CN1863640B - 涂层系统的生产方法 - Google Patents

涂层系统的生产方法 Download PDF

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CN1863640B
CN1863640B CN2004800292235A CN200480029223A CN1863640B CN 1863640 B CN1863640 B CN 1863640B CN 2004800292235 A CN2004800292235 A CN 2004800292235A CN 200480029223 A CN200480029223 A CN 200480029223A CN 1863640 B CN1863640 B CN 1863640B
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coating
composition
indenture
fusing point
matrix
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CN1863640A (zh
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赖纳·安东
克里斯琴·贝尔
布里吉特·海内克
迈克尔·奥特
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Siemens AG
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Abstract

现有技术一般用焊料充填凹痕和/或裂缝，而焊料会与将要涂敷的涂层生成对涂层的机械特性具有不良影响的脆性相。通过按本发明的方法，可以从焊料(13)中除去会生成脆性相(16)的成分。这一点可以通过下述方法而实现，即，涂敷一种同样会与所述成分发生反应的第二材料(22)，并在涂敷涂层(7)之前将所述第二材料(22)和所述脆性相(16)一起除去。

Description

涂层系统的生产方法
技术领域
本发明涉及一种生产一个带有一基质的涂层系统的方法。
背景技术
涡轮叶片和其他用于高温技术领域的结构部件在长时间使用后会出现各种裂缝或腐蚀区域，因此需要对结构部件进行再处理来去除这些裂缝或腐蚀区域，在此过程中，结构部件上经过处理的部位会出现一个凹痕。
这些裂缝或凹痕一般用焊料进行充填。
据在本发明范围内所做的研究的结果所示，多组分焊料通常含有可降低熔点的物质(例如硼)或其他会与一种密封性涂层(例如防腐涂层、隔热涂层)生成脆性相(例如硼化铬)的成分。
因而，这类涂层系统的机械性能不佳，特别是当其处于高温环境中时。此外，涂层的防氧化功能和防腐功能也会有所减弱。
发明内容
因此，本发明的目的在于提供一种方法和一种结构部件，所述方法可以通过充填涂层系统下面的凹痕来改善涂层系统的上述性能。
本发明基于如下认识，即，焊料的一种组分会与将要涂敷的涂层以非希望的形式发生反应。
本发明的目的通过一种生产一个带有一基质的涂层系统的方法而实现，具体而言这种方法是，在一个中间步骤中施加一种第二材料，这种第二材料和第一材料(例如一焊料)发生反应，并通过与第一材料至少部分地生成化合物来除去第一材料中的非希望成分。
随后，同时除去第二材料和从第一材料中所析出的非希望成分。这样，第一材料与涂层之间的界面上不再含有下述成分，即，会与将要涂敷的涂层的材料以非希望的形式发生反应的成分。
第二材料也可以只是涂敷在第一材料上，在第一材料和将要涂敷的涂层之间创造一个间隔，从而阻止第一材料的成分和所述涂层发生反应，或显著降低发生这种情况的可能性。这样，由第二材料构成的涂层就形成了一个扩散阻挡层或扩散屏障。
从属权利要求涉及的是其他有利措施。
从属权利要求中所列举的措施可以以有利的方式组合起来。
附图说明
下面根据附图对本发明的一个实施例进行说明，其中：
图1为根据现有技术的一种涂层系统；
图2至图6为按本发明的方法的工序；
图7为一个燃气轮机；
图8为一个燃烧室；以及
图9为一个汽轮机。
具体实施方式
图1所示的涂层系统1至少由一个基质4和至少一个涂层7组成。
涂层系统1例如是一个汽轮机或燃气轮机100的一个结构部件(叶片120、130，燃烧室内衬155......)。
与此相应地，基质4例如是用一种铁基、镍基或钴基超级合金制成，也就是说，基质4是金属基质。基质4也可以是陶瓷基质。
涂层7为陶瓷或金属涂层，例如由一种MCrAlX合金构成。
其中，M代表铁(Fe)、钴(Co)或镍(Ni)族元素中的至少一种元素。X代表稀土元素中的至少一种元素，特别是钇。
基质4上有一个例如由于长时间使用某个结构部件或在生产过程中所形成的凹痕10(裂缝，凹槽，铣槽)。
当基质4处于这种状态时，还无法对其进行正常地涂覆。
必要时先对凹痕10进行预先的净化处理(除去氧化物)，再用一种第一多组分材料13充填凹痕10。所述的第一多组分材料例如是一种焊料13。
焊料13含有例如在较高温度下会与涂层7发生反应的、可降低熔点的成分。所述降低熔点的成分含有硼。
通常情况下，可降低熔点的成分是使焊料粘度变低、从而顺利渗入并完全充填狭缝的必要条件。
焊料13例如含有硼(B)或含硼化合物，硼或含硼化合物会与MCrAlX涂层7中的铬(Cr)生成易脆裂的、会对涂层的机械性能和/或防腐性能造成不良影响的硼化铬相16。
第一多组分材料13中的至少一种组分(可降低熔点的成分)和涂层7在随后的热处理或运行使用过程中发生反应时就会生成这种非希望的相16。
其中，硼扩散到涂层7中，同时/或者，从涂层7中渗出的铬扩散到充填着材料13的凹痕10中。
图2显示的是按本发明的方法的第一个步骤。
凹痕10已用焊料13充填，并在必要时通过焊接热处理与基质4相连接。在此，需要材料13中含有可降低熔点的成分，以便将材料13通过凹痕10连接到基质4上。
