EP2576138B2 - Procédé pour l'enlèvement de revêtements céramiques par décapage au co2 à l'état solide - Google Patents

Procédé pour l'enlèvement de revêtements céramiques par décapage au co2 à l'état solide Download PDF

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Publication number
EP2576138B2
EP2576138B2 EP11723670.3A EP11723670A EP2576138B2 EP 2576138 B2 EP2576138 B2 EP 2576138B2 EP 11723670 A EP11723670 A EP 11723670A EP 2576138 B2 EP2576138 B2 EP 2576138B2
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European Patent Office
Prior art keywords
solid
coating
blasting
substrate
ceramic
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EP11723670.3A
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German (de)
English (en)
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EP2576138A1 (fr
EP2576138B1 (fr
Inventor
Andrea Scrivani
Carlo Giolli
Bruno Antonio Allegrini
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A&G Chemical Production Srl
Turbocoating SpA
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A&G Chemical Production Srl
Turbocoating SpA
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
    • B24C1/00—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods
    • B24C1/003—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods using material which dissolves or changes phase after the treatment, e.g. ice, CO2
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
    • B24C1/00—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods
    • B24C1/08—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods for polishing surfaces, e.g. smoothing a surface by making use of liquid-borne abrasives

Definitions

  • Ceramic thick coatings are defined as the protective layer with a thickness greater than 100 ⁇ m while the thin films are defined as protective layers with a thickness lower than 100 ⁇ m.
  • Ceramic thick coatings are made by thermal spray technologies as Air Plasma Spray (APS), Vacuum Plasma Spray (VPS), Suspension Plasma Spray (SPS), Solution Precursor Plasma Spray (SPPS) and High Velocity Oxygen Fuel (HVOF), mainly.
  • Ceramic Thin Films are applied by Chemical Vapor Deposition (CVD) and Physical Vapor Deposition (PVD), mainly. Thick Ceramic Coatings are used for different application:
  • Dry-ice particle blasting is similar to sand blasting, plastic bead blasting, or soda blasting where a media is accelerated in a pressurized air stream (or other inert gas) to impact the surface to be cleaned or prepared.
  • a pressurized air stream or other inert gas
  • the media that impacts the surface is solid carbon dioxide (CO 2 ) particles.
  • CO 2 solid carbon dioxide
  • One unique aspect of using dry-ice particles as a blast media is that the particles sublimate (vaporize) upon impact with the surface. The combined impact energy dissipation and extremely rapid heat transfer between the pellet and the surface cause instantaneous sublimation of the solid CO 2 into a gas.
  • the gas expands to nearly eight hundred times the volume of the particle in a few milliseconds in what is effectively a "micro-explosion" at the point of impact that aids the coating removal process. Because of the CO 2 vaporizing, the dry-ice blasting process does not generate any secondary waste. All that remains to be collected is the removed coating.
  • the kinetic energy associated with dry-ice blasting is a function of the particle mass density and impact velocity. Since CO 2 particles have a relatively low density, the process relies on high particle velocities to achieve the needed impact energy. The high particle velocities are the result of supersonic propellant or air-stream velocities.
  • the CO 2 particles have a very low temperature of -109°F (-78.5°C). This inherent low temperature gives the dry-ice blasting process unique thermodynamically induced surface mechanisms that affect the coating or contaminate in greater or lesser degrees, depending on coating type. Because of the temperature differential between the dry ice particles and the surface being treated, a phenomenon known as thermal shock can occur. As a material's temperature decreases, it becomes brittle, enabling the particle impact to break-up the coating and sever the chemical bond that is weakened by the lower temperature. The thermal gradient or differential between two dissimilar materials with different thermal expansion coefficients can serve to break the bond between the two materials. This thermal shock is most evident when blasting a nonmetallic coating or contaminate bonded to a metallic substrate.
