EP0985745A1 - Haftbeschichtung für wärmedämmendes Beschichtungssystem - Google Patents

Haftbeschichtung für wärmedämmendes Beschichtungssystem Download PDF

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Publication number
EP0985745A1
EP0985745A1 EP98307244A EP98307244A EP0985745A1 EP 0985745 A1 EP0985745 A1 EP 0985745A1 EP 98307244 A EP98307244 A EP 98307244A EP 98307244 A EP98307244 A EP 98307244A EP 0985745 A1 EP0985745 A1 EP 0985745A1
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EP
European Patent Office
Prior art keywords
bond coat
component
thermal
barrier coating
coating system
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Granted
Application number
EP98307244A
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English (en)
French (fr)
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EP0985745B1 (de
Inventor
Ramgopal Darolia
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General Electric Co
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General Electric Co
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Application filed by General Electric Co filed Critical General Electric Co
Priority to DE69835208T priority Critical patent/DE69835208T2/de
Priority to EP98307244A priority patent/EP0985745B1/de
Priority to JP26927098A priority patent/JP3579262B2/ja
Publication of EP0985745A1 publication Critical patent/EP0985745A1/de
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    • 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
    • C23C28/00—Coating 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

Definitions

  • This invention relates to a bond coat for thermal barrier coating systems of the type used to protect components exposed to high temperature environments, such as the hostile thermal environment of a gas turbine engine. More particularly, this invention is directed to a thermal barrier coating system that includes a binary NiAl bond coat deposited by a physical vapor deposition technique and on which a thermal insulating ceramic layer is deposited, wherein the thermal life of the coating system is greatly enhanced by very limited additions of zirconium to the bond coat material.
  • TBC thermal barrier coatings
  • thermal barrier coatings must have low thermal conductivity, strongly adhere to the article, and remain adherent throughout many heating and cooling cycles. The latter requirement is particularly demanding due to the different coefficients of thermal expansion between materials having low thermal conductivity and superalloy materials typically used to form turbine engine components.
  • Thermal barrier coating systems capable of satisfying the above requirements have generally required a metallic bond coat deposited on the component surface, followed by an adherent ceramic layer that serves to thermally insulate the component.
  • Metal oxides such as zirconia (ZrO 2 ) that is partially or fully stabilized by yttria (Y 2 O 3 ), magnesia (MgO) or other oxides, have been widely employed as the material for the thermal-insulating ceramic layer.
  • the ceramic layer is typically deposited by air plasma spraying (APS), low pressure plasma spraying (LPPS), or a physical vapor deposition (PVD) technique, such as electron beam physical vapor deposition (EBPVD) which yields a strain-tolerant columnar grain structure.
  • Bond coats are typically formed of an oxidation-resistant aluminum-based intermetallic such as a diffusion aluminide or platinum aluminide, or an oxidation-resistant aluminum-containing alloy such as MCrAlY (where M is iron, cobalt and/or nickel).
  • the aluminum content of the above-noted bond coat materials provides for the slow growth of a strong adherent continuous aluminum oxide layer (alumina scale) at elevated temperatures.
  • This thermally grown oxide (TGO) protects the bond coat from oxidation and hot corrosion, and chemically bonds the ceramic layer to the bond coat.
  • bond coat materials are particularly alloyed to be oxidation-resistant, the oxidation that occurs over time at elevated temperatures gradually depletes aluminum from the bond coat. Eventually, the level of aluminum within the bond coat is sufficiently depleted to prevent further slow growth of the protective oxide, and to allow for the more rapid growth of nonprotective oxides. At such time, spallation may occur at the interface between the bond coat and the aluminum oxide layer or the interface between the oxide layer and the ceramic layer.
  • the ability of the bond coat to form the desired aluminum oxide layer can be hampered by the interdiffusion of elements between the superalloy and bond coat, such as during formation of a diffusion aluminide coating and during high temperature exposure.
  • elements such as nickel, cobalt, chromium, titanium, tantalum, tungsten and molybdenum can increase the growth rate of aluminum oxide and form voluminous, nonadherent oxides or oxide scales that may be deleterious to the adhesion of the ceramic layer.
  • the present invention provides a thermal barrier coating on an article designed for use in a hostile thermal environment, such as turbine, combustor and augmentor components of a gas turbine engine.
  • the invention is particularly directed to increasing the spallation resistance of a thermal barrier coating system with a bond coat that exhibits significantly improved oxidation resistance.
  • the thermal barrier coating system of this invention employs a bond coat of a nickel aluminide alloy over which a thermal-insulating ceramic layer is deposited, with the bond coat serving the traditional role of promoting adhesion of the ceramic layer to the article.
