EP1591549A1 - Method for repairing local damage to a thermal barrier coating of a component - Google Patents

Method for repairing local damage to a thermal barrier coating of a component Download PDF

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Publication number
EP1591549A1
EP1591549A1 EP04101783A EP04101783A EP1591549A1 EP 1591549 A1 EP1591549 A1 EP 1591549A1 EP 04101783 A EP04101783 A EP 04101783A EP 04101783 A EP04101783 A EP 04101783A EP 1591549 A1 EP1591549 A1 EP 1591549A1
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EP
European Patent Office
Prior art keywords
layer
heat protection
adhesive layer
protection layer
heat
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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.)
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Application number
EP04101783A
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German (de)
French (fr)
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EP1591549B1 (en
Inventor
Andreas Bögli
Maxim Dr. Konter
Regina Dr. Schlegel
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General Electric Technology GmbH
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Alstom Technology AG
Alstom Schweiz AG
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Priority to AT04101783T priority Critical patent/ATE462023T1/en
Priority to EP04101783A priority patent/EP1591549B1/en
Priority to DE502004010936T priority patent/DE502004010936D1/en
Publication of EP1591549A1 publication Critical patent/EP1591549A1/en
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Publication of EP1591549B1 publication Critical patent/EP1591549B1/en
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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
    • 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
    • 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
    • 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
    • C23C4/01—Selective coating, e.g. pattern coating, without pre-treatment of the material to be coated
    • 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
    • F01D5/005—Repairing methods or devices
    • 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
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23R—GENERATING COMBUSTION PRODUCTS OF HIGH PRESSURE OR HIGH VELOCITY, e.g. GAS-TURBINE COMBUSTION CHAMBERS
    • F23R2900/00—Special features of, or arrangements for continuous combustion chambers; Combustion processes therefor
    • F23R2900/00019—Repairing or maintaining combustion chamber liners or subparts

Definitions

  • the present invention relates to the field of thermal Machinery. It relates to a method for repairing a local damage in the heat protection coating of a component according to the preamble of Claim 1.
  • the multi-layer heat protection coating usually comprises an adhesive layer applied to the base material (Bond Coating BC) and the actual heat protection layer (Thermal Barrier Coating TBC), most of which are ceramic (e.g., columnar) Material exists.
  • BC Ond Coating BC
  • TBC Thermal Barrier Coating
  • In operation forms at the boundary between the adhesive layer and the heat protection layer still a thermally grown oxide layer (Thermally Grown Oxide TGO) from which the adhesive layer against further Oxidation and corrosion protects and the adhesion of the heat protection layer continues improved.
  • the object is solved by the entirety of the features of claim 1.
  • the essence of the invention is that before the direct application of a ceramic filling layer first, the metallic adhesive layer up to a predetermined depth is removed to defined ratios in the restore chemical composition of the adhesive layer. This will it is possible the original mechanical properties of the Heat protection coating also in the area of repaired local To realize damage.
  • a preferred embodiment of the inventive method is characterized characterized in that the adhesive layer in the upper thickness range one of the has original deviant chemical composition, and that the predetermined depth is selected so that at least the thickness range of Adhesive layer with the deviating chemical composition removed becomes.
  • a thermally grown oxide layer is arranged before the removal of the adhesive layer first in a cleaning process in the area the local damage any residues of the heat protection layer and the Oxide layer removed.
  • the thickness of the adhesive layer can be selectively reduced and unnecessary material removal is avoided, it is expedient that the removal of the adhesive layer, the remaining thickness is controlled. This is preferably done in that the thickness control the FSEC (F requency S canning E ddy C urrent) technique is used.
  • FSEC Frequency S canning E ddy C urrent
  • the ceramic filling layer is applied beyond the surface of the heat protection layer, and if the surface of the ceramic filling layer then by mechanical Machining, in particular grinding and / or polishing, the surface of Heat protection layer is adjusted.
  • the inventive method can be installed in particular on site Components is performed. It can also be used as part of service work or to repair new components.
  • the method shown in Fig. 1-4 is based on a from a Base material 11 manufactured component 10, e.g. a turbine blade or the like.,
  • the on the outer surface with a heat protection coating 12, 13, 14 is provided.
  • the heat protection coating 12, 13, 14 comprises a directly on the surface of the Base material 11 applied metallic adhesive layer (bond coating BC) 12, and a ceramic heat protection layer disposed over the adhesion layer 12 (Thermal barrier coating TBC) 14.
  • Thermal barrier coating TBC Thermally grown oxide layer
  • thermally grown oxide TBO thermally grown oxide
  • the heat protection coating 12, 13, 14 now has a local according to FIG. 1 Damage 15, which essentially results in a local flaking of the ceramic heat protection layer 14 consists.
  • the Heat protection layer 14 completely chipped, while the oxide layer 13 and the underlying metallic adhesive layer 12 are virtually intact. Let it However, there are other configurations of local damage imagine, for example, parts of the heat protection layer 14 still are present, or the layers 13 and 12 are partially damaged.
  • a suitable Material removal method Remains of the ceramic heat protection layer 14 and the underlying Oxide layer 13 or its radicals by means of a suitable Material removal method removed.
  • the material removal is preferably carried out through suitable masks 18, which ensure that the lateral Extent of material removal is limited and defined. Furthermore result from the use of masks 18 evenly beveled Edge areas on the layers 12, 13, 14, for the liability of the later padded material are beneficial.
  • the underlying metallic adhesive layer 12 within the Material removal 16 is removed to a predetermined depth (Fig. 2).
  • the predetermined depth of the removal of the adhesive layer 12 depends on how far in the depth of the chemical composition of the adhesive layer 12 compared to the original chemical composition due to Surface processes such as e.g. the formation of the oxide layer 13 has changed.
  • test method which is called FSECT (Frequency Scanning eddy current) technique is known and induced the formation of Eddy currents in an electrically conductive multi-layer composite in dependence from the induction frequency.
  • FIG. 3 On this newly formed surface of the adhesive layer 12 is now shown in FIG. 3 one of the heat protection layer 14 in composition and orientation corresponding ceramic filling layer 17 applied, which by the local Damage 15 and the material removal resulting depression fills and even beyond the surface 20 of the heat protection layer 14 ( Figure 4). Also the order of the ceramic filling layer 17 can by suitable masks 19 through to limit the order laterally.
  • the remaining adhesive layer 12 has the same properties as the original adhesive layer, results in a layer composite 11, 12, 17, the has largely the same mechanical properties as the original layer composite 11, 12, 14 before the formation of the oxide layer 13.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • General Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Coating By Spraying Or Casting (AREA)

