EP2537959A1 - Multiple wear-resistant coating and method for its production - Google Patents

Multiple wear-resistant coating and method for its production Download PDF

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Publication number
EP2537959A1
EP2537959A1 EP11170936A EP11170936A EP2537959A1 EP 2537959 A1 EP2537959 A1 EP 2537959A1 EP 11170936 A EP11170936 A EP 11170936A EP 11170936 A EP11170936 A EP 11170936A EP 2537959 A1 EP2537959 A1 EP 2537959A1
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Prior art keywords
layer
chromium
layers
high hardness
coating
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EP11170936A
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German (de)
French (fr)
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EP2537959B1 (en
Inventor
Thomas Dr. Uihlein
Wolfgang Eichmann
Falko Dr. Heutling
Stefan Schneiderbanger
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MTU Aero Engines AG
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MTU Aero Engines GmbH
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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
    • 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
    • C23C28/32—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer
    • C23C28/324—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 matrix material layer comprising a mixture of at least two metals or metal phases or a metal-matrix material with hard embedded particles, e.g. WC-Me
    • 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
    • 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
    • C23C28/34—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
    • C23C28/347—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 layers adapted for cutting tools or wear applications
    • 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
    • C23C28/40—Coatings including alternating layers following a pattern, a periodic or defined repetition
    • C23C28/42—Coatings including alternating layers following a pattern, a periodic or defined repetition characterized by the composition of the alternating layers
    • 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
    • C23C28/40—Coatings including alternating layers following a pattern, a periodic or defined repetition
    • C23C28/44—Coatings including alternating layers following a pattern, a periodic or defined repetition characterized by a measurable physical property of the alternating layer or system, e.g. thickness, density, hardness

Definitions

  • the present invention relates to a coating for components of a gas turbine or an aircraft engine with a multi-layer of several partial layers of different hardness and a method for producing such a coating and thus equipped components of a gas turbine or an aircraft engine, in particular vanes and blades.
  • hot gas corrosion protection layers are known, as for example in the DE 10 2005 060 243 A1 or the EP 0 587 341 A1 are described. Another example is in the WO 2010/138096 given. These oxidation protection layers are based essentially on MCrAlY coatings in which M is formed by iron, cobalt or nickel. In this case, it is particularly important to have a corresponding chromium content of the coating, which can be increased by enriching the chromium content. The chromium content ensures that a slowly growing, dense chromium oxide layer is formed, which prevents further oxidation. However, such layers are not suitable for use in areas with high wear or erosion stress.
  • two different types of anti-wear or anti-erosion layers are combined to achieve, through the combination, an improvement in property profile in terms of wear resistance as well as hot gas corrosion resistance.
  • the coating comprises a layer of high hardness as well as a multi-layer with several partial layers of different hardness.
  • the information on the hardness here are initially relative to see and on the one hand in relation to the base material of the component to be coated as well as within the layers or sub-layers in the coating.
  • the layer of high hardness which, for example, lies in the range of a hardness of .gtoreq.20 HRC, in particular .gtoreq.40 HRC and above.
  • the hardness of the high hardness layer may be equal to or higher than these values for many applications.
  • the hardness to be adjusted can be adapted to this base material, so that even lower hardness values are possible in individual cases. The same applies to the multi-layer system and the sublayers located therein.
  • first partial wear protection system with a layer of high hardness and a second partial wear protection system with a multi-layer
  • the coating according to the invention for all angles of incidence of impinging particles provides protection, since the multi-layer for small angles of incidence in the range of 0 ° to 30 ° has good properties, while the layer of high hardness is most effective at large angles of incidence of 60 ° to 90 °.
  • the multi-layer layer may comprise a plurality of hard and soft sub-layers, which are arranged alternately, so that a soft and a hard sub-layer are on top of each other and this sequence is repeated several times.
  • Such wear layers are known by themselves from the prior art (see above) and therefore require no further explanation.
  • the soft layers can be realized for example by soft metallic sublayers or soft ceramic sublayers, while the hard sublayers are usually produced by ceramic sublayers.
  • the thickness of a single partial layer of the multi-layer layer which in turn may itself consist of several partial layers, can be in the range of a few nanometers up to 20 micrometers, preferably up to 10 micrometers.
  • the hard sublayers may be formed by nitrides or nitrogen rich layers of chromium, aluminum and / or titanium.
  • the soft sub-layers may be formed on the basis of iron, cobalt, nickel, titanium, chromium or aluminum alloys or corresponding ceramic materials, such as CrN.
  • the multilayer film is deposited by physical vapor deposition (PVD) deposition, while the high-hardness layer is applied between the multilayer film and the component to be coated by a high-speed spattering process such as thermal spraying or cold gas spraying.
  • PVD physical vapor deposition
  • the high hardness layer is formed by a metal alloy layer which has high hardness by means of dispersion hardening, precipitation hardening or solid solution strengthening, but at the same time has a certain ductility and in particular avoids the negative mechanical properties of materials hardened with high carbide contents.
  • alloys based on cobalt such as CoMoCrSi alloys or CoCrWSi alloys, such as, for example, are suitable for use here.
  • MCrAlY alloys can also be provided with dispersion particles of oxides, nitrides and / or borides, where M is iron, cobalt or nickel.
  • These layers not only provide sufficient hardness, but can also have a corresponding chromium content to improve the hot gas corrosion resistance to form a slowly growing and dense chromium oxide layer, in particular chromium contents of ⁇ 18 wt .-%, preferably ⁇ 20 wt .-%.
  • chromium contents ⁇ 18 wt .-%, preferably ⁇ 20 wt .-%.
  • carbide content can be limited to the range of unavoidable impurities by avoiding carbon contents or suitable composition of the other alloy constituents.
  • a chromium-rich layer can be produced by chromium plating, that is, by diffusing chrome.
  • the chromium content in the chromium-rich layer may be up to 30% by volume, preferably up to 20% by volume.
  • chromium plating can be applied to coatings on steel components.
  • the high-hardness sprayed layer can be smoothed by polishing or grinding or other suitable methods, such that a high-quality PVD coating is obtained, especially in a subsequent direct application of the PVD multilayer coating results.
  • a porous layer may be formed between the component to be coated and the high hardness layer to provide a layer in the formation of microcracks in outer layers of the protection system which prevents crack growth due to crack tip broadening in the pores.
  • the porous layer can be produced in particular by cold gas spraying.
  • the thickness of the high-hardness layer may be selected to be up to 150 microns, more preferably up to 100 microns, while the high-chromium layer may have a thickness of up to 20 microns, preferably up to 10 microns.
  • a corresponding, coated component of a gas turbine or an aircraft engine can only be partially coated and, in particular in certain areas where certain requirements are not met, can only be provided with one of the partial layer systems, for example with the layer of high hardness, with the layer of high hardness including a chromium-rich layer or merely with a multilayer or other combinations of the individual sub-layers of the presented coating system.
  • the component to be coated may in particular be components based on iron, nickel or titanium materials.
  • the Fig. 1 shows a partial cross section through a first coating according to the invention on a component 1.
  • the coating comprises a layer 2 of high hardness and a multi-layer coating 3. Both the layer 2 high hardness and the multi-layer 3 are already a wear protection coating, but the structure the individual part wear protection coating and their mode of action are different. However, a balanced property profile of the entire wear-resistant coating can be achieved by combining the different partial wear-protection coatings.
  • the layer 2 of high hardness, ie the first part wear protection coating is realized by a hard alloy or by another metal layer with high hardness, which is achieved for example by dispersion hardening, precipitation hardening or solid solution hardening.
  • ceramic particles can be incorporated into the alloy such as oxides, nitrides, borides, for example alumina.
  • corresponding materials which can be used for the high hardness layer 2 are cobalt base alloys such as CoMoCrSi or CoCrWSi alloys marketed under the trade names Tribaloy and Stellite.
  • MCrAlY alloys with M equal to iron, cobalt or nickel can be used, which can be provided in particular with dispersion particles, such as alumina, to increase the hardness.
  • the layer 2 of high hardness is applied by means of high-speed spraying processes, such as thermal spraying, also known as high-velocity oxide-fuel (HVOF) spraying or flame spraying.
  • high-speed spraying processes such as thermal spraying, also known as high-velocity oxide-fuel (HVOF) spraying or flame spraying.
  • the high hardness layer 2 After application of the high-hardness layer by cold gas spraying or flame spraying, the high hardness layer 2 can be smoothed if necessary, for example by appropriate grinding and polishing.
  • the multi-layer layer is applied in layers by means of vapor deposition (Physical Vapor Deposition PVD).
  • the multilayer 3 comprises a sequence of soft and hard sub-layers 4, 5, 6, 7, soft sub-layers 4, 6 alternating with hard sub-layers 5, 7.
  • the outer layer is preferably formed by a hard part-layer 7.
  • the hard sub-layers 5, 7 may be formed by ceramic materials, in particular nitrides or nitrogen-rich layers of aluminum, titanium or chromium with additions of yttrium or carbon. In addition, however, other ceramic materials are conceivable, especially on an oxide basis.
  • the soft sub-layers 4, 6 may also be formed of ceramic materials with the same chemical elements, with a higher proportion of the metallic elements, for example, a lower hardness is adjustable.
  • the soft sub-layers 4, 6 may be formed by metallic layers based on iron, cobalt, nickel, titanium, chromium or aluminum or combinations thereof. An example of a layer sequence could be given for example by the formation of the soft sub-layers 4, 6 as CrN layers and the hard sub-layers as CrAIN layers.
  • the soft sub-layers 4, 6 and / or the hard sub-layers 5, 7 can in turn themselves be composed of several layers.
  • the layer thickness of the partial layers 4 to 7 of the multi-layer layer 3 can be selected in the range of a few nanometers to a few micrometers.
  • the layer 2 of high hardness can also be deposited with a layer thickness of about 100 microns.
  • the Fig. 2 shows a further embodiment of a coating according to the invention, in which the identical components with the exception of the coated component with the same reference numerals, only increased by 10, are provided.
  • a layer 12 of high hardness and a multi-layer 13 with the partial layers 14 to 17 are again provided on the component 10.
  • the layer of high hardness 12 and the multi-layer 13 are constructed in the same manner as in the embodiment of Fig. 1 so that an additional description is unnecessary.
  • a chromium-rich layer 11 formed by chromating the high-hardness layer 12.
  • the chromium-rich layer 11 may be formed as a diffusion layer formed in the previously deposited high hardness layer 12 by diffusing the chromium.
  • the chromium content may in particular be up to 30% by volume, preferably up to 20% by volume, of chromium.
  • the chromium-rich layer enhances high-temperature corrosion resistance because the chromium forms a dense, thin chromium oxide layer that prevents further hot gas corrosion.
  • the Fig. 3 shows in a further embodiment, a coating according to the invention on a component 100, which for the most part of the coating from the Fig. 2 equivalent. Accordingly, again with the exception of the name of the component, the reference numerals for the Components chosen so that these compared to the embodiment of Fig. 1 only increased by 100.
  • Fig. 3 That's how it shows Fig. 3 a coating having a high hardness layer 102 followed by a chromium rich layer 111 and a multilayer 103 having sublayers 104 to 107.
  • the high hardness layer 102 and the multi-layer layer 103 correspond to the layers 12 and 2, and 13 and 3, respectively, of the previously described embodiments and need no further explanation.
  • the chromium-rich layer 111 corresponds to the chromium-rich layer 11 and is therefore also known.
  • an additional porous layer 101 is provided between the high hardness layer 102 and the component 100. This layer can be applied for example by cold gas spraying.
  • the porous layer 101 is effected by the defined introduction of porosity that any resulting microcracks from the outer layers of the protection system in crack growth can not penetrate into the base material of the component 100, but are prevented in the pores due to the dulling of the crack tip on the further crack growth .
  • the composition of the porous layer 101 is preferably selected to be similar to that of the base material of the component 100.
  • the components 1, 10, 100 can be formed in particular by iron, nickel or titanium-based alloys, the designation base alloy indicating here that the component with the largest proportion is formed by iron, nickel or titanium.

