CN1894071A - 去除热阻涂层的方法 - Google Patents

去除热阻涂层的方法 Download PDF

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CN1894071A
CN1894071A CNA2004800374305A CN200480037430A CN1894071A CN 1894071 A CN1894071 A CN 1894071A CN A2004800374305 A CNA2004800374305 A CN A2004800374305A CN 200480037430 A CN200480037430 A CN 200480037430A CN 1894071 A CN1894071 A CN 1894071A
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盖伊·林·汉利
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Abstract

简单地讲，本发明提供了一种方法，其采用一种包含有非研磨微粒介质的空气射流，该射流在低压下工作能够有选择地将热阻涂层从部件上去掉，而不会损坏到金属基材。本方法有选择地将热阻涂层从部件的冷却孔上去掉。

Description

去除热阻涂层的方法
技术领域
本发明总的来讲涉及一种用来从金属部件上去除热阻涂层的方法，其特别涉及一种从燃气涡轮发动机部件如燃烧室内衬的冷却孔去除热阻陶瓷涂层的方法。
背景技术
燃气涡轮发动机(宇航发动机和工业发动机)在设计上应使其镍钴超耐热合金部件能够在其熔点附近的温度下操作。热阻涂层(TBC)的重要功能就是对那些在高温下工作的部件进行热绝缘。典型的涡轮部件有燃烧室(参见图1中的燃烧室10)、导管、排气嘴、涡轮叶片以及喷嘴导流片。TBC的特征是它们的导热系数很低，在曝露于热流中时，涂层的温度梯度很大。
最通常的TBC材料是经氧化钇稳定处理的氧化锆(YSZ)，其能阻抗高达1150℃热冲击和热疲劳。通常可通过空气等离子喷涂(APS)、低压等离子喷涂(LPPS)或者是物理蒸气沉积(PVD)工艺如电子束物理蒸气沉积(EBPVD)沉积上一层陶瓷层。通常会在基材上预先涂上一层粘性层。该粘性涂层用来吸收金属基材和陶瓷TBC因热膨胀系数的不同而产生的残余应力，从而避免其在涂覆系统中继续发展，同时还能防止氧化和侵蚀。典型的粘性涂层包括，但不限于，MCrAlY，其中M是Ni、Co、Fe或其混合物，或者是扩散的氧化铝或铂铝涂层。
人们一直希望能提高燃气涡轮发动机的效率，由此就导致燃烧室以及涡轮发动机高温部分的温度不断提高。为了补偿所增加的这部分温度，通常会在热负荷很大时使用散流孔来冷却。发动机部件如附图1所示的燃烧室10的冷却用散流孔是由激光打孔而成的直径很小(0.010到0.060英寸)的散流孔11，其角度和形式应能将所需的冷却空气输送到发动机部件。散热孔冷却系统通常与发动机部件上的TBC涂层一起使用，其最大的好处就是能够经受很高的温度梯度。降低金属基材的温度从而能够延长发动机部件的寿命。此外，这些冷却孔和TBC系统能够减少金属基材的温度梯度从而减少热疲劳的驱动力。这些系统的好处是，部件的耐用性更好，燃气温度更高，同时发动机的性能和效率更高。
激光打孔技术(如Nd:YAG激光器)可用来在燃气涡轮发动机的高温部分中冲击加工出冷却孔。这些部分优选由热阻涂层(TBC)保护。因此激光打孔技术需在部件的金属基材和TBC中同时打出通孔才能加工出冷却孔，然而在该加工过程中会出现由激光所形成的损害。在TBC与金属粘性涂层和金属基材的交界处会产生微结构损害，从而导致TBC脱胶以及陶瓷绝热涂层的损坏(散裂)，这一点对于金属基材来说是有害的，因为这么高的热负荷会对部件的耐用性和使用寿命产生不利影响。
现在已开发出各种技术来在加工和维修的过程中将热阻涂层从部件去除下来。专利文献US6004620、EP1340587A2以及US6620457B2均公开了一种带或不带(研磨或非研磨)微粒介质的喷水系统，其中用到一个包含液体的射流，该射流在5000磅/平方英寸到50000磅/平方英寸的高流体压力下工作从而将沉积的热阻涂层去掉。该喷水方法在5000磅/平方英寸下工作一个循环只会给涂层下面的基材产生“最小限度的”磨损和侵蚀。增加循环和/或提高压力则会增加磨损和侵蚀。
发明内容
简单地讲，本发明提供了一种方法，其采用一种包含有非研磨微粒介质的空气射流，该喷嘴在低压下工作能够有选择地将热阻涂层从部件上去掉，而不会损坏到金属基材。本方法有选择地将热阻涂层从部件的冷却孔上去掉。
附图说明
图1所示为用来实现本发明方法的装置的侧示图。
具体实施方式
本发明提供一种方法，其采用一种包含有非研磨微粒介质的低压的仅有空气的射流，其能有效地去掉沉积的热阻涂层，而不会磨损侵蚀到下面的金属基材，这是因为空气的压力很低并且没有研磨介质。本方法可用来对部件进行无数次操作，而不会产生明显的磨损和侵蚀。
本方法采用非研磨微粒介质，其优选为干燥的球形介质，其在控制的低压空气流下能够有效地磨削去除热阻涂层，而不会影响到部件的金属基体。本方法能够有效地去除某些部件上TBC涂层，这些部件包括但不限于，散流空气冷却孔以及空气冷却孔，同时也能去除那些其上不需要或者是不想有TBC的部件上的TBC涂层。
