EP0379699B1 - Method for enhancing the corrosion and erosion resistance of the blade of a rotary thermal apparatus and blade produced ba said method - Google Patents

Method for enhancing the corrosion and erosion resistance of the blade of a rotary thermal apparatus and blade produced ba said method Download PDF

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Publication number
EP0379699B1
EP0379699B1 EP89123291A EP89123291A EP0379699B1 EP 0379699 B1 EP0379699 B1 EP 0379699B1 EP 89123291 A EP89123291 A EP 89123291A EP 89123291 A EP89123291 A EP 89123291A EP 0379699 B1 EP0379699 B1 EP 0379699B1
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EP
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Prior art keywords
blade
weight
corrosion
base material
protective layer
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EP89123291A
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German (de)
French (fr)
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EP0379699A1 (en
Inventor
Benno Basler
Tibor Koromzay
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ABB Asea Brown Boveri Ltd
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ABB Asea Brown Boveri Ltd
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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/288—Protective coatings for blades
    • 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
    • C23C4/06—Metallic material
    • C23C4/067—Metallic material containing free particles of non-metal elements, e.g. carbon, silicon, boron, phosphorus or arsenic
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S428/00—Stock material or miscellaneous articles
    • Y10S428/922—Static electricity metal bleed-off metallic stock
    • Y10S428/9335—Product by special process
    • Y10S428/937—Sprayed metal
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12736—Al-base component
    • Y10T428/1275—Next to Group VIII or IB metal-base component
    • Y10T428/12757—Fe

Definitions

  • the invention relates to a method according to the introductory part of patent claim 1.
  • the invention also relates to a blade which can be obtained by the method according to patent claim 1.
  • Rotating thermal machines are mainly steam turbines, gas turbines and turbo compressors.
  • the blades used in these machines are to be effectively protected against operational attacks, in particular erosion and corrosion, but also oxidation, wear and damage.
  • the blades of rotating thermal machines are often provided with protective layers. This is used in both steam and gas turbine blades as well as compressor blades. The main thing is to increase resistance to corrosion and oxidizing attack as well as erosion and wear (wear and tear).
  • the elements Cr, Al, Si forming the oxide cover layers occupy a special position.
  • Layers that have a high Al content have been used, among other things, as filler material for carbide-containing coatings (Cr2C3; WC) in engine construction.
  • the invention is based on the object of a method for increasing the corrosion (Cl and SO4 ions) and erosion resistance (particle and drop impact erosion) of a blade of a rotating thermal machine in the presence of H2O- Steam and at comparatively moderate temperatures (450 ° C), which is particularly suitable for ferritic and / or ferritic-martensitic base material of the blade.
  • the invention as defined in claim 5, is also based on the object of specifying a blade obtained by the method according to claim 1, in which a long service life is ensured by avoiding or at least delaying the occurrence of pitting corrosion.
  • a compressor blade for an axial compressor was provided with a protective layer.
  • the scoop was first degreased and cleaned in trichloroethane, whereupon the blade and the pale / foot transition were sandblasted.
  • the coating of the blade was carried out using a high-speed flame spraying process with a particle speed of 400 m / s and a gas speed of 1000 m / s with nitrogen as the conveying gas.
  • the aluminum alloy powder was conveyed by means of nitrogen into a combustion chamber operated with propane and oxygen.
  • the liquefied particles were thrown onto the workpiece as fine drops under high excess pressure.
  • the blade stood in a device that covered the blade root.
  • the protective layer was applied with the hand-held spray gun.
  • the applied protective layer was measured using a metallographic cut and was in Average 8 to 15 ⁇ m.
  • a plastic in the present case polytetrafluoroethylene was applied to this metal protective layer using a conventional paint spraying process.
  • This smooth surface layer had an average thickness of 6 to 10 ⁇ m and a roughness of approximately 2 ⁇ m.
  • the coated compressor blade was subjected to a corrosion resistance test. For this purpose, it was immersed in a test solution and then stored in a climatic cabinet for 4 hours. This cycle was repeated a total of 60 times.
  • a compressor blade of the same dimensions and composition was coated according to Example 1 with an aluminum alloy and a plastic. Now a scratch of 10 mm in length and a total of 25 ⁇ m in depth parallel to the longitudinal axis was made on the coated blade, the profile of which just barely grasped the base material with its tip. The blade was then subjected to the same corrosion tests as in Example 1. Thanks to the local element formation (aluminum layer functions as a "sacrificial anode”), the base material was largely protected, while the aluminum layer on the flanks of the scratch was only slightly degraded.
  • the protective layer according to the invention can be expected to have a long service life under practical conditions of use.
  • a compressor blade was provided with a protective layer.
  • the material of the blade consisted of a martensitic-austenitic two-phase steel with a low austenite content and was available in a tempered condition.
  • the aluminum alloy was sprayed on using an industrial robot. 3 spray coats were carried out. The thickness of the applied layer averaged 90 to 100 ⁇ m. A plastic layer of approx. 10 to 15 ⁇ m thickness was additionally applied to this metal protective layer using a conventional paint spraying process. The coated blade was subjected to the same corrosion test as in Example 1. No attack was then found.
  • a used compressor blade with wing profile was provided with a protective layer.
  • the metal layer was sprayed on by hand using the high-speed flame spraying process.
  • the thickness of the protective layer fluctuated between 25 and 45 ⁇ m.
  • the metallographic tests after the corrosion test indicated above showed an unchanged, unaffected surface zone.
  • the invention is not restricted to the exemplary embodiments.
  • the method for increasing the corrosion and erosion resistance of a blade of a rotating thermal machine which essentially consists of a ferritic and / or ferritic-martensitic base material, is carried out by applying a firmly adhering surface protective layer, in that one of 6 to 15 parts by weight % Silicon and the remainder essentially aluminum protective layer is sprayed onto the surface of the base material by the high-speed process with a particle speed of at least 300 m / s.
  • the base material consists of a chromium-containing steel with 12 to 13 wt .-% chromium and other additives.
  • the protective layer advantageously contains 10 to 12% by weight of silicon and the remainder essentially aluminum.
  • a cover layer made of a heat-resistant plastic is preferably additionally applied to said protective layer.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Plasma & Fusion (AREA)
  • Physics & Mathematics (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)

