CN1994732A - 热障涂覆制品及其制造方法 - Google Patents
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Abstract
一种涂覆制品包括基底;和设置在所述基底上的多层热障涂层,该多层热障涂层包括至少第一层,该第一层包括第一陶瓷成分,其具有小于1W/m°K的导热率;第二层,其具有大于或等于致密竖直裂缝8%钇稳定的二氧化锆的抗腐蚀性,其中所述百分比基于钇和氧化锆的总重量;和第三层,其包括第一陶瓷成分或第二成分,其中所述第一、第二和第三层布置成使第一陶瓷成分和第二成分在交替层中。
Description
技术领域
本发明通常涉及热障涂覆制品及其制造方法。
背景技术
当暴露于高温(即,大于或等于大约1300℃)和氧化环境中时,金属会氧化、腐蚀并变得易碎。这些环境在用于发电应用的涡轮机中产生。热障涂层(TBC)在施加到例如涡轮机的金属部件上时可以减少高温,和腐蚀及氧化环境对该金属部件的影响。
该热障涂层典型地包括陶瓷材料,其沉积在金属基底上或沉积在金属基底上的粘合涂层上用于更好地粘接。通过氧化钇(Y2O3)、氧化镁(MgO)或其他的氧化物实现部分或完全稳定的金属氧化物,例如氧化锆(ZrO2)已经广泛地使用为陶瓷材料。该陶瓷材料典型地通过空气等离子体喷涂(APS)、低压等离子体喷涂(LPPS)或例如电子束物理汽相沉积(EB-PVD)的物理汽相沉积(PVD)技术沉积,其产生容许应变的柱状晶粒结构。所述粘合涂层可以包括抗氧化保护材料,例如铝、铬、铝合金和铬合金。
为了该热障涂层在其保护的部件设计使用周期内保持有效,重要的是该热障涂层具有并保持低导热率。近年来,对降低热障涂层的导热率已经有了进展。然而,即使利用这些进步,在与通过氧化钇实现部分或完全稳定的氧化锆相比,材料可以不利地具有更低的室温粒子抗腐蚀性,甚至可以具有更低的断裂韧度。
因此,一直存在对具有低导热率,同时具有优异的抗腐蚀和抗粒子冲击性的热障涂层的需要。
发明内容
本发明公开了热障涂覆制品及其制造方法。在一个实施例中,涂覆制品包括基底;和设置在所述基底上的多层热障涂层,该多层热障涂层至少包括第一层,该第一层包括第一陶瓷成分,其具有小于1W/m°K的导热率;第二层,其具有大于或等于致密竖直裂缝(densevertically cracked)8%钇稳定的二氧化锆的抗腐蚀性,其中所述百分比基于钇和氧化锆的总重量;和第三层,其包括第一陶瓷成分或第二成分,其中所述第一、第二和第三层布置成使第一陶瓷成分和第二成分在交替层中。
在另一个实施例中,涂覆制品包括基底和设置在该基底上的多层热障涂层。该基底可以包括金属、金属合金或包括至少一种前述材料的组合。该多层热障包括第一层,该第一层包括第一陶瓷成分,该第一陶瓷成分包括稳定的钇钆镱;第二层,该第二层包括第二陶瓷成分,该第二陶瓷成分包括由8wt%的氧化钇部分稳定的氧化锆,其中重量百分数基于氧化锆和氧化钇的总重量;和第三层,该第三层包括第一陶瓷成分或第二陶瓷成分,其中所述第一、第二和第三层布置成使第一陶瓷成分和第二成分在交替层中。
在一个实施例中,一种用于制造涂覆制品的方法,包括将多层热障涂层设置在基底上,该多层热障涂层至少包括第一层,该第一层包括第一陶瓷成分,其具有小于1W/m°K的导热率;第二层,其具有大于或等于致密竖直裂缝8%钇稳定的二氧化锆的抗腐蚀性,其中所述百分比基于钇和氧化锆的总重量;和第三层,其包括第一陶瓷成分或第二成分,其中所述第一、第二和第三层布置成使第一陶瓷成分和第二成分在交替层中。
上文描述的及其他特征通过下面的附图和详细说明进行举例说明。
附图说明
参见示例性附图,其中相同的元件在所述多个附图中以相同的数字标记:
图1为多层热障涂层和涂覆制品的实施例的部分侧面剖视图;和
图2为多层热障涂层和涂覆制品的另一个实施例的部分侧面剖视图。
