汽相蒸沉(PVD)将陶瓷隔热层沉积在汽轮机部件上的方法，该方法包括用电子束蒸发形成隔热层的化合物并于部件处建立一种具有控制氧含量的气氛来接受该隔热层。
授予Czech等人的US5,154,885，5,268,238，5,273,712和5,401,307公开了用于汽轮机部件的增强的涂层体系，包括MCrAlY合金保护涂层。公开的MCrAlY合金具有严格平衡的化学成分以得到特别好的耐腐蚀性和抗氧化性，以及特别好的与用作基体的高温合金的性能间的相配性(机械性能、化学性能)。该MCrAlY合金是镍基和/或钴基的。也讨论了其它元素的加入，特别是硅和铼。已表明了铼是特别有利的添加元素。也表明所有MCrAlY合金非常适合作为粘合层用于粘结隔热层，特别是在下面公开的本发明范围之内。
在由W.Dienst著的《高温材料》一书(WerkstofftechnicheVerlagesgesellschaft mbH，Karlsmhe，DE，1978)中，公开了用于高温合金的抗氧化涂层，见第6章第92页。特别是，铝化物涂层可用于镍或钴合金，而硅化物涂层可用于钒、钼、钨、铌或钽合金。硅化物涂层可基本上由VSi2、MoSi2或WSi2组成；也考虑到(Cr；Ti；Nb)Si2和(Cr，Ti，Ta)Si2，特别是对于铌和钽合金。可以通过包埋烧结工艺随后进行扩散回火而将硅化物层涂于基体上。
如同现有技术中广泛讨论的那样，高温下遭受腐蚀物质侵蚀(包括由氧化物质或其它腐蚀性化学品的侵蚀)的如汽轮机部件那样的制品也常常会被磨蚀。对于暴露于热气流中的汽轮机部件尤为如此，该热气流可能携带固体颗粒如分布其中的灰尘颗粒，并使汽轮机部件遭受这些颗粒引起的磨蚀。
所述金属保护层于使用温度下本质上是相当韧性的并且在这种磨蚀侵蚀下不是太易损坏。如果这种保护层受到颗粒的冲击，颗粒会粘附在该涂层上，甚至可能会由此而变形，但不太可能使基体产生裂纹或甚至产生散裂。
对于在汽轮机部件表面形成的并且遭受磨蚀侵蚀的陶瓷隔热层来说情况就完全不同了。由于陶瓷本质是脆性的，如果陶瓷涂层遭受颗粒的碰撞或冲击则必须考虑产生裂纹和散裂，所述颗粒是随热气流沿部件吹过时冲击或碰撞涂层的。
最需要考虑的是部件表面区域内增加的磨蚀侵蚀，下文中将该区域定义为“危险区域”，该区域在或大或小程度上横向暴露于吹过的热气流。对于汽轮机的翼面部件来说，该翼面部件包括用于固定该部件的固定部分和遭受汽轮机中热气流的翼面部分，其危险区域包括翼面部分的导向边，该导向边由吹过该部件的气流所确定。
本领域内的技术人员尚未对上述的磨蚀侵蚀完全认识或甚至解释清楚。然而已知的最终也许可以避免磨蚀问题的措施仅是避免热气流中颗粒杂质的含量，这不仅严格要求用于汽轮机中燃料的纯度，而且还必须严格选择装配在该汽轮机中的任何一种最终作为燃烧零件热屏蔽的陶瓷，使其类型为最不可能有相当大量的颗粒产生。另一种方法可能最终依赖于仅位于上述定位的部件危险区域外侧面上的陶瓷隔热层。
然而这意味着危险区域必须只有用金属涂层防护，由于没有热屏蔽其本身也需要极强的冷却。因此，不能尽可能地充分利用陶瓷隔热层的潜力。考虑到对改善汽轮机发动机的热效率这一日益增加的需求，而现有技术的另一缺点是已知涂层体系的热负载方面的潜力会很快耗尽，为改善热效率，需要增高热气流进入汽轮机时的温度。因此，一直需要发明这样一些保护涂层体系，能够在迄今为止只有用陶瓷隔热层才能达到的使用温度下对腐蚀及磨蚀提供保护作用，并能承受上文所解释的由磨蚀破坏所引起的陶瓷隔热层的各种问题。这种新的保护层体系未必包括陶瓷层，特别是如果预计到热负载不是太大时或者如果使用具有足够高的热负载能力的高级基体时。这种高级基体可能正好是陶瓷基体。
依据本发明的一个目的，提供了一种用于高温部件的磨蚀/腐蚀保护涂层以及一种保护这种部件的方法，克服了上述这种普通类型的已知方案和方法的缺点。该新的保护层在所讨论的高温下必须有足够的韧性，由此保护其下面的组织免受包括颗粒冲击破坏的磨蚀，并且必须是足够耐腐蚀的以承受长时间的各种腐蚀侵蚀。该新的涂层还必须具有诸如热膨胀系数和其它机械/化学性能的各种性能，并使这些性能最大程度地与其下面的组织结构，特别是所述的高温合金的性能相匹配。
