EP1923478A1 - Roughend bond coating - Google Patents

Roughend bond coating Download PDF

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Publication number
EP1923478A1
EP1923478A1 EP20060023663 EP06023663A EP1923478A1 EP 1923478 A1 EP1923478 A1 EP 1923478A1 EP 20060023663 EP20060023663 EP 20060023663 EP 06023663 A EP06023663 A EP 06023663A EP 1923478 A1 EP1923478 A1 EP 1923478A1
Authority
EP
European Patent Office
Prior art keywords
particle stream
powder particles
characterized
substrate
coating
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP20060023663
Other languages
German (de)
French (fr)
Inventor
Knut Halberstadt
Werner Dr. Stamm
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Siemens AG
Original Assignee
Siemens AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Siemens AG filed Critical Siemens AG
Priority to EP20060023663 priority Critical patent/EP1923478A1/en
Publication of EP1923478A1 publication Critical patent/EP1923478A1/en
Application status is Withdrawn legal-status Critical

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    • CCHEMISTRY; METALLURGY
    • C23COATING 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
    • C23CCOATING 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
    • C23C24/00Coating starting from inorganic powder
    • CCHEMISTRY; METALLURGY
    • C23COATING 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
    • C23CCOATING 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
    • C23C28/00Coating 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
    • C23C28/02Coating 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 only coatings only including layers of metallic material
    • C23C28/021Coating 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 only coatings only including layers of metallic material including at least one metal alloy layer
    • C23C28/022Coating 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 only coatings only including layers of metallic material including at least one metal alloy layer with at least one MCrAlX layer
    • CCHEMISTRY; METALLURGY
    • C23COATING 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
    • C23CCOATING 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
    • C23C4/00Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying

Abstract

The high speed physical vapor deposition or cold spray method for coating a substrate with a bonding agent layer, comprises generating a particle stream (8) of a coating material (15), depositing the particle stream on the substrate, heating the particle stream at 550-650 [deg] C, and adding powder particles (14) with a larger particle size of 45-85 mu m to the particle stream. The particles accelerate on a speed of sound and then added to the particle stream. A turbine blade (9) is coated as substrate with the bonding agent layer. An independent claim is included for a device for coating a substrate with a bonding agent layer.

