EP0500854B1 - A coating, and a coating method, for a steam turbine and adjoining steel surfaces - Google Patents

A coating, and a coating method, for a steam turbine and adjoining steel surfaces Download PDF

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Publication number
EP0500854B1
EP0500854B1 EP91915315A EP91915315A EP0500854B1 EP 0500854 B1 EP0500854 B1 EP 0500854B1 EP 91915315 A EP91915315 A EP 91915315A EP 91915315 A EP91915315 A EP 91915315A EP 0500854 B1 EP0500854 B1 EP 0500854B1
Authority
EP
European Patent Office
Prior art keywords
coating
chromium
aluminum
steel
weight
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Revoked
Application number
EP91915315A
Other languages
German (de)
French (fr)
Other versions
EP0500854A1 (en
Inventor
Jaakko Tenkula
Bjarne Hellman
Jorma Majava
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Telatek Oy
Original Assignee
Telatek Oy
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Publication date
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Application filed by Telatek Oy filed Critical Telatek Oy
Publication of EP0500854A1 publication Critical patent/EP0500854A1/en
Application granted granted Critical
Publication of EP0500854B1 publication Critical patent/EP0500854B1/en
Anticipated expiration legal-status Critical
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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
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • 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
    • C23C4/18—After-treatment
    • 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
    • F01D25/00—Component parts, details, or accessories, not provided for in, or of interest apart from, other groups
    • F01D25/007—Preventing corrosion

Definitions

  • the invention relates to a coating intended for protecting the interior surfaces of a steam turbine and the adjoining pipes and superheaters, the coating preventing the erosive and corrosive wear caused by steam.
  • the invention also relates to a method for coating the interior surfaces of a steam turbine and the adjoining pipes and superheaters.
  • the damage caused by wear may lead to the need for fill-in and repair weldings which are difficult to carry out, and even replacement of the turbine casing and pipes.
  • Ceramic coatings have, for example, the following disadvantages:
  • the primary object of the present invention is to provide a coating which can be used for coating the casing, division planes, piping, superheaters and other parts of a steam turbine so that reliable and long-term protection, suitable for the conditions involved, is obtained for the steel surfaces. It is a further object of the invention that the coating work can be carried out on the site rapidly and economically, and that the coating is also well suited for the coating of surfaces which are to be machined.
  • the coating on a steel part according to the invention is characterized in that the coating comprises a coating layer which is obtainable by the thermal spraying of a steel alloyed with chromium and aluminum in the below stated amounts, which, during the coating process, oxidize in the spray, whereby chromium and aluminum oxides are formed which will remain inside the coating, surrounded by a steel matrix, and on the surface of the coating layer there will form, after the coating process, under the oxidizing effect of air, a dense chromium and aluminum oxide film.
  • the coating method according to the invention is characterized in that a coating material of steel alloyed with chromium and aluminum in the below stated amounts is sprayed thermally onto the surface being coated, and this coating material oxidizes in the spray during the coating process, whereby chromium and aluminum oxides are formed which will remain inside the coating, surrounded by a steel matrix, and that, after the coating process, the coating which has been formed will be exposed to the oxidizing effect of air, whereby a dense chromium and aluminum oxide film will be formed on the surface of the coating.
  • the coating material used is a steel containing chromium 20 - 45 % by weight, aluminum 5 - 15 % by weight and molybdenum 0 - 5 % by weight, and especially preferably chromium 22 - 30 % by weight, aluminum 5 - 8 % by weight and molybdenum 0 - 3 % by weight.
  • the coating material may be thread-like or pulverous.
  • the chromium and aluminum oxide film in the coating according to the invention formed under the effect of oxidation after the coating process, is strong and dense, and will prevent erosive and corrosive wear caused by wet steam.
  • the coating according to the invention can be prepared by thermal spraying, by using flame, arc, plasma and/or supersonic spraying, but primarily arc, plasma and/or supersonic spraying, in order to obtain good adhesion of the coating to the base material.
  • the coating according to the invention a layer with good adhesion to the base material, a steel coating which contains a large amount of oxides, and a surface layer which consists of a dense oxide film.
  • the thickness of the coating should be at minimum 0.3 mm, preferably, however, 0.5 mm.
  • the thickness of the coating may be up to 2.5 mm without its pealing off because of internal shrinkage of the coating.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Engineering & Computer Science (AREA)
  • Organic Chemistry (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Ultra Sonic Daignosis Equipment (AREA)
  • Transition And Organic Metals Composition Catalysts For Addition Polymerization (AREA)
  • External Artificial Organs (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Vehicle Body Suspensions (AREA)
  • Circuit Arrangements For Discharge Lamps (AREA)