基质4在凹痕10范围内的表面19上涂敷了一种第二材料22，所述第二材料构成一个局部涂层，所谓“局部”指的是：第二材料22所占的面积(＝凹痕10的横截面面积＞小于(＜20％)涂层7的面积。由第二材料22涂敷的这个涂层的厚度例如小于将要涂敷的涂层7的厚度。
第二材料22例如是铬、一种含铬化合物，或含铬合金，或一种其他金属的合金。材料22也可以是其他的物质。
可以通过膏、浆、胶带(强力胶带)、或等离子喷涂等手段将第二材料22涂敷在基质的表面上，所述的这些材料均至少含有高比例的材料22。
在涂敷所述涂层(7)之前，对所述焊料进行一次焊接热处理，从而使其在所述凹痕(10)中与所述基质(4)相连接。
如图3所示，在除杂热处理，特别是在高温下单独进行的扩散热处理过程中，但也有可能例如同时在上述焊接热处理进行的过程中，也就是，当基质4、第一材料13及第二材料22一起随着热处理的进行而温度升高时，会生成例如以析出物形态出现的相16(化合物)，由此，第一材料(焊料)13中至少有一种非希望组分被析出，这种组分会与将要涂敷在基质上的涂层7(参见图5)生成非希望的相16。
这些相例如是在焊接热处理过程中未被化合的硼所生成的硼化铬。材料22中也可能存在溶解在间隙(晶格)中的硼。
相16可能生成在第二材料22和/或位于凹痕10中的第一材料13中。
因此，第二材料22例如是涂层7的一个成分，例如是MCrAlX涂层中的铬。
但也可以选择一种不含有涂层7中任何一种元素或成分的材料。
所选择的这种材料必须可以只和第一材料13中的至少一种非希望组分发生反应，以避免这种非希望组分与涂层7以非希望的形式发生反应。
在这种状态下(参见图6)，即，当第二材料22以化合物的形式结合了第一材料13中的非希望组分，从而使其无法再与涂层7的材料发生反应时，就可以进行涂敷了。由材料22构成的涂层同时还形成了一个可以防止继续渗出的非希望组分发生扩散的扩散阻挡层或扩散屏障。
如图4所示，也可以(特别是通过研磨)将第二材料22和/或带有脆性相16的材料13除去。
随后进行涂层7的涂敷，参见图5。
由于第一材料13至少在靠近表面19的地方几乎不再含有会与涂层7的材料发生反应并生成非希望化合物的非希望组分，因此，即使下一步对基质4进行热处理也不会在涂层7中生成脆性相。
通过上述方法制造而得的结构部件可以是一个新制的结构部件，也可以是一个使用过的结构部件。这种方法主要应用在结构部件的补焊(Refurbishment)技术领域中。
在此过程中，首先要除去原来的涂层。接着对缺陷(裂缝)进行补焊翻新，必要时进行再次涂层，主要是先涂敷一个MCrAlX涂层，再涂敷一个陶瓷隔热涂层。
图7显示的是一个燃气轮机100的纵向局部剖视图。
燃气轮机100的内部具有一个支承在一个旋转轴102上的转子103，转子103围绕旋转轴102旋转，又称为涡轮转子。沿着转子103依次布置着一个吸进壳体104、一个压缩机105、一个配有若干个共轴布置的燃烧器107的、例如呈环形的燃烧室110(特别是环形燃烧室106)、一个涡轮108和一个排气室109。环形燃烧室106和一个例如呈环形的热气通道111连通。在热气通道中，例如有四个串联在一起的、共同构成了涡轮108的涡轮级112。
每个涡轮级112由两个叶片环组成。从工作介质113的流动方向上看，热气通道111中的每个导向叶片列115后面布置着一个由工作叶片120所组成的工作叶片列125。
导向叶片130固定在定子143上，而组成一个工作叶片列125的工作叶片120则通过一个涡轮叶轮盘133安装在转子103上。转子103上耦接着一个发电机或一个做功机器(图中未显示)。
燃气轮机100工作时，压缩机105通过吸进壳体104吸入空气135，并对这部分空气进行压缩。在压缩机105靠近涡轮一侧的一端上生成的压缩空气被输送到燃烧器107上，并在这里与一种燃料混合。这部分由压缩空气和燃料构成的混合物在燃烧室110中燃烧，形成一种工作介质113。从燃烧室110中出来的工作介质113沿着热气通道111流过导向叶片130和工作叶片120。工作介质113在工作叶片120上膨胀并传递动量，从而使得工作叶片120驱动转子103，再由转子103驱动与其耦接的做功机器。
燃气轮机100工作时，与工作介质113接触的结构部件承受着一定的热负荷。从工作介质113的流动方向上看，构成第一涡轮级112的导向叶片130和工作叶片120与覆盖在环形燃烧室106上的隔热石，是热负荷最高的结构部件。为了使这部分导向叶片和工作叶片能够经受住其所在位置的温度，要用一冷却剂对它们进行冷却。叶片120、130同样可以具有防腐(MCrAlX；M＝Fe、Co、Ni，X＝Y、稀土元素)和防热(隔热涂层，例如ZrO2、Y2O4-ZrO2)的涂层。
导向叶片130具有一个朝着涡轮108的内壳138的导向叶片根部(图中未显示)和一个位于所述导向叶片根部对面的导向叶片顶部。导向叶片顶部朝向转子103，并固定在定子143的一个紧固环140上。
图8显示的是一个燃气轮机的一个燃烧室110。燃烧室110设计成例如所谓的环形燃烧室，具有复数个燃烧器102，从切线方向上看，这些燃烧器围绕涡轮轴103布置，并通向一个共同的燃烧室空间。因此从整体上看，燃烧室110具有一个环形结构，可以围绕涡轮轴103布置。
为了达到较高的效率，燃烧室110设计能使用具有较高温度的工作介质M，其中，“较高温度”指的是约1000℃至1600℃。为了即使在存在诸如此类不利于材料的工作参数的情况下也能实现较长的持续工作时间，燃烧室壁153朝向工作介质M的一侧上配备了一个由热屏蔽元件155构成的内衬。每个热屏蔽元件155朝向工作介质的一侧由耐高温材料制成，或者其上配有一个特别耐热的防护层。此外，鉴于燃烧室110内部的高温，还为热屏蔽元件155和/或支持件设置了一个冷却系统。
所述燃烧室110的一个特别功能是可以探测热屏蔽元件155的损耗情况。为此，燃烧室壁153和热屏蔽元件155之间布置了复数个温度传感器158。

