EP0995817A1 - Wärmeschutz-Beschichtung und Herstellungsverfahren - Google Patents

Wärmeschutz-Beschichtung und Herstellungsverfahren Download PDF

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EP0995817A1
EP0995817A1 EP99308241A EP99308241A EP0995817A1 EP 0995817 A1 EP0995817 A1 EP 0995817A1 EP 99308241 A EP99308241 A EP 99308241A EP 99308241 A EP99308241 A EP 99308241A EP 0995817 A1 EP0995817 A1 EP 0995817A1
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Prior art keywords
bond coat
weight percent
substrate
mixtures
group
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French (fr)
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EP0995817B1 (de
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Wolfram Beele
Astrid Helennia Francoise Van Lieshout
Gillion Herman Marijnissen
Douglas Hugh Maxwell
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Sulzer Metco Coatings BV
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Interturbine NV
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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
    • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/32—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer
    • C23C28/321—Coatings 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
    • 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
    • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/32—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer
    • C23C28/321—Coatings 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
    • C23C28/3215—Coatings 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
    • 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
    • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/32—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer
    • C23C28/325—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer with layers graded in composition or in physical properties
    • 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
    • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/34—Coatings 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
    • C23C28/345—Coatings 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
    • 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
    • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/34—Coatings 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
    • C23C28/345—Coatings 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
    • C23C28/3455—Coatings 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