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  • Chemical & Material Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Ceramic Engineering (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
  • Coating By Spraying Or Casting (AREA)

Abstract

A coating layer comprises multilayer film (3) consisting of sublayers (4-7) of different hardness. The multilayer film comprises repeated sequence of hard and soft sublayers. The outermost sub-layer is a hard layer. The layer (2) with high hardness is formed using dispersed particles containing cobalt-molybdenum chromium silicon alloy, cobalt-chromium-tungsten-silicon alloy, metal (M)-chromium-aluminum-yttrium alloy, their oxide, nitride and/or boride (M is iron, cobalt or nickel). An independent claim is included for manufacture of coated component (1).

Description

GEBIET DER ERFINDUNGFIELD OF THE INVENTION

Die vorliegende Erfindung betrifft eine Beschichtung für Bauteile einer Gasturbine oder eines Flugtriebwerks mit einer Mehrlagenschicht aus mehreren Teilschichten unterschiedlicher Härte sowie ein Verfahren zur Herstellung einer derartigen Beschichtung und damit ausgestattete Bauteile einer Gasturbine oder eines Flugtriebwerks, wie insbesondere Leit- und Laufschaufeln.The present invention relates to a coating for components of a gas turbine or an aircraft engine with a multi-layer of several partial layers of different hardness and a method for producing such a coating and thus equipped components of a gas turbine or an aircraft engine, in particular vanes and blades.

STAND DER TECHNIKSTATE OF THE ART

Aufgrund der hohen Belastungen bei Gasturbinen und Flugtriebwerken durch hindurch strömende Fluide und in den Fluiden enthaltene Feststoffpartikel ist es bekannt, an entsprechenden Bauteilen, wie insbesondere Leitschaufeln und Laufschaufeln eine Schutzbeschichtung gegen Verschleiß vorzusehen. Hierfür haben sich beispielsweise Mehrlagenbeschichtungen mit einer Vielzahl von Teilschichten bewährt, bei denen die Teilschichten durch eine Abfolge von weichen und harten Schichten gebildet sind, die beispielsweise durch physikalische Gasphasenabscheidung (Physical Vapor Deposition PVD) abgeschieden werden können. Beispiele hierfür sind in der DE 10 2006 001 864 A1 , DE 10 2008 019 891 A1 oder der DE 10 2008 023 590 A1 mit weiteren Verweisen auf entsprechenden Stand der Technik beschrieben.Due to the high loads on gas turbines and aircraft engines through fluids flowing therethrough and solid particles contained in the fluids, it is known to provide a protective coating against wear on corresponding components, in particular guide vanes and rotor blades. For this purpose, for example, multi-layer coatings having a multiplicity of partial layers have proven successful, in which the partial layers are formed by a sequence of soft and hard layers which can be deposited, for example, by physical vapor deposition (PVD). Examples are in the DE 10 2006 001 864 A1 . DE 10 2008 019 891 A1 or the DE 10 2008 023 590 A1 with further references to the relevant prior art.