  • Dry Ice stripping should enable the removal of ceramic TC without modifying the MCrAlY bond coat characteristics and mainly the surface morphology.
  • WO01/66365 discloses a coating removal system having a solid particle nozzle with a detector for detecting particle flow and associated method
  • an apparatus for removing a coating from a substrate, comprising a nozzle having an outlet and adapted to direct a particle stream therethrough at a predetermined flow rate, a signal source for emitting a signal capable of traversing the particle stream, and a signal sensor positioned to detect the signal emitted by the signal source once the signal has passed through the particle stream.
  • the particle stream is directed from the outlet of the nozzle toward a coating on a substrate to remove the coating from the substrate.
  • This method does not include the step of pre-demaging the ceramic coating before removing the ceramic layer using dry ice blasting as included instead in the previous cited patent [ US20080178907 ].
  • the pre-damaging using shot peening or another sand blasting method using abrasive media shows the risk to damage the substrate characteristics as roughness and thickness.
  • the only pre-heating is not able to pre-damage the ceramic coating.
  • the pre-heating alone or the combination of pre-heating and quenching are not able to pre-damage or to remove the ceramic coating as a TBC or to get faster the dry ice stripping process.
  • the only thermal shock is not able to remove the ceramic coating. Dry Ice Blasting is not able to remove in a fast way the ceramic coatings treated with shot peening or/and pre-heating as indicate in the previous cited patent [ US20080178907 ].
  • This method includes only pre-heating by irradiation performed during or immediately before the blasting with solid CO 2 . This is due to the ceramic coating damage mechanism.
  • the density of the solid CO 2 pellets is proportional to the shock wave power. The more the pellets are dense, the more the gas volume growing during the sublimation is greater, the more the shock wave is stronger.
  • the equipment used in this invention is able to maintain high the density of the CO 2 pellets sudden out of the spray gun nozzle.
  • the mass flow of the solid CO 2 pellets is proportional to the shock wave power. The more the amount of Dry Ice pellets interact with the coating surface subliming, the stronger is the shock wave.
  • the present invention refers to a method and an equipment to remove ceramic protective coatings 2 (i.e. Thermal Barrier Coating such a Yttria Partially Stabilized Zirconia - YPSZ) with high removal efficiency and without damaging the substrate 1 characteristics.
  • ceramic protective coatings 2 i.e. Thermal Barrier Coating such a Yttria Partially Stabilized Zirconia - YPSZ
  • the removing of the ceramic coating 2 without damaging the substrate 1 characteristics is obtained by a combination of coating/substrate pre-heating by irradiation immediately before ( Fig.2 (b) ) or during the stripping ( Fig.2 (a) ) and improved solid CO 2 4 blasting parameters.
  • the substrate 1 can be metallic, ceramic, plastic or composite.
  • the substrate characteristics not affected by the present invention are the substrate thickness and roughness.
  • Substrate thickness can vary in an range of 1 ⁇ m to 1 m.
  • the substrate can be rough (Ra > 9 ⁇ m) or smooth (Ra ⁇ 9 ⁇ m).
  • the stripping method is a single stage process where only a combination of a pre-heating during or immediately before the blasting with solid CO 2 4 can lead to the ceramic coating stripping.
  • the equipment to remove ceramic protective coatings is divided in two parts: Pre-heating Station 5 and Sand Blasting Machine Station 20. This method does not include the step of pre-damaging the ceramic coating 2 before stripping step by dry ice blasting.
  • the substrates 1 coated with ceramic coating 2 are pre-heated in sequence in the pre-heating stations 5 ( Fig.3 ) up to the maximum temperature that the substrate can tolerate.
  • the pre-heating station 5 is able to heat the coating/substrate up to a maximum temperature of 1000°C.
  • the coated component in moved in the solid CO 2 blasting station 20.
  • the coating stripping using solid CO 2 blasting with optimized parameters is performed up to the quenching of the process at room temperature.
