EP1806429B1 - Cold spray apparatus and method with modulated gasstream - Google Patents
Cold spray apparatus and method with modulated gasstream Download PDFInfo
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- EP1806429B1 EP1806429B1 EP06000403A EP06000403A EP1806429B1 EP 1806429 B1 EP1806429 B1 EP 1806429B1 EP 06000403 A EP06000403 A EP 06000403A EP 06000403 A EP06000403 A EP 06000403A EP 1806429 B1 EP1806429 B1 EP 1806429B1
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- cold
- cold spraying
- pressure
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- particle stream
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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
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B1/00—Nozzles, spray heads or other outlets, with or without auxiliary devices such as valves, heating means
- B05B1/02—Nozzles, spray heads or other outlets, with or without auxiliary devices such as valves, heating means designed to produce a jet, spray, or other discharge of particular shape or nature, e.g. in single drops, or having an outlet of particular shape
- B05B1/08—Nozzles, spray heads or other outlets, with or without auxiliary devices such as valves, heating means designed to produce a jet, spray, or other discharge of particular shape or nature, e.g. in single drops, or having an outlet of particular shape of pulsating nature, e.g. delivering liquid in successive separate quantities ; Fluidic oscillators
- B05B1/083—Nozzles, spray heads or other outlets, with or without auxiliary devices such as valves, heating means designed to produce a jet, spray, or other discharge of particular shape or nature, e.g. in single drops, or having an outlet of particular shape of pulsating nature, e.g. delivering liquid in successive separate quantities ; Fluidic oscillators the pulsating mechanism comprising movable parts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
- B05B7/14—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas designed for spraying particulate materials
- B05B7/1481—Spray pistols or apparatus for discharging particulate material
- B05B7/1486—Spray pistols or apparatus for discharging particulate material for spraying particulate material in dry state
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
- B05B7/16—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed
- B05B7/1606—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed the spraying of the material involving the use of an atomising fluid, e.g. air
- B05B7/1613—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed the spraying of the material involving the use of an atomising fluid, e.g. air comprising means for heating the atomising fluid before mixing with the material to be sprayed
- B05B7/162—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed the spraying of the material involving the use of an atomising fluid, e.g. air comprising means for heating the atomising fluid before mixing with the material to be sprayed and heat being transferred from the atomising fluid to the material to be sprayed
- B05B7/1626—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed the spraying of the material involving the use of an atomising fluid, e.g. air comprising means for heating the atomising fluid before mixing with the material to be sprayed and heat being transferred from the atomising fluid to the material to be sprayed at the moment of mixing
Abstract
Description
Die Erfindung betrifft eine Kaltgasspritzanlage und ein Kaltgasspritzverfahren.The invention relates to a cold gas spraying plant and a cold gas spraying process.
Aus dem Stand der Technik sind verschiedene Verfahren zur Herstellung von Schichten bekannt, die auf Bauteile aufgebracht und bei hohen Temperaturen eingesetzt werden. Dies sind Verdampfungsverfahren, wie z. B. PVD oder CVD oder thermische Spritzverfahren (Plasmaspritzen, HVOF:
Ein anderes Beschichtungsverfahren stellt das Kaltgasspritzverfahren dar, das aus den Patenten
Beim Kaltgasspritzen kommen pulverförmige Werkstoffe zum Einsatz, die Korngrößen von größer 5µm, idealerweise zwischen 20 und 40µm aufweisen. Aus kinetisch energetischen Gründen ist das Verspritzen von nanopartikulären Werkstoffen um nanostrukturierte Beschichtungen zu erzielen bisher nicht möglich.Various methods for the production of layers which are applied to components and used at high temperatures are known from the prior art. These are evaporation methods, such as. B. PVD or CVD or thermal spraying (plasma spraying, HVOF:
Another coating method is the cold gas spraying, which is the patents
In cold gas spraying, powdered materials are used which have particle sizes of greater than 5 μm , ideally between 20 and 40 μm . For kinetic energetic reasons, the spraying of nanoparticulate materials to achieve nanostructured coatings has not been possible so far.
Die
Die
The
Es ist daher Aufgabe der Erfindung, das Kaltgasspritzverfahren zu verbessern, insbesondere so, dass auch nanokristalline Pulver verspritzt werden können.It is therefore an object of the invention to improve the cold spray process, in particular so that nanocrystalline powder can be sprayed.
Die Aufgabe wird gelöst durch eine Kaltgasspritzanlage gemäß Anspruch 1 und ein Kaltgasspritzverfahren gemäß Anspruch 29.The object is achieved by a cold gas spraying system according to
Die in den Unteransprüchen aufgelisteten Maßnahmen können beliebig in vorteilhafter Art und Weise beliebig miteinander kombiniert werden.The measures listed in the dependent claims can be arbitrarily combined with each other in an advantageous manner.
Die Erfindung wird anhand der Figuren näher und beispielhaft erläutert.The invention will be explained in more detail and by way of example with reference to the figures.
- Figur 1FIG. 1
- eine Kaltgasspritzanlage nach dem Stand der Technik,a cold gas spraying system according to the prior art,
- Figur 2 - 8Figure 2-8
- eine erfindungsgemäß ausgestaltete Kaltgasspritzanlage,an inventively designed cold gas spraying system,
- Figur 9FIG. 9
- eine Gasturbine,a gas turbine,
- Figur 10FIG. 10
- eine perspektivische Ansicht einer Turbinenschaufel unda perspective view of a turbine blade and
- Figur 11FIG. 11
- eine Brennkammer.a combustion chamber.