Weitere Verschleißschutzschichten sind in der US 2010/0304181 A1 und der US 2010/0304084 A1 beschrieben. Diese Schichten weisen ein Zweischichtsystem auf, bei dem eine dispersionsgehärte erste Schicht aus einer Nickel-Chrom-Matrix oder MCrAIX-Matrix mit M = Fe, Co, Ni und X = Seltenerdelement mit Metallkarbiden unterhalb einer abschließenden Metall-Nitrid-Schicht angeordnet ist. Der hohe Anteil an Karbiden, insbesondere Chromkarbiden führt jedoch zu einer negativen Beeinflussung der mechanischen Eigenschaften, insbesondere der Schwingfestigkeitseigenschaften.Further wear protection layers are in the US 2010/0304181 A1 and the US 2010/0304084 A1 described. These layers comprise a two-layer system in which a dispersion-hardened first layer of a nickel-chromium matrix or MCrAIX matrix with M = Fe, Co, Ni and X = rare-earth element with metal carbides is arranged underneath a final metal-nitride layer. However, the high content of carbides, in particular chromium carbides, leads to a negative influence on the mechanical properties, in particular the vibration resistance properties.

Allerdings unterliegen die Bauteile von Gasturbinen oder Flugtriebwerken nicht nur einer Beanspruchung durch Verschleiß aufgrund von Erosion, sondern durch die dort herrschenden hohen Temperaturen hat insbesondere auch die Heißgaskorrosion einen wichtigen Einfluss auf die Lebensdauer der entsprechenden Bauteile. Um diesem Problem zu begegnen, sind Heißgaskorrosionsschutzschichten bekannt, wie sie beispielsweise in der DE 10 2005 060 243 A1 oder der EP 0 587 341 A1 beschrieben sind. Ein weiteres Beispiel ist in der WO 2010/138096 gegeben. Diese Oxidationsschutzschichten basieren im Wesentlichen auf MCrAlY-Beschichtungen, bei denen M durch Eisen, Kobalt oder Nickel gebildet ist. Hierbei kommt es insbesondere auf einen entsprechenden Chromgehalt der Beschichtung an, der durch eine Chromanreicherung noch erhöht werden kann. Der Chromanteil sorgt dafür, dass sich eine langsam wachsende, dichte Chromoxidschicht ausbildet, die weitere Oxidation verhindert. Allerdings sind derartige Schichten nicht für den Einsatz in Bereichen mit hoher Verschleiß- oder Erosionsbelastung geeignet.However, the components of gas turbines or aircraft engines not only subject to wear due to erosion, but by the prevailing high In particular, hot-gas corrosion has an important influence on the service life of the corresponding components. To address this problem, hot gas corrosion protection layers are known, as for example in the DE 10 2005 060 243 A1 or the EP 0 587 341 A1 are described. Another example is in the WO 2010/138096 given. These oxidation protection layers are based essentially on MCrAlY coatings in which M is formed by iron, cobalt or nickel. In this case, it is particularly important to have a corresponding chromium content of the coating, which can be increased by enriching the chromium content. The chromium content ensures that a slowly growing, dense chromium oxide layer is formed, which prevents further oxidation. However, such layers are not suitable for use in areas with high wear or erosion stress.

OFFENBARUNG DER ERFINDUNGDISCLOSURE OF THE INVENTION AUFGABE DER ERFINDUNGOBJECT OF THE INVENTION

Obwohl mit den oben beschriebenen Schichtsystemen bereits gute Erfolge erzielt werden, ist es ersichtlich, dass aufgrund der Komplexität des Eigenschaftsprofils und der zum Teil divergierenden Ziele und Maßnahmen eine weitere Verbesserung von Verschleißschutzbeschichtungen hinsichtlich einer besseren Heißgaskorrosionsbeständigkeit oder umgekehrt eine Verbesserung von Heißgaskorrosionsschutzschichten hinsichtlich einer besseren Verschleißbeständigkeit wünschenswert ist. Es ist deshalb Aufgabe der vorliegenden Erfindung eine Verschleißschutz- bzw. Erosionsschutzschicht sowie ein Verfahren zu ihrer Herstellung bereitzustellen, welche eine Verbesserung der Hochtemperaturoxidationsbeständigkeit ermöglicht. Gleichzeitig soll die Erosionsschutzwirkung beibehalten oder verbessert werden. Zudem soll die Aufbringung der Schicht einfach und zuverlässig durchführbar sein.Although good results have already been achieved with the layer systems described above, it is evident that due to the complexity of the property profile and the partly divergent goals and measures, a further improvement of wear protection coatings in terms of better hot gas corrosion resistance or conversely, improvement of hot gas corrosion protection layers for better wear resistance is desirable is. It is therefore an object of the present invention to provide a wear protection or erosion protection layer and a process for their preparation, which enables an improvement in the high-temperature oxidation resistance. At the same time, the erosion protection effect should be maintained or improved. In addition, the application of the layer should be easy and reliable feasible.

TECHNISCHE LÖSUNGTECHNICAL SOLUTION

Diese Aufgabe wird gelöst durch eine Beschichtung mit den Merkmalen des Anspruchs 1 sowie ein Verfahren zur Herstellung der Beschichtung mit den Merkmalen des Anspruchs 14. Weiterhin betrifft die Erfindung ein entsprechendes Bauteil für eine Gasturbine oder ein Flugtriebwerk nach dem Anspruch 11. Vorteilhafte Ausgestaltungen sind Gegenstand der abhängigen Ansprüche.This object is achieved by a coating with the features of claim 1 and a method for producing the coating with the features of claim 14. Furthermore, the invention relates to a corresponding component for a gas turbine or an aircraft engine according to claim 11. Advantageous embodiments are the subject of dependent claims.

Bei der vorliegenden Erfindung werden zwei unterschiedliche Arten von Verschleißschutz- oder Erosionsschutzschichten miteinander kombiniert, um durch die Kombination eine Verbesserung des Eigenschaftsprofils sowohl hinsichtlich der Verschleißbeständigkeit als auch hinsichtlich einer Heißgaskorrosionsbeständigkeit zu erzielen.In the present invention, two different types of anti-wear or anti-erosion layers are combined to achieve, through the combination, an improvement in property profile in terms of wear resistance as well as hot gas corrosion resistance.

Entsprechend ist vorgesehen, dass die Beschichtung eine Schicht hoher Härte sowie eine Mehrlagenschicht mit mehreren Teilschichten unterschiedlicher Härte umfasst. Die Angaben zur Härte sind hierbei zunächst relativ zu sehen und zwar einerseits im Verhältnis zum Grundwerkstoff des zu beschichtenden Bauteils als auch innerhalb der Schichten bzw. Teilschichten in der Beschichtung. So ist klar, dass bei einem Mehrlagenschichtsystem mit Teilschichten unterschiedlicher Härte die Angabe der Härte relativ der einzelnen Teilschichten zueinander erfolgt, während die Angabe einer Schicht hoher Härte beschreibt, dass die Schicht gegenüber dem Grundwerkstoff des zu beschichtenden Bauteils eine höhere Härte aufweist.Accordingly, it is provided that the coating comprises a layer of high hardness as well as a multi-layer with several partial layers of different hardness. The information on the hardness here are initially relative to see and on the one hand in relation to the base material of the component to be coated as well as within the layers or sub-layers in the coating. Thus, it is clear that in a multi-layer system with partial layers of different hardness indicating the hardness relative to the individual sub-layers to each other, while indicating a layer of high hardness describes that the layer relative to the base material of the component to be coated has a higher hardness.

