EP2977487B1 - Verfahren zur Glättung der Oberfläche einer Beschichtung - Google Patents

Verfahren zur Glättung der Oberfläche einer Beschichtung Download PDF

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Publication number
EP2977487B1
EP2977487B1 EP14178573.3A EP14178573A EP2977487B1 EP 2977487 B1 EP2977487 B1 EP 2977487B1 EP 14178573 A EP14178573 A EP 14178573A EP 2977487 B1 EP2977487 B1 EP 2977487B1
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Prior art keywords
coating
roughness
thermal barrier
ceramic thermal
barrier coating
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English (en)
French (fr)
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EP2977487A1 (de
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Daniel Renusch
Gregoire Etienne Witz
Hans-Peter Bossmann
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Ansaldo Energia IP UK Ltd
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Ansaldo Energia IP UK Ltd
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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
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • C23C24/082—Coating starting from inorganic powder by application of heat or pressure and heat without intermediate formation of a liquid in the 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
    • C23C28/04—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 only coatings of inorganic non-metallic material
    • C23C28/042—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 only coatings of inorganic non-metallic material including a refractory ceramic layer, e.g. refractory metal oxides, ZrO2, rare earth oxides
    • 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
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/90—Coating; Surface treatment

Definitions

  • the present invention relates to a method for smoothing the rough surface of thermal barrier coatings (TBC's) which are used for protection of thermal high loaded components, such as gas turbine blades, vanes or combustor parts.
  • TBC's thermal barrier coatings
  • smoothing the surface of the coating means that the roughness of said surface is reduced.
  • gas turbine components are made of alloys, for example Ni-, Co- or Fe-based superalloys, which can resist high temperatures of more than 1000 °C there is a need for further increasing the operating temperature of the turbines to improve the efficiency of the gas turbines.
  • This can be achieved among others for example by applying a thermal barrier coating onto the surface of the superalloy component.
  • Most of the applied TBC's are ceramic-based coatings, preferably yttria-stabilized zirconia (YSZ). Such a material has a much higher temperature resistance than the above mentioned superalloys.
  • the TBC's are usually applied by thermal spray techniques, such as plasma spray processes like APS (Air/Atmospheric Plasma Spraying), VPS (Vacuum Plasma Spraying) or the very expensive EB-PVD (Electron Beam Physical Vapor Deposition).
  • plasma spray processes like APS (Air/Atmospheric Plasma Spraying), VPS (Vacuum Plasma Spraying) or the very expensive EB-PVD (Electron Beam Physical Vapor Deposition).
  • APS technique is cheaper with respect to EB-PVD, but it has the disadvantage of a relative rough surface which can cause problems with respect to aerodynamic drag losses of appropriate coated gas turbine components.
  • surface roughness increases turbulent heat transfer from the hot combustion gases to the component and thus reduces aerodynamic performance.
  • the efficacy of the TBC is improved by introducing porosity in to the coating.
  • this inherent porosity will place a limit on the smoothness.
  • the polishing process can open the closed pores.
  • a component used in a high-temperature environment such as the combustor section of a gas turbine, is coated with a TBC made of yttria-stabilized zirconia, which provides the thermal protection for the substrate of the component.
  • a bond coat for example made of MCrAlY, is applied between the substrate and the TBC to promote adhesion of the TBC.
  • the TBC is sprayed onto the bond coat by APS which results in a certain degree of inhomogeneity and porosity and in a rough surface of about 5-13 ⁇ m Ra. This leads to problems with respect to erosion resistance, transmissivity to infrared radiation and aerodynamic performance.
  • the TBC is over-coated by a multilayer outer coating which is formed of two layers having different compositions.
