EP1902160B1 - Ceramic heat insulating layer - Google Patents

Ceramic heat insulating layer Download PDF

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Publication number
EP1902160B1
EP1902160B1 EP06764032A EP06764032A EP1902160B1 EP 1902160 B1 EP1902160 B1 EP 1902160B1 EP 06764032 A EP06764032 A EP 06764032A EP 06764032 A EP06764032 A EP 06764032A EP 1902160 B1 EP1902160 B1 EP 1902160B1
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EP
European Patent Office
Prior art keywords
thermal barrier
coating
barrier coating
component
intermetallic compound
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EP06764032A
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German (de)
French (fr)
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EP1902160A1 (en
Inventor
Mohamed Youssef Nazmy
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General Electric Technology GmbH
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Alstom Technology AG
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    • 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
    • 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
    • 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
    • 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
    • C23C28/36—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including layers graded in composition or physical properties
    • 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
    • C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material

Definitions

  • the invention relates to the field of materials technology. It relates to a ceramic thermal barrier coating, which for coating thermally highly stressed components such. As blades of a gas turbine, is used.
  • thermal barrier coatings thermal barrier coatings
  • TBC thermal barrier coatings
  • Y 2 O 3 yttria
  • ZrO 2 zirconia
  • adhesive layers of MCrAIY are often provided between the thermal barrier coating and the surface of the component, where M stands for metal, specifically for Ni, Fe, Co or combinations thereof.
  • Plasma spraying such as. As plasma spraying in air (Air Plasma Spraying APS), low pressure plasma spraying (LPPS), vacuum plasma spraying (VPS) or flame spraying, such. High Velocity Oxygen Fuel (HVOF), as well as Physical Vapor Deposition (PVD), e.g. B. by electron beam (Electron Beam Physical Vapor Deposition EP-PVD) known (see, eg. US 6,352,788 B2 . US 6,544,665 B2 ).
  • Air Plasma Spraying APS Air Plasma Spraying APS
  • LPPS low pressure plasma spraying
  • VPS vacuum plasma spraying
  • HVOF High Velocity Oxygen Fuel
  • PVD Physical Vapor Deposition
  • B. by electron beam Electro Beam Physical Vapor Deposition EP-PVD
  • APS-sprayed TBCs have e.g. B. a high degree of inhomogeneities and porosity, which advantageously reduces the heat transfer through the TBC.
  • B a high degree of inhomogeneities and porosity
  • One of these countermeasures is, for example, the spraying of thicker layers. This is disadvantageous on the one hand very expensive, on the other hand practically impossible in many cases.
  • Typical TBC layer thicknesses are approx. 250-300 ⁇ m.
  • Al 2 O 3 (at least 0.1-3 mol%) in the microstructure of a TBC bring.
  • the Al 2 O 3 does not combine with the matrix of the ceramic layer, but forms deposits and thus prevents grain growth. However, this does not have a positive influence on the voltage gradient and thus on the reduction of the danger of the TBC breaking away.
  • EP 0799 904 A1 are known graded TBC, in the microstructure also oxides, preferably Al 2 O 3 , which were previously mixed with metallic materials, preferably alloyed nickel aluminides and then evaporated, were introduced. This achieves improved corrosion resistance under thermal cycling.
  • a Ni or NiCo aluminide layer for example NiCrAlY
  • Y 2 O 3 yttrium oxide
  • ZrO 2 stabilized zirconia
  • Such layers lead to improved thermal fatigue behavior of the components and good high-temperature oxidation resistance with acceptable adhesive strength.
  • the aim of the invention is to avoid the mentioned disadvantages of the prior art.
  • the invention is based on the object to develop an improved ceramic thermal barrier coating based on yttria (Y 2 O 3 ) stabilized zirconia (ZrO 2 ) for coating a component of a nickel-base superalloy, which is characterized by a long service life and high Oxidation resistance and ductility distinguished.
  • this object is achieved in that the thermal barrier coating on the basis of yttria (Y 2 O 3 ) stabilized zirconia (ZrO 2 ) in addition to production-related impurities still at least one high-temperature and oxidation-resistant intermetallic compound whose volume fraction as a function of the distance from the Surface of the nickel-based superalloy continuously or stepwise, preferably in exponential or linear form, decreases, wherein the intermetallic compound YRh and / or Erlr.
  • Y 2 O 3 yttria
  • ZrO 2 stabilized zirconia
  • the advantage of the invention is that a gradual change in the composition of the thermal barrier coating as a function of the thickness of the thermal barrier coating produces a less steep gradient of stress. This leads to a higher elongation tolerance of the TBC layer and thus on the one hand to an increased life under thermal stress (no chipping) and on the other hand to the possibility to apply thicker thermal barrier coatings and thus to use the coated components at higher temperatures.
  • the intermetallic compounds YRh and Erlr used are oxidation-resistant and have sufficient ductility over a wide temperature range. Also have They have a low tendency to interdiffuse and have a high melting point.
  • Distributive is when the volume fraction of the intermetallic compound in the layer at the surface of the component about 80 vol .-% and at the free surface is about 5%.
  • the invention is applicable to all components which are exposed to high temperatures and oxidative / corrosive environmental influences, such. As blades, heat accumulation segments or parts of the combustion chambers of gas turbines.
  • Fig. 1 shows in perspective view as an example of such components 1, a blade of a gas turbine.
  • the blade 1 consists of a blade root 2, a platform 3 and an airfoil 4, in which cooling air channels are present, the openings in Fig. 1 are denoted by 5.
