EP0750054A1 - Procédé d'érosion de surface de superalliages par un jet liquide - Google Patents

Procédé d'érosion de surface de superalliages par un jet liquide Download PDF

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Publication number
EP0750054A1
EP0750054A1 EP96109797A EP96109797A EP0750054A1 EP 0750054 A1 EP0750054 A1 EP 0750054A1 EP 96109797 A EP96109797 A EP 96109797A EP 96109797 A EP96109797 A EP 96109797A EP 0750054 A1 EP0750054 A1 EP 0750054A1
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EP
European Patent Office
Prior art keywords
substrate
erosion
ksi
liquid jet
liquid
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.)
Ceased
Application number
EP96109797A
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German (de)
English (en)
Inventor
Thomas Alan Taylor
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.)
Praxair ST Technology Inc
Praxair Technology Inc
Original Assignee
Praxair ST Technology Inc
Praxair Technology Inc
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Praxair ST Technology Inc, Praxair Technology Inc filed Critical Praxair ST Technology Inc
Publication of EP0750054A1 publication Critical patent/EP0750054A1/fr
Ceased legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
    • B24C1/00—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods
    • 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

Definitions

  • This invention relates to a method for applying thermal spray coatings to superalloys and, more particularly, to a method for preparing a surface of the superalloy to enable the thermal spray coating to adhere rigidly thereto.
  • metallic substrates which are to be coated by a thermal spray coating process are initially roughened by a grit blast to achieve a surface roughness which enables a good mechanical bond to be achieved.
  • the grit blast by its nature, leaves a residue of grit inclusions within the substrate.
  • the grit material may include silicon carbide and iron particles, but in most applications is comprised of angular aluminum particles. Silicon carbide is no longer employed for grit blasting of high temperature superalloys due to concerns of forming low-melting phases which possibly affect stress/rupture life. Today, substantially all grit blasting is performed using alumina particles.
  • the term "superalloy" includes cobalt, titanium and nickel-based alloys which exhibit both high strength and hardness levels.
  • grit inclusions present a concern. Interface specifications, between a superalloy substrate and the coating, limit the amount of included grit.
  • the coatings of turbine blades for use in aircraft engines must meet highly stringent interface inclusion limitations.
  • the prior art has had to conform to the grit inclusion limits, while achieving a desired level of surface roughness to assure a rigid bond for a subsequently applied coating.
  • a liquid jet is employed to roughen the surface of a substrate so as to enable a subsequent thermal spray coating material to adhere tightly to the surface.
  • the substrate is preferably a superalloy that is either nickel or cobalt based.
  • the method initially provides a high pressure liquid jet and moves the liquid jet across the substrate surface at a rate so as to deliver liquid to the surface in a range of amounts of at least approximately 0.7 kg/cm 2 to approximately 5.5 kg/cm 2 .
  • the high pressure liquid jet is preferably provided from a reservoir that is maintained at a pressure in the range of approximately 28 ksi to 52 ksi.
  • a preferred embodiment employs an initial blast of a grit to the surface of the substrate to remove a smooth finish from the substrate, prior to the application of the liquid jet. The initial grit blast enables substantially lessened pressures and amounts of applied liquid mass to accomplish desired ranges of surface roughening.
  • Fig. 1 is a plot of metal erosion versus mass of water delivered, showing erosion of IN-718 for reservoir-pressures of 30 ksi, 40 ksi, and 50 ksi.
  • Fig. 2 is a plot of metal erosion versus mass of water delivered, showing erosion of aged IN-718 for reservoir pressures of 30 ksi, 40 ksi, and 50 ksi.
  • Fig. 3 is a plot of metal erosion versus mass of water delivered showing erosion of a grit blasted IN-718 for reservoir pressures of 30 ksi, 40 ksi, and 50 ksi.
  • Fig. 4 is a plot of metal erosion versus water jet pressure for IN-718, showing a comparison between a grit blast surface and a surface which has not been grit blasted.
  • Fig. 5 is a plot of erosion weight loss versus mass of water delivered for a variety of superalloys from a reservoir maintained at 50 ksi.
  • Fig. 6 is a plot of metal erosion versus mass of water delivered for MAR-M 509 from a reservoir maintained at 32 ksi, 40 ksi, and 52 ksi.
  • Fig. 7 is a plot of erosion weight loss versus mass of water delivered, showing erosion of RENE 80 for a reservoir maintained at 40 ksi and 50 ksi.
  • Fig. 8 is a plot of surface roughness versus erosion weight loss for RENE 80 under the conditions shown in the plot of Fig. 7.
  • Fig. 9 is a plot of erosion weight loss versus mass of water delivered for 3 steel samples by a water jet from a reservoir maintained at 50 ksi.
  • Fig. 10 is a plot of threshold pressure versus hardness to achieve an initial erosion by a water jet of IN-718, MAR-M 509 and RENE 80.