Abstract

The present invention relates to the protection of the casing, division planes, piping, superheaters and other steel parts of a steam turbine which are subjected in a turbine plant to some corrosive and erosive wear caused by steam, the coating comprising a coating layer produced by the thermal spraying of a steel, alloyed amply with chromium and aluminum, which during the coating process oxidizes strongly in the spray, whereby large amounts of chromium and aluminum oxides are formed, which will remain inside the coating, surrounded by a steel matrix, and after the coating process there will form on the surface of the coating layer, under the oxidizing action of air, a dense chromium and aluminum oxide layer. Another object of the invention is a related coating method.

Description

  • The invention relates to a coating intended for protecting the interior surfaces of a steam turbine and the adjoining pipes and superheaters, the coating preventing the erosive and corrosive wear caused by steam. The invention also relates to a method for coating the interior surfaces of a steam turbine and the adjoining pipes and superheaters.
  • As stated in Swedish Patents/Patent Applications No. 762881 and 771073, steel surfaces exposed to hot, damp steam at high pressures and velocities are subject to heavy erosive and corrosive wear.
  • The damage caused by wear may lead to the need for fill-in and repair weldings which are difficult to carry out, and even replacement of the turbine casing and pipes.
  • Such repair and replacement work causes long stoppages and thereby large financial losses owing to reduced production. This is the case in particular in large power plants such as nuclear power plants.
  • For example the following coatings have been used for protecting turbine pipes:
    • 1. Ceramic coating with a nickel-aluminum alloy in the adhesive layer. The thickness of the adhesive layer is 10 - 25 µm and that of the ceramic coating 50 - 250 µm.
    • 2. Metallic so-called triple-layer coating, in which the adhesive layer is a nickel-aluminum alloy (t = 50 - 100 µm), the intermediate layer is a chromium steel (approx. 13 % Cr, with a layer thickness of approx. 200 µm), and the surface layer is a stainless or acid-resistant steel (Cr = approx. 18 %, Ni = 5 - 8 %, and Mn = approx. 8 %, with a layer thickness of approx. 200 µm).
  • Ceramic coatings have, for example, the following disadvantages:
    • poor shock resistance, for example, when foreign bodies enter the turbine or the pipes, they may break the coating;
    • the thermal expansion coefficient of a ceramic coating is very low compared with that of carbon steel, so that great or rapid variations in the temperature may lead to the cracking of the coating. A crack in the coating may, in turn, lead to rapid local damage to the base material;
    • ceramic coatings are good insulators. The coating of a turbine casing with a ceramic material could disturb intra-turbine thermal conduction and cause unexpected deformation during operation;
    • with a ceramic coating it is difficult to coat seal surfaces which are to be machined. The coating may have a hardness higher than 1000 HV, and therefore it is difficult to machine, and, furthermore, the coating tends to crack;
    • it is difficult to achieve a sufficient layer thickness with a ceramic coating if the coating is to be used for filling cavities.
  • So-called triple-layer coating has functioned satisfactorily in pipe systems. However, this coating has the following disadvantages:
    • in a triple-layer coating, each interface between the different coatings constitutes a strong barrier to thermal conduction, and so problems similar to those involved with ceramic coatings may appear in thermal conduction in the turbine casing;
    • if it is necessary to fill cavities in coating surfaces which are to be machined, there is the risk that the machines surface will run through different layers;
    • if the triple-layer coating is damaged in operation, for example owing to strong local erosion, it must be repaired by first removing the old coating entirely and by then recoating the surface, layer by layer.
  • The primary object of the present invention is to provide a coating which can be used for coating the casing, division planes, piping, superheaters and other parts of a steam turbine so that reliable and long-term protection, suitable for the conditions involved, is obtained for the steel surfaces. It is a further object of the invention that the coating work can be carried out on the site rapidly and economically, and that the coating is also well suited for the coating of surfaces which are to be machined.
