EP0792948A1 - Wärmehemmende Beschichtung mit verbesserter Unterschicht und Gegenstände mit dieser Wärmehemmende Beschichtung - Google Patents

Wärmehemmende Beschichtung mit verbesserter Unterschicht und Gegenstände mit dieser Wärmehemmende Beschichtung Download PDF

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EP0792948A1
EP0792948A1 EP97400436A EP97400436A EP0792948A1 EP 0792948 A1 EP0792948 A1 EP 0792948A1 EP 97400436 A EP97400436 A EP 97400436A EP 97400436 A EP97400436 A EP 97400436A EP 0792948 A1 EP0792948 A1 EP 0792948A1
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thermal barrier
barrier coating
ceramic
coating
metal
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French (fr)
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EP0792948B1 (de
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Serge Alexandre Alperine
Pierre Josso
Jean-Paul Fournes
Jacques Louis Leger
André Hubert Louis Malie
Denis Georges Manesse
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Office National dEtudes et de Recherches Aerospatiales ONERA
Safran Aircraft Engines SAS
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Office National dEtudes et de Recherches Aerospatiales ONERA
Societe Nationale dEtude et de Construction de Moteurs dAviation SNECMA
Sochata
SNECMA SAS
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    • CCHEMISTRY; METALLURGY
    • C23COATING 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
    • C23CCOATING 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
    • C23C28/00Coating 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
    • C23C28/30Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/32Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer
    • C23C28/321Coatings 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
    • CCHEMISTRY; METALLURGY
    • C23COATING 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
    • C23CCOATING 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
    • C23C28/00Coating 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
    • C23C28/30Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/32Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer
    • C23C28/321Coatings 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
    • C23C28/3215Coatings 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
    • CCHEMISTRY; METALLURGY
    • C23COATING 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
    • C23CCOATING 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
    • C23C28/00Coating 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
    • C23C28/30Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/34Coatings 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
    • C23C28/345Coatings 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
    • CCHEMISTRY; METALLURGY
    • C23COATING 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
    • C23CCOATING 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
    • C23C28/00Coating 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
    • C23C28/30Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/34Coatings 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
    • C23C28/345Coatings 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
    • C23C28/3455Coatings 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
    • CCHEMISTRY; METALLURGY
    • C23COATING 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
    • C23CCOATING 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
    • C23C4/00Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/02Pretreatment of the material to be coated, e.g. for coating on selected surface areas
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12493Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12535Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.] with additional, spatially distinct nonmetal component
    • Y10T428/12542More than one such component
    • Y10T428/12549Adjacent to each other
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12493Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12535Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.] with additional, spatially distinct nonmetal component
    • Y10T428/12611Oxide-containing component
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12493Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12535Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.] with additional, spatially distinct nonmetal component
    • Y10T428/12611Oxide-containing component
    • Y10T428/12618Plural oxides

Definitions

  • the invention relates to a thermal barrier coating and its sub-layer for metal parts made of superalloy. It applies in particular to hot parts of turbomachinery.
  • Turbine engine manufacturers, both terrestrial and aeronautical, have been confronted for more than thirty years with the imperatives of increasing the efficiency of turbomachines, reducing their specific fuel consumption as well as polluting emissions of CO x , SO types x , NO x and unburnt.
  • One of the ways to meet these requirements consists in approaching the fuel combustion stoichiometry and therefore in increasing the temperature of the gases leaving the combustion chamber and attacking the first stages of the turbine. This trend in the evolution of turbomachinery has been a constant over the past thirty years.
  • thermal barrier An alternative to this change of family of materials consists in depositing on the hot parts in superalloys a thermal insulating coating called "thermal barrier".
  • This ceramic insulating coating makes it possible, on a cooled part, to create a thermal gradient in permanent operating conditions through the ceramic, the total amplitude of which can exceed 200 ° C.
  • the operating temperature of the underlying metal is reduced accordingly with a considerable impact on the volume of cooling air required, the service life of the part and the specific consumption of the engine.