  • Fig. 11 is a plot of mass of water delivered versus water jet pressure to achieve a 4.5 mg/cm 2 erosion for both cobalt-based and nickel based superalloys.
  • a high pressure waterjet is used to roughen a superalloy's surface in preparation for a subsequent thermal spray coating.
  • the objective is to reduce to a minimum, interface inclusions in the superalloy surface from the roughening step.
  • abrasive material is added to the high pressure waterjet and dramatically enhances its cutting rate.
  • This invention employs no abrasives in the waterjet, only a pure liquid that has been filtered and cleaned by reverse osmosis.
  • a pure waterjet exhibiting a requisite pressure can provide sufficient surface erosion of a superalloy (or other metal) with little or no surface inclusions which adversely affect a later-applied thermal spray coating.
  • the waterjet spray further provides a cleaning action on the substrate surface.
  • the useful range of waterjet erosion of a substrate is when an adequate level of roughness has been obtained, with a minimum of substrate removal.
  • the roughness minimum required for a thermal spray coating is approximately 80 microinches and in one superalloy (i.e. IN-718) is achieved at approximately 5 mg/cm 2 removal (approximately 1/4 mil of thickness of the substrate).
  • the roughness maximum for a subsequent thermal spray coating is approximately 500 microinches due to self masking and shadowing of a subsequent thermal spray coating and, thus, incomplete coverage at the interface and reduced bond strength.
  • an average thickness removal minimum is approximately 0.2 mils, which corresponds to a removal of approximately 4.5 mg/cm 2 of a typical superalloy surface.
  • the maximum thickness removal that can be accepted is approximately 2 mils. This limit is based on a concern for the reduction in cross section of a thin wall superalloy used for turbine blade applications. Such a thickness removal corresponds to approximately 45 mg/cm 2 erosion of the substrate surface.
  • an adequate and useful roughness for a subsequent thermal spray coating is approximately 160 microinches and is obtained in IN-718 at 10 mg/cm 2 erosion.
  • the preferred ranges of roughness, erosion and thickness loss are as follows:
  • the above ranges can be achieved by application of a pure waterjet that is scanned across the surface in a raster manner.
  • the waterjet must exhibit a pressure that is at least above the threshold pressure for the alloy being roughened. Further, the scan rate of the waterjet is set so that the mass of water applied per unit area is greater than a critical delivered amount.
  • a single erosion trace had a width of approximately 1.5 mm (0.06 inches).
  • the alloy substrates were weighed before and after waterjet exposure as well as their thicknesses were measured. The erosion was calculated as milligrams of mans lost, per square centimeter of surface area. Most of the samples were round buttons, 25.4 mm in diameter and 3.2 mm thick but some were of odd coupon dimensions, cut from turbine blade roots or sheet stock.
  • the high pressure pump had the following water flow rates through the 0.4 mm orifice. At 207,276 and 345 MPa (30, 40 and 50 ksi) reservoir pressures: 3.49, 3.97, and 4.50 liters/minute.
  • the IN-718 was solution annealed for one hour at 954°C (1750°F) and had a Rockwell B hardness of 103.
  • the MAR-M 509 coupons were in an as - cast condition with a superficial Rockwell C hardness of 31.0.
  • the RENE 80 coupon were cut transversely from a directionally solidified rod, which had been given a standard solution anneal of four hours at 1200°C in vacuum, with a final hardness of 39.4 HRc.
  • the original MAR - M 509 surfaces were ground and then vibratory finished with triangular aluminum media in water, producing an initial surface finish of 0.5 micrometers.
  • the RENE 80 was surface ground to a 0.3 micrometer finish. The eroded surfaces were examined on a scanning electron microscope and the roughness measured with a portable Taylor-Hobsen profilometer at a 0.76 mm (0.03 inches) cutoff setting.
  • Fig. 1 is a plot for IN-718 of mass of water delivered (in kg/cm 2 ) versus metal eroded (mg/cm 2 ). Two important features of the waterjet erosion process are evident from the plot of Fig. 1. One is that there is a minimum mass of water required to impinge on the IN-718 substrate before there is a measurable erosion, that is, an incubation period. Thus, at 40 ksi, substantial erosion does not occur until after 0.8 kg/cm 2 of water has been delivered across the substrate. At such time, erosion commences and increases in exponential fashion. At 50 ksi, the incubation period terminates at approximately 0.5 kg/cm 2 .
  • the second feature is that there is a threshold pressure required for measurable erosion and that 30 ksi is only slightly above that threshold.
  • the erosion threshold jet pressure can be determined from the initial slopes of the curves. It has been determined that a threshold for solution annealed IN-718 is approximately 28.5 ksi(196 MPa). From the Bernoulli equation, the threshold pressure can be converted to jet velocity, and thus the corresponding threshold velocity for IN-718 is 650 meters per second.
  • Fig. 2 Similar erosion conditions were performed on an aged IN-718 coupon which had been annealed for one hour at 1750°F and then aged, for eight hours, at 1325°F plus an additional 10 hours at 1150°F.