依据本发明的上述和其它目的，提供了一种遭受磨蚀和腐蚀侵蚀的制品，该制品包括由镍或钴基高温合金制成的基体，以及位于该基体上的硅化物涂层。
依据本发明的另一特点，该硅化物涂层含有MoSi2，优选是作为主要成分，或者仅由MoSi2组成。
依据本发明的又一特点，该制品是具有翼面部分和安装部分的汽轮机翼面部件，该翼面部分定义为在工作过程中暴露于沿该制品吹过的气流中的部分具有由气流吹过所确定的导向边和出气边，并具有凸面负压面和凹面压力面，这两个面将所述导向边与所述出气边相连接。该翼面部分具有由其在气流中的方向所确定的导向边，并且该硅化物涂层优选地位于并覆盖在包括该导向边的翼面中的危险区域上。
该翼面部分也具有由其在气流中的方向所确定的出气边，并且该硅化物涂层优选地位于并覆盖在相邻于该出气边的翼面的压力面中的危险区域上。
该翼面部分具有遭受气流中颗粒的磨蚀侵蚀的危险区域。依据本发明的另一特点，该硅化物涂层位于并覆盖在该危险区域上。
依据本发明的上述和其它目的，还提供了一种遭受磨蚀和腐蚀侵蚀的制品，包括：镍或钴基高温合金制成的基体；位于该基体上的并具有给定的韧性的隔热层；以及位于该隔热层上并具有比所给定韧性更高的韧性的保护涂层。尽管在所考虑的温度下韧性极低的隔热层(即陶瓷)暴露于气流中，当固体颗粒冲撞在部件上时会引起切削和磨蚀，但保护涂层的较高的韧性会使该涂层“捕获”颗粒并防止任何进一步的损害。
如上所述，该保护涂层是硅化物涂层，它可以包括MoSi2或基本上由MoSi2组成。
依据本发明的再一特点，该隔热层含有作为主要成分的陶瓷，并且优选是柱状晶粒陶瓷。
依据本发明的又一特点，该制品包括位于隔热层和基体之间的粘合层，该粘合层将隔热层粘合在基体上。
依据本发明的又一特点，该粘合层含有选自金属间铝化物和MCrAlY合金的一种材料。
依据本发明的上述和其它目的，提供了一种保护具有镍或钴基高温合金制成的基体的制品免受腐蚀和腐蚀侵蚀的方法。该方法包括用硅化物涂层涂覆由镍或钴基高温合金制成的基体。
依据本发明的另一方案，用热喷涂法涂覆该基体。
依据本发明的又一方案，用物理汽相沉积法涂覆该基体。
依据本发明的再一方案，提供了一种保护具有镍或钴基高温合金制成的基体的制品免受腐蚀和磨蚀侵蚀的方法。该方法包括：将一隔热层涂覆于由镍或钴基高温合金制成的基体上，该隔热层具有给定的韧性；以及用一保护涂层涂覆该隔热层，该保护涂层的韧性高于该给定的韧性。
可用热喷涂法、空气等离子体喷涂或物理汽相沉积方法将隔热层涂覆在基体上，按照隔热层的技术要求并与本领域的技术人员的知识相一致来选择涂覆工艺。
依据本发明的又一方案，该方法还包括在涂覆隔热层之前在基体上涂覆粘合层的步骤。
最后，依据本发明提供了一种保护制品免受腐蚀和磨蚀侵蚀的方法，所述制品具有镍或钴基高温合金制成的基体并具有位于基体上的破坏了的硅化物涂层，该方法包括用新的硅化物涂层涂覆该制品。
认为是本发明特征的其它特点在所附的权利要求中给出。
尽管本文以用于高温部件的磨蚀/腐蚀保护涂层以及保护这种部件的方法为实施例说明和解释本发明，然而并不将本发明限于这种具体的说明，因为在不背离本发明的精神下以及在本发明的权利要求所相当的范围内可以做出各种变化和结构上的改变。
当结合附图阅读了特定实施例的下述说明之后会更好地理解本发明的构成以及本发明的其它目的及优点。
图1是具有基体和包括硅化物涂层的保护涂层体系的部件的部分截面图，该截面是沿图2中的I-I线截取的；
图2是包括图1所示基体和保护涂层体系的汽轮机翼面部件的透视图；
图3是表明另一实施例的类似图1的视图；以及
图4是又一实施例的类似的视图。
