CN1807090A - 带有阻挡层的层状系统及其制造方法 - Google Patents

带有阻挡层的层状系统及其制造方法 Download PDF

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CN1807090A
CN1807090A CNA2006100057397A CN200610005739A CN1807090A CN 1807090 A CN1807090 A CN 1807090A CN A2006100057397 A CNA2006100057397 A CN A2006100057397A CN 200610005739 A CN200610005739 A CN 200610005739A CN 1807090 A CN1807090 A CN 1807090A
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barrier layer
layered system
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CN1807090B (zh
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克努特·哈伯斯塔特
沃纳·施塔姆
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Abstract

本发明公开了一种带有阻挡层的层状系统及其制造方法。按照现有技术的构件为避免腐蚀具有一保护层，其中，该保护层中的一种金属元素(例如铝)形成一种保护性的氧化物层。但这种金属元素也以不期望的方式扩散到基层中。按照本发明的层状系统(1)具有一阻止所述扩散的金属阻挡层(7)，其中，该阻挡层(7)具有PdAl2、Ta2Al、NbAl2或Nb3Al类型的至少一种金属间相。

Description

带有阻挡层的层状系统及其制造方法
技术领域
本发明涉及一种带有阻挡层的层状系统及一种制造这种层状系统的相应方法。
背景技术
应用在高温下的构件，尤其是透平机中的构件具有由MCrAlX类型的合金组成的防腐蚀层，其中，该MCrAlX合金中的铝在这保护层的表面上形成一层保护性氧化层。但铝元素也会从这一保护层中扩散到所述基体材料中，而这却是不期望看到的。在US 4477538、JP11124688A与US5427866以及DE 19842417这些专利文献中公开了一些由铂或钯制成的金属层位于基层和保护层或外层之间。
发明内容
因此，本发明要解决的技术问题就是要克服上面的问题。
为解决上述技术问题，本发明首先提供一种层状系统，它至少包括一基层、一位于该基层上的保护层以及在该基层和保护层之间的一阻挡层，其中，该保护层尤其可带有在其之上的一隔热层，按照本发明，所述阻挡层至少部分设计成金属间相，该金属间相从PdAl2、Ta2Al、NbAl2或Nb3Al这组铝化合物中选择，并且所述保护层由一种MCrAlX合金组成。
本发明另外还建议了两种制造所述层状系统的方法，按照第一种方法是采用一种泥釉来制造所述阻挡层；而按照第二种方法则是用一种电解方法来制造所述阻挡层。
如此制造出的层状系统具有改善的防腐蚀性，因为铝很少或几乎不会扩散到基体材料中，并因此导致与现有技术相比防腐蚀层中的铝随时间的流失减少。同样，也会有更少的元素从基体材料中扩散到所述防腐蚀层中。这一点可以通过改善所述阻挡层作为阻挡扩散层的阻挡效果来实现。
按照本发明的层状系统的一种扩展设计，所述阻挡层主要由至少一种金属间相组成。
按照本发明的层状系统的另一种扩展设计，所述阻挡层具有一金属基体，后者包含一种金属间相的颗粒。
所述阻挡层也可具有仅仅一种金属间相，但也可由多种金属间相构成。
所述阻挡层优选相对于所述保护层设计得更薄，尤其是最多只有50μm厚，优选最多只有5μm厚。比较有利的是，所述阻挡层的厚度为所述保护层厚度的1％-17％。
