EP0984839A1 - Materiau a gradient d'indice metal-ceramique, produit realise a partir dudit materiau et procede pour produire un materiau a gradient d'indice metal-ceramique - Google Patents

Materiau a gradient d'indice metal-ceramique, produit realise a partir dudit materiau et procede pour produire un materiau a gradient d'indice metal-ceramique

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Publication number
EP0984839A1
EP0984839A1 EP98934822A EP98934822A EP0984839A1 EP 0984839 A1 EP0984839 A1 EP 0984839A1 EP 98934822 A EP98934822 A EP 98934822A EP 98934822 A EP98934822 A EP 98934822A EP 0984839 A1 EP0984839 A1 EP 0984839A1
Authority
EP
European Patent Office
Prior art keywords
ceramic
additive
metal
concentration
gradient
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.)
Granted
Application number
EP98934822A
Other languages
German (de)
English (en)
Other versions
EP0984839B1 (fr
Inventor
Ralph Borchert
Monika Willert-Porada
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.)
Siemens AG
Original Assignee
Siemens AG
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 Siemens AG filed Critical Siemens AG
Publication of EP0984839A1 publication Critical patent/EP0984839A1/fr
Application granted granted Critical
Publication of EP0984839B1 publication Critical patent/EP0984839B1/fr
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/02—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/11—Making porous workpieces or articles
    • B22F3/1103—Making porous workpieces or articles with particular physical characteristics
    • B22F3/1109—Inhomogenous pore distribution
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • 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.]
    • Y10T428/12535—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.] with additional, spatially distinct nonmetal component
    • Y10T428/12611—Oxide-containing component
    • Y10T428/12618—Plural oxides