  • the nickel aluminide bond coat contains zirconium and/or other reactive elements such as hafnium, yttrium and cesium, but is otherwise predominantly of the beta ( ⁇ ) NiAl phase.
  • the bond coat of this invention develops a continuous aluminum oxide layer that promotes the adhesion of the ceramic layer to the bond coat.
  • the bond coat is deposited by a physical vapor deposition process (PVD), such as by magnetron sputtering, electron beam physical vapor deposition (EBPVD) and jet vapor deposition (JVD), though other deposition processes such as vacuum plasma spray (VPS), low pressure plasma spray (LPPS) and air plasma spray (APS) deposition are possible.
  • PVD physical vapor deposition process
  • EBPVD electron beam physical vapor deposition
  • JVD jet vapor deposition
  • VPS vacuum plasma spray
  • LPPS low pressure plasma spray
  • APS air plasma spray
  • the ceramic layer can be deposited on the bond coat by known techniques, including plasma spraying and PVD techniques.
  • An aluminum oxide layer is preferably grown on the bond coat, either by heat treatment prior to deposition of the bond coat or during deposition of the ceramic layer.
  • the bond coat is not a traditional diffusion aluminide or MCrAlY coatings, but instead is a binary NiAl alloy consisting essentially of nickel and aluminum in stoichiometric amounts and containing zirconium in a very limited amount that has been unexpectedly found to drastically increase the service life of the thermal barrier coating system.
  • zirconium additions of between 0.05 and 0.5 atomic percent have been shown to improve the life of a thermal barrier coating system by a factor of about two to in excess of ten when subjected to thermal cycle testing, with the best results appearing to be obtained at or near 0.1 atomic percent zirconium.
  • the sensitivity that thermal life has for the zirconium content of the NiAl bond coat is particularly evident with increasing test temperatures, indicating that the bond coat of this invention is particularly advantageous for more demanding applications. It is believed that other reactive elements, such as hafnium, yttrium and cesium, would have a similar effect on a NiAl bond coat.
  • the bond coat is deposited in such a manner as to minimize diffusion of the bond coat constituents into the surface of the article.
  • a diffusion zone of not more than five micrometers is preferably achieved by the preferred PVD techniques.
  • This reduced level of interaction between the bond coat and substrate promotes the formation of an initial layer of essentially pure aluminum oxide, promotes the slow growth of the protective aluminum oxide layer during service, and reduces the formation of voluminous nonadherent oxides of substrate constituents that tend to diffuse into the bond coat.
  • minimal substrate material must be removed during refurbishment of the thermal barrier coating system, when both the bond coat and thermal-insulating ceramic layer must be removed to allow deposition of a new bond coat and ceramic layer on the substrate.
  • the present invention is generally applicable to components that operate within environments characterized by relatively high temperatures, and are therefore subjected to severe thermal stresses and thermal cycling.
  • Notable examples of such components include the high and low pressure turbine nozzles and blades, shrouds, combustor liners and augmentor hardware of gas turbine engines.
  • One such example is the high pressure turbine blade 10 shown in Figure 1.
  • the blade 10 generally includes an airfoil 12 against which hot combustion gases are directed during operation of the gas turbine engine, and whose surface is therefore subjected to severe attack by oxidation, corrosion and erosion.
  • the airfoil 12 is anchored to a turbine disk (not shown) with a dovetail 14 formed on a root section 16 of the blade 10.
  • Cooling passages 18 are present in the airfoil 12 through which bleed air is forced to transfer heat from the blade 10. While the advantages of this invention will be described with reference to the high pressure turbine blade 10 shown in Figure 1, the teachings of this invention are generally applicable to any component on which a thermal barrier coating system may be used to protect the component from its environment.
  • the coating system 20 includes a ceramic layer 26 bonded to the blade substrate 22 with a bond coat 24.
  • the substrate 22 (blade 10) is preferably a high-temperature material, such as an iron, nickel or cobalt-base superalloy.
  • the ceramic layer 26 is preferably deposited by physical vapor deposition (PVD), though other deposition techniques could be used.
  • a preferred material for the ceramic layer 26 is an yttria-stabilized zirconia (YSZ), with a preferred composition being about 6 to about 8 weight percent yttria, though other ceramic materials could be used, such as yttria, nonstabilized zirconia, or zirconia stabilized by ceria (CeO 2 ), scandia (Sc 2 O 3 ) or other oxides.
  • the ceramic layer 26 is deposited to a thickness that is sufficient to provide the required thermal protection for the underlying substrate 22 and blade 10, generally on the order of about 125 to about 300 micrometers.
  • the surface of the bond coat 24 oxidizes to form an aluminum oxide layer 28 to which the ceramic layer 26 chemically bonds.
  • the bond coat 24 is a nickel aluminide alloy of predominantly the beta ( ⁇ ) NiAl phase with a very limited addition of zirconium.