  • a ceramic coating cannot, as a general rule, not be deposited directly on the superalloy, and requires the interposition of a metallic undercoat endowed with multiple functionalities.
  • This underlay plays a mechanical adaptation role between the superalloy substrate and the ceramic coating.
  • the thermal barrier coatings are composed of a mixture of oxides, most often based on zirconia. This oxide constitutes in fact a most interesting compromise between a material having a low thermal conductivity and a relatively high coefficient of expansion, close to that of the alloys based on nickel and / or cobalt on which it is desired to deposit it.
  • zirconia partially stabilized with yttrium oxide ZrO 2 + 6 at 8% by mass of Y 2 O 3 .
  • zirconia it is also possible to use another addition oxide chosen from the oxides of cerium, calcium, magnesium, lanthanum, ytterbium and scandium in particular.
  • the ceramic coating can be deposited on the part to be coated using various methods, most of which belong to two distinct families: sprayed coatings and coatings deposited physically by the vapor phase.
  • the zirconia-based oxide deposition is carried out by techniques related to plasma spraying.
  • the coating consists of a stack of melted ceramic droplets then impact hardened, flattened and stacked so as to form an imperfectly densified deposit with a thickness of between 50 ⁇ m and 1 mm.
  • One of the characteristics of this type of coating is an inherently high roughness (Ra typically between 5 and 35 ⁇ m).
  • the microstructure of this type of coating makes it not very capable of withstanding the tearing forces present during thermal cycling in service, because of the differential of expansion coefficient between the superalloy and the oxide. Its mode of degradation in service is therefore characterized by the slow propagation of a crack in the ceramic parallel to the ceramic / metal interface. It is a cohesive rupture.
  • the mechanically weak point of the coating comprising the ceramic and the undercoat is then not the ceramic / undercoat interface itself, but rather the ceramic itself. Consequently, the sub-layers which are well suited to this type of ceramic deposit are preferably very plastic at high temperature, this in order to compensate by their own deformation those imposed on the ceramic by its differential expansion with the superalloy substrate.
  • the problem is significantly different.
  • Such a deposition can be carried out using devices such as evaporation under electronic bombardment.
  • the coating consists of an assembly of very fine balusters (typically between 0.2 and 10 ⁇ m in diameter) oriented substantially perpendicular to the surface to be coated.
  • the thickness of such a coating can be between 20 and 600 ⁇ m.
  • Such an assembly has the advantageous property of reproducing without altering the surface condition of the covered substrate.
  • final roughnesses far less than a micrometer can be obtained, which is very advantageous for the aerodynamic properties of the blade.
  • the object of the invention is to produce a thermal barrier coating comprising a ceramic coating with columnar structure and an undercoat very adherent to the ceramic and to the superalloy to be coated, the undercoat being designed so as to ensure increased adhesion. of the interfacial alumina layer in all circumstances, to resist the phenomena of high temperature interdiffusion with the superalloy and to exhibit excellent resistance to stresses of the hot corrosion type so as to give the coating an increased service life and a better reliability over time.
  • the invention consists in producing an aluminide thermal barrier sublayer and in introducing into the sublayer at least one metal of the platinum mine with which is associated at least one metal which promotes the formation of the allotropic variety. ⁇ of alumina. The platinum mine metal maintains a good quality oxide layer for a longer time than a simple aluminide.
  • a coating of nickel aluminide and / or of cobalt modified with a platinum mine metal such as in particular palladium is a noble metal with a very strong chemical affinity with the nickel aluminide ⁇ -NiAl. It is possible to incorporate into a nickel aluminide coating of the ⁇ -NiAl type up to 35% or 40% in moles of palladium without changing the crystallographic structure. Palladium in solid solution in nickel aluminide plays several roles.
  • Palladium like the other metals of the platinum mine significantly increases the thermodynamic activity of aluminum and therefore allows the alloy to remain aluminum-forming even when a significant part of the aluminum reserve of the coating is used up.