Definitions

  • Metal-ceramic gradient material product thereof and method for producing a metal-ceramic gradient material
  • the invention relates to a metal-ceramic gradient material, a product thereof, in particular a heat shield or a gas turbine blade, and to a method for producing a metal-ceramic gradient material.
  • the high porosity of the layers between 40% and 79% is used to introduce molten metal into the cavities of the fiber ceramic body by means of pressure casting in order to produce a defect-free composite.
  • a piston crown can be produced which has a strongly abruptly changing gradient in metal and ceramic. Due to the low thermal conductivity of the ceramic components, a thermal barrier is formed and the piston is thus insulated. In addition, the ceramic fiber reinforces the coblen and thus improves the thermal shock resistance of the piston.
  • FGM Functional Gradient Material
  • the object of the invention is to provide a metal-ceramic material for use at high temperatures over a long period of time. Further objects of the invention are the details of a method for producing a metal-ceramic material and a product for a high operating temperature.
  • This first-mentioned object is achieved according to the invention by a metal-ceramic gradient material, in particular for a heat shield or a gas turbine blade, comprising a metallic base material, a ceramic and an additive for high-temperature oxidation protection, the concentration of the metallic base material being from a metal-rich zone decreases in a ceramic-rich zone, the concentration of the additive having a concentration gradient.
  • the object directed to a product is achieved by a product comprising a metal-ceramic gradient material with an additive for high-temperature oxidation protection.
  • the object directed to a process is achieved by a powder metallurgical production process in which a metal-ceramic gradient material is produced from a powder spill with a concentration gradient for an additive for high-temperature oxidation protection by pressing and sintering.
  • the invention is based on the knowledge of forming a functional gradient material (FGM) with regard to the function of the resistance to oxidation.
  • FGM functional gradient material
  • the gradient of the composition over the functional cross-section of a component can range from 100% ceramic to 100% metal, but gradients of other limit concentrations or "partial gradients" can also be used for certain purposes in addition to a continuous gradient for certain components symmetrical gradients possible, for example ceramic-metal-ceramic or combinations of the composition gradients mentioned.
  • An FGM can also be seen as a link between classic layer systems and typical ceramic matrix systems with 2D or 3D reinforcement elements, whereby in the structure between the pure ceramic and metal components there is a transition from the dispersion material with a ceramic matrix to interpenetrating networks of ceramic and metal towards a dispersion material with a metal matrix.
  • further material classes eg organic polymers or amorphous materials such as oxidic and non-oxidic glasses, is possible to achieve special combinations of properties.
  • the property profile can be modified by introducing several ceramic or metallic materials.
  • Ceramic-metal FGM which consist of 8Y-ZrO 2 -NiCr8020, for example, can be interesting as thermal insulation systems, since the composition gradient is suitable for minimizing thermomechanical stresses and thus increasing the thickness of the thermal insulation layer.
  • a decisive criterion for the use of such FGM for thermal insulation is, however, the resistance to oxidation, which cannot be guaranteed with the help of metallic intermediate layers due to the special microstructure.
  • a gradient of the composition results in a spatially "smeared” and enlarged ceramic / metal interface compared to a layer composite.
  • the oxidation-inhibiting intermediate layer previously used in layer composites eg NiCrAlY
  • WDS thermal insulation layer system
  • the ceramic-rich zones of an FGM should have a higher density compared to plasma-sprayed WDS, which results in a high oxygen ion conductivity of the 8Y-Zr0 2 , an increased heat conduction and a low temperature change resistance .
  • the invention therefore provides for the use of an additive for high-temperature oxidation protection with a concentration gradient.
  • a special microstructure can be set in the ceramic area, depending on the requirements, so that good thermal insulation and resistance to temperature changes as well as stability against shrinkage due to re-sintering are achieved with the lowest possible porosity.
  • the metal-ceramic gradient material does not consist of a layer system, but rather of a penetration structure in which the ceramic phase passes over the metal base material via an additive (here preferred: ZrS ⁇ 0 4 ).
  • This additive not only brings about a dramatic reduction in oxygen diffusion, but preferably also ensures that the metallic surface is covered with thermodynamically stable oxides and silicates.
  • the additive preferably has low thermal expansion and good adhesion to both the ceramic and the metal. It is preferably thermally stable and preferably does not form any low-melting eutectics with the ceramic, in particular a ZrO 2 layer, or with the metal or its
  • Corrosion products This results in an improvement in the long-term oxidation resistance compared to classic layer systems comprising a metallic base material, a metal-based adhesive layer and a ceramic, and the prevention of flaking.
  • the additive preferably forms a stable network of strongly branching microcracks and closed porosity. This results in a low modulus of elasticity module in the ceramic-rich areas and a reduction in the thermal conductivity. Both are desired effects for use at high temperatures, since they have a direct influence on the thermal shock resistance and the thermal insulation properties of the system. This results in an improvement in both the oxidation stability and the system stability, even with improved thermal insulation properties. This has an effect when used in a product charged with a hot gas, for. B. a gas turbine, directly on the availability (reliability) and the possible turbine inlet temperatures, ie on cooling air consumption or increase in efficiency.