Claims (8)

1.一种生产一个带有一基质(4)的涂层系统(1)的方法，其中，所述基质(4)具有一个有待充填的凹痕(10)，用一焊料(13)作为第一材料充填所述凹痕(10)，所述焊料含有至少一种降低熔点的成分，从而在充填后的凹痕(10)范围内在所述基质(4)上涂敷一个涂层(7)，如果这一降低熔点的成分扩散到所述涂层(7)中，就会对所述涂层(7)的特性造成不利影响，其特征在于，
在涂敷上述涂层(7)之前的一个步骤中，只在充填后的凹痕(10)范围内涂敷一第二材料(22)，所述第二材料是铬或铬化合物或合金；然后，
在涂敷上述涂层(7)之前的一个步骤中，进行一次除杂热处理，从而使得所述至少一种降低熔点的成分从位于所述凹痕(10)中的所述焊料中析出，且至少部分进入所述第二材料(22)，
在所述除杂热处理之后和在所述基质(4)上涂敷所述涂层(7)之前，通过研磨处理将所述第二材料(22)和从所述焊料中析出的所述至少一种降低熔点的成分除去，使得所述的降低熔点的成分几乎不能或根本不能扩散到所述涂层(7)中。
2.根据权利要求1所述的方法，其特征在于，所述降低熔点的成分含有硼。
3.根据权利要求1所述的方法，其特征在于，所述除杂热处理以扩散热处理的形式进行。
4.根据权利要求1所述的方法，其特征在于，将一种铁基、镍基或钴基超级合金用作所述基质(4)。
5.根据权利要求1所述的方法，其特征在于，将一种MCrAlX合金用作所述涂层(7)，其中，M是铁族、钴族或镍族元素中的至少一种元素，X是稀土元素中的至少一种元素。
6.根据权利要求1所述的方法，其特征在于，将一种MCrAlX合金用作所述涂层(7)，其中，M是铁族、钴族或镍族元素中的至少一种元素，X是钇。
7.根据权利要求1所述的方法，其特征在于，所述第二材料(22)涂敷的厚度比所述涂层(7)的厚度小。
8.根据权利要求1所述的方法，其特征在于，所述第二材料(22)通过一种膏、浆或胶带涂敷。
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