  • the practical consequence is that under identical conditions of use, a sub-layer of aluminide modified by a metal of platinum mine will maintain a layer of good quality oxide for a longer time than would an under-layer in simple aluminide.
  • Palladium like the other metals in the platinum mine, significantly increases the diffusion coefficient of aluminum in nickel aluminide; thus aluminum can diffuse more easily towards the external surface of the underlayer to compensate for the progressive depletion of the latter during the formation of an interfacial layer alumina. This phenomenon ensures better availability of the aluminum reserve of the sublayer to form an interfacial layer of perennial alumina, compared to the case of a palladium-free aluminide sublayer.
  • Palladium by a steric effect in the ⁇ -NiAl type aluminide, facilitates the mechanisms of rise of dislocations, allowing the sub-layer to accommodate the growth constraints exerted on the layer of interfacial alumina, disagrees between the crystal lattice parameters of the metal making up the superalloy and alumina.
  • the presence of palladium makes it possible to obtain a layer of interfacial alumina that is less constrained and therefore both more compact and more adherent to the metal of the sublayer than in the case of the oxidation of an aluminide in l absence of palladium.
  • palladium leads to sublayers having the same type of ductility as the simple aluminide, unlike the aluminides modified by platinum. This property can be observed by measuring the Vickers hardnesses of the different undercoats in their external part, but also on metallographic section by the absence of cracks in the external part of the undercoat, as will be described in the examples illustrating the detailed description of the invention.
  • the use of palladium in a modified aluminide undercoat also has definite economic appeal compared to the use of platinum.
  • platinum and palladium are not the only elements to promote the formation of good quality alumina layers when are alloyed with the intermetallic NiAl with a ⁇ structure.
  • ruthenium also has this interesting set of properties.
  • the sublayer may comprise several metals of the platinum mine, such as for example, an alloy of palladium and / or platinum and / or ruthenium.
  • Another important aspect of the invention resides in the use of at least one metal which promotes the formation of the allotropic variety ⁇ of alumina such as, for example, chromium, conjugated with the metal of the platinum mine, in the thermal barrier underlay.
  • Chromium plays a crucial role in the mechanisms of formation of the interfacial alumina layer, in particular during the first hours of exposure to high temperature.
  • the addition of chromium in small quantities (between 0.1 and 10% by mass for example) in the thermal barrier undercoat has the effect of promoting the almost immediate formation of the allotropic variety ⁇ of alumina by growth epitaxial on chromium oxide nodules Cr 2 O 3 .
  • the oxidation of the sublayer begins with the formation of alumina of the allotropic variety ⁇ .
  • This variety ⁇ of alumina is highly constrained and not very adherent to the underlying metal.
  • the thermodynamically stable variety ⁇ is also formed, but over an oxide sublayer which is certainly discontinuous but has very little adhesion, which limits the overall adhesion of the oxide layer.
  • this transformation Al 2 O 3 ⁇ -> Al 2 O 3 ⁇ is accompanied by a strong change in volume of the crystallographic mesh which creates high stresses in the oxide layer, very unfavorable for its adhesion on the underlying metal.
  • the adhesion of the oxide layer is reinforced by the fact that the ⁇ variety of alumina is formed immediately.
  • Other metals promoting the formation of the ⁇ allotropic variety alumina can also be used such as for example iron and / or manganese.
  • the examples will be limited to chromium, which also has the advantage of improving the resistance of the coating to hot corrosion.
  • said chromium In order for the chromium introduced into an aluminide underlay modified by a precious metal of the platinum mine to effectively promote the formation of the allotropic variety ⁇ of alumina, said chromium must be present in sufficient proportion in the upper part of the sublayer where the interfacial alumina layer is formed.
  • the introduction of chromium into the upper part of the undercoat can be carried out by different methods.
  • the addition of chromium to the sublayer can be carried out by a suitable heat treatment allowing the diffusion of chromium from the substrate to the surface of the sublayer.
