DE102014222686A1 - Double-layered thermal barrier coating by different coating methods - Google Patents

Double-layered thermal barrier coating by different coating methods Download PDF

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DE102014222686A1
DE102014222686A1 DE102014222686.4A DE102014222686A DE102014222686A1 DE 102014222686 A1 DE102014222686 A1 DE 102014222686A1 DE 102014222686 A DE102014222686 A DE 102014222686A DE 102014222686 A1 DE102014222686 A1 DE 102014222686A1
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layer
ceramic layer
outermost
thermal barrier
oxide
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DE102014222686.4A
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German (de)
Inventor
Arturo Flores Renteria
Sascha Martin Kyeck
Catrina MICHEL
Torsten Neddemeyer
Ingo Reinkensmeier
Alexandr Sadovoy
Peter Sahm
Tolga Yagci
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Siemens AG
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Siemens AG
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    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/134—Plasma spraying
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/32—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer
    • C23C28/321—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer with at least one metal alloy layer
    • C23C28/3215—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer with at least one metal alloy layer at least one MCrAlX layer
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/34—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates
    • C23C28/345—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer
    • C23C28/3455—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer with a refractory ceramic layer, e.g. refractory metal oxide, ZrO2, rare earth oxides or a thermal barrier system comprising at least one refractory oxide layer
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
    • C23C4/11—Oxides

Abstract

Durch eine äußerste keramische Schicht, hergestellt durch Suspension Plasma Spray, wird ein verbesserter Schutz gegen CMAS-Verunreinigungen erzielt, wobei diese auf eine keramische Schicht aus dem Stand der Technik aufgebracht wird.An outermost ceramic layer, prepared by suspension plasma spray, provides improved protection against CMAS impurities, applied to a prior art ceramic layer.

Description

Die Erfindung betrifft ein keramisches Wärmedämmschichtsystem, bei dem zwei keramische Schichten hergestellt werden, für die verschiedene Herstellungsverfahren und damit verschiedene Mikrostrukturen erzielt werden. The invention relates to a ceramic thermal barrier coating system in which two ceramic layers are produced, for which different production processes and thus different microstructures are achieved.

Beschichtete heißgasbeaufschlagte Bauteile sind während des Betriebes einer Gasturbine bei hohen Temperaturen einem Angriff von CMAS (Calcium-Magnesium-Aluminium-Silikate) ausgesetzt, welcher zur Abplatzung der keramischen Beschichtung (TBC) führen und somit die Lebensdauer einer Turbinenschaufel signifikant reduzieren kann. Coated components exposed to hot gas are subjected to attack by CMAS (calcium-magnesium-aluminum-silicates) during operation of a gas turbine at high temperatures, which can lead to the spalling of the ceramic coating (TBC) and thus significantly reduce the service life of a turbine blade.

Es ist daher Aufgabe der Erfindung oben genanntes Problem zu lösen. It is therefore an object of the invention to solve the above-mentioned problem.

Die Aufgabe wird gelöst durch ein keramisches Wärmedämmschichtsystem nach Anspruch 1. The object is achieved by a ceramic thermal barrier coating system according to claim 1.

In den Unteransprüchen sind weitere vorteilhafte Maßnahmen aufgelistet, die beliebig miteinander kombiniert werden können, um weitere Vorteile zu erzielen. In the dependent claims further advantageous measures are listed, which can be combined with each other in order to achieve further advantages.

