EP1705266A2 - Auftragen einer Haftbeschichtung auf Motorbauteile mittels eines Kaltsprühverfahrens - Google Patents

Auftragen einer Haftbeschichtung auf Motorbauteile mittels eines Kaltsprühverfahrens Download PDF

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Publication number
EP1705266A2
EP1705266A2 EP06251532A EP06251532A EP1705266A2 EP 1705266 A2 EP1705266 A2 EP 1705266A2 EP 06251532 A EP06251532 A EP 06251532A EP 06251532 A EP06251532 A EP 06251532A EP 1705266 A2 EP1705266 A2 EP 1705266A2
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EP
European Patent Office
Prior art keywords
step comprises
process according
scfm
range
depositing
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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.)
Granted
Application number
EP06251532A
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English (en)
French (fr)
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EP1705266A3 (de
EP1705266B1 (de
Inventor
Andrew Debiccari
Melvin Freling
Jeffrey D. Haynes
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.)
RTX Corp
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United Technologies Corp
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Filing date
Publication date
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Publication of EP1705266A2 publication Critical patent/EP1705266A2/de
Publication of EP1705266A3 publication Critical patent/EP1705266A3/de
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Publication of EP1705266B1 publication Critical patent/EP1705266B1/de
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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
    • F01D5/288—Protective coatings for blades
    • 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
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/02—Coating starting from inorganic powder by application of pressure only
    • C23C24/04—Impact or kinetic deposition of particles
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/90—Coating; Surface treatment
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
    • F05D2300/611—Coating