  • the substrate is previously coated with a modifier layer containing a precious metal from the platinum mine, for example a nickel-palladium deposit, this deposit being followed by a diffusion annealing operation, the temperature and duration of which are chosen so that the diffusion of the platinum mine metal into the substrate is shallow and allows the diffusion of chromium from the substrate to the surface of the modifier layer.
  • the energy activation barrier for the diffusion of a precious metal such as platinum or palladium being high compared to that of chromium, diffusion annealing is carried out at a temperature below a limit temperature above from which the precious metals of the platinum mine diffuse faster than the chromium.
  • the temperature of the diffusion annealing is chosen to be less than 1100 ° C. and preferably less than 900 ° C.
  • the duration of the diffusion annealing is adapted as a function of the annealing temperature chosen and of the desired chromium concentration in the upper part of the undercoat. Typically, the duration of the annealing is greater than one hour and preferably greater than or equal to two hours. Diffusion annealing is then followed by an aluminization operation.
  • the addition of chromium to the sublayer can be carried out by a chromization operation.
  • the chromizing operation must be carried out just before or during the aluminizing operation so as, on the one hand, to find the chromium in the outermost part of the final coating and, on the other hand to avoid the formation of a diffusion barrier for all of the elements of the undercoat, in the event that the chromium is deposited in a continuous layer.
  • the sub-layers are produced on a nickel-based superalloy substrate such as IN 100, AM 3, AM 1, DS 200, PD 21, C1023 and N 5 including the composition is recalled in Table 1 shown in Figure 1.
  • a coating of nickel aluminide of the standard low activity type was then produced on this sample by case hardening activated in the case. At the end of this operation, the sample had a healthy surface and a satin pink color.
  • a metallographic section made perpendicular to the surface shows that the coating obtained is approximately 60 ⁇ m thick, single-phase and that it has a structure divided into three zones of uneven thickness.
  • the first zone located at the top of the coating is approximately 30 ⁇ m thick and has a negative palladium concentration gradient (The palladium concentration decreases from the top of the coating towards the substrate).
  • the composition of this zone can be written ⁇ - (Ni x , Pd 1-x ) Al, with 0.4 ⁇ x ⁇ 0.9.
  • the second zone is composed of nickel aluminide of the ⁇ -NiAl type containing a little palladium in solid solution. These two zones also contain chromium in a mass proportion of 0.5% to 5%. The presence of chromium in the sublayer, and in particular in an upper part of the sublayer, ensures the immediate formation of the allotropic variety ⁇ of alumina which is very adherent to the underlying metal.
  • the third zone approximately 10 ⁇ m thick, is characteristic coatings obtained by diffusion. It should be noted that microhardness measurements carried out on this coating have shown that they are equivalent to those obtained on a simple aluminide coating. This shows that the sub-layer according to the invention is not very fragile and unlikely to crack in service.
  • Identical coatings obtained on the same type of substrate were subjected to oxidation tests at 1100 ° C and corrosion tests at 850 ° C in the presence of molten sodium sulfate. These two types of tests are cycled; a cycle consists in bringing the test sample from approximately 200 ° C (or from room temperature if it is the first cycle) to the test temperature (1100 ° C for oxidation or 850 ° C for corrosion) in 5 minutes approximately then maintain it at this temperature for one hour and cool it to approximately 200 ° C in less than 5 minutes by forced air convection.
  • the sample is additionally contaminated by a deposit of approximately 50 ⁇ g / cm 2 of sodium sulfate (Na 2 SO 4 ) every 50 cycles.
  • Na 2 SO 4 sodium sulfate
  • the end of the tests extended up to 1000 cycles of one hour, it was found to be resistant to oxidation and to hot corrosion identical to that found with a coating of nickel aluminide modified by a pre-deposit of platinum such as RT22 marketed by the company Chromalloy UK.