  • the blade 1 is anchored with its blade root 2 in circumferential grooves in the rotor of the gas turbine, not shown.
  • the blade 4 is subjected to hot combustion gases, so that the surface 7 of the airfoil 4 is exposed to both the hot combustion gases and attacks by oxidation, corrosion and erosion.
  • the blade 4 is therefore on its outer surface 7 with a metallic adhesive layer 6 (in Fig. 1 not visible), on which a ceramic thermal barrier coating 8 is sprayed.
  • the base material of the rotor blade 1 of the gas turbine for example, consists of a directionally solidified nickel base superalloy CM 247 with the following chemical composition (in wt .-%): 0.07 C, 8.1 Cr, 9.2 Cr, 0.5 Mo, 9.5 W, 3.2 Ta, 5.6 Al, 0.7 Ti, 0.015 B, 0.015 Zr, 1.4 Hf, balance Ni.
  • the turbine blade may preferably consist of a single crystal alloy, for example with the following chemical composition (in% by weight): 7.7-8.3 Cr, 5.0-5.25 Co, 2.0-2.1 Mo, 7.8-8.3 W, 5.8-6.1 Ta, 4.9-5.1 Al, 1.3-1.4 Ti, 0.11-0.15 Si, 0.11-0.15 Hf, 200-750 ppm C, 50-400 ppm B, balance nickel and manufacturing impurities.
  • These base materials are provided on their outer surface 7 with a metallic adhesive layer 6, preferably of the type MCrAIY, where M is metal (Ni, Co, Fe or combinations thereof). in the In this case, NiCrAlY was used for the adhesive layer 6.
  • the Alvers adhesive layers of this type form an Al 2 O 3 -Zdertik 9, which forms by thermal oxidation of the adhesive layer 6. This Al 2 O 3 layer 9 chemically bonds the ceramic thermal barrier coating to the adhesive layer 6 and the substrate (nickel-base superalloy).
  • the TBC 8 consists of yttria (Y 2 O 3 ) stabilized zirconia (ZrO 2 ) with about 7% yttria present.
  • the thermal barrier coating 8 is sprayed by means of known thermal spraying, for example by means of APS.
  • the ceramic powder is first mixed with powder of at least one intermetallic compound 12, in the present example of YRh, and then this powder mixture is thermally sprayed onto the adhesive layer 6.
  • the volume fraction of the intermetallic compound 12 is very high, here 80 vol .-%.
  • Fig. 3 This is in Fig. 3 1, where the schematic profile of the volume fractions of intermetallic compounds 12 or zirconium oxide (ZrO 2 ) stabilized with yttrium oxide (Y 2 O 3 ) in the thermal barrier coating 8 is shown as a function of the distance from the adhesive layer 6, ie, the thickness of the thermal barrier coating 8 becomes.
  • the volume fraction of intermetallic compound 12 decreases continuously here exponentially. In other examples, it may also be linear or stepwise decreasing.
  • the ceramic thermal barrier coatings produced by APS consist of individual grains and have a relatively large porosity.
  • Fig. 2 These grains are designated by the reference numeral 10 and the pores by the reference numeral 11.
  • the intermetallic compound 12, here YRh preferably deposits in these pores 11.
  • the intermetallic compounds, such as YRh or Erlr are resistant to oxidation and have sufficient ductility in a wide temperature range. In addition, they have little tendency for interdiffusion and have a high melting point. Due to the gradual change in the composition of the thermal barrier coating as a function of the thickness of the thermal barrier coating, a less steep stress gradient is advantageously generated in the layer. This leads to a higher elongation tolerance of the thermal barrier coating and thus on the one hand to increased life under thermal stress (no chipping) and on the other hand to the possibility to apply thicker thermal barrier coatings and thus use the coated components at higher temperatures.
  • layer thicknesses of approximately 250-300 ⁇ m could be sprayed by means of APS in the case of conventional yttria-stabilized zirconium oxide thermal barrier coatings, layer thicknesses of up to approximately 2 mm can easily be achieved in the present invention.
  • the invention is not limited to the example described.
  • the following intermetallic compound is also suitable for achieving the advantages according to the invention: Erlr, since these intermetallic compounds are resistant to oxidation, have good ductility in all temperature ranges, and have a low tendency to interdiffuse and have high melting points. Due to the gradual grading of the volume fraction of intermetallic compound a less steep voltage gradient is achieved, so that the thermal barrier coating substantially is more strain tolerant and thus has a longer life under thermal stress.
  • novel thermal barrier coatings can also be applied to other thermally highly loaded gas turbine components, such as heat shields or combustion chamber liner, wherein the base material of the component z.
  • B. Hastalloy or Haynes 230 may be and the adhesive layer z.
  • B. may be a NiCoCrAIY layer.
  • thermal spraying of the TBC according to the present invention also other spraying methods are suitable as APS, z. Eg EB-PVD.
  • the thermal barrier coatings produced are stalk-shaped.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • General Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Inorganic Insulating Materials (AREA)
  • Insulated Conductors (AREA)
  • Cylinder Crankcases Of Internal Combustion Engines (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)

Abstract

A ceramic thermal barrier coating (8) for coating the surface (7) of a component (1) of a nickel-based superalloy, and an adhesive coating optionally applied thereon (6), preferably a gas turbine component, includes zirconium oxide (ZrO2) stabilized by yttrium oxide (Y2O3) and production-related impurities, as well as at least one high-temperature and oxidation resistant intermetallic compound, for example NiAl, YRh, ErIr, the volume fraction of which decreases continuously or in stages as the distance from the surface (7) of the component (1)/the adhesive coating (6) increases. Advantageously, a less steep stress gradient is produced by gradually varying the composition of the thermal barrier coating (8). This leads to an increased expansion tolerance of the thermal barrier coating (8) and thus, on the one hand, to an increased lifetime under thermal loading (no flaking) and, on the other hand, the possibility of applying thicker thermal barrier coatings (8), and there for of using the coated components (1) at higher temperatures.