本方法能用激光打孔工艺(如果需要的话)来加工或修理部件，从而在应用或恢复热阻涂层之前形成或恢复空气冷却孔。本方法的一个主要优点在于其能在进行所需的激光打孔之后加上热阻涂层，从而消除激光对TBC的损坏(散裂)以及激光对部件金属基体的热损坏或损伤，这些损坏会影响到部件的耐用性和使用寿命。
本方法的另一个优点是通过对粗糙边缘或锐利边缘的平滑和圆角处理能够提高空气冷却孔内壁和边缘的表面性能，从而明显地提高空气冷却孔的气流特性。燃烧室室壁的气流测试表明：这种处理之后，空气的质量流量增加了14.6％。在激光打孔并清理毛刺之后燃烧室内衬壁的气流测试结果表明其质量流量为0.333093LBM/S(磅/每秒质量流量)，而同一内壁在加上TBC并使用本处理之后的气流测试结果表明其质量流量为0.382348LBM/S。
该方法可用附图1所示的干空气喷射系统1，其包括但不限于：一壳体(图中未示出)、轮盘2、多个空气喷嘴3、一个干空气供应压力容器和介质处理单元4、一个用来使空气喷嘴移动的机构5、一个介质处理/回收单元以便进行过滤和球形颗粒分离(图中未示出)以及一个可编程控制器(图中未示出)。该干空气喷射系统装置采用一个介质回收单元，从而在处理过程中提供连续地介质过滤和球形颗粒分离，由此保持该方法的效率并在空气冷却孔的孔中以及孔的附近产生最佳的表面性能，这一点是我们希望的，由此能提高空气冷却孔的排气系数。
本方法采用一种只有空气的输送系统，其在低压下工作，该压力优选在约20磅/平方英寸(PSIG)到约100PSIG之间，从而使中间的非研磨性微粒介质流流到工作区域从而切掉并去掉沉积的热阻涂层，而不会影响到部件的金属基体表面。优选的非研磨性介质是：其中直径在约0.002到0.010英寸(约0.05到0.25毫米)的颗粒至少占70％，优选为至少占95％的球形介质。直径大约为0.003英寸的球形玻璃介质可用作非研磨介质。
由于部件不断变化的几何结构和设计，干空气喷射系统的喷嘴可以以任易的一种方式来进行连接从而达到所需的位置将中间流的球形介质输送到工作区域，从而以不断变化的冲角从部件上切下并去掉沉积的热阻涂层，其中的部件包括但不限于空气冷却孔的内壁、边缘和表面。也可根据需要采用人工干空气喷射喷嘴来完成该处理。在将TBC从冷却孔去掉的过程中，空气射流可指向冷却孔并对着带有热阻涂层表面的相反面，如在图1所示的燃烧室10的外表面12具有TBC涂层时，空气射流应从内表面对着冷却孔。除了将TBC从冷却孔去除之外，空气射流还要与冷却孔同轴对齐(即，基本上与冷却孔处于同一角度)。
本发明可用于加工或维修过程中涂有热阻层的部件。为了加工新的部件，可在其它所有操作都进行完之后再涂上TBC，这包括在激光打孔和加工之后。由于涂上TBC的操作可作为本发明的最后加工操作之一，因此加到部件上的TBC的质量和整体性就能得到保证，并且其与TBC涂覆中与部件一起正常加工出来的测试样件具有相同的质量水平和特性。在部件的加工过程中，该方法可根据需要去除TBC从而实现部件加工所需的调整和/或维修。为了对部件进行维修，本方法可用来仔细地去除TBC从而准备出该部件以便检测和维修。在维修操作完成之后，这包括但不限于焊接、碾磨、热处理以及激光打孔和加工之后，可重新涂上TBC，并且本方法可根据需要去除不想要的任何TBC。
这种只有空气的低压介质球冲孔方法可以是一种可控的系统，其在大多数去除TBC的应用中均采用大约20PSIG到100PSIG低空气压力下工作的直径非常小(在0.003英寸的直径范围内)的球形介质。某些去除TBC的应用可能要求处理参数和/或介质能在本发明的保护范围进行变化。本方法没有什么攻击性，其不会对金属基体产生磨损或侵蚀，并且其非常经济并且处理的结果具有一致性。在采用本发明之后，冷却孔的气流测试也表明部件的气流特性有明显地改进。
实例
喷气发动机高温部分燃烧室(其由镍或钴基的超耐热合金材料制造)在制造时由激光冲孔制有空气冷却孔。该部分的燃气通路(高温侧)的表面首先是涂上一层金属粘接层，其主要是镍并包含有铬、铝以及氧化钇(或者是另一种反应元素)。该金属粘接层通过等离子喷涂工艺喷涂成一定的厚度，该厚度通常约为0.005到0.008英寸(大约为0.13到0.020mm)。在喷涂上粘接层后，空气冷却孔采用激光打孔工艺制造并生成所需的入射角从而实现部件所需的空气冷却特性。在激光打孔后，对部件进行清洗从而去掉激光熔渣或者是激光打孔过程中产生的废料。在激光打孔和清洗之后，可通过等离子喷涂工艺喷涂形成大约0.001到0.003英寸厚的粘接涂层，该粘接涂层可选择同种材料。然后是通过等离子喷涂工艺喷涂形成陶瓷顶层，该陶瓷顶层主要是由6％到8％氧化钇稳定处理的氧化锆，其厚度大约为0.005到0.020英寸(大约为0.13到0.50mm)。在喷涂陶瓷顶层的过程中，该部件的空气冷却孔会被热阻涂层(陶瓷顶层)部分堵塞从而限制了冷却空气流。
图1中所示的一种型号为Model RSSA-8的Guyson干空气喷射系统用来提供一种干空气射流，其工作压力为40到60PSIG，所采用的是直径为0.003英寸的球形玻璃介质(至少70％的球形颗粒的直径为0.003英寸)。该干空气射流基本上以空气冷却孔相同的入射角朝向部件(与涂有热阻层的表面相反)的金属表面侧(非涂覆侧)从而将经沉积限制了空气流的热阻涂层去掉。
沉积的热阻涂层从空气冷却孔被完全去除从而给部件提供所需的冷却空气流。此外，该空气冷却孔的表面和边缘经修整(光滑及圆整处理)能使空气冷却孔的排气系数提高从而使空气流的质量流量大约提高15％。