Description

Technisches GebietTechnical field

Die Erfindung bezieht sich ein Verfahren nach dem einleitenden Teil von Patentanspruch 1. Die Erfindung betrifft auch eine durch das Verfahren gemäss Patentanspruch 1 erhältliche Schaufel.The invention relates to a method according to the introductory part of patent claim 1. The invention also relates to a blade which can be obtained by the method according to patent claim 1.

Rotierende thermische Maschinen sind hierbei vor allem Dampfturbinen, Gasturbinen und Turbokompressoren. Die in diesen Maschinen verwendeten Schaufeln sollen wirksam gegen betriebliche Angriffe, wie insbesondere Erosion und Korrosion, aber auch Oxidation, Verschleiss und Beschädigung geschützt werden.Rotating thermal machines are mainly steam turbines, gas turbines and turbo compressors. The blades used in these machines are to be effectively protected against operational attacks, in particular erosion and corrosion, but also oxidation, wear and damage.

Stand der TechnikState of the art

Um den zahlreichen Beanspruchungen Genüge leisten zu können, werden die Schaufeln rotierender thermischer Maschinen vielfach mit Schutzschichten versehen. Davon wird sowohl bei Dampf- und Gasturbinenschaufeln wie bei Kompressorschaufeln Gebrauch gemacht. Es gilt vor allem, den Widerstand gegen Korrosion und oxydierenden Angriff sowie gegen Erosion und Abnutzung (Verschleiss) zu erhöhen. Unter den verwendeten Stoffen für Schutzschichten nehmen die oxydische Deckschichten bildenden Elemente Cr, Al, Si eine Sonderstellung ein. Schichten, die einen hohen Al-Gehalt aufweisen, sind unter anderem als Füllmaterial für karbidhaltige Überzüge (Cr₂C₃; WC) im Triebwerksbau verwendet worden.In order to be able to meet the numerous demands, the blades of rotating thermal machines are often provided with protective layers. This is used in both steam and gas turbine blades as well as compressor blades. The main thing is to increase resistance to corrosion and oxidizing attack as well as erosion and wear (wear and tear). Among the substances used for protective layers, the elements Cr, Al, Si forming the oxide cover layers occupy a special position. Layers that have a high Al content have been used, among other things, as filler material for carbide-containing coatings (Cr₂C₃; WC) in engine construction.

