EP1491658A1 - Verfahren für das Auftragen eines mehrschichtigen Systems - Google Patents

Verfahren für das Auftragen eines mehrschichtigen Systems Download PDF

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Publication number
EP1491658A1
EP1491658A1 EP20030405463 EP03405463A EP1491658A1 EP 1491658 A1 EP1491658 A1 EP 1491658A1 EP 20030405463 EP20030405463 EP 20030405463 EP 03405463 A EP03405463 A EP 03405463A EP 1491658 A1 EP1491658 A1 EP 1491658A1
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EP
European Patent Office
Prior art keywords
coating
rivets
tbc
metallic bond
mcraly
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.)
Withdrawn
Application number
EP20030405463
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English (en)
French (fr)
Inventor
Abdus Suttar Dr. Khan
Reinhard Fried
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
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Alstom Technology AG filed Critical Alstom Technology AG
Priority to EP20030405463 priority Critical patent/EP1491658A1/de
Publication of EP1491658A1 publication Critical patent/EP1491658A1/de
Withdrawn legal-status Critical Current

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Classifications

    • 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
    • F01D5/284—Selection of ceramic materials
    • 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
    • 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
    • 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.
  • soldered, sintered-on rivets represent very stable and positively locking anchor points for the TBC layer which is to be sprayed on, so that comparatively thick, stably adhering ceramic thermal barrier coatings can be produced.
  • the 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 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). It is noted that 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. Further in contrast to plasma spray process the plating process has no line of sight limitation and can coat complex contour surfaces without any difficulty. In addition 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. Generally, the MCrAlY can have a ⁇ / ⁇ '- or ⁇ / ⁇ -structu re.
  • 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.
  • a metallic bond coating 6 is deposited to the surface 8 of the article 1 by an electroplating process.
  • the surface 8 is prepared by cleaning, grit blasting and other preparation methods including chemical etching.
  • a number of rivets 9 are deposited on top of the bond coating 6.
  • a Thermal Barrier Coating (TBC) as ceramic coating 7 such as Y stabilized zirconia is deposited on top of the metallic bond coating 6 and 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 the metallic bond coating 6.
  • 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.
  • soldered, sintered-on rivets 8 represent very stable and positively locking anchor points for the TBC layer which is to be sprayed on, so that comparatively thick, stably adhering ceramic thermal barrier coatings can be produced.
  • the 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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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Ceramic Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
EP20030405463 2003-06-26 2003-06-26 Verfahren für das Auftragen eines mehrschichtigen Systems Withdrawn EP1491658A1 (de)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP20030405463 EP1491658A1 (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
EP20030405463 EP1491658A1 (de) 2003-06-26 2003-06-26 Verfahren für das Auftragen eines mehrschichtigen Systems

Publications (1)

Publication Number Publication Date
EP1491658A1 true EP1491658A1 (de) 2004-12-29

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Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1522604B1 (de) * 2003-10-02 2007-02-14 Siemens Aktiengesellschaft Schichtsystem und Verfahren zur Herstellung eines Schichtsystems
DE102005050873A1 (de) * 2005-10-21 2007-04-26 Rolls-Royce Deutschland Ltd & Co Kg Verfahren zur Herstellung einer segmentierten Beschichtung und nach dem Verfahren hergestelltes Bauteil
WO2008153709A1 (en) * 2007-05-22 2008-12-18 Corning Incorporated Method for bonding refractory ceramic and metal related application
DE102011077620A1 (de) 2011-06-16 2012-12-20 Rolls-Royce Deutschland Ltd & Co Kg Bauelement, Verfahren zur Herstellung eines Bauelementes und Flugzeugtriebwerk mit einem Bauelement
EP2589872A2 (de) 2011-11-04 2013-05-08 Rolls-Royce Deutschland Ltd & Co KG Bauelement und Turbomaschine mit einem solchen Bauelement
WO2014053185A1 (de) * 2012-10-05 2014-04-10 Siemens Aktiengesellschaft Verfahren zur aufbereitung einer gasturbinenschaufel sowie gasturbine mit derartiger schaufel
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
US10190435B2 (en) 2015-02-18 2019-01-29 Siemens Aktiengesellschaft Turbine shroud with abradable layer having ridges with holes
US10189082B2 (en) 2014-02-25 2019-01-29 Siemens Aktiengesellschaft Turbine shroud with abradable layer having dimpled forward zone
US10196920B2 (en) 2014-02-25 2019-02-05 Siemens Aktiengesellschaft Turbine component thermal barrier coating with crack isolating engineered groove features
US10408079B2 (en) 2015-02-18 2019-09-10 Siemens Aktiengesellschaft Forming cooling passages in thermal barrier coated, combustion turbine superalloy components
EP3611343A1 (de) 2018-08-13 2020-02-19 Rolls-Royce Deutschland Ltd & Co KG Bauelement mit einer haftstruktur für eine turbomaschine, verfahren zur herstellung eines bauelementes mit einer haftstruktur für eine turbomaschine und turbomaschine mit einem bauelement mit einer haftstruktur
US10995620B2 (en) 2018-06-21 2021-05-04 General Electric Company Turbomachine component with coating-capturing feature for thermal insulation
EP4421292A1 (de) * 2023-02-27 2024-08-28 Rolls-Royce plc Beschichtungssystem und verfahren zu dessen wartung