Gleichwohl lässt sich beispielsweise für die Schicht hoher Härte ein Richtwert angeben, der beispielsweise im Bereich einer Härte von ≥ 20 HRC, insbesondere ≥40 HRC und darüber liegt. Die Härte der Schicht hoher Härte kann für viele Anwendungen gleich oder höher diesen genannten Werten sein. Allerdings ist klar, dass je nach Grundwerkstoff des zu beschichtenden Bauteils die einzustellende Härte auf diesen Grundwerkstoff abgestimmt werden kann, so dass im Einzelfall auch geringere Härtewerte möglich sind. Gleiches gilt für das Mehrlagenschichtsystem und die darin befindlichen Teilschichten.Nevertheless, it is possible, for example, to specify a guide value for the layer of high hardness which, for example, lies in the range of a hardness of .gtoreq.20 HRC, in particular .gtoreq.40 HRC and above. The hardness of the high hardness layer may be equal to or higher than these values for many applications. However, it is clear that depending on the base material of the component to be coated, the hardness to be adjusted can be adapted to this base material, so that even lower hardness values are possible in individual cases. The same applies to the multi-layer system and the sublayers located therein.

Durch die Kombination eines ersten Teilverschleißschutzsystems mit einer Schicht hoher Härte und eines zweiten Teilverschleißschutzsystems mit einer Mehrlagenschicht kann beispielsweise erreicht werden, dass die erfindungsgemäße Beschichtung für alle Auftreffwinkel von auftreffenden Teilchen einen Schutz bietet, da die Mehrlagenschicht für kleine Auftreffwinkel im Bereich von 0° bis 30° gute Eigenschaften aufweist, während die Schicht hoher Härte bei großen Auftreffwinkeln von 60° bis 90° am wirksamsten ist.By combining a first partial wear protection system with a layer of high hardness and a second partial wear protection system with a multi-layer can be achieved, for example, that the coating according to the invention for all angles of incidence of impinging particles provides protection, since the multi-layer for small angles of incidence in the range of 0 ° to 30 ° has good properties, while the layer of high hardness is most effective at large angles of incidence of 60 ° to 90 °.

Die Mehrlagenschicht kann insbesondere eine Vielzahl von harten und weichen Teilschichten umfassen, die abwechselnd angeordnet sind, sodass sich eine weiche und eine harte Teilschicht übereinander befinden und diese Abfolge mehrmals wiederholt wird. Derartige Verschleißschichten sind für sich alleine aus dem Stand der Technik bekannt (siehe oben) und bedürfen deshalb keiner näheren Erläuterung.In particular, the multi-layer layer may comprise a plurality of hard and soft sub-layers, which are arranged alternately, so that a soft and a hard sub-layer are on top of each other and this sequence is repeated several times. Such wear layers are known by themselves from the prior art (see above) and therefore require no further explanation.

Die weichen Schichten können beispielsweise durch weiche metallische Teilschichten oder weiche keramische Teilschichten realisiert werden, während die harten Teilschichten üblicherweise durch keramische Teilschichten erzeugt werden. Die Dicke einer einzelnen Teilschicht der Mehrlagenschicht, die wiederum selbst aus mehreren Teilschichten bestehen kann, kann im Bereich von wenigen Nanometern bis zu 20 Mikrometern, vorzugsweise bis zu 10 Mikrometern liegen.The soft layers can be realized for example by soft metallic sublayers or soft ceramic sublayers, while the hard sublayers are usually produced by ceramic sublayers. The thickness of a single partial layer of the multi-layer layer, which in turn may itself consist of several partial layers, can be in the range of a few nanometers up to 20 micrometers, preferably up to 10 micrometers.

Insbesondere können die harten Teilschichten durch Nitride oder Stickstoffreiche Schichten aus Chrom, Aluminium und/oder Titan gebildet sein. Die weichen Teilschichten können auf Basis von Eisen, Kobalt, Nickel, Titan, Chrom oder Aluminium-Legierungen oder entsprechenden keramischen Werkstoffen, wie beispielsweise CrN gebildet sein.In particular, the hard sublayers may be formed by nitrides or nitrogen rich layers of chromium, aluminum and / or titanium. The soft sub-layers may be formed on the basis of iron, cobalt, nickel, titanium, chromium or aluminum alloys or corresponding ceramic materials, such as CrN.

Die Mehrlagenschicht wird erfindungsgemäß durch PVD-Abscheidung (Physikalische Gasphasenabscheidung Physical Vapor Deposition) abgeschieden, während die Schicht hoher Härte zwischen der Mehrlagenschicht und dem zu beschichtenden Bauteil mittels eines Hochgeschwindigkeitsspritzverfahrens aufgebracht wird, wie beispielsweise durch thermisches Spritzen oder Kaltgasspritzen.According to the invention, the multilayer film is deposited by physical vapor deposition (PVD) deposition, while the high-hardness layer is applied between the multilayer film and the component to be coated by a high-speed spattering process such as thermal spraying or cold gas spraying.

Die Schicht hoher Härte ist durch eine Metalllegierungsschicht gebildet, die mittels Dispersionshärtung, Ausscheidungshärtung oder Mischkristallverfestigung eine hohe Härte aufweist, aber gleichzeitig eine gewisse Duktilität besitzt und insbesondere die negativen mechanischen Eigenschaften von Materialien vermeidet, die mit hohen Karbidanteilen gehärtet sind. Hier bieten sich insbesondere Legierungen auf Basis von Kobalt, wie beispielsweise CoMoCrSi-Legierungen oder CoCrWSi-Legierungen an, wie z. B. Stellite oder Triballoy (Markennamen der Fa. Deloro Stellite). Darüber hinaus können auch MCrAlY-Legierungen mit Dispersionspartikeln aus Oxiden, Nitriden und/oder Boriden vorgesehen werden, wobei M gleich Eisen, Kobalt oder Nickel ist. Diese Schichten bieten nicht nur eine ausreichende Härte, sondern können zur Verbesserung der Heißgaskorrosionsbeständigkeit auch einen entsprechenden Chrom-Gehalt zur Ausbildung einer langsam wachsenden und dichten Chromoxidschicht aufweisen, insbesondere Chromgehalte von ≥ 18 Gew.-%, vorzugsweise ≥ 20 Gew.-%. Allerdings ist durch Abstimmung mit den übrigen Legierungsbestandteilen die Ausbildung von Karbiden, insbesondere Chromkarbiden oder eines zu hohen Anteils an Karbiden zu vermeiden. Insbesondere kann der Karbidgehalt durch Vermeidung von Kohlenstoffanteilen bzw. geeignete Zusammensetzung der übrigen Legierungsbestandteile auf den Bereich unvermeidbarer Verunreinigungen beschränkt sein.The high hardness layer is formed by a metal alloy layer which has high hardness by means of dispersion hardening, precipitation hardening or solid solution strengthening, but at the same time has a certain ductility and in particular avoids the negative mechanical properties of materials hardened with high carbide contents. In particular, alloys based on cobalt, such as CoMoCrSi alloys or CoCrWSi alloys, such as, for example, are suitable for use here. B. Stellite or Triballoy (brand name of Fa. Deloro Stellite). In addition, MCrAlY alloys can also be provided with dispersion particles of oxides, nitrides and / or borides, where M is iron, cobalt or nickel. These layers not only provide sufficient hardness, but can also have a corresponding chromium content to improve the hot gas corrosion resistance to form a slowly growing and dense chromium oxide layer, in particular chromium contents of ≥ 18 wt .-%, preferably ≥ 20 wt .-%. However, by voting with the rest Alloy components to avoid the formation of carbides, especially chromium carbides or too high a proportion of carbides. In particular, the carbide content can be limited to the range of unavoidable impurities by avoiding carbon contents or suitable composition of the other alloy constituents.