Zum Stand der Technik werden folgende Druckschriften angegeben:

  • F.N. Davis, C.E. Grinnell, "Engine Experience of Turbine Rotor Blade Materials and Coatings", The American Society of Mechanical Engineers, 345 E. 47 St. New York, N.Y. 10017, 82-GT-244
  • SermeTel Technische Information: "SermaLoy J-Prozess STS", SermeTel GmbH, Weilenburgstrasse 49, D-5628 Heiligenhaus, BRD
  • Mark F. Mosser and Bruce G. McMordie, "Evaluation of Aluminium/Ceramic Coating on Fasteners to Eliminate Galvanic Corrosion", Reprinted from SP-649-Corrosion: Coatings and Steels, International Congress and Exposition, Detroit, Michigan, February 24-28, 1986, ISSN 0148-7191, Copyright 1986 Society of Automotive Engineers, Inc.
  • Thomas F. Lewis III, "Gator-Gard, The Process, Coatings, and Turbomachinery Applications", Presented at the International Gas Turbine Conference and Exhibit, Düsseldorf, West Germany - June 8-12, 1986, The American Society of Mechanical Engineers, 345 E. 47 St., New York, N.Y. 10017, 86-GT-306
  • H.J. Kolkman, "New Erosion Resistant Compressor Coatings", Presented at the Gas Turbine and Aeroengine Congress, Amsterdam, The Netherlands - June 6-9, 1988, The American Society of Mechanical Engineers, 345 E. 47 St., New York, N.Y. 10017, 88-GT-186.
The following publications are given regarding the state of the art:
  • FN Davis, CE Grinnell, "Engine Experience of Turbine Rotor Blade Materials and Coatings", The American Society of Mechanical Engineers, 345 E. 47 St. New York, NY 10017, 82-GT-244
  • SermeTel Technical Information: "SermaLoy J-Process STS", SermeTel GmbH, Weilenburgstrasse 49, D-5628 Heiligenhaus, FRG
  • Mark F. Mosser and Bruce G. McMordie, "Evaluation of Aluminum / Ceramic Coating on Fasteners to Eliminate Galvanic Corrosion", Reprinted from SP-649-Corrosion: Coatings and Steels, International Congress and Exposition, Detroit, Michigan, February 24-28 , 1986, ISSN 0148-7191, Copyright 1986 Society of Automotive Engineers, Inc.
  • Thomas F. Lewis III, "Gator-Gard, The Process, Coatings, and Turbomachinery Applications", Presented at the International Gas Turbine Conference and Exhibit, Duesseldorf, West Germany - June 8-12, 1986, The American Society of Mechanical Engineers, 345 E. 47 St., New York, NY 10017, 86-GT-306
  • HJ Kolkman, "New Erosion Resistant Compressor Coatings", Presented at the Gas Turbine and Aeroengine Congress, Amsterdam, The Netherlands - June 6-9, 1988, The American Society of Mechanical Engineers, 345 E. 47 St., New York, NY 10017, 88-GT-186.

Darstellung der ErfindungPresentation of the invention

Der Erfindung, wie sie in Patentanspruch 1 definiert ist, liegt die Aufgabe zugrunde, ein Verfahren zur Erhöhung des Korrosions- (Cl- und SO₄-Ionen) und Erosionswiderstandes (Partikel- und Tropfenschlagerosion) einer Schaufel einer rotierenden thermischen Maschine bei Anwesenheit von H₂O-Dampf und bei vergleichsweise mässigen Temperaturen (450 °C) anzugeben, welches sich besonders für ferritisches und/oder ferritisch-martensitisches Grundmaterial der Schaufel eignet. Der Erfindung, wie sie in Patentanspruch 5 definiert ist, liegt zugleich auch die Aufgabe zugrunde, eine nach dem Verfahren gemäss Patentanspruch 1 erhaltene Schaufel anzugeben, bei der durch das Vermeiden oder mindestens das Hinauszögern des Auftretens von Lochfrass-Korrosion eine grosse Lebensdauer gewährleistet ist.The invention, as defined in claim 1, is based on the object of a method for increasing the corrosion (Cl and SO₄ ions) and erosion resistance (particle and drop impact erosion) of a blade of a rotating thermal machine in the presence of H₂O- Steam and at comparatively moderate temperatures (450 ° C), which is particularly suitable for ferritic and / or ferritic-martensitic base material of the blade. The invention, as defined in claim 5, is also based on the object of specifying a blade obtained by the method according to claim 1, in which a long service life is ensured by avoiding or at least delaying the occurrence of pitting corrosion.