Claims (27)

1、一种用来从一部件的金属基体表面去除热阻陶瓷涂层的方法，其包含：
使一空气射流对着该部件基体表面的热阻涂层，该射流内含非研磨颗粒介质并以低压从一喷嘴喷出，其中的低压应不足以损坏基体的表面，但应足以去除热阻陶瓷涂层。
2、如权利要求1的方法，其中空气射流的压力大约为20PSIG到100PSIG。
3、如权利要求2的方法，其中的介质基本为球形。
4、如权利要求3的方法，其中的球形介质颗粒的直径大约为0.002到0.010英寸。
5、如权利要求4的方法，其中的介质为玻璃珠。
6、如权利要求1的方法，其中的部件为一涡轮发动机部件。
7、如权利要求6的方法，其中的涡轮发动机部件为一燃烧室。
8、一种用来从金属涡轮发动机部件的冷却孔去除热阻陶瓷涂层的方法，其包含：
使一空气射流对着该部件的冷却孔，该射流内含非研磨颗粒介质并以低压从一喷嘴喷出，其中的低压应不足以损坏冷却孔的金属表面，但足以去除热阻陶瓷涂层。
9、如权利要求8的方法，其中空气射流的压力大约为20PSIG到100PSIG。
10、如权利要求9的方法，其中的介质基本为球形。
11、如权利要求10的方法，其中的球形介质颗粒的直径大约为0.002到0.010英寸。
12、如权利要求11的方法，其中的介质为玻璃珠。
13、如权利要求12的方法，其中的涡轮发动机部件为一燃烧室。
14、如权利要求8的方法，其中的空气射流指向冷却孔并对着带有热阻涂层表面的相反面。
15、如权利要求9的方法，其中的空气射流基本上以冷却孔的角度指向冷却孔。
16、如权利要求8的方法，其中的空气射流包绕冷却孔的金属边缘。
17、如权利要求8的方法，其中的冷却孔采用一种激光打孔工艺在涡轮部件上打出。
18、一种用来在其上涂覆有热阻涂层的涡轮发动机部件上形成冷却孔的方法，其包含：
在该部件上打出冷却孔；
给这个包含有冷却孔的部件表面涂上一层热阻陶瓷涂层；以及
使一空气射流对着该部件的冷却孔，该射流内含非研磨颗粒介质并以低压从一喷嘴喷出，其中的低压应不足以损坏冷却孔的金属表面，但足以去除热阻涂层。
19、如权利要求18的方法，其中空气射流的压力大约为20PSIG到100PSIG。
20、如权利要求19的方法，其中的介质基本为球形。
21、如权利要求20的方法，其中的球形介质颗粒的直径大约为0.002到0.010英寸。
22、如权利要求21的方法，其中的介质为玻璃珠。
23、如权利要求22的方法，其中的涡轮发动机部件为一燃烧室。
24、如权利要求16的方法，其中的空气射流指向冷却孔并对着带有热阻涂层表面的相反面。
25、如权利要求18的方法，其中的空气射流基本上以冷却孔的角度指向冷却孔。
26、如权利要求18的方法，其中的空气射流包绕冷却孔的金属边缘。
27、如权利要求18的方法，其中的冷却孔采用一种激光打孔工艺在涡轮部件上打出。
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