  • the aged IN-718 had a Rockwell B hardness of 115. Note that the metal erosion values were considerably less than those shown in Fig. 1, evidencing a distinct dependence upon substrate hardness.
  • Fig. 4 a direct comparison is shown between metal erosion values for a sample which was grit blasted and then subjected to a waterjet roughening procedure versus a portion of the same sample which was subjected to the waterjet roughening procedure, without the initial grit blast.
  • the amount of metal erosion is plotted against waterjet pressure and it is to be noted that erosion commences at a considerably lesser pressure when the sample has been grit blasted as compared to the non-grit blasted sample.
  • Fig. 5 the mass of water delivered to the substrate is plotted against erosion weight loss for a variety of materials which have been subjected to a 50 ksi waterjet roughening procedure.
  • the IN-718 data discussed above solution annealed 1hr at 1750°F
  • erosion data for an IN-718 coupon in an over-solution condition (4hrs. at 1975°F) has been added as well as data for a sample of titanium - 6 wt. percent aluminum - 4 wt. percent vanadium.
  • the titanium alloy behaved somewhat like the IN-718 (1 hr./1750°F), but the IN-718 (4 hrs./1975°F) exhibited a much higher erodability for a like mass of water delivered.
  • MAR-M 509 erosion as a function of mass of water delivered to the substrate is shown in Fig. 6.
  • the 359 MPa (52 ksi) erosion data curve increases exponentially with increasing mass of water impingement.
  • a similar but still exponential curve is seen at 276 MPa (40 ksi), with both curves suggesting a threshold or incubation period occurring at the initiation of the erosion action.
  • Fig. 7 the erosion of RENE 80 is shown in a plot of erosion weight loss versus mass of water delivered. Note that it is clearly seen that there is a threshold value of approximately 1 kg/cm 2 before measurable erosion occurs.
  • the surface roughness of the eroded RENE 80 coupons is shown in Fig. 8 as a function of erosion weight loss.
  • the roughness rises quickly with erosion and then moves towards a limiting value of approximately 30 micrometers at a very high eroded weight loss.
  • the 220 mg/cm 2 weight loss corresponds to approximately a 10.6 mil surface removal. This is substantially more than the modest surface removal required for thermal spray preparation.
  • a weight loss of approximately 10 mg/cm 2 it was found that a roughness of approximately 5 micrometers occurred which was quite adequate for a subsequent thermal spray application.
  • Fig. 9 the results of waterjet erosion tests on steels having hardnesses of 40, 50 and 60 Rockwell “C" are shown.
  • the erosion weight loss is substantially dependent upon the hardness of the substrate, as well as the applied waterjet pressure and mass of water delivered.
  • a nickel based superalloy turbine blade was cleaned and roughened in one step using appropriate waterjet parameters found above.
  • the blade had a dark surface oxide originally, but it was removed completely by the waterjet roughening procedure.
  • the erosion weight loss of the blade was 10.7 mg/cm 2 , about 0.012 mm thickness removal.
  • the blade was then coated with an MCrAlY overlay (where M is, nickel, cobalt or iron) by an argon shrouded plasma spray, heat treated in a vacuum, finished and peened. An excellent bond was obtained and the interface was absolutely clean everywhere.
  • Fig. 10 a plot is shown of threshold pressure versus hardness (Rockwell B) for the three principal superalloys that were studied, IN-718; MAR-M 509 and RENE 80. Note that as the hardness increases, the threshold pressure increases in an exponential fashion.
  • the mass of water delivered is plotted against waterjet pressure for both cobalt-based superalloys and nickel-based superalloys.
  • the mass of water delivered was that required to achieve a 4.5 mg/cm 2 erosion of the substrate.
  • the mass of water delivered varies from approximately 0.7 kg/cm 2 at 52 ksi to 5.5 kg/cm 2 at approximately 31.5 ksi.
  • the nickel based superalloys exhibit a lesser mass of water required to achieve a similar erosion state and at lower waterjet pressures (e.g. approximately 1.5 kg/cm 2 at 40 ksi.
  • Table 5 denotes the critical mass of water needed to achieve the stated levels of erosion in the variety of substrates subjected to test.
  • Each of the entries in Table 5 establishes, for at least a minimum erosion level of 4.5 mg/cm 2 , the mass of required water at the indicated pressure. Also, there is an entry (for all but one substrate) which indicates the mass of water required to achieve a maximum level of erosion of 45 mg/cm 2 .
  • the entries in Table 5 which have an asterisk are interpolated values between experimentally achieved values.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Plasma & Fusion (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Physics & Mathematics (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Perforating, Stamping-Out Or Severing By Means Other Than Cutting (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
EP96109797A 1995-06-19 1996-06-18 Procédé d'érosion de surface de superalliages par un jet liquide Ceased EP0750054A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US49234495A 1995-06-19 1995-06-19
US492344 1995-06-19