  • the NiAl bond coat 24 is formed using a PVD process, preferably sputtering, electron beam physical vapor deposition (EBPVD) or jet vapor deposition (JVD), though it is foreseeable that other deposition techniques could be used, such as plasma spraying.
  • an adequate thickness for the NiAl bond coat 24 is about fifty micrometers in order to protect the underlying substrate 22 and provide an adequate supply of aluminum for oxide formation, though thicknesses of about 25 to about 125 micrometers are believed to be suitable.
  • the preferred PVD techniques are preferably carried out to reduce the diffusion of the bond coat 24 into the substrate 22.
  • deposition of the bond coat 24 results in virtually no diffusion between the bond coat 24 and substrate 22.
  • a very thin diffusion zone 30 of not more than above five micrometers, typically about 2.5 to 5 micrometers, may develop.
  • a preferred heat treatment is conducted at about 1800°F (about 980°C) for about two to four hours in an inert atmosphere, such as argon.
  • the minimal thickness of the diffusion zone 30 promotes the initial formation of the oxide layer 28 as essentially pure aluminum oxide, promotes the slow growth of the protective aluminum oxide layer 28 during service, reduces the formation of voluminous nonadherent oxides at the bond coat-ceramic layer interface, and reduces the amount of substrate material that must be removed during refurbishment of the thermal barrier coating system 20. Accordingly, articles such as the blade 10 shown in Figure 1 can be refurbished more times than would be possible if a traditional bond coat were used.
  • an optional diffusion barrier layer 32 between the NiAl bond coat 24 and substrate 22 may be included to further inhibit interdiffusion and thereby improve the service life of the coating system 20.
  • the initial aluminum oxide formed by the NiAl bond coat 24 provides the ground work for a slow growing oxide scale (thermally grown oxide; TGO).
  • TGO thermalally grown oxide
  • the diffusion barrier layer 32 is additionally beneficial. Suitable processes for forming the barrier layer 32 include carburizing the substrate 22 in accordance with U.S. Patent No. 5,334,263 to Schaeffer, and depositing a layer of AlN or Al-O-N on the substrate 22 by a PVD technique or chemical vapor deposition (CVD).
  • the NiAl bond coat 24 is a binary NiAl alloy consisting essentially of nickel and aluminum in stoichiometric amounts and containing zirconium in a very limited amount that has been unexpectedly found to drastically increase the service life of the thermal barrier coating system.
  • NiAl bond coats containing between about 0.05 and about 0.5 atomic percent zirconium have been shown to drastically improve the life, i.e., increase the spallation resistance, of a thermal barrier coating system.
  • specimens of a nickel-base superalloy were provided with thermal barrier coating systems that included a bond coat over which 7% yttria-stabilized zirconia (YSZ) was deposited by EBPVD to a thickness of about 125 micrometers.
  • the bond coats for a first group of superalloy specimens were conventional platinum aluminide (PtAl) diffusion bond coats having a nominal thickness of about 60 to 75 micrometers.
  • Second and third groups of superalloy specimens were coated with a NiAl bond coat containing zirconium at levels of either about 0.05 or about 0.1 atomic percent in accordance with this invention.
  • buttons were formed of NiAl in accordance with this invention to contain zirconium at levels of either about 0.1 or about 0.5 atomic percent.
  • the buttons had a diameter of about one inch (about 25 millimeters) and a thickness of about 0.125 inch (about 3 millimeters) .
  • the NiAl buttons were also coated with 7% YSZ deposited by EBPVD to a thickness of about 125 micrometers.
  • the thermal barrier coatings deposited on the NiAl+Zr specimens were considerably more resistant to spallation than those deposited on the conventional diffusion PtAl bond coat.
  • the thermal cycle lives exhibited by the NiAl+Zr specimens containing more than 0.05 atomic percent zirconium were greater by a factor of at least two over the PtAl bond coat specimens at 2075°F and 2150°F.
  • the improvement in thermal life was unexpectedly good for the specimens whose NiAl bond coats contained 0.1 atomic percent zirconium, particularly at 2150°F where these specimens exhibited an improved thermal cycle life by a factor of ten over the PtAl bond coat specimens.
  • NiAl+Zr bond coats will increase the thermal cycle life of such coatings to that of the button specimens.
  • improved deposition techniques will result in NiAl+0.05Zr bond coats having a thermal cycle life between that of the Zr-free NiAl button specimens and the NiAl+0.1Zr button specimens.
  • NiAl+0.5 button specimens exhibited a minimum life of almost twice that of the Zr-free NiAl buttons.
  • NiAl+0.5Zr bond coats are expected to exhibit improved thermal cycle life over a Zr-free NiAl bond coat, it is apparent that optimum results are obtained with a zirconium content of between 0.05 and 0.5 atomic percent, and likely at or near 0.1 atomic percent. Furthermore, these tests indicated that thermal barrier coating systems equipped with NiAl+Zr bond coats, and particularly the NiAl+0.1Zr bond coat, can be used to considerable advantage in demanding applications where temperatures exceed 2150°F.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physical Vapour Deposition (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Solid-Phase Diffusion Into Metallic Material Surfaces (AREA)
  • Coating By Spraying Or Casting (AREA)
EP98307244A 1998-09-08 1998-09-08 Haftbeschichtung für wärmedämmendes Beschichtungssystem Revoked EP0985745B1 (de)