Zwischen der Schicht mit hoher Härte und der Mehrlagenschicht kann eine Chrom-reiche Schicht durch Inchromierung, also durch Eindiffundieren von Chrom erzeugt werden. Der Chromanteil in der Chrom-reichen Schicht kann bis zu 30 Vol.-%, vorzugsweise bis zu 20 Vol.-% betragen. Die Inchromierung kann insbesondere bei Beschichtungen auf Bauteilen aus Stahl angewendet werden.Between the high-hardness layer and the multi-layer layer, a chromium-rich layer can be produced by chromium plating, that is, by diffusing chrome. The chromium content in the chromium-rich layer may be up to 30% by volume, preferably up to 20% by volume. In particular, chromium plating can be applied to coatings on steel components.

Vor dem Aufbringen der Chrom-reichen Schicht oder der weiteren Beschichtung mit der Mehrlagenschicht kann die gespritzte Schicht hoher Härte durch Polieren oder Schleifen oder sonstige geeignete Verfahren geglättet werden, sodass sich insbesondere bei einer nachfolgenden direkten Aufbringung der PVD-Mehrlagenbeschichtung eine PVD-Beschichtung hoher Qualität ergibt.Prior to the application of the chromium-rich layer or the further coating with the multilayer coating, the high-hardness sprayed layer can be smoothed by polishing or grinding or other suitable methods, such that a high-quality PVD coating is obtained, especially in a subsequent direct application of the PVD multilayer coating results.

Zusätzlich kann zwischen dem zu beschichtenden Bauteil und der Schicht hoher Härte eine poröse Schicht ausgebildet werden, um bei der Entstehung von Mikrorissen in äußeren Lagen des Schutzsystems eine Schicht vorzusehen, die das Risswachstum durch eine Rissspitzenverbreiterung in den Poren verhindert.In addition, a porous layer may be formed between the component to be coated and the high hardness layer to provide a layer in the formation of microcracks in outer layers of the protection system which prevents crack growth due to crack tip broadening in the pores.

Die poröse Schicht kann insbesondere durch Kaltgasspritzen erzeugt werden.The porous layer can be produced in particular by cold gas spraying.

Die Dicke der Schicht hoher Härte kann mit bis zu 150 Mikrometer, insbesondere bis zu 100 Mikrometer gewählt werden, während die Schicht mit hohem Chrom-Anteil eine Dicke von bis zu 20 Mikrometer, vorzugsweise bis zu 10 Mikrometer aufweisen kann.The thickness of the high-hardness layer may be selected to be up to 150 microns, more preferably up to 100 microns, while the high-chromium layer may have a thickness of up to 20 microns, preferably up to 10 microns.

Ein entsprechendes, beschichtetes Bauteil einer Gasturbine oder eines Flugtriebwerks kann nur teilweise beschichtet sein und kann insbesondere in bestimmten Bereichen, in denen bestimmte Anforderungen nicht gegeben sind, nur mit einem der Teilschichtsysteme versehen sein, beispielsweise mit der Schicht hoher Härte, mit der Schicht hoher Härte einschließlich einer Chrom-reichen Schicht oder lediglich mit einer Mehrlagenschicht oder andersartigen Kombinationen der einzelnen Teilschichten des vorgestellten Beschichtungssystems.A corresponding, coated component of a gas turbine or an aircraft engine can only be partially coated and, in particular in certain areas where certain requirements are not met, can only be provided with one of the partial layer systems, for example with the layer of high hardness, with the layer of high hardness including a chromium-rich layer or merely with a multilayer or other combinations of the individual sub-layers of the presented coating system.

Bei dem zu beschichtenden Bauteil kann es sich insbesondere um Bauteile auf Basis von Eisen-, Nickel- oder Titanwerkstoffen handeln.The component to be coated may in particular be components based on iron, nickel or titanium materials.

KURZBESCHREIBUNG DER FIGURENBRIEF DESCRIPTION OF THE FIGURES

Die beigefügten Zeichnungen zeigen in rein schematischer Weise in

Fig. 1
eine teilweise Querschnittsansicht durch ein erfindungsgemäß beschichtetes Bauteil nach einer ersten Ausführungsform,
Fig. 2
eine teilweise Querschnittsansicht durch ein erfindungsgemäß beschichtetes Bauteil nach einer zweiten Ausführungsform; und in
Fig. 3
eine teilweise Querschnittsansicht einer erfindungsgemäßen Beschichtung nach einer dritten Ausführungsform.
The accompanying drawings show in a purely schematic manner in FIG
Fig. 1
a partial cross-sectional view through a coated according to the invention component according to a first embodiment,
Fig. 2
a partial cross-sectional view through a coated according to the invention component according to a second embodiment; and in
Fig. 3
a partial cross-sectional view of a coating according to the invention according to a third embodiment.

AUSFÜHRUNGSBEISPIELEEMBODIMENTS

Weitere Vorteile, Kennzeichen und Merkmale der vorliegenden Erfindung werden bei der nachfolgenden detaillierten Beschreibung von Ausführungsbeispielen anhand der beigefügten Zeichnungen deutlich. Die Erfindung ist jedoch nicht auf diese Ausführungsbeispiele beschränkt, sondern der Schutzbereich richtet sich alleine nach den beigefügten Ansprüchen.Further advantages, characteristics and features of the present invention will become apparent in the following detailed description of embodiments with reference to the accompanying drawings. However, the invention is not limited to these embodiments, but the scope of protection is based solely on the appended claims.

Die Fig. 1 zeigt einen teilweisen Querschnitt durch eine erste erfindungsgemäße Beschichtung auf einem Bauteil 1. Die Beschichtung umfasst eine Schicht 2 hoher Härte sowie eine Mehrlagenbeschichtung 3. Sowohl die Schicht 2 hoher Härte als auch die Mehrlagenschicht 3 stellen für sich bereits eine Verschleißschutzbeschichtung dar, wobei jedoch der Aufbau der einzelnen Teilverschleißschutzbeschichtung und ihre Wirkungsweise unterschiedlich sind. Durch die Kombination der unterschiedlichen Teilverschleißschutzbeschichtungen kann jedoch ein ausgewogenes Eigenschaftsprofil der gesamten Verschleißschutzbeschichtung erzielt werden. Die Schicht 2 hoher Härte, also die erste Teilverschleißschutzbeschichtung wird durch eine Hartlegierung oder durch eine sonstige metallische Schicht mit hoher Härte realisiert, die beispielsweise durch Dispersionshärtung, Ausscheidungshärtung oder Mischkristallhärtung erzielt wird. Bei der Dispersionshärtung können insbesondere keramische Partikel in die Legierung eingelagert werden, wie beispielsweise Oxide, Nitride, Boride, beispielsweise Aluminiumoxid. Beispiele für entsprechende Werkstoffe, die für die Schicht 2 hoher Härte eingesetzt werden können, sind Kobaltbasislegierungen, wie beispielsweise CoMoCrSi- oder CoCrWSi-Legierungen, die unter den Handelsbezeichnungen Tribaloy und Stellite vertrieben werden. Darüber hinaus können auch MCrAlY-Legierungen mit M gleich Eisen, Kobalt oder Nickel zum Einsatz kommen, die insbesondere mit Dispersionspartikeln, wie Aluminiumoxid, zur Erhöhung der Härte versehen sein können.The Fig. 1 shows a partial cross section through a first coating according to the invention on a component 1. The coating comprises a layer 2 of high hardness and a multi-layer coating 3. Both the layer 2 high hardness and the multi-layer 3 are already a wear protection coating, but the structure the individual part wear protection coating and their mode of action are different. However, a balanced property profile of the entire wear-resistant coating can be achieved by combining the different partial wear-protection coatings. The layer 2 of high hardness, ie the first part wear protection coating is realized by a hard alloy or by another metal layer with high hardness, which is achieved for example by dispersion hardening, precipitation hardening or solid solution hardening. In dispersion hardening, in particular ceramic particles can be incorporated into the alloy such as oxides, nitrides, borides, for example alumina. Examples of corresponding materials which can be used for the high hardness layer 2 are cobalt base alloys such as CoMoCrSi or CoCrWSi alloys marketed under the trade names Tribaloy and Stellite. In addition, MCrAlY alloys with M equal to iron, cobalt or nickel can be used, which can be provided in particular with dispersion particles, such as alumina, to increase the hardness.