按照本发明的层状系统的一种有利设计，所述阻挡层由带有金属间相的纳米级晶体颗粒组成，后者的晶粒尺寸尤其小于500nm。所述阻挡层还优选具有超塑性。
按照本发明的层状系统的另一种有利设计，所述基层是一种超级高温合金，尤其是一种铁基、钴基或镍基超级高温合金。
按照本发明的层状系统可以是一个透平机构件，尤其是汽轮机或燃气轮机的构件，尤其是一个透平叶片或一个热屏元件。
按照本发明的第一种用于制造层状系统的方法的一种有利设计，将所述泥釉涂刷在所述基层上。按照另一种设计则是喷涂所述泥釉。
按照本发明的第二种用于制造层状系统的方法的一种有利设计，将一些用于制造所述阻挡层的材料颗粒弥散在一种电解液中并使之电解沉积。优选将用于形成所述阻挡层的有待沉积出的元素溶解在一种电解液中。
按照本发明的用于制造层状系统的方法的一种有利设计，可通过对所述阻挡层进行热处理来使之与所述基层结合。
上述各种技术措施可按照有利的方式方法任意组合。
附图说明
下面借助附图所示实施方式对本发明予以详细说明，附图中：
图1表示按本发明的一个层状系统；
图2表示一个透平叶片；
图3表示一个燃烧室；
图4表示一台燃气轮机。
具体实施方式
图1示出了按照本发明的一种层状系统1。
该层状系统1例如是一个透平机构件，诸如一个用于飞机或发电站的汽轮机或燃气轮机100(参见图4)上的构件，在此尤其可以是一个透平叶片120，130(参见图2)或一个热屏元件155(参见图3)。
尤其在透平机构件上的所述基层4由一种铁基、钴基或镍基超级高温合金组成。
在该基层4上以公知的方式涂覆有至少一层尤其可由MCrAlX类合金组成的保护层10。
为了应用在特别高的温度下，在所述保护层10上可能还要有一陶瓷隔热层13(图1中用虚线示出)。这样一来，所述保护层10就不仅是防氧化和/或防腐蚀的保护层，而且也是将所述陶瓷隔热层15结合在所述基层4上的中间粘合层。
按照本发明，在该基层4和保护层10之间有一阻挡层7，该阻挡层7至少部分具有从PdAl2、Ta2Al、NbAl2或Nb3Al这组铝化合物中选择出的一种金属间相。该金属间相阻止铝从保护层10中扩散到基层4中。
金属间合金(相)具有一种晶体结构，它相对于构成它的两种或更多种合金成分有完全不同的特性并且按固有的、与参与形成它的金属的结构不一致的品格结构类型结晶。这种金属间相可以化学计量地组成，但它可以构成同样好的混合晶体区并具有一种有秩序的或无秩序的分布。在本申请背景技术部分中提到的现有技术文献所公开的由铂或钯制成的层是纯粹的金属层，而不是金属间相层。
按照本发明的一种优选设计，所述阻挡层7主要由至少一种金属间相组成，也就是说由一个为PdAl2、Ta2Al、NbAl2或Nb3Al中的一种金属间相型的基体组成，但该基体也可以包含多种金属间相而形成一个金属间相混合物。所述阻挡层7的基体例如可由纳米级晶体颗粒组成。
同样，所述金属间相可尤其作为纳米级晶体形式的颗粒存在于另一种金属基体中，例如存在于基层4的超级高温合金中或MCrAlX类合金中。该晶体颗粒的尺寸小于500nm，尤其小于300nm或小于100nm。
为了制造所述金属间相的阻挡层7，也可首先将Pd、Ta或Nb涂覆在基层4上，然后渗铝，然后再通过适当的热处理将所涂覆的材料转换成一种金属间相。其他实施例可以是一种铂基金属间相。
所述阻挡层7可相对于所述保护层10设计得特别薄，尤其是最多只有50μm厚，优选最多只有5μm厚，并且可例如通过电解法和/或用尤其是纳米级的粉末颗粒来制造，由此来实现薄的层厚度。所述阻挡层7也因此不仅可由微米级颗粒组成的一层颗粒层组成也可由好几层颗粒层组成。
由MCrAlX类合金制成的一层保护层10例如大约为300μm厚，这样，所述阻挡层7的厚度可有利地为所述保护层10厚度的1％-17％。这一点完全适用于所述阻挡层7和位于其上的保护层10。
所述金属间相具有一高的熔融温度，这样一来，当其应用在高温下时就能保持其结构，而不会因为相互扩散而溶解掉。
所述阻挡层7可尤其通过相应选择其组成材料或形态而具有尤其在高温下的超塑性。例如可通过一种纳米级的晶体结构(晶粒尺寸)来实现这一点。