具体实施方式
本发明公开了热障涂覆制品及其制造方法。如将要详细讨论的那样,所述热障涂层为多个涂层,包括第一陶瓷成分和第二陶瓷成分的交替层。人们已经意外地发现,当多个涂层包括一层以上时,所述一层包括第一陶瓷成分或第二陶瓷成分,可以获得材料性质中的协同效应。所述第一陶瓷成分选择为赋予所述多个涂层低导热率,而第二陶瓷成分选择为赋予所述多个涂层优异的抗腐蚀和抗粒子冲击性。
当在此使用时,术语“低导热率”是指导热率小于1瓦特/开氏温度(W/m°K)。
术语“第一”、“第二”等在此处不表示任何顺序、数量或重要性,而是用于区分一个元件与另一个元件,并且术语“一”在此处不表示数量限制,而是表示存在至少一种所提及物品。与数量结合使用的修饰词“大约”包括所述值并且具有上下文所表示的含义(例如,包括与特定量的测量相关的误差度)。此处公开的范围包括在内并可独立结合(例如,“高达大约25wt%,或更具体地,大约5-20wt%”的范围包括“大约5-25wt%”的范围的端点和所有中间值等)。
本发明的热障涂层用于各种涡轮发动机(例如,燃气涡轮发动机)零部件,所述零部件由例如金属基底的基底形成,所述金属基底包括多种金属和金属合金,包括超级合金。在各种实施例中,这些零部件在(或暴露于)高温(即,大于或等于大约1300℃)下工作。这些涡轮发动机零部件可以包括例如叶片或轮叶的涡轮翼、涡轮壳体、涡轮机喷嘴、例如内衬和偏转板的燃烧室部件、燃气涡轮发动机的增压器零件等。该热障涂层还可以覆盖一部分或全部基底。例如,相对于例如叶片的翼,热障涂层可用于保护、覆盖或遮盖所述翼的基底的一部分而不是全部基底,例如,热障涂层覆盖所述翼的前缘、后缘和其他表面,而不是连接区域。尽管下面的讨论将针对涡轮发动机零部件的金属基底,但是应当理解,热障涂层可用于工作在(或暴露于)高温下的其他制品的基底。
现在参见图1,显示了通常以10表示的热障涂覆制品的实施例。该制品10包括基底12。该基底12可以包括金属、金属合金以及包括至少一种前述材料的组合物。在一个实施例中,基底12包括基于镍、钴和/或铁的金属合金。例如,基底12可以包括高温、耐热合金,例如超级合金。适当的高温合金包括但不限于美国专利No.4,116,723和No.5,399,313中公开的材料。如上所述,基底12的类型可以根据应用广泛变化,但是它典型地为涡轮机零部件的形式,例如翼(例如,叶片)或涡轮壳体。
制品10还可以包括可选的粘合涂层14,其设置为与作为相邻层的基底12物理相连。粘合涂层14由金属抗氧化材料制成,其包括下面的基底12并使热障涂层16能更好地粘接到基底12上。用于粘合涂层14的适当材料包括但不限于MCrAIY合金粉末,其中M代表例如金属,例如铁、镍、铂或钴,或NiAl(Zr)成分,以及各种贵金属扩散铝化物,例如铂铝化物,以及简单的铝化物(即,没有贵金属形成的铝化物)。粘合涂层14可以通过适当的技术施加、沉积或其他方法形成在基底12上,所述技术例如物理汽相沉积(PVD),包括电子束物理汽相沉积(EB-PVD),等离子体喷涂,包括空气等离子体喷雾(APS)和真空等离子体喷涂(VPS),或者其他热喷涂沉积方法,例如高速含氧燃料(HVOF)喷涂,爆震或丝网喷涂(wire spray),化学汽相沉积(CVD),扩散渗碳处理(pack cementation)和在金属扩散铝化物的情况下汽相形成铝化物。在一个实施例中,等离子体喷涂或扩散技术用于沉积粘合涂层14。粘合涂层14的厚度根据应用而改变,但是通常,粘合涂层14的厚度为大约25-500微米,特别地,50-350微米。
