EP1428982B1 - Méthode pour déposer localement un revêtement de type MCrAlY - Google Patents

Méthode pour déposer localement un revêtement de type MCrAlY Download PDF

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Publication number
EP1428982B1
EP1428982B1 EP02406066A EP02406066A EP1428982B1 EP 1428982 B1 EP1428982 B1 EP 1428982B1 EP 02406066 A EP02406066 A EP 02406066A EP 02406066 A EP02406066 A EP 02406066A EP 1428982 B1 EP1428982 B1 EP 1428982B1
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EP
European Patent Office
Prior art keywords
coating
coatings
mcraiy
article
areas
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.)
Expired - Lifetime
Application number
EP02406066A
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German (de)
English (en)
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EP1428982A1 (fr
Inventor
Abdus Suttar Khan
Thomas Duda
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.)
General Electric Technology GmbH
Original Assignee
Alstom Technology AG
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Filing date
Publication date
Application filed by Alstom Technology AG filed Critical Alstom Technology AG
Priority to EP02406066A priority Critical patent/EP1428982B1/fr
Priority to DE60231084T priority patent/DE60231084D1/de
Priority to US10/726,593 priority patent/US20040159552A1/en
Priority to JP2003407617A priority patent/JP2004190140A/ja
Publication of EP1428982A1 publication Critical patent/EP1428982A1/fr
Application granted granted Critical
Publication of EP1428982B1 publication Critical patent/EP1428982B1/fr
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
    • C25D5/02—Electroplating of selected surface areas
    • C25D5/022—Electroplating of selected surface areas using masking means
    • 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
    • C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/288—Protective coatings for blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/80—Repairing, retrofitting or upgrading methods