  • An inner layer of the coating contains alumina in a first silica-containing matrix material that is free of zinc titanate.
  • An outer layer of the coating contains alumina, a glass material and zinc titanate in a second silica-containing matrix material.
  • the thickness, structure and properties of the outer coating can be tailored by the firing temperature and durations used for each inner and outer layer.
  • the outer layer of the coating has a low surface roughness Ra ⁇ 3 ⁇ m and forms the outermost surface of the component. As a result the new coating reduces the component temperature by reducing the convective and radiant heat transfer thereto. But the deposition of two different layers to the underlying TBC is expensive.
  • US 2007/0099013 A1 discloses also a method for manufacturing a TBC coated machine component, wherein a "smooth coat" ceramic layer is applied onto the component subsequent to the TBC. Because some of these smooth coat materials do not have a good adherence to the underlying TBC the smooth coat layer may spall during curing. To overcome the chipping of the smooth layer it is proposed in this document to deposit two TBC's, the outer thermal barrier coating having a higher porosity than the inner one, such to reduce the risk of delamination of the smooth coating layer. Such a solution is also cost intensive due to the necessity to deposit two different layers of TBC that means an additional layer of TBC is required.
  • the method for smoothing the surface of the protective coating includes the steps of applying the slurry/gel to the TBC surface, heating the slurry/gel coating to remove volatile material and then further heating to cure the coating and bond it to the underlying protective coating.
  • a slurry comprising zirconia means a good match of the thermal expansion coefficient of the TBC and the smooth layer. Matching the composition is a good way to reduce the thermo-mechanical stresses, but if the coating is too thick it will not prevent the formation of vertical cracks in the smooth layer. Unfortunately, such cracks reduce the aerodynamic efficiency of the smooth coating reducing the benefit of the coating.
  • the challenge according to those documents is to provide a smooth layer that has a low roughness (Ra ⁇ 6 ⁇ m, preferentially ⁇ 3 ⁇ m) without reducing the lifetime of the underlying thermal barrier coating.
  • the roughness that can be achieved with the smooth layer is strongly affected by the layer porosity. Therefore a low porosity in the coating prior to polishing ( ⁇ 1 %) is necessary.
  • the coating is stiff with a high Young's modulus. Due to this high modulus, thermo-mechanical stresses linked to the difference in the coefficient of thermal expansion between the smooth layer and the underlying TBC can be sufficient to induce cracking in one or both coatings. Depending on the coating architecture this can lead either to early TBC spallation or to smooth layer chipping and reduction of the aerodynamic performance.
  • the disclosed method for reducing the roughness of a first coating with a defined coating composition and a thermal expansion coefficient, said coating covering the surface of a component to be thermally high loaded comprises that
  • the last mentioned step is done by polishing the slurry down to the point where the "peaks” in the underlying TBC roughness are at the surface (visibly), and only the “valleys” in the TBC roughness remain filled with slurry coating.
  • the coating has to be manufactured such that it is dense, fully cured but only partially sintered to avoid too much recrystallization of the filler material.
  • the slurry coating can be described as a "machinable ceramic".
  • the curing resp. partially sintering of the slurry coating is done at a temperature in the range of 500 to 800 °C.
  • the slurry coating is a zirconia based slurry coating with a small amount of alumina silicate or zirconium silicate.
  • the zirconia can be un-stabilized or preferably stabilized, more preferably stabilized with Y 2 O 3 , CaO, MgO or any combinations thereof.
  • the slurry coating binder is a silicate solution, phosphate solution or silicon emulsion.
  • the first coating is a ceramic thermal barrier coating (TBC), preferably made of chemically stabilized zirconia. By using those materials it is realized that the thermal expansion coefficients of both coatings are close to each other.