Weg zur Ausführung der ErfindungWay of carrying out the invention

Die Erfindung wird anhand der nachfolgenden Ausführungsbeispiele beschrieben:The invention is described using the following exemplary embodiments:

Ausführungsbeispiel 1:Example 1:

Eine Verdichterschaufel für einen Axialkompressor wurde mit einer Schutzschicht versehen. Die Schicht hatte Tragflügelprofil, wobei das Schaufelblatt folgende Abmessungen aufwies: Breite = 80 mm Grösste Dicke = 9 mm Profilhöhe = 14 mm Radiale Länge = 210 mm A compressor blade for an axial compressor was provided with a protective layer. The layer had an airfoil profile, the airfoil having the following dimensions: width = 80 mm Greatest thickness = 9 mm Profile height = 14 mm Radial length = 210 mm

Der Werkstoff der Schaufel war ein martensitischer Stahl, der im voll vergütetem Gefügezustand vorlag und folgende Zusammensetzung aufwies: Cr = 12 Gew.-% Mo = 1 Gew.-% Ni = 0,5 Gew.-% C = 0,25 Gew.-% Fe = Rest The material of the blade was a martensitic steel, which was in the fully tempered structural state and had the following composition: Cr = 12% by weight Mon = 1% by weight Ni = 0.5% by weight C. = 0.25% by weight Fe = Rest

Die Schaufel wurde zunächst in Trichloräthan entfettet und gereinigt, worauf das Blatt und der Uebergang Blass/Fuss sandgestrahlt wurde. Die Beschichtung der Schaufel wurde nach einem Hochgeschwindigkeits-Flammspritzverfahren mit einer Partikelgeschwindigkeit von 400 m/s und einer Gasgeschwindigkeit von 1000 m/s mit Stickstoff als Fördergas durchgeführt. Als Beschichtungsmaterial wurde eine Aluminiumlegierung der nachfolgenden Zusammen-setzung verwendet, die in Pulverform vorlag: Si = 12,8 Gew.-% Mn = 0,22 Gew.-% Mg = 0,34 Gew.-% Ti = 0,1 Gew.-% Al = Rest The scoop was first degreased and cleaned in trichloroethane, whereupon the blade and the pale / foot transition were sandblasted. The coating of the blade was carried out using a high-speed flame spraying process with a particle speed of 400 m / s and a gas speed of 1000 m / s with nitrogen as the conveying gas. An aluminum alloy of the following composition, which was in powder form, was used as the coating material: Si = 12.8% by weight Mn = 0.22% by weight Mg = 0.34% by weight Ti = 0.1% by weight Al = Rest

Gemäss dem hier angewendeten Beschichtungsverfahren mit der Markenbezeichnung "Jet-Kote" wurde das Aluminiumlegie rungspulver mittels Stickstoff in eine mit Propan und Sauerstoff betriebene Brennkammer gefördert. Die verflüssigten Partikel wurden als feine Tropfen unter hohem Ueberdruck auf das Werkstück geschleudert. Dabei stand die Schaufel in einer Vorrichtung, die den Schaufelfuss abdeckte. Die Aufbringung der Schutzschicht erfolgte mit der von Hand geführten Spritzpistole. Die aufgetragene Schutzschicht wurde anhand eines metallographischen Schliffes gemessen und betrug im Mittel 8 bis 15 µm. Auf diese Metall-Schutzschicht wurde nach einem herkömmlichen Lackspritzverfahren ein Kunststoff (im vorliegenden Fall Polytetrafluoräthylen) aufgetragen. Diese glatte Oberflächenschicht hatte eine durchschnittliche Dicke von 6 bis 10 µm und eine Rauheit von ca. 2 µm.According to the coating process used here with the brand name "Jet-Kote", the aluminum alloy powder was conveyed by means of nitrogen into a combustion chamber operated with propane and oxygen. The liquefied particles were thrown onto the workpiece as fine drops under high excess pressure. The blade stood in a device that covered the blade root. The protective layer was applied with the hand-held spray gun. The applied protective layer was measured using a metallographic cut and was in Average 8 to 15 µm. A plastic (in the present case polytetrafluoroethylene) was applied to this metal protective layer using a conventional paint spraying process. This smooth surface layer had an average thickness of 6 to 10 µm and a roughness of approximately 2 µm.