热障涂层16设置在基底12上。当使用粘合涂层14时,热障涂层16设置为与粘合涂层14物理相连。热障涂层16包括多层。尽管层数根据应用改变,但是热障涂层包括至少三层。每层的厚度以及热障涂层16的总厚度也根据应用改变。通常,热障涂层16包括足以保护下面的基底12的厚度。例如,热障涂层16的总厚度为大约25-2,500微米。在这个范围内,热障涂层16可以大于75微米,特别地,大于或等于300微米。还是在这个范围内,热障涂层16可以小于或等于1,500微米,特别地,小于或等于1,000微米。
在一个实施例中,热障涂层16包括第一TBC层18,第二TBC层20,第三TBC22和第四TBC层24。所述第一TBC层16设置在粘合涂层14上并与其物理相连。第二TBC层20设置在第一TBC层16上并与其物理相连。第三TBC层22设置在第二TBC层20和第四TBC层24之间。在一个实施例中,第三层22设置为与第二TBC层20和第四TBC层24中的每一个物理相连。第四TBC层24设置在第三TBC层22上并与其物理相连。
第一TBC层18和第三TBC层22包括第一陶瓷成分,其选择为赋予热障涂层16低导热率。第二TBC层20和第四TBC层包括第二陶瓷成分,其选择为赋予热障涂层16优异的抗腐蚀和粒子冲击性。换言之,热障涂层16包括第一陶瓷成分和第二陶瓷成分的交替层。
第一TBC层18和第三TBC层的第一陶瓷成分包括低导热率,即,导热率小于1瓦特/开氏温度(W/m°K)。在一个实施例中,导热率为大约0.25-0.75W/m°K,特别地,大约0.25-0.75W/m°K。
在一个实施例中,第一陶瓷成分包括大约46-97摩尔百分比的基础氧化物,大于2-25摩尔百分比的主要稳定剂,大约0.25-25摩尔百分比的 A族掺杂剂,和大约0.25-25摩尔百分比的B族掺杂剂。所述基础氧化物包括氧化锆(ZrO2)、二氧化铪(HfO2)或包括至少一种前述材料的组合。所述主要的稳定剂包括氧化钇(Y2O3)、氧化镝(Dy2O3)、氧化铒(Er2O3)或包括至少一种前述材料的组合。A族掺杂剂包括氧化钪(Sc2O3)、氧化镱(Yb2O3)、镍(II)氧化物(NiO)、铬(III)氧化物(Cr2O3)、钴(II)氧化物(CoO)、铁(III)氧化物(Fe2O3)、镁(II)氧化物(MgO)、钛(IV)氧化物(TiO2)、钌(IV)氧化物(RuO2)、氧化钽(Ta2O5)、氧化铒(Er2O3)、碱土金属氧化物、过渡金属氧化物或包括至少一种前述材料的组合。B族掺杂剂包括氧化钕(Nd2O3)、氧化钆(Gd2O3)、氧化钐(Sm2O3)、氧化铕(Eu2O3)或包括至少一种前述材料的组合。在一个实施例中,第一陶瓷成分包括稳定的钇钆镱成分,例如美国专利No.6,812,176中公开的材料,该文献在此引入作为参考。
第二陶瓷成分包括大于或等于致密竖直裂缝8%钇稳定的二氧化锆的抗腐蚀性,其中所述百分比基于钇和氧化锆的总重量。
用于第二陶瓷成分的适当材料包括但不限于氧化锆(ZrO2),其由氧化钇(Y2O3)、氧化镁(MgO)或二氧化铈(CeO2)部分(例如,6-8重量百分数)或完全稳定(例如,大于或等于15重量百分数)以产生抵抗相变的四边形微观结构。用于氧化锆的其他稳定剂包括但不限于二氧化铪(HfO2)、氧化钆(Gd2O3)、氧化镝(Dy2O3)、氧化铒(Er2O3)、氧化钕(Nd2O3)、氧化钐(Sm2O3)、氧化镱(Yb2O3)和包括至少一种前述材料的组合。
在一个实施例中,第二陶瓷成分包括氧化钇稳定的二氧化锆(YSZ),特别地,由氧化钇部分稳定的氧化锆。特别地,氧化钇稳定的氧化锆包括大约4-8重量百分数的氧化钇,其中所述重量百分数基于氧化钇和氧化锆的总重量。
热障涂层16的各种层可以通过任何适当的方法设置在基底上。所述适当的方法包括但不限于物理汽相沉积(PVD),包括电子束物理汽相沉积(EB-PVD),等离子体喷涂,空气等离子体喷涂(APS)、真空等离子体喷涂(VPS),或者其他热喷涂沉积方法,例如高速含氧燃料(HVOF)喷涂,爆震或丝网喷涂,以及化学汽相沉积(CVD)。