Description

Technisches GebietTechnical area

Die Erfindung bezieht sich auf das Gebiet der Werkstofftechnik. Sie betrifft eine keramische Wärmedämmschicht, welche zum Beschichten thermisch hochbelasteter Bauteile, wie z. B. Laufschaufeln einer Gasturbine, eingesetzt wird.The invention relates to the field of materials technology. It relates to a ceramic thermal barrier coating, which for coating thermally highly stressed components such. As blades of a gas turbine, is used.

Stand der TechnikState of the art

Um die Effizienz von Gasturbinen zu erhöhen werden diese bei sehr hohen Betriebstemperaturen gefahren. Die den heissen Gasen ausgesetzten Bauteile, z. B. Leit- und Laufschaufeln oder Brennkammerelemente, werden daher bekanntermassen auf ihrer Oberfläche mit Wärmedämmschichten (Thermal Barrier Coatings, TBC) versehen, um höhere Betriebstemperaturen zu erreichen bzw. die Lebensdauer der Bauteile zu verlängern. Diese Wärmedämmschichten bestehen üblicherweise aus einem keramischen Material, meist aus mit Yttriumoxid (Y2O3) stabilisiertem Zirkonoxid (ZrO2), das auf die Oberfläche der oftmals aus Nickelbasis-Superlegierungen bestehenden Bauteile aufgebracht wird. Um die Haftung der keramischen Schicht auf dem Bauteil zu verbessern, werden zwischen der Wärmedämmschicht und der Oberfläche des Bauteiles oftmals Haftschichten aus MCrAIY vorgesehen, wobei M für Metall, und zwar für Ni, Fe, Co oder Kombinationen daraus, steht.In order to increase the efficiency of gas turbines, they are operated at very high operating temperatures. The hot gases exposed components, eg. As guide and blades or combustion chamber elements are therefore known to be provided on its surface with thermal barrier coatings (thermal barrier coatings, TBC) to achieve higher operating temperatures and to extend the life of the components. These thermal barrier coatings usually consist of a ceramic material, usually of yttria (Y 2 O 3 ) stabilized zirconia (ZrO 2 ), the is applied to the surface of the often made of nickel-base superalloys components. In order to improve the adhesion of the ceramic layer on the component, adhesive layers of MCrAIY are often provided between the thermal barrier coating and the surface of the component, where M stands for metal, specifically for Ni, Fe, Co or combinations thereof.

Es ist bekannter Stand der Technik, die TBC thermisch aufzuspritzen. Als mögliche Verfahren zum Aufbringen dieser Schichten sind Plasmaspritzen, wie z. B. Plasmaspritzen in Luft (Air Plasma Spraying APS), Niederdruck-Plasmaspritzen (Low Pressure Plasma Spraying LPPS), Vakuum-Plasmaspritzen (Vacuum Plasma Spraying VPS) oder Flammenspritzen, wie z. B. Hochgeschwindigkeitsflammenspritzen (High Velocity Oxygen Fuel HVOF), sowie physikalische Dampfabscheidung (Physical Vapour Deposition PVD), z. B. mittels Elektronenstrahl (Electron Beam Physical Vapour Deposition EP-PVD) bekannt (siehe z. B. US 6,352,788 B2 , US 6,544,665 B2 ).It is well known in the art to thermally spray on the TBC. As a possible method for applying these layers are plasma spraying, such as. As plasma spraying in air (Air Plasma Spraying APS), low pressure plasma spraying (LPPS), vacuum plasma spraying (VPS) or flame spraying, such. High Velocity Oxygen Fuel (HVOF), as well as Physical Vapor Deposition (PVD), e.g. B. by electron beam (Electron Beam Physical Vapor Deposition EP-PVD) known (see, eg. US 6,352,788 B2 . US 6,544,665 B2 ).

Mit Hilfe des EP-PVD-Verfahren werden säulenartige Schichten erzeugt, die eine dehnungstolerante Kornstruktur aufweisen, die fähig ist sich bei unterschiedlicher Beanspruchung auszudehnen oder zusammenzuziehen, so dass keine Spannungen erzeugt werden, welche beispielsweise zum Abplatzen der Schichten führen würden. Nachteilig sind bei diesem Verfahren aber die hohen Kosten.With the aid of the EP-PVD method, columnar layers are produced which have an expansion-tolerant grain structure that is capable of expanding or contracting under different loads, so that no stresses are generated which would, for example, cause the layers to flake off. The disadvantage of this method but the high cost.