Das Pulver für eine Beschichtung 13 wird durch eine Düse 8 auf ein Substrat 10, beispielsweise ein Bauteil (Turbinenschaufel 120, 130, (
Kaltspritzen bedeutet, dass Temperaturen bis maximal 80°C - 550°C, insbesondere 400°C bis 550°C verwendet werden. Die Substrattemperatur liegt bei 80°C bis 100°C. Die Geschwindigkeiten liegen bei 300m/s bis 2000m/s.
The powder for a
Cold spraying means that temperatures up to a maximum of 80 ° C - 550 ° C, especially 400 ° C to 550 ° C are used. The substrate temperature is 80 ° C to 100 ° C. The speeds are at 300m / s to 2000m / s.
Diese Beeinflussung der Eigenschaften des Kaltgaspartikelstroms 7 kann periodisch oder aperiodisch während eines Beschichtungsvorgangs erfolgen. Ebenso kann während eines Beschichtungsvorgangs auf Beschichtungszeiten mit periodischen Änderungen aperiodische Änderungen folgen oder umgekehrt. Vorzugsweise erfolgt nur eine periodische Änderung des oder der Eigenschaften.
This influencing of the properties of the cold
Das Beeinflussungsmittel kann zum Beispiel ein Pulsheizmittel 25 sein, das das Hochdruckgas des Hochdruckgaserzeugers wechselhaft, vorzugsweise pulsierend erhitzt und so zu einer Modulation des Kaltgaspartikelstroms 7 führt. Das Pulsheizmittel 25 kann auch Teil des Heizers 19 sein.The influencing means may be, for example, a pulse heating means 25 which alternately, preferably pulsatingly, heats the high-pressure gas of the high-pressure gas generator and thus leads to a modulation of the cold
Ebenso kann ein Ventil 32 als Beeinflussungsmittel, insbesondere eine gelochte Scheibe (Chopper) 32 vor der Düseeintrittsöffnung 8' angebracht sein. Da diese den Kaltgaspartikelstrom 7 periodisch oder aperiodisch unterbricht, wird ein pulsierender Kaltgaspartikelstrom 7 in Richtung des Substrats 10 erzeugt, der lokal unterschiedliche Partikeldichten p in Strahlrichtung bewirkt. Wenn das Ventil 32 verschlossen ist, staut sich das Material vor der Düse 8 und es baut sich ein höherer Druck auf, der sich nach dem Öffnen des Ventils wieder entspannt.Likewise, a
Ein modulierter Kaltgaspartikelstrom 7 kann auch dadurch erzeugt werden, dass aus dem Pulverbehälter 16 das Pulver in wechselhaft veränderten Mengen pro Zeiteinheit, vorzugsweise pulsierend dem Hochdruckgas hinzugefügt wird. Dies kann beispielsweise durch insbesondere piezoelektrische Injektoren 35 als Beeinflussungsmittel erfolgen.A modulated cold
Ebenso kann der Kaltgaspartikelstrom 7 durch Druckerzeuger 29 als Beeinflussungsmittel, vorzugsweise durch piezoelektrische Druckerzeuger 29 moduliert werden, die am Anfang der Lavaldüse 8 oder auf der Düse 8 angeordnet sind und die den Querschnitt der Lavaldüse wechselhaft verändern.
So kann die Düse 8 ein piezoelektrisches Material oder eine innere piezoelektrische Beschichtung aufweisen, das oder durch die durch Anlegen einer Spannung sich ausdehnen oder sich zusammenziehen und so den Querschnitt des Kaltgaspartikelstroms 7 verändern und damit die Partikeldichte p, den Druck p und die Geschwindigkeit des Kaltgaspartikelstroms 7 verändern.Likewise, the cold
Thus, the
Ebenso kann der Kaltgaspartikelstrom 7 im Bereich der Düse 8 durch eine akustische Welleneinkopplung mittels eines Welleneinkopplers 26, insbesondere durch einen Ultraschallgeber beeinflusst werden, der auf der Düse 8 aufliegt. Diese verhindern von allem ein Anhaften von Partikeln in der Düse 8.Likewise, the cold
Auch kann das Hochdruckgas durch ein Hochdruckventil 36 als Beeinflussungsmittel gesteuert werden. Das Hochdruckventil 36 ist bspw. im Hochdruckgaserzeuger integriert oder entlang einer Leitung 37 vorhanden, die das Gas aus dem Hochdruckgaserzeuger 22 zu dem Pulver führt.Also, the high pressure gas can be controlled by a
Die Beeinflussungsmittel 25, 26, 29, 32, 35, 36 können einzeln, gepaart oder mehrfach vorhanden sein und zum Einsatz kommen.The influencing means 25, 26, 29, 32, 35, 36 can be used singly, paired or multiple and used.