Definitions

  • the present invention relates to protective coatings for metallic articles and more particularly to an improved bond coat of a ceramic thermal barrier coating system for superalloy substrates.
  • hot section components such as turbine blade and vane airfoils, combustors, and exhaust nozzles are subject to oxidizing and corrosive, high temperature combustion effluent gas. Because these components often are subjected concurrently to high magnitude thermally and mechanically induced stress, the art has developed a variety of techniques in the design and manufacture of these components to ensure maintenance of structural and metallurgical integrity throughout the operating range of the engine.
  • components typically are manufactured from material compositions such as nickel- and cobalt-base superalloys having desirable properties at elevated, operating range temperatures.
  • the selected alloy In the case of turbine airfoils, the selected alloy generally is formed by casting. For enhanced high temperature strength, grain structure advantageously may be controlled during solidification of the casting to produce a directionally solidified or single crystal form, thereby providing greater strength for a given alloy composition.
  • both internal and external cooling schemes are employed extensively to maintain component temperatures below critical levels.
  • Tailored film cooling of external surfaces and sophisticated turbulent flow cooling of serpentine shaped internal cavities in the cast airfoils are routinely utilized in advanced gas turbine engine designs, respectively, to decrease the thermal energy input to the component and reduce the temperature rise thereof.
  • Ceramic coatings are prone to delamination at or near the ceramic/substrate interface due to differences in coefficients of thermal expansion between the relatively brittle ceramic and the more ductile superalloy substrate. Subsequently, the ceramic may spall or separate from the component surface. This failure mechanism is aggravated and accelerated under conditions of thermal cycling inherent in gas turbine engine operation.
  • methods of providing strain tolerant ceramic coatings have been developed. Certain moderate service applications employ porous or pre-cracked ceramic layers. In more harsh operating environments, such as those found in advanced gas turbine engines, the art exploits strain tolerant open columnar ceramic crystal structures, such as those described in U.S. Pat. No. 4,321,311 to Strangman.
  • the bond coat employs a composition designed both to enhance the chemical bond strength between the ceramic and metal substrate as well as to serve as a protective coating in the event of premature ceramic topcoat loss.
  • MCrAlY alloy metallic bond coat typically specified by gas turbine engine designers
  • M is iron, cobalt, nickel, or mixtures thereof.
  • PVD physical vapor deposition
  • low pressure plasma spraying low pressure plasma spraying
  • the MCrAlY class of alloys are characteristically very resistant to oxidation at the elevated temperatures experienced by hot section components due to their ability to form a thin adherent protective external film of aluminum oxide or alumina.
  • the alumina film also provides a chemically compatible surface on which to grow the insulative ceramic topcoat.
  • the ceramic topcoat most commonly employ zirconium oxide or zirconia, either partially or fully stabilized through the addition of oxides of yttrium, magnesium, or calcium.
  • the multilayered coating By growing an open columnar structured stabilized zirconia on the alumina film, the multilayered coating exhibits improved integrity under cyclic thermal conditions over ceramic coatings disposed directly on the metallic substrate, thereby providing the intended insulative protection to the underlying component over an extended period.
  • aluminides are popular compositions for gas turbine engine components and include nickel, cobalt, and iron modified aluminides as well as platinum modified aluminides.
  • aluminides are intermediate phases or intermetallic compounds with physical, chemical, and mechanical properties substantially different from the more conventional MCrAlY bond coats.
  • some aluminide compositions are known to be useful coatings in and of themselves for protecting iron-, cobalt-, and nickel-base alloys from oxidation and corrosion; however, some aluminides may be used as bond coats for ceramic topcoats in TBC systems.
  • the aluminide-based TBC system is similar to the MCrAlY-based TBC system insofar as the aluminide bond coat is first formed on the substrate surface by conventional diffusion processes such as pack cementation as described by Duderstadt et al. in U.S. Pat. No. 5,238,752 and Strangman in published U.K. Patent Application GB 2,285,632A, the disclosures of which are incorporated herein by reference.
  • the aluminide coated component also has a surface composition which readily forms a protective alumina film when oxidized.
  • the weak link in the aluminide-based TBC is the strength of the bond between the aluminide bond coat and the intermediate alumina layer.
  • the aluminide/alumina bond is inherently relatively weak.
  • the failure mechanism for these conventional aluminide diffusion coatings is the repeated formation, spalling, and reformation of the alumina film under thermal cycling conditions of typical gas turbine engine service, with the eventual depletion of aluminum in the aluminide bond coat below a critical concentration.
  • aluminide bond coats typically are applied by lower cost processes and do not include the expensive strategic constituent chromium required in MCrAlY bond coats.