Die Schicht 2 hoher Härte wird erfindungsgemäß mittels Hochgeschwindigkeitsspritzverfahren, wie thermisches Spritzen, auch High-Velocity-Oxyde-Fuel (HVOF) - Spritzen oder Flammspritzen genannt, aufgebracht. Auch Kaltgasspritzen, bei welchem die aufzuspritzenden Partikel nicht erwärmt werden sondern lediglich aufgrund ihrer hohen kinetischen Energie beim Auftreffen auf das Bauteil eine Verbindung mit dem Bauteil und untereinander eingehen, kann eingesetzt werden.According to the invention, the layer 2 of high hardness is applied by means of high-speed spraying processes, such as thermal spraying, also known as high-velocity oxide-fuel (HVOF) spraying or flame spraying. Even cold gas spraying, in which the aufzuspritzenden particles are not heated but only due to their high kinetic energy when hitting the component connect to the component and each other, can be used.

Nach dem Aufbringen der Schicht hoher Härte mit Kaltgasspritzen oder Flammspritzen kann die Schicht 2 hoher Härte bei Bedarf geglättet werden, beispielsweise durch entsprechendes Schleifen und Polieren.After application of the high-hardness layer by cold gas spraying or flame spraying, the high hardness layer 2 can be smoothed if necessary, for example by appropriate grinding and polishing.

Danach wird die Mehrlagenschicht mittels Gasphasenabscheidung (Physical Vapor Deposition PVD) schichtweise aufgebracht. Die Mehrlagenschicht 3 umfasst eine Abfolge von weichen und harten Teilschichten 4, 5, 6, 7, wobei weiche Teilschichten 4, 6 sich mit harten Teilschichten 5, 7 abwechseln. Die äußere Schicht wird bevorzugt durch eine harte Teilschicht 7 gebildet.Thereafter, the multi-layer layer is applied in layers by means of vapor deposition (Physical Vapor Deposition PVD). The multilayer 3 comprises a sequence of soft and hard sub-layers 4, 5, 6, 7, soft sub-layers 4, 6 alternating with hard sub-layers 5, 7. The outer layer is preferably formed by a hard part-layer 7.

Die harten Teilschichten 5, 7 können durch keramische Werkstoffe, insbesondere Nitride oder Stickstoff-reiche Schichten aus Aluminium, Titan oder Chrom mit Zusätzen von Yttrium oder Kohlenstoff gebildet sein. Daneben sind jedoch auch andere keramische Werkstoffe insbesondere auf Oxidbasis vorstellbar. Die weichen Teilschichten 4, 6 können ebenfalls aus keramischen Werkstoffen mit denselben chemischen Elementen gebildet sein, wobei durch einen höheren Anteil der metallischen Elemente beispielsweise eine geringere Härte einstellbar ist. Darüber hinaus können die weichen Teilschichten 4, 6 durch metallische Schichten auf der Basis von Eisen, Kobalt, Nickel, Titan, Chrom oder Aluminium oder Kombinationen daraus gebildet sein. Ein Beispiel für eine Schichtabfolge könnte beispielsweise durch die Ausbildung der weichen Teilschichten 4, 6 als CrN-Schichten und der harten Teilschichten als CrAlN-Schichten gegeben sein. Die weichen Teilschichten 4, 6 und/oder die harten Teilschichten 5, 7 können wiederum selbst aus mehreren Schichten aufgebaut sein.The hard sub-layers 5, 7 may be formed by ceramic materials, in particular nitrides or nitrogen-rich layers of aluminum, titanium or chromium with additions of yttrium or carbon. In addition, however, other ceramic materials are conceivable, especially on an oxide basis. The soft sub-layers 4, 6 may also be formed of ceramic materials with the same chemical elements, with a higher proportion of the metallic elements, for example, a lower hardness is adjustable. In addition, the soft sub-layers 4, 6 may be formed by metallic layers based on iron, cobalt, nickel, titanium, chromium or aluminum or combinations thereof. An example of a layer sequence could be given for example by the formation of the soft sub-layers 4, 6 as CrN layers and the hard sub-layers as CrAIN layers. The soft sub-layers 4, 6 and / or the hard sub-layers 5, 7 can in turn themselves be composed of several layers.

Die Schichtdicke der Teilschichten 4 bis 7 der Mehrlagenschicht 3 kann im Bereich von wenigen Nanometern bis zu einigen Mikrometern gewählt werden.The layer thickness of the partial layers 4 to 7 of the multi-layer layer 3 can be selected in the range of a few nanometers to a few micrometers.

Die Schicht 2 hoher Härte kann ferner mit einer Schichtdicke von ca. 100 Mikrometern abgeschieden werden.The layer 2 of high hardness can also be deposited with a layer thickness of about 100 microns.

Die Fig. 2 zeigt ein weiteres Ausführungsbeispiel einer erfindungsgemäßen Beschichtung, bei welcher die identischen Komponenten mit Ausnahme des beschichteten Bauteils mit den gleichen Bezugszeichen, lediglich um 10 erhöht, versehen sind. So ist auf dem Bauteil 10 wiederum eine Schicht 12 hoher Härte sowie eine Mehrlagenschicht 13 mit den Teilschichten 14 bis 17 vorgesehen. Die Schicht hoher Härte 12 und die Mehrlagenschicht 13 sind in gleicher Weise aufgebaut wie im Ausführungsbeispiel der Fig. 1, sodass sich eine zusätzliche Beschreibung erübrigt. Zusätzlich ist zwischen der Schicht 12 hoher Härte und der Mehrlagenschicht 13 eine Chrom-reiche Schicht 11 vorgesehen, die durch Inchromierung der Schicht 12 hoher Härte ausgebildet worden ist. Entsprechend kann die Chrom-reiche Schicht 11 als Diffusionsschicht ausgebildet sein, die in die vorher abgeschiedene Schicht 12 hoher Härte durch Eindiffundieren des Chroms entstanden ist. Darüber hinaus ist es auch denkbar eine Chrom-reiche Auflageschicht oder eine Kombination aus Diffusionsschicht und Auflageschicht zu bilden.The Fig. 2 shows a further embodiment of a coating according to the invention, in which the identical components with the exception of the coated component with the same reference numerals, only increased by 10, are provided. Thus, a layer 12 of high hardness and a multi-layer 13 with the partial layers 14 to 17 are again provided on the component 10. The layer of high hardness 12 and the multi-layer 13 are constructed in the same manner as in the embodiment of Fig. 1 so that an additional description is unnecessary. In addition, between the high-hardness layer 12 and the multi-layer 13, there is provided a chromium-rich layer 11 formed by chromating the high-hardness layer 12. Accordingly, the chromium-rich layer 11 may be formed as a diffusion layer formed in the previously deposited high hardness layer 12 by diffusing the chromium. In addition, it is also conceivable to form a chromium-rich overlay layer or a combination of diffusion layer and overlay layer.