Vorzugsweise wird das Material M durch den oder die Pulverinjektoren 35 pulsartig dem Kaltgaspartikelstrom 7 zugeführt und die Geschwindigkeit v des Kaltgaspartikelstroms 7 wird moduliert.Preferably, the material M is supplied by the or the
Das Mischen des Hochdruckgases, das aus dem Hochdruckgaserzeuger 22 stammt und des Pulvers, das aus dem Pulverbehälter 16 gelangt, kann vor der Düseneintrittsöffnung 8' in einer Kammer 4 erfolgen (
Die Beeinflussungsmittel 25, 32, 35, 36 können entweder nur vor der Düseneintrittsöffnung 8' angeordnet sein (
Insbesondere kann bei der Düse 8 der Durchmesser Φ, die Temperatur T und/oder der Druck p wechselhaft verändert werden, um den Kaltgaspartikelstrom 7 zu beeinflussen.In particular, in the
Ebenso kann die Düse 8 beheizt werden, um eine konstante Temperatur T des Kaltgaspartikelstroms 7 zu erzeugen oder die Temperatur T des Kaltgaspartikelstroms 7 wechselhaft zu verändern.Likewise, the
Die gesamte Kaltgasspritzanlage 1 kann in einer Vakuumkammer (nicht dargestellt) angeordnet sein.The entire cold
Kaltspritzen bedeutet, dass Temperaturen bis maximal 80°C - 550°C, insbesondere 400°C bis 550°C verwendet werden. Die Substrattemperatur liegt bei 80°C bis 100°C.
Die Geschwindigkeiten liegen bei 300m/s bis 2000m/s, insbesondere bis 900m/s.Cold spraying means that temperatures up to a maximum of 80 ° C - 550 ° C, especially 400 ° C to 550 ° C are used. The substrate temperature is 80 ° C to 100 ° C.
The speeds are from 300m / s to 2000m / s, especially up to 900m / s.
In
In
In
Die Eigenschaften des Kaltgaspartikelstroms 7 können bei einem Beschichtungsvorgang einzeln oder zusammen verändert werden, insbesondere wenn die Veränderung in die gleiche Richtung wirkt, also Temperaturerhöhung und Druckerhöhung.The properties of the cold
Durch Temperaturerhöhung, Druckmodulation oder Querschnittsverengung der Düse 8 des Kaltgaspartikelstroms 7 werden höhere Partikelgeschwindigkeiten erreicht und damit ein besseres Beschichtungsergebnis erzielt.By increasing the temperature, pressure modulation or cross-sectional constriction of the
Zur Erzeugung eines gepulsten Kaltgaspartikelstromes 7 sind also verschiedene Verfahren denkbar:
Ventil 32 vor der Düse 8 oder rotierende gelochte Scheibe im Gasstrom vor der Düse 8,- periodische Verengung des Querschnitts der Düse 8, vorzugsweise durch piezoelektrische Keramiken bzw. Materialien,
- pulsierende Gaserhitzung,
- Beeinflussung der Trägergasgeschwindigkeit durch akustische Welleneinkopplung.
-
Valve 32 in front of thenozzle 8 or rotating perforated disc in the gas flow in front of thenozzle 8, - periodic constriction of the cross section of the
nozzle 8, preferably by piezoelectric ceramics or materials, - pulsating gas heating,
- Influence of the carrier gas velocity by acoustic wave coupling.
Die pulsierende Injektion von Pulverteilchen kann vorzugsweise durch einen piezoelektrischen Pulverinjektor 35 erfolgen.
Besonders Korngrößen kleiner 1µm, vorzugsweise kleiner 500nm (Nanopartikel) können mit den modulierten Kaltgaspartikelströmen 7 verspritzt werden.The pulsed injection of powder particles may preferably be effected by a
Particularly grain sizes smaller than 1 μ m, preferably less than 500 nm (nanoparticles) may be sprayed with the modulated cold gas particle streams. 7
Ebenso können mehrere Pulverinjektoren 35 mit verschiedenen Pulvermaterialien M eingesetzt werden, um gradierte oder Vielfachbeschichtungen zu erzielen.Likewise,
Bezüglich der Materialauswahl sind keine Einschränkungen gegeben, sodass also Metalle, Metalllegierungen, Halbmetalle sowie Verbindungen hiervon (Karbide, Nitride, Oxide, Sulfide, Phosphate etc.) sowie Halbleiter, Hochtemperatursupraleiter, Magnetwerkstoffe, Gläser und/oder Keramiken verspritzt werden können.With regard to the selection of materials, there are no restrictions, so that metals, metal alloys, semimetals and compounds thereof (carbides, nitrides, oxides, sulfides, phosphates, etc.) as well as semiconductors, high-temperature superconductors, magnetic materials, glasses and / or ceramics can be sprayed.
In
Die Materialien der Pulverbehälter 16, 16' können gleichzeitig hinzugefügt werden oder nur ein Pulverbehälter 16, 16' ist aktiv.
Insbesondere wenn die Partikel verschiedene Partikelgrößen aufweisen ist es sinnvoll, die Geschwindigkeit v des Kaltgaspartikelstroms zu verändern, damit z. B. der gleiche Impuls bei kleineren, d. h. leichteren Partikeln erreicht wird.
Hier können auch zwei Gasheizer und oder zwei Hochdruckgaserzeuger verwendet werden.In
The materials of the
In particular, if the particles have different particle sizes, it makes sense to change the velocity v of the cold gas particle stream, thus z. B. the same pulse at smaller, ie lighter particles is achieved.
Here also two gas heaters and or two high-pressure gas generators can be used.
Die
Die Gasturbine 100 weist im Inneren einen um eine Rotationsachse 102 drehgelagerten Rotor 103 mit einer Welle 101 auf, der auch als Turbinenläufer bezeichnet wird.
