EP2913421A1 - Article revêtu et procédé de production de revêtement - Google Patents

Article revêtu et procédé de production de revêtement Download PDF

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Publication number
EP2913421A1
EP2913421A1 EP15156132.1A EP15156132A EP2913421A1 EP 2913421 A1 EP2913421 A1 EP 2913421A1 EP 15156132 A EP15156132 A EP 15156132A EP 2913421 A1 EP2913421 A1 EP 2913421A1
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EP
European Patent Office
Prior art keywords
ceramic
erosion resistance
modified
chromium
anodic material
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP15156132.1A
Other languages
German (de)
English (en)
Inventor
Surinder Singh Pabla
Krishnamurthy Anand
Kalaga Murali Krishna
Padmaja Parakala
Bala Srinivasan Parthasarathy
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.)
General Electric Co
Original Assignee
General Electric Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by General Electric Co filed Critical General Electric Co
Publication of EP2913421A1 publication Critical patent/EP2913421A1/fr
Withdrawn legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/286—Particular treatment of blades, e.g. to increase durability or resistance against corrosion or erosion
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/06—Metallic material
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/284—Selection of ceramic materials
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/288—Protective coatings for blades
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31678—Of metal

Definitions

  • the present invention is directed to a coated article and a method for producing a coating. More specifically, the present invention is directed to a coated article and a method for producing a coating containing an anodic material and ceramic particles.
  • Gas and steam turbine components particularly rear stage gas turbine compressor blades, rear stage gas turbine compressor vanes and centrifugal pump impellers, in addition to pipelines, are subjected to water droplet erosion, particulate deposition and corrosion pitting induced cracking issues caused by on-line water washing.
  • the preceding surface degradation mechanisms may also result in undesirable increases in surface roughness.
  • Fouling of components may cause corrosion of the components underneath the deposits through a crevice corrosion mechanism. Additionally, particulates in the intake air may cause erosion through foreign object damage to the components thereby causing corrosion.
  • Water wash cycles are often performed to remove the particulates that have built up on the components. However, the water wash cycles expose the components to increased amounts of moisture, which may cause corrosion of the components by dissolving and leaching corrosive agents entrapped in the surface deposits, and accelerated corrosion to any portions of the components damaged by foreign object damage.
  • the water wash cycles may utilize chemicals to remove complex particulate buildup. These chemicals may increase corrosion of the components and increase maintenance cost of the components.
  • Coating systems which require more than one coating layer to address corrosion, oxidation, fouling and/or erosion are undesirable because multiple layers may result in excessive overall thickness of the component so coated. Additionally, multiple coatings may increase the likelihood of undesirable alterations in the aerodynamics or fluid dynamics of the component, or detrimental increases in the weight of the component.
  • Unchecked corrosion, oxidation, fouling and/or erosion of the exposed surfaces of the gas turbine or steam turbine components, or of pipelines, may result in undesirable increases in surface roughness, thereby decreasing the efficiency.
  • Coated components and methods for producing coated components that do not suffer from one or more of the above drawbacks would be desirable in the art.
  • a method for producing a coating includes providing a substrate defining a substrate surface having a substrate erosion resistance and applying a matrix and ceramic particles to the substrate surface.
  • the matrix includes an anodic material having an anodic erosion resistance.
  • the ceramic particles include a first ceramic having a first ceramic erosion resistance and a second ceramic having a second ceramic erosion resistance.
  • the first ceramic erosion resistance is greater than the second ceramic erosion resistance, greater than the anodic erosion resistance, and greater than the substrate erosion resistance.
  • the second ceramic interacts inchoately with the anodic material during the applying to form modified ceramic particles and modified anodic material formations.
  • the modified ceramic particles are capable of forming a passive oxide film.
  • a coated article in another embodiment, includes a substrate defining a substrate surface having a substrate erosion resistance and a coating on the substrate surface.
  • the coating includes a matrix and ceramic particles.
  • the matrix includes an anodic material having an anodic erosion resistance.