Der Vorteil ist die Erzeugung eines „Lotusblüteneffektes". Dieser Effekt kann durch Modifikation der Beschichtung durch folgende Prozessschritte erfolgen:
Als letzter Schritt des TBC-Beschichtungsprozesses, indem die Förderung des Beschichtungsmaterials von pulverförmig (Atmospheric Plasma Spray, APS) zu flüssig (Suspension Plasma Spray, SPS) umgestellt wird. Letztgenannte Suspension bildet beim Aufbringen auf das Substrat eine Schicht mit Primär- und Sekundär-Dendriten aus, welche die Anhaftung von Flüssigkeiten verhindert. The advantage is the creation of a "lotus blossom effect." This effect can be achieved by modifying the coating by means of the following process steps:
As a final step in the TBC coating process, switching the delivery of the coating material from powdered (Atmospheric Plasma Spray, APS) to liquid (Suspension Plasma Spray, SPS). The latter suspension, when applied to the substrate, forms a layer of primary and secondary dendrites which prevents the adhesion of liquids.

Mithilfe dieser Lösung wird die CMAS-Schädigung von beschichteten heißgasbeaufschlagten Bauteilen vermieden und somit eine höhere Lebensdauer erreicht. This solution avoids CMAS damage to coated components exposed to hot gases, resulting in a longer service life.

Es zeigen: Show it:

1 ein erfindungsgemäßes Wärmedämmschichtsystem im Querschnitt 1 an inventive thermal barrier coating system in cross section

2 eine Aufsicht auf ein erfindungsgemäßes Wärmedämmschichtsystem. 2 a plan view of an inventive thermal barrier coating system.

Die Figuren und die Beschreibung stellen nur Ausführungsbeispiele der Erfindung dar. The figures and the description represent only embodiments of the invention.

1 zeigt ein erfindungsgemäßes keramisches Schichtsystem 1. Das keramische Wärmedämmschichtsystem 1 weist ein Substrat 4, insbesondere ein metallisches Substrat 4, auf. Bei Turbinenbauteilen ist dies eine Nickel- oder Kobaltbasierte Superlegierung. Auf dem Substrat 4 ist vorzugsweise eine metallische Haftvermittlerschicht 7, insbesondere eine Überzugsschicht, ganz insbesondere aus einer NiCoCrAlY-Legierung aufgebracht. 1 shows a ceramic layer system according to the invention 1 , The ceramic thermal barrier coating system 1 has a substrate 4 , in particular a metallic substrate 4 , on. For turbine components, this is a nickel- or cobalt-based superalloy. On the substrate 4 is preferably a metallic adhesion promoter layer 7 , in particular a coating layer, very particularly applied from a NiCoCrAlY alloy.

Diese NiCoCrAlY-Legierung kann durch weitere Elemente wie Rhenium (Re), Tantal (Ta), Eisen (Fe), Silizium (Si), Hafnium (Hf) und/oder Titan (Ti) modifiziert sein. Ebenso können anstatt Yttrium (Y) oder mit Yttrium (Y) andere seltene Erdelemente vorhanden sein. This NiCoCrAlY alloy may be modified by other elements such as rhenium (Re), tantalum (Ta), iron (Fe), silicon (Si), hafnium (Hf) and / or titanium (Ti). Likewise, other rare earth elements may be present instead of yttrium (Y) or yttrium (Y).

Zweck dieser metallischen Haftvermittlerschicht 7 ist die Anbindung an eine keramische Schicht und eine Oxidationsschutzfunktion des Substrats 4, weil auf der metallischen Haftvermittlerschicht 7 eine Oxidschicht aufwächst, die schon bei der Herstellung vorhanden ist und auf jeden Fall im Betrieb entsteht. Purpose of this metallic adhesion promoter layer 7 is the connection to a ceramic layer and an oxidation protection function of the substrate 4 because on the metallic primer layer 7 grows an oxide layer, which is already present in the production and in any case arises during operation.

Auf der metallischen Haftvermittlerschicht 7 ist eine innere keramische Schicht 8 aufgebracht, die vorzugsweise eine Porosität von 15% ± 3% aufweist. Die innere keramische Schicht 8 wird durch ein Spritzverfahren unter Verwendung von Pulver aufgebracht, insbesondere durch thermische Spritzverfahren, ganz insbesondere mittels HVOF oder APS. Dementsprechend weist die innere keramische Schicht 8 flache Körner auf, wobei „flach“ sich auf die Oberfläche des Substrats 4 bezieht. On the metallic primer layer 7 is an inner ceramic layer 8th applied, which preferably has a porosity of 15% ± 3%. The inner ceramic layer 8th is applied by a spraying process using powder, in particular by thermal spraying, in particular by means of HVOF or APS. Accordingly, the inner ceramic layer 8th flat grains on, being "flat" on the surface of the substrate 4 refers.