现在详细地参照附图，首先从图1看出制品的基体1，特别是汽轮机部件，在工作过程中该部件承受大的热负载并同时遭受腐蚀和磨蚀侵蚀。该基体1是由这样的材料制成的，即当其承受大的热负载并且可能承受由剧烈的力如离心力所产生的附加机械负载时该材料有足够的强度和结构稳定性。广泛承认的和在汽轮机发动机中广泛使用的用于这一目的的材料是镍或钴基高温合金。
为了限制施于基体1上的热负载，基体1上具有隔热层2。该隔热层2由柱状晶粒陶瓷制成，特别是基本上由稳定的或部分稳定的氧化锆组成。该隔热层2通过中间层3粘结在基体1上。通过用MCrAlY层4涂覆基体1而制得中间层3，该MCrAlY层4由MCrAlY合金组成，优选的MCrAlY合金如上述授予Czech等人的US5,154,885、5,268,238、5,273,712和5,401,307任一专利中所述。在该MCrAlY层4上产生薄氧化铝层5。该氧化层5作为隔热层2的粘结体。
本发明新的特点是将一硅化物涂层6位于隔热层2上。该硅化物涂层的韧性在高于900℃的温度下明显高于形成隔热层2的陶瓷的韧性，因此可比陶瓷更适宜承受磨蚀侵蚀。悬浮在沿部件流动并冲击该硅化物涂层6的气流中的所有固体颗粒会被停留并存留于其中，可能引起硅化物涂层6的轻微变形，但几乎不可能使其产生裂纹或散裂。因为该硅化物涂层6在很大程度上是化学惰性的，它在所述温度下也能承受腐蚀侵蚀，因此对隔热层2提供优异的保护作用。隔热层2与硅化物涂层完好地结合对基体1提供了三种保护作用。即对腐蚀和磨蚀侵蚀的保护作用以及对过量热负载的保护作用。
该硅化物涂层6具体是由金属硅化物如MnSi2，MoSi2或WSi2的化合物制成。优选地，该硅化物涂层是由MoSi2制成。该化合物特别可用热喷涂法或物理汽相沉积法涂覆，并且该化合物的热膨胀系数几乎只是稍微不同于所包括的其它材料(小于3×10-6/K的差值)的热膨胀系数，因此在热负载下不会产生显著的应变。还有，MoSi2与其它材料的粘合很好。
考虑所有这些特点，已经发现MoSi2提供优异的保护作用，该保护作用持续的时间，至少相应于在该部件两次修正之间所合理选择的时间，在该部件不工作时可对其进行检测，如果必要可在其上涂覆新的硅化物涂层6。
图2示出了完整的汽轮机部件，即汽轮机翼面部件7，准确说是汽轮机叶片。
该部件7具有翼面部分8和安装部分9，翼面部分8在工作过程中形成汽轮机发动机的“工作零件”，部件7固定在安装部分9处并在其上定位。在工作过程中，翼面部分8承受沿其流过的热气流10的作用。如由其功能所决定的，该翼面部分8具有气流10与之相遇的导向边和气流10离之而去的出气边。边11和12由凸面负压面13和凹面压力面14连接。在工作过程中，气流10在压力面14处产生相对高的压力而在负压面13处产生相对低的压力，因此该翼面8产生压差，使该部件所附属的汽轮机旋转。该热气流10携带有氧气，产生氧化型腐蚀侵蚀；其它化学物质产生蚀刻型腐蚀侵蚀；以及携带有分散的颗粒状固体，产生磨蚀侵蚀。磨蚀侵蚀主要发生在由气流10确定的翼面部分8的导向边11处以及包括导向边11的翼面部分8的危险区域15，该危险区域15也可以确定为包括相邻于该导向边11的全部翼面部分8的整个区域，该区域被气流10携带的小颗粒直接冲击。另一个危险区域16位于相邻于出气边12的压力面14上。在工作过程中，气流10沿着型线吹向压力面14。随气流10吹过的颗粒在离心力的作用下被导向弯曲程度低于气流10自身的流轨上，因此该颗粒与压力面14相碰撞。这种碰撞最可能发生在出气边12附近，因此将此处确定为危险区域16。
将硅化物涂层6涂覆在部件7上，至少覆盖危险区域15和16，优选地覆盖整个翼面部分8。
为了进一步降低在工作过程中施于部件7上的热负载，在部件7上形成冷却通道17。然而，重要的是，通常通过从汽轮机发动机中放出压缩空气来进行冷却，由此减少了可用于燃烧的空气的量。由于通常希望使这种减少保持较低水平，因此部件7的优异保护作用是非常有用的，它包括由涂层体系产生的对过量热负载的保护作用。
参照图3和图4，硅化物层可以直接沉积在基体上。另一种方案，用于部件的保护涂层可以只包括用本发明的硅化物涂层保护的陶瓷隔离层2。