  • the ceramic particles include a first ceramic having a first ceramic erosion resistance and a second ceramic having a second ceramic erosion resistance.
  • the coating also includes modified ceramic particles and modified anodic material formations formed by an inchoate interaction between the second ceramic and the anodic material.
  • the first ceramic erosion resistance is greater than the second ceramic erosion resistance, greater than the anodic erosion resistance, and greater than the substrate erosion resistance.
  • the modified ceramic particles are capable of forming a passive oxide film.
  • a coated article and a method for producing a coating are provided.
  • Embodiments of the present disclosure in comparison to methods and articles not using one or more of the features disclosed herein, decrease substrate corrosion, decrease substrate oxidation, decrease substrate fouling, decrease substrate erosion, decrease the rate at which the surface roughness of a substrate increases, decrease maintenance costs, increase efficiency, or a combination thereof.
  • a coated article 100 is depicted.
  • the coated article 100 is any suitable component, for example, a compressor blade 102 (shown), a compressor vane, a centrifugal pump impeller or a pipeline.
  • blade as used herein is intended to be synonymous with the term "bucket.”
  • the coated article 100 includes a substrate 202 defining a substrate surface 204 having a substrate erosion resistance, and a coating 206 on the substrate surface 204.
  • the coating 206 includes a matrix 210 including an anodic material 212 having an anodic erosion resistance, and ceramic particles 214.
  • the anodic material 212 may be anodic with respect to the substrate 202.
  • the ceramic particles 214 include a first ceramic 216 having a first ceramic erosion resistance and a second ceramic 218 having a second ceramic erosion resistance.
  • the coating 206 also includes modified ceramic particles 220 and modified anodic material formations 222 formed from an inchoate interaction between the second ceramic 218 and the anodic material 212.
  • the coating 206 defines a coating surface 224 which is exposed to the external environment.
  • the first ceramic erosion resistance is greater than the second ceramic erosion resistance, greater than the anodic erosion resistance, and greater than the substrate erosion resistance.
  • the anodic material 212 includes Cr 70% Ni 30% (wt%), a mixture of Ni 80 %Al 20 % (wt%) and Ni 95% Al 5% (wt%), cobalt and aluminum particles in a sacrificial metallic undercoat with a ceramic overcoat, a metallurgically bonded aluminide with an aluminum surface layer, NiCrAl, or a combination thereof.
  • the anoidic material is Cr 70% Ni 30% (wt%).
  • the anodic material 212 is operative to protect the substrate surface 204 from corrosion during downtime, which is endemic in peaking turbine components and not uncommon even in base loaded turbine components.
  • the first ceramic 216 is tungsten carbide and the second ceramic 218 is chromium carbide, chromium nitride or a combination of chromium carbide and chromium nitride.
  • the anodic material 212 contains chromium and nickel, and the second ceramic interacts inchoately with the chromium and nickel in the anodic material 212 during the applying to form the modified ceramic particles 220 and the modified anodic material formations 222.
  • the modified ceramic particles 220 include at least one of modified chromium carbide particles having a range of chromium carbide stoichiometries and modified chromium nitride particles having a range of chromium nitride stoichiometries.
  • modified chromium carbide particles having a range of chromium carbide stoichiometries
  • modified chromium nitride particles having a range of chromium nitride stoichiometries.
  • the coating 206 contains from about 30% to about 60% by weight tungsten carbide, alternatively from about 30% to about 40%, alternatively from about 40% to about 50%, alternatively from about 50% to about 60%. In an additional embodiment, the coating 206 further contains from about 20% to about 50% by weight of one or both of chromium carbide and chromium nitride, alternatively from about 20% to about 30%, alternatively from about 30% to about 40% alternatively from about 40% to about 50%. In a further embodiment, the coating 206 also contain balance essentially anodic material 212.
  • the modified ceramic particles 220 are capable of forming a passive oxide film 302.
  • the passive oxide film 302 forms under standard rear stage turbine compressor operating conditions.
  • Known rear stage turbine compressor operating conditions include, for example, elevated pressures 10-25 times atmospheric pressure, and being subjected to adiabatic heating to 250-677 °C.
  • the passive oxide film 302 defines the coating surface 224.
  • the passive oxide film 302 resists increases in the roughness of the coating surface 224 caused by oxidation. Without being bound by theory, it is believed that because the passive oxide film 302 include materials which are oxides, these materials will not undergo further oxidation.