Im Gegensatz dazu haben APS-gespritze TBC z. B. einen hohen Grad an Inhomogenitäten und Porosität, was vorteilhaft den Wärmetransfer durch die TBC reduziert. Während des Betriebes einer Gasturbine erhöht aber sich durch Strukturveränderungen, z. B. Kornwachstum, die thermische Leitfähigkeit, so dass Gegenmassnahmen getroffen werden müssen um einen ausreichenden Wärmeschutz zu erreichen. Eine dieser Gegenmassnahmen ist beispielsweise das Spritzen dickerer Schichten. Dies ist nachteilig einerseits sehr teuer, andererseits praktisch oftmals nicht machbar. Übliche TBC-Schichtdicken sind ca. 250-300 µm.In contrast, APS-sprayed TBCs have e.g. B. a high degree of inhomogeneities and porosity, which advantageously reduces the heat transfer through the TBC. During operation of a gas turbine but increased by structural changes, eg. As grain growth, the thermal conductivity, so that countermeasures must be taken to achieve adequate thermal protection. One of these countermeasures is, for example, the spraying of thicker layers. This is disadvantageous on the one hand very expensive, on the other hand practically impossible in many cases. Typical TBC layer thicknesses are approx. 250-300 μm.

Gemäss US 6,544,665 B2 wird deshalb vorgeschlagen, z. B. Al2O3 (mindestens 0.1-3 Mol-%) in die Mikrostruktur einer TBC einzubringen. Das Al2O3 verbindet sich nicht mit der Matrix der keramischen Schicht, sondern bildet Ablagerungen und verhindert damit das Kornwachstum. Einen positiven Einfluss auf den Spannungsgradienten und damit auf die Senkung der Abplatzgefahr der TBC hat dies aber nicht.According to US 6,544,665 B2 is therefore proposed, for. B. Al 2 O 3 (at least 0.1-3 mol%) in the microstructure of a TBC bring. The Al 2 O 3 does not combine with the matrix of the ceramic layer, but forms deposits and thus prevents grain growth. However, this does not have a positive influence on the voltage gradient and thus on the reduction of the danger of the TBC breaking away.

Aus EP 0799 904 A1 sind gradierte TBC bekannt, in deren Mikrostruktur ebenfalls Oxide, vorzugsweise Al2O3, welche vorgängig mit metallischen Materialien, vorzugsweise legierten Nickel-Aluminiden gemischt und dann verdampft worden sind, eingebracht wurden. Dadurch wird eine verbesserte Korrosionsbeständigkeit unter thermischer Wechselbeanspruchung erreicht.Out EP 0799 904 A1 are known graded TBC, in the microstructure also oxides, preferably Al 2 O 3 , which were previously mixed with metallic materials, preferably alloyed nickel aluminides and then evaporated, were introduced. This achieves improved corrosion resistance under thermal cycling.

Weiterhin ist bekannt (siehe beispielsweise Z.L.Dong et al: "Microstructure formation in plasma-sprayed functuonally graded NiCoCrAIY/yttria-stabilized zirconia coatings", Surface and Coatings Technology 114 (1999), S. 181-186 und Y.-S. Song et al: "High-temperature properties of plasma-prayed coatings of YSZ/NiCrAIY on Inconel substrate", Materials Science and Engineering A 332 (2002), S. 129-133 ), thermisch stark belastete Gasturbinenkomponenten mit funktional gradierten Schichten zu versehen. Diese Schichten bestehen aus einer Ni- oder NiCo-Aluminidschicht, beispielsweise NiCrAlY, als Haftschicht, welche auf der Oberfläche des metallischen Substrates aufgebracht ist (= unterste Schichtlage), aus einer äusseren TBC-Schicht (= oberste Schichtlage), bestehend aus mit Yttriumoxid (Y2O3) stabilisiertem Zirkonoxid (ZrO2), und aus mehreren Zwischenschichtlagen, bei denen jeweils das Haftschichtmaterial mit dem TBC-Material in unterschiedlichen Verhältnissen gemischt ist. Derartige Schichten führen zu einem verbesserten thermischen Ermüdungsverhalten der Bauteile und zu einer guten Hochtemperatur-Oxidationsbeständigkeit mit vertretbarer Haftfestigkeit.Furthermore, it is known (see, for example ZLDong et al: "Microstructure formation in plasma-sprayed functionally graded NiCoCrAlY / yttria-stabilized zirconia coatings", Surface and Coatings Technology 114 (1999), pp. 181-186 and Y.-S. Song et al: "High-temperature properties of plasma-coated coatings of YSZ / NiCrAlY on Inconel substrate", Materials Science and Engineering A 332 (2002), pp. 129-133 ), to provide thermally heavily loaded gas turbine components with functionally graded layers. These layers consist of a Ni or NiCo aluminide layer, for example NiCrAlY, as an adhesion layer, which is applied to the surface of the metallic substrate (= lowest layer layer), from an outer TBC layer (= uppermost layer layer) consisting of yttrium oxide ( Y 2 O 3 ) stabilized zirconia (ZrO 2 ), and of several interlayer layers in which the adhesive layer material is mixed with the TBC material in different proportions. Such layers lead to improved thermal fatigue behavior of the components and good high-temperature oxidation resistance with acceptable adhesive strength.

Darstellung der ErfindungPresentation of the invention

Ziel der Erfindung ist es, die genannten Nachteile des Standes der Technik zu vermeiden. Der Erfindung liegt die Aufgabe zu Grunde, zur Beschichtung einer Komponente aus einer Nickelbasis-Superlegierung eine verbesserte keramische Wärmedämmschicht auf der Grundlage von mit Yttriumoxid (Y2O3) stabilisiertem Zirkonoxid (ZrO2) zu entwickeln, welche sich durch eine hohe Lebensdauer und hohe Oxidationsbeständigkeit und Duktilität auszeichnet.The aim of the invention is to avoid the mentioned disadvantages of the prior art. The invention is based on the object to develop an improved ceramic thermal barrier coating based on yttria (Y 2 O 3 ) stabilized zirconia (ZrO 2 ) for coating a component of a nickel-base superalloy, which is characterized by a long service life and high Oxidation resistance and ductility distinguished.