现在参见图2,显示了通常以30表示的热障涂覆制品的另一个实施例。该制品30包括基底32。用于基底32的适当材料包括但不限于上文相对于基底12所描述的那些材料。热障涂层44设置在基底32上。热障涂层44包括第一TBC层34、第二TBC层36、第三TBC层38、第四TBC层40和第五TBC层42。第一TBC层34设置在基底32上并与其物理相连。第二TBC层36设置在第一TBC层34上并与其物理相连。第三层38设置为与第二TBC层36和第四TBC层40中的每一个物理相连。第五TBC层42设置在第四TBC层40上并与其物理相连。
第一TBC层34和第四TBC层40每个都包括上述讨论过的第一陶瓷材料,并且第二TBC层36和第五TBC层42包括也在上文讨论过的第二陶瓷材料。第三TBC层38包括不同于第一和第二陶瓷成分中每一个的陶瓷成分。换句话说,包括第一陶瓷材料或第二陶瓷材料的层可以彼此物理相连或不相连。但是,例如第三TBC层38的各种附加层可以设置在包括第一陶瓷材料的层(例如,第四TBC层40)和包括第二陶瓷材料的层(例如,第二TBC层36)之间。
用于第三TBC层38的适当材料包括但不限于氧化锆(ZrO2),其由氧化钇(Y2O3)、氧化镁(MgO)或二氧化铈(CeO2)部分(例如,6-8重量百分数)或完全稳定(例如,大于或等于15重量百分数)以产生抵抗相变的四边形微观结构。用于氧化锆的其他稳定剂包括但不限于二氧化铪(HfO2)、氧化钆(Gd2O3)、氧化镝(Dy2O3)、氧化铒(Er2O3)、氧化钕(Nd2O3)、氧化钐(Sm2O3)、氧化镱(Yb2O3)和包括至少一种上述材料的组合。
热障涂层44的各种层可以通过任何适当的方法设置在基底32上。所述适当的方法包括但不限于物理汽相沉积(PVD),包括电子束物理汽相沉积(EB-PVD),等离子体喷涂,空气等离子体喷涂(APS)、真空等离子体喷涂(VPS),或者其他热喷涂沉积方法,例如高速含氧燃料(HVOF)喷涂,爆震或丝网喷涂,以及化学汽相沉积(CVD)。
此外,上文针对图1和2讨论过的热障涂层可以是致密竖直裂缝(DVC)热障涂层,例如用于高温翼部件上的涂层,或者多孔热障涂层,例如用于相对较低温度(例如,温度小于大约1,300℃)部件的涂层。
有利地注意到,当与仅包括单层的热障涂层比较时,或者当与不包括第一陶瓷材料和第二陶瓷材料的交替层的热障涂层比较时,本发明公开的热障涂层在导热率和抗冲击性上均得到改善。同样,涂有所述热障涂层的制品可以具有更长的使用寿命。
尽管本发明已经参照示例性实施例进行了描述,但是本领域的技术人员应当理解,在不脱离本发明的范围的情况下,可以进行各种变形,并且等效物可以由其构件替代,另外,在不脱离本发明实质的情况下,根据本发明教导,可以进行许多改进以适应特别的情况和材料。因此,本发明不限于作为执行本发明的最佳方式而公开的特定实施例,本发明可以包括落入附加权利要求范围内的所有实施例。
部件列表
10热障涂覆制品
12基底
14粘合涂层
16热障涂层
18第一热障涂层
20第二热障涂层
22第三热障涂层
24第四热障涂层
30热障涂覆制品
32基底
34第一热障涂层
36第二热障涂层
38第三热障涂层
40第四热障涂层
42第五热障涂层
44热障涂层
Claims (10)
1.一种涂覆制品(10),包括:
基底(12);和
设置在基底(12)上的多层热障涂层(16),该多层热障涂层包括至少
第一层(18),包括具有导热率小于1W/m°K的第一陶瓷成分;
第二层(20),具有大于或等于致密竖直裂缝8%钇稳定的二氧化锆的抗腐蚀性,其中所述百分比基于钇和氧化锆的总重量,和
第三层(22),包括第一陶瓷成分或第二成分,
其中所述第一(18)、第二(20)和第三(22)层布置成使得第一陶瓷成分和第二成分在交替层中。