  • An identical coating obtained on the same type of substrate was, this time, subjected to isothermal oxidation at 1100 ° C. for 100 hours.
  • This test aims, for example, to prepare a substrate to receive the deposit of a thermal barrier, said substrate being pre-coated with a sublayer resistant to oxidation and to hot corrosion.
  • a mass gain of 0.3 mg / cm 2 was observed, corresponding to an alumina thickness of approximately 1.7 ⁇ m.
  • a micrographic examination of the alumina layer obtained shows that it is dense, continuous and adherent.
  • the thickness of alumina obtained on a simple nickel aluminide can reach 5 ⁇ m after 100 hours of isothermal oxidation under conditions identical.
  • Example 2 The procedure was as in Example 1, replacing the low activity aluminization in the body with a low activity aluminization in the vapor phase (known as "APVS").
  • the nickel-based substrate was covered with a palladium-nickel pre-deposit of approximately 10 ⁇ m, then was annealed under an air pressure of less than 10 -5 Torr for 2 hours at 850 ° C. and introduced into a semi-sealed box containing an aluminum donor cement consisting of coarse shot of a chromium-aluminum alloy activated by 1% by weight of ammonium bifluoride (NH 4 F, HF). The whole is then brought to 1050 ° C. for 15 hours under argon.
  • NH 4 F, HF ammonium bifluoride
  • the sample had a healthy surface and a bright pink color.
  • a metallographic section made perpendicular to the surface shows that the coating obtained is approximately 60 ⁇ m thick, single-phase and that it has a structure divided into three zones of uneven thickness. The thicknesses and the compositions of each of the three zones are identical to those of the zones obtained in Example 1.
  • Example 2 The procedure was as in Example 1, replacing the low activity aluminization in the box with a high activity aluminization deposited by painting.
  • the nickel base substrate was covered with a palladium-nickel pre-deposit of approximately 10 ⁇ m, then was annealed under an air pressure below 10 -5 Torr for 2 hours at 850 ° C and coated with a paint.
  • Sermaloy J type aluminizing agent sold by Sermatech Inc.
  • the layer of paint deposited had a thickness of approximately 100 ⁇ m.
  • the whole After a drying operation of half an hour at 80 ° C in air and a pre-diffusion operation of half an hour in air at 350 ° C, as specified in the given application standards by the manufacturer of the product, the whole is then brought to 1020 ° C for 4 hours under argon.
  • the sample had a healthy and black surface.
  • the sample After a micro-sandblasting operation intended to remove the slag inherent in this type of aluminization, the sample had a dark pink color characteristic of a coating modified by a palladium pre-deposit.
  • a metallographic section made perpendicular to the surface shows that the coating obtained is approximately 60 ⁇ m thick, single-phase and that it has a structure divided into three zones of uneven thickness.
  • the first zone located at the top of the coating is approximately 30 ⁇ m thick and has a negative palladium concentration gradient (from the top of the coating to the substrate).
  • the composition of this zone can be written ⁇ - (Ni x , Pd 1-x ) Al, with 0.4 ⁇ x ⁇ 0.9.
  • the second zone about 20 ⁇ m thick, is composed of nickel aluminide of the ⁇ -NiAl type containing a little palladium in solid solution. These two zones also contain chromium in a mass proportion of 0.5% to 5%.
  • the third zone approximately 10 ⁇ m thick, is characteristic of the coatings obtained by diffusion.
  • This coating also contains molecules such as silicon (favorable for good adhesion of the oxide layer formed in service), silica and traces of phosphorus. It should be noted that microhardness measurements carried out on this coating have shown that they are always equivalent to that of a simple aluminide coating.
  • Example 2 The procedure was as in Example 2, modifying the pre-deposit of palladium nickel.
  • the nickel-based substrate was previously coated with a palladium-nickel pre-deposit as in Example 2, but with a thickness of approximately 15 ⁇ m.
