EP3623498A1 - Reparaturverfahren von features ausserhalb der sichtlinie über eine mehrschichtige beschichtung - Google Patents

Reparaturverfahren von features ausserhalb der sichtlinie über eine mehrschichtige beschichtung Download PDF

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Publication number
EP3623498A1
EP3623498A1 EP19197228.0A EP19197228A EP3623498A1 EP 3623498 A1 EP3623498 A1 EP 3623498A1 EP 19197228 A EP19197228 A EP 19197228A EP 3623498 A1 EP3623498 A1 EP 3623498A1
Authority
EP
European Patent Office
Prior art keywords
depositing
protective layer
base layer
line
sight
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.)
Pending
Application number
EP19197228.0A
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English (en)
French (fr)
Inventor
Matthew Grow
Chris Vargas
William Bogue
Steven Ivory
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.)
RTX Corp
Original Assignee
United Technologies Corp
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 United Technologies Corp filed Critical United Technologies Corp
Publication of EP3623498A1 publication Critical patent/EP3623498A1/de
Pending legal-status Critical Current

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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
    • C23C28/02—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 only including layers of metallic material
    • C23C28/021—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 only including layers of metallic material including at least one metal alloy layer
    • C23C28/022—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 only including layers of metallic material including at least one metal alloy layer with 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
    • C23C28/321—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
    • C23C10/00—Solid state diffusion of only metal elements or silicon into metallic material surfaces
    • C23C10/02—Pretreatment of the material to be coated
    • 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
    • C23C28/02—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 only including layers of metallic material
    • C23C28/021—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 only including layers of metallic material including at least one metal alloy layer
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D3/00—Electroplating: Baths therefor
    • C25D3/02—Electroplating: Baths therefor from solutions
    • C25D3/12—Electroplating: Baths therefor from solutions of nickel or cobalt
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
    • C25D5/02—Electroplating of selected surface areas
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
    • C25D5/34—Pretreatment of metallic surfaces to be electroplated