Entlang des Rotors 103 folgen aufeinander ein Ansauggehäuse 104, ein Verdichter 105, eine beispielsweise torusartige Brennkammer 110, insbesondere Ringbrennkammer, mit mehreren koaxial angeordneten Brennern 107, eine Turbine 108 und das Abgasgehäuse 109.
Die Ringbrennkammer 110 kommuniziert mit einem beispielsweise ringförmigen Heißgaskanal 111. Dort bilden beispielsweise vier hintereinander geschaltete Turbinenstufen 112 die Turbine 108.
Jede Turbinenstufe 112 ist beispielsweise aus zwei Schaufelringen gebildet. In Strömungsrichtung eines Arbeitsmediums 113 gesehen folgt im Heißgaskanal 111 einer Leitschaufelreihe 115 eine aus Laufschaufeln 120 gebildete Reihe 125.The
The
Along the
The
Each
Die Leitschaufeln 130 sind dabei an einem Innengehäuse 138 eines Stators 143 befestigt, wohingegen die Laufschaufeln 120 einer Reihe 125 beispielsweise mittels einer Turbinenscheibe 133 am Rotor 103 angebracht sind.
An dem Rotor 103 angekoppelt ist ein Generator oder eine Arbeitsmaschine (nicht dargestellt).The guide vanes 130 are fastened to an
Coupled to the
Während des Betriebes der Gasturbine 100 wird vom Verdichter 105 durch das Ansauggehäuse 104 Luft 135 angesaugt und verdichtet. Die am turbinenseitigen Ende des Verdichters 105 bereitgestellte verdichtete Luft wird zu den Brennern 107 geführt und dort mit einem Brennmittel vermischt. Das Gemisch wird dann unter Bildung des Arbeitsmediums 113 in der Brennkammer 110 verbrannt. Von dort aus strömt das Arbeitsmedium 113 entlang des Heißgaskanals 111 vorbei an den Leitschaufeln 130 und den Laufschaufeln 120. An den Laufschaufeln 120 entspannt sich das Arbeitsmedium 113 impulsübertragend, so dass die Laufschaufeln 120 den Rotor 103 antreiben und dieser die an ihn angekoppelte Arbeitsmaschine.During operation of the
Die dem heißen Arbeitsmedium 113 ausgesetzten Bauteile unterliegen während des Betriebes der Gasturbine 100 thermischen Belastungen. Die Leitschaufeln 130 und Laufschaufeln 120 der in Strömungsrichtung des Arbeitsmediums 113 gesehen ersten Turbinenstufe 112 werden neben den die Ringbrennkammer 110 auskleidenden Hitzeschildelementen am meisten thermisch belastet.
Um den dort herrschenden Temperaturen standzuhalten, können diese mittels eines Kühlmittels gekühlt werden.
Ebenso können Substrate der Bauteile eine gerichtete Struktur aufweisen, d.h. sie sind einkristallin (SX-Struktur) oder weisen nur längsgerichtete Körner auf (DS-Struktur).
Als Material für die Bauteile, insbesondere für die Turbinenschaufel 120, 130 und Bauteile der Brennkammer 110 werden beispielsweise eisen-, nickel- oder kobaltbasierte Superlegierungen verwendet.
Solche Superlegierungen sind beispielsweise aus der
To withstand the prevailing temperatures, they can be cooled by means of a coolant.
Likewise, substrates of the components can have a directional structure, ie they are monocrystalline (SX structure) or have only longitudinal grains (DS structure).
As a material for the components, in particular for the
Such superalloys are for example from
Die Leitschaufel 130 weist einen dem Innengehäuse 138 der Turbine 108 zugewandten Leitschaufelfuß (hier nicht dargestellt) und einen dem Leitschaufelfuß gegenüberliegenden Leitschaufelkopf auf. Der Leitschaufelkopf ist dem Rotor 103 zugewandt und an einem Befestigungsring 140 des Stators 143 festgelegt.The
Die
Die Strömungsmaschine kann eine Gasturbine eines Flugzeugs oder eines Kraftwerks zur Elektrizitätserzeugung, eine Dampfturbine oder ein Kompressor sein.The turbomachine may be a gas turbine of an aircraft or a power plant for power generation, a steam turbine or a compressor.
Die Schaufel 120, 130 weist entlang der Längsachse 121 aufeinander folgend einen Befestigungsbereich 400, eine daran angrenzende Schaufelplattform 403 sowie ein Schaufelblatt 406 und eine Schaufelspitze 415 auf.
Als Leitschaufel 130 kann die Schaufel 130 an ihrer Schaufelspitze 415 eine weitere Plattform aufweisen (nicht dargestellt).The
As a
Im Befestigungsbereich 400 ist ein Schaufelfuß 183 gebildet, der zur Befestigung der Laufschaufeln 120, 130 an einer Welle oder einer Scheibe dient (nicht dargestellt).
Der Schaufelfuß 183 ist beispielsweise als Hammerkopf ausgestaltet. Andere Ausgestaltungen als Tannenbaum- oder Schwalbenschwanzfuß sind möglich.In the mounting
The
Die Schaufel 120, 130 weist für ein Medium, das an dem Schaufelblatt 406 vorbeiströmt, eine Anströmkante 409 und eine Abströmkante 412 auf.The
Bei herkömmlichen Schaufeln 120, 130 werden in allen Bereichen 400, 403, 406 der Schaufel 120, 130 beispielsweise massive metallische Werkstoffe, insbesondere Superlegierungen verwendet.