Definitions

  • the present invention relates to a process for applying a coating to a component, such as a turbine blade or a combustion chamber liners, used in an engine.
  • LPPS low-pressure plasma spray
  • Cold gas dynamic spraying or "cold spray” has been recently introduced as a new metallization spray technique to deposit powder metal without inclusions onto a substrate.
  • a supersonic jet of helium and/or nitrogen is formed by a converging/diverging nozzle and is used to accelerate the powder particles toward the substrate to produce cold spray deposits or coatings. Deposits adhere to the substrate and previously deposited layers through plastic deformation and bonding.
  • U.S. Patent Nos. 5,302,414 and 6,502,767 illustrate cold gas dynamic spraying techniques.
  • the process of the present invention has particular utility in applying bond coats to airfoil portions of turbine blades, vanes or combustion chamber liners for protection against oxidation.
  • the present invention relates to a process for applying a coating to a component used in an engine.
  • the process of the present invention may be used to apply a MCrAlY coating to at least one surface of an airfoil portion on a turbine blade where M is Ni and/or Co or a variation. It may also be used to apply a bond coat to a combustion chamber liner used in rocket engines.
  • the cold spray process for depositing powdered materials onto portions of a component which needs to be restored is advantageous in that it provides sufficient energy to accelerate particles to high enough velocities such that, upon impact, the particles plastically deform and bond to the surface of the component being restored or onto a previously deposited layer.
  • the cold spray process allows the build up of a relative dense coating or structural deposit. Cold spray does not metallurgically transform the particles from their solid state.
  • any pre-existing coating on the article or component When preparing to coat an article or component, it is often necessary to remove any pre-existing coating on the article or component. Any suitable stripping technique may be used to remove any pre-existing coating and to provide a fresh surface to which a coating material can be deposited. For example, any pre-existing coating may be stripped using mechanical or chemical techniques.
  • the article or component 10 may be a turbine blade or vane used in a turbine engine.
  • the system 8 includes a spray gun 22 having a converging/diverging nozzle 20 through which the powdered coating material is sprayed onto the surface 24.
  • the article or component 10 may be formed from any suitable material known in the art.
  • the article or component 10 may be formed from a superalloy material such as a nickel based alloy.
  • the article or component 10 may be formed from a nickel or copper-based alloy.
  • the article or component 10 may be held stationary or may be articulated, rotated, or translated by any suitable means (not shown) known in the art.
  • the material to be deposited is a powdered material.
  • the powdered coating material may comprise any suitable coating material known in the art.
  • the coating material can be a MCrAlY material where M is nickel or cobalt, such as NiCoCrAlY, NiCrAlY or CoCrAlY.
  • the coating material may be a copper alloy such as a copper-chromium alloy or a copper-chromium-aluminum alloy.
  • the coating material may form a stand alone coating or a bond coat for metallic and ceramic overcoats.
  • the powdered coating materials that are used to form the deposit on the surface 24 may have a diameter of 5-80 microns, preferably a diameter of 10 microns or less if the alloy material being deposited is hard. In a most preferred embodiment, the powdered coating materials has a diameter in the range of from about 5.0 microns to 10 microns. Smaller particle sizes enable the achievement of higher particle velocities. Below 5 microns in diameter, the particles risk getting swept away from the surface 24 due to a bow shock layer above the surface 24, i.e. insufficient mass to propel the particle through the bow shock. The narrower the particle size distribution, the more uniform the particle velocity will be. This is because the smaller particles in the spray/plume will hit the slower, larger ones and effectively reduce the velocity of both.
  • the particles to be deposited may be accelerated to supersonic velocities using compressed gas, such as a gas selected from the group consisting of helium, nitrogen, another inert gas, and mixtures thereof.
  • compressed gas such as a gas selected from the group consisting of helium, nitrogen, another inert gas, and mixtures thereof.
  • Helium is a preferred gas because it produces the highest velocity due to its low molecular weight.
  • the bonding mechanism employed by the process of the present invention for transforming the powdered coating material into a deposit is strictly solid state, meaning that the particles plastically deform but do not melt. Any oxide layer that may have formed on the particles, or is present on the surface 24, or is present in a previously deposited layer, is broken up and fresh oxide-free contact is made at very high pressures.
  • the powdered coating material used to form the deposit may be fed to the spray gun 22 using any thermal spray feeder known in the art with the capability to feed the powder or the stated size.
  • One such feeder that may be used is manufactured by Powder Feed Dynamics of Cleveland, Ohio. This feeder has an auger type feed mechanism. Fluidized bed feeders and barrel roll feeders with an angular slit may also be used.
  • the feeder may be pressurized with a gas selected from the group consisting of helium, nitrogen, another inert gas, and mixtures thereof.
  • Feeder pressures are generally 15 psi (103 kPa) above the main gas or head pressures, which pressures are usually in the range of from 200 psi (1.38 MPa) to 500 psi (3.45 MPa), depending on the powdered coating material composition.
  • the main gas is preferably heated so that gas temperatures are in the range of from 600 degrees Fahrenheit (315°C)to 1200 degrees Fahrenheit (649°C). If desired, the main gas may be heated as high as approximately 1250 degrees Fahrenheit (677°C) depending on the material being deposited.