  • The coating on a steel part according to the invention is characterized in that the coating comprises a coating layer which is obtainable by the thermal spraying of a steel alloyed with chromium and aluminum in the below stated amounts, which, during the coating process, oxidize in the spray, whereby chromium and aluminum oxides are formed which will remain inside the coating, surrounded by a steel matrix, and on the surface of the coating layer there will form, after the coating process, under the oxidizing effect of air, a dense chromium and aluminum oxide film.
  • The coating method according to the invention is characterized in that a coating material of steel alloyed with chromium and aluminum in the below stated amounts is sprayed thermally onto the surface being coated, and this coating material oxidizes in the spray during the coating process, whereby chromium and aluminum oxides are formed which will remain inside the coating, surrounded by a steel matrix, and that, after the coating process, the coating which has been formed will be exposed to the oxidizing effect of air, whereby a dense chromium and aluminum oxide film will be formed on the surface of the coating.
  • According to the invention, the coating material used is a steel containing chromium 20 - 45 % by weight, aluminum 5 - 15 % by weight and molybdenum 0 - 5 % by weight, and especially preferably chromium 22 - 30 % by weight, aluminum 5 - 8 % by weight and molybdenum 0 - 3 % by weight. The coating material may be thread-like or pulverous.
  • The chromium and aluminum oxide film in the coating according to the invention, formed under the effect of oxidation after the coating process, is strong and dense, and will prevent erosive and corrosive wear caused by wet steam.
  • The coating according to the invention can be prepared by thermal spraying, by using flame, arc, plasma and/or supersonic spraying, but primarily arc, plasma and/or supersonic spraying, in order to obtain good adhesion of the coating to the base material.
  • Thus there is formed in the coating according to the invention a layer with good adhesion to the base material, a steel coating which contains a large amount of oxides, and a surface layer which consists of a dense oxide film.
  • In order that no galvanic corrosion should occur on the interface between the base material and the coating, the thickness of the coating should be at minimum 0.3 mm, preferably, however, 0.5 mm. The thickness of the coating may be up to 2.5 mm without its pealing off because of internal shrinkage of the coating.
  • The advantages of the coating according to the invention as compared with previous ones are as follows:
    • 1. The very dense chromium and aluminum oxide film formed on the surface of the coating provides excellent protection against corrosion and erosion. Nevertheless, the coating is very tough.
      If the coated surface is damaged, for example under the effect of a foreign body which has entered the turbine, the oxides inside the coating will prevent propagation of the damage.
      Thus the coating provides the protective effect of a ceramic coating, but it has the toughness and strength of a metal coating.
    • 2. The adhesion of the coating to the base material is very good. When arc or plasma spraying is used, an adhesion strength greater than 60 N/mm is obtained, which is approximately double the adhesion strength of a flame-sprayed nickel and aluminum alloy.
      Good adhesion guarantees that the coating will not become detached by minor impacts, and that it will also be possible to coat narrow edges. Furthermore, good adhesion enables the surface to be machined.
    • 3. The thermal expansion coefficient of the coating is close to the thermal expansion coefficient of carbon steel, so that deformation due to thermal shock and thermal expansion will not damage the coating.
    • 4. Since the coating is made up of one single layer and it can be sprayed approx. 2 mm thick, the coating is suitable for protecting very large seal surfaces which are to be machined.
    • 5. Although the coating contains large amounts of hard oxides, its macro-hardness is only 250 - 350 HV units, so that the coating will be easy to machine.
    • 6. Thermal conduction will not cause problems, since the only interface hampering thermal conduction is the interface between the coating and the base material.
    • 7. Patching of the coating is easy to perform locally, without removing all of the old coating.
    • 8. The cobalt content of the coating is very low (approx. 0.02 %), and so the coating is highly suitable for use in nuclear power plants, also on surfaces on the active side.
      In a nuclear power plant the division planes and some of the turbine casing above and below the division planes were coated by arc spraying with a coating according to the invention, the analysis of which was 22 % Cr and 5 % Al.
      After eight years of use the turbine was opened, whereupon it was observed that the division planes were completely flawless and that the coating above and below the division planes had endured very well. On the other hand, the base material had worn off up to more than 10 mm in the area adjacent to the border of the coating.

