EP2069080B1 - Method for making heat barrier coatings - Google Patents

Method for making heat barrier coatings Download PDF

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Publication number
EP2069080B1
EP2069080B1 EP07820675A EP07820675A EP2069080B1 EP 2069080 B1 EP2069080 B1 EP 2069080B1 EP 07820675 A EP07820675 A EP 07820675A EP 07820675 A EP07820675 A EP 07820675A EP 2069080 B1 EP2069080 B1 EP 2069080B1
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EP
European Patent Office
Prior art keywords
coating
layers
angles
torch
coated
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Active
Application number
EP07820675A
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German (de)
English (en)
French (fr)
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EP2069080A1 (en
Inventor
Nelso Antolotti
Andrea Scrivani
Gabriele Rizzi
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.)
Turbocoating SpA
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Turbocoating SpA
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Priority to PL07820675T priority Critical patent/PL2069080T3/pl
Publication of EP2069080A1 publication Critical patent/EP2069080A1/en
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    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • 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
    • C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
    • C23C4/11—Oxides
    • 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
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying

Definitions

  • the present invention relates to the development of a thick TBC coating, for application on gas turbine components, mainly on heat shields, combustion chambers and turbine wall covering panels, and the method for making it.
  • the present invention relates to coatings, typically of ceramic material, deposited on a previously deposited layer used as a bond coat, said layers being obtained by Thermal Spray processes, such as:
  • these coatings improve corrosion and heat-oxidation resistance of components, such as gas turbines and aeronautical engines.
  • US 5 897 921 discloses a method for making thick thermal barrier coatings according to the preamble of claim 1.
  • the above mentioned deposits may be, for instance, of a metal material obtained from a M-CrAlY alloy (where M means Ni,Co,Fe or a combination thereof) followed by yttria partially stabilized zirconia (YPSZ) coatings.
  • M means Ni,Co,Fe or a combination thereof
  • YPSZ yttria partially stabilized zirconia
  • TBC thermal barrier coatings
  • the present invention relates to the particular method for depositing thick coatings, i.e. the particular handling/pivoting of the torch relative to the surface on which the coating has to be deposited, to obtain an improved coating microstructure as compared with currently available ones.
  • the present invention applies to both thick and thin coatings.
  • the structure so obtained improves resistance of the coating to thermal cycling fatigue (TFC), and thereby increases the performances of the components coated thereby (reduced operating temperatures and extended life of the component).
  • TFC thermal cycling fatigue
  • the principle of thermal spray technologies consists in supplying energy to the material to be deposited until it melts, and transfer it to the substrate to be coated.
  • Energy may be supplied to the material to be deposited from various sources: energy deriving from combustion between oxygen and a fuel, either in gas form (propane, acetylene, hydrogen) or in liquid form (kerosene) or deriving from recombination of ions in a plasma.
  • Thermal spray technologies include:
  • the coating results from successive deposition of various numbers of layers which join together to form the coating (passes).
  • This invention provides a combination of successive tilts for the various passes that leads to an ideal coating structure: fine porosity with small pores evenly diffused over the coating structure.
  • numeral 5 designates a component to be coated by TBC as described above; the component 5 may be part of a gas or aeronautical turbine.
  • the surface 3 is the one to be coated with the thick TBC.
  • thermal barrier coating system 11 according to the inventive specifications is shown, which barrier 11 is laid over the surface 3 of the component 5.
  • the thermal barrier coating system (TBC) 11 has a substrate 15 acting as a binder and/or a plurality of other layers designed for other possible purposes, such as: corrosion resistance, adhesion, diffusion barrier.
  • the substrate 15 is preferably deposited on the surface 3 of the component 5 using a conventional well-known process.
  • the coating 15 is deposited on said substrate 15 to act as a thermal battier, using the method as described below.
  • This microstructure has pores 23 of varying sizes according to the deposition technologies and the parameters being used.
  • Such porosities are characterized by a highly homogeneous arrangement, as ensured by the inventive deposition system.
  • the dispersion of the pores 21 and 23 is shown, whose number changes depending on the energy supplied during deposition. Therefore, the structure exhibits a variable porosity with fine pores evenly dispersed in the body of the coating obtained by the method of the present invention.
  • High ceramic cohesion areas 21 are also visible.
  • FIG. 4 a schematic view of one of the combinations of the method for depositing the coating 13 is shown, which is carried out through successive passes at different angles of incidence of the torch 33.
  • a cylindrical component to be coated was pivoted about its own axis and the torch was displaced over a rectilinear path along a straight line parallel to the axis of rotation of the component to be coated.
  • the torch tilt relative to an ideal surface tangent to the one to be coated may be described as follows: the torch 33 carries out a first deposition step at a certain angle ⁇ relative to the surface 3 to be coated; then, the torch 33 is pivoted to such a position as to form a second angle of incidence ⁇ , other than ⁇ , to carry out another deposition step on the coating that has just been laid at a tilt angle ⁇ ; finally, the torch 33 is positioned/pivoted to form a third angle of incidence ⁇ and a further deposition step is carried out.
  • This 3-pass cycle with 3 tilts can be repeated a number of times until reaching the desired thickness.
  • a constant tilt pass may be repeated n times, which means that the cycle may include:
  • the above cycle may be repeated a desired number of times.
  • the succession of the various passes at different tilts provides a coating microstructure composed of fine pores evenly dispersed in the coating structure.
  • the number of pores increases with the energy used during the deposition.
  • the scope of the present invention encompasses both the mechanical component 1 (such as the gas or aeronautical turbine) having thick TBC coatings (typically of thicknesses from 0.8 to 3 mm) of ceramic material, such as yttrium oxide stabilized zirconia, obtained by a Thermal Spray process, deposited on the bond coat surface of the component, and the method for making it, in which the thermal coating 13 is obtained with three or more different tilts of the deposition torch 22, at different and well-defined angles relative to the surface to be sprayed.
  • the mechanical component 1 such as the gas or aeronautical turbine
  • TBC coatings typically of thicknesses from 0.8 to 3 mm
  • ceramic material such as yttrium oxide stabilized zirconia
  • angles ⁇ , ⁇ and ⁇ are preferably as follows:
  • the order in which the torch 33 is tilted to form the various incidence angles ⁇ , ⁇ and ⁇ for deposition of the coating within each cycle can change and different combinations from the above may be provided.
  • the present method allows the head 33 to operate at angles in a range from 30° to 150° relative to the tangent to the surface 3 to be coated.
  • the torch 33 is tilted at least at three different angles, by carrying out a deposition step for each of them, a required number of passes being performed for each angle.
  • the scope of the present invention obviously encompasses all the coatings obtained with the above method, for any substrate and component (not necessarily a part of a gas turbine or an aeronautical engine) coated with the TBC.
  • the coating 13 may be composed of zirconia, possibly stabilized with other materials (e.g. ceria, dysprosia, ytterbia, Ca or Mg oxide) or other ceramic materials (alumina, titania, spinels, perovskite, etc.).
  • other materials e.g. ceria, dysprosia, ytterbia, Ca or Mg oxide
  • ceramic materials alumina, titania, spinels, perovskite, etc.
  • the invention as described herein provides an essential contribution to the thermal cycling fatigue resistance of TBC coatings, particularly thanks to the structure of the coating.
  • thermal cycling fatigue resistance is obtained regardless of the porosity (from 11% to 28% in the tests).
  • the above deposition method applies to deposition of thermal barriers and of ceramic materials in general, regardless of the parameters being used to supply enough energy to the powder for such powder to be melted.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Organic Chemistry (AREA)
  • Plasma & Fusion (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Physics & Mathematics (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Building Environments (AREA)
  • Road Signs Or Road Markings (AREA)
  • Dowels (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)
  • Heating, Cooling, Or Curing Plastics Or The Like In General (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
EP07820675A 2006-10-05 2007-09-28 Method for making heat barrier coatings Active EP2069080B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PL07820675T PL2069080T3 (pl) 2006-10-05 2007-09-28 Sposób wytwarzania pokryć stanowiących barierę cieplną