Solche Superlegierungen sind beispielsweise aus der
Die Schaufel 120, 130 kann hierbei durch ein Gussverfahren, auch mittels gerichteter Erstarrung, durch ein Schmiedeverfahren, durch ein Fräsverfahren oder Kombinationen daraus gefertigt sein.In
Such superalloys are for example from
The
Werkstücke mit einkristalliner Struktur oder Strukturen werden als Bauteile für Maschinen eingesetzt, die im Betrieb hohen mechanischen, thermischen und/oder chemischen Belastungen ausgesetzt sind.
Die Fertigung von derartigen einkristallinen Werkstücken erfolgt z.B. durch gerichtetes Erstarren aus der Schmelze. Es handelt sich dabei um Gießverfahren, bei denen die flüssige metallische Legierung zur einkristallinen Struktur, d.h. zum einkristallinen Werkstück, oder gerichtet erstarrt.
Dabei werden dendritische Kristalle entlang dem Wärmefluss ausgerichtet und bilden entweder eine stängelkristalline Kornstruktur (kolumnar, d.h. Körner, die über die ganze Länge des Werkstückes verlaufen und hier, dem allgemeinen Sprachgebrauch nach, als gerichtet erstarrt bezeichnet werden) oder eine einkristalline Struktur, d.h. das ganze Werkstück besteht aus einem einzigen Kristall. In diesen Verfahren muss man den Übergang zur globulitischen (polykristallinen) Erstarrung meiden, da sich durch ungerichtetes Wachstum notwendigerweise transversale und longitudinale Korngrenzen ausbilden, welche die guten Eigenschaften des gerichtet erstarrten oder einkristallinen Bauteiles zunichte machen.Workpieces with a monocrystalline structure or structures are used as components for machines which are exposed to high mechanical, thermal and / or chemical stresses during operation.
The production of such monocrystalline workpieces, for example, by directed solidification from the melt. These are casting methods in which the liquid metallic alloy solidifies into a monocrystalline structure, ie a single-crystal workpiece, or directionally.
Here, dendritic crystals are aligned along the heat flow and form either a columnar grain structure (columnar, ie grains that run the entire length of the workpiece and here, in common parlance, referred to as directionally solidified) or a monocrystalline structure, ie the whole Workpiece consists of a single crystal. In these processes, it is necessary to avoid the transition to globulitic (polycrystalline) solidification, since non-directional growth necessarily produces transverse and longitudinal grain boundaries which negate the good properties of the directionally solidified or monocrystalline component.
Ist allgemein von gerichtet erstarrten Gefügen die Rede, so sind damit sowohl Einkristalle gemeint, die keine Korngrenzen oder höchstens Kleinwinkelkorngrenzen aufweisen, als auch Stängelkristallstrukturen, die wohl in longitudinaler Richtung verlaufende Korngrenzen, aber keine transversalen Korngrenzen aufweisen. Bei diesen zweitgenannten kristallinen Strukturen spricht man auch von gerichtet erstarrten Gefügen (directionally solidified structures).
Solche Verfahren sind aus der
Such methods are known from
Ebenso können die Schaufeln 120, 130 Beschichtungen gegen Korrosion oder Oxidation aufweisen, z. B. (MCrA1X; M ist zumindest ein Element der Gruppe Eisen (Fe), Kobalt (Co), Nickel (Ni), X ist ein Aktivelement und steht für Yttrium (Y) und/oder Silizium und/oder zumindest ein Element der Seltenen Erden, bzw. Hafnium (Hf)). Solche Legierungen sind bekannt aus der
Die Dichte liegt vorzugsweise bei 95% der theoretischen Dichte.
Auf der MCrA1X-Schicht (als Zwischenschicht oder als äußerste Schicht) bildet sich eine schützende Aluminiumoxidschicht (TGO = thermal grown oxide layer).Likewise, the
The density is preferably 95% of the theoretical density.
A protective aluminum oxide layer (TGO = thermal grown oxide layer) forms on the MCrA1X layer (as intermediate layer or as outermost layer).
Auf der MCrA1X kann noch eine Wärmedämmschicht vorhanden sein, die vorzugsweise die äußerste Schicht ist, und besteht beispielsweise aus ZrO2, Y2O3-ZrO2, d.h. sie ist nicht, teilweise oder vollständig stabilisiert durch Yttriumoxid und/oder Kalziumoxid und/oder Magnesiumoxid.
Die Wärmedämmschicht bedeckt die gesamte MCrA1X-Schicht. Durch geeignete Beschichtungsverfahren wie z.B. Elektronenstrahlverdampfen (EB-PVD) werden stängelförmige Körner in der Wärmedämmschicht erzeugt.
Andere Beschichtungsverfahren sind denkbar, z.B. atmosphärisches Plasmaspritzen (APS), LPPS, VPS oder CVD. Die Wärmedämmschicht kann poröse, mikro- oder makrorissbehaftete Körner zur besseren Thermoschockbeständigkeit aufweisen. Die Wärmedämmschicht ist also vorzugsweise poröser als die MCrAlX-Schicht.On the MCrA1X may still be present a thermal barrier coating, which is preferably the outermost layer, and consists for example of ZrO 2 , Y 2 O 3 -ZrO 2 , ie it is not, partially or completely stabilized by yttria and / or calcium oxide and / or magnesium oxide.