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JP (1) JPH0911200A (fr)
CA (1) CA2179335C (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1304395A1 (fr) * 2001-10-19 2003-04-23 Sulzer Markets and Technology AG Procédé de fabrication d'une couche obtenue par pulvérisation thermique
EP1308227A1 (fr) * 2001-10-31 2003-05-07 DaimlerChrysler AG Procédé de surmoulage d'un insert métallique
EP1507018A1 (fr) * 2003-08-15 2005-02-16 Walbar Metals, Inc. Procédé de traitment d'une turbine de gaz préalable du revêtement
WO2007087989A1 (fr) * 2006-02-02 2007-08-09 Daimler Ag Conditionnement de surface pour couCHEs de pulvérisation thermique

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3503073C2 (de) 1984-02-02 1986-10-23 Shimpo Kogyo K.K., Kyoto Automatisches Getriebe für Kraftfahrzeuge
CN115287559A (zh) * 2022-07-14 2022-11-04 武汉大学 利用高压水射流的钛合金材料梯度微纳结构的制备方法

Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2413225A1 (fr) * 1977-12-30 1979-07-27 Metallisation Ste Nouvelle Procede pour donner l'aspect de bronze patine par le temps a des pieces diverses recouvertes de bronze
JPS589972A (ja) * 1981-07-11 1983-01-20 Kansai Metarikon Kogyosho:Kk 金属表面の腐食ならびに応力腐食割れ防止および進行阻止法
JPS6044267A (ja) * 1983-08-20 1985-03-09 Toyota Motor Corp 溶射層の密着性向上方法
EP0245602A2 (fr) * 1986-05-15 1987-11-19 ALFRED TEVES GmbH Procédé et dispositif pour l'ébarbage de pièces usinées
DE4032862A1 (de) * 1990-10-12 1992-04-16 Bergmann Borsig Gmbh Verfahren zur vorbehandlung metallischer oberflaechen fuer thermische spritzbeschichtungen
US5128172A (en) * 1990-10-12 1992-07-07 Whittick Thomas E Continuous coating process with inductive heating
EP0509536A2 (fr) * 1991-04-19 1992-10-21 EDWARDS, KNIESE & CO HOCHVAKUUM GmbH Procédé et dispositif pour la régénération des objets chargés de polluants
EP0568315A1 (fr) * 1992-04-28 1993-11-03 Progressive Technologies, Inc. Dispositif et méthode pour nettoyer par jet sous pression de surfaces métalliques
JPH06106213A (ja) * 1992-09-30 1994-04-19 Kawasaki Steel Corp 冷間圧延ミル出側ロールの寿命延長方法
EP0618040A1 (fr) * 1993-03-26 1994-10-05 Fuji Oozx Inc. Procédé de traitement de surface d'un poussoir de soupape