In der Chrom-reichen Schicht kann der Chromanteil insbesondere bis zu 30 Vol.%, vorzugsweise bis zu 20 Vol.% Chrom betragen. Die Chrom-reiche Schicht bewirkt insbesondere eine Verbesserung der Hochtemperaturkorrosionsbeständigkeit, da das Chrom eine dichte, dünne Chromoxidschicht ausbildet, die eine weitere Heißgaskorrosion verhindert.In the chromium-rich layer, the chromium content may in particular be up to 30% by volume, preferably up to 20% by volume, of chromium. In particular, the chromium-rich layer enhances high-temperature corrosion resistance because the chromium forms a dense, thin chromium oxide layer that prevents further hot gas corrosion.

Die Fig. 3 zeigt in einem weiteren Ausführungsbeispiel eine erfindungsgemäße Beschichtung auf einem Bauteil 100, welche zum großen Teil der Beschichtung aus der Fig. 2 entspricht. Entsprechend werden wiederum mit Ausnahme der Bezeichnung des Bauteils die Bezugszeichen für die Komponenten so gewählt, dass diese gegenüber dem Ausführungsbeispiel der Fig. 1 lediglich um 100 erhöht sind.The Fig. 3 shows in a further embodiment, a coating according to the invention on a component 100, which for the most part of the coating from the Fig. 2 equivalent. Accordingly, again with the exception of the name of the component, the reference numerals for the Components chosen so that these compared to the embodiment of Fig. 1 only increased by 100.

So zeigt die Fig. 3 eine Beschichtung mit einer Schicht 102 hoher Härte, der eine Chrom-reichen Schicht 111 und eine Mehrlagenschicht 103 mit den Teilschichten 104 bis 107 folgen. Die Schicht 102 hoher Härte und die Mehrlagenschicht 103 entsprechen den Schichten 12 bzw. 2 sowie 13 bzw. 3 der vorher beschriebenen Ausführungsbeispiele und bedürfen keiner zusätzlichen Erläuterung. Die Chrom-reiche Schicht 111 entspricht der Chrom-reichen Schicht 11 und ist von daher ebenfalls bekannt. Bei der Ausführungsform der Fig. 3 ist lediglich eine zusätzliche poröse Schicht 101 zwischen der Schicht 102 hoher Härte und dem Bauteil 100 vorgesehen. Diese Schicht kann beispielsweise durch Kaltgasspritzen aufgebracht werden. Mittels der porösen Schicht 101 wird durch die definierte Einbringung von Porosität bewirkt, dass eventuell entstehende Mikrorisse aus den äußeren Lagen des Schutzsystems beim Risswachstum nicht in den Grundwerkstoff des Bauteils 100 eindringen können, sondern in den Poren aufgrund der Abstumpfung der Rissspitze am weiteren Risswachstum gehindert werden. Die Zusammensetzung der porösen Schicht 101 wird vorzugsweise ähnlich der des Grundwerkstoffs des Bauteils 100 gewählt.That's how it shows Fig. 3 a coating having a high hardness layer 102 followed by a chromium rich layer 111 and a multilayer 103 having sublayers 104 to 107. The high hardness layer 102 and the multi-layer layer 103 correspond to the layers 12 and 2, and 13 and 3, respectively, of the previously described embodiments and need no further explanation. The chromium-rich layer 111 corresponds to the chromium-rich layer 11 and is therefore also known. In the embodiment of the Fig. 3 only an additional porous layer 101 is provided between the high hardness layer 102 and the component 100. This layer can be applied for example by cold gas spraying. By means of the porous layer 101 is effected by the defined introduction of porosity that any resulting microcracks from the outer layers of the protection system in crack growth can not penetrate into the base material of the component 100, but are prevented in the pores due to the dulling of the crack tip on the further crack growth , The composition of the porous layer 101 is preferably selected to be similar to that of the base material of the component 100.

Die Bauteile 1, 10, 100 können insbesondere durch Eisen-, Nickel- oder Titanbasislegierungen gebildet werden, wobei die Bezeichnung Basislegierung hier angibt, dass die Komponente mit dem größten Anteil durch Eisen, Nickel oder Titan gebildet wird.The components 1, 10, 100 can be formed in particular by iron, nickel or titanium-based alloys, the designation base alloy indicating here that the component with the largest proportion is formed by iron, nickel or titanium.

Obwohl die vorliegende Erfindung anhand des Ausführungsbeispiels detailliert beschrieben worden ist, ist für den Fachmann selbstverständlich, dass die Erfindung nicht auf diese Ausführungsbeispiele beschränkt ist, sondern das vielmehr Abwandlungen oder Ergänzungen in der Weise möglich sind, dass einzelne Merkmale weggelassen oder andersartige Kombinationen von Merkmalen vorgenommen werden können, ohne das der Schutzbereich der beigefügten Ansprüche verlassen wird. Die vorliegende Erfindung offenbart insbesondere sämtliche Kombinationen der vorgestellten Einzelmerkmale.Although the present invention has been described in detail with reference to the embodiment, it will be understood by those skilled in the art that the invention is not limited to these embodiments, but rather modifications or additions are possible in such a way that individual features omitted or made different combinations of features without departing from the scope of the appended claims. In particular, the present invention discloses all combinations of the featured individual features.

Claims (17)