Description

  • The invention relates to a HS-PVD or cold spray method for coating a substrate with a primer layer in which a particle stream of a coating material is produced, deposited on the substrate and subjected to a subsequent heat treatment.
    The invention further relates to a device for carrying out the method.
  • It is known in the prior art to provide substrates such as turbine blades by means of an HS-PVD (High Speed Physical Vapor Deposition) method with an adhesion promoter layer, for example of MCrAlY. For this purpose, an MCrAlY vapor cloud is generated from an MCrAlY ingot by means of an accelerated argon ion current. By electrical and magnetic fields, this vapor is discharged through a gap and in the direction of the substrate to be coated, on which also an electric field is applied, accelerated and deposited there. Subsequently, the applied MCrAlY layer is subjected to a heat treatment.
  • It is also known to apply an MCrAlY primer layer to a turbine blade by a cold spray method. A MCrAlY powder with a grain size of approx. 22 μm - 45 μm is heated in a gas stream via a preheating unit to a temperature of up to 600 ° C and then accelerated to a speed of up to 3 Mach with the necessary kinetic Provide energy. The thus formed particle stream is deposited on the substrate and then also subjected to a heat treatment.
  • In the case of the two known methods, in each case a smooth homogeneous MCrAlY coating is obtained, which is poorly suited for a coating with a thermal barrier coating such as, for example, an APS-TBC. This is particularly due to the adhesion of the thermal barrier coating to the primer layer is too low.
  • Object of the present invention is therefore to provide a method of the type mentioned in such a way that a rough adhesion promoter layer can be applied to the substrate, which ensures better adhesion of the thermal barrier coating.
  • This object is achieved in a method of the type mentioned in that powder particles are added to the particle flow with a larger grain size.
  • The basic idea of the invention is therefore to add to the particle stream of the coating material, which is produced by an HS-PVD or by a cold spray process, powder particles whose grain size is greater than the grain size of the particles. The thus modified mixed particle flow is then deposited on the component, so that a coating is obtained in which at least particles or particles with two different grains are contained. This layer may also be formed as a duplex layer, wherein only the upper layer, the coarse grain size is added. After the subsequent heat treatment, a bonding agent layer is obtained, which has a rough surface due to the different grain sizes of the particles or particles contained. These surface properties ensure a firm connection of any later applied thermal barrier coating.
  • According to a first embodiment of the invention it is provided that MCrAlY is used as the coating material. This material is particularly suitable because it ensures good adhesion to various substrates and further forms a chemically and physically resistant substrate for various thermal barrier coatings.
  • It is also envisaged that powder particles from the coating material can be added to the particle stream. This gives a primer layer with a homogeneous material composition. Alternatively or additionally, it is also possible to add powder particles which do not consist of the coating material to the particle stream.
  • The grain size of the powder particles can be between 45 μm to 85 μm. In this case, a primer layer is obtained in which the powder particles are embedded in a matrix of finer particles, so that a high roughness is obtained.
  • According to a further embodiment of the invention, it is provided that the powder particles are accelerated to a speed in the range of the speed of sound and then added to the particle stream. In this way it is ensured that the powder particles are completely incorporated into the primer layer, since it is excluded that parts of the powder particles are elastically reflected by the surface of the substrate due to a too high speed.
  • It may be useful to heat the powder particles prior to adding to the particle stream to prevent the temperature level of the particle stream from being reduced by the addition of the powder particles. The temperature should be in the range between 550 ° C and 650 ° C in particular.
  • As a substrate, a turbine blade can be coated with the adhesion promoter layer. It is advantageous that the adhesion promoter layer obtained particularly well meets the high requirements during operation of a turbine and ensures strong adhesion of a possibly applied to her thermal barrier coating.
  • The object is likewise achieved by a device for carrying out the method according to the invention.
  • In the following the invention will be explained in more detail with reference to two embodiments with reference to the accompanying drawings.
  • In the drawings show
  • FIG. 1
    a schematic representation of a first device according to the invention, and
    FIG. 2
    a schematic representation of a second device according to the invention.
  • FIG. 1 shows a first device according to the invention for carrying out the method according to the invention. The device comprises a cold spray device 1 and a powder particle feeder 2. The cold spray device has a gas supply device 3, which is additionally provided with a heating device, not shown, for heating the gas. The gas supply device 3 is connected via a line 4 with a spray device 5. The spraying device 5 is further connected via a line 2 to a powder reservoir 6, which contains powdered particles of a coating material of MCrAlY with a grain size of 15 to 30 microns. The spraying device 5 also has a dispensing nozzle 7, from which a particle stream 8 is delivered in the direction of a turbine blade 9 to be coated.
  • The feeder 2 includes a reservoir 10 containing powder particles of MCrAlY having a grain size of 45 to 85 μm and a preheating unit 11 for preheating the powder particles and finally an acceleration unit 13 arranged immediately before a discharge opening 12 for accelerating the powder particles.
  • A stream of powder particles 14 exits from the discharge opening 12 and hits the surface of the turbine blade 9 simultaneously with the particle stream 8.
  • In order to coat the turbine blade 9 with an MCrAlY adhesion promoter layer with the device according to the invention, a gas is provided in the gas supply device 3 and heated to a temperature of up to 600 ° C. This gas flows through the conduit 4 into the spray device 5, in which the particles originating from the powder reservoir 6 are injected into the gas flow.
  • The resulting gas-particle mixture is then accelerated in the spraying device 5 to a speed of up to 3 Mach, discharged through the discharge nozzle 7 in the direction of the turbine blade 9, on the surface of which it finally strikes. Due to their high kinetic energy, the MCrAlY particles are cold-welded to the substrate and to each other.
  • At the same time, the powder particles are delivered to the preheating unit 11 in the supply device 2 from the reservoir 10 and heated in this to a temperature of about 600 ° C. From the preheating unit 11, the powder particles enter the acceleration unit 13, where they are accelerated to a speed in the range of the speed of sound and then discharged through the outlet opening 12 in the direction of the turbine blade 9.
  • The resulting stream of powder particles 14 impinges on the surface of the turbine blade 9 simultaneously with the particle stream 8 while mixing with it. Finally, a mixed beam is deposited.
  • In the formed on the surface of the turbine blade 9 coating 15 are both powdered particles with a grain size of 15 microns to 30 microns as well as powder particles with a grain size between 45 microns to 85 microns included.
  • After the coating 15 is applied to the turbine blade 9, this is subjected to a subsequent heat treatment by means of a heater, not shown, in which the powder particles react by diffusion with the substrate so as to form a firmly adhering rough adhesion promoter layer.
  • FIG. 2 shows a second device according to the invention for coating a substrate with a bonding agent layer. The apparatus comprises a HS-PVD device 16 and a powder particle feeder 2.
  • The HS-PVD device 16 has an exit plate 18 and an ion source 17 which contains a cathode, not shown, of an MCrAlY ingot from which an MCrAlY ion vapor cloud is generated by means of an argon ion stream, also not shown.
  • At the exit slit 18 of the HS-PVD device 16 and on the turbine blade 9, an electric field is applied with the aid of the current source 19. As a result of this, the MCrAlY ions are bundled through the outlet gap 18 and emitted in the direction of the turbine blade 9 as a focused particle stream 8. This strikes the surface of a turbine blade 9 and is deposited there.
  • The feeder 2 is identical to the feeder 2 described in FIG.
  • In order to coat the turbine blade 9 with the second device according to the invention, 16 MCrAlY ions are generated in the ion source 17 of the HS-PVD device, said ions being generated by means of the applied electric field through the outlet gap 18 are bundled to the particle stream 8 and discharged in the direction of the turbine blade 9.
  • At the same time in the manner described above of the feeder 2 powder particles whose grain size is between 45 microns and 85 microns, heated, accelerated and discharged in the direction of the turbine blade 9.
  • These powder particles impinge on the surface of the turbine blade 9 simultaneously with the particle stream 8 in the manner already described above and together with these form a coating 15.
  • Subsequent heat treatment forms the primer layer in its final form.
  • Because of their large roughness, the two primer layers described above are very well suited for ensuring strong adhesion of a thermal barrier coating applied to them.