Definitions

  • This invention relates according to claim 1 to a method of depositing a MCrAlY-coating.
  • MCrAlY overlay coatings are used for protection of turbine blades and vanes.
  • MCrAlY protective overlay coatings are widely known in the prior art. They are a family of high temperature coatings, wherein M is selected from one or a combination of iron, nickel and cobalt.
  • US-A-3,528,861 or US-A-4,585,481 are disclosing such kind of oxidation resistant coatings.
  • US-A-4, 152,223 as well discloses such method of coating and the coating itself.
  • ⁇ / ⁇ -MCrAlY-coating there is another class of overlay MCrAlY coatings which are based on a ⁇ / ⁇ '-gamma/gamma prime-structure, which is for example disclosed in US-A-4,546,052 or US-A-4,973,445 .
  • the advantages of ⁇ / ⁇ '-coatings is that they have a negligible thermal expansion mismatch with alloy of the underlying turbine article and are likely to have a better thermal mechanical properties.
  • US-A-4,313,760 discloses a superalloy coating composition with good oxidation, corrosion and fatigue resistance. Additional examples MCrAlY coatings are known from US-B1-6,280,857 , US-B1-6,221,181 , US-A-5,455,119 , US-A-5,154,885 , US-A-5, 035,958 or US-B1-6,207,297 . They all deal primarily with improving the oxidation resistance of MCrAlY coatings.
  • Thermal barrier coatings are used to provide thermal insulation of the components in various types of engines e.g. in turbine engines.
  • Thermal Barrier Coatings are known from different patents.
  • US-A-4,055,705 , US-A-4,248,940 , US-A-4,321,311 or US-A-4,676,994 disclose a TBC-coating for the use in the turbine blades and vanes.
  • the ceramics used are yttria stabilized zirconia and applied by plasma spray ( US-A-4, 055,705 , US-A-4, 248,940 ) or by electron beam process ( US-A-4, 321,311 , US-A-4, 676,994 ) on top of the MCrAlY bond coat.
  • the coatings on turbine blades or vanes can fail by one or more of the following degradation modes. These are oxidation, corrosion, TMF (Thermal Mechanical Fatigue) and a combination of TMF and oxidation. Coatings failure in a turbine engine solely by oxidation is not a typical scenario. Further, in advanced turbine engines, incidences of corrosion are not common due to higher engine operating temperature and use of cleaner fuels. What is commonly observed is that the MCrAlY coatings are cracked by TMF. Subsequently the cracks allow oxygen diffusion into the substrate. Since the substrate is not oxidation resistant the advancing oxygen (through the cracks) causes the oxidation of the underlying substrate and triggers the failure of the components. It is therefore important that the coatings be resistant to fatigue as well as oxidation since fatigue cracking appears to be one of the primary triggering mechanisms of the failure of the coatings.
  • TMF Thermal Mechanical Fatigue
  • One approach of improving the fatigue resistance of coatings is by modification of the composition of the coatings and secondly by the use of a thin coating or possibly a combination of both.
  • US-A-4,346,137 and US-A-4,758,480 described a method of improving the fatigue resistance of overlay coatings by a modification of composition.
  • the platinum was added to MCrAlY coatings, which reduces the thermal expansion mismatch between the coatings and the substrate, hence also reduces the propensity of the coatings to cracking. This results in a significant improvement of the TMF life of the coatings.
  • the US-A-4,758,480 discloses a class of protected coatings for superalloys in which the coating compositions are based on the composition of the underlying substrate. By tailoring the coatings to the substrate composition, diffusional stability results and other mechanical properties of the coating such as coefficient of thermal expansion and modulas, are brought closer to the substrate. The coatings thus obtained showed both increased oxidation and TMF resistance.
  • the increase of coating thickness decreases TMF life of coatings; the problem is then to find a method that allows a deposition of thin protective coatings on complex turbine airfoils.
  • a literature search shows that the MCrAlY overlay coatings are generally deposited by plasma spray process (i.e. APS, VPS, LPPS or HVOF) or electron beam physical vapor deposition (EB-PVD) and sputtering.
  • plasma spray process i.e. APS, VPS, LPPS or HVOF
  • EB-PVD electron beam physical vapor deposition
  • a line of sight limitation Since airfoils contain many complex contoured surface i.e. airfoil to platform transition area, leading edge etc., the line of sight limitation present a difficulty in getting a good uniform coverage of coatings with thickness uniformity.
  • US-A-5,558,758 , US-A-5,824,205 and US-A-5,833,829 described the deposition of MCrAlY coatings by electroplated process.
  • the process involves a deposition of the coating precursor, CrAlM2 powder in a M1 bath where M2 is one or more of Si, Ti, Hf, Ga, Nb, Mn, Pt and rare earth elements and M1 consists of Ni, Co, Fe alone or in combination.
  • the as-deposited coating is heat-treated to obtain the final coating structure.
  • the stress strain distribution and thermal-mechanical loading are different area to area.
  • some local area i.e. zone in an airfoil may be sensitive to oxidation or corrosion or thermal mechanical fatigue, or possibly a combination of one or more of degradation mode.
  • a local coating with appropriate set of properties could be potentially beneficial in increasing the lifetime of airfoils.
  • the plasma spray process generally used for manufacturing of coating is not ideal for local coating - it has a line of sight limitation and cannot coat effectively many 'difficult to coat area' such as platform to airfoil transition area with good thickness control.
  • EP-B1-0 139 396 disclosed a process of local coating of turbine blade by plasma spraying of MCrAlY coatings.
  • US-B1-6,435,830 and US-B1-6,270,318 wherein the underside of the platform is coated locally with a corrosion resistant coating.
  • local coatings for repair or refurbish of components degraded by oxidation or corrosion For example, US-B1-6,203,847 provided a method of repairing by first plating the affected areas with Pt or noble metals then aluminising the surfaces.