The thermal barrier coating covers the entire MCrA1X layer. By means of suitable coating processes, such as electron beam evaporation (EB-PVD), stalk-shaped grains are produced in the thermal barrier coating.
Other coating methods are conceivable, for example atmospheric plasma spraying (APS), LPPS, VPS or CVD. The thermal barrier coating may have porous, micro- or macro-cracked grains for better thermal shock resistance. The thermal barrier coating is therefore preferably more porous than the MCrAlX layer.
Die Schaufel 120, 130 kann hohl oder massiv ausgeführt sein. Wenn die Schaufel 120, 130 gekühlt werden soll, ist sie hohl und weist ggf. noch Filmkühllöcher 418 (gestrichelt angedeutet) auf.The
Die
Zur Erzielung eines vergleichsweise hohen Wirkungsgrades ist die Brennkammer 110 für eine vergleichsweise hohe Temperatur des Arbeitsmediums M von etwa 1000°C bis 1600°C ausgelegt. Um auch bei diesen, für die Materialien ungünstigen Betriebsparametern eine vergleichsweise lange Betriebsdauer zu ermöglichen, ist die Brennkammerwand 153 auf ihrer dem Arbeitsmedium M zugewandten Seite mit einer aus Hitzeschildelementen 155 gebildeten Innenauskleidung versehen.To achieve a comparatively high efficiency, the
Aufgrund der hohen Temperaturen im Inneren der Brennkammer 110 kann zudem für die Hitzeschildelemente 155 bzw. für deren Halteelemente ein Kühlsystem vorgesehen sein. Die Hitzeschildelemente 155 sind dann beispielsweise hohl und weisen ggf. noch in den Brennkammerraum 154 mündende Kühllöcher (nicht dargestellt) auf.Due to the high temperatures inside the
Jedes Hitzeschildelement 155 aus einer Legierung ist arbeitsmediumsseitig mit einer besonders hitzebeständigen Schutzschicht (MCrA1X-Schicht und/oder keramische Beschichtung) ausgestattet oder ist aus hochtemperaturbeständigem Material (massive keramische Steine) gefertigt.
Diese Schutzschichten können ähnlich der Turbinenschaufeln sein, also bedeutet beispielsweise MCrA1X: M ist zumindest ein Element der Gruppe Eisen (Fe), Kobalt (Co), Nickel (Ni), X ist ein Aktivelement und steht für Yttrium (Y) und/oder Silizium und/oder zumindest ein Element der Seltenen Erden, bzw. Hafnium (Hf). Solche Legierungen sind bekannt aus der
These protective layers may be similar to the turbine blades, so for example MCrA1X means: M is at least one element of the group iron (Fe), cobalt (Co), nickel (Ni), X is an active element and stands for yttrium (Y) and / or silicon and / or at least one element of the rare earths, or hafnium (Hf). Such alloys are known from the
Auf der MCrA1X kann noch eine beispielsweise keramische Wärmedämmschicht vorhanden sein und besteht beispielsweise aus ZrO2, Y2O3-ZrO2, d.h. sie ist nicht, teilweise oder vollständig stabilisiert durch Yttriumoxid und/oder Kalziumoxid und/oder Magnesiumoxid.
Durch geeignete Beschichtungsverfahren wie z.B. Elektronenstrahlverdampfen (EB-PVD) werden stängelförmige Körner in der Wärmedämmschicht erzeugt.
Andere Beschichtungsverfahren sind denkbar, z.B. atmosphärisches Plasmaspritzen (APS), LPPS, VPS oder CVD. Die Wärmedämmschicht kann poröse, mikro- oder makrorissbehaftete Körner zur besseren Thermoschockbeständigkeit aufweisen.On the MCrA1X may still be present, for example, a ceramic thermal barrier coating and consists for example of ZrO 2 , Y 2 O 3 -ZrO 2 , ie it is not, partially or completely stabilized by yttria and / or calcium oxide and / or magnesium oxide.
By means of suitable coating processes, such as electron beam evaporation (EB-PVD), stalk-shaped grains are produced in the thermal barrier coating.
Other coating methods are conceivable, for example atmospheric plasma spraying (APS), LPPS, VPS or CVD. The thermal barrier coating may have porous, micro- or macro-cracked grains for better thermal shock resistance.