Claims (10)

  1. An HS-PVD or cold spray method for coating a substrate with a primer layer in which a particle stream (8) is produced from a coating material, deposited on the substrate (9) and subjected to a subsequent heat treatment,
    characterized in that
    the particle stream (8) powder particles (14) are added with a larger grain size.
  2. Method according to claim 1,
    characterized in that
    as coating material MCrAlY is used.
  3. Method according to one of the preceding claims,
    characterized in that
    the particle stream (8) powder particles (14) are added from the coating material.
  4. Method according to one of the preceding claims,
    characterized in that
    Powder particles (14) with a grain size between 45 microns to 85 microns the particle stream (8) is added.
  5. Method according to one of the preceding claims,
    characterized in that
    the powder particles (14) are accelerated to a speed in the range of the speed of sound and then added to the particle stream (8).
  6. Method according to one of the preceding claims,
    characterized in that
    the powder particles (14), before they are added to the particle stream (8), are heated, in particular to a temperature in the range between 550 ° C and 650 ° C.
  7. Method according to one of the preceding claims,
    characterized in that
    as substrate (9) a turbine blade is coated with the adhesion promoter layer.
  8. Device for coating a substrate (9) with a primer layer,
    with a cold spray (1) or HS-PVD device (16) for generating and depositing a particle stream (8) from a coating material on the substrate (9) and
    with a heating device for heat treatment of the deposited coating material (15),
    characterized,
    in that it has a feed device (2) for injecting powder particles into the particle stream (8).
  9. Device according to claim 8,
    characterized in that
    the feed device (2) has a preheating unit (11) for preheating the powder particles.
  10. Device according to one of claims 8 or 9,
    characterized in that
    the feed device (2) has an acceleration unit (13) for accelerating the powder particles.
EP20060023663 2006-11-14 2006-11-14 Roughend bond coating Withdrawn EP1923478A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP20060023663 EP1923478A1 (en) 2006-11-14 2006-11-14 Roughend bond coating