  • the aluminide bond coats have a substantially higher melting point and lower density. These are important considerations when coating parts such as turbine blade airfoils which operate at high temperatures and high rotational speeds. More important, however, aluminide bond coats exhibit substantially lower solubility for the substrate alloy solute elements, thereby retarding their diffusion in service to the critically important aluminide/alumina interfacial bond.
  • Major deficiencies associated with aluminide bond coats are related to-the inherent metallurgical characteristics resulting from creation of the bond coat by diffusion.
  • Production of a conventional aluminide bond coat relies upon reaction of the substrate alloy with aluminum from an aluminum rich gaseous source and interdiffusion with the metallic substrate.
  • the gaseous aluminum source may be produced by any of a variety of conventional methods.
  • Duderstadt et al. discusses production of an aluminide bond coat on a nickel- or cobalt-base superalloy substrate preferably by the pack cementation method. According to this method, aluminum from an aluminum halide gas in the pack mixture reacts and interdiffuses with the substrate surface over time at elevated temperature.
  • Strangman discusses production of aluminide bond coats by reacting a nickel-, iron-, or cobalt-base superalloy component substrate with an aluminum rich vapor at elevated temperature. Strangman refers exclusively to the term "diffusion aluminide" as characteristic of the resultant bond coat. This characterization accurately corresponds to the method of aluminide bond coat production, namely by diffusion. As a result of the diffusion method, the aluminide bond coat contains nickel, iron, or cobalt from the substrate of the component being coated, depending on the primary constituent of the superalloy substrate. Further, many of the base alloying elements of the substrate which are ultimately detrimental to TBC system integrity are necessarily also contained in the reaction product aluminide forming on the component surface. These alloying elements therefore are present in the aluminide bond coat as produced, and are available to affect detrimentally the alumina film that eventually forms thereon.
  • aluminide bond coats Another significant deficiency of aluminide bond coats is related to the aluminide composition as it affects adherence of the alumina film or scale.
  • Strangman discloses the addition of silicon, hafnium,.platinum, and oxides particles such as alumina, yttria, and hafnia to the aluminide composition to improve alumina film adherence.
  • the beneficial effects of these elements are offset, at least partially, by the presence of the base alloy elements previously described which are detrimental to satisfactory alumina adherence.
  • aluminide compositions are used not as bond coats in TBC systems, but rather solely as protective coatings without ceramic topcoats.
  • a goal of those skilled in the art is to protect the underlying article substrate from chemically aggressive effluent gases by retarding environmental deterioration of the substrate alloy due to accelerated oxidation and hot corrosion.
  • reactive element additions primarily to aluminide coatings used solely for coating purposes.
  • thermal operating margin must be factored into the design of the gas turbine engine to preclude overtemperature and failure of hot section components.
  • combustion parameters By limiting combustion parameters to less than stoichiometric, the realizable efficiency of the engine is reduced, with increase in fuel consumption as well as levels of unburnt hydrocarbons and other pollutants.
  • baseline engine operating parameters are premised on the existence of uniform ceramic topcoats, and ceramic topcoat life is often significantly less than underlying component life. This means engines must be removed from service for maintenance at predetermined intervals, based, for example, on operating hours or thermal cycles. Combustor, turbine, and exhaust modules are disassembled and the coated parts removed, stripped, inspected and recoated.
  • an improved TBC system and methods of application are disclosed, primarily for use on nickel- and cobalt-base superalloy articles, such as hot section components of gas turbine engines, as well as for use on iron-base superalloy articles.
  • Superalloys are generally defined as a class of metallic alloys suitable for high strength, high temperature applications and which have enhanced oxidation resistance.
  • a superalloy substrate is first coated with a bond coat having an MAlY composition where M is nickel, cobalt, iron, or combinations thereof.
  • An intermediate layer of alumina is formed on the MAlY bond coat and a ceramic topcoat is applied overall.
  • the chemical symbol "Y" signifies the use of reactive elements such as yttrium.
  • alumina signifies predominantly aluminum oxide, which may be altered by the presence of reactive elements to contain, for example, yttrium or zirconium oxides.
  • the alumina layer may also be referred to as a thermally grown oxide layer or TGO layer.
  • the bond strength or adherence between the MAlY bond coat and alumina film is enhanced over conventional aluminide and MCrAlY bond coats by substantially restricting the composition of the bond coat to between about 10 to 30 weight percent aluminum, between trace amounts and about 3 weight percent yttrium or other reactive element such as zirconium, hafnium, scandium, or any of the lanthanides (i.e. atomic number 57-71, inclusive) either alone or in mixtures thereof, and balance selected from nickel, cobalt and iron, either alone or in mixtures thereof.
  • the invention provides a substantial reduction in diffusion of substrate alloy constituents through the MAlY bond coat, and maintenance of a strong MAlY/alumina bond, resistant to degradation as a function of time at elevated temperature, with a concomitant enhancement in ceramic topcoat integrity.