  • the component is then moved in another pre-heating station 5 while another hot component is moved into the stripping station 20 ( Fig.3 ).
  • the steps of pre-heating and solid CO 2 blasting are repeated for each substrate up to the complete coating removal.
  • the Sand Blasting Machine Station 20 for blasting by solid CO 2 4 used in the method consists of a compressor, a feeder unit to feed dry ice into one or more spray guns 3.
  • dry-ice particles are delivered and metered by various mechanical means to the inlet end of a hose and are drawn through the hose to the nozzle by means of vacuum produced by an ejector-type nozzle.
  • a stream of compressed air (supplied by the second hose) is sent through a primary nozzle and expands as a high velocity jet confined inside a mixing tube.
  • this type of nozzle produces vacuum on the cavity around the primary jet and can therefore drag particles up through the ice hose and into the mixing tube where they are accelerated as the jet mixes with the entrained air/particle mixture.
  • the exhaust Mach number from this type of nozzle is, in general, slightly supersonic. Advantages of this type of system are relative simplicity and lower material cost, along with an overall compact feeder system.
  • Pellet blast machines are also differentiated into dry ice block shaver blasters and dry-ice pellet blasters.
  • Pellet blast machines have a hopper that is filled with pre-manufactured CO 2 pellets.
  • the hopper uses mechanical agitation to move the pellets to the bottom of the hopper and into the feeder system.
  • the pellets are extruded through a die plate under great pressure.
  • the pellets are available in several sizes ranging from 0.040 inch (1 mm) to 0.120 inch (3 mm) in diameter.
  • the 0.120 inch (3 mm) in diameter pellets are commercially available.
  • the solid CO 2 blasting machine station use a continuous (not pulsing) solid CO 2 blasting flow (constant pressure). Said continuous flow is obtained using a core in the feeder device ( Figure 4 ) in combination with a spray two-hose nozzle gun 3 ( Figure 5 ).
  • the Dry Ice is fed using a special feeding device as schematized in Figure 4 .
  • the dry ice pellets contained in a box 9 are moved by a rotating scoop 10 in a large hole 11.
  • An air pressure flow (in a range of 1-5 bar) coming from 13 moves the pellets accumulated in 12 in the direction 14 up to the two-hose nozzle of the spray gun 3.
  • the two-hose nozzle is schematized in Figure 5 .
  • Solid CO 2 pellets are fed in the main nozzle hose 17 by axial injection 16 in the internal injector 18.
  • a second pipe with high pressure air up to thirty bar is connected with the convergent/divergent nozzle 19 ( Fig.5 ).
  • the high pressure air is accelerated by convergent/divergent nozzle up to supersonic speed.
  • the dry ice pellets 4 are injected directly in the accelerated high pressure air stream after the nozzle throat 19.
  • the continuous flow shows a mass flow of solid CO 2 4 in a range of about 100 - 3500 g/min and a pressure in a range of 1 - 30 bar.
  • a continuous flow of solid CO 2 is very important in order to reach very high removal rate. In fact if the flow is pulsed not only solid CO 2 will arrive on the coating surface but cool air, too.
  • the cool air will decrease the substrate/coating temperature without a contribution to the stripping process that is due to the shock waves due to the solid CO 2 sublimation. In that way the removal rate will be less than using a continuous flow of solid CO 2 .
  • High pressure is very important to increase the mass flow and to increase the removal rate. In fact, when the shock waves crumble ceramic coatings, the high pressure aids ceramic fragments removal.
  • the solid CO 2 Pellets used for blasting have very high density (Density 1.4 -1.6 g/cm 3 ).
  • the CO 2 pellets density is very important because the more is the density, the more is the shock wave power due to the solid CO 2 sublimation.
  • the sand blasting equipment is designed to maintain the pellets density in a range of 1.525 - 1.6 g/cm 3 before the impact on the ceramic coating. This is obtained using in combination the above mentioned feeder and two-hose nozzle.
  • the pre-heating systems is performed by IR lamps 6 using irradiation.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Processing Of Solid Wastes (AREA)