Definitions

  • the present disclosure relates to a method of using a multi-layer coating for dimensional restoration of a non-line of sight surface, more particularly to repairing a non-line of sight worn surface of a gas turbine engine component that is subjected to high operating temperatures.
  • Welding also requires adequate line-of-sight to some degree to allow the welding torch and filler metal to access the worn features.
  • welding may cause significant distortion of the part and/or a reduction of parent material properties to the point of being unusable (e.g., scrapped).
  • Plating does not require line-of-sight, however, the most common electrolytic platings, such as nickel, suffer from softening and oxidation at temperatures above approximately 1000 °F (537.8 °C). However, temperatures up to approximately 1300 °F (704.4 °C) are expected for certain gas turbine engine components that have one or more non-line of sight surfaces requiring dimensional restoration. Thus, these high operating temperature requirements prevent conventional electrolytic nickel plating from being utilized to repair worn non-line of the sight surfaces. It is recognized that wear may not be the only cause for a part requiring dimensional restoration; other causes may include part growth due to creep mechanisms, part distortion, and/or excessive machining.
  • FIG. 1 is a simplified illustration showing a surface that requires dimensional restoration of a non-line of sight surface.
  • the surface may be a mating surface associated with a high pressure compressor rear hub 100 and a high pressure turbine 1 st stage heat shield 102 of a gas turbine engine. Surfaces of these two components 100, 102 fit with tight tolerance requirements.
  • FIG. 2 is an exploded view of a mating surface 104 on the high pressure compressor rear hub 100 that contacts a face to face surface on the high pressure turbine 1 st stage heat shield 102. Use of the engine causes the mating surface 104 of the high pressure compressor rear hub 100 to wear, as shown in FIG. 3 . Because of the tight confines in area and the high operating temperature the non-line of sight surface 104 is exposed to, conventional techniques used to repair line of sight features cannot be used to repair the non-line of sight surface 104.
  • aspects of the disclosure are directed to a method of repairing a non-line of sight feature on a surface, the method comprising machining a worn irregular non-line of sight surface to provide a substantially planar repair surface, depositing an nickel plate base layer having a base layer thickness on the substantially planar repair surface, and depositing a protective layer having a protective layer thickness on the nickel plate base layer.
  • Depositing the protective layer may comprise depositing using vapor deposition.
  • Depositing using vapor deposition may comprise one of physical vapor deposition (PVD), electron-beam physical vapor deposition (EBPVD), or chemical vapor deposition (CVD).
  • PVD physical vapor deposition
  • EBPVD electron-beam physical vapor deposition
  • CVD chemical vapor deposition
  • Depositing the protective layer may comprise depositing MCrAlY.
  • Depositing the protective layer may comprise depositing a cobalt alloy.
  • Depositing the protective layer may comprise depositing the protective layer using at least one of a powder pack process, or locally applying at least one of paint, paste, slurry or thermal spray.
  • the protective layer may comprise an aluminide.
  • the protective layer may comprise a chromide.
  • the protective layer may have thickness of about 0.001 to 0.002 inches (0.0254 to 0.0508 mm) and the base layer thickness may be about 0.0005 to 0.002 inches (0.0127 to 0.0508 mm).
  • Depositing the nickel plate base layer may comprise depositing an electrolytic nickel plate base layer.
  • Depositing the nickel plate base layer may comprise depositing an electroless nickel plate base layer
  • aspects of the disclosure are also directed to a method of repairing a non-line of sight feature on a surface of a gas turbine engine component, the method comprising machining a worn irregular non-line of sight surface of the gas turbine engine component to provide a substantially planar repair surface, depositing a nickel plate base layer having a base layer thickness on the substantially planar repair surface, and depositing a protective layer having a protective layer thickness on the nickel plate base layer.
  • Depositing the protective layer may comprise one of physical vapor deposition (PVD), electron-beam physical vapor deposition (EBPVD), or chemical vapor deposition (CVD).
  • PVD physical vapor deposition
  • EBPVD electron-beam physical vapor deposition
  • CVD chemical vapor deposition
  • Depositing the protective layer may comprise depositing at least one of MCrAlY and cobalt alloy.
  • Depositing the protective layer may comprise applying at least one of a diffused aluminide and a diffused chromide.
  • Depositing the nickel plate base layer may comprise depositing an electrolytic nickel plate base layer.
  • aspects of the disclosure are further directed to a method of repairing a feature on a surface, the method comprising machining a worn irregular sight surface to provide a substantially planar repair surface, depositing a nickel plate base layer having a base layer thickness on the substantially planar repair surface, and depositing a protective layer having a protective layer thickness on the nickel plate base layer.
  • the depositing using vapor deposition may comprise one of physical vapor deposition (PVD), electron-beam physical vapor deposition (EBPVD), or chemical vapor deposition (CVD).
  • PVD physical vapor deposition
  • EBPVD electron-beam physical vapor deposition
  • CVD chemical vapor deposition
  • the protective layer may comprise at least one of MCrAlY, cobalt alloy, diffused aluminide and diffused chromide.
  • Depositing the nickel plate base layer may comprise depositing an electrolytic nickel plate base layer.
  • Non - line of sight feature(s) or “non-line of sight surface(s)” are feature(s)/surface(s) of a part where typical dimensional restoration processes, such as welding and plasma spray processes, cannot be utilized due to geometrical constraints of the part and/or inadequate accessibility of the associated equipment involved. It is known that existing techniques for bouncing or reflecting thermal spray streams off nearby features are often employed to repair such surfaces, however, it is important to note that they require a higher degree of line-of-sight versus the proposed method.
  • a non-line of sight/limited line of sight surface 402 that is worn is machined or ground using a tool 404.
  • the non-line of sight/limited line of sight surface 402 may be, for example, a surface on the high pressure compressor rear hub (e.g., see hub 100 in FIG. 1 ).
  • the tool may be a cutting head or a grinding tool, for example, of a CNC machine.
  • the worn surface 402 ( FIG. 4A ) is machined/ground to provide a substantially planar surface 406, which may then be cleaned to prepare for subsequent processing.
  • a nickel plate base layer 408 is then deposited onto the substantially planar surface 406.
  • the base layer 408 provides dimensional restoration to bring the worn surface 402 ( FIG. 4A ) to an acceptable condition (e.g., thickness).
  • the nickel plate base layer 408, which is a non-line of sight surface/limited line of sight surface can be deposited using an electroless or electrolytic nickel plating technique and has a base thickness of about 0.5-2 mils (0.0005 to 0.002 inches or 0.0127 to 0.0508 mm) and 3-20 mils (0.003 to 0.02 inches or 0.0762 to 0.508 mm), respectively.
  • the nickel plate base layer 408 may be deposited for example using the methodology set forth in SAE's known process AMS 2424 for electrolytic nickel plating.
  • the base layer 408 may also be deposited using an electroless plating process (e.g., SAE AMS 2404). It is also contemplated that the base layer 408 may be a material other than nickel, such as for example copper plating.
  • nickel plate base layer is known to have poor oxidation and abrasion resistance, especially above 1000 deg. F (538 deg. C), which may lead to accelerated wear and possible spallation, liberating coating, et cetera.
  • a relatively thin protective layer may be applied to protect the nickel plated base layer 408 .
  • a protective layer 410 is deposited on the nickel plate base layer 408.
  • the protective layer 410 provides oxidation and/or abrasion resistance and/or otherwise modify the wear couple at the mating surfaces to protect the base layer 408 (e.g., from deterioration).
  • the protective layer 410 may be deposited using vapor deposition.
  • the protective layer 410 may, for example, be diffused aluminide having a thickness of about 0.001 - 0.002 inches (0.0254 - 0.0508 mm).
  • the protective layer 410 may be deposited using a powder pack process, vapor phase, or locally applied in the form of paint/ paste/slurry/thermal spray.
  • the protective layer 410 may also be deposited using vapor deposition processes, such as for example, physical vapor deposition (PVD) (e.g., CATARC® PVD), electron-bean physical vapor deposition (EBPVD), chemical vapor deposition(CVD), et cetera, to a thickness of about 0.0005-0.002 inches (0.0127 - 0.0508 mm).
  • PVD physical vapor deposition
  • EBPVD electron-bean physical vapor deposition
  • CVD chemical vapor deposition
  • the protective layer 410 may also be a MCrAlY type coating deposited to a thickness of about 0.0005-0.002 inches (0.0127 - 0.0508 mm), including Stellite/cobalt coatings.
  • the MCrAlY type protective coating may be deposited using vapor deposition.
  • the sum of the nickel base layer thickness and the protective layer thickness may be equal to the original component thickness dimension in order provide the desired dimensional restoration.
  • FIG. 5 is a flow-chart illustration of an embodiment of a method of repairing worn non-line of sight features using a multi-layer coating.
  • a non-line of sight surface/limited line of sight surface e.g., see surface 402 in FIG. 4A
  • a nickel plate base layer e.g., see layer 408 in FIG. 4C
  • a protective layer e.g., see layer 410 in FIG. 4C
  • the vapor deposition process occurs in a deposition chamber under controlled conditions. It is contemplated of course the repair method may also be used to features/surfaces that have a line of sight.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • Electrochemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Chemical Vapour Deposition (AREA)
EP19197228.0A 2018-09-14 2019-09-13 Reparaturverfahren von features ausserhalb der sichtlinie über eine mehrschichtige beschichtung Pending EP3623498A1 (de)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US16/131,734 US20200087794A1 (en) 2018-09-14 2018-09-14 Method of repairing a non-line of sight feature via a multi-layer coating

