CN1182459A - 带有保护性涂层体系的高温合金元件 - Google Patents

带有保护性涂层体系的高温合金元件 Download PDF

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CN1182459A
CN1182459A CN96193451A CN96193451A CN1182459A CN 1182459 A CN1182459 A CN 1182459A CN 96193451 A CN96193451 A CN 96193451A CN 96193451 A CN96193451 A CN 96193451A CN 1182459 A CN1182459 A CN 1182459A
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沃尔夫拉姆·比利
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Abstract

用一种耐热、耐腐蚀和耐侵蚀的保护性涂层覆盖到镍基或钴基高温合金基体(1)上。在该基体上沉积一层锚定层(5)。此锚定层由掺杂氮的氧化物形成。此氧化物特别是指氧化铝。在锚定层上沉积一层陶瓷涂层(2)。改性此锚定层能防止扩散成分穿过锚定层传递到热障层中。

Description

带有保护性涂层体系 的高温合金元件
本发明涉及一种表面涂有各种保护性涂层的高温合金元件。
Stecura等人的美国专利4,055,705;Ulion等人的美国专利4,321,310;和Strangman的美国专利4,321,311公开了由镍基或钴基高温合金制造的气体涡轮机元件用的一些涂层体系。所述的一种涂层包括一种由陶瓷制得的热障层,特别是该层具有柱状颗粒结构,它位于粘合层或粘合涂层之上,而此粘合层紧靠基体,并将热障层粘合到基体上。粘合层是从MCrAlY型合金制备,该合金又称之为在含有至少一种铁、钴和镍的基质中包含铬、铝和稀土金属(如钇)的合金。其它元素也可以在MCrAlY合金中存在,以下有举例说明。此粘合层的重要特点是在MCrAlY合金上形成一个薄层,并用于粘接热障层。这层可以是氧化铝或是混合有氧化铬的氧化铝,这取决于此MCrAlY合金的组成和形成该层的氧化环境温度。最后可通过单独的涂覆方法如PVD法有目的地涂敷一氧化铝层。
Duder Stadt等人的美国专利5,238,752公开一种用于气体涡轮机元件的涂层体系,该体系也包括一陶瓷热障层和一将热障层粘接到基体上的粘合层或粘合涂层。此粘合层由铝金属互化物、尤其是镍铝化物或铂铝化物制得。此粘合层还有一用来粘接热障层的氧化铝薄层。
Ulion等人的美国专利5,262,245记载了由于取消热障层下方的粘合层而使气体涡轮机元件上热障层的涂层体系得以简化的研究结果。为此,公开了一种用于高温合金的组合物,可用此组合物形成气体涡轮机元件的基体,并经过适当处理在其外表面上产生氧化铝层。此氧化铝层用来将陶瓷热障层直接结合在基体上,在基体和热障层之间无需特殊粘合层。按其最宽范围来讲,此高温合金基本构成为(以重量百分比表示):3~12Cr,3~10W,6~12Ta,4~7Al,0~15Co,0~3Mo,0~15Re,0~0.0020B,0~0.045C,0~0.8Hf,0~2Nb,0~1V,0~0.01Zr,0~0.07Ti,0~10的贵金属,0~0.1包括Sc和Y的稀土金属,余量为Ni。
Giggins,Jr,等人的美国专利5,087,477给出了一种通过物理气相沉积法在气体涡轮机元件上设置一陶瓷热障层的方法,包括用电子束蒸发形成热障层的化合物,并在此元件处建立带有可调节氧量的气氛以接收热障层。
Czech等人的美国专利5,154,885;5,268,238;5,273,712;和5,401,307记载了用于气体涡轮机元件的高温涂层体系,包括MCrAlY合金的保护涂层。所公开的MCrAlY合金具有精确平衡组成,可以显示出优异的耐腐蚀性和抗氧化性以及其与基底的高温合金之间有优异的相容性。MCrAlY合金的主要成分是镍和/或钴。加入的其它元素,尤其是硅和铼也在上述文献上作了讨论。尤其是铼显示出是一种极佳的添加成分。所给出的所有MCrAlY合金皆适合用作结合热障层的粘合层,下文中公开本发明的具体内容。
前述的美国专利5,401,307中还包括对高温合金的鉴定,认为这些高温合金适用于制造那些在运行过程中必须承受高机械载荷和高热载的气体涡轮机元件。更具体的给出了四类高温合金。各类高温合金有以下基本组成(以重量百分比表示):
1. 0.03~0.05C,18~19Cr,12~15Co,3~6Mo,1~1.5W,2~2.5Al,3~5Ti,可以加或不加少量成分Ta,Nb,B和/或Zr,余量Ni。