Beschichtung für Bauteile einer Gasturbine oder eines Flugtriebwerks mit einer Mehrlagenschicht (3, 13, 103) aus mehreren Teilschichten (4,5,6,7; 14, 15, 16, 17; 104, 105, 106, 107) unterschiedlicher Härte, wobei die Mehrlagenschicht (3, 13, 103) eine wiederholte Abfolge von harten und weichen Teilschichten (4, 5, 6, 7; 14, 15, 16, 17; 104, 105, 106, 107) umfasst, wobei insbesondere die äußerste Teilschicht eine harte Schicht ist,
dadurch gekennzeichnet, dass
unterhalb der Mehrlagenschicht zwischen dem Bauteil und der Mehrlagenschicht eine Schicht (2, 12, 102) hoher Härte mit einer Zusammensetzung angeordnet ist, die sich von der Zusammensetzung der Teilschichten der Mehrlagenschicht unterscheidet, wobei die Schicht hoher Härte eine höhere Härte als das zu beschichtende Bauteil aufweist und eine CoMoCrSi-Legierung, eine CoCrWSi-Legierung oder eine MCrAlY-Legierung mit Dispersionspartikeln aus Oxiden, Nitriden und/oder Boriden ist, wobei M gleich Fe, Co oder Ni ist.A coating for components of a gas turbine or an aircraft engine with a multi-layer layer (3, 13, 103) of a plurality of partial layers (4, 5, 6, 7, 15, 16, 17, 104, 105, 106, 107) of different hardness, wherein the multi-layer layer (3, 13, 103) comprises a repeated sequence of hard and soft sub-layers (4, 5, 6, 7; 14, 15, 16, 17; 104, 105, 106, 107), wherein in particular the outermost sub-layer has a hard layer is,
characterized in that
below the multilayer between the member and the multilayer, a high hardness layer (2, 12, 102) having a composition different from the composition of the sublayers of the multilayer film is disposed, the high hardness layer having higher hardness than the component to be coated and is a CoMoCrSi alloy, a CoCrWSi alloy or an MCrAlY alloy with dispersion particles of oxides, nitrides and / or borides, where M is Fe, Co or Ni. Beschichtung nach Anspruch 1,
dadurch gekennzeichnet, dass
die Mehrlagenschicht (3, 13, 103) eine wiederholte Abfolge einer weichen metallischen Teilschicht und einer harten keramischen Teilschicht oder einer weichen keramischen Teilschicht und einer harten keramischen Teilschicht aufweist, wobei insbesondere die Dicke der Teilschichten der Mehrlagenschicht im Bereich von einigen wenigen nm bis zu 20 µm, vorzugsweise 10 µm liegt.Coating according to claim 1,
characterized in that
the multi-layer layer (3, 13, 103) has a repeated sequence of a soft metallic sub-layer and a hard ceramic sub-layer or a soft ceramic sub-layer and a hard ceramic sub-layer, wherein in particular the thickness of the sub-layers of the multi-layer layer in the range of a few nm to 20 μm, preferably 10 microns. Beschichtung nach einem der vorhergehenden Ansprüche,
dadurch gekennzeichnet, dass
die harten Teilschichten der Mehrlagenschicht Nitride oder stickstoffreiche Schichten mit Chrom, Aluminium und/oder Titan umfassen, während die weichen Teilschichten der Mehrlagenschicht durch Schichten auf Basis von Fe, Co, Ni, Ti, Cr, Al und Kombinationen daraus gebildet sind.Coating according to one of the preceding claims,
characterized in that
the hard sub-layers of the multi-layer layer comprise nitrides or nitrogen-rich layers with chromium, aluminum and / or titanium, while the soft sub-layers of the multilayer layer are formed by layers based on Fe, Co, Ni, Ti, Cr, Al and combinations thereof. Beschichtung nach einem der vorhergehenden Ansprüche,
dadurch gekennzeichnet, dass
die Schicht (2, 12, 102) hoher Härte durch eine Metalllegierungsschicht gebildet ist, die mittels Dispersionshärtung, Ausscheidungshärtung oder Mischkristallverfestigung eine hohe Härte aufweist.Coating according to one of the preceding claims,
characterized in that
the high hardness layer (2, 12, 102) is formed by a metal alloy layer formed by Dispersion hardening, precipitation hardening or solid solution hardening has a high hardness. Beschichtung nach einem der vorhergehenden Ansprüche,
dadurch gekennzeichnet, dass
die Schicht hoher Härte einen hohen Cr-Anteil von insbesondere ≥ 18 Gew.-%, vorzugsweise ≥ 20 Gew.-% aufweist, insbesondere bei gleichzeitig niedrigem Cr-Karbid-Anteil von < 5 Vol.-%, insbesondere < 1 Vol.-%, bei welchem sichergestellt ist, dass sich eine schützende Chromoxidschicht ausbildet.Coating according to one of the preceding claims,
characterized in that
the layer of high hardness has a high Cr content of in particular ≥ 18% by weight, preferably ≥ 20% by weight, in particular with a simultaneously low Cr carbide content of <5% by volume, in particular <1% by volume. %, which ensures that a protective chromium oxide layer is formed. Beschichtung nach einem der vorhergehenden Ansprüche,
dadurch gekennzeichnet, dass
zwischen der Schicht (2, 12, 102) hoher Härte und der Mehrlagenschicht eine Schicht (11, 111) mit hohem Chrom-Anteil angeordnet ist, wobei der Chrom-Anteil bis zu 30 Vol.-%, vorzugsweise bis zu 20 Vol.-% beträgt.Coating according to one of the preceding claims,
characterized in that
a layer (11, 111) with a high chromium content is arranged between the layer (2, 12, 102) of high hardness and the multilayer layer, the chromium content being up to 30% by volume, preferably up to 20% by volume. % is. Beschichtung nach einem der vorhergehenden Ansprüche,
dadurch gekennzeichnet, dass
unterhalb der Schicht (2, 12, 102) hoher Härte zwischen der Schicht hoher Härte und dem Bauteil eine poröse Schicht (101) ausgebildet ist.Coating according to one of the preceding claims,
characterized in that
below the high hardness layer (2, 12, 102) between the high hardness layer and the component, a porous layer (101) is formed. Beschichtung nach einem der vorhergehenden Ansprüche,
dadurch gekennzeichnet, dass
die Schicht hoher Härte eine Dicke bis zu 150 µm, insbesondere bis zu 100 µm aufweist.Coating according to one of the preceding claims,
characterized in that
the layer of high hardness has a thickness of up to 150 μm, in particular up to 100 μm. Beschichtung nach Anspruch 6,
dadurch gekennzeichnet, dass
die Schicht mit hohem Chrom-Anteil eine Dicke von bis zu 20 µm, vorzugsweise bi zu 10 µm aufweist.Coating according to claim 6,
characterized in that
the high chromium layer has a thickness of up to 20 microns, preferably bi to 10 microns. Beschichtung nach einem der vorhergehenden Ansprüche,
dadurch gekennzeichnet, dass
sie mit dem Verfahren nach einem der Ansprüche 14 bis 17 hergestellt ist.Coating according to one of the preceding claims,
characterized in that
it is produced by the method according to one of claims 14 to 17. Bauteil für eine Gasturbine oder ein Flugtriebwerk, insbesondere eine Leit- oder Laufschaufel mit einer Beschichtung nach einem der Ansprüche 1 bis 10.Component for a gas turbine or an aircraft engine, in particular a guide or moving blade with a coating according to one of claims 1 to 10. Bauteil nach Anspruch 11,
dadurch gekennzeichnet, dass
die Schicht mit hohem Chrom-Anteil (11, 111) und/oder die Mehrlagenschicht (3, 13, 103) über das Bauteil (1, 10, 100) verteilt nur in Teilbereichen abgeschieden wird.Component according to claim 11,
characterized in that
the layer with a high proportion of chromium (11, 111) and / or the multi-layer layer (3, 13, 103) distributed over the component (1, 10, 100) is deposited only in some areas. Bauteil nach Anspruch 11 oder 12,
dadurch gekennzeichnet, dass
das Bauteil (1, 10, 100) aus einem Fe-, Ni- oder Ti-Basiswerkstoff gebildet ist.Component according to claim 11 or 12,
characterized in that
the component (1, 10, 100) is formed from an Fe, Ni or Ti base material. Verfahren zur Herstellung einer Beschichtung für ein Bauteil einer Gasturbine oder eines Flugtriebwerks, insbesondere nach einem der Ansprüche 1 bis 10, bei welchem eine Schicht (2, 12, 102) hoher Härte mittels Kaltgasspritzen oder Heißgasspritzen aufgebracht wird und anschließend eine Mehrlagenschicht (3, 13, 103) durch PVD-Abscheidung abgeschieden wird.Process for producing a coating for a component of a gas turbine or an aircraft engine, in particular according to one of Claims 1 to 10, in which a layer (2, 12, 102) of high hardness is applied by means of cold gas spraying or hot gas spraying and subsequently a multilayer coating (3, 13 , 103) is deposited by PVD deposition. Verfahren nach Anspruch 14,
dadurch gekennzeichnet, dass
die Schicht (11, 111) mit hohem Chrom-Anteil durch Inchromierung aufgebracht wird.Method according to claim 14,
characterized in that
the layer (11, 111) with high chromium content is applied by chromium plating. Verfahren nach Anspruch 14 oder 15,
dadurch gekennzeichnet, dass
die poröse Schicht (101) durch Kaltgasspritzen aufgebracht wird.Method according to claim 14 or 15,
characterized in that
the porous layer (101) is applied by cold gas spraying. Verfahren nach einem der Ansprüche 14 bis 16,
dadurch gekennzeichnet, dass
die Schicht (2, 12, 102) hoher Härte nach dem Aufbringen und vor der weiteren Beschichtung geglättet wird.Method according to one of claims 14 to 16,
characterized in that
the high hardness layer (2, 12, 102) is smoothed after application and before further coating.
EP20110170936 2011-06-22 2011-06-22 Multiple wear-resistant coating and method for its production Not-in-force EP2537959B1 (en)

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