Priority Applications (3)

Application Number Priority Date Filing Date Title
DE69835208T DE69835208T2 (de) 1998-09-08 1998-09-08 Haftbeschichtung für wärmedämmendes Beschichtungssystem
EP98307244A EP0985745B1 (de) 1998-09-08 1998-09-08 Haftbeschichtung für wärmedämmendes Beschichtungssystem
JP26927098A JP3579262B2 (ja) 1998-09-08 1998-09-24 遮熱コーティング系用ボンディングコート

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP98307244A EP0985745B1 (de) 1998-09-08 1998-09-08 Haftbeschichtung für wärmedämmendes Beschichtungssystem
JP26927098A JP3579262B2 (ja) 1998-09-08 1998-09-24 遮熱コーティング系用ボンディングコート

Publications (2)

Publication Number Publication Date
EP0985745A1 true EP0985745A1 (de) 2000-03-15
EP0985745B1 EP0985745B1 (de) 2006-07-12

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EP98307244A Revoked EP0985745B1 (de) 1998-09-08 1998-09-08 Haftbeschichtung für wärmedämmendes Beschichtungssystem

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Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1260602A1 (de) * 2001-05-23 2002-11-27 Sulzer Metco AG Verfahren zum Erzeugen eines wärmedämmenden Schichtsystems auf einem metallischen Substrat
US6607789B1 (en) * 2001-04-26 2003-08-19 General Electric Company Plasma sprayed thermal bond coat system
EP1541714A1 (de) * 2003-11-13 2005-06-15 General Electric Company Verfahren zur Reparatur von Bauteilen mit einer Umgebungshaftschicht und repariertes Bauteil
EP1600518A2 (de) * 2004-05-27 2005-11-30 General Electric Company Nickelaluminid-Beschichtung mit verbesserter Oxidfestigkeit
US7078073B2 (en) 2003-11-13 2006-07-18 General Electric Company Method for repairing coated components
US7094444B2 (en) 2003-11-13 2006-08-22 General Electric Company Method for repairing coated components using NiAl bond coats
US7264887B2 (en) * 2002-01-10 2007-09-04 Alstom Technology Ltd. MCrAlY bond coating and method of depositing said MCrAlY bond coating
WO2009053992A1 (en) * 2007-10-26 2009-04-30 The Secretary, Department Of Atomic Energy, Govt. Of India, A process for producing body centered cubic (b2) nickel aluminide (nial) coating of controlled thickness on nickel-base alloy surfaces
US7838083B1 (en) 2005-01-28 2010-11-23 Sandia Corporation Ion beam assisted deposition of thermal barrier coatings
CN115198271A (zh) * 2022-07-15 2022-10-18 广东省科学院新材料研究所 一种高热匹配性热障涂层及其制备方法与应用

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6497758B1 (en) * 2000-07-12 2002-12-24 General Electric Company Method for applying a high-temperature bond coat on a metal substrate, and related compositions and articles
US6730413B2 (en) * 2001-07-31 2004-05-04 General Electric Company Thermal barrier coating
JP4716328B2 (ja) * 2006-07-05 2011-07-06 財団法人電力中央研究所 遮熱コーティングの寿命管理方法
JP4716329B2 (ja) * 2006-07-05 2011-07-06 財団法人電力中央研究所 遮熱コーティングの寿命管理方法
JP7402869B2 (ja) * 2018-10-17 2023-12-21 エリコン・サーフェス・ソリューションズ・アクチェンゲゼルシャフト，プフェフィコーン 超合金基板用のｐｖｄバリアコーティング