  • the gas may be heated to keep it from rapidly cooling and freezing once it expands past the throat of nozzle 20.
  • the net effect is a surface temperature on the article or component 10 of about 115 degrees Fahrenheit (46°C) during deposition. Any suitable means known in the art may be used to heat the gas.
  • the nozzle 20 may pass over the surface 24 of the article or component 10.
  • the number of passes is a function of the thickness of the material to be applied.
  • the process of the present invention is capable of forming a deposit having any desired thickness.
  • the main gas that is used to deposit the powdered metal particles onto the surface 24 may be passed through the nozzle 20 via inlet 30 at a flow rate of from 0.001 SCFM (0.028 1/m) to 50 SCFM (1416 l/m), preferably in the range of from 15 SCFM (425 1/m) to 35 SCFM (991 l/m).
  • the foregoing flow rates are preferred if helium is used as the main gas.
  • the nitrogen may be passed through the nozzle 20 at a flow rate of from 0.001 SCFM (0.028 l/m) to 30 SCFM (849 l/m), preferably from 4.0 SCFM (113 l/m) to 30 SCFM (849 l/m), more preferably 4.0 SCFM (113 l/m) to 8.0 SCFM (227 l/m).
  • the main gas temperature may be in the range of from 600 degrees Fahrenheit (315°C) to 1200 degrees Fahrenheit (649°C), preferably from 700 degrees Fahrenheit (371°C) to 1000 degrees Fahrenheit (539°C), and most preferably from 725 degrees Fahrenheit (385°C) to 900 degrees Fahrenheit (482°C).
  • the pressure of the spray gun 22 may be in the range of from 200 psi (1.38 MPa) to 500 psi (3.45 MPa), preferably from 200 psi (1.38 MPa) to 400 psi (2.76 MPa), and most preferably from 275 psi (1.80 MPa) to 375 psi (2.59 MPa).
  • the powdered coating material is preferably fed from a hopper, which is under a pressure in the range of from 10 (69 kPa) to 50 psi (345 kPa) higher than the specific main gas pressure, preferably 15 psi (103 kPa) higher, to the spray gun 22 via line 34 at a rate in the range of from 10 grams/min to 100 grams/min, preferably from 10 grams/min to 50 grams/min.
  • the powdered coating material is fed to the spray gun 22 using a non-oxidizing carrier gas.
  • the carrier gas may be introduced via inlet 30 at a flow rate of from 0.001 SCFM (0.028 1/m) to 50 SCFM (1416 l/m), preferably from 8.0 SCFM (227 1/m) to 15 SCFM (425 l/m).
  • the foregoing flow rate is useful if helium is used as the carrier gas. If nitrogen by itself or mixed with helium is used as the carrier gas, a flow rate of from 0.001 SCFM (0.028 1/m) to 30 SCFM (849 1/m), preferably from 4.0 to 10 SCFM (113 l/m to 238 l/m), may be used.
  • the spray nozzle 20 is held at a distance from the surface 24. This distance is known as the spray distance and may be in the range of from 10 mm. to 50 mm.
  • the velocity of the powdered coating particles leaving the spray nozzle 20 may be in the range of from 825 m/s to 1400 m/s, preferably from 850 m/s to 1200 m/s.
  • the process of the present invention is advantageous over the current LPPS processes.
  • the powder in LPPS, the powder is melted. In the process of the present invention, the powder is not melted.
  • LPPS requires the use of a vacuum chamber which limits the size of the article or component which can be coated.
  • the process of the present invention does not require a vacuum chamber and may be performed in the open. As a result, there is no restriction on the size of the article or component which can be coated.
  • Still another advantage of the cold spray process of the present invention is that the as-deposited coating is at least 97% dense.
  • coated articles may be capable of having a bond strength capable of 10 ksi.
  • the process of the present invention may be used to form any type of coating.
  • the process may be employed to form a MCrAlY bond coat on an airfoil portion and/or some other portion of a blade or vane used in a turbine engine, such as a gas turbine engine.
  • FIG. 2 is a photograph of a cold spray deposited NiCrAlY coating 100.
  • the coating was formed by using powdered NiCrAlY coating material having a mean particle size of 10 microns using a helium gas at a pressure of 320 psi (2.21 MPa) at a temperature of 850 degrees Fahrenheit (454 degrees Centigrade). The coating material particles were fed at a rate of 25 grams/min.
  • the spray nozzle was spaced from the surface being coated by a distance of 1.0 inches (25.4 mm).
  • the nozzle was traversed at a speed of 50 inches (1.27 m) per minute with a step size of 0.030 inches (0.76 mm).
  • the substrate material 102 was Inconel 718, 0.125 inches (3.175 mm) thick.
  • the applied NiCrAlY coating thickness was 0.015 inches (0.38 mm).
  • an additional coating layer or layers may be formed over the bond coat.
  • Any suitable technique known in the art may be used to apply the overcoat layer(s).
  • the overcoat materials make be metallic or ceramic in composition.
  • the cold spray process offers many other advantages over other processes. Since the powders are not heated to high temperatures, no oxidation, decomposition, or other degradation of the feedstock materials occurs. Other potential advantages include the formation of compressive residual surface stresses and retaining the microstructure of the feedstock. Also, because relatively low temperatures are used, thermal distortion of the substrate will be minimized. Because the feedstock is not melted, cold spray offers the ability to deposit materials that cannot be sprayed conventionally due to the formation of brittle intermetallics or a propensity to crack upon cooling or during subsequent heat treatments.
  • Yet another advantage is that with cold spray, it is possible to spray over a blade/vane surface and not have the coating bridge the cooling holes in the surface.
  • the ability to apply a coating in a repair/refurbish operation and not have to go back and clean out the holes, or at least greatly reduce the labor required to do this is a great advantage over current operations.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Coating By Spraying Or Casting (AREA)
EP06251532A 2005-03-23 2006-03-22 Auftragen einer Haftbeschichtung auf Motorbauteile mittels eines Kaltsprühverfahrens Active EP1705266B1 (de)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US11/088,380 US20060216428A1 (en) 2005-03-23 2005-03-23 Applying bond coat to engine components using cold spray