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0288156A1 (de) * 1987-03-24 1988-10-26 BAJ Limited Überzug
EP0776985A1 (de) * 1995-12-02 1997-06-04 Abb Research Ltd. Verfahren zur Aufbringung einer metallischen Haftschicht für keramische Wärmedämmschichten auf metallische Bauteile
DE10057187A1 (de) * 2000-11-17 2002-05-23 Alstom Switzerland Ltd Verfahren für die Herstellung von Verbundaufbauten zwischen metallischen und nichtmetallischen Materialien
EP1253294A2 (de) * 2001-04-28 2002-10-30 ALSTOM (Switzerland) Ltd Gasturbinendichtung

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0288156A1 (de) * 1987-03-24 1988-10-26 BAJ Limited Überzug
EP0776985A1 (de) * 1995-12-02 1997-06-04 Abb Research Ltd. Verfahren zur Aufbringung einer metallischen Haftschicht für keramische Wärmedämmschichten auf metallische Bauteile
DE10057187A1 (de) * 2000-11-17 2002-05-23 Alstom Switzerland Ltd Verfahren für die Herstellung von Verbundaufbauten zwischen metallischen und nichtmetallischen Materialien
EP1253294A2 (de) * 2001-04-28 2002-10-30 ALSTOM (Switzerland) Ltd Gasturbinendichtung

Cited By (25)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1522604B1 (de) * 2003-10-02 2007-02-14 Siemens Aktiengesellschaft Schichtsystem und Verfahren zur Herstellung eines Schichtsystems
DE102005050873A1 (de) * 2005-10-21 2007-04-26 Rolls-Royce Deutschland Ltd & Co Kg Verfahren zur Herstellung einer segmentierten Beschichtung und nach dem Verfahren hergestelltes Bauteil
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
WO2008153709A1 (en) * 2007-05-22 2008-12-18 Corning Incorporated Method for bonding refractory ceramic and metal related application
CN101827952B (zh) * 2007-05-22 2012-08-08 康宁股份有限公司 接合耐火陶瓷和金属的相关应用的方法
DE102011077620A1 (de) 2011-06-16 2012-12-20 Rolls-Royce Deutschland Ltd & Co Kg Bauelement, Verfahren zur Herstellung eines Bauelementes und Flugzeugtriebwerk mit einem Bauelement
US9458763B2 (en) 2011-11-04 2016-10-04 Rolls-Royce Deutschland Ltd & Co Kg Component and turbomachine having a component
DE102011085801A1 (de) 2011-11-04 2013-05-08 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Bauelement und Turbomaschine mit einem Bauelement
EP2589872A2 (de) 2011-11-04 2013-05-08 Rolls-Royce Deutschland Ltd & Co KG Bauelement und Turbomaschine mit einem solchen Bauelement
US10215034B2 (en) 2012-10-05 2019-02-26 Siemens Aktiengesellschaft Method for treating a gas turbine blade and gas turbine having said blade
WO2014053185A1 (de) * 2012-10-05 2014-04-10 Siemens Aktiengesellschaft Verfahren zur aufbereitung einer gasturbinenschaufel sowie gasturbine mit derartiger schaufel
US10995625B2 (en) 2012-10-05 2021-05-04 Siemens Aktiengesellschaft Method for treating a gas turbine blade and gas turbine having said blade
US9243511B2 (en) 2014-02-25 2016-01-26 Siemens Aktiengesellschaft Turbine abradable layer with zig zag groove pattern
US9920646B2 (en) 2014-02-25 2018-03-20 Siemens Aktiengesellschaft Turbine abradable layer with compound angle, asymmetric surface area ridge and groove pattern
US9151175B2 (en) 2014-02-25 2015-10-06 Siemens Aktiengesellschaft Turbine abradable layer with progressive wear zone multi level ridge arrays
US10189082B2 (en) 2014-02-25 2019-01-29 Siemens Aktiengesellschaft Turbine shroud with abradable layer having dimpled forward zone
US10196920B2 (en) 2014-02-25 2019-02-05 Siemens Aktiengesellschaft Turbine component thermal barrier coating with crack isolating engineered groove features
US10221716B2 (en) 2014-02-25 2019-03-05 Siemens Aktiengesellschaft Turbine abradable layer with inclined angle surface ridge or groove pattern
US10323533B2 (en) 2014-02-25 2019-06-18 Siemens Aktiengesellschaft Turbine component thermal barrier coating with depth-varying material properties
US10190435B2 (en) 2015-02-18 2019-01-29 Siemens Aktiengesellschaft Turbine shroud with abradable layer having ridges with holes
US10408079B2 (en) 2015-02-18 2019-09-10 Siemens Aktiengesellschaft Forming cooling passages in thermal barrier coated, combustion turbine superalloy components
US10995620B2 (en) 2018-06-21 2021-05-04 General Electric Company Turbomachine component with coating-capturing feature for thermal insulation
EP3611343A1 (de) 2018-08-13 2020-02-19 Rolls-Royce Deutschland Ltd & Co KG Bauelement mit einer haftstruktur für eine turbomaschine, verfahren zur herstellung eines bauelementes mit einer haftstruktur für eine turbomaschine und turbomaschine mit einem bauelement mit einer haftstruktur
US11073029B2 (en) 2018-08-13 2021-07-27 Rolls-Royce Deutschland Ltd & Co Kg Construction element having a bond structure for a turbo engine, method for the production of a construction element having a bond structure for a turbo engine, and turbo engine having a construction element having a bond structure
EP4421292A1 (de) * 2023-02-27 2024-08-28 Rolls-Royce plc Beschichtungssystem und verfahren zu dessen wartung

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