Die beschichtete Verdichterschaufel wurde einer Prüfung auf Korrosionsbeständigkeit unterworfen. Zu diesem Zweck wurde sie in eine Prüflösung getaucht und danach in einem Klimaschrank während 4 h ausgelagert. Dieser Zyklus wurde insgesamt 60 x wiederholt. Die Prüflösung bestand aus einer wässrigen Lösung der folgenden Salze:
220 g/l    (NH₄)₂FeSO₄ . 6H₂O
50 g/l    NaCl p H = 3 - 3,5 Temperatur Klimaschrank = 45 °C Luftfeuchtigkeit = 100 % Prüfdauer/Zyklus = 4 h Zahl der Zyklen = 60 The coated compressor blade was subjected to a corrosion resistance test. For this purpose, it was immersed in a test solution and then stored in a climatic cabinet for 4 hours. This cycle was repeated a total of 60 times. The test solution consisted of an aqueous solution of the following salts:
220 g / l (NH₄) ₂FeSO₄. 6H₂O
50 g / l NaCl p H = 3 - 3.5 Temperature cabinet = 45 ° C humidity = 100% Test duration / cycle = 4 h Number of cycles = 60

Die metallographischen Untersuchungen zeigten, dass nach diesen Korrosionsversuchen weder an den aufgebrachten Schichten noch am Grundmaterial irgendwelche Veränderungen festgestellt werden konnten.
Zum Vergleich wurde eine nach einem herkömmlichen Spritzverfahren mit je einer Aluminiumschicht und einer Kunststoffschicht versehene Verdichterschaufel geprüft. Nach 60 Prüfzylen waren die Schutzschichten weitgehend zerstört und lamellenförmige Schuppen herausgebrochen.The metallographic examinations showed that after these corrosion tests, no changes could be found either on the applied layers or on the base material.
For comparison, a compressor blade was tested using a conventional spraying method, each with an aluminum layer and a plastic layer. After 60 test cycles, the protective layers were largely destroyed and lamellar scales broke out.

Ausführungsbeispiel 2:Example 2:

Eine Verdichterschaufel gleicher Abmessungen und Zusammensetzung wurde gemäss Beispiel 1 mit einer Aluminiumlegierung und einem Kunststoff beschichtet. Nun wurde auf der beschichteten Schaufel ein der Längsachse paralleler Kratzer von 10 mm Länge und total durchschnittlich 25 µm Tiefe angebracht, dessen Profil also mit seiner Spitze gerade noch das Grundmaterial knapp erfasste. Dann wurde die Schaufel den gleichen Korrosionsprüfungen wie in Beispiel 1 unterworfen. Dank der Lokalelementbildung (Aluminiumschicht funktioniert als "Opferanode") wurde das Grundmaterial weitgehend geschützt, während die Aluminiumschicht an den Flanken des Kratzers nur geringfügig abgebaut wurde. Durch die Wanderung der Al-Ionen im korrosiven Medium als "Elektrolyt" und deren Entladung an der elektropositiven Elektrode (Fe) des Grundmaterials kommt der korrosive Angriff in vielen Fällen zum Stillstand. Durch diese Simulierung der Oberflächenbeschädigung durch auftreffende Partikel im Betrieb und deren Verhalten unter korrosiver Atmosphäre wurde bewiesen, dass die erfindungsgemässe Schutzschicht unter praktischen Einsatzbedingungen eine lange Lebensdauer zu erwarten lässt.A compressor blade of the same dimensions and composition was coated according to Example 1 with an aluminum alloy and a plastic. Now a scratch of 10 mm in length and a total of 25 µm in depth parallel to the longitudinal axis was made on the coated blade, the profile of which just barely grasped the base material with its tip. The blade was then subjected to the same corrosion tests as in Example 1. Thanks to the local element formation (aluminum layer functions as a "sacrificial anode"), the base material was largely protected, while the aluminum layer on the flanks of the scratch was only slightly degraded. Due to the migration of the Al ions in the corrosive medium as "electrolyte" and their discharge at the electropositive electrode (Fe) of the base material, the corrosive attack comes to a standstill in many cases. By simulating the surface damage caused by impinging particles during operation and their behavior under a corrosive atmosphere, it was proven that the protective layer according to the invention can be expected to have a long service life under practical conditions of use.