  • a further benefit from the exclusion of chromium from the bond coat relates to the high vapor pressure of chromium and chromium oxidation products.
  • intermediate operational temperatures for example between about 700°C and about 950°C
  • the beneficial effects of chromium for sulfidation or hot corrosion resistance typically dominate detrimental effects; however, at higher service temperatures, pure oxidation resistance and thermal protection are dominant goals of those skilled in the art. It is in this operating range, where advanced TBC systems are required to perform, that high chromium content in the bond coat can be detrimental.
  • the MAlY/alumina bond is stronger than that of a conventional modified aluminide/alumina bond.
  • the growth rate of the alumina film is reduced by the presence of yttrium or other reactive element and the combined effect exhibits improvement over conventional aluminide-based TBC systems.
  • an improved TBC system and methods of application are disclosed, primarily for use on nickel- and cobalt-base superalloy articles such as hot section components of gas turbine engines, as well as for use on iron-base superalloy articles.
  • a superalloy substrate is first coated with a noble metal bond coat having a composition including aluminum, one or more noble metals, and one or more reactive elements, with the balance being nickel, cobalt, iron, or combinations thereof.
  • An intermediate layer of alumina is formed on the noble metal bond coat and a ceramic topcoat is applied overall.
  • the term "noble metal” refers to inactive or inert, corrosion resistant elements, namely ruthenium, rhodium, palladium, silver, osmium, iridium, platinum, and gold.
  • the bond strength or adherence between the noble metal bond coat and alumina film is enhanced over conventional aluminide and MCrAlY bond coats by substantially restricting the composition of the bond coat to between about 10 to 30 weight percent aluminum, between about 2 and 60 weight percent noble metal, between trace amounts and about 3 weight percent yttrium or other reactive element such as zirconium, hafnium, scandium, or any of the lanthanides, either alone or in mixtures thereof, and balance selected from nickel, cobalt and iron, either alone or in mixtures thereof.
  • the bond strength between the noble metal bond coat and the alumina film is substantially enhanced over conventional TBC systems, in part, due to the presence of the reactive elements.
  • the noble metal bond coat composition and the reactive elements therein interfere with the diffusion mechanism of constituents from the substrate alloy through the bond coat. Accordingly, diffusion of the constituents into the alumina layer is reduced, as is the growth rate of the alumina layer. Additionally, crack initiation and propagation, which tends to occur at the interface of the bond coat and alumina layer, is reduced, so that cyclic life of the TBC system is improved. This effect is due to oxide precipitates of the reactive elements, which are present as dopes at the bond coat/alumina layer interface. Mechanisms useful for explaining the beneficial influence of the oxide precipitates are described by authors such as E.
  • yttrium and/or other reactive element first is deposited on the substrate using electron beam PVD followed by gas phase or pack cementation aluminizing.
  • this method has the deficiencies previously described with respect to diffusion aluminides, the presence of yttrium or other reactive element markedly improves the oxide scale adherence for the aforementioned reasons. Simple physical or chemical vapor deposition of reactive elements on the surface of a conventional aluminide coating could be effected to bring about the desired surface composition modification.
  • ion PVD or sputtering may be employed to coat the substrate using a prealloyed MAlY cathode.
  • Yet another preferred method employs vacuum or low pressure plasma spraying of prealloyed MAlY powder onto the substrate.
  • One additional method involves the deposition of nickel and simultaneous deposition of an aluminum yttrium alloy powder.
  • the coated component is subsequently subjected to a thermal processing cycle to metallurgically bond the coating to the component surface and in the last example to compositionally homogenize the coating.
  • a heat treatment in vacuum for approximately two hours at about 1080°C would be employed to effect the metallurgical bond.
  • the noble metal bond coat may be applied by PVD, for example electron beam PVD, using one source or multiple sources containing aluminum, one or a mixture of noble metals, and one or a mixture of reactive elements.
  • the noble metal bond coat may be applied by thermal spraying techniques such as plasma spraying of a powder containing aluminum, one or a mixture of noble metals, and one or a mixture of reactive elements.
  • the noble metal bond coat can be applied by a combination of methods, using a multiple step approach, for example by depositing one or a mixture of noble metals and one or a mixture of reactive elements in a single step or separate steps. The deposition of these layers may be accomplished in any order, followed by deposition of the aluminum.
  • the coated component is subsequently subjected to a thermal processing cycle to metallurgically bond the coating to the component surface and/or to compositionally homogenize the coating.
  • a heat treatment in vacuum for approximately two hours at about 1080°C would be employed to effect the metallurgical bond.
  • the noble metal bond coat thus produced at most contain traces of alloying constituents from the superalloy substrate, because the composition of the noble metal bond coat is established prior to its application onto the substrate surface and because its application does not exploit a diffusion reaction involving the substrate. Accordingly, the bond coat is substantially chromium-free. Some minor amount of chromium might diffuse into the bond coat over an extended period at operational temperatures.