Publications (3)

Publication Number Publication Date
EP1705266A2 true EP1705266A2 (de) 2006-09-27
EP1705266A3 EP1705266A3 (de) 2007-01-17
EP1705266B1 EP1705266B1 (de) 2009-09-02

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EP06251532A Active EP1705266B1 (de) 2005-03-23 2006-03-22 Auftragen einer Haftbeschichtung auf Motorbauteile mittels eines Kaltsprühverfahrens

Country Status (7)

Country Link
US (1) US20060216428A1 (de)
EP (1) EP1705266B1 (de)
JP (1) JP2006265732A (de)
CN (1) CN1837406A (de)
AT (1) ATE441739T1 (de)
DE (1) DE602006008847D1 (de)
SG (1) SG126092A1 (de)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2009103268A1 (de) * 2008-02-20 2009-08-27 Mtu Aero Engines Gmbh Verfahren zur beschichtung von bauteilen
DE102009032564A1 (de) * 2009-07-10 2011-01-13 Mtu Aero Engines Gmbh Verfahren zur Panzerung von Bauteilen aus einem TiAI-Basiswerkstoff, sowie entsprechende Bauteile
WO2010149141A3 (de) * 2009-06-25 2011-03-03 Mtu Aero Engines Gmbh Verfahren zum herstellen und/oder reparieren einer schaufel für eine strömungsmaschine
EP2327812A1 (de) * 2009-11-30 2011-06-01 General Electric Company Kaltgasgespritzte Vorderkante eines Stromlinienabschnitts aus Verbundwerkstoff
ITCO20130018A1 (it) * 2013-05-17 2014-11-18 Nuovo Pignone Srl Metodo per il trattamento di un componente per prevenire l'erosione di tale componente
EP3012350A1 (de) * 2014-10-21 2016-04-27 United Technologies Corporation Kaltspritzherstellung von maxmet-verbundwerkstoffen

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US7367488B2 (en) * 2005-05-10 2008-05-06 Honeywell International, Inc. Method of repair of thin wall housings
EP1772228A1 (de) * 2005-10-07 2007-04-11 Siemens Aktiengesellschaft Verfahren zum Reparieren eines Bauteils mit einer gerichteten Mikrostruktur
US8192792B2 (en) * 2006-10-27 2012-06-05 United Technologies Corporation Cold sprayed porous metal seals
US20080131612A1 (en) * 2006-11-30 2008-06-05 Honeywell International, Inc. Method for making an environment-resistant and thermal barrier coating system on a component
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US8147982B2 (en) 2007-12-19 2012-04-03 United Technologies Corporation Porous protective coating for turbine engine components
KR101043588B1 (ko) * 2008-07-25 2011-06-22 재단법인 철원플라즈마 산업기술연구원 내 플라즈마 세라믹 코팅막 형성방법
BRPI0903741A2 (pt) * 2009-06-17 2011-03-01 Mahle Metal Leve Sa mancal de deslizamento, processo de fabricação e motor de combustão interna
DE102009036407A1 (de) * 2009-08-06 2011-02-10 Mtu Aero Engines Gmbh Abreibbarer Schaufelspitzenbelag
JP5186528B2 (ja) * 2010-04-23 2013-04-17 日本発條株式会社 導電部材及びその製造方法
JP5565315B2 (ja) * 2010-05-18 2014-08-06 トヨタ自動車株式会社 半導体装置の製造方法
CN102376942B (zh) * 2010-08-16 2015-02-04 甘肃大象能源科技有限公司 一种锂离子电池正极极片的制作方法及用其制作的正极极片
EP2707172B1 (de) * 2011-05-10 2019-07-10 Sulzer Turbo Services Venlo B.V. Verfahren zur beschichtung eines substraten
JP5967534B2 (ja) * 2012-08-17 2016-08-10 東北電力株式会社 熱遮蔽被膜の形成方法および熱遮蔽被膜被覆部材
EP2719544B1 (de) * 2012-10-10 2015-12-16 Artio Sarl Verfahren zur Herstellung eines Rotationstiefdruckzylinders
KR101785049B1 (ko) * 2013-12-17 2017-10-12 아주대학교산학협력단 내식성 코팅물 및 그 제조방법
GB2541610B (en) * 2014-06-06 2021-04-07 Nat Res Council Canada Bi-layer iron coating of lightweight metallic substrate
US11982236B2 (en) 2017-12-22 2024-05-14 General Electric Company Titanium alloy compressor case
US11167864B2 (en) * 2018-04-27 2021-11-09 The Boeing Company Applying cold spray erosion protection to an airfoil
JP2019112723A (ja) * 2019-03-13 2019-07-11 ヌオーヴォ ピニォーネ ソチエタ レスポンサビリタ リミタータＮｕｏｖｏ Ｐｉｇｎｏｎｅ Ｓ．Ｒ．Ｌ． 構成部品の浸食を防止するために当該構成部品を処理するための方法
US11104998B2 (en) * 2019-07-20 2021-08-31 General Electric Company Cold spray repair of engine components
CN111996524A (zh) * 2020-07-21 2020-11-27 国营芜湖机械厂 一种飞机液压系统铝合金活塞杆耐磨层损伤的修复方法