Citations (5)

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JPS6144170A (ja) * 1984-08-09 1986-03-03 Toshiba Corp 摺動部材の表面加工法
EP0471505A2 (de) * 1990-08-11 1992-02-19 Johnson Matthey Public Limited Company Beschichteter Gegenstand
US5302465A (en) * 1992-10-26 1994-04-12 The United States Of America As Represented By The Administrator Of The National Aeronautics And Space Administration Plasma sprayed ceramic thermal barrier coating for NiAl-based intermetallic alloys
WO1997029219A2 (en) * 1996-02-07 1997-08-14 N.V. Interturbine Improved thermal barrier coating system and methods
US5759640A (en) * 1996-12-27 1998-06-02 General Electric Company Method for forming a thermal barrier coating system having enhanced spallation resistance

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US3450512A (en) * 1966-07-05 1969-06-17 United Aircraft Corp Coated nickel base engine alloys
FR2745590B1 (fr) * 1996-02-29 1998-05-15 Snecma Revetement de barriere thermique a sous-couche amelioree et pieces revetues par une telle barriere thermique

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS6144170A (ja) * 1984-08-09 1986-03-03 Toshiba Corp 摺動部材の表面加工法
EP0471505A2 (de) * 1990-08-11 1992-02-19 Johnson Matthey Public Limited Company Beschichteter Gegenstand
US5302465A (en) * 1992-10-26 1994-04-12 The United States Of America As Represented By The Administrator Of The National Aeronautics And Space Administration Plasma sprayed ceramic thermal barrier coating for NiAl-based intermetallic alloys
WO1997029219A2 (en) * 1996-02-07 1997-08-14 N.V. Interturbine Improved thermal barrier coating system and methods
US5759640A (en) * 1996-12-27 1998-06-02 General Electric Company Method for forming a thermal barrier coating system having enhanced spallation resistance

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
PATENT ABSTRACTS OF JAPAN vol. 10, no. 203 (C - 360) 16 July 1986 (1986-07-16) *

Cited By (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6607789B1 (en) * 2001-04-26 2003-08-19 General Electric Company Plasma sprayed thermal bond coat system
US8168261B2 (en) 2001-05-23 2012-05-01 Sulzer Metco A.G. Process for applying a heat shielding coating system on a metallic substrate
EP1260602A1 (de) * 2001-05-23 2002-11-27 Sulzer Metco AG Verfahren zum Erzeugen eines wärmedämmenden Schichtsystems auf einem metallischen Substrat
US7264887B2 (en) * 2002-01-10 2007-09-04 Alstom Technology Ltd. MCrAlY bond coating and method of depositing said MCrAlY bond coating
US7371426B2 (en) 2003-11-13 2008-05-13 General Electric Company Method for repairing components using environmental bond coatings and resultant repaired components
US7078073B2 (en) 2003-11-13 2006-07-18 General Electric Company Method for repairing coated components
US7094444B2 (en) 2003-11-13 2006-08-22 General Electric Company Method for repairing coated components using NiAl bond coats
EP1541714A1 (de) * 2003-11-13 2005-06-15 General Electric Company Verfahren zur Reparatur von Bauteilen mit einer Umgebungshaftschicht und repariertes Bauteil
US7070866B2 (en) 2004-05-27 2006-07-04 General Electric Company Nickel aluminide coating with improved oxide stability
EP1600518A3 (de) * 2004-05-27 2006-03-29 General Electric Company Nickelaluminid-Beschichtung mit verbesserter Oxidfestigkeit
EP1600518A2 (de) * 2004-05-27 2005-11-30 General Electric Company Nickelaluminid-Beschichtung mit verbesserter Oxidfestigkeit
US7838083B1 (en) 2005-01-28 2010-11-23 Sandia Corporation Ion beam assisted deposition of thermal barrier coatings
WO2009053992A1 (en) * 2007-10-26 2009-04-30 The Secretary, Department Of Atomic Energy, Govt. Of India, A process for producing body centered cubic (b2) nickel aluminide (nial) coating of controlled thickness on nickel-base alloy surfaces
CN115198271A (zh) * 2022-07-15 2022-10-18 广东省科学院新材料研究所 一种高热匹配性热障涂层及其制备方法与应用

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EP0985745B1 (de) 2006-07-12
JP2000096259A (ja) 2000-04-04
JP3579262B2 (ja) 2004-10-20

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