Erfindungsgemäss wird diese Aufgabe dadurch gelöst, dass die Wärmedämmschicht auf der Grundlage von mit Yttriumoxid (Y2O3) stabilisiertem Zirkonoxid (ZrO2) neben herstellungsbedingten Verunreinigungen noch mindestens eine hochtemperatur- und oxidationsbeständige intermetallische Verbindung aufweist, deren Volumenanteil in Abhängigkeit vom Abstand von der Oberfläche der Nickel-Basis-Superlegierung kontinuierlich oder stufenweise, vorzugsweise in exponentieller oder linearer Form, abnimmt, wobei die intermetallische Verbindung YRh und/oder Erlr ist.According to the invention, this object is achieved in that the thermal barrier coating on the basis of yttria (Y 2 O 3 ) stabilized zirconia (ZrO 2 ) in addition to production-related impurities still at least one high-temperature and oxidation-resistant intermetallic compound whose volume fraction as a function of the distance from the Surface of the nickel-based superalloy continuously or stepwise, preferably in exponential or linear form, decreases, wherein the intermetallic compound YRh and / or Erlr.

Der Vorteil der Erfindung besteht darin, dass durch die allmähliche Veränderung der Zusammensetzung der Wärmedämmschicht in Abhängigkeit von der Dicke der Wärmedämmschicht ein weniger steiler Spannungsgradient erzeugt wird. Dies führt zu einer höheren Dehnungstoleranz der TBC-Schicht und damit einerseits zu einer erhöhten Lebensdauer bei thermischer Beanspruchung (kein Abplatzen) und anderseits zur Möglichkeit, dickere Wärmedämmschichten aufzubringen und somit die beschichteten Bauteile bei höheren Temperaturen einzusetzen. Die verwendeten intermetallischen Verbindungen YRh und Erlr sind oxidationsbeständig und besitzen in einem grossen Temperaturbereich eine ausreichende Duktilität. Ausserdem haben sie nur eine geringe Tendenz zur Interdiffusion und besitzen einen hohen Schmelzpunkt.The advantage of the invention is that a gradual change in the composition of the thermal barrier coating as a function of the thickness of the thermal barrier coating produces a less steep gradient of stress. This leads to a higher elongation tolerance of the TBC layer and thus on the one hand to an increased life under thermal stress (no chipping) and on the other hand to the possibility to apply thicker thermal barrier coatings and thus to use the coated components at higher temperatures. The intermetallic compounds YRh and Erlr used are oxidation-resistant and have sufficient ductility over a wide temperature range. Also have They have a low tendency to interdiffuse and have a high melting point.

Verteilhaft ist, wenn der Volumenanteil der intermetallischen Verbindung in der Schicht an der Oberfläche der Komponente ca. 80 Vol.-% und an der freien Oberfläche ca. 5 % beträgt.Distributive is when the volume fraction of the intermetallic compound in the layer at the surface of the component about 80 vol .-% and at the free surface is about 5%.

Kurze Beschreibung der ZeichnungShort description of the drawing

In der Zeichnung ist ein Ausführungsbeispiel der Erfindung dargestellt.In the drawing, an embodiment of the invention is shown.

Es zeigen.

Fig. 1
eine perspektivische Darstellung einer Laufschaufel einer Gasturbine;
Fig. 2
einen Schnitt entlang der Linie II-II in Fig. 1 und
Fig. 3
einen schematischen Verlauf der Volumenanteile in der TBC in Abhängigkeit vom Abstand vom Grundsubstrat.
Show it.
Fig. 1
a perspective view of a blade of a gas turbine;
Fig. 2
a section along the line II-II in Fig. 1 and
Fig. 3
a schematic course of the volume fractions in the TBC as a function of the distance from the base substrate.

Es sind nur die für die Erfindung wesentlichen Merkmale dargestellt. Gleiche Elemente haben in unterschiedlichen Figuren gleiche Bezugszeichen.Only the essential features of the invention are shown. Identical elements have the same reference numerals in different figures.

Wege zur Ausführung der ErfindungWays to carry out the invention

Nachfolgend wird die Erfindung anhand eines Ausführungsbeispieles näher erläutert.The invention will be explained in more detail with reference to an embodiment.

Die Erfindung ist anwendbar für alle Komponenten, welche hohen Temperaturen und oxidativen/korrosiven Umwelteinflüssen ausgesetzt sind, wie z. B. Schaufeln, Wärmestausegmente oder Teile der Brennkammern von Gasturbinen.The invention is applicable to all components which are exposed to high temperatures and oxidative / corrosive environmental influences, such. As blades, heat accumulation segments or parts of the combustion chambers of gas turbines.