Abstract

Process for improving local damage in the heat protection coating (14) of a component comprises removing a metallic adhesion layer (12) to a prescribed depth and applying a ceramic filler layer (17) on the adhesion layer to fill the heat protection layer.

Description

TECHNISCHES GEBIETTECHNICAL AREA

Die vorliegende Erfindung bezieht sich auf das Gebiet der thermischen Maschinen. Sie betrifft ein Verfahren zum Ausbessern einer lokalen Beschädigung in der Hitzeschutzbeschichtung eines Bauteils gemäss dem Oberbegriff des Anspruchs 1.The present invention relates to the field of thermal Machinery. It relates to a method for repairing a local damage in the heat protection coating of a component according to the preamble of Claim 1.

STAND DER TECHNIKSTATE OF THE ART

Thermisch stark beanspruchte Bauteile, wie sie beispielsweise bei der Beschaufelung, der Brennkammerauskleidung oder als Schutzschilde im Heissgaskanal einer Gasturbine eingesetzt sind, werden häufig mit einer metallischen Schutzschicht oder einer mehrschichtigen Hitzeschutzbeschichtung überzogen, um das darunterliegende Basismaterial vor den über höher werdenden Heissgastemperaturen zu schützen. Die mehrschichtige Hitzeschutzbeschichtung umfasst dabei meist eine auf das Basismaterial aufgebrachte Haftschicht (Bond Coating BC) und die eigentliche Hitzeschutzschicht (Thermal Barrier Coating TBC), die meist aus einem (z.B. säulenförmig aufgetragenen) keramischen Material besteht. Im Betrieb bildet sich an der Grenze zwischen der Haftschicht und der Hitzeschutzschicht noch eine thermisch gewachsene Oxidschicht (Thermally Grown Oxide TGO) aus, welche die Haftschicht gegen weitere Oxidation und Korrosion schützt und die Haftung der Hitzeschutzschicht weiter verbessert.Highly stressed components, such as those in the Blading, the combustion chamber lining or as protective shields in the Hot gas duct of a gas turbine are often used with a metallic protective layer or a multi-layer heat protection coating coated to the underlying base material above the above To protect hot gas temperatures. The multi-layer heat protection coating usually comprises an adhesive layer applied to the base material (Bond Coating BC) and the actual heat protection layer (Thermal Barrier Coating TBC), most of which are ceramic (e.g., columnar) Material exists. In operation forms at the boundary between the adhesive layer and the heat protection layer still a thermally grown oxide layer (Thermally Grown Oxide TGO) from which the adhesive layer against further Oxidation and corrosion protects and the adhesion of the heat protection layer continues improved.

Durch die ständige thermische Wechselbelastung und den Einfluss der strömenden Heissgase und im Heissgasstrom mitgeführter Fremdkörper kann es bei längerem Betrieb zu lokalen Abplatzungen der Schutzbeschichtung kommen, die dann möglichst rasch und zuverlässig ausgebessert werden müssen, um den Betrieb möglichst schnell wieder aufnehmen und möglichst lange ungestört aufrechterhalten zu können. Zur Ausbesserung muss in den Bereichen der lokalen Beschädigung die Abfolge der Schichten der Schutzbeschichtung wieder sukzessive aufgebaut werden, so dass das Bauteil wieder vollumfänglich geschützt ist.Due to the constant thermal cycling and the influence of the flowing hot gases and in the hot gas flow entrained foreign body can during prolonged operation, local flaking of the protective coating occurs which must then be repaired as quickly and reliably as possible Resume operation as quickly as possible and undisturbed for as long as possible to be able to maintain. To be repaired must be in the areas of local Damage the sequence of layers of protective coating again be built successively so that the component again fully is protected.