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EP3623498A1 true EP3623498A1 (de) 2020-03-18

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20240133040A1 (en) * 2022-10-24 2024-04-25 General Electric Company Coating system for components in need of repair

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1013786A1 (de) * 1998-12-22 2000-06-28 GE Aviation Services Operation (Pte) Ltd. Verfahren zur Reparatur eines Turbinebauteiles aus einer Superlegierung
EP1123987A1 (de) * 2000-02-11 2001-08-16 General Electric Company Reparierbare Diffusionsaluminidbeschichtungen
EP1411148A1 (de) * 2002-10-15 2004-04-21 ALSTOM Technology Ltd Verfahren zur MCrAlY-Haftungsbeschichtung auf einen beschichteten Gegenstand und beschichteter Gegenstand
US8541069B2 (en) 2011-04-11 2013-09-24 United Technologies Corporation Method of guided non-line of sight coating
US9885110B2 (en) 2014-08-06 2018-02-06 United Technologies Corporation Pressure modulated coating

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4241147A (en) * 1978-10-23 1980-12-23 Alloy Surfaces Company, Inc. Diffusion aluminized age-hardenable stainless steel
US6352636B1 (en) * 1999-10-18 2002-03-05 General Electric Company Electrochemical system and process for stripping metallic coatings
US6875529B1 (en) * 2003-12-30 2005-04-05 General Electric Company Thermal barrier coatings with protective outer layer for improved impact and erosion resistance
US7521128B2 (en) * 2006-05-18 2009-04-21 Xtalic Corporation Methods for the implementation of nanocrystalline and amorphous metals and alloys as coatings
US20180298496A1 (en) * 2017-04-14 2018-10-18 Hamilton Sundstrand Corporation Corrosion and fatigue resistant coating for a non-line-of-sight (nlos) process

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1013786A1 (de) * 1998-12-22 2000-06-28 GE Aviation Services Operation (Pte) Ltd. Verfahren zur Reparatur eines Turbinebauteiles aus einer Superlegierung
EP1123987A1 (de) * 2000-02-11 2001-08-16 General Electric Company Reparierbare Diffusionsaluminidbeschichtungen
EP1411148A1 (de) * 2002-10-15 2004-04-21 ALSTOM Technology Ltd Verfahren zur MCrAlY-Haftungsbeschichtung auf einen beschichteten Gegenstand und beschichteter Gegenstand
US8541069B2 (en) 2011-04-11 2013-09-24 United Technologies Corporation Method of guided non-line of sight coating
US9885110B2 (en) 2014-08-06 2018-02-06 United Technologies Corporation Pressure modulated coating

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20240133040A1 (en) * 2022-10-24 2024-04-25 General Electric Company Coating system for components in need of repair

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