2. 0.1~0.5C,18~22Cr,18~19Co,0~2W,0~4Mo,0~1.5Ta,0~1Nb,1~3Al,2~4Ti,0~0.75Hf,可以加或不加少量成分B和/或Zr,余量Ni。
3. 0.07~0.1C,12~16Cr,8~10Co,1.5~2Mo,2.5~4W,1.5~5Ta,0~1Nb,3~4Al,3.5~5Ti,0~0.1Zr,0~1Hf,可以加或不加少量的B,余量Ni。
4. 约0.25C,24~30Cr,10~11Ni,7~8W,0~4Ta,0~0.3Al,0~0.3Ti,0~0.6Zr,可以加或不加少量的B,余量Co。
关于改性氧化铝化合物,尤其是掺杂有氮的氧化铝化合物的信息可从本发明人的题为“Schichtentwicklungen fur Hochtemperaturan-wendungen inthermischen Maschinen”[用于热机的高温涂料研制]的论文中获悉,该论文以“Fortschritts-Berichte VDI,Reihe5”[VDI的进展报告,编号5]出版,序号345,VDI-Verlag,Dusseldorf,Germany,1994。这篇文章还包括关于以层状结构的方式沉积诸如氧化铝化合物等方法方面的报导。
其它关于改性氧化铝化合物方面的报导可以从L.Peichl和D.Bettridge的题目为“用于航空气体涡轮机的贴面和浸渗涂层”的文章中得知,该文章在由D.Coutsouradis等人编辑,Kluwer学术出版公司,Dordrecht荷兰,1994出版的题目为“现代动力工程材料,第一部”[Materials for Advanced PowerEngineering,Part One]一书的第717-740页中登载,还可从O.Knotek,E.Lugscheider,F.Loffler和W.Beele的发表在“表面与涂装技术”[Surface andCoating Techniques]第68/69卷(1994),第22~26页的论文中获悉。
关于在制品的基体上设置热障层的常规操作方法包括在制品上产生一氧化物层,或者是通过在制品上涂覆一适宜粘合层,继而在氧化条件下在其表面生成氧化物层,或者所选择的制品材料本身就能够在其自身表面上生成氧化物层。此氧化物层可用来固定后来设置在其上的热障层。
在热载下制品内会产生扩散过程。特别是那些有扩散活性化学成分,如铪、钛、钨和硅构成该制品大多数高温合金的成分可穿过氧化物层迁入热障层,此扩散活性化学成分由于改性后损害了它的基本性质,因而引起热障层破坏。这种情况尤其产生在由氧化锆(如部分稳定的氧化锆)制得的热障层中,因为几乎所有氧化锆化合物必须依靠某些成分来确定和稳定其特殊性质。这类成分的作用有可能是由扩散或其他方法而迁移到化合物中的化学成分所赋予。
为保证设置在基体上含有扩散活性化学成分的热障层在所需要的那么长的时间内保持其基本性质,因此就需要避免这些有扩散活性的化学成分迁移到热障层。
然而,这方面现在尚未引起本领域工作者的重视。他们仅仅考虑用氧化物层来固定高温合金基体上的热障层,而未顾及扩散的化学成分传送到热障层。
因此,本发明的一个目的是提供一种带有保护性涂层的高温合金元件。它克服了前述这种已知类型器件的缺陷,并通过适当改变锚定层来将扩散成分透过锚定层迁移入热障层的情况维持在最低状态或者抑制住。
本发明的前述和其他目的是提供这样的一种制品,它含有:由镍基或钴基高温合金形成的基体;沉积在该基体上的一锚定层,此锚定层含有掺杂氮的氧化物;和沉积在锚定层之上的陶瓷涂层。
根据本发明的优选特征,此氧化物包含氧化铝或氧化铬,尤其是该氧化物基本上由氧化铝构成。
根据本发明的附加特征,该制品包括由锚定层覆盖的扩散活性化学成分。此扩散活性化学成分优选的是选自铪、钛、钨和硅中的一种元素。更具体地,此扩散活性成分含在基体中或沉积在基体上的粘合层中。
根据本发明的另一特征,此陶瓷涂层包括ZrO2。在另一种研究方案中,此陶瓷涂层基本上由ZrO2和一种选自Y2O3、CeO2、LaO和MgO的稳定剂构成。
在一种优选实施方案中,此锚定层的厚度小于3μm。
根据本发明的另一特征,此锚定层含有1~10原子百分数氮,优选为2~5原子百分数氮。
根据本发明的又一附加特征,此锚定层还掺杂另一种化学成分,此成分也被此锚定层覆盖。在本发明的一种实施方案中,此另一种化学成分是铬。尤其是,此另一种化学成分包含在基底和其上的粘合层中。
根据本发明的另一附加特征,此锚定层掺杂有另一种化学成分,而此另一种化学成分也存在于陶瓷涂层中。
根据本发明的又一附加特征,此制品在基底和锚定层之间有一粘合层。
在一优选方案中,该粘合层由一种金属铝化物形成,或者他由一种MCrAlY合金形成。
根据本发明的另一特征,锚定层掺杂另一种化学成分,且此另一种成分也存在于粘合层中。