Patent Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2413225A1 (fr) * 1977-12-30 1979-07-27 Metallisation Ste Nouvelle Procede pour donner l'aspect de bronze patine par le temps a des pieces diverses recouvertes de bronze
JPS589972A (ja) * 1981-07-11 1983-01-20 Kansai Metarikon Kogyosho:Kk 金属表面の腐食ならびに応力腐食割れ防止および進行阻止法
JPS6044267A (ja) * 1983-08-20 1985-03-09 Toyota Motor Corp 溶射層の密着性向上方法
EP0245602A2 (fr) * 1986-05-15 1987-11-19 ALFRED TEVES GmbH Procédé et dispositif pour l'ébarbage de pièces usinées
DE4032862A1 (de) * 1990-10-12 1992-04-16 Bergmann Borsig Gmbh Verfahren zur vorbehandlung metallischer oberflaechen fuer thermische spritzbeschichtungen
US5128172A (en) * 1990-10-12 1992-07-07 Whittick Thomas E Continuous coating process with inductive heating
EP0509536A2 (fr) * 1991-04-19 1992-10-21 EDWARDS, KNIESE & CO HOCHVAKUUM GmbH Procédé et dispositif pour la régénération des objets chargés de polluants
EP0568315A1 (fr) * 1992-04-28 1993-11-03 Progressive Technologies, Inc. Dispositif et méthode pour nettoyer par jet sous pression de surfaces métalliques
JPH06106213A (ja) * 1992-09-30 1994-04-19 Kawasaki Steel Corp 冷間圧延ミル出側ロールの寿命延長方法
EP0618040A1 (fr) * 1993-03-26 1994-10-05 Fuji Oozx Inc. Procédé de traitement de surface d'un poussoir de soupape

Non-Patent Citations (3)

* Cited by examiner, † Cited by third party
Title
PATENT ABSTRACTS OF JAPAN vol. 18, no. 380 (M - 1639) 18 July 1994 (1994-07-18) *
PATENT ABSTRACTS OF JAPAN vol. 7, no. 77 (C - 159) 30 March 1983 (1983-03-30) *
PATENT ABSTRACTS OF JAPAN vol. 9, no. 172 (M - 397) 17 July 1985 (1985-07-17) *

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1304395A1 (fr) * 2001-10-19 2003-04-23 Sulzer Markets and Technology AG Procédé de fabrication d'une couche obtenue par pulvérisation thermique
EP1308227A1 (fr) * 2001-10-31 2003-05-07 DaimlerChrysler AG Procédé de surmoulage d'un insert métallique
US6739377B2 (en) 2001-10-31 2004-05-25 Daimlerchrysler Ag Process for incorporating a metallic semi-finished product by casting
EP1507018A1 (fr) * 2003-08-15 2005-02-16 Walbar Metals, Inc. Procédé de traitment d'une turbine de gaz préalable du revêtement
WO2007087989A1 (fr) * 2006-02-02 2007-08-09 Daimler Ag Conditionnement de surface pour couCHEs de pulvérisation thermique
US8209831B2 (en) 2006-02-02 2012-07-03 Daimler Ag Surface conditioning for thermal spray layers
DE102006004769B4 (de) 2006-02-02 2022-05-25 Mercedes-Benz Group AG Oberflächenkonditionierung für thermische Spritzschichten

Also Published As

Publication number Publication date
CA2179335C (fr) 1999-09-07
JPH0911200A (ja) 1997-01-14
MX9602384A (es) 1998-10-31
CA2179335A1 (fr) 1996-12-20

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