  • the passive oxide film 302 is uniformly, or substantially uniformly, distributed on the matrix 210.
  • the passive oxide film 302 has a thickness of between about 0.1 ⁇ m to about 3 ⁇ m, alternatively between about 0.1 ⁇ m to about 2 ⁇ m, alternatively between about 0.1 ⁇ m to about 1 ⁇ m, alternatively between about 1 ⁇ m to about 2 ⁇ m, alternatively between about 2 ⁇ m to about 3 ⁇ m, alternatively between about 0.1 ⁇ m to about 1.5 ⁇ m, alternatively between about 1.5 ⁇ m to about 3 ⁇ m, alternatively between about 0.1 ⁇ m to about 0.5 ⁇ m, alternatively between about 0.5 ⁇ m to about 1 ⁇ m, alternatively between about 1 ⁇ m to about 1.5 ⁇ m, alternatively between about 1.5 ⁇ m to about 2 ⁇ m.
  • the coating 206 is produced by any suitable method.
  • a method for applying the coating 206 includes providing the substrate 202 defining the substrate surface 204 and applying the matrix 210 and the ceramic particles 214 to the substrate surface 204. Applying the matrix 210 and the ceramic particles 214 to the substrate surface 204 may be accomplished by any suitable coating techniques, such as, but not limited to, thermal spray, air plasma spray (APS), high velocity oxygen fuel (HVOF) thermal spray, high velocity air fuel spraying (HVAF), vacuum plasma spray (VPS), electron-beam physical vapor deposition (EBPVD), chemical vapor deposition (CVD), ion plasma deposition (IPD), combustion spraying with powder or rod, cold spray, sol gel, electrophoretic deposition, tape casting, polymer derived ceramic coating, slurry coating, dip-application, vacuum-coating application, curtain-coating application, brush-application, roll-coat application, and agglomeration and sintering followed by spray drying.
  • suitable coating techniques such as, but not limited to, thermal spray,
  • the ceramic particles 214 have an average particle diameter ranging from about 0.3 ⁇ m to about 5 ⁇ m, alternatively from about 0.3 ⁇ m to about 2.5 ⁇ m, alternatively from about 2.5 ⁇ m to about 5 ⁇ m, alternatively from about 0.3 ⁇ m to about 2 ⁇ m, alternatively from about 2 ⁇ m to about 3.5 ⁇ m, alternatively from about 3.5 ⁇ m to about 5 ⁇ m, alternatively from about 0.3 ⁇ m to about 1 ⁇ m, alternatively from about 2 ⁇ m to about 3 ⁇ m, alternatively from about 3 ⁇ m to about 4 ⁇ m, alternatively from about 4 ⁇ m to about 5 ⁇ m.
  • the coating 206 has an average distance between the ceramic particles 214 ranging from about 0.2 ⁇ m to about 2 ⁇ m, alternatively from about 0.2 ⁇ m to about 1 ⁇ m, alternatively from about 1 ⁇ m to about 2 ⁇ m, alternatively from about 0.2 ⁇ m to about 0.8 ⁇ m, alternatively from about 0.8 ⁇ m to about 1.4 ⁇ m, alternatively from about 1.4 ⁇ m to about 2 ⁇ m.
  • the coating 206 has a thickness of between about 50 ⁇ m to about 250 ⁇ m, alternatively between about 50 ⁇ m to about 150 ⁇ m, alternatively between about 100 ⁇ m to about 200 ⁇ m, alternatively between about 150 ⁇ m to about 250 ⁇ m, alternatively between about 50 ⁇ m to about 100 ⁇ m, alternatively between about 100 ⁇ m to about 150 ⁇ m, alternatively between about 150 ⁇ m to about 200 ⁇ m, alternatively between about 200 ⁇ m to about 250 ⁇ m.
  • the coating 206 consists essentially of a single matrix 210 of anodic material 212 with a plurality of ceramic particles 214 dispersed therein.
  • a single matrix 210 of anodic material 212 allows for the thickness of the coating 206 to be minimized.
  • the ceramic particles 214 including the first ceramic 216 having a first ceramic erosion resistance are capable of resisting increases in the roughness of the coating surface 224. Without being bound by theory, it is believed that the increased hardness of the first ceramic 216 relative to the hardness of the second ceramic 218 and the anodic material 212 confers resistance to deposition of particles and subsequent corrosion of the coating surface 224.
  • the property corresponding to erosion resistance includes erosion of the coating 206 of less than about 76 ⁇ m over about 48,000 hours of operation under standard rear stage turbine compressor operating conditions.
  • the anodic material 212 in the matrix 210 is capable of resisting increases in the roughness of the coating surface 224. Without being bound by theory, it is believed that the anodic material 212 protects the substrate 202 from corrosion by undergoing anodic dissolution preferentially as the substrate 202 is placed at a nobler cathodic potential compared to the matrix 210.
  • the anodic material 212 is metallic in nature and possesses necessary toughness and ductility.
  • the matrix 210 is strengthened by ceramic particles 214.
  • the first ceramic 216 in the ceramic particles 214 address erosion resistance.
  • the second ceramic 218 in the ceramic particles 214 such as chromium carbide and chromium nitride dissolves during application, such as by thermal spray, to release free chromium, which further augments the anodic nature of the matrix 210.
EP15156132.1A 2014-02-28 2015-02-23 Article revêtu et procédé de production de revêtement Withdrawn EP2913421A1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US14/193,241 US20150247413A1 (en) 2014-02-28 2014-02-28 Coated article and method for producing coating