Aus der EP-B1-0 808 913 ist ein Verfahren zur Reparatur von Hitzeschutzbeschichtungen bekannt, das die folgenden Schritte umfasst:

  • Es wird die Haftschicht BC, die durch die lokale Abplatzung exponiert ist, gereinigt, um Oxide und Reste der keramischen Hitzeschutzschicht TBC zu entfernen.
  • Die Haftschicht BC wird behandelt, um ihrer Oberfläche eine Struktur zu verleihen.
  • Es wird auf der Oberfläche der Haftschicht keramisches Material abgelagert, welches eine die Haftschicht vollständig bedeckende keramische Schicht bildet.
From EP-B1-0 808 913 a method for the repair of heat protection coatings is known, which comprises the following steps:
  • The adhesive layer BC exposed by the local spalling is cleaned to remove oxides and remnants of the ceramic heat protection layer TBC.
  • The adhesive layer BC is treated to impart a texture to its surface.
  • It is deposited on the surface of the adhesive layer ceramic material, which forms a completely covering the adhesive layer ceramic layer.

Weiterhin ist in der US-A-6,569,492 ein Verfahren zur Reparatur von beschädigten oder verbrauchten MCrAlY-Schichten eines Bauteils, offenbart, welches Bauteil bei Temperaturen eingesetzt worden ist, bei denen in der MCrAIY-Schicht eine Verarmung Al und Cr stattgefunden hat. Dieses Verfahren umfasst die folgenden Schritte:

  • Die MCrAlY-Schicht wird lokal durch Ersetzen mit neuem MCrAIY ausgebessert.
  • Die teilweise verarmte MCrAIY-Schicht wird auf der gesamten Oberfläche des Bauteils aluminisiert oder chromiert, so dass Al oder Cr zumindest teilweise in die verarmte MCrAIY-Schicht eindiffundieren und den Gehalt der MCrAIY-Schicht an Al oder Cr wieder auffüllen kann.
  • Das Verfahren ist auch anwendbar, selbst wenn eine keramische Beschichtung vorliegt. Die keramische Beschichtung, z.B. eine Hitzeschutzschicht TBC, die sich oberhalb der MCrAlY-Schicht befindet, wird mit einem geeigneten Verfahren, z.B. mittels Säurereinigung, entfernt, bevor die MCrAIY-Schicht in der oben beschriebenen Weise aufgearbeitet wird. Das Bauteil wird anschliessend wieder mit einer TBC-Schicht überzogen.
Further, US-A-6,569,492 discloses a method for repairing damaged or spent MCrAlY layers of a device, which device has been used at temperatures where depletion of Al and Cr has taken place in the MCrAlY layer. This procedure includes the following steps:
  • The MCrAlY layer is repaired locally by replacing with new MCrAIY.
  • The partially depleted MCrAlY layer is aluminised or chromium-plated over the entire surface of the device so that Al or Cr can at least partially diffuse into the depleted MCrAlY layer and replenish the content of the MCrAlY layer of Al or Cr.
  • The method is also applicable even if there is a ceramic coating. The ceramic coating, eg a thermal protection layer TBC, which is located above the MCrAlY layer is removed by a suitable method, eg by means of acid cleaning, before the MCrAlY layer is worked up in the manner described above. The component is then coated again with a TBC layer.

Weitere Ausbesserungsverfahren sind aus den Druckschriften US-A-5,735,448, US-A-6,042,880, US-A-6,203,847, US-A-6,235,352, US-A-6,274,193, US-A-6,305,077, US-A-6,465,040 und US-A-6,605,364 bekannt.Further repair methods are known from the documents US-A-5,735,448, US-A-6,042,880, US-A-6,203,847, US-A-6,235,352, US-A-6,274,193, US-A-6,305,077, US-A-6,465,040 and US-A-6,605,364.

Das bekannte Verfahren gemäss der EP-B1-0 808 913 birgt verschiedene Probleme und Nachteile:

  • Die Haftschicht wird nur bearbeitet, um deren Oberfläche zu strukturieren. Später entsteht eine thermisch gewachsene Oxidschicht (TGO) auf der Oberfläche der behandelten Haftschicht.
  • Die chemische Zusammensetzung der verbleibenden Haftschicht (BC) und der neu wachsende TGO-Schicht verändert sich, und zwar in erster Linie entsprechend dem Wachsen der TGO-Schicht.
  • Die verbleibende Haftschicht und die neu gewachsene TGO-Schicht haben im Vergleich zu ihrem ursprünglichen Zustand verschlechterte Eigenschaften:
  • o Wegen der internen Oxidation und Ausscheidung von sekundären Phasen (z.B. σ- oder α-Phasen) nahe der Oberfläche ist der Prozess nicht vorhersagbar.
  • o Nach dem Einsatz des Bauteils bei hohen Temperaturen ist im oberen Teil der Haftschicht (BC) wegen der Bildung des TGO und der Diffusion von Aluminium zur Oberfläche der Aluminiumgehalt deutlich verringert, d.h., die Schicht zeigt nahe der Oberfläche den niedrigsten Al-Gehalt. Es besteht daher die erhebliche Gefahr, dass anstelle von reinem Al2O3 gemischte Oxide wachsen und die Hitzeschutzschicht TBC schnell wieder abplatzt.
The known method according to EP-B1-0 808 913 has several problems and disadvantages:
  • The adhesive layer is only processed to structure its surface. Later, a thermally grown oxide layer (TGO) is formed on the surface of the treated adhesive layer.
  • The chemical composition of the remaining adhesive layer (BC) and the newly growing TGO layer changes, primarily according to the growth of the TGO layer.
  • The remaining adhesive layer and the newly grown TGO layer have degraded properties compared to their original state:
  • o Due to the internal oxidation and precipitation of secondary phases (eg σ- or α-phases) near the surface, the process is unpredictable.
  • o After use of the component at high temperatures, the aluminum content is significantly reduced in the upper part of the adhesive layer (BC) because of the formation of TGO and the diffusion of aluminum to the surface, ie the layer has the lowest Al content near the surface. There is therefore the considerable risk that, instead of pure Al 2 O 3, mixed oxides grow and the heat protection layer TBC rapidly flakes off again.

Beim Verfahren der US-A-6,569,492 ist nachteilig, dass die MCrAIY-Schicht aluminisiert bzw. chromiert werden muss, was nicht vor Ort an der Maschine durchgeführt werden kann.In the process of US Pat. No. 6,569,492, it is disadvantageous that the MCrAlY layer aluminized or chromized, which is not on site at the machine can be carried out.

DARSTELLUNG DER ERFINDUNGPRESENTATION OF THE INVENTION

Es ist Aufgabe der Erfindung, ein Verfahren zum Ausbessern einer lokalen Beschädigung in der Hitzeschutzbeschichtung eines Bauteils anzugeben, welches die Nachteile bekannter Verfahren vermeidet und sich insbesondere durch eine deutlich verbesserte Lebensdauer des ausgebesserten Bauteils auszeichnet.It is an object of the invention to provide a method for repairing a local Indicate damage in the heat protection coating of a component which avoid the disadvantages of known methods and in particular by a markedly improved service life of the repaired component.

Die Aufgabe wird durch die Gesamtheit der Merkmale des Anspruchs 1 gelöst. Der Kern der Erfindung liegt darin, dass vor dem direkten Auftragen einer keramischen Füllschicht zunächst die metallische Haftschicht bis zu einer vorgegebenen Tiefe abgetragen wird, um definierte Verhältnisse bei der chemischen Zusammensetzung der Haftschicht wiederherzustellen. Dadurch wird es möglich, die ursprünglichen mechanischen Eigenschaften der Hitzeschutzbeschichtung auch im Bereich der ausgebesserten lokalen Beschädigung zu verwirklichen.The object is solved by the entirety of the features of claim 1. The essence of the invention is that before the direct application of a ceramic filling layer first, the metallic adhesive layer up to a predetermined depth is removed to defined ratios in the restore chemical composition of the adhesive layer. This will it is possible the original mechanical properties of the Heat protection coating also in the area of repaired local To realize damage.

Eine bevorzugte Ausgestaltung des erfindungsgemässen Verfahrens zeichnet sich dadurch aus, dass die Haftschicht im oberen Dickenbereich eine von der ursprünglichen abweichende chemische Zusammensetzung aufweist, und dass die vorgegebene Tiefe so gewählt ist, dass zumindest der Dickenbereich der Haftschicht mit der abweichenden chemischen Zusammensetzung abgetragen wird.A preferred embodiment of the inventive method is characterized characterized in that the adhesive layer in the upper thickness range one of the has original deviant chemical composition, and that the predetermined depth is selected so that at least the thickness range of Adhesive layer with the deviating chemical composition removed becomes.

Insbesondere werden, wenn zwischen der Haftschicht und der darüber liegenden Hitzeschutzschicht eine thermisch gewachsene Oxidschicht angeordnet ist, vor dem Abtragen der Haftschicht zunächst in einem Reinigungsprozess im Bereich der lokalen Beschädigung etwaige Reste der Hitzeschutzschicht und der Oxidschicht entfernt.In particular, when between the adhesive layer and the overlying Heat protection layer, a thermally grown oxide layer is arranged before the removal of the adhesive layer first in a cleaning process in the area the local damage any residues of the heat protection layer and the Oxide layer removed.

Damit die Dicke der Haftschicht gezielt reduziert werden kann und unnötiger Materialabtrag vermieden wird, ist es zweckmässig, dass beim Abtragen der Haftschicht die verbleibende Dicke kontrolliert wird. Dies geschieht vorzugsweise dahingehend, dass zur Dickenkontrolle die FSEC(Frequency Scanning Eddy Current)-Technik eingesetzt wird.Thus, the thickness of the adhesive layer can be selectively reduced and unnecessary material removal is avoided, it is expedient that the removal of the adhesive layer, the remaining thickness is controlled. This is preferably done in that the thickness control the FSEC (F requency S canning E ddy C urrent) technique is used.