Das Material für die innere keramische Schicht 8 ist vorzugsweise teilstabilisiertes Zirkonoxid. Die Teilstabilisierung wird vorzugweise durch Yttriumoxid und vorzugsweise durch einen Gewichtsanteil von 8 Gew.-% Yttriumoxid erreicht. The material for the inner ceramic layer 8th is preferably partially stabilized zirconium oxide. The partial stabilization is preferably achieved by yttrium oxide and preferably by a weight fraction of 8% by weight yttrium oxide.

Auf der Oberfläche 13 dieser keramischen Schicht 8 ist eine weitere keramische, äußerste Schicht 11 aufgebracht, die vorzugsweise mittels des Suspension Plasma Sprays (SPS) hergestellt wird. On the surface 13 this ceramic layer 8th is another ceramic outermost layer 11 applied, which is preferably prepared by means of the suspension plasma spray (SPS).

Das Material für die äußerste keramische Schicht 11 ist vorzugsweise Zirkonoxid und vorzugsweise das gleiche wie das der inneren keramischen Schicht 8. Ebenso vorzugsweise können aber auch andere Materialien wie Pyrochlore, Gadoliniumzirkonat, -hafnat oder Mischungen aus Gadoliniumoxid, Hafniumoxid, Zirkoniumoxid, verwendet werden. The material for the outermost ceramic layer 11 is preferably zirconia and preferably the same as that of the inner ceramic layer 8th , However, preferably also other materials such as pyrochlore, gadolinium zirconate, hafnate or mixtures of gadolinium oxide, hafnium oxide, zirconium oxide can be used.

Das SPS-Verfahren weist eine gewisse stängelartige Struktur mit Haupt- und Nebendendriten auf, wie es in 2 dargestellt ist. The SPS process has some stalk-like structure with major and minor dendrites as found in 2 is shown.

Claims (7)