  • alumina growth on the deposited noble metal bond coat and application of the ceramic topcoat may be accomplished by conventional methods.
  • the ceramic topcoat may have multiple layers, adjacent layers of which have generally columnar grain microstructures with different grain orientation directions, as disclosed in U.S. Ser. No. 08/987,354 filed December 9, 1997, and entitled "Thermal Barrier Coating Ceramic Structure,” the disclosure of which is herein incorporated by reference in its entirety.
  • FIG. 1 Depicted in FIG. 1 is a schematic, cross-sectional view of a typical turbofan gas turbine engine 10 depicting hot section components, shown generally at 12, suitable for application of a MAlY-base or noble metal-base TBC system in accordance with preferred embodiments of the present invention.
  • the engine 10 includes, in serial flow relation from inlet to exhaust, an inlet frame 14, a two stage low pressure compressor (“LPC”) or fan 16, a three stage high pressure compressor (“HPC”) 18, a combustor 20, a single stage high pressure turbine (“HPT”) 22, a two stage low pressure turbine (“LPT”) 24, a turbine frame 26, and an exhaust nozzle 28.
  • LPC two stage low pressure compressor
  • HPC three stage high pressure compressor
  • HPC combustor
  • HPT single stage high pressure turbine
  • LPT two stage low pressure turbine
  • Compressed air exiting the HPC 18 is mixed with fuel in the combustor 20 and ignited.
  • the high temperature, high energy combustion effluent passes through both the HPT 22 and LPT 24 where energy is extracted to drive the HPC 18 and fan 16.
  • Each turbine stage, for example HPT 22 includes a set of stationary turbine vanes 30 and rotating turbine blades 32 disposed in the effluent stream to optimize flow orientation and energy extraction.
  • the effluent After passing through the turbine frame 24, which supports the rotating components of the engine 10, the effluent is mixed with the fan flow and passes through the exhaust nozzle 28, producing a net force or thrust which propels the engine 10 forward.
  • Hot section components 12 exposed to the high temperature, corrosive combustion effluent may be coated with the MAlY or noble metal bond coat TBC systems, in accordance with the teachings of this invention, to protect the superalloy substrate from excessive temperature as well as oxidation during engine operation.
  • FIG. 2A depicted is an enlarged schematic, cross-sectional view of a portion of a superalloy article 34, such as an airfoil wall of a turbine blade 32, coated with the MAlY bond coat TBC system in accordance with a preferred embodiment of the present invention.
  • Schematic representation and relative thickness of each layer of the multilayered TBC systems depicted in FIGS. 2A and 2B are meant for illustrative purposes only and in no manner are intended to restrict the scope of the invention.
  • the article 34 in FIG. 2A includes a substrate 36, a portion of which is depicted.
  • the substrate 36 is preferably composed of an iron-, nickel-, or cobalt-base superalloy; however, it is contemplated that the MAlY bond coat of the present invention may be suitable for use with any superalloy or other metallic substrates with which it may form an adequate bond.
  • adequate bond may be characterized as adherence equal or superior to that between other layers in the TBC system.
  • MAlY bond coat 38 having a composition of about 10 to 30 weight percent aluminum, between trace amounts and about 3 weight percent of a reactive element such as yttrium, zirconium, hafnium, scandium, or any of the lanthanides or mixtures thereof, and balance being nickel, cobalt, iron, or mixtures thereof.
  • bond coat 38 includes about 20 to 22 weight percent aluminum, about 0.2 to 0.4 weight percent yttrium, and balance nickel.
  • chromium is purposely omitted from the bond coat 38, although some inconsequential, inadvertent trace amount might conceivably exist therein.
  • the bond coat 38 is preferably produced by means of low pressure or vacuum plasma spray using a prealloyed powder, rather than conventional diffusion methods such as pack cementation.
  • An exemplary plasma spray method is disclosed, for example, in U.S. Pat. No. Re. 33,876 to Goward et al., the disclosure of which is incorporated herein by reference.
  • the composition of the bond coat 38 may be controlled better and the migration of base alloy elements from the substrate 36, which might otherwise pose a detriment to bond coat/alumina adherence, may be reduced markedly.
  • a relatively thin diffusion zone 40 inherently forms between the bond coat 38 and substrate 36, supporting the bond therebetween.
  • a ceramic topcoat 44 is disposed on the alumina film 42 to achieve the desired insulative properties of the TBC system. As depicted, the preferred ceramic topcoat 44 has a columnar microstructure, substantially consistent with that disclosed in U.S. Pat. No. 4,321,311 to Strangman, the disclosure of which is incorporated herein by reference.
  • the columnar ceramic topcoat 44 preferably is produced by electron beam PVD, although other techniques consistent with the production of such columnar microstructure may be used as desired.
  • An exemplary PVD method and apparatus is disclosed in U.S. Pat. No. 4,880,614 to Strangman et al., the disclosure of which is incorporated herein by reference.
  • a multilayered columnar ceramic topcoat with at least two grain orientation directions may be employed.
  • FIG. 2B depicted is an enlarged schematic, cross-sectional view of a portion of a superalloy article 134 coated with a TBC system in accordance with an alternative embodiment of the present invention.
  • the article 134 includes a substrate 136, preferably composed of an iron-, nickel-, or cobalt-base superalloy.