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US5302414A (en) * 1990-05-19 1994-04-12 Anatoly Nikiforovich Papyrin Gas-dynamic spraying method for applying a coating
US5302414B1 (en) * 1990-05-19 1997-02-25 Anatoly N Papyrin Gas-dynamic spraying method for applying a coating
US6365222B1 (en) * 2000-10-27 2002-04-02 Siemens Westinghouse Power Corporation Abradable coating applied with cold spray technique
US20020073982A1 (en) * 2000-12-16 2002-06-20 Shaikh Furqan Zafar Gas-dynamic cold spray lining for aluminum engine block cylinders
US20040110021A1 (en) * 2001-08-01 2004-06-10 Siemens Westinghouse Power Corporation Wear and erosion resistant alloys applied by cold spray technique
US20030126800A1 (en) * 2001-12-05 2003-07-10 Siemens Westinghouse Power Corporation Mixed powder deposition of components for wear, erosion and abrasion resistant applications
EP1398394A1 (de) * 2002-08-13 2004-03-17 Howmet Research Corporation Kaltsprühverfahren zum Beschichten einer MCrAlX-Legierung
GB2394479A (en) * 2002-10-18 2004-04-28 United Technologies Corp Cold Spray Process for Coating Substrates
EP1659195A2 (de) * 2004-11-23 2006-05-24 United Technologies Corporation Kaltes, gasdynamisches Spritzverfahren von hochfestem Kupfer

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2009103268A1 (de) * 2008-02-20 2009-08-27 Mtu Aero Engines Gmbh Verfahren zur beschichtung von bauteilen
WO2010149141A3 (de) * 2009-06-25 2011-03-03 Mtu Aero Engines Gmbh Verfahren zum herstellen und/oder reparieren einer schaufel für eine strömungsmaschine
DE102009032564A1 (de) * 2009-07-10 2011-01-13 Mtu Aero Engines Gmbh Verfahren zur Panzerung von Bauteilen aus einem TiAI-Basiswerkstoff, sowie entsprechende Bauteile
EP2327812A1 (de) * 2009-11-30 2011-06-01 General Electric Company Kaltgasgespritzte Vorderkante eines Stromlinienabschnitts aus Verbundwerkstoff
ITCO20130018A1 (it) * 2013-05-17 2014-11-18 Nuovo Pignone Srl Metodo per il trattamento di un componente per prevenire l'erosione di tale componente
WO2014184363A1 (en) * 2013-05-17 2014-11-20 Nuovo Pignone Srl A method for treating a component to prevent erosion of such component
CN105339525A (zh) * 2013-05-17 2016-02-17 诺沃皮尼奥内股份有限公司 用于处理构件来防止这样的构件的腐蚀的方法
EP3012350A1 (de) * 2014-10-21 2016-04-27 United Technologies Corporation Kaltspritzherstellung von maxmet-verbundwerkstoffen
EP3012350B1 (de) 2014-10-21 2018-05-16 United Technologies Corporation Kaltspritzherstellung von maxmet-verbundwerkstoffen
US10000851B2 (en) 2014-10-21 2018-06-19 United Technologies Corporation Cold spray manufacturing of MAXMET composites

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EP1705266A3 (de) 2007-01-17
ATE441739T1 (de) 2009-09-15
DE602006008847D1 (de) 2009-10-15
US20060216428A1 (en) 2006-09-28
JP2006265732A (ja) 2006-10-05
CN1837406A (zh) 2006-09-27
EP1705266B1 (de) 2009-09-02
SG126092A1 (en) 2006-10-30

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