Keramisches Wärmedämmschichtsystem (1) zumindest aufweisend ein Substrat (4), insbesondere ein metallisches Substrat (4), optional eine metallische Haftvermittlerschicht (7) auf dem Substrat (4), eine innere keramische Schicht (8), die durch ein Spritzverfahren mit Pulver, insbesondere durch ein thermisches Spritzverfahren, ganz insbesondere durch APS oder HVOF hergestellt wurde und eine äußerste keramische Schicht (11) auf der inneren keramischen Schicht (8), die mittels einer Flüssigkeit, insbesondere mittels Suspension Plasma Spray, hergestellt wurde. Ceramic thermal barrier coating system ( 1 ) at least comprising a substrate ( 4 ) in particular a metallic substrate ( 4 ), optionally a metallic adhesion promoter layer ( 7 ) on the substrate ( 4 ), an inner ceramic layer ( 8th ) produced by a powder injection process, in particular by a thermal spraying process, more particularly by APS or HVOF, and an outermost ceramic layer ( 11 ) on the inner ceramic layer ( 8th ), which was prepared by means of a liquid, in particular by means of suspension plasma spray. Schichtsystem nach Anspruch 1, bei dem die äußerste keramische Schicht (11) eine stängelartige Struktur aufweist, insbesondere mit Haupt- und Nebendendriten. Layer system according to Claim 1, in which the outermost ceramic layer ( 11 ) has a stalk-like structure, in particular with major and minor dendrites. Schichtsystem nach einem der beiden Ansprüche 1 oder 2, bei dem die innere keramische Schicht (8) eine plättchenförmige Struktur aufweist. Layer system according to either of claims 1 or 2, in which the inner ceramic layer ( 8th ) has a platelet-shaped structure. Schichtsystem nach einem oder beiden der Ansprüche 1 oder 3, bei dem die innere keramische Schicht (8) Zirkonoxid aufweist, insbesondere teilstabilisiertes Zirkonoxid, ganz insbesondere stabilisiert durch Yttriumoxid. Layer system according to one or both of Claims 1 or 3, in which the inner ceramic layer ( 8th ) Zirconium oxide, in particular partially stabilized zirconium oxide, very particularly stabilized by yttrium oxide. Schichtsystem nach einem oder mehreren der Ansprüche 1, 2, 3 oder 4, bei dem die äußerste keramische Schicht (11) Zirkonoxid, insbesondere teilstabilisiertes Zirkonoxid aufweist, ganz insbesondere stabilisiert durch Yttriumoxid. Layer system according to one or more of claims 1, 2, 3 or 4, in which the outermost ceramic layer ( 11 ) Zirconium oxide, in particular partially stabilized zirconium oxide, in particular stabilized by yttrium oxide. Schichtsystem nach einem oder mehreren der Ansprüche 1, 2, 3 oder 4, bei dem das Material der äußersten keramischen Schicht (11) Pyrochlore, insbesondere Gadoliniumzirkonat oder Gadoliniumhafnat oder Mischungen von Oxiden mit Gadoliniumoxid, aufweist. Layer system according to one or more of claims 1, 2, 3 or 4, in which the material of the outermost ceramic layer ( 11 ) Pyrochlore, in particular gadolinium zirconate or gadolinium hafnate or mixtures of oxides with gadolinium oxide. Schichtsystem nach einem oder mehreren der Ansprüche 1, 2, 3, 4, 5 oder 6, bei dem die Dicke der inneren keramischen Schicht (8) mindestens zweimal so dick ist wie die Schichtdicke der äußersten keramischen Schicht (11). Layer system according to one or more of claims 1, 2, 3, 4, 5 or 6, in which the thickness of the inner ceramic layer ( 8th ) is at least twice as thick as the layer thickness of the outermost ceramic layer ( 11 ).
DE102014222686.4A 2014-11-06 2014-11-06 Double-layered thermal barrier coating by different coating methods Withdrawn DE102014222686A1 (en)

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102015223576A1 (en) * 2015-11-27 2017-06-01 Siemens Aktiengesellschaft Local two-layer thermal barrier coating
CN107245687A (en) * 2017-06-09 2017-10-13 天津大学 A kind of toughness rare earth phosphate/zirconates composite thermal barrier coating and preparation method thereof
CN111118438A (en) * 2020-01-14 2020-05-08 武汉理工大学 High-temperature high-emissivity heat dissipation coating and preparation method and application thereof
US11673097B2 (en) 2019-05-09 2023-06-13 Valorbec, Societe En Commandite Filtration membrane and methods of use and manufacture thereof

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Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102015223576A1 (en) * 2015-11-27 2017-06-01 Siemens Aktiengesellschaft Local two-layer thermal barrier coating
US10662787B2 (en) 2015-11-27 2020-05-26 Siemens Aktiengesellschaft Local two-layer thermal barrier coating
CN107245687A (en) * 2017-06-09 2017-10-13 天津大学 A kind of toughness rare earth phosphate/zirconates composite thermal barrier coating and preparation method thereof
US11673097B2 (en) 2019-05-09 2023-06-13 Valorbec, Societe En Commandite Filtration membrane and methods of use and manufacture thereof
CN111118438A (en) * 2020-01-14 2020-05-08 武汉理工大学 High-temperature high-emissivity heat dissipation coating and preparation method and application thereof
CN111118438B (en) * 2020-01-14 2021-12-17 武汉理工大学 High-temperature high-emissivity heat dissipation coating and preparation method and application thereof

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