  • the MAlY bond coat of the present embodiment of the invention also may be suitable for use with any superalloy or other metallic substrates-with which it may form an adequate bond.
  • a MAlY bond coat 138 having a composition of about 10 to 30 weight percent aluminum, between trace amounts and about 3 weight percent of a reactive element such as yttrium, zirconium, hafnium, scandium, or any of the lanthanides or mixtures thereof, and balance being nickel, cobalt, iron or mixtures thereof.
  • bond coat 138 includes about 20 to 22 weight percent aluminum, about 0.25 to 0.4 weight percent yttrium, and balance nickel.
  • chromium is purposely omitted from the bond coat 138.
  • the bond coat 138 is produced by first applying yttrium to the substrate 136 by any conventional method, such as electron beam PVD.
  • the MAlY bond coat 138 may be produced by gas phase aluminizing.
  • the superalloy substrate 136 is reacted with an aluminum halide gas at elevated temperature for a length of time sufficient to produce the desired bond coat thickness and composition in accordance with the aforementioned constituent ranges.
  • the method is not restricted to gas phase aluminizing in that any source of aluminum may be employed to support the aluminizing step.
  • the MAlY bond coat 138 includes both the aluminide coating and embedded yttrium rich intermetallic phase particles 148.
  • the coating formed will be nickel aluminide.
  • the substrate is a cobalt-base alloy, the coating formed will be cobalt aluminide.
  • zirconium, hafnium, scandium, or any of the lanthanides were applied in sufficiently high concentration, the resultant particles 148 would be rich in the applied reactive element.
  • a relatively thin diffusion zone 140 inherently forms between the bond coat 138 and substrate 136 supporting the bond therebetween.
  • the diffusion zone 140 may contain the diffused reactive element first applied.
  • a ceramic topcoat 144 is disposed on the alumina film 142 to achieve the desired insulative properties of the TBC system.
  • the preferred ceramic topcoat 144 has a non-columnar but strain tolerant morphology produced by plasma spraying techniques, although other conventional methods of application may be employed as desired.
  • the plasma sprayed ceramic topcoat 144 may be uniformly dense, or may exhibit controlled porosity as depicted generally at 146, having a substantially nonporous external surface and increasing porosity proximate the alumina layer 142.
  • the average thickness of individual layers of the multilayered TBC systems depicted in FIGS. 2A and 2B may be selected by those skilled in the art to achieve a desired insulative result.
  • the thickness of bond coat 38, 138 may be between about 40 and 120 microns; the thickness of the alumina film 42, 142 between about 0.1 and 3 microns; and the thickness of the ceramic topcoat 44, 144 between about 80 and 350 microns. These ranges are exemplary. Values outside these ranges, alone or in combination, are considered within the scope of the invention.
  • the thickness of bond coat 38, 138 may be between about 50 and 80 to 90 microns; that of the alumina film 42, 142 may be between about 0.5 and 1.5 microns; and that of the ceramic topcoat 44, 144 may be between about 100 and 150 microns.
  • FIG. 3A depicted is an enlarged schematic, cross-sectional view of a portion of a superalloy article 234, such as an airfoil wall of a turbine blade 232, coated with the noble metal bond coat TBC system in accordance with another preferred embodiment of the present invention.
  • Schematic representation and relative thickness of each layer of the multilayered TBC systems depicted in FIGS. 3A and 3B are meant for illustrative purposes only and in no manner are intended to restrict the scope of the invention.
  • the article 234 in FIG. 3A includes a substrate 236, a portion of which is depicted.
  • the substrate 236 is preferably composed of an iron-, nickel-, or cobalt-base superalloy; however, it is contemplated that the noble metal bond coat of the present invention may be suitable for use with any superalloy or other metallic substrates with which it may form an adequate bond.
  • a noble metal bond coat 238 having a composition of about 10 to 30 weight percent aluminum, about 2 to 60 weight percent noble metal, between trace amounts and about 3 weight percent of a reactive element such as yttrium, zirconium, hafnium, scandium, or any of the lanthanides or mixtures thereof, and balance being nickel, cobalt, iron, or mixtures thereof.
  • bond coat 238 includes about 20 to 25 weight percent aluminum, about 30 to 40 weight percent platinum, about 0.2 to 0.4 weight percent yttrium, about 0.03 to 0.06 weight percent zirconium, and balance being nickel, cobalt, iron, and mixtures thereof.
  • the bond coat 238 is preferably produced by means of low pressure or vacuum plasma spray using a prealloyed powder containing aluminum, one or a mixture of noble metals, and one or a mixture of reactive elements, rather than conventional diffusion methods such as pack cementation.
  • a plasma spray method the composition of the bond coat 238 may be controlled better and the migration of base alloy elements from the substrate 236, which might otherwise pose a detriment to bond coat/alumina adherence, may be reduced markedly.
  • a relatively thin diffusion zone 240 inherently forms between the bond coat 238 and substrate 236 supporting the bond therebetween.
  • a ceramic topcoat 244 is disposed on the alumina film 242 to achieve the desired insulative properties of the TBC system.
  • the preferred ceramic topcoat 244 has a columnar microstructure, which may be produced by electron beam PVD, although other techniques consistent with the production of such columnar microstructure may be used as desired.
  • a multilayered columnar ceramic topcoat with at least two grain orientation directions may be employed.