为了不会形成容易产生裂纹的阻挡层7及避免由此所导致的层状系统1的机械强度或抗腐蚀性的降低，阻挡层7具有一定塑性很重要。
所述阻挡层7可以按照各种方式方法来制造。
例如可采用一种泥釉来制造所述阻挡层7。这种泥釉可由用于制造该阻挡层7的材料的粉末(例如部分或完全为纳米级晶体)、一种载体溶剂(例如水或酒精)以及可能还有一种结合剂(例如树脂)组成。
所述泥釉可涂刷或喷涂在所述基层4的表面上。通过对其进行干燥，所述载体溶剂逸出，所述结合剂可能还会被烧掉。之后再对其进行密实和粘结式热处理。
同样，也可用一种电解方法来制造所述阻挡层7。按此方法，将一些用于制造所述阻挡层7的粉末颗粒(例如部分或完全为纳米级晶体)弥散在一种电解液中并使之电解沉积，和/或将形成所述阻挡层(7)的其中一种元素或所有元素溶解在电解液中，然后从该溶液中分离出并沉积在基层4上。在此，也可以对这样形成的所述阻挡层7随后进行热处理。
图2用透视图表示一种涡轮机的工作叶片120或导向叶片130，它沿纵轴线121延伸。
该涡轮机可以是飞机的燃气轮机或发电的动力装置、汽轮机或压气机。
叶片120、130沿纵轴线121彼此相继地有固定区400、与之相邻的叶片平台403以及叶身406。作为导向叶片130，叶片130可以在其叶片顶部415有另一个平台(未表示)。
固定区400构成叶根183，它用于将叶片120、130固定在轴或轮盘上(未表示)。叶根183可以例如设计为倒“T”形。也可以不同地设计为枞树形或燕尾形叶根。叶片120、130有流入边或前缘409和流出边或后缘412，它们用于一种在叶身406上流过的介质。
传统的叶片120、130在叶片120、130的所有区域400、403、406内例如采用实心的金属材料，尤其是超级高温合金。例如由EP 1204776B1、EP 1306454、EP 1319729A1、WO 99/67435或WO 00/44949已知这种超级高温合金；这些文件是本申请公开内容的一部分。叶片120、130在这里可以通过铸造方法，也可以借助定向凝固、通过锻造方法、通过铣削方法或这些方法的组合制造。
有单晶结构的工件用作一些机器的构件，这些机器在运行中遭受高机械、热和/或化学负荷。这些单晶工件的制造例如通过熔融金属的定向凝固实现。在这里涉及铸造方法，按此方法液态的金属合金定向凝固为单晶结构，亦即单晶工件。在这种情况下树枝状的晶体沿热流方向定向，并构成或一种柱状结晶的晶粒结构(沿工件全长延伸的柱，亦即晶粒，以及在这里按习惯用语称为定向凝固)，或一种单晶结构，亦即整个工件由单一晶体组成。按此方法，人们必须避免转变为球状(多晶体)凝固，因为通过不定向生长必然构成横向和纵向晶界，它们使定向凝固或单晶构件良好的特性消失。若一般论及定向凝固的组织，则既指单晶体，它们没有晶界或最多有小角度晶界，也指柱状晶体结构，它们也许有沿纵向延伸的晶界，但没有横向的晶界。对于所述的这两种晶体结构人们也称之为定向凝固组织(directionally solidified structures)。由US-PS 6024792和EP 0892090A1已知这些方法；这些文件也是本申请公开内容的一部分。
同样，叶片120、130可以有防腐蚀或氧化的涂层(MCrAlX；其中，M是铁(Fe)、钴(Co)、镍(Ni)元素组中至少一种，X是一种活性元素以及代表钇(Y)和/或硅(Si)和/或至少一种稀土元素或铪(Hf))。由EP 0486489B1、EP0786017B1、EP 0412397B1或EP 1306454A1已知这些合金，它们也应是本申请公开内容的一部分。
在MCrAlX上面还可以存在一个隔热层以及例如由ZrO2、Y2O4-ZrO2组成，也就是说，它没有、部分或完全通过氧化钇和/或氧化钙和/或氧化镁稳定化。采用恰当的涂层方法，例如热电子束蒸镀(EB-PVD)，在隔热层内造成柱状晶粒。
再加工(整修)的意思是，构件120、130在其使用后必要时必须除去保护层(例如通过喷砂)。然后进行去除腐蚀和/或氧化层或产物。有可能还要修理构件120、130内的裂纹。然后进行构件120、130的重新涂层以及重新使用构件120、130。