Besonders günstig ist es, wenn das Abtragen der Schichten und/oder das Auffüllen der Hitzeschutzschicht zur Erzeugung eines definierten Randbereichs durch entsprechende Masken hindurch erfolgt.It is particularly favorable if the removal of the layers and / or the Filling the heat protection layer to produce a defined edge area takes place through appropriate masks.

Um beim Reparieren eine möglichst gleichmässige Oberfläche des Bauteils zu erhalten, ist es von Vorteil, wenn im zweiten Schritt die keramische Füllschicht über die Oberfläche der Hitzeschutzschicht hinausgehend aufgetragen wird, und wenn die Oberfläche der keramischen Füllschicht dann durch mechanische Bearbeitung, insbesondere Schleifen und/oder Polieren, der Oberfläche der Hitzeschutzschicht angeglichen wird.In order to repair as even as possible a surface of the component obtained, it is advantageous if in the second step, the ceramic filling layer is applied beyond the surface of the heat protection layer, and if the surface of the ceramic filling layer then by mechanical Machining, in particular grinding and / or polishing, the surface of Heat protection layer is adjusted.

Das erfindungsgemässe Verfahren kann insbesondere vor Ort an eingebauten Bauteilen durchgeführt wird. Es kann aber auch im Rahmen von Servicearbeiten oder zur Ausbesserung neuer Bauteile durchgeführt wird. The inventive method can be installed in particular on site Components is performed. It can also be used as part of service work or to repair new components.

KURZE ERLÄUTERUNG DER FIGURENBRIEF EXPLANATION OF THE FIGURES

Die Erfindung soll nachfolgend anhand von Ausführungsbeispielen im Zusammenhang mit der Zeichnung näher erläutert werden. Es zeigen

Fig. 1-4
verschiedene Teilschritte bei der Reparatur einer lokalen Beschädigung der Hitzeschutzbeschichtung eines Bauteils gemäss einem bevorzugten Ausführungsbeispiel der Erfindung.
The invention will be explained in more detail with reference to embodiments in conjunction with the drawings. Show it
Fig. 1-4
Various sub-steps in the repair of a local damage of the heat protection coating of a component according to a preferred embodiment of the invention.

WEGE ZUR AUSFÜHRUNG DER ERFINDUNGWAYS FOR CARRYING OUT THE INVENTION

Das in Fig. 1-4 dargestellte Verfahren geht aus von einem aus einem Basismaterial 11 gefertigten Bauteil 10, z.B. einer Turbinenschaufel oder dgl., die auf der Aussenfläche mit einer Hitzeschutzbeschichtung 12, 13, 14 versehen ist. Die Hitzeschutzbeschichtung 12, 13, 14 umfasst eine direkt auf die Oberfläche des Basismaterials 11 aufgebrachte metallische Haftschicht (bond coating BC) 12, sowie eine über der Haftschicht 12 angeordnete keramische Hitzeschutzschicht (thermal barrier coating TBC) 14. Zwischen den beiden Schichten 12 und 14 befindet sich eine thermisch gewachsene Oxidschicht (thermally grown oxide TBO) 13, die entsteht, wenn das Bauteil 10 (z.B. während seines Einsatzes in einer Maschine) hohen Temperaturen ausgesetzt ist.The method shown in Fig. 1-4 is based on a from a Base material 11 manufactured component 10, e.g. a turbine blade or the like., The on the outer surface with a heat protection coating 12, 13, 14 is provided. The heat protection coating 12, 13, 14 comprises a directly on the surface of the Base material 11 applied metallic adhesive layer (bond coating BC) 12, and a ceramic heat protection layer disposed over the adhesion layer 12 (Thermal barrier coating TBC) 14. Between the two layers 12 and 14 is a thermally grown oxide layer (thermally grown oxide TBO) 13 which results when the component 10 (e.g., during its insertion into a machine) is exposed to high temperatures.

Die Hitzeschutzbeschichtung 12, 13, 14 hat nun gemäss Fig. 1 eine lokale Beschädigung 15, die im wesentlichen in einem lokalen Abplatzen der keramischen Hitzeschutzschicht 14 besteht. Im gezeigten Beispiel ist die Hitzeschutzschicht 14 vollständig abgeplatzt, während die Oxidschicht 13 und die darunter liegende metallische Haftschicht 12 praktisch unversehrt sind. Es lassen sich jedoch durchaus auch andere Konfigurationen der lokalen Beschädigung vorstellen, bei denen beispielsweise Teile der Hitzeschutzschicht 14 noch vorhanden sind, oder die Schichten 13 und 12 teilweise beschädigt sind. The heat protection coating 12, 13, 14 now has a local according to FIG. 1 Damage 15, which essentially results in a local flaking of the ceramic heat protection layer 14 consists. In the example shown is the Heat protection layer 14 completely chipped, while the oxide layer 13 and the underlying metallic adhesive layer 12 are virtually intact. Let it However, there are other configurations of local damage imagine, for example, parts of the heat protection layer 14 still are present, or the layers 13 and 12 are partially damaged.