  • FIG. 3B depicted is an enlarged schematic, cross-sectional view of a portion of a superalloy article 334 coated with a TBC system in accordance with another alternative embodiment of the present invention.
  • the article 334 includes a substrate 336, preferably composed of an iron-, nickel-, or cobalt-base superalloy.
  • the noble metal bond coat of the present embodiment of the invention also may be suitable for use with any superalloy or other metallic substrates with which it may form an adequate bond.
  • a noble metal bond coat 338 having a composition of about 10 to 30 weight percent aluminum, about 2 to 60 weight percent noble metal, between trace amounts and about 3 weight percent of a reactive element such as yttrium, zirconium, hafnium, scandium, or any of the lanthanides or mixtures thereof, and balance being nickel, cobalt, iron, or mixtures thereof.
  • bond coat 338 includes about 20 to 25 weight percent aluminum, about 30 to 40 weight percent platinum, about 0.2 to 0.4 weight percent yttrium, about 0.03 to 0.06 weight percent zirconium, and balance being nickel, cobalt, iron, and mixtures thereof.
  • chromium is purposely omitted from the bond coat 338.
  • the bond coat 338 is produced by first applying one or more reactive elements to the substrate 336 by any conventional method, such as electron beam or other PVD technique, or chemical vapor deposition ("CVD"). Thereafter, the noble metal bond coat 338 may be produced by gas phase aluminizing. According to this process, the superalloy substrate 336 is reacted with an aluminum halide gas at elevated temperature for a length of time sufficient to produce the desired bond coat thickness and composition in accordance with the aforementioned constituent ranges.
  • the method is not restricted to gas phase aluminizing in that any source of aluminum may be employed to support the aluminizing step.
  • alternative methods include pack cementation, ion vapor deposition from either a pack source or any other aluminum bearing gas, electroplating, and electrophoteric techniques.
  • the noble metal bond coat 338 includes both the aluminide coating and embedded reactive element rich intermetallic phase particles 348.
  • the coating formed will be nickel aluminide.
  • the substrate is a cobalt-base alloy, the coating formed will be cobalt aluminide.
  • a relatively thin diffusion zone 340 inherently forms between the bond coat 338 and substrate 336 supporting the bond therebetween.
  • the diffusion zone 340 may contain the diffused reactive element first applied.
  • a ceramic topcoat 344 is disposed on the alumina film 342 to achieve the desired insulative properties of the TBC system.
  • the preferred ceramic topcoat 344 has a non-columnar but strain tolerant morphology produced by plasma spraying techniques, although other conventional methods of application may be employed as desired.
  • the plasma sprayed ceramic topcoat 344 may be uniformly dense, or may exhibit controlled porosity as depicted generally at 346, having a substantially nonporous external surface and increasing porosity proximate the alumina layer 342.
  • the average thickness of individual layers of the multilayered TBC systems depicted in FIGS. 3A and 3B may be selected by those skilled in the art to achieve a desired insulative result.
  • the thickness of bond coat 238, 338 may be between about 20 and 120 microns; the thickness of the alumina film 242, 342 between about 0.1 and 3 microns; and the thickness of the ceramic topcoat 244, 344 between about 80 and 350 microns. These ranges are exemplary. Values outside these ranges, alone or in combination, are considered within the scope of the invention.
  • the thickness of bond coat 238, 338 may be between about 20 and 70 microns; that of the alumina film 242, 342 may be between about 0.5 and 1.5 microns; and that of the ceramic topcoat 244, 344 may be between about 100 and 150 microns.
  • the noble metal bond coat includes the equivalent of a noble metal layer having a thickness of about 2 to 5 microns, a reactive element layer having a thickness of up to about 3 microns, and an aluminum layer having a thickness of about 30 to 60 microns, the balance being nickel, cobalt, iron, or mixtures thereof.
  • the noble metal layer may be deposited by PVD or electroplating, the reactive element layer by PVD or CVD, and the aluminum layer by pack cementation, gas phase CVD, ion vapor deposition, electroplating, or electrophoteric techniques. Diffusion of the aluminum may occur either during or after the coating process.
  • the noble metal bond coat can be applied by a combination of methods, using a multi-step approach, such as depositing one or a mixture of noble metals followed by depositing an aluminide compound of aluminum with one or a mixture of reactive elements by pack cementation, gas phase CVD, ion vapor deposition, electroplating, or electrophoteric techniques.
  • the noble metal bond coat may be applied by depositing a layer of one or a mixture of reactive elements by PVD and, following the deposition, diffusing this layer into the substrate. Thereafter, a layer of one or a mixture of noble metals is deposited by electroplating and, following the deposition, this layer is diffused into the substrate, if the process so requires. Lastly, the bond coat may be aluminized using a vapor phase deposition technique as discussed hereinabove.
  • the ceramic topcoat may be a partially (e.g. 6 to 8 weight percent) yttria stabilized zirconia coating with a columnar structure which is deposited on top of the noble metal bond coat.
  • the alumina layer having a thickness of about 0.1 to 0.4 microns can grow on the bond coat either before, during, or after deposition of the ceramic topcoat, although growth of the alumina layer during ceramic deposition may be a preferred method.