  • the metallic base material is preferably a chromium-nickel alloy, for example NiCr8020, and the ceramic comprises zirconium oxide, which can be partially stabilized, for example, with yttrium (8Y-Zr0 2 ).
  • This FGM e.g. 8Y-Zr0 2 -
  • NiCr8020-FGM shows a slight tendency to oxidize by adding an additive in the volume of the FGM, even at high temperatures of up to over 1000 ° C.
  • this additive enables the FGM to be highly stable to oxidation.
  • the chemical effect means a reduction in the oxygen ion conductivity of the ceramic, in particular 8Y-Zr0 2 , and a high dissolving power for Cr oxide and other bunoxides, which result from the oxidation of the metals.
  • the additive preferably has good wetting and adhesion both to metals and to the ceramic, in particular ZrO 2 .
  • the additive therefore causes the grain boundaries of the ceramic, in particular the 8Y-Zr0 2 , to be covered with precipitates, e.g. B. of Si0 2nd cause.
  • precipitates e.g. B. of Si0 2nd cause.
  • a reduction in the oxygen conductivity of the ceramic is preferably achieved even at high temperatures of over 800 ° C.
  • a slowdown in metal oxidation can also be achieved if the evaporation of the oxides formed and oxygen understoichiometry, which could lead to the formation of volatile suboxides, are prevented by the additive.
  • a silicate or phosphate, stannate, titanate
  • an additive is preferably provided, which enables the targeted introduction of strongly branching microcracks and / or the formation of metastable, closed pores, which on the one hand reduce the elasticity module of the ceramic-rich zones of the FGM and on the other hand in the metal-containing zones of the FGM absorb the local tensile stresses around the metal grains.
  • the porosity and the crack network also cause a deterioration in the heat conduction.
  • the use of unstabilized Zr0 2 as a microcrack trigger is due to the t ⁇ m conversion z. B. effective with densely sintered ceramic materials.
  • the additive is preferably ceramic itself and has a very low linear thermal expansion and / or a strong anisotropy of thermal expansion. Good adhesion to both the actual ceramic, e.g. B. to 8Y-Zr0 2 , as well as to the metal, the additive is able to absorb tensile stresses between these two components of an FGM or to reduce them by microcracking.
  • the density and extent of the crack network can be influenced by the grain size and the volume fraction of the additive.
  • the additive is also thermally stable and preferably does not form extremely low melting eutectics with the oxidation products or the components of the FGM.
  • ZrSi0 4 is preferably suitable as an additive.
  • Other possible additives are mullite, zirconyl or Al phosphates, glass ceramics. With such an additive, the advantages of the FGM in terms of increasing the thickness of the WDS can be exploited by providing oxidation protection at the metal-ceramic interface in the dimensions of the structural components, ie the metal-ceramic agglomerates and grains , which also has the required microstructural features.
  • the metal-ceramic gradient material is preferably used to produce a product which is exposed to a hot, possibly aggressive gas, such as a component of a gas turbine, an oven or the like.
  • a hot, possibly aggressive gas such as a component of a gas turbine, an oven or the like.
  • gradient systems containing ZrSi0 4 can be used as materials for thermal protection systems in the hot gas path of gas turbines. Heat shields can do this more easily
  • the metal-ceramic gradient material and a method for its production are explained in more detail with the aid of the drawing.
  • the production of the green bodies, the sintering and physical examinations are given here. Show it:
  • FIG. 6 Comparison of the oxidation resistance of linear 8Y-ZrO2-NiCr8020-FGM and linear 8Y-Zr02-ZrSiO4-NiCr8020-FGM.
  • Fig. 7a b Ceramic layer of an oxidation-resistant gradient material after thermal etching at 1450 ° C in air, 0.5 h . Overview (a), grain structure (b)
  • the metallic-ceramic functional gradient materials are manufactured by powder metallurgy. 8Y-ZrO 2 -NiCr8020-FGM, 8Y-ZrO 2 -ZrSiO 4 -NiCr8020-FGM, (as well as 8Y-ZrO 2 -ZrPO 4 -NiCr8020-FGM and with the same ceramic composition-steel-, -TiAl- or NiAl intermetallic see compounds, -Mo as well as all combinations of substances
  • the FGM green bodies consist of 8Y-Zr0 2 powder (d50 0.3 ⁇ m, commercially available from Tosoh available) and ⁇ 25 ⁇ m N ⁇ Cr8020 powder (Ampersmt, commercially available from HC Starck GmbH, Germany) and ZrS 04 powder (commercial, 99%).
  • silicone molds dry fill of up to 12 individual mixtures, the volume fraction of which is ceramic (including 20%
  • ZrS ⁇ 0 4 increases from layer to layer, cylindrical samples with dimensions ⁇ 35 mm x 15 mm are formed.
  • the ZrS ⁇ 0 4 is first ground with the metal powder in a planetary mill and then mixed with the corresponding amount of 8Y-Zr0 2 .
  • the addition of the additives is possible not only in the form of powders, but also by coating with precursors or by infiltration of green bodies with precursor compounds.
  • Fig. La shows a linear gradient between the metal and Zr0 2 .
  • the gradient between the metallic component and the assembled ceramic is also linear, but the proportion of the individual ceramic components (Zr0 2 and ZrS ⁇ 0 4 ) changes nonlinearly.
  • the portion of ZrS ⁇ 0 4 has a high portion with a maximum in the area of a small portion of metal and hm drops to larger portions of the metal to zero before the portion of Zr0 2 decreases to zero.
  • Other gradients for example linear, exponential or periodic, are also possible.