  • 2 ⁇ m of electrolytic chromium was deposited from a conventional hard chromium bath. This chromium deposit can constitute a source of promoter metal for the ⁇ allotropic variety of alumina.
  • the whole was then annealed under an air pressure of less than 10 -5 Torr for 2 hours at 850 ° C. and aluminized as in Example 1. At the end of this operation the sample presented a healthy surface and satin pink color.
  • a metallographic section made perpendicular to the surface shows that the coating obtained is approximately 60 ⁇ m thick, two-phase and that it has a structure divided into three zones of uneven thickness.
  • the first zone located at the top of the coating is approximately 30 ⁇ m thick and has a negative palladium concentration gradient (from the top of the coating to the substrate).
  • the composition of this zone can be written ⁇ - (Ni x , Pd 1-x ) Al, with 0.4 ⁇ x ⁇ 0.9.
  • fine precipitates of ⁇ -Cr characteristics of an aluminization modified by chromium.
  • the second zone is composed of nickel aluminide of the ⁇ -NiAl type containing a little palladium in solid solution.
  • the third zone approximately 10 ⁇ m thick, is characteristic of the coatings obtained by diffusion. However, it should be noted that this zone seems less disturbed than in the previous examples. This is due to the fact that the chromium of the substrate has less diffused towards the coating during construction because this element was present in the modifying pre-deposit.
  • microhardness measurements carried out on this coating showed that they were equivalent to those of a simple aluminide coating modified by chromium (460 Hv 50 ). Tests of high temperature oxidation, of hot corrosion and of isothermal oxidation at 1100 ° C. gave results comparable to those noted in Example 1, or even better in the case of hot corrosion.
  • Examples 5 to 8 described below are illustrations of ceramic coating of the thermal barrier type comprising a sub-layer described in examples 1 to 4 above.
  • Palladium-modified aluminide coatings were deposited according to the method described in Example 1 on N5 alloy discs with a diameter of 25mm and a thickness of 6mm.
  • the N5 alloy the composition of which is given in Table 1 shown in FIG. 1, is a monocrystalline superalloy used in the manufacture of blades and turbine distributors.
  • a thermal barrier coating was then deposited in yttria zirconia (ZrO 2 - 6 to 8% by mass of Y 2 O 3 ) of thickness substantially equal to 125 ⁇ m. This coating was deposited by evaporation under electronic bombardment, at a temperature close to 850 ° C., by a technique described for example in American patent US 5,087,477.
  • this ceramic coating has also been deposited on discs, of the same alloy, having been coated beforehand, either with an MCrAlY alloy sublayer deposited by plasma spraying under reduced pressure, or with an MCrAlY alloy sublayer produced by evaporation under electronic bombardment (EBPVD), these two sublayers corresponding to the state of the art cited in patents US 4,321,311 and US 4,401,697. Samples of the same nature were finally produced with sublayers in simple aluminide NiAl and in aluminide modified by platinum, as described for example in American patent US 5,238,752.
  • Example 5 Samples identical to those described in Example 5 were subjected to an oven cycling experiment identical to that described in Example 5 except for the test temperature of 1100 ° C. and the duration of the cycles using 24 hour temperature steps.
  • the palladium-modified sublayer according to the invention gives the thermal barrier coating a very advantageous resistance to spalling.
  • Example 7 Samples according to Example 7 were produced with different alloys such as the IN100 superalloys as substrate. They were tested according to the three test methods described respectively in Examples 5, 6, 7. In all cases, it appears that the lifetime of the thermal barrier coatings obtained with a sublayer according to the invention is much higher than that obtained with MCrAlY type sublayers or simple aluminides.
  • the thickness of the sub-layer may be different from that chosen in the examples, but preferably between 10 ⁇ m and 500 ⁇ m.
  • the amounts of platinum-containing metal and of metal promoting the formation of an oxide layer consisting of the ⁇ allotropic variety of alumina may be different from those chosen in the examples.