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
EP20060023663 EP1923478A1 (en) 2006-11-14 2006-11-14 Roughend bond coating
EP07802608A EP2089559A2 (en) 2006-11-14 2007-08-15 Roughend bond coating
PCT/EP2007/058427 WO2008058776A2 (en) 2006-11-14 2007-08-15 Rough bonding agent layer
US12/514,601 US20100092662A1 (en) 2006-11-14 2007-08-15 Rough Bonding Agent Layers by Means of HS-PVD or Cold Spray

Publications (1)

Publication Number Publication Date
EP1923478A1 true EP1923478A1 (en) 2008-05-21

Family

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Family Applications (2)

Application Number Title Priority Date Filing Date
EP20060023663 Withdrawn EP1923478A1 (en) 2006-11-14 2006-11-14 Roughend bond coating
EP07802608A Withdrawn EP2089559A2 (en) 2006-11-14 2007-08-15 Roughend bond coating

Family Applications After (1)

Application Number Title Priority Date Filing Date
EP07802608A Withdrawn EP2089559A2 (en) 2006-11-14 2007-08-15 Roughend bond coating

Country Status (3)

Country Link
US (1) US20100092662A1 (en)
EP (2) EP1923478A1 (en)
WO (1) WO2008058776A2 (en)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103827352A (en) * 2011-08-30 2014-05-28 西门子能源有限公司 Method of forming thermal barrier coating system with engineered surface roughness
EP2612954A3 (en) * 2012-01-05 2014-06-25 General Electric Company Applying bond coat using cold spraying processes and articles thereof

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4386112A (en) * 1981-11-02 1983-05-31 United Technologies Corporation Co-spray abrasive coating
WO2002099254A1 (en) * 2001-06-06 2002-12-12 Chromalloy Gas Turbine Corporation Abradeable seal system
US20030126800A1 (en) * 2001-12-05 2003-07-10 Siemens Westinghouse Power Corporation Mixed powder deposition of components for wear, erosion and abrasion resistant applications
EP1327702A1 (en) * 2002-01-10 2003-07-16 ALSTOM (Switzerland) Ltd Mcraiy bond coating and method of depositing said mcraiy bond coating

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4696855A (en) * 1986-04-28 1987-09-29 United Technologies Corporation Multiple port plasma spray apparatus and method for providing sprayed abradable coatings
US5817372A (en) * 1997-09-23 1998-10-06 General Electric Co. Process for depositing a bond coat for a thermal barrier coating system
CA2433613A1 (en) * 2002-08-13 2004-02-13 Russel J. Ruprecht, Jr. Spray method for mcralx coating
KR100515608B1 (en) * 2003-12-24 2005-09-16 재단법인 포항산업과학연구원 Cold spray apparatus with powder preheating apparatus

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4386112A (en) * 1981-11-02 1983-05-31 United Technologies Corporation Co-spray abrasive coating
WO2002099254A1 (en) * 2001-06-06 2002-12-12 Chromalloy Gas Turbine Corporation Abradeable seal system
US20030126800A1 (en) * 2001-12-05 2003-07-10 Siemens Westinghouse Power Corporation Mixed powder deposition of components for wear, erosion and abrasion resistant applications
EP1327702A1 (en) * 2002-01-10 2003-07-16 ALSTOM (Switzerland) Ltd Mcraiy bond coating and method of depositing said mcraiy bond coating

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103827352A (en) * 2011-08-30 2014-05-28 西门子能源有限公司 Method of forming thermal barrier coating system with engineered surface roughness
CN103827352B (en) * 2011-08-30 2016-04-27 西门子能源有限公司 Form the method for the thermal barrier coating system of the surfaceness had through design
EP2612954A3 (en) * 2012-01-05 2014-06-25 General Electric Company Applying bond coat using cold spraying processes and articles thereof

Also Published As

Publication number Publication date
EP2089559A2 (en) 2009-08-19
US20100092662A1 (en) 2010-04-15
WO2008058776A3 (en) 2008-07-31
WO2008058776A2 (en) 2008-05-22

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