In jedem Fall werden zunächst gemäss Fig. 1 in einem ersten Schritt etwaige Reste der keramischen Hitzeschutzschicht 14 sowie die darunterliegende Oxidschicht 13 oder deren Reste mittels eines geeigneten Materialabtragverfahrens abgetragen. Der Materialabtrag erfolgt vorzugsweise durch geeignete Masken 18 hindurch, die sicherstellen, dass die laterale Ausdehnung des Materialabtrags begrenzt und definiert ist. Darüber hinaus ergeben sich durch die Verwendung von Masken 18 gleichmässig abgeschrägte Randbereiche an den Schichten 12, 13, 14, die für die Haftung des später aufgefüllten Materials von Vorteil sind.In any case, initially in accordance with FIG. 1 in a first step Remains of the ceramic heat protection layer 14 and the underlying Oxide layer 13 or its radicals by means of a suitable Material removal method removed. The material removal is preferably carried out through suitable masks 18, which ensure that the lateral Extent of material removal is limited and defined. Furthermore result from the use of masks 18 evenly beveled Edge areas on the layers 12, 13, 14, for the liability of the later padded material are beneficial.

Wesentlich für die Qualität der Reparatur ist jedoch, dass über die Oxidschicht 13 hinaus die darunterliegende metallische Haftschicht 12 innerhalb des Materialabtrags 16 bis zu einer vorgegebenen Tiefe abgetragen wird (Fig. 2). Die vorgegebene Tiefe des Abtrags der Haftschicht 12 richtet sich danach, wie weit in die Tiefe hinein sich die chemische Zusammensetzung der Haftschicht 12 gegenüber der ursprünglichen chemischen Zusammensetzung aufgrund von Oberflächenprozessen wie z.B. der Bildung der Oxidschicht 13 verändert hat. Hat sich die chemische Zusammensetzung der Haftschicht 12 beispielsweise in der oberen Hälfte der Schichtdicke verändert, wird etwas mehr als die Hälfte der Haftschicht 12 abgetragen, um sicherzugehen, dass die nach dem Abtrag neu entstehende Oberfläche der Haftschicht 12 die ursprüngliche chemische Zusammensetzung aufweist. Damit der Abtrag der Haftschicht 12 nur so tief wie nötig erfolgt, ist es von Vorteil, die Restdicke der Haftschicht ein oder mehrere Male während des Abtragsprozesses zu messen und kontrollieren. Als geeignet für diese Messung hat sich Prüfverfahren erwiesen, das als FSECT(Frequency Scanning Eddy Current)-Technik bekannt ist und die Ausbildung von induzierten Wirbelströmen in einem elektrisch leitenden Mehrschichtverbund in Abhängigkeit von der Induktionsfrequenz auswertet.Essential for the quality of the repair, however, is that via the oxide layer 13 In addition, the underlying metallic adhesive layer 12 within the Material removal 16 is removed to a predetermined depth (Fig. 2). The predetermined depth of the removal of the adhesive layer 12 depends on how far in the depth of the chemical composition of the adhesive layer 12 compared to the original chemical composition due to Surface processes such as e.g. the formation of the oxide layer 13 has changed. Has the chemical composition of the adhesive layer 12, for example in the the upper half of the layer thickness changes, is slightly more than half of the Adhesive layer 12 removed to ensure that after the removal of new resulting surface of the adhesive layer 12 the original chemical Composition has. Thus, the removal of the adhesive layer 12 only as deep as is necessary, it is advantageous, the remaining thickness of the adhesive layer one or more Measure and check times during the removal process. As suitable For this measurement has proved test method, which is called FSECT (Frequency Scanning eddy current) technique is known and induced the formation of Eddy currents in an electrically conductive multi-layer composite in dependence from the induction frequency.

Auf diese neu entstandene Oberfläche der Haftschicht 12 wird nun gemäss Fig. 3 einer der Hitzeschutzschicht 14 in Zusammensetzung und Orientierung entsprechende keramische Füllschicht 17 aufgebracht, welche die durch die lokale Beschädigung 15 und den Materialabtrag entstandene Vertiefung auffüllt und sogar über die Oberfläche 20 der Hitzeschutzschicht 14 (Fig. 4) hinausreicht. Auch der Auftrag der keramischen Füllschicht 17 kann durch geeignete Masken 19 hindurch erfolgen, um den Auftrag lateral zu begrenzen.On this newly formed surface of the adhesive layer 12 is now shown in FIG. 3 one of the heat protection layer 14 in composition and orientation corresponding ceramic filling layer 17 applied, which by the local Damage 15 and the material removal resulting depression fills and even beyond the surface 20 of the heat protection layer 14 (Figure 4). Also the order of the ceramic filling layer 17 can by suitable masks 19 through to limit the order laterally.

Da die verbleibende Haftschicht 12 dieselben Eigenschaften aufweist, wie die ursprüngliche Haftschicht, ergibt sich ein Schichtverbund 11, 12, 17, der die weitgehend die gleichen mechanischen Eigenschaften aufweist, wie der ursprüngliche Schichtverbund 11, 12, 14 vor dem Entstehen der Oxidschicht 13.Since the remaining adhesive layer 12 has the same properties as the original adhesive layer, results in a layer composite 11, 12, 17, the has largely the same mechanical properties as the original layer composite 11, 12, 14 before the formation of the oxide layer 13.