叶片120、130可以设计为空心或实心的。若叶片120、130应当冷却，则它是空心的以及必要时还有气膜冷却孔418(用虚线表示)。
叶片120、130例如具有相应的大多为金属的涂层(MCrAlX)作为防腐蚀层，并且大多还具有一陶瓷层作为耐热层。
图3表示燃气轮机的燃烧室110。燃烧室110例如设计为所谓的环形燃烧室，其中，许多绕旋转轴线102沿周向排列的燃烧器107通入一公共的燃烧室腔内。为此，燃烧室110在其总体上设计为环形结构，它围绕旋转轴线102定位。
为达到比较高的效率，针对比较高的工质M的温度约为1000℃至1600℃来设计燃烧室110。为了即使在这些对于材料不利的运行参数下仍能有比较长的使用寿命，燃烧室壁153在其面朝工质M的那一侧加上用热屏元件155构成的内衬。
每个热屏元件155在工质一侧配备有特别耐热的护层或用耐高温材料制造。这可以是实心陶瓷块或有MCrAlX和/或陶瓷涂层的合金。燃烧室壁及其涂层的材料可类似于透平叶片。
基于燃烧室110内部这种高的温度，还可以为热屏元件155或为它们的固定元件设置冷却系统。
图4作为范例表示燃气轮机100的局部纵剖面。燃气轮机100内部有一个绕旋转轴线102旋转支承的转子103，它亦称为透平机转子。沿转子103彼此相继的是一个进气机匣104、一个压气机(压缩机)105、一个包括多个同轴排列的燃烧器107的例如花托状燃烧室110，尤其环形燃烧室106、一个透平机108和排气机匣109。环形燃烧室106与例如环形的热燃气通道111连通。在那里例如四个串联的透平级112构成透平机108。每个透平级112例如由两个叶片环构成。沿工质113的流动方向看，在热燃气通道111内，在导向叶排115后跟随着一个由工作叶片120构成的叶排125。
在这里导向叶片130固定在定子143的内机匣138上，而一个排125的工作叶片120例如借助透平机轮盘133安装在转子103上。在转子103上连接一发电机或一工作机械(未表示)。
在燃气轮机100运行时，压气机105通过进气机匣104吸入并压缩空气135。将在压气机105透平机一侧的端部处制备的压缩空气导向燃烧器107并在那里与燃料混合。此混合物然后在燃烧室110内燃烧形成工质113。工质113从那里出发沿热燃气通道111流过导向叶片130和工作叶片120。工质113在工作叶片120上传输冲量地膨胀，所以工作叶片120驱动转子103，以及转子103驱动与其连接的工作机械。
遭遇热工质113的构件在燃气轮机100运行期间承受热负荷。除了覆盖着环形燃烧室106的热屏元件外沿工质113流动方向看的第一透平级112的导向叶片130和工作叶片120承受的热负荷最大。为了能承受住在那里存在的温度，它们可以借助冷却剂冷却。同样这些构件的基质也可以有定向结构，也就是说，它们是单晶的(SX结构)或只有纵向的晶粒(DS结构)。作为构件的材料，尤其透平叶片120、130和燃烧室110构件的材料，例如采用铁基、镍基或钴基的超级高温合金。
例如由EP 1204776B1、EP 1306454、EP 1319729A1、WO 99/67435或WO 00/44949已知这种超级高温合金；这些文件是本申请公开内容的一部分。
叶片120、130同样可以有防腐蚀的涂层(MCrAlX；M是铁(Fe)、钴(Co)、镍(Ni)元素组中至少一种，X是一种活性元素以及代表钇(Y)和/或硅和/或至少一种烯土元素或铪)。由EP 0486489B1、EP 0786017B1、EP 0412397B1或EP 1306454A1已知这些合金，它们应是本申请公开内容的一部分。
在MCrAlX上面还可以存在一个隔热层以及例如由ZrO2、Y2O4-ZrO2组成，也就是说，它没有、部分或完全通过氧化钇和/或氧化钙和/或氧化镁稳定化。采用恰当的涂层方法，例如热电子束放射(EB-PVD)，在隔热层内造成柱状晶粒。
导向叶片130具有一个面朝透平机108内机匣138的导叶叶根(图中未表示)以及一个与导叶片根对置的导叶端部。导叶端部面朝转子103以及固定在定子143的固定环140上。