Wiederaufarbeitung (Refurbishment) bedeutet, dass Turbinenschaufeln 120, 130, Hitzeschildelemente 155 nach ihrem Einsatz gegebenenfalls von Schutzschichten befreit werden müssen (z.B. durch Sandstrahlen). Danach erfolgt eine Entfernung der Korrosions- und/oder Oxidationsschichten bzw. -produkte. Gegebenenfalls werden auch noch Risse in der Turbinenschaufel 120, 130 oder dem Hitzeschildelement 155 repariert. Danach erfolgt eine Wiederbeschichtung der Turbinenschaufeln 120, 130, Hitzeschildelemente 155 und ein erneuter Einsatz der Turbinenschaufeln 120, 130 oder der Hitzeschildelemente 155.Refurbishment means that
Claims (46)
- Cold spraying installation,
which includes
at least one powder container (16, 16'),
a high-pressure gas generator (22) for generating a high-pressure gas,
a gas heater (19) and
a nozzle (8),
from which emerges a cold gas particle stream (7),
characterized in that
the cold spraying installation (1) has influencing means (25, 26, 29, 32, 35, 35', 36)
which lead to a variable change in at least one of the properties temperature (T), pressure (p), particle density (ρ), particle material (M), velocity (v) of the cold gas particle stream (7). - Cold spraying installation according to Claim 1,
characterized in that
the influencing means (25, 26, 29, 32, 35, 35', 36) can be used to vary the at least one property of the cold gas particle stream (7) periodically. - Cold spraying installation according to Claim 1,
characterized in that
the influencing means (25, 26, 29, 32, 35, 35', 36) can be used to change the at least one property of the cold gas particle stream (7) aperiodically. - Cold spraying installation according to Claim 1, 2 or 3,
characterized in that
there is at least one powder injector (35, 35') as influencing means,
by which the powder from the powder container (16, 16') can be fed to the high-pressure gas in pulsed fashion,
with the result that it is possible to change the particle density (ρ) of the cold gas particle stream (7). - Cold spraying installation according to Claim 1, 2, 3 or 4,
characterized in that
there is a pulsed heating means (25) as influencing means,
in particular as part of the gas heater (19),
by which means (25) the high-pressure gas can be variably heated,
with the result that the temperature of the cold gas particle stream (7) can also be changed. - Cold gas spraying installation according to Claim 1, 2, 3, 4 or 5,
characterized in that
the cold gas spraying installation (1), upstream of the nozzle inlet opening (8') of the nozzle (8), has a valve (32),
in particular a rotating perforated disk (32),
as influencing means,
by which the nozzle (8) can be closed from time to time,
so that the particle density (ρ) in the cold gas particle stream (7) can be variably changed. - Cold spraying installation according to Claim 1, 2, 3, 4, 5, or 6,
characterized in that
the cold spraying installation (1), in the region of the nozzle (8) or as part of the nozzle (8), has mechanically acting pressure generators (29),
in particular including piezo-electrics,
as influencing means,
by which the cross section (F) of the nozzle (8) can be variably changed. - Cold spraying installation according to one or more of the preceding Claims,
characterized in that
acoustic wave introduction means (26),
in particular ultrasonic generators in the region of or on the nozzle (8),
are present as influencing means,
by which the cold gas particle stream (7) can be compressed or expanded. - Cold spraying installation according to one or more of the preceding claims,
characterized in that
there is a high-pressure valve (36) in the high-pressure gas generator (22) or at a line (37) of the high-pressure gas generator (22)
as influencing means,
which can variably interrupt the flow of the high-pressure gas out of the high-pressure gas generator (22), so that the pressure (p) in the cold gas particle stream (7) can be variably changed. - Cold spraying installation according to one or more of the preceding claims,
characterized in that
there are influencing means (26, 29, 32, 36) for changing the diameter (Φ) of the nozzle (8), the temperature (T) and/or the pressure (p) in the nozzle (8). - Cold spraying installation according to one or more of the preceding claims,
characterized in that
the influencing means (25, 29, 32, 35, 35', 36) are arranged only upstream of the nozzle inlet opening (8'). - Cold spraying installation according to one or more of the preceding Claims 1 to 10,
characterized in that
the influencing means (26, 29) are arranged only downstream of the nozzle inlet opening (8'). - Cold spraying installation according to one or more of the preceding claims,
characterized in that
it (1) is arranged inside a vacuum chamber. - Cold spraying installation according to Claim 1 or 4,
characterized in that
the high-pressure gas and powder can be mixed upstream of the nozzle (8). - Cold spraying installation according to Claim 1 or 4,
characterized in that
the high-pressure gas and powder can be mixed in the nozzle (8). - Cold spraying installation according to Claim 1, 4, 14 or 15,
characterized in that
there are two powder containers (16, 16') and two powder injectors (35, 35'). - Cold spraying installation according to Claim 1 or 5,
characterized in that
the only influencing means present is a pulsed heating means (25) - Cold spraying installation according to Claim 1 or 4,
characterized in that
the only influencing means present is a powder injector (35). - Cold spraying installation according to Claim 1 or 7,
characterized in that
the only influencing means present are mechanically acting pressure generators (29). - Cold spraying installation according to Claim 1 or 6,
characterized in that
the only influencing means present is a valve (32). - Cold spraying installation according to Claim 1 or 9,
characterized in that
the only influencing means present is a high-pressure valve (36) . - Cold spraying installation according to Claim 4, 5 or 16,
characterized in that
the only influencing means present are powder injectors (35) and pulsed heating means (25). - Cold spraying installation according to Claim 4 or 9,
characterized in that
the only influencing means present are a high-pressure valve (36) and pulsed heating means (25). - Cold spraying installation according to Claim 1, 5 or 7,
characterized in that