通过在涂层体系中提供一种化合物，本发明满足了本说明书前面部分所涉及的需求，所述涂层体系具有三种保护作用的特征，即防腐蚀、磨蚀以及过量热负载的作用。

Claims (18)

1.一种遭受磨蚀和腐蚀侵蚀的制品，包括镍或钴基高温合金制成的基体、位于所述基体上的并具有给定的韧性的隔热层、以及位于所述隔热层上的并具有比该给定韧性更高的韧性的硅化物涂层。
2.权利要求1的制品，其中所述的保护涂层含MoSi2。
3.权利要求1的制品，其中所述的保护涂层基本上由MoSi2组成。
4.权利要求1-3中任一项的制品，其中所述的隔热层含有陶瓷。
5.权利要求1-4中任一项的制品，其中所述的隔热层是柱状晶粒陶瓷。
6.权利要求1-5中任一项的制品，包括位于所述隔热层和所述基体之间的粘合层，该粘合层将所述隔热层粘合在所述基体上。
7.权利要求6的制品，其中所述的粘合层含有选自金属间铝化物和MCrAlY合金的一种材料。
8.权利要求1-7中任一项的制品，其中所述的基体、所述的隔热层和所述的保护层构成一个包括翼面部分和安装部分的汽轮机翼面部件，所述翼面部分定义为在工作过程中暴露于沿该制品吹过的气流中的部分，它具有由气流吹过所确定的导向边和出气边，并具有凸面负压面和凹面压力面，这两个面将所述导向边和所述出气边相连接。
9.权利要求8的制品，其中所述的硅化物涂层位于并覆盖在包括所述导向边的所述翼面的危险区域上。
10.权利要求8或9的制品，其中所述的硅化物涂层位于并覆盖在相邻于所述出气边的所述压力面中的危险区域上。
11.权利要求8-10中任一项的制品，其中所述的翼面部分具有一个遭受散布于气流中颗粒的磨蚀侵蚀的危险区域，并且所述的危险区域由所述保护涂层所覆盖。
12.一种保护具有镍或钴基高温合金制成的基体的制品免受腐蚀和磨蚀侵蚀的方法，该方法包括：
将一隔热层涂覆于该基体上，该隔热层具有给定的韧性；以及
用硅化物涂层涂覆该隔热层，该硅化物涂层的韧性高于该给定韧性。
13.权利要求12的方法，其中涂覆隔热层的步骤包括在涂覆该隔热层之前在基体上涂覆粘合层的步骤。
14.权利要求12或13的方法，其中该涂覆步骤包括用硅化物涂层涂覆该隔热层。
15.权利要求12-14中任一项的方法，该方法包括用热喷涂法涂覆该隔热层。
16.权利要求12-14中任一项的方法，该方法包括用物理汽相沉积法涂覆该隔热层。
17.一种保护制品免受腐蚀和磨蚀侵蚀的方法，所述制品具有镍或钴基高温合金制成的基体并具有位于基体上的破坏了的硅化物涂层，该方法包括用另外的硅化物涂层涂覆该制品。
18.一种保护制品的方法，所述的制品具有镍或钴基高温合金制成的基体、涂覆在该基体上的隔热层、以及位于该隔热层上的破坏了的硅化物涂层，其中所述的隔热层具有给定的韧性，该方法包括用另外的硅化物涂层涂覆该隔热层，该另外的硅化物涂层的韧性显著高于该给定韧性。
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IN187892B (zh) 2002-07-20
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ES2162048T3 (es) 2001-12-16
UA48169C2 (uk) 2002-08-15
CZ315797A3 (cs) 1998-03-18
EP0820535A1 (en) 1998-01-28
RU2167220C2 (ru) 2001-05-20
WO1996031636A1 (en) 1996-10-10
JP3464003B2 (ja) 2003-11-05
DK0820535T3 (da) 2002-01-07
CN1185183A (zh) 1998-06-17
JPH11506500A (ja) 1999-06-08

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