Bei Einsatz transportabler Geräte für den Materialabtrag und den Auftrag der keramischen Füllschicht 17 kann das beschriebene Reparaturverfahren ohne Schwierigkeiten zur Ausbesserung lokaler Beschädigungen bei eingebauten Bauteilen "vor Ort" erfolgen. Es ist aber auch denkbar, das Verfahren im Rahmen von Servicearbeiten oder zur Ausbesserung neuer Bauteile durchzuführen.When using portable equipment for material removal and the order of ceramic filling layer 17, the repair method described without Trouble repairing local damage when installed Components are made "on site". It is also conceivable, the procedure in the context servicing or repairing new components.

BEZUGSZEICHENLISTELIST OF REFERENCE NUMBERS

1010
Bauteilcomponent
1111
Basismaterial (Bauteil)Base material (component)
1212
Haftschicht (bond coating BC)Adhesive layer (bond coating BC)
1313
Oxidschicht (thermisch gewachsen; TGO)Oxide layer (thermally grown, TGO)
1414
Hitzeschutzschicht (keramisch; TBC)Heat protection layer (ceramic, TBC)
1515
lokale Beschädigung (Abplatzung)local damage (spalling)
1616
Materialabtragmaterial removal
1717
keramische Füllschichtceramic filling layer
18,1918.19
Maskemask
2020
Oberflächesurface

Claims (9)

Verfahren zum Ausbessern einer lokalen Beschädigung (15) in der Hitzeschutzbeschichtung eines Bauteils (10), wobei die Hitzeschutzbeschichtung eine metallische Haftschicht (12) und eine über der metallischen Haftschicht (12) aufgebrachte keramische Hitzeschutzschicht (14) umfasst, und wobei die lokale Beschädigung (15) durch ein lokales Abplatzen der Hitzeschutzschicht (14) hervorgerufen worden ist, dadurch gekennzeichnet, dass in einem ersten Schritt die metallische Haftschicht (12) bis zu einer vorgegebenen Tiefe abgetragen wird, und dass in einem zweiten Schritt auf die dickenreduzierte Haftschicht (12) zum Auffüllen der Hitzeschutzschicht (14) eine keramische Füllschicht (17) aufgetragen wird.A method for repairing a local damage (15) in the heat-protective coating of a component (10), wherein the heat-protective coating comprises a metallic adhesive layer (12) and a ceramic heat-protective layer (14) applied over the metallic adhesive layer (12), and wherein the local damage ( 15) has been caused by a local flaking of the heat protection layer (14), characterized in that in a first step the metallic adhesive layer (12) is removed to a predetermined depth, and that in a second step, the thickness-reduced adhesive layer (12) for filling the heat protection layer (14), a ceramic filling layer (17) is applied. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass die Haftschicht (12) im oberen Dickenbereich eine von der ursprünglichen abweichende chemische Zusammensetzung aufweist, und dass die vorgegebene Tiefe so gewählt ist, dass zumindest der Dickenbereich der Haftschicht (12) mit der abweichenden chemischen Zusammensetzung abgetragen wird.A method according to claim 1, characterized in that the adhesive layer (12) in the upper thickness range has a different chemical composition from the original, and that the predetermined depth is selected so that at least the thickness range of the adhesive layer (12) with the deviating chemical composition removed becomes. Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass zwischen der Haftschicht (12) und der darüber liegenden Hitzeschutzschicht (13) eine thermisch gewachsene Oxidschicht (13) angeordnet ist, und dass vor dem Abtragen der Haftschicht (12) zunächst in einem Reinigungsprozess im Bereich der lokalen Beschädigung (15) etwaige Reste der Hitzeschutzschicht (14) und einer Oxidschicht (13) entfernt werden.Method according to claim 1 or 2, characterized in that a thermally grown oxide layer (13) is arranged between the adhesion layer (12) and the overlying heat protection layer (13), and that before the removal of the adhesion layer (12), first in a cleaning process in the Area of local damage (15) any residues of the heat protection layer (14) and an oxide layer (13) are removed. Verfahren nach einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, dass beim Abtragen der Haftschicht (12) die verbleibende Dicke kontrolliert wird. Method according to one of claims 1 to 3, characterized in that the removal of the adhesive layer (12), the remaining thickness is controlled. Verfahren nach Anspruch 4, dadurch gekennzeichnet, dass zur Dickenkontrolle die FSEC(Frequency Scanning Eddy Current)-Technik eingesetzt wird.A method according to claim 4, characterized in that (F requency S canning urrent E ddy C) to the thickness control, the FSEC technique is used. Verfahren nach einem der Ansprüche 1 bis 5, dadurch gekennzeichnet, dass das Abtragen der Schichten (12, 13) und/oder das Auffüllen der Hitzeschutzschicht (14) zur Erzeugung eines definierten Randbereichs durch entsprechende Masken (18, 19) hindurch erfolgt.Method according to one of claims 1 to 5, characterized in that the removal of the layers (12, 13) and / or the filling of the heat protection layer (14) for generating a defined edge region through corresponding masks (18, 19) through. Verfahren nach einem der Ansprüche 1 bis 6, dadurch gekennzeichnet, dass im zweiten Schritt die keramische Füllschicht (17) über die Oberfläche (20) der Hitzeschutzschicht (14) hinausgehend aufgetragen wird, und dass die Oberfläche der keramischen Füllschicht (17) dann durch mechanische Bearbeitung, insbesondere Schleifen und/oder Polieren, der Oberfläche (20) der Hitzeschutzschicht (14) angeglichen wird.Method according to one of claims 1 to 6, characterized in that in the second step, the ceramic filling layer (17) over the surface (20) of the heat protection layer (14) outgoing is applied, and that the surface of the ceramic filling layer (17) then by mechanical Processing, in particular grinding and / or polishing, the surface (20) of the heat protection layer (14) is adjusted. Verfahren nach einem der Ansprüche 1 bis 7, dadurch gekennzeichnet, dass das Verfahren vor Ort an eingebauten Bauteilen (10) durchgeführt wird.Method according to one of claims 1 to 7, characterized in that the method is performed on-site on built-in components (10). Verfahren nach einem der Ansprüche 1 bis 7, dadurch gekennzeichnet, dass das Verfahren im Rahmen von Servicearbeiten oder zur Ausbesserung neuer Bauteile (10) durchgeführt wird.Method according to one of claims 1 to 7, characterized in that the method is carried out in the context of service work or for repair of new components (10).
EP04101783A 2004-04-28 2004-04-28 Method for repairing local damage to a thermal barrier coating of a component Expired - Lifetime EP1591549B1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
AT04101783T ATE462023T1 (en) 2004-04-28 2004-04-28 METHOD FOR REPAIRING LOCAL DAMAGE IN THE HEAT PROTECTION COATING OF A COMPONENT
EP04101783A EP1591549B1 (en) 2004-04-28 2004-04-28 Method for repairing local damage to a thermal barrier coating of a component
DE502004010936T DE502004010936D1 (en) 2004-04-28 2004-04-28 Method for repairing local damage in the heat-protective coating of a component

