EP1491657B1 - Verfahren für das Auftragen eines mehrschichtigen Systems - Google Patents

Verfahren für das Auftragen eines mehrschichtigen Systems Download PDF

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Publication number
EP1491657B1
EP1491657B1 EP03405462A EP03405462A EP1491657B1 EP 1491657 B1 EP1491657 B1 EP 1491657B1 EP 03405462 A EP03405462 A EP 03405462A EP 03405462 A EP03405462 A EP 03405462A EP 1491657 B1 EP1491657 B1 EP 1491657B1
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EP
European Patent Office
Prior art keywords
coating
rivets
tbc
article
metallic bond
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
EP03405462A
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English (en)
French (fr)
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EP1491657A1 (de
Inventor
Andus Suttar Khan
Reinhard Fried
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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 AT03405462T priority Critical patent/ATE338150T1/de
Priority to EP03405462A priority patent/EP1491657B1/de
Priority to DE60308002T priority patent/DE60308002D1/de
Publication of EP1491657A1 publication Critical patent/EP1491657A1/de
Application granted granted Critical
Publication of EP1491657B1 publication Critical patent/EP1491657B1/de
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • 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
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
    • 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
    • C23C28/34—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
    • 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
    • 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

Definitions

  • the invention relates to a process of method of applying a coating system to the surface of an article according to the independent claim.
  • Components designed for use in the area of high temperature environment e.g. blades or vanes of a gas turbine, are usually coated with environmentally resistant coatings.
  • the coating protects the base material against corrosion and oxidation due to the thermal effect of the hot environment.
  • Most turbine components are coated for protection from oxidation and/or corrosion with, for example, a MCrAlY coating (base coat) and some are also coated with a thermal barrier coating (TBC) for thermal insulation.
  • 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 disclose such kind of oxidation resistant coatings.
  • US-A-4,152,223 as well discloses such method of coating and the coating itself.
  • Thermal-Barrier-Coatings are known in the state of the art from different patents, i.e 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 wherein the yttria stabilized zirconia is applied on top of the MCrAlY bond coat.
  • the plasma sprayed TBCs generally fail by delamination and a number of factors are thought to contribute to the delamination of the TBC:
  • US-A-5,863,668 and US-A-6,093,454 are using two layer bond coats, the first layer is MCrAlX and the second layer is MCrAlX mixed with chromia, alumina and other oxides.
  • US-A-4,457,948 provided a stress relief in the TBC by a post-coating heat-treatment by a rapid quenching from elevated temperature which resulted in a cracking of the TBC.
  • US-A-5,073,433 provided a stress relief by a vertical segmentation of a dense TBC.
  • a dense TBC is required for the preferred crack morphology.
  • Other examples provided in the literature are of US-B1-6,224,963 where a segmented TBC was produced by a laser drilling in the selected area in the TBC.
  • US-A-5,681,616 produces a segmented TBC by abrading a portion of the TBC with a high pressure liquid jet.
  • TGO pure aluminum oxide
  • MCrAlY bond coating Promoting a pure aluminum oxide TGO on a MCrAlY bond coating have not been very successful.
  • a post coating heat-treatment generally do not promote alumina scale at lower temperatures i.e. below 950°C.
  • the advantages of the invention include, inter alia, that the surface of the rivets could be made extremely rough.
  • the rivets can be stamped on or soldered-on the surface or cast features on the surface.
  • the MCrAlY bond coating in this invention upon which TBC is built will be deposited by an electroplating process according to unpublished patent application with application no. EP02405881.0 (internal reference number of the applicant B02/046-0).
  • the cost of the application of a metallic bond coating 6 by an electroplating process is significantly less than that of conventional plasma spray process.
  • the electroplating process has a thickness control of ⁇ 25 ⁇ m or better. This thickness control is desired to reduce the effects of properties of metallic bond coating 6 on the stability of the TBC.
  • the electroplating process can apply MCrAlY bond coating with a layer thickness in the range of 25 to 400 ⁇ m, preferably in the range of 50 to 300 ⁇ m.
  • a thin coating increase the TMF life of the coating.
  • the plating process has no line of sight limitation and can coat complex contour surfaces without any difficulty.
  • the metallic bond coating 6 thus manufactured contains very little oxygen as impurity such as mixed oxides.