Fig. 1 zeigt in perspektivischer Darstellung als ein Beispiel derartiger Komponenten 1 eine Laufschaufel einer Gasturbine. Die Laufschaufel 1 besteht aus einem Schaufelfuss 2, einer Plattform 3 und einem Schaufelblatt 4, in welchem Kühlluftkanäle vorhanden sind, deren Öffnungen in Fig. 1 mit 5 bezeichnet sind. Die Laufschaufel 1 wird mit ihrem Schaufelfuss 2 in Umfangsnuten im nicht dargestellten Rotor der Gasturbine verankert. Während des Betriebes der Turbine wird das Schaufelblatt 4 mit heissen Verbrennungsgasen beaufschlagt, so dass die Oberfläche 7 des Schaufelblattes 4 sowohl den heissen Verbrennungsgasen als auch Angriffen durch Oxidation, Korrosion und Erosion ausgesetzt ist. Zum Schutz vor Oxidation/Korrosion sowie zu hoher thermischer Belastung ist das Schaufelblatt 4 daher auf seiner äusseren Oberfläche 7 mit einer metallischen Haftschicht 6 (in Fig. 1 nicht sichtbar) versehen, auf der eine keramische Wärmedämmschicht 8 aufgespritzt ist. Fig. 1 shows in perspective view as an example of such components 1, a blade of a gas turbine. The blade 1 consists of a blade root 2, a platform 3 and an airfoil 4, in which cooling air channels are present, the openings in Fig. 1 are denoted by 5. The blade 1 is anchored with its blade root 2 in circumferential grooves in the rotor of the gas turbine, not shown. During operation of the turbine, the blade 4 is subjected to hot combustion gases, so that the surface 7 of the airfoil 4 is exposed to both the hot combustion gases and attacks by oxidation, corrosion and erosion. For protection against oxidation / corrosion and high thermal stress, the blade 4 is therefore on its outer surface 7 with a metallic adhesive layer 6 (in Fig. 1 not visible), on which a ceramic thermal barrier coating 8 is sprayed.

In der Schnittdarstellung gemäss Fig. 2 ist das Beschichtungssystem gut zu erkennen. Der Grundwerkstoff der Laufschaufel 1 der Gasturbine besteht beispielsweise aus einer gerichtet erstarrten Nickel-Basissuperlegierung CM 247 mit folgender chemischer Zusammensetzung (Angaben in Gew.-%): 0.07 C, 8.1 Cr, 9.2 Cr, 0.5 Mo, 9.5 W, 3.2 Ta, 5.6 Al, 0.7 Ti, 0.015 B, 0.015 Zr, 1.4 Hf, Rest Ni.In the sectional view according to Fig. 2 the coating system is easy to recognize. The base material of the rotor blade 1 of the gas turbine, for example, consists of a directionally solidified nickel base superalloy CM 247 with the following chemical composition (in wt .-%): 0.07 C, 8.1 Cr, 9.2 Cr, 0.5 Mo, 9.5 W, 3.2 Ta, 5.6 Al, 0.7 Ti, 0.015 B, 0.015 Zr, 1.4 Hf, balance Ni.

In einem anderen beispiel kann die Turbinenschaufel vorzugsweise aus einer Einkristalllegierung, beispielsweise mit folgender chemischer Zusammensetzung bestehen (Angaben in Gew.-%): 7.7-8.3 Cr, 5.0-5.25 Co, 2.0-2.1 Mo, 7.8-8.3 W, 5.8-6.1 Ta, 4.9-5.1 Al, 1.3-1.4 Ti, 0.11-0.15 Si, 0.11-0.15 Hf, 200-750 ppm C, 50-400 ppm B, Rest Nickel und herstellungsbedingte Verunreinigungen.In another example, the turbine blade may preferably consist of a single crystal alloy, for example with the following chemical composition (in% by weight): 7.7-8.3 Cr, 5.0-5.25 Co, 2.0-2.1 Mo, 7.8-8.3 W, 5.8-6.1 Ta, 4.9-5.1 Al, 1.3-1.4 Ti, 0.11-0.15 Si, 0.11-0.15 Hf, 200-750 ppm C, 50-400 ppm B, balance nickel and manufacturing impurities.

Diese Grundwerkstoffe (Substrate) sind auf ihrer äusseren Oberfläche 7 mit einer metallischen Haftschicht 6, vorzugsweise des Typs MCrAIY versehen, wobei M für Metall steht (Ni, Co, Fe oder deren Kombinationen). Im vorliegenden Falle wurde NiCrAlY für die Haftschicht 6 verwendet. Die Alreichen Haftschichten dieses Typs bilden eine Al2O3-Zunderschicht 9, die sich durch thermische Oxidation der Haftschicht 6 bildet. Diese Al2O3-Schicht 9 bindet chemisch die keramische Wärmedämmschicht an die Haftschicht 6 und das Substrat (Nickel-Basissuperlegierung).These base materials (substrates) are provided on their outer surface 7 with a metallic adhesive layer 6, preferably of the type MCrAIY, where M is metal (Ni, Co, Fe or combinations thereof). in the In this case, NiCrAlY was used for the adhesive layer 6. The Alreichen adhesive layers of this type form an Al 2 O 3 -Zderschicht 9, which forms by thermal oxidation of the adhesive layer 6. This Al 2 O 3 layer 9 chemically bonds the ceramic thermal barrier coating to the adhesive layer 6 and the substrate (nickel-base superalloy).