Claims (18)

1.一种层状系统(1)，它至少包括一基层(4)、一位于该基层(4)上的保护层(10)以及在该基层(4)和保护层(10)之间的一阻挡层(7)，其中，该保护层(10)尤其可带有在其之上的一隔热层(13)，其特征在于，所述阻挡层(7)至少部分设计成金属间相，该金属间相从PdAl2、Ta2Al、NbAl2或Nb3Al这组铝化合物中选择，并且所述保护层(10)由一种MCrAlX合金组成。
2.按照权利要求1所述的层状系统，其特征在于，所述阻挡层(7)主要由至少一种金属间相组成。
3.按照权利要求1所述的层状系统，其特征在于，所述阻挡层(7)具有一金属基体，后者包含一种金属间相的颗粒。
4.按照权利要求1、2或3所述的层状系统，其特征在于，所述阻挡层(7)具有仅仅一种金属间相。
5.按照权利要求1所述的层状系统，其特征在于，所述阻挡层(7)仅仅由一种或多种金属间相构成。
6.按照权利要求1至5中任一项所述的层状系统，其特征在于，所述阻挡层(7)相对于所述保护层(10)设计得更薄，尤其是最多只有50μm厚，优选最多只有5μm厚。
7.按照权利要求1或6所述的层状系统，其特征在于，所述阻挡层(7)的厚度为所述保护层(10)厚度的1％-17％。
8.按照权利要求1至7中一项或多项所述的层状系统，其特征在于，所述阻挡层(7)由带有金属间相的纳米级晶体颗粒组成，后者的晶粒尺寸尤其小于500nm。
9.按照权利要求1至8中一项或多项所述的层状系统，其特征在于，所述阻挡层(7)具有超塑性。
10.按照权利要求1所述的层状系统，其特征在于，所述基层(4)是一种超级高温合金，尤其是一种铁基、钴基或镍基超级高温合金。
11.按照权利要求1或10所述的层状系统，其特征在于，所述层状系统(1)是一个透平机构件，尤其是汽轮机或燃气轮机(100)的构件，尤其是一个透平叶片(120，130)或一个热屏元件(155)。
12.一种制造按照权利要求1至11中一项或多项所述层状系统的方法，其特征在于，采用一种泥釉来制造所述阻挡层(7)。
13.按照权利要求10所述的方法，其特征在于，将所述泥釉涂刷在所述基层(4)上。
14.按照权利要求10所述的方法，其特征在于，喷涂所述泥釉。
15.一种制造按照权利要求1至9中一项或多项所述层状系统的方法，其特征在于，用一种电解方法来制造所述阻挡层(7)。
16.按照权利要求15所述的方法，其特征在于，将一些用于制造所述阻挡层(7)的材料颗粒弥散在一种电解液中并使之电解沉积。
17.按照权利要求15或16所述的方法，其特征在于，将所述阻挡层(7)的有待沉积的元素溶解在一种电解液中。
18.按照权利要求12至17所述的方法，其特征在于，通过对所述阻挡层(7)进行热处理来使之与所述基层(4)结合。
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CN108603503A (zh) * 2015-12-23 2018-09-28 艾默生环境优化技术有限公司 具有热和声音优化的晶格芯部的增材制造的压缩机部件
US10557464B2 (en) 2015-12-23 2020-02-11 Emerson Climate Technologies, Inc. Lattice-cored additive manufactured compressor components with fluid delivery features
US10634143B2 (en) 2015-12-23 2020-04-28 Emerson Climate Technologies, Inc. Thermal and sound optimized lattice-cored additive manufactured compressor components
US10982672B2 (en) 2015-12-23 2021-04-20 Emerson Climate Technologies, Inc. High-strength light-weight lattice-cored additive manufactured compressor components
CN108603503B (zh) * 2015-12-23 2021-06-04 艾默生环境优化技术有限公司 具有热和声音优化的晶格芯部的增材制造的压缩机部件
US11248595B2 (en) 2015-12-23 2022-02-15 Emerson Climate Technologies, Inc. Lattice-cored additive manufactured compressor components with fluid delivery features
US11448221B2 (en) 2015-12-23 2022-09-20 Emerson Electric Co. Thermal and sound optimized lattice-cored additive manufactured compressor components

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CN1807090B (zh) 2011-06-01
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DE502005007982D1 (de) 2009-10-08
EP1681374A1 (de) 2006-07-19

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