  • a MCrAlY coating is Ni-23Co-18Cr-10Al-0.5Y.
  • the MCrAlY can have a ⁇ / ⁇ '- or ⁇ / ⁇ -structure.
  • the thick segmented TBC will be deposited using a known state of the art plasma spray process with conventional equipment.
  • the invention disclosed here will not require a dense TBC and will be built up consisting of a high porosity in the range of 10 to 20 %.
  • the present invention is a process for manufacturing of a thick layer of the ceramic coating with an intended thickness of at least between 1 to 10 mm. It is intuitively obvious that the nature of segmentation cracks in the TBC will depend on rivet distribution, rivet size, thickness of the rivets and rivet length.
  • This invention is particularly useful when applied to articles such as blades, vanes or any other gas turbine component operating at high temperatures and coated with MCrAlY as bond coating and with TBC as ceramic coating.
  • the inventive coating system including the rivets can be placed locally on the pressure or suction side or on the platform of said turbine blade or vane.
  • 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.
  • the article 1 consists of a nickel or cobalt base super alloy such as disclosed in the state of the art, e.g. from the document US 5,888,451, US 5,759,301 or from US 4,643,782, which is known as "CMSX-4".
  • CMSX-4 nickel or cobalt base super alloy
  • the article 1 can be single crystal (SX) or directionally solidified (DS).
  • the invention is related to a process of applying a coating system to the surface 8 of the article 1.
  • the surface 8 is prepared by cleaning, grit blasting and other preparation methods including chemical etching.
  • a number of rivets 9 are placed on top of the surface 8 of said article 1 and a metallic bond coating 6 is deposited on the surface 8 of the article 1 and the rivets 9 by an electroplating process.
  • a Thermal Barrier Coating (TBC) as ceramic coating 7 such as Y stabilized zirconia is deposited on top of the metallic bond coating 6 containing the rivets 9.
  • the cost of the application of a metallic bond coating 6 by an electroplating process is significantly less than that of conventional plasma spray process.
  • the electroplating process has a thickness control of ⁇ 25 ⁇ m or better, whereas a conventional plasma spray coating process have thickness scatter of ⁇ 75 ⁇ m or more.
  • a thickness control ⁇ 25 ⁇ m or better of the metallic bond coating 6 is desired to reduce the effects of properties of metallic bond coating 6 on the stability of the TBC.
  • the electroplating process can apply MCrAlY bond coating with a layer thickness of 25 to 400 ⁇ m, preferably in the in the range of 50 to 300 ⁇ m.
  • a thin coating increase the TMF life of the coating.
  • the plating process has no line of sight limitation and can coat complex contour surfaces without any difficulty.
  • the metallic bond coating 6 thus manufactured contains very little oxygen as impurity such as mixed oxides.
  • a MCrAlY coating is Ni-23Co-18Cr-10Al-0.5Y.
  • the MCrAlY can have a ⁇ / ⁇ '- or ⁇ / ⁇ -structure.
  • rivets 9 in form of a wire or a pin or a wire mesh can be placed on top of said surface 8 of the article 1.
  • Such rivets 9 can be made from stainless steel, nickel base, cobalt or iron alloys.
  • the advantages of the invention include, inter alia, that the surface of the rivets 6 could be made extremely rough.
  • the rivets 6 can be stamped on or soldered on the surface 8 or cast features on the surface 8.
  • the rivets 6 are distributed in a way as to induce segmentation of the ceramic coating 7 applied afterwards on top of the bond coating 6.
  • the thick segmented TBC will be deposited using a known state of the art plasma spray process with conventional equipment.
  • the invention disclosed here will not require a dense TBC and will be built up consisting of a high porosity in the range of 10 to 20 %.
  • the present invention is a process for manufacturing of a thick layer of the ceramic coating with an intended thickness of at least between 1 to 10 mm. It is intuitively obvious that the nature of segmentation cracks in the TBC will depend on rivet distribution, rivet size, thickness of the rivets and rivet length.
  • the invention is particularly advantageous when applied to a blade or a vane or any other gas turbine component consisting of a nickel or cobalt base alloy exposed to a high temperature environment and coated with MCrAlY as bond coating and with TBC as ceramic coating.
  • the inventive coating system including the rivets 9 can be placed locally on the pressure or suction side or on the platform 3 of said turbine blade or vane.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Metallurgy (AREA)
  • Inorganic Chemistry (AREA)
  • General Engineering & Computer Science (AREA)
  • Plasma & Fusion (AREA)
  • Physics & Mathematics (AREA)
  • Ceramic Engineering (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Electroplating Methods And Accessories (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Production Of Multi-Layered Print Wiring Board (AREA)