  • the described method is for coating systems where the first coating is applied by atmospheric plasma spraying and has therefore a relative high roughness and high porosity, which can cause the above described disadvantages, for example reduction of aerodynamic performance.
  • the disclosed coating system for surface protection of a thermally high loaded component which is produced with a method according to claims 1 is characterized in that the coating system consists of a first underlying coating and a second slurry coating overlaying the first coating, wherein both coatings (1, 2) have a chemical composition with a similar thermal expansion coefficient, and wherein the second coating is very dense with a porosity ⁇ 1%, fully cured, but only partly sintered and wherein the second coating does only cover locally the first coating, so that said coating system finally comprises a reduced roughness with respect to the roughness of the originally applied first coating.
  • the coating system for surface protection of a thermally loaded component has a second coating which is only completely sintered as a result of the first firing in the engine.
  • the disclosed coating system is applied onto the surface of a gas turbine component made of a Ni-, Co-, Fe-based superalloy or combinations thereof, wherein the first coating is a ceramic thermal barrier coating, preferably made of chemically stabilized zirconia and the second coating is made by applying of a zirconia based slurry.
  • the present invention is related to a method for smoothing the rough surface of thermal barrier coatings (TBC's) which are used for protection of thermal high loaded components, such as gas turbine blades, vanes or combustor parts.
  • TBC's thermal barrier coatings
  • TBC's especially applied by atmospheric plasma spraying methods onto the surface of above mentioned components have a relative high roughness.
  • For improving the aerodynamic behavior which allows increasing the turbine efficiency it is necessary to provide a smooth surface layer by an efficient method which is cheaper and faster with respect to the known methods in the prior art. Additionally, to improve perform in-service the smooth surface layer needs to be thinner.
  • the present application discloses a method for reducing the roughness Ra of a first coating 1 with a defined coating composition and a thermal expansion coefficient, said coating 1 covering the surface of a component 3 to be thermally high loaded, the method comprises that in a first step the roughness of said coating 1 is measured and in a following step a second slurry coating 2 is prepared for applying onto the surface of the first coating 1, whereby the coating composition of the second coating 2 is tailored to have a similar thermal expansion coefficient like the first coating 1.
  • the method is characterized in
  • the coating has to be manufactured such that it is dense, fully cured, but only partially sintered to avoid too much recrystallization of the filler material.
  • the curing resp. partially sintering of the slurry coating is done at a temperature in the range of 500-800 °C.
  • Fig. 1 shows a photo of the microstructure (cross section) of a typical TBC 1 with a smooth layer 2 on the top according to one embodiment of the invention, where the desired reduction in surface roughness is achieved.
  • the smooth layer 2 is very thin to the extent that the slurry fills the "valleys" in the underlying TBC roughness.
  • the "peaks" in the underlying TBC roughness are not covered by the slurry coating.
  • the slurry is in the “valleys” of the underlying TBC roughness.
  • the “peaks” in the underlying TBC roughness are not covered by the slurry coating.
  • the embodiment in Fig. 1 is a component produced with the method according to the present disclosure.
  • the component is made of Hastelloy X base material. It has an APS MCrAlY bond coat.
  • the TBC (first coating 1) is APS 7 wt% yttria-stabilized zirconia.
  • the slurry coating (second coating 2) is un-stabilized zirconia with the addition of a small amount of alumina silicate.
  • the slurry coating binder was a water based silicon emulsion.
  • the average initial TBC roughness Ra was 17.2 ⁇ m.
  • the average initial TBC thickness was 941 ⁇ m, measured non-destructively with eddy-current equipment.
  • the slurry coating was applied with a commercial paint sprayer. The number of spray passes N was 6.