  • the concentration gradient of the additive can be essentially continuous. It is also possible that the concentration gradient of the additive extends from the ceramic-rich zone to the metal-rich zone, the concentration of the additive has a maximum, in particular between the metal-rich zone and the ceramic-rich zone, the concentration of the additive is approx. 5 vol.% In the metal-rich zone increases to approx. 30 vol.% And decreases in the ceramic-rich zone to approx.
  • the concentration of the additive can also change monotonically from the ceramic-rich zone to the metal-rich zone.
  • the grain size distribution of the additive can be bimodal, in particular one Fine grain fraction with a grain diameter smaller than 10 ⁇ m and a coarse grain fraction with grain diameter larger than 100 ⁇ m.
  • the additive can form pores, in particular with a diameter between 0.1 ⁇ m and 5 ⁇ m, preferably between 1.0 ⁇ m and 2.0 ⁇ m, reduced by the thermal conductivity and hinders re-sintering and the thermal shock resistance is increased.
  • the silicone matrices loaded with powder are evacuated and pressed isostatically at 300 MPa.
  • the sintering is carried out without pressure by means of microwaves, by means of a combined conventional microwave heating or by conventional heating in a resistance-heated furnace.
  • Ar, Ar-H 2 , H 2 , N 2 , He or combinations of these gases are used as sintering gases. Sintering takes place depending on the material composition and smut activity of the powders and mixtures used, with or without a temperature gradient (for example T (Zr0 2 )> T (NiCr)).
  • the hard, linear thermal expansion, the elastic modulus and the mechanical losses were determined with the help of Vickers impressions, with a TMA and a DMA.
  • the slow crack propagation was examined on notched 3 PB samples (SENB).
  • the structure is characterized using REM-EDX.
  • 8Y-ZrO 2 -ZrS ⁇ O 4 -NiCr8020-FGM was estimated using limit value curves from tabulated data of the pure substances and the structural features.
  • the FGM undergoes a slight sintering.
  • Fig. 7a, b thermalally etched
  • Fig. 8a, b after 300h / 1200 ° C
  • the crack opening of the isotropic crack network which starts from the large ZrSi0 4 grains, increases.
  • the 8Y-Zr0 2 agglomerates show compaction and grain growth, from ⁇ 2 ⁇ m to approx. 5 ⁇ m.
  • the ceramic zones of the FGM are extremely fine-grained compared to sprayed thermal bond coats (TBC).
  • TBC sprayed thermal bond coats
  • the mechanical resistance of the FGM is supported by small ZrSi0 bridge grains, as shown in Fig. 9.
  • ZrSi0 4 acts as an oxidation inhibitor, with segregation of Si0 2 at the grain boundaries of densely sintered 8Y-ZrSi0 4 significantly reducing the oxygen ion conductivity of Zr0 2 .
  • Crystalline ZrSi0 4 should have a similar effect.
  • the thermal expansion of ZrSi0 4 is considerably lower than that of 8Y-Zr0 2 (4.5 »10 ⁇ 6 Wm ⁇ K " 1 compared to 8-10 »10 ⁇ 6 Wm ⁇ K " 1 ) and of NiCr8020, which means that when Sintering temperature creates a network of fine cracks.
  • ZrSi0 4 has a good one Solubility for other oxides and is thermodynamically stable up to 1650 ° C. Any oxidation products could thus have an improved adhesion to the metal and protect the metal against further oxidative attack.
  • decomposed ZrSi0 is likely to reassociate to crystalline ZrSi0 4 already at 1200 ° C., so that the formation of pores can be prevented by evaporation of SiO or other volatile oxides.
  • the crack network should significantly reduce the thermal conductivity and the modulus of elasticity of the ceramic-rich zones of the FGM, which leads to improved resistance to temperature changes (TWB).
  • TWB temperature changes
  • the type of introduction of the ZrSi0 4 is therefore important for the delicacy of the ZrSi0 4 distribution and the resulting crack network.
  • ZrSi0 4 may not be stable under the conditions of plasma spraying and may dissociate in t-Zr0 2 and Si0 2 glass depending on the cooling conditions. SiO frequently escapes. The decomposition takes place above 1650 ° C. A reassociation takes place within a few hours at temperatures between 1200-1400 ° C. The regression of ZrSi0 4 is accelerated by Zr0 2 and by grinding the PDZ (Plasma Dissociated Zircon). Severe cracking may occur during reassociation. By sintering at 1700 ° C in air, ZrSi0 4 can also be obtained as a single-phase ceramic.
  • a powder metallurgical production route is therefore advantageous for 8Y-Zr0 2 -ZrSi0- NiCr8020- FGM.
  • the entire FGM there is then a uniform distribution of SiO 2 , which takes place, among other things, through dissociation-reassociation of the silicate.
  • the time and the oxygen-containing atmosphere are jointly responsible for the re-sintering.
  • 7a, 8a show an FGM sample of the same composition and microstructure as the samples used for oxidation, but which are thermally etched to make the grain boundaries visible in the ceramic area was in air at 1459 ° C / 0.5 h. Compared to the unetched sample, the porosity and agglomerate structure and grain size (approx. 2 ⁇ m) are comparable. Due to the sintering of the FGM under an Ar / H 2 atmosphere, the Zr0 2 obtained is not optimally compressed since the oxygen is missing in the sintering atmosphere.
  • ZrSi0 4 or comparable additives such as phosphates etc. is not limited to a gradient material of the type 8Y-ZrO 2 -NiCr8020.
  • ZrSi0 4 can also be used as oxidation protection against the active oxidation of porous SiC.
  • the SiC-Zr0 2 composite material is preferably sintered without pressure when a sufficiently thick ZrSi0 4 layer is formed around the SiC grains. Sintering is also carried out using microwaves. Because of the porosity of the body, the weight changes (increase and decrease) are related to the specific surface. In this case, no increase in the specific surface area was found which should occur in a competitive reaction between passive and active oxidation.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Materials Engineering (AREA)
  • Compositions Of Oxide Ceramics (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Ceramic Products (AREA)