Die TBC 8 besteht aus mit Yttriumoxid (Y2O3) stabilisiertem Zirkonoxid (ZrO2), wobei etwa 7 % Yttriumoxid vorhanden ist. Die Wärmedämmschicht 8 wird mittels bekannter thermischer Spritzverfahren beispielsweise mittels APS aufgespritzt. Dazu wird das keramische Pulver zunächst mit Pulver aus mindestens einer intermetallischen Verbindung 12, im vorliegenden Beispiel aus YRh, gemischt und anschliessend diese Pulvermischung auf die Haftschicht 6 thermisch aufgespritzt. Im ersten Verfahrensschritt ist der Volumenanteil der intermetallischen Verbindung 12 sehr hoch, hier 80 Vol.-%. Die beiden Verfahrensschritte werden nun mehrfach wiederholt werden, wobei die Pulvermischung jeweils einen geringeren Volumenanteil an der intermetallischen Verbindung YRh aufweist als in den vorangegangenen Verfahrensschritten und die Pulvermischung jeweils auf die bereits im vorangegangenen Verfahrensschritt aufgespritzte Schicht aufgespritzt wird, so dass letztlich eine Wärmedämmschicht 8 mit einem über die Schichtdicke abnehmenden Volumenanteil an intermetallischer Verbindung 12 gebildet wird. Letztlich sind an der Oberfläche der fertig beschichteten Komponente 1 nur noch ca. 5 Vol.-% YRh vorhanden.The TBC 8 consists of yttria (Y 2 O 3 ) stabilized zirconia (ZrO 2 ) with about 7% yttria present. The thermal barrier coating 8 is sprayed by means of known thermal spraying, for example by means of APS. For this purpose, the ceramic powder is first mixed with powder of at least one intermetallic compound 12, in the present example of YRh, and then this powder mixture is thermally sprayed onto the adhesive layer 6. In the first process step, the volume fraction of the intermetallic compound 12 is very high, here 80 vol .-%. The two process steps will now be repeated several times, wherein the powder mixture in each case has a smaller volume fraction of the intermetallic compound YRh than in the preceding process steps and the powder mixture is sprayed onto the sprayed already in the previous process step layer, so that ultimately a thermal barrier coating 8 with a via the layer thickness decreasing volume fraction of intermetallic compound 12 is formed. Finally, only about 5 vol .-% YRh are present on the surface of the finished coated component 1.

Dies ist in Fig. 3 dargestellt, wo der schematische Verlauf der Volumenanteile an intermetallischer Verbindungen 12 bzw. an mit Yttriumoxid (Y2O3) stabilisiertem Zirkonoxid (ZrO2) in der Wärmedämmschicht 8 in Abhängigkeit vom Abstand von der Haftschicht 6, d.h. von der Dicke der Wärmedämmschicht 8 gezeigt wird. Der Volumenanteil an intermetallischer Verbindung 12 nimmt hier kontinuierlich exponentiell ab. In anderen Beispielen kann er auch linear oder stufenweise abnehmend sein.This is in Fig. 3 1, where the schematic profile of the volume fractions of intermetallic compounds 12 or zirconium oxide (ZrO 2 ) stabilized with yttrium oxide (Y 2 O 3 ) in the thermal barrier coating 8 is shown as a function of the distance from the adhesive layer 6, ie, the thickness of the thermal barrier coating 8 becomes. The volume fraction of intermetallic compound 12 decreases continuously here exponentially. In other examples, it may also be linear or stepwise decreasing.

Es ist bekannt, dass die durch APS erzeugten keramischen Wärmedämmschichten aus einzelnen Körner bestehen und eine relativ grosse Porosität aufweisen. In Fig. 2 sind diese Körner mit dem Bezugszeichen 10 und die Poren mit dem Bezugszeichen 11 bezeichnet. Bei der erfindungsgemässen Wärmedämmschicht 8 lagert sich die intermetallische Verbindung 12, hier YRh, bevorzugt in diesen Poren 11 ab. Die intermetallischen Verbindungen, wie beispielsweise YRh oder Erlr, sind oxidationsbeständig und besitzen in einem grossen Temperaturbereich eine ausreichende Duktilität. Ausserdem haben sie nur eine geringe Tendenz zur Interdiffusion und besitzen einen hohen Schmelzpunkt. Durch die allmähliche Veränderung der Zusammensetzung der Wärmedämmschicht in Abhängigkeit von der Dicke der Wärmedämmschicht wird mit Vorteil ein weniger steiler Spannungsgradient in der Schicht erzeugt. Dies führt zu einer höheren Dehnungstoleranz der Wärmedämmschicht und damit einerseits zu einer erhöhten Lebensdauer bei thermischer Beanspruchung (kein Abplatzen) und anderseits zur Möglichkeit, dickere Wärmedämmschichten aufzubringen und somit die beschichteten Bauteile bei höheren Temperaturen einzusetzen.It is known that the ceramic thermal barrier coatings produced by APS consist of individual grains and have a relatively large porosity. In Fig. 2 These grains are designated by the reference numeral 10 and the pores by the reference numeral 11. In the case of the thermal barrier coating 8 according to the invention, the intermetallic compound 12, here YRh, preferably deposits in these pores 11. The intermetallic compounds, such as YRh or Erlr, are resistant to oxidation and have sufficient ductility in a wide temperature range. In addition, they have little tendency for interdiffusion and have a high melting point. Due to the gradual change in the composition of the thermal barrier coating as a function of the thickness of the thermal barrier coating, a less steep stress gradient is advantageously generated in the layer. This leads to a higher elongation tolerance of the thermal barrier coating and thus on the one hand to increased life under thermal stress (no chipping) and on the other hand to the possibility to apply thicker thermal barrier coatings and thus use the coated components at higher temperatures.