Claims (5)

  1. A coating on a steel part useful for protecting the casing, division planes, piping, superheaters and other steel parts of a steam turbine which are subjected in a turbine plant to some corrosive and erosive wear caused by hot wet steam, which is obtainable by thermally spraying a steel alloyed with 20 to 45 and preferably 22 to 30% by weight of chromium, 5 to 15 and preferably 5 to 8% by weight of aluminum and 0 to 5 and preferably 0 to 3% by weight of molybdenum onto the surface of the part to be coated, the chromium and aluminum oxidizing in the spray during the coating process, whereby chromium and aluminum oxides are formed which will remain inside the coating, surrounded by a steel matrix, and by exposing the surface of the so formed coating layer to the oxidising effect of air to form a dense chromium and aluminum oxide film.
  2. A coating according to Claim 1 consisting of one layer with a thickness of 0.3 to 2.5 mm.
  3. A method for coating the casing, division planes, piping, superheaters and other steel parts of a steam turbine which are subjected in a turbine plant to some corrosive and erosive wear caused by hot wet steam, in which a steel alloyed with 20 to 45 and preferably 22 to 30% by weight of chromium, 5 to 15 and preferably 5 to 8% by weight of aluminum and 0 to 5 and preferably 0 to 3% by weight of molybdenum in thermally sprayed onto the surface of the part to be coated, the chromium and aluminum oxidizing in the spray during the coating process, whereby chromium and aluminum oxides are formed which will remain inside the coating, surrounded by a steel matrix, and in which the surface of the so formed coating layer is exposed to the oxidizing effect of air to form a dense chromium and aluminum oxide film.
  4. A method according to Claim 3 in which one layer with a thickness of 0.3 to 2.5 mm is formed.
  5. A method according to Claim 3 or 4 in which the thermal spraying is carried out by the arc, plasma or supersonic method.
EP91915315A 1990-09-04 1991-09-03 A coating, and a coating method, for a steam turbine and adjoining steel surfaces Revoked EP0500854B1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
FI904369A FI88935C (en) 1990-09-04 1990-09-04 Process for coating a steam turbine and associated steel surfaces
FI904369 1990-09-04
PCT/FI1991/000269 WO1992004480A1 (en) 1990-09-04 1991-09-03 A coating, and a coating method, for a steam turbine and adjoining steel surfaces

Publications (2)

Publication Number Publication Date
EP0500854A1 EP0500854A1 (en) 1992-09-02
EP0500854B1 true EP0500854B1 (en) 1995-01-04

Family

ID=8531016

Family Applications (1)

Application Number Title Priority Date Filing Date
EP91915315A Revoked EP0500854B1 (en) 1990-09-04 1991-09-03 A coating, and a coating method, for a steam turbine and adjoining steel surfaces

Country Status (13)

Country Link
EP (1) EP0500854B1 (en)
AT (1) ATE116690T1 (en)
CA (1) CA2067727A1 (en)
CZ (1) CZ281667B6 (en)
DE (1) DE69106494T2 (en)
DZ (1) DZ1526A1 (en)
ES (1) ES2066464T3 (en)
FI (1) FI88935C (en)
HU (1) HU212746B (en)
PL (1) PL167643B1 (en)
RU (1) RU2085612C1 (en)
SK (1) SK281564B6 (en)
WO (1) WO1992004480A1 (en)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FI96970C (en) * 1994-08-09 1996-09-25 Telatek Oy Method for rehabilitating steel surfaces
GB201106276D0 (en) * 2011-04-14 2011-05-25 Rolls Royce Plc Annulus filler system

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA1004964A (en) * 1972-05-30 1977-02-08 Union Carbide Corporation Corrosion resistant coatings and process for making the same
US3864093A (en) * 1972-11-17 1975-02-04 Union Carbide Corp High-temperature, wear-resistant coating

Also Published As

Publication number Publication date
DZ1526A1 (en) 2004-09-13
ES2066464T3 (en) 1995-03-01
HU9201467D0 (en) 1992-09-28
PL167643B1 (en) 1995-10-31
FI88935C (en) 1993-07-26
FI88935B (en) 1993-04-15
RU2085612C1 (en) 1997-07-27
CA2067727A1 (en) 1992-03-05
FI904369A (en) 1992-03-05
FI904369A0 (en) 1990-09-04
DE69106494T2 (en) 1995-05-11
DE69106494D1 (en) 1995-02-16
HUT60792A (en) 1992-10-28
WO1992004480A1 (en) 1992-03-19
CZ281667B6 (en) 1996-12-11
EP0500854A1 (en) 1992-09-02
HU212746B (en) 1996-10-28
CS271591A3 (en) 1992-04-15
ATE116690T1 (en) 1995-01-15
SK281564B6 (en) 2001-05-10

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