Ausführungsbeispiel 3:Example 3:

Eine Verdichterschaufel wurde mit einer Schutzschicht versehen. Der Tragflügel des Schaufelblattes hatte die nachfolgenden Abmessungen: Breite = 100 mm Grösste Dicke = 10,5 mm Profilhöhe = 18 mm Radiale Länge = 265 mm A compressor blade was provided with a protective layer. The airfoil wing had the following dimensions: width = 100 mm Greatest thickness = 10.5 mm Profile height = 18 mm Radial length = 265 mm

Der Werkstoff der Schaufel bestand aus einem martensitisch-austenitischen Zweiphasenstahl mit geringem Austenitanteil und lag im vergüteten Zustand vor. Die Zusammensetzung war die folgende: CR = 15,5 Gew.-% Mo = 1,28 Gew.-% Ni = 5,4 Gew.-% C = 0,2 Gew.-% Fe = Rest The material of the blade consisted of a martensitic-austenitic two-phase steel with a low austenite content and was available in a tempered condition. The composition was as follows: CR = 15.5% by weight Mon = 1.28% by weight Ni = 5.4% by weight C. = 0.2% by weight Fe = Rest

Nach dem üblichen Entfetten, Reinigen und Sandstrahlen wurde das Schaufelblatt zusätzlich gezielt kugelgestrahlt. Durch diese Oberflächenbehandlung wurde die Randzone des Grundmaterials kaltverformt und verdichtet, so dass sie Druckeigenspannungen aufwies. Damit wurde erreicht, dass die Wechselfestigkeit (Ermüdungsfestigkeit) durch Abbau der Spannungen auf der Zugseite im Betrieb erhöht wurde. Für die Beschichtung der Schaufel nach dem Hochgeschwindigkeits-Flammspritzverfahren mit einer Partikelgeschwindigkeit von 450 m/s und einer Gasgeschwindigkeit von 1200 m/s mit Stickstoff als Fördermittel wurde eine Aluminiumlegierung der nachfolgenden Zusammensetzung verwendet: Si = 10,65 Gew.-% Mn = 0,37 Gew.-% Mg = 0,1 Gew.-% Al = Rest After the usual degreasing, cleaning and sandblasting, the airfoil was also shot peened. As a result of this surface treatment, the edge zone of the base material was cold worked and compressed so that it had residual compressive stresses. It was thus achieved that the fatigue strength was increased by reducing the tension on the train side during operation. An aluminum alloy of the following composition was used to coat the blade using the high-speed flame spraying process with a particle speed of 450 m / s and a gas speed of 1200 m / s with nitrogen as the conveying medium: Si = 10.65% by weight Mn = 0.37% by weight Mg = 0.1% by weight Al = Rest

Das Aufspritzen der Aluminiumlegierung erfolgte mit einem Industrieroboter. Es wurden 3 Spritzgänge durchgeführt. Die Dicke der aufgetragenen Schicht betrug im Durchschnitt 90 bis 100 µm. Auf diese Metall-Schutzschicht wurde zusätzlich eine Kunststoffschicht von ca. 10 bis 15 µm Dicke nach einem üblichen Lackspritzverfahren aufgetragen.
Die beschichtete Schaufel wurde der gleichen Prüfung auf Korrosion unterzogen wie in Beispiel 1. Es konnte danach keinerlei Angriff festgestellt werden.The aluminum alloy was sprayed on using an industrial robot. 3 spray coats were carried out. The thickness of the applied layer averaged 90 to 100 μm. A plastic layer of approx. 10 to 15 µm thickness was additionally applied to this metal protective layer using a conventional paint spraying process.
The coated blade was subjected to the same corrosion test as in Example 1. No attack was then found.

Ausführungsbeispiel 4:Example 4:

Eine gebrauchte Verdichterschaufel mit Tragflügelprofil wurde mit einer Schutzschicht versehen. Das Schaufelblatt hatte die nachfolgenden Abmessungen: Breite = 63 mm Grösste Dicke = 8 mm Profilhöhe = 12 mm Radiale Länge = 140 mm A used compressor blade with wing profile was provided with a protective layer. The airfoil had the following dimensions: width = 63 mm Greatest thickness = 8 mm Profile height = 12 mm Radial length = 140 mm