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EP04101783A EP1591549B1 (en) 2004-04-28 2004-04-28 Method for repairing local damage to a thermal barrier coating of a component

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EP1794340A1 (en) * 2004-10-07 2007-06-13 Siemens Aktiengesellschaft Method for producing a layer system
US8221825B2 (en) 2009-03-30 2012-07-17 Alstom Technology Ltd. Comprehensive method for local application and local repair of thermal barrier coatings
EP3202954A1 (en) * 2016-02-08 2017-08-09 United Technologies Corporation Repairing a coating with a pre-configured coating patch
US10717166B2 (en) 2016-12-02 2020-07-21 General Electric Company Motorized apparatus for use with rotary machines
WO2020233925A1 (en) * 2019-05-22 2020-11-26 Siemens Aktiengesellschaft Method for carrying out method for implementing energy conversion installation service measures, and energy conversion installation

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US10494926B2 (en) 2017-08-28 2019-12-03 General Electric Company System and method for maintaining machines

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EP0808913A1 (en) * 1996-05-24 1997-11-26 General Electric Company Method for repairing a thermal barrier coating
US6235352B1 (en) * 1999-11-29 2001-05-22 Electric Power Research Institute, Inc. Method of repairing a thermal barrier coating
EP1197585A2 (en) * 2000-10-12 2002-04-17 General Electric Company Method for repairing a thermal barrier coating and repaired coating formed thereby

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EP0808913A1 (en) * 1996-05-24 1997-11-26 General Electric Company Method for repairing a thermal barrier coating
US6235352B1 (en) * 1999-11-29 2001-05-22 Electric Power Research Institute, Inc. Method of repairing a thermal barrier coating
EP1197585A2 (en) * 2000-10-12 2002-04-17 General Electric Company Method for repairing a thermal barrier coating and repaired coating formed thereby

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1794340A1 (en) * 2004-10-07 2007-06-13 Siemens Aktiengesellschaft Method for producing a layer system
EP1794341A1 (en) * 2004-10-07 2007-06-13 Siemens Aktiengesellschaft Method for producing a layer system
US8221825B2 (en) 2009-03-30 2012-07-17 Alstom Technology Ltd. Comprehensive method for local application and local repair of thermal barrier coatings
EP3202954A1 (en) * 2016-02-08 2017-08-09 United Technologies Corporation Repairing a coating with a pre-configured coating patch
US10927684B2 (en) 2016-02-08 2021-02-23 Raytheon Technologies Corporation Repairing a coating with a pre-configured coating patch
US10717166B2 (en) 2016-12-02 2020-07-21 General Electric Company Motorized apparatus for use with rotary machines
WO2020233925A1 (en) * 2019-05-22 2020-11-26 Siemens Aktiengesellschaft Method for carrying out method for implementing energy conversion installation service measures, and energy conversion installation
US12055063B2 (en) 2019-05-22 2024-08-06 Siemens Energy Global GmbH & Co. KG Method for carrying out servicing measures on an energy conversion installation

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ATE462023T1 (en) 2010-04-15
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