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  • Chemical & Material Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Ceramic Engineering (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
  • Paints Or Removers (AREA)
  • Insulated Conductors (AREA)
  • Coating By Spraying Or Casting (AREA)
EP99308241A 1998-10-19 1999-10-19 Wärmeschutz-Beschichtung und Herstellungsverfahren Expired - Lifetime EP0995817B1 (de)

Applications Claiming Priority (2)

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US17486498A 1998-10-19 1998-10-19
US174864 1998-10-19

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EP0995817B1 EP0995817B1 (de) 2007-05-16

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1008672A1 (de) * 1998-12-11 2000-06-14 General Electric Company Durch Platin modifizierte Aluminid-Diffusionsverbundschicht für thermische Sperrschichtsysteme
EP1321541A2 (de) * 2001-12-20 2003-06-25 General Electric Company Schicht und Beschichtungssysteme auf Nickelaluminid-Basis
EP1801257A3 (de) * 2005-12-21 2009-03-11 United Technologies Corporation Hochfeste NiPtAIHf-Bindeschicht
US10443447B2 (en) 2016-03-14 2019-10-15 General Electric Company Doubler attachment system

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Publication number Priority date Publication date Assignee Title
WO1979000343A1 (en) * 1977-12-05 1979-06-14 Secr Defence Improvements in or relating to nickel-,cobalt-,and iron based alloys
US5238752A (en) * 1990-05-07 1993-08-24 General Electric Company Thermal barrier coating system with intermetallic overlay bond coat
EP0718419A2 (de) * 1994-12-24 1996-06-26 ROLLS-ROYCE plc Hochtemperatur-Schutzschicht für Superlegierung und Verwendungsverfahren
EP0733723A1 (de) * 1995-03-21 1996-09-25 Howmet Corporation Wärmehemmendes Beschichtungssystem
WO1997029219A2 (en) * 1996-02-07 1997-08-14 N.V. Interturbine Improved thermal barrier coating system and methods

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1979000343A1 (en) * 1977-12-05 1979-06-14 Secr Defence Improvements in or relating to nickel-,cobalt-,and iron based alloys
US5238752A (en) * 1990-05-07 1993-08-24 General Electric Company Thermal barrier coating system with intermetallic overlay bond coat
EP0718419A2 (de) * 1994-12-24 1996-06-26 ROLLS-ROYCE plc Hochtemperatur-Schutzschicht für Superlegierung und Verwendungsverfahren
EP0733723A1 (de) * 1995-03-21 1996-09-25 Howmet Corporation Wärmehemmendes Beschichtungssystem
WO1997029219A2 (en) * 1996-02-07 1997-08-14 N.V. Interturbine Improved thermal barrier coating system and methods

Non-Patent Citations (1)

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Title
STECURA S: "EFFECTS OF YTTRIUM, ALUMINUM AND CHROMIUM CONCENTRATIONS IN BOND COATINGS ON THE PERFORMANCE OF ZIRCONIA-YTTRIA THERMAL BARRIERS", THIN SOLID FILMS,CH,ELSEVIER-SEQUOIA S.A. LAUSANNE, vol. 73, no. 2, 23 April 1980 (1980-04-23), pages 481 - 489, XP002032197, ISSN: 0040-6090 *

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1008672A1 (de) * 1998-12-11 2000-06-14 General Electric Company Durch Platin modifizierte Aluminid-Diffusionsverbundschicht für thermische Sperrschichtsysteme
EP1321541A2 (de) * 2001-12-20 2003-06-25 General Electric Company Schicht und Beschichtungssysteme auf Nickelaluminid-Basis
EP1321541A3 (de) * 2001-12-20 2003-07-30 General Electric Company Schicht und Beschichtungssysteme auf Nickelaluminid-Basis
EP1801257A3 (de) * 2005-12-21 2009-03-11 United Technologies Corporation Hochfeste NiPtAIHf-Bindeschicht
EP2447391A2 (de) * 2005-12-21 2012-05-02 United Technologies Corporation Hochfeste Ni-Pt-Al-Hf-Haftschicht
US10443447B2 (en) 2016-03-14 2019-10-15 General Electric Company Doubler attachment system

Also Published As

Publication number Publication date
ES2288002T3 (es) 2007-12-16
DE69936088T2 (de) 2008-01-24
ATE362555T1 (de) 2007-06-15
EP0995817B1 (de) 2007-05-16
DE69936088D1 (de) 2007-06-28

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