Das Grundmaterial der Schaufel war ein martensitischer Stahl im hochfest vergüteten Gefügezustand, dessen Zusammensetzung nachstehend wiedergegeben ist: Cr = 11,73 Gew.-% Mo = 0,8 Gew.-% V = 0,1 Gew.-% C = 0,22 Gew.-% Fe = Rest The base material of the shovel was a martensitic steel in a highly strengthened structural state, the composition of which is shown below: Cr = 11.73% by weight Mon = 0.8% by weight V = 0.1% by weight C. = 0.22% by weight Fe = Rest

Im vorliegenden Fall handelte es sich um eine nach üblichen Verfahren beschichtete Schaufel, welche beträchtliche Betriebsschäden in Form von Lochfrass-Korrosion, die sich teilweise auch auf das Grundmaterial erstreckte, aufwies. Diese gebrauchte Schaufel wurde zunächst entfettet, überschliffen und sandgestrahlt, um die Schäden zu beseitigen. Dann wurde die Oberflächenzone des Grundmaterials durch Kugelstrahlen verdichtet. Die Beschichtung erfolgte mit einer Aluminiumlegierung folgender Zusammensetzung: Si = 6,84 Gew.-% Mn = 0,3 Gew.-% Mg = 0,36 Gew.-% Ti = 0,1 Gew.-% Al = Rest In the present case, it was a blade coated by conventional methods, which showed considerable operational damage in the form of pitting corrosion, which in some cases also extended to the base material. This used shovel was first degreased, ground and sandblasted to remove the damage. Then the surface zone of the base material was compacted by shot peening. The coating was made with an aluminum alloy of the following composition: Si = 6.84% by weight Mn = 0.3% by weight Mg = 0.36% by weight Ti = 0.1% by weight Al = Rest

Das Aufspritzen der Metallschicht erfolgte von Hand nach dem Hochgeschwindigkeits-Flammspritzverfahren. Die Dicke der Schutzschicht schwankte zwischen 25 und 45 µm. Die metallographischen Prüfungen nach dem oben angegebenen Korrosionsversuch ergaben eine unveränderte, nicht angegriffene Oberflächenzone.The metal layer was sprayed on by hand using the high-speed flame spraying process. The thickness of the protective layer fluctuated between 25 and 45 µm. The metallographic tests after the corrosion test indicated above showed an unchanged, unaffected surface zone.

Die Erfindung ist nicht auf die Ausführungsbeispiele beschränkt.The invention is not restricted to the exemplary embodiments.

Das Verfahren zur Erhöhung des Korrosions- und Erosions-widerstandes einer Schaufel einer rotierenden thermischen Maschine, die im wesentlichen aus einem ferritischen und/oder ferritisch-martensitischen Grundmaterial besteht, wird durch Aufbringen einer festhaftenden Oberflächenschutzschicht durchgeführt, indem eine aus 6 bis 15 Gew.-% Silicium und als Rest im wesentlichen aus Aluminium bestehende Schutzschicht nach dem Hochgeschwindigkeitsverfahren mit einer Partikelgeschwindig-keit von mindestens 300 m/s auf die Oberfläche des Grundmaterials aufgespritzt wird. Vorzugsweise besteht das Grundmaterial aus einem chromhaltigen Stahl mit 12 bis 13 Gew.-% Chrom und weiteren Zusätzen. Die Schutzschicht enthält in vorteilhafter Weise 10 bis 12 Gew.-% Silicium und als Rest im wesentlichen Aluminium. Auf die besagte Schutzschicht wird zur Verfeinerung der Oberfläche vorzugsweise zusätzlich eine Deckschicht aus einem wärmebeständigen Kunststoff aufgetragen.The method for increasing the corrosion and erosion resistance of a blade of a rotating thermal machine, which essentially consists of a ferritic and / or ferritic-martensitic base material, is carried out by applying a firmly adhering surface protective layer, in that one of 6 to 15 parts by weight % Silicon and the remainder essentially aluminum protective layer is sprayed onto the surface of the base material by the high-speed process with a particle speed of at least 300 m / s. Preferably the base material consists of a chromium-containing steel with 12 to 13 wt .-% chromium and other additives. The protective layer advantageously contains 10 to 12% by weight of silicon and the remainder essentially aluminum. In order to refine the surface, a cover layer made of a heat-resistant plastic is preferably additionally applied to said protective layer.