Während bei konventionellen mit Yttriumoxid stabilisierten Zirkonoxid-Wärmedämmschichten Schichtdicken von ca. 250-300 µm mittels APS gespritzt werden konnten, sind bei der vorliegenden Erfindung Schichtdicken bis ca. 2 mm problemlos machbar.While layer thicknesses of approximately 250-300 μm could be sprayed by means of APS in the case of conventional yttria-stabilized zirconium oxide thermal barrier coatings, layer thicknesses of up to approximately 2 mm can easily be achieved in the present invention.

Selbstverständlich ist die Erfindung nicht auf das beschriebene Beispiel beschränkt. Neben dem bereits erwähnten YRh ist auch die folgende intermetallische Verbindung geeignet, die erfindungsgemässen Vorteile zu erreichen: Erlr , da diese intermetallischen Verbindungen oxidationsbeständig sind, in allen Temperaturbereichen eine gute Duktilität aufweisen, sowie eine geringe Tendenz zur Interdiffusion und hohe Schmelzpunkte haben. Infolge der allmählichen Abstufung des Volumenanteils an intermetallischer Verbindung wird ein weniger steiler Spannungsgradient erreicht, so dass die Wärmedämmschicht wesentlich dehnungstoleranter ist und damit eine längere Lebensdauer bei thermischer Beanspruchung aufweist.Of course, the invention is not limited to the example described. In addition to the YRh already mentioned, the following intermetallic compound is also suitable for achieving the advantages according to the invention: Erlr, since these intermetallic compounds are resistant to oxidation, have good ductility in all temperature ranges, and have a low tendency to interdiffuse and have high melting points. Due to the gradual grading of the volume fraction of intermetallic compound a less steep voltage gradient is achieved, so that the thermal barrier coating substantially is more strain tolerant and thus has a longer life under thermal stress.

Die erfindungsgemässen Wärmedämmschichten können auch auf andere thermisch hochbelastete Gasturbinenkomponenten, wie beispielsweise Wärmeschutzschilder oder Brennkammerliner, aufgebracht werden, wobei der Grundwerkstoff der Komponente z. B. Hastalloy oder Haynes 230 sein kann und die Haftschicht z. B. eine NiCoCrAIY-Schicht sein kann.The novel thermal barrier coatings can also be applied to other thermally highly loaded gas turbine components, such as heat shields or combustion chamber liner, wherein the base material of the component z. B. Hastalloy or Haynes 230 may be and the adhesive layer z. B. may be a NiCoCrAIY layer.

Schliesslich sind zum thermischen Spritzen der TBC gemäss vorliegender Erfindung auch andere Spritzverfahren als APS geeignet, z. B. EB-PVD. Die damit erzeugten Wärmedämmschichten sind stängelförmig.Finally, for thermal spraying of the TBC according to the present invention, also other spraying methods are suitable as APS, z. Eg EB-PVD. The thermal barrier coatings produced are stalk-shaped.

Selbstverständlich ist es auch möglich, die TBC direkt auf die Oberfläche der Komponente zu spritzen, d.h. ohne eine zusätzliche Haftschicht.Of course, it is also possible to inject the TBC directly onto the surface of the component, i. without an additional adhesive layer.

BezugszeichenlisteLIST OF REFERENCE NUMBERS

11
Komponente, z. B. LaufschaufelComponent, e.g. B. Blade
22
Schaufelfussblade root
33
Plattformplatform
44
Schaufelblattairfoil
55
Öffnungen der KühlluftkanäleOpenings of the cooling air ducts
66
Haftschichtadhesive layer
77
Oberfläche der KomponenteSurface of the component
88th
Wärmedämmschicht, TBCThermal barrier coating, TBC
99
Al2O3-SchichtAl 2 O 3 layer
1010
Korngrain
1111
Porepore
1212
Intermetallische VerbindungIntermetallic compound

Claims (5)

  1. Ceramic thermal barrier coating (8) for coating the surface (7) of a component (1) consisting of a nickel-based superalloy and an adhesive coating optionally applied thereon (6), the thermal barrier coating (8) preferably consisting of zirconium oxide (ZrO2) stabilized by yttrium oxide (Y2O3) and production-related impurities, and the thermal barrier coating (8) comprises at least one high-temperature and oxidation resistant intermetallic compound, the volume fraction of which decreases continuously or in stages as the distance from the surface (7) of the component (1)/the adhesive coating (6) increases, characterized in that the intermetallic compound is YRh and/or ErIr.
  2. Thermal barrier coating (8) as claimed in Claim 1, characterized in that the volume fraction of the intermetallic compound decreases exponentially as the distance from the surface (7) of the component (1)/the adhesive coating (6) increases.
  3. Thermal barrier coating (8) as claimed in Claim 1, characterized in that the volume fraction of the intermetallic compound decreases linearly as the distance from the surface (7) of the component (1)/the adhesive coating (6) increases.
  4. Thermal barrier coating (8) as claimed in Claim 1, characterized in that the volume fraction of the intermetallic compound in the coating is approximately 80% on the surface (7) of the component (1) and approximately 5% on the free surface.
  5. Gas turbine component, characterized in that it is coated with a thermal barrier coating (8) as claimed in one of Claims 1-4.
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US20100104764A1 (en) 2010-04-29
WO2007006681A1 (en) 2007-01-18
ATE426052T1 (en) 2009-04-15
US20080241560A1 (en) 2008-10-02
EP1902160A1 (en) 2008-03-26
DE502006003197D1 (en) 2009-04-30

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