  • the eddy-current thickness measurements of the as sprayed slurry plus the TBC had an average value of 982 ⁇ m, thus the average slurry coting 2 thickness T was 41 ⁇ m.
  • the slurry was cured at 700°C for 5h. After curing the slurry coating 2 was polished with a fine grit wet silicon-carbide paper. After polishing the finial average roughness Ra' was found to be 2.8 ⁇ m.
  • the non-destructive eddy-current thickness measurements of the as smooth layer plus the TBC had an average value of 945 ⁇ m. From the cross section photos the deepest slurry filed "valley" depth was 21 ⁇ m.
  • the partially sintered slurry coating 2 is inherently softer than the TBC coating 1.
  • the abrasion rate is relatively high.
  • the zirconia based slurry coating has a small amount of alumina silicate or zirconium silicate.
  • the zirconia can be unstabilized or stabilized with Y 2 O 3 , CaO, MgO or any combinations thereof.
  • the slurry coating binder is a silicate solution, phosphate solution or silicon emulsion.
  • the first coating is a ceramic thermal barrier coating (TBC), preferably made of chemically stabilized zirconia. By using those materials it is realized that the thermal expansion coefficients of both coatings are close to each other.
  • the described method is effective for coating systems where the first coating is applied by atmospheric plasma spraying and has therefore a relative high roughness, which can cause the above described disadvantages, for example reduction of aerodynamic performance.
  • the disclosed coating system or surface protection of a thermally high loaded component which is produced with a method according to claims 1 is characterized in that the coating system consists of a first underlying coating and a second slurry coating overlaying the first coating, wherein both coatings 1, 2 have a chemical composition with a similar thermal expansion coefficient, and wherein the second coating is very dense with a porosity ⁇ 1%, fully cured, but only partly sintered and wherein the second coating does only cover locally the first coating, so that said coating system finally comprises a reduced roughness with respect to the roughness of the originally applied first coating.
  • the coating system for surface protection of a thermally loaded component has a second coating which is only completely sintered as a result of the first firing in the engine.
  • the disclosed coating system is applied onto the surface of a gas turbine component made of a Ni-, Co-, Fe-based superalloy or combinations thereof, wherein the first coating is a ceramic thermal barrier coating, preferably made of chemically stabilized zirconia and the second coating is made by applying of a zirconia based slurry.
  • Fig. 2 shows schematically the results after different steps of the disclosed method.
  • Fig. 2a shows the first coating 1 prior to the applying of the second coating - the high roughness Ra is clearly to be seen, it is about 8-18 ⁇ m.
  • Fig. 2b shows the system with the first coating 1 and the applied second coating 2.
  • the roughness of the first coating Ra is the same like in Fig. 2a , but the overlying coating 2 may provide a smooth surface however it is too thick (with an average thickness T ⁇ 2xRa) and may crack during serves.
  • Fig. 2c shows the result after the last step of the described method according to claim 1.
  • the coating system comprises the first coating 1 with the second coat 2 and a reduced roughness Ra' (which is about 1-6 ⁇ m) with respect to the originally applied coating 1.
  • the reduced thickness T' of the second coating 2 is T' ⁇ Ra, such that finally the second coating 2 does cover the first coating 1 only locally.
  • Fig. 3 shows in a photo the surface of a coating in service, when the smooth surface coating is too thick (prior art). A lot of undesired cracks can be recognized.
  • Fig. 4 shows in a photo the surface of a coating system manufactured according to the present invention.
  • the dark spots are the TBC appearing at the surface after the polishing step. Microcracks / cracks can't be recognized.
  • the dark spots are the "peaks" in the underlying TBC roughness appearing at the surface.
  • the durability of the coating is ensured, providing improved aerodynamic performance over a long period of operation. There is also no thermal barrier coating lifetime reduction due to the smoothened surface.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • General Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)