Claims (9)

  1. Verfahren für die Anwendung eines Beschichtungssystems auf die Oberfläche (8) eines Gegenstandes (1), welches folgende Schritte aufweist:
    - Anbringen einer Anzahl von Nieten (9) auf der Oberfläche (8) des Gegenstandes (1),
    - Aufbringen einer metallischen Haftbeschichtung (6) auf die Oberfläche (8) und die Nieten (9) durch einen Galvanisierungsprozess,
    - Aufbringen einer keramischen Beschichtung (7) auf die metallische Haftbeschichtung (6), die die Nieten (9) enthält,
    wobei als metallische Haftbeschichtung (6) MCrAIY mit einer γ/γ'- oder γ/β-Struktur angewandt wird.
  2. Verfahren nach Anspruch 1, wobei eine Schichtdicke der metallischen Haftbeschichtung (6) in einem Bereich von 25 bis 400 µm angewandt wird.
  3. Verfahren nach Anspruch 2, wobei eine Schichtdicke der metallischen Haftbeschichtung (6) in einem Bereich von 50 bis 300 µm angewandt wird.
  4. Verfahren nach einem der Ansprüche 1 bis 3, wobei mittels eines Plasmasprühprozesses eine keramische Beschichtung (7) mit einer Dicke in einem Bereich von 1 mm bis 10 mm angewandt wird.
  5. Verfahren nach Anspruch 4, wobei eine keramische Beschichtung (7) mit einer Porosität von 10 bis 20 % angewandt wird.
  6. Verfahren nach einem der Ansprüche 1 bis 5, wobei die Nieten (9) auf der Oberfläche (8) des Gegenstandes (1) eingeschlagene, aufgeschweißte oder angegossene Strukturen sind.
  7. Verfahren nach einem der Ansprüche 1 bis 6, wobei Nieten in der Form eines Drahtes, eines Stifts oder eines Drahtgitters auf der Oberfläche (8) des Gegenstandes (1) angebracht werden.
  8. Verfahren nach Anspruch 7, welches den Schritt des Verwendens von Nieten (9) aufweist, die aus Edelstahl, Nickelbasis-, Kobaltbasis- oder Eisenbasislegierungen hergestellt sind.
  9. Verfahren nach einem der Ansprüche 1 bis 8, wobei das Beschichtungssystem lokal auf die Druck- oder Saugseite oder auf die Plattform (3) eines Turbinenblatts oder einer Turbinenschaufel als dem Gegenstand (1) angebracht wird.
EP03405462A 2003-06-26 2003-06-26 Verfahren für das Auftragen eines mehrschichtigen Systems Expired - Lifetime EP1491657B1 (de)

Priority Applications (3)

Application Number Priority Date Filing Date Title
AT03405462T ATE338150T1 (de) 2003-06-26 2003-06-26 Verfahren für das auftragen eines mehrschichtigen systems
EP03405462A EP1491657B1 (de) 2003-06-26 2003-06-26 Verfahren für das Auftragen eines mehrschichtigen Systems
DE60308002T DE60308002D1 (de) 2003-06-26 2003-06-26 Verfahren für das Auftragen eines mehrschichtigen Systems