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EP2913421A1 true EP2913421A1 (fr) 2015-09-02

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EP (1) EP2913421A1 (fr)
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Publication number Priority date Publication date Assignee Title
CN112853353B (zh) * 2020-12-31 2022-03-15 北京科技大学 一种纳米填料改性陶瓷涂层的制备方法

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1227169A2 (fr) * 2001-01-25 2002-07-31 Fujimi Incorporated Poudre à pulvériser et procédé de sa préparation
US20090297720A1 (en) * 2008-05-29 2009-12-03 General Electric Company Erosion and corrosion resistant coatings, methods and articles
WO2010094256A1 (fr) * 2009-02-21 2010-08-26 Mtu Aero Engines Gmbh Système de revêtement de protection contre l'érosion pour des composants de turbines à gaz
EP2226409A2 (fr) * 2009-03-06 2010-09-08 General Electric Company Surface portante de compresseur de turbine résistant à l'érosion et à la corrosion et son procédé de fabrication
EP2395123A1 (fr) * 2010-06-09 2011-12-14 General Electric Company Composition et procédé d'application d'un revêtement protecteur

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1227169A2 (fr) * 2001-01-25 2002-07-31 Fujimi Incorporated Poudre à pulvériser et procédé de sa préparation
US20090297720A1 (en) * 2008-05-29 2009-12-03 General Electric Company Erosion and corrosion resistant coatings, methods and articles
WO2010094256A1 (fr) * 2009-02-21 2010-08-26 Mtu Aero Engines Gmbh Système de revêtement de protection contre l'érosion pour des composants de turbines à gaz
EP2226409A2 (fr) * 2009-03-06 2010-09-08 General Electric Company Surface portante de compresseur de turbine résistant à l'érosion et à la corrosion et son procédé de fabrication
EP2395123A1 (fr) * 2010-06-09 2011-12-14 General Electric Company Composition et procédé d'application d'un revêtement protecteur

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
FANG W ET AL: "Processing optimization, surface properties and wear behavior of HVOF spraying WC-CrC-Ni coating", JOURNAL OF MATERIALS PROCESSING TECHNOLOGY, ELSEVIER, NL, vol. 209, no. 7, 1 April 2009 (2009-04-01), pages 3561 - 3567, XP026076692, ISSN: 0924-0136, [retrieved on 20080903], DOI: 10.1016/J.JMATPROTEC.2008.08.024 *

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JP2015165045A (ja) 2015-09-17
US20150247413A1 (en) 2015-09-03

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