Claims (9)

  1. Procédé pour enlever des revêtements en céramique (2) appliqués sur des substrats (1) en métal, céramique, plastique ou composite, comprenant un moyen de décapage par une phase de bombardement avec du CO2 solide (4); ledit procédé étant appliqué sans changer ni endommager les caractéristiques d'épaisseur et de rugosité du substrat (1), le procédé étant configuré de manière à préparer le substrat (1) pour être couvert par une nouvelle couche de céramique (2); dans lequel le procédé prévoit une combinaison d'un revêtement (2) et d'un dispositif de préchauffage (1) du substrat par irradiation pendant ou immédiatement avant ledit décapage par bombardement avec du CO2 solide (4), caractérisé en ce que lesdits composants sont préchauffés dans la séquence de préchauffage dans les stations (5), puis le revêtement est enlevé par décapage du CO2 solide (4) jusqu'au refroidissement du processus, précisément jusqu'à la température ambiante; les opérations de bombardement et de préchauffage du CO2 solide sont répétées pour chaque substrat, jusqu'à l'élimination complète du revêtement.
  2. Procédé selon la revendication 1, caractérisé en ce qu'il est appliqué à un écoulement continu de bombardement du CO2 solide, et précisément non pulsé.
  3. Procédé selon la revendication 2, caractérisé en ce que ledit écoulement de bombardement du CO2 solide est appliqué avec une pression constante.
  4. Procédé selon la revendication 1, caractérisé en ce que ledit préchauffage du revêtement/substrat par irradiation est appliqué à une vitesse comprise entre 1°C/ min et 100°C/min.
  5. Procédé selon la revendication 1, caractérisé en ce que le préchauffage du revêtement/substrat par irradiation est augmenté jusqu'à 1000°C.
  6. Procédé selon la revendication 2, caractérisé en ce que ledit écoulement continu applique un débit massique du CO2 solide compris entre environ 100 et 3500 g/min.
  7. Procédé selon la revendication 2, caractérisé en ce que ledit écoulement continu peut faire varier la pression entre 1 et 30 bar.
  8. Procédé selon la revendication 1, caractérisé en ce qu'il est capable de produire un jet de CO2 solide en préservant la densité des boulettes entre 1,525 et 1,6 g/cm3 avant l'impact sur le revêtement céramique.
  9. Procédé selon la revendication 1, caractérisé en ce que le revêtement céramique est retiré à une vitesse comprise entre 1 et 100 cm2/min.
EP11723670.3A 2010-04-29 2011-04-27 Procédé pour l'enlèvement de revêtements céramiques par décapage au co2 à l'état solide Active EP2576138B2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ITPR2010A000031A IT1399945B1 (it) 2010-04-29 2010-04-29 Metodo e apparato per rimuovere ricoprimenti ceramici, con sabbiatura di anidride carbonica allo stato solido.
PCT/IB2011/051839 WO2011135526A1 (fr) 2010-04-29 2011-04-27 Procédé et équipement pour l'enlèvement de revêtements céramiques par décapage au co2 à l'état solide

Publications (3)

Publication Number Publication Date
EP2576138A1 EP2576138A1 (fr) 2013-04-10
EP2576138B1 EP2576138B1 (fr) 2015-02-11
EP2576138B2 true EP2576138B2 (fr) 2023-04-05

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US (1) US20130040538A1 (fr)
EP (1) EP2576138B2 (fr)
CN (1) CN103108725B (fr)
CA (1) CA2797184A1 (fr)
IT (1) IT1399945B1 (fr)
WO (1) WO2011135526A1 (fr)

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US8679246B2 (en) * 2010-01-21 2014-03-25 The University Of Connecticut Preparation of amorphous mixed metal oxides and their use as feedstocks in thermal spray coating
WO2013144022A1 (fr) 2012-03-28 2013-10-03 Alstom Technology Ltd Procédé pour retirer une céramique
WO2016033612A1 (fr) * 2014-08-29 2016-03-03 Hzo, Inc. Équipement pour enlever les revêtements de protection de substrats
KR20160065226A (ko) * 2014-11-07 2016-06-09 세메스 주식회사 기판 처리 장치 및 기판 처리 방법
JP6718477B2 (ja) 2018-03-08 2020-07-08 三菱重工業株式会社 積層造形方法
CN109536868A (zh) * 2018-11-27 2019-03-29 广东省新材料研究所 石油输送分流环的内孔超音速火焰喷涂金属陶瓷涂层的方法
US11441974B2 (en) 2019-08-01 2022-09-13 Applied Materials, Inc. Detection of surface particles on chamber components with carbon dioxide
TWI832028B (zh) 2019-12-31 2024-02-11 美商冷卻噴射公司 粒子噴射系統及從一噴射噴嘴排出一挾帶粒子流之方法

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Also Published As

Publication number Publication date
ITPR20100031A1 (it) 2011-10-30
IT1399945B1 (it) 2013-05-09
CN103108725B (zh) 2015-07-08
WO2011135526A1 (fr) 2011-11-03
CA2797184A1 (fr) 2011-11-03
EP2576138A1 (fr) 2013-04-10
EP2576138B1 (fr) 2015-02-11
US20130040538A1 (en) 2013-02-14
CN103108725A (zh) 2013-05-15

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