the only influencing means present are pulsed heating means (25) and mechanically acting pressure generators (29). - Cold spraying installation according to Claim 1, 4, 7 or 16,
characterized in that
the only influencing means present are powder injectors (35) and mechanically acting pressure generators (29). - Cold spraying installation according to Claim 1, 4 or 5,
characterized in that
the only influencing means present are pulsed heating means (25), mechanically acting pressure generators (29) and powder injectors (35). - Cold spraying installation according to Claim 1, 4, 9 or 19,
characterized in that
the only influencing means present are pulsed heating means (25), a high-pressure valve (36) and powder injector (35). - Cold spraying installation according to Claim 1,
characterized in that
only the properties temperature (T), pressure (p), particle density (ρ), particle material (M), velocity (v) of the cold gas particle stream can be changed. - Cold spraying process,
in particular using the cold spraying installation according to one or more of Claims 1 to 28,
characterized in that
at least one of the parameters temperature (T), pressure (p), particle density (ρ), particle material (M), velocity (v) of a cold gas particle stream (7) is variably changed. - Cold spraying process according to Claim 29,
characterized in that
only the particle density (ρ) of the cold gas particle stream (7) is changed. - Cold spraying process according to Claim 29,
characterized in that
only the temperature (T) of the cold gas particle stream (7) is changed. - Cold spraying process according to Claim 29,
characterized in that
only the velocity (v) of the cold gas particle stream (7) is changed. - Cold spraying process according to Claim 29,
characterized in that
only the particle material (M) of the cold gas particle stream (7) is changed. - Cold spraying process according to Claim 29,
characterized in that
only the pressure (p) of the cold gas particle stream (7) is changed. - Cold spraying process according to Claim 29, 30, 31, 32, 33 or 34,
characterized in that
the at least one parameter of the cold gas particle stream (7) is changed periodically. - Cold spraying process according to Claim 29, 30, 31, 32, 33 or 34,
characterized in that
the at least one parameter of the cold gas particle stream (7) is changed aperiodically. - Cold spraying process according to Claim 29,
characterized in that
two properties of the cold gas particle stream (7) are changed simultaneously. - Cold spraying process according to Claim 29 or 37,
characterized in that
during a coating operation only the temperature (T) and the particle density (ρ) of the cold gas particle stream (7) are changed. - Cold spraying process according to Claim 29 or 37,
characterized in that
during a coating operation only the temperature (T) and the velocity (v) of the cold gas particle stream (7) are changed. - Cold spraying process according to Claim 29 or 37,
characterized in that
during a coating operation only the temperature (T) and the pressure (p) of the cold gas particle stream (7) are changed. - Cold spraying process according to Claim 29 or 37,
characterized in that
during a coating operation only the pressure (p) and the particle density (ρ) of the cold gas particle stream (7) are changed. - Cold spraying process according to Claim 29 or 37,
characterized in that
during a coating operation only the pressure (p) and the material (M) of the cold gas particle stream (7) are changed. - Cold spraying process according to Claim 29,
characterized in that
during a coating operation only the particle density (ρ) and the velocity (v) of the cold gas particle stream (7) is changed. - Cold spraying process according to Claim 29,
characterized in that
during a coating operation only the material (M) and the velocity (v) of the cold gas particle stream (7) is changed. - Cold spraying process according to one or more of the preceding claims,
characterized in that
the high-pressure gas and powder are mixed upstream of the nozzle (8). - Cold spraying installation as set forth in one or more of the preceding claims,
characterized in that
the high-pressure gas and powder are mixed in the nozzle (8).
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE502006001063T DE502006001063D1 (en) | 2006-01-10 | 2006-01-10 | Cold spraying and cold spraying with modulated gas flow |
AT06000403T ATE400674T1 (en) | 2006-01-10 | 2006-01-10 | COLD SPRAYING SYSTEM AND COLD SPRAYING PROCESS WITH MODULATED GAS FLOW |
EP06000403A EP1806429B1 (en) | 2006-01-10 | 2006-01-10 | Cold spray apparatus and method with modulated gasstream |
RU2007100423/05A RU2426602C2 (en) | 2006-01-10 | 2007-01-09 | Cold gas spraying plant and method of cold gas sparying with modulated gas flow |
US11/651,730 US7631816B2 (en) | 2006-01-10 | 2007-01-10 | Cold spraying installation and cold spraying process with modulated gas stream |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP06000403A EP1806429B1 (en) | 2006-01-10 | 2006-01-10 | Cold spray apparatus and method with modulated gasstream |
Publications (2)
Publication Number | Publication Date |
---|---|
EP1806429A1 EP1806429A1 (en) | 2007-07-11 |
EP1806429B1 true EP1806429B1 (en) | 2008-07-09 |
Family
ID=36032100
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP06000403A Not-in-force EP1806429B1 (en) | 2006-01-10 | 2006-01-10 | Cold spray apparatus and method with modulated gasstream |
Country Status (5)
Country | Link |
---|---|
US (1) | US7631816B2 (en) |
EP (1) | EP1806429B1 (en) |
AT (1) | ATE400674T1 (en) |
DE (1) | DE502006001063D1 (en) |
RU (1) | RU2426602C2 (en) |
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US11898986B2 (en) | 2012-10-10 | 2024-02-13 | Westinghouse Electric Company Llc | Systems and methods for steam generator tube analysis for detection of tube degradation |
US11935662B2 (en) | 2019-07-02 | 2024-03-19 | Westinghouse Electric Company Llc | Elongate SiC fuel elements |
US11662300B2 (en) | 2019-09-19 | 2023-05-30 | Westinghouse Electric Company Llc | Apparatus for performing in-situ adhesion test of cold spray deposits and method of employing |
Also Published As
Publication number | Publication date |
---|---|
ATE400674T1 (en) | 2008-07-15 |
EP1806429A1 (en) | 2007-07-11 |
US7631816B2 (en) | 2009-12-15 |
RU2007100423A (en) | 2008-08-10 |
RU2426602C2 (en) | 2011-08-20 |
DE502006001063D1 (en) | 2008-08-21 |
US20070187525A1 (en) | 2007-08-16 |
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