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP03405462A EP1491657B1 (de) 2003-06-26 2003-06-26 Verfahren für das Auftragen eines mehrschichtigen Systems

Publications (2)

Publication Number Publication Date
EP1491657A1 EP1491657A1 (de) 2004-12-29
EP1491657B1 true EP1491657B1 (de) 2006-08-30

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EP03405462A Expired - Lifetime EP1491657B1 (de) 2003-06-26 2003-06-26 Verfahren für das Auftragen eines mehrschichtigen Systems

Country Status (3)

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EP (1) EP1491657B1 (de)
AT (1) ATE338150T1 (de)
DE (1) DE60308002D1 (de)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9151175B2 (en) 2014-02-25 2015-10-06 Siemens Aktiengesellschaft Turbine abradable layer with progressive wear zone multi level ridge arrays
US9243511B2 (en) 2014-02-25 2016-01-26 Siemens Aktiengesellschaft Turbine abradable layer with zig zag groove pattern

Families Citing this family (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102005050873B4 (de) * 2005-10-21 2020-08-06 Rolls-Royce Deutschland Ltd & Co Kg Verfahren zur Herstellung einer segmentierten Beschichtung und nach dem Verfahren hergestelltes Bauteil
US8303247B2 (en) * 2007-09-06 2012-11-06 United Technologies Corporation Blade outer air seal
US8818078B2 (en) * 2012-02-03 2014-08-26 Solar Turbines Inc. Apparatus and method for optically measuring creep
WO2013144022A1 (en) 2012-03-28 2013-10-03 Alstom Technology Ltd Method for removing a ceramic
RU2662003C2 (ru) 2014-02-25 2018-07-23 Сименс Акциенгезелльшафт Компонент газовой турбины, газотурбинный двигатель, способ изготовления компонента газотурбинного двигателя
US8939706B1 (en) 2014-02-25 2015-01-27 Siemens Energy, Inc. Turbine abradable layer with progressive wear zone having a frangible or pixelated nib surface
US10443444B2 (en) 2014-05-21 2019-10-15 United Technologies Corporation Cost effective manufacturing method for GSAC incorporating a stamped preform
EP3029274B1 (de) 2014-10-30 2020-03-11 United Technologies Corporation Thermisch gespritztes bonding einer keramikstruktur auf ein substrat
US10408079B2 (en) 2015-02-18 2019-09-10 Siemens Aktiengesellschaft Forming cooling passages in thermal barrier coated, combustion turbine superalloy components
WO2016133583A1 (en) 2015-02-18 2016-08-25 Siemens Aktiengesellschaft Turbine shroud with abradable layer having ridges with holes
US10995620B2 (en) 2018-06-21 2021-05-04 General Electric Company Turbomachine component with coating-capturing feature for thermal insulation

Family Cites Families (4)

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Publication number Priority date Publication date Assignee Title
GB8706951D0 (en) * 1987-03-24 1988-04-27 Baj Ltd Overlay coating
DE19545025A1 (de) * 1995-12-02 1997-06-05 Abb Research Ltd Verfahren zur Aufbringung einer metallischen Haftschicht für keramische Wärmedämmschichten auf metallische Bauteile
DE10057187B4 (de) * 2000-11-17 2011-12-08 Alstom Technology Ltd. Verfahren für die Herstellung von Verbundaufbauten zwischen metallischen und nichtmetallischen Materialien
DE10121019A1 (de) * 2001-04-28 2002-10-31 Alstom Switzerland Ltd Gasturbinendichtung

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9151175B2 (en) 2014-02-25 2015-10-06 Siemens Aktiengesellschaft Turbine abradable layer with progressive wear zone multi level ridge arrays
US9243511B2 (en) 2014-02-25 2016-01-26 Siemens Aktiengesellschaft Turbine abradable layer with zig zag groove pattern

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Publication number Publication date
EP1491657A1 (de) 2004-12-29
ATE338150T1 (de) 2006-09-15
DE60308002D1 (de) 2006-10-12

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