  • the invention is not limited to the use of palladium as a metal of the platinum mine but it extends to all of the metals of the platinum mine such as in particular platinum itself and ruthenium as well as 'to combinations of these metals.
  • the invention is not limited to the use of chromium as a promoter metal for the formation of the ⁇ allotropic variety of alumina, but also extends to the use of manganese, iron and combinations of these metals.

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EP97400436A 1996-02-29 1997-02-27 Wärmehemmende Beschichtung mit verbesserter Unterschicht und Gegenstände mit dieser Wärmehemmende Beschichtung Expired - Lifetime EP0792948B1 (de)

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FR9602536A FR2745590B1 (fr) 1996-02-29 1996-02-29 Revetement de barriere thermique a sous-couche amelioree et pieces revetues par une telle barriere thermique
FR9602536 1996-02-29

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EP1094131B1 (de) 1999-10-23 2004-05-06 ROLLS-ROYCE plc Korrosionsschutzschicht für metallisches Werkstück und Verfahren zur Herstellung einer korrosionsschützenden Beschichtung auf ein metallisches Werkstück
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US6682827B2 (en) * 2001-12-20 2004-01-27 General Electric Company Nickel aluminide coating and coating systems formed therewith
US6886327B1 (en) 2002-03-20 2005-05-03 The United States Of America As Represented By The Administrator Of The National Aeronautics And Space Administration NiAl-based approach for rocket combustion chambers
US6669471B2 (en) 2002-05-13 2003-12-30 Visteon Global Technologies, Inc. Furnace conveyer belt having thermal barrier
JP4173762B2 (ja) * 2003-04-04 2008-10-29 株式会社神戸製鋼所 α型結晶構造主体のアルミナ皮膜の製造方法および積層皮膜被覆部材の製造方法
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FR2870858B1 (fr) * 2004-05-28 2007-04-06 Snecma Moteurs Sa Procede de fabrication ou de reparation d'un revetement sur un substrat metallique
DE102004045049A1 (de) * 2004-09-15 2006-03-16 Man Turbo Ag Verfahren zum Aufbringen einer Schutzschicht
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US7846261B2 (en) * 2006-02-14 2010-12-07 Aeromet Technologies, Inc. Methods of using halogen-containing organic compounds to remove deposits from internal surfaces of turbine engine components
US7597934B2 (en) * 2006-02-21 2009-10-06 General Electric Company Corrosion coating for turbine blade environmental protection
FR2926137B1 (fr) * 2008-01-03 2012-07-06 Snecma Procede de determination de l'adherence d'une couche de barriere thermique en ceramique formee sur un substrat
JP5481993B2 (ja) * 2009-07-23 2014-04-23 株式会社Ihi アルミナイズド処理方法
FR2979014B1 (fr) 2011-08-10 2013-08-30 Snecma Procede de determination de l'apparition de decohesions dans une couche de revetement en ceramique transparente formee sur un substrat
FR2979015B1 (fr) * 2011-08-10 2013-08-30 Snecma Procede de determination de l'adherence d'une couche de barriere thermique en ceramique formee sur un substrat par application d'une impulsion laser cote barriere thermique
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CN106767070A (zh) * 2017-01-12 2017-05-31 山东大学 一种平板式环路热管蒸发器及环路热管
CN115640632A (zh) * 2022-10-14 2023-01-24 港珠澳大桥管理局 钢箱梁桥涂层服役状态评估方法、装置、设备和介质

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Publication number Publication date
US5843585A (en) 1998-12-01
EP0792948B1 (de) 2001-06-13
FR2745590A1 (fr) 1997-09-05
DE69705141D1 (de) 2001-07-19
FR2745590B1 (fr) 1998-05-15
DE69705141T2 (de) 2002-03-14
CA2196744A1 (fr) 1997-08-29
JPH09324278A (ja) 1997-12-16
CA2196744C (fr) 2004-05-18
JP3961606B2 (ja) 2007-08-22
ES2158459T3 (es) 2001-09-01

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