  • US-B1-6,274,193 restored a protective coating in a local areas with a replacement aluminide coating.
  • the aim of the present invention is to find a MCrAlY-bond or overlay coating with good oxidation and fatigue resistance according to the requirements on local areas of a gas turbine component. Another aim is to find a method of depositing a MCrAlY-coating on a turbine component with uniformity. Yet another aim of the invention is to deposit a thin MCrAlY-coating on a large industrial gas turbine blade or vane with a good thickness control of the deposited layer.
  • the process of the invention has a thickness control of ⁇ 20 ⁇ m of the thickness of the deposited layer, where as conventional plasma spray coating processes have thickness scatters of ⁇ 75 ⁇ m or even more.
  • a coating with a layer thickness in a range of 25-400 ⁇ m can be applied.
  • a thinner coating increase the TMF life of the coating.
  • the used electroplated process has no line of sight limitation and can coat complex contour surfaces without any difficulty.
  • the coating/masking step is repeated at different local areas on the surface of the article.
  • the different areas are coated with different MCrAIY-coatings.
  • the MCrAlY-coatings are selected according to the required properties in said areas in respect to one or a combination of oxidation, corrosion, thermal mechanical fatigue (TMF).
  • TMF thermal mechanical fatigue
  • Examples of electroplated ⁇ / ⁇ ' and that of ⁇ / ⁇ -MCrAlY local coatings are Ni-24Cr-5Al-1Ta-1.2Si-0.3Y and Ni-23C0-18Cr-10Al.0.5Y, respectively, or known from the European patent application EP-A1-1 411 210 , which has the same applicant as the present application.
  • the present invention is generally applicable to components that operate within environments characterised by relatively high temperature, and are therefore subjected to severe thermal stresses and thermal cycling.
  • Notable examples of such components include the high and low pressure nozzles and blades, shrouds, combustor liners and augmentor hardware of gas turbine engines.
  • Fig. 1 shows as an example such an article 1 as blades or vanes comprising a blade 2 against which hot combustion gases are directed during operation of the gas turbine engine, a cavity, not visible in Figure 1, and cooling holes 4, which are on the external surface 5 of the component 1 as well as on the platform 3 of the component. Through the cooling holes 4 cooling air is ducted during operation of the engine to cool the external surface 5.
  • the external surface 5 is subjected to severe attack by oxidation, corrosion and erosion due to the hot combustion gases and more importantly TMF cracking due to thermal mechanical loading.
  • the article 1 consists of a nickel or cobalt base super alloy such as disclosed, by way of an example, in US-A-5,759,301 .
  • the article 1 is a single crystal (SX) or directionally solidified (DS). While the advantages of this invention is described with reference to a turbine blade or vane as shown in Fig. 1, the invention is generally applicable to any component on which a coating system may be used to protect the component from its environment.
  • the present invention individualized local or zone-coating 6 by using an electroplated method.
  • the TMF life of the electroplated coating 6 was at least 2 times higher than the life of the plasma sprayed coatings. It is noted that the cost of the application of a coating 6 by an electroplated process is with advantage a third of a conventional plasma spray coating.
  • the process of the invention has a thickness control of ⁇ 20 ⁇ m of the thickness of the deposited layer, where as conventional plasma spray coating processes have thickness scatters of ⁇ 75 ⁇ m or even more. Thus, a coating with a layer thickness in a range of 25-400 ⁇ m can be applied. A thinner coating 6 increase the TMF life of the coating 6.
  • the used electroplated process has no line of sight limitation and can coat complex contour surfaces without any difficulty.
  • the target coatings 6 shall be selected from the MCrAlX family of coatings tailored for oxidation/corrosion or fatigue resistance according the requirements at the local zone.
  • the coatings 6 shall be applied in steps. Initially the areas not be coated are masked and the target area is coated by the electroplated method.
  • Another previously masked area is coated, whereas the other areas is previously masked.
  • To be able to coat the mask from the target area is removed and at the same time mask the previously coated area.
  • the process of masking and coating of target areas are repeated as often as necessary.
  • the surface will appear as if decorated with a series of 'patch coatings' each distinct from the other.
  • the different areas are coated with different MCrAlY-coatings 6.
  • the MCrAlY-coatings are selected according to the required properties in said areas in respect to one or a combination of oxidation, corrosion, thermal mechanical fatigue (TMF).
  • TMF thermal mechanical fatigue
  • One example of localized coating could be the TMF resistant coating on the platform/airfoil transition area of gas turbine blades and vanes and a highly oxidation resistant coating provided on the upper airfoil - the tip section.
  • the masks used are wax and organic polymers. These masks can be applied and removed easily and do not leave any residue or chemical impurity behind on the surface.
  • the method can be used as a repair process for a used MCrAlY-coating 6.
  • Examples of electroplated ⁇ / ⁇ ' and that of ⁇ / ⁇ -MCrAlY local coatings are Ni-24Cr-5Al-1Ta-1.2Si-0.3Y and Ni-23C0-18Cr-10Al.0.5Y, respectively, or known from the European patent application EP-A1-1 411 210 , which has the same applicant as the present application.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • General Engineering & Computer Science (AREA)
  • Electrochemistry (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Electroplating Methods And Accessories (AREA)
  • Coating By Spraying Or Casting (AREA)