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IT000087A ITPR20060087A1 (it) 2006-10-05 2006-10-05 Metodologia per realizzare ricoprimenti per barriera termica, ricoprimenti e struttura ottenuta e componenti cosi' rivestiti
PCT/EP2007/060287 WO2008040678A1 (en) 2006-10-05 2007-09-28 Method for making heat barrier coatings, coatings and structure obtained thereby as well as components coated therewith

Publications (2)

Publication Number Publication Date
EP2069080A1 EP2069080A1 (en) 2009-06-17
EP2069080B1 true EP2069080B1 (en) 2010-11-03

Family

ID=38896136

Family Applications (1)

Application Number Title Priority Date Filing Date
EP07820675A Active EP2069080B1 (en) 2006-10-05 2007-09-28 Method for making heat barrier coatings

Country Status (7)

Country Link
EP (1) EP2069080B1 (it)
AT (1) ATE486975T1 (it)
DE (1) DE602007010327D1 (it)
ES (1) ES2355859T3 (it)
IT (1) ITPR20060087A1 (it)
PL (1) PL2069080T3 (it)
WO (1) WO2008040678A1 (it)

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2145974A1 (de) * 2008-07-16 2010-01-20 Siemens Aktiengesellschaft Verfahren zum Hochgeschwindigkeits-Flammenspritzen
WO2009144109A1 (de) * 2008-05-29 2009-12-03 Siemens Aktiengesellschaft Verfahren zum hochgeschwindigkeits-flammspritzen
EP2128300A1 (de) * 2008-05-29 2009-12-02 Siemens Aktiengesellschaft Verfahren zum Hochgeschwindigkeits-Flammenspritzen
DE102009023605A1 (de) * 2009-06-02 2010-12-09 Daimler Ag Vorrichtung und Verfahren zum thermischen Beschichten
US9556505B2 (en) * 2012-08-31 2017-01-31 General Electric Company Thermal barrier coating systems and methods of making and using the same
CN108018522A (zh) * 2017-12-08 2018-05-11 广东省新材料研究所 一种曲折柱状结构的热障涂层陶瓷层及其制备方法

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AU7818975A (it) * 1975-02-13 1976-08-19
JPH07299545A (ja) * 1994-05-09 1995-11-14 Nippon Steel Corp 連続鋳造用双ベルトのコーティング材溶射方法
US5897921A (en) * 1997-01-24 1999-04-27 General Electric Company Directionally solidified thermal barrier coating
EP1396556A1 (en) * 2002-09-06 2004-03-10 ALSTOM (Switzerland) Ltd Method for controlling the microstructure of a laser metal formed hard layer

Also Published As

Publication number Publication date
ATE486975T1 (de) 2010-11-15
PL2069080T3 (pl) 2011-04-29
DE602007010327D1 (de) 2010-12-16
EP2069080A1 (en) 2009-06-17
ES2355859T3 (es) 2011-03-31
ITPR20060087A1 (it) 2008-04-06
WO2008040678A1 (en) 2008-04-10

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