Abstract

L'invention concerne un matériau à gradient d'indice métal-céramique, notamment pour bouclier thermique ou auget de turbine à gaz, qui comprend un matériau de base métallique, une céramique et un additif pour assurer une protection antioxydation à température élevée. La concentration du matériau de base métallique diminue d'une zone riche en métal en une zone riche en céramique. La concentration de l'additif présente un gradient d'indice de concentration.
EP98934822A 1997-05-28 1998-05-28 Materiau a gradient d'indice metal-ceramique, produit realise a partir dudit materiau et procede pour produire un materiau a gradient d'indice metal-ceramique Expired - Lifetime EP0984839B1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE19722390 1997-05-28
DE19722390 1997-05-28
PCT/DE1998/001465 WO1998053940A1 (fr) 1997-05-28 1998-05-28 Materiau a gradient d'indice metal-ceramique, produit realise a partir dudit materiau et procede pour produire un materiau a gradient d'indice metal-ceramique

Publications (2)

Publication Number Publication Date
EP0984839A1 true EP0984839A1 (fr) 2000-03-15
EP0984839B1 EP0984839B1 (fr) 2002-03-20

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EP98934822A Expired - Lifetime EP0984839B1 (fr) 1997-05-28 1998-05-28 Materiau a gradient d'indice metal-ceramique, produit realise a partir dudit materiau et procede pour produire un materiau a gradient d'indice metal-ceramique

Country Status (5)

Country Link
US (1) US6322897B1 (fr)
EP (1) EP0984839B1 (fr)
JP (1) JP2002502462A (fr)
DE (1) DE59803436D1 (fr)
WO (1) WO1998053940A1 (fr)

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GB2380147A (en) * 2000-11-09 2003-04-02 Bradford Particle Design Ltd Particulate products
DE102023203166A1 (de) 2022-09-20 2024-03-21 Siemens Healthcare Gmbh Vakuumgehäuse mit einem urgeformten Werkstoffverbund

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JP2002502462A (ja) 2002-01-22
WO1998053940A1 (fr) 1998-12-03
US6322897B1 (en) 2001-11-27
DE59803436D1 (de) 2002-04-25
EP0984839B1 (fr) 2002-03-20

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