2.如权利要求1所述的涂覆制品(10),还包括设置在基底(12)上并与其物理相连的粘合涂层(14)。
3.如权利要求1所述的涂覆制品(10),其中导热率为大约0.25-0.75W/m°K。
4.如权利要求1所述的涂覆制品(10),其中导热率为大约0.50-0.75W/m°K。
5.如权利要求1所述的涂覆制品(10),其中第一层(18)设置为与基底(12)物理相连并设置为与第二层(20)物理相连;并且第三层(22)设置为与第二层(20)物理相连并包括第一陶瓷成分。
6.如权利要求1所述的涂覆制品(10),其中基底(12)包括金属、金属合金或包括至少一种前述材料的组合。
7.如权利要求1所述的涂覆制品(10),其中第一陶瓷成分包括:
大约46-97摩尔百分比的基础氧化物,其中所述基础氧化物包括氧化锆(ZrO2)、二氧化铪(HfO2)或包括至少一种前述材料的组合;
大约2-25摩尔百分比的主要的稳定剂,其中所述主要的稳定剂包括氧化钇(Y2O3)、氧化镝(Dy2O3)、氧化铒(Er2O3)或包括至少一种前述材料的组合;
大约0.25-25摩尔百分比的A族掺杂剂,其中所述A族掺杂剂包括氧化钪(Sc2O3)、氧化镱(Yb2O3)、镍(II)氧化物(NiO)、铬(III)氧化物(Cr2O3)、钴(II)氧化物(CoO)、铁(III)氧化物(Fe2O3)、镁(II)氧化物(MgO)、钛(IV)氧化物(TiO2)、钌(IV)氧化物(RuO2)、氧化钽(Ta2O5)、氧化铒(Er2O3)、碱土金属氧化物、过渡金属氧化物或包括至少一种前述材料的组合;和
大约0.25-25摩尔百分比的B族掺杂剂,其中所述B族掺杂剂包括氧化钕(Nd2O3)、氧化钆(Gd2O3)、氧化钐(Sm2O3)、氧化铕(Eu2O3)或包括至少一种上述材料的组合。
8.如权利要求1所述的涂覆制品(10),其中第一陶瓷成分包括稳定的钇钆镱。
9.如权利要求1所述的涂覆制品(10),其中第二陶瓷成分包括由氧化钇(Y2O3)、氧化镁(MgO)或二氧化铈(CeO2)部分或全部稳定的氧化锆(ZrO2)。
10.一种制造涂覆制品(10)的方法,包括:
将多层热障涂层(16)设置在基底(12)上,所述多层热障涂层(16)包括至少:
第一层(18),其包括具有导热率小于1W/m°K的第一陶瓷成分;
第二层(20),其具有大于或等于致密竖直裂缝8%钇稳定的二氧化锆的抗腐蚀性,其中所述百分比基于钇和氧化锆的总重量;和
第三层(22),包括第一陶瓷成分或第二成分;
其中所述第一(18)、第二(20)和第三(22)层布置成使得第一陶瓷成分和第二成分在交替层中。
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2006
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2007
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- 2007-01-08 CN CNA2007100014659A patent/CN1994732A/zh active Pending
- 2007-01-09 JP JP2007001437A patent/JP2007211343A/ja not_active Withdrawn
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US20080107920A1 (en) | 2008-05-08 |
EP1806434A1 (en) | 2007-07-11 |
JP2007211343A (ja) | 2007-08-23 |
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