Claims (5)

  1. Procédé de dépôt d'un revêtement (6) de type MCrAlY sur la surface (5) d'un monocristal (SX) ou sur un objet (1) qui a subi une solidification orientée ("Directionnally Solidified" - DS), procédé comprenant l'étape qui consiste à revêtir uniquement une zone locale de l'objet (1) par un revêtement (6) en MCrAlY γ/γ' ou γ/β par un procédé d'électroplacage, dans lequel l'étape qui consiste à recouvrir uniquement une zone locale de l'objet (1) par un revêtement (6) de MCrAlY par un procédé d'électroplacage est répétée en différentes zones locales de la surface (5) de l'objet (1) et dans lequel les différentes zones sont recouvertes de différents revêtements de type MCrAlY, les revêtements de type MCrAlY étant sélectionnés en fonction des propriétés requises dans lesdites zones concernant une des propriétés : oxydation, corrosion, fatigue thermomécanique ("Thermal Mechanical Fatigue" - TMF) ou leurs combinaisons.
  2. Procédé selon la revendication 1, dans lequel pendant l'étape qui consiste recouvrir uniquement une zone locale de l'objet (1) par le revêtement (6) de type MCrAlY par un procédé d'électroplacage, les zones qui ne sont pas recouvertes sont masquées par un matériau de masquage.
  3. Procédé selon la revendication 2, dans lequel les zones qui ne doivent pas être recouvertes sont masquées par de la cire ou des polymères organiques.
  4. Procédé selon l'une quelconque des revendications 1 à 3, dans lequel on utilise le procédé comme opération de réparation d'un revêtement (6) usé de type MCrAlY.
  5. Procédé selon l'une quelconque des revendications 1 à 4, pour recouvrir un élément (1) d'une turbine à gaz, par exemple une pale ou une aube.
EP02406066A 2002-12-06 2002-12-06 Méthode pour déposer localement un revêtement de type MCrAlY Expired - Lifetime EP1428982B1 (fr)

Priority Applications (4)

Application Number Priority Date Filing Date Title
EP02406066A EP1428982B1 (fr) 2002-12-06 2002-12-06 Méthode pour déposer localement un revêtement de type MCrAlY
DE60231084T DE60231084D1 (de) 2002-12-06 2002-12-06 Verfahren zur selektiven Abscheidung einer MCrAlY-Beschichtung
US10/726,593 US20040159552A1 (en) 2002-12-06 2003-12-04 Method of depositing a local MCrAIY-coating
JP2003407617A JP2004190140A (ja) 2002-12-06 2003-12-05 局部的なＭＣｒＡｌＹコーティングを付着させる方法

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP02406066A EP1428982B1 (fr) 2002-12-06 2002-12-06 Méthode pour déposer localement un revêtement de type MCrAlY

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EP1428982A1 EP1428982A1 (fr) 2004-06-16
EP1428982B1 true EP1428982B1 (fr) 2009-02-04

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EP (1) EP1428982B1 (fr)
JP (1) JP2004190140A (fr)
DE (1) DE60231084D1 (fr)

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JP3708909B2 (ja) * 2002-06-28 2005-10-19 独立行政法人科学技術振興機構 レニウム含有合金皮膜を被着してなる耐高温酸化性耐熱合金部材の製造方法

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US20040159552A1 (en) 2004-08-19

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