根据本发明的另一特征,由基体、粘合层(如果存在)、锚定层和陶瓷涂层形成气体涡轮机元件。具体说是,此气体涡轮机元件是气体涡轮机的机翼构件,它包括固定部件和翼面部件,固定部件用于在运行中牢固地固定该元件,而翼面部件是暴露在运行时沿着该元件冒出蒸汽的气流中,锚定层和陶瓷层都沉积在该机翼部件的表面上。
根据本发明上述和其它目的,本发明还提供了一种将陶瓷涂层用到该制品由镍或钴基高温合金所形成的基体上的方法。特别是如上所述,此基体上可以有一个粘合层。该方法包括下述步骤:
-在由镍或钴基高温合金形成的基体上设置一层由掺杂氮的氧化物组成的锚定层;和
-在此锚定层上设置一层陶瓷涂层。
根据本发明的附加的方法,设置锚定层的步骤是通过物理汽相沉积方法完成的。优选使用包括溅射法或电子束蒸发法。
根据本发明的另一种方案,设置锚定层的步骤包括:
-在基体上设置一层由基本上无氮的另一种氧化物构成的层;
-在该层周围形成含氮气氛;和
-使该层和气氛经受高温,并使氮扩散进入该层而形成锚定层。
陶瓷涂层也可用物理蒸发沉积法(PVD)设置到此体系中。
被认为是作为本发明特征的其他特点都在后附的权利要求书中陈述。
尽管以下实施例举例说明本发明带有保护涂层体系的高温合金元件,但这并不意味着限制在所给出的具体细节中,因为本发明可以作出各种改进和结构上的变化都不会偏离本发明的构思,且都在本权利要求书的所要求保护的范围内。
然而,本发明的构成连同它的附加目的和优点将通过下叙具体实施方案再结合附图会很清楚地理解。在图中:
图1是基体的部分剖面图,有保护性涂层体系,且其上结合有一层陶瓷涂层;和
图2是图1中所示的包括基体和保护性涂层体系的气体涡轮机机翼部件的透视图。
参照附图中的具体编号,首先看图1,制品的基体1,更具体讲是气体涡轮机元件,它在运行中需经受高热同时受到腐蚀和侵蚀作用。基体1是由这样一种材料形成:当承受热载和不可避免的由于剧烈力(如离心力)而引起的机械载荷时,该材料能够保证强度和结构稳定性。为此目的普遍认可并广泛使用在气体涡轮机发动机中的材料是镍或钴基高温合金。
为了阻止施加在基体1上的热载荷,在其上安置了热障层2。如上所述,热障层2由柱状颗粒陶瓷构成,具体的组成基本上是一种稳定的或部分稳定的氧化锆。热障层2通过中间层3锚定到基体1上。中间层3由设置在基体1上的粘合层4制成,此粘合层4由MCrAlY合金构成,优选的是公开在美国专利US5,154,885;5,268,238;5,273,712和5,401,307中的MCrAlY合金,继而按照所述方式在粘合层4上生成锚定层5。此粘合层4具有某些与现有技术中公知的粘合层相同的作用,尤其与基体1有紧密的结合。锚定层5对于热障层2起到锚定作用。粘合层4和锚定层5两者形成中间层3。
附图中并未标出层4和5的厚度。锚定层5的厚度在实际中可能远远低于粘合层4的厚度,其值仅仅为几个原子级的层厚,如上面所指出的那样。
锚定层5基本上由氧化物构成,即掺杂氮的氧化铝。氮的含量并不需要很高,且认为几个原子百分数的氮含量就起作用。
氮掺杂在锚接层5中的作用在于:分布在氧化物晶体中的氮原子导致离子晶体中电荷分布平衡失调,并且因此而阻止原子穿过离子晶体扩散,其中该氧化物晶体是由荷正电的金属离子和O2离子构成的离子晶体。据推断加入少量显著不同于构成晶体的原子或相关离子的原子将导致晶体产生不规则性,并使其不能传递或不渗透正在扩散的原子,这样就不再使这些成分具备容易穿透晶体所需的规则晶格。如果加氮的量相当大,且远远超过可认为是一种掺杂的量加入,当然可能会将氧化物晶体完全重组,形成由金属、氧和氮组分的规则晶格点阵构成的晶体。
可用几种方法制得锚定层5,特别是通过一种PVD法,如电子束PVD、离子溅射镀覆法和阴极电弧-PVD法,或者将氧化物在氮气氛中热处理。这种热处理通常在700℃~1100℃范围的温度内进行。含氮气氛还用来提供PVD方法中所用氮,该方法包括从适宜原料中蒸发所需金属和氧化物,再加入氮气氛中的氮。一般,含氮气氛基本上由氩、氧和氮构成,总压力在10-2~1Pa之间。
图2示出了完整的气体涡轮机元件,即气体涡轮机机翼部件6,具体说是气体涡轮机叶片。该部件6有一个翼面部分7,其在运行中作为汽轮发动机的“作用构件”;一个固定部件8,部件6在此处被牢牢地固定在其位置上,以及一个密封件9,它与相邻部件的密封部件一同构成一密封机构以在运行过程中防止蒸汽10沿着翼面部位7流出。
图1的断面取自图2中的虚线I-I位置。
再参见图1,此锚定层5和热障层2新型组合的特殊优点总结如下:当锚定层含有较高含量的由金属和氧构成的化合物时,由于氮的破坏作用使得几乎无法确定其准确化学式,但用于固定热障层2确实是很适宜的。在沉积锚定层5之后且通常在同一设备中,使用已在沉积锚定层5中用过的尽可能多的装置,使该热障层2立即方便地沉积在基体1表面上。由此得的锚定层5和热障层2的结合体具有本领域现有技术中已知的这类结合体的全部优点以及由于能抑制这些扩散活性成分迁移到热障层2中而使之另外还具有实际上延长了使用寿命的特点。