Claims (4)

  1. Verfahren zum Verringern der Rauheit (Ra) einer keramischen Wärmesperrbeschichtung (1) mit einer definierten Beschichtungszusammensetzung und einem definierten Wärmeausdehnungskoeffizienten, wobei die keramische Wärmesperrbeschichtung (1) die Oberfläche einer Ni-, Co- und Fe-basierten Superlegierungskomponente (3) einer Gasturbine, die stark wärmebelastet werden soll, abdeckt, wobei
    - in einem ersten Schritt die keramische Wärmesperrbeschichtung (1) durch atmosphärisches Plasmaspritzen auf die Oberfläche einer Komponente (3) aufgebracht wird und die Rauheit (RA) der keramischen Wärmesperrbeschichtung (1) gemessen wird und
    - in einem folgenden Schritt eine zirkonoxidbasierte Aufschlämmungsbeschichtung (2) mit Aluminiumoxidsilikat- oder Zirkoniumsilikat-Zusatzstoffen und einem Aufschlämmungsbeschichtungsbindemittel, das eine Silikatlösung, eine Phosphatlösung oder eine Siliziumemulsion ist, zum Aufbringen auf die Oberfläche der keramischen Wärmesperrbeschichtung (1) angefertigt wird, wobei die Beschichtungszusammensetzung der zirkonoxidbasierten Aufschlämmungsbeschichtung (2) zugeschnitten ist, einen ähnlichen Wärmeausdehnungskoeffizienten wie die keramische Wärmesperrbeschichtung (1) zu besitzen;
    - Berechnen einer Mindestzahl von Beschichtungsspritzdurchgängen (N), die erforderlich ist, um die zirkonoxidbasierte Aufschlämmungsbeschichtung (2) mit einer Dicke (T), die mindestens das Doppelte der Rauheit (Ra) der keramischen Wärmesperrbeschichtung (1) beträgt,
    - Anwenden der zirkonoxidbasierten Aufschlämmungsbeschichtung (2) mit der berechneten Anzahl von Spritzdurchgängen (N) auf die Oberfläche der keramischen Wärmesperrbeschichtung (1);
    - vollständiges Härten, aber lediglich teilweises Sintern der zirkonoxidbasierten Aufschlämmungsbeschichtung (2) bei einer Temperatur im Bereich von 300 bis 800 °C;
    - Polieren der zirkonoxidbasierten Aufschlämmungsbeschichtung (2); und
    - vollständiges Sintern der zirkonoxidbasierten Beschichtung (2) erst nach der ersten Exposition zu einem wärmebelasteten Betrieb der Komponente (3); wobei der Polierschritt durchgeführt wird, bis die Spitzenwerte der Rauheit (Ra) erreicht werden, derart, dass die Dicke (T) der zirkonoxidbasierten Aufschlämmungsbeschichtung (2) eine verringerte Dicke (T') wird, die im Wesentlichen gleich der Rauheit (Ra) der keramischen Wärmesperrbeschichtung (1) ist, derart, dass schließlich die zirkonoxidbasierte Aufschlämmungsbeschichtung (2) die keramische Wärmesperrbeschichtung (1) lediglich lokal bei den Tälern der Rauheit (Ra) abdeckt.
  2. Verfahren nach Anspruch 1, gekennzeichnet durch ein Härten bzw. teilweises Sintern der Aufschlämmungsbeschichtung (2) bei einer Temperatur im Bereich von 500 bis 800 °C.
  3. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass das Zirkonoxid mit Y2O3, CaO, MgO oder einer beliebigen Kombination davon stabilisiert wird.
  4. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass die keramische Wärmesperrbeschichtung (1) aus chemisch stabilisiertem Zirkonoxid hergestellt ist.
EP14178573.3A 2014-07-25 2014-07-25 Verfahren zur Glättung der Oberfläche einer Beschichtung Active EP2977487B1 (de)

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CN115044898B (zh) * 2022-06-24 2023-09-01 武汉苏泊尔炊具有限公司 炊具的制造方法和炊具

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US6294261B1 (en) * 1999-10-01 2001-09-25 General Electric Company Method for smoothing the surface of a protective coating
WO2009030049A1 (en) * 2007-09-06 2009-03-12 Alcan International Limited A coating for metallurgical surfaces
US9624583B2 (en) * 2009-04-01 2017-04-18 Rolls-Royce Corporation Slurry-based coating techniques for smoothing surface imperfections
US8986779B2 (en) * 2009-07-31 2015-03-24 General Electric Company Methods of improving surface roughness of an environmental barrier coating and components comprising environmental barrier coatings having improved surface roughness

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