Claims (5)

  1. Process for increasing the resistance to corrosion and erosion of a vane of a rotating heat engine, which vane consists essentially of a ferritic and/or ferritic-martensitic base material, by applying a firmly adhering protective surface layer, characterized in that a protective layer consisting of 6 to 15% by weight of silicon and the remainder consisting essentially of aluminium, is sprayed onto the surface of the base material using the high-speed process with a particle velocity of at least 300 m/s.
  2. Process according to Claim 1, characterized in that the base material consists of a chromiferous steel with 12 to 13% Cr by weight and further additions.
  3. Process according to Claim 1 or 2, characterized in that the protective layer contains 10 to 12% silicon by weight and the remainder contains essentially aluminium.
  4. Process according to one of Claims 1 to 3, characterized in that in addition a top layer made of a thermostable plastic is applied to the protective layer.
  5. Vane of a rotating heat engine, the vane essentially consisting of a ferritic and/or ferritic-martensitic base material, having a protective layer which consists of 6 to 15% by weight of silicon and the remainder consists essentially of aluminium, obtainable by the process according to Patent Claim 1.
EP89123291A 1989-01-26 1989-12-15 Method for enhancing the corrosion and erosion resistance of the blade of a rotary thermal apparatus and blade produced ba said method Expired - Lifetime EP0379699B1 (en)

Applications Claiming Priority (2)

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CH252/89 1989-01-26
CH252/89A CH678067A5 (en) 1989-01-26 1989-01-26

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EP0379699A1 EP0379699A1 (en) 1990-08-01
EP0379699B1 true EP0379699B1 (en) 1993-10-06

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GB9218859D0 (en) * 1992-09-05 1992-10-21 Rolls Royce Plc Aluminide-silicide coatings
RU95110753A (en) * 1992-10-05 1997-01-27 Сименс АГ (DE) Protection against corrosive and erosive effects for substrate made of chromium steel at temperatures up to about 500 c
SE508860C2 (en) * 1997-03-18 1998-11-09 Abb Stal Ab Device on a guide rail arranged in a rotor machine and a rotatable turbine rail
WO2000070190A1 (en) * 1999-05-14 2000-11-23 Siemens Aktiengesellschaft Component and method for producing a protective coating on a component
US7546683B2 (en) * 2003-12-29 2009-06-16 General Electric Company Touch-up of layer paint oxides for gas turbine disks and seals
DE102007028321A1 (en) * 2007-06-15 2008-12-18 Alstom Technology Ltd. Process for surface treatment of Cr steels
FR2978931B1 (en) 2011-08-10 2014-05-09 Snecma METHOD FOR PRODUCING A PROTECTIVE REINFORCEMENT ON THE EDGE OF A BLADE
US9309895B2 (en) 2012-06-18 2016-04-12 Kennametal Inc. Closed impeller with a coated vane
US9737933B2 (en) 2012-09-28 2017-08-22 General Electric Company Process of fabricating a shield and process of preparing a component
KR20160053121A (en) 2014-10-31 2016-05-13 현대자동차주식회사 Coating method for shift fork and shift fork with amorphous coating layer by using the same
JP6375238B2 (en) * 2015-02-05 2018-08-15 三菱日立パワーシステムズ株式会社 Steam turbine and surface treatment method thereof

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GB973012A (en) * 1962-03-27 1964-10-21 Grundy Teddington Ltd Method of marking metal articles such as casks and like containers
JPS56102546A (en) * 1980-01-22 1981-08-17 Toyota Motor Corp Sliding member
GB2116215B (en) * 1982-03-06 1985-09-25 Rolls Royce Improvements in or relating to flame sprayed coatings
US4500364A (en) * 1982-04-23 1985-02-19 Exxon Research & Engineering Co. Method of forming a protective aluminum-silicon coating composition for metal substrates
DE3247054C1 (en) * 1982-12-20 1984-05-10 Goetze Ag, 5093 Burscheid Spray powder for the production of wear-resistant coatings
JPS60149761A (en) * 1984-01-13 1985-08-07 Showa Denko Kk Coating method for providing corrosion resistance
US4707379A (en) * 1985-12-24 1987-11-17 Ceskoslovenska Akademie Ved Protective layer for carbonaceous materials and method of applying the same
JPS63303048A (en) * 1987-06-03 1988-12-09 Toyota Motor Corp Shift fork

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US5120613A (en) 1992-06-09
DE58905843D1 (en) 1993-11-11
JP2895135B2 (en) 1999-05-24
CH678067A5 (en) 1991-07-31
JPH02230902A (en) 1990-09-13
EP0379699A1 (en) 1990-08-01

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