Claims (23)

1.一种制品,包括:
-由镍基或钴基高温合金构成的基体;
-沉积在所述基体上的锚定层,此锚定层含有掺杂氮的氧化物;及
-沉积在所述锚定层上的陶瓷涂层。
2.根据权利要求1的制品,其中所述氧化物包括氧化铝和/或氧化铬。
3.根据权利要求2的制品,其中所述氧化物基本上由氧化铝构成。
4.根据前述权利要求中任一项的制品,包括由所述锚定层覆盖的扩散活性化学成分。
5.根据权利要求4的制品,其中所述扩散活性化学成分是选自铪、钛、钨和硅中的一种元素。
6.根据前述权利要求中任一项的制品,其中所述陶瓷涂层包括ZrO2
7.根据权利要求6的制品,其中所述陶瓷涂层基本上由ZrO2和选自Y2O3、CeO2、LaO和MgO中的一种稳定剂构成。
8.根据前述权利要求中任一项的制品,其中所述锚定层的厚度小于3μm。
9.根据前述权利要求中任一项的制品,其中所述锚定层含有1~10原子百分数的氮。
10.根据权利要求9的制品,其中所述锚定层含有2~5原子百分数的氮。
11.根据前述权利要求任一项的制品,其中所述锚定层还掺杂另一种化学成分,而此化学成分也被所述锚定层覆盖。
12.根据权利要求11的制品,其中所述另一种化学成分是铬。
13.根据前述权利要求中任一项的制品,其中所述锚定层掺杂另一种化学成分,此化学成分也存在于陶瓷涂层中。
14.根据前述权利要求中任一项的制品,包括插在所述基体和所述锚定层之间的一粘合层。
15.根据权利要求14的制品,其中所述粘合层由金属铝化物形成。
16.根据权利要求14或15的制品,其中所述粘合层由一种MCrAlY合金形成。
17.根据权利要求14至16中任一项的制品,其中所述锚定层掺杂另一种化学成分,此另一种化学成分也存在于粘合层中。
18.根据前述权利要求中任一项的制品,其中所述基体、所述锚定层和所述陶瓷涂层构成气体涡轮机元件。
19.根据权利要求18的制品,其中所述气体涡轮机元件是一种包含一个固定部分和一个翼面部分构成的气体涡轮机机翼构件,所述固定部分是用于在操作中紧紧地固定该元件,而所述翼面部分是在运行中暴露在沿着所述元件冒出的蒸汽气流中;所述锚定层和所述陶瓷层沉积在所述翼面部分上。
20.一种将陶瓷涂层涂覆到由镍基或钴基高温合金形成基体的制品上的方法,该方法包括:
-在此基体上设置一层掺杂氮的氧化物的锚定层;及
-在此锚定层上设置一陶瓷涂层。
21.根据权利要求20的方法,其中设置锚定层的步骤由物理气相沉积法完成。
22.根据权利要求20或21的方法,其中设置锚定层的步骤包括:
-在此基体上设置一层含有基本上无氮的另一种氧化物的层;
在该层周围形成含氮气氛;
-使该层和气氛经受高温并使氮扩散入此层中而形成锚定层。
23.根据权利要求20~22中任一项的方法,其中设置陶瓷涂层的步骤由物理气相沉积法完成。
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CZ289159B6 (cs) 2001-11-14
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US6071556A (en) 2000-06-06
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