EP3701060B1 - Procédé de réparation d'un matériau monocristallin - Google Patents
Procédé de réparation d'un matériau monocristallin Download PDFInfo
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- EP3701060B1 EP3701060B1 EP18796582.7A EP18796582A EP3701060B1 EP 3701060 B1 EP3701060 B1 EP 3701060B1 EP 18796582 A EP18796582 A EP 18796582A EP 3701060 B1 EP3701060 B1 EP 3701060B1
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- substrate
- monocrystalline
- repairing method
- powder
- coating
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- 239000000463 material Substances 0.000 title claims description 42
- 239000000758 substrate Substances 0.000 claims description 90
- 239000000843 powder Substances 0.000 claims description 29
- 238000000576 coating method Methods 0.000 claims description 27
- 239000011248 coating agent Substances 0.000 claims description 24
- 238000010438 heat treatment Methods 0.000 claims description 22
- 229910045601 alloy Inorganic materials 0.000 claims description 18
- 239000000956 alloy Substances 0.000 claims description 18
- 239000002245 particle Substances 0.000 claims description 17
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 14
- 239000007789 gas Substances 0.000 claims description 14
- 239000001257 hydrogen Substances 0.000 claims description 10
- 229910052739 hydrogen Inorganic materials 0.000 claims description 10
- 238000002844 melting Methods 0.000 claims description 10
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- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 claims description 9
- 238000001556 precipitation Methods 0.000 claims description 8
- 238000000137 annealing Methods 0.000 claims description 7
- 229910052759 nickel Inorganic materials 0.000 claims description 7
- 238000001816 cooling Methods 0.000 claims description 6
- 238000010290 vacuum plasma spraying Methods 0.000 claims description 4
- 229910000531 Co alloy Inorganic materials 0.000 claims description 3
- 239000012300 argon atmosphere Substances 0.000 claims description 2
- 230000005670 electromagnetic radiation Effects 0.000 claims description 2
- 230000008439 repair process Effects 0.000 description 25
- 239000013078 crystal Substances 0.000 description 20
- 230000008569 process Effects 0.000 description 19
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 18
- 238000007711 solidification Methods 0.000 description 18
- 230000008023 solidification Effects 0.000 description 18
- 239000000523 sample Substances 0.000 description 14
- 238000003466 welding Methods 0.000 description 10
- 229910052786 argon Inorganic materials 0.000 description 9
- 230000007704 transition Effects 0.000 description 9
- 229910001011 CMSX-4 Inorganic materials 0.000 description 7
- 239000007921 spray Substances 0.000 description 7
- 229910000601 superalloy Inorganic materials 0.000 description 7
- 229910003460 diamond Inorganic materials 0.000 description 6
- 239000010432 diamond Substances 0.000 description 6
- 230000035882 stress Effects 0.000 description 6
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- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 3
- 239000012298 atmosphere Substances 0.000 description 3
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 3
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- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 2
- KRHYYFGTRYWZRS-UHFFFAOYSA-N Fluorane Chemical compound F KRHYYFGTRYWZRS-UHFFFAOYSA-N 0.000 description 2
- 229910000990 Ni alloy Inorganic materials 0.000 description 2
- 229910052804 chromium Inorganic materials 0.000 description 2
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- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 2
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- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
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- 238000007792 addition Methods 0.000 description 1
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- 229910017052 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
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- 238000007749 high velocity oxygen fuel spraying Methods 0.000 description 1
- 238000001513 hot isostatic pressing Methods 0.000 description 1
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- 229910052748 manganese Inorganic materials 0.000 description 1
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- 229910052719 titanium Inorganic materials 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
Images
Classifications
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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
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/137—Spraying in vacuum or in an inert atmosphere
-
- 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
- C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
-
- 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
- C23C4/073—Metallic material containing MCrAl or MCrAlY alloys, where M is nickel, cobalt or iron, with or without non-metal elements
-
- 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
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/134—Plasma spraying
-
- 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
- C23C4/18—After-treatment
Definitions
- the invention relates to the field of metals and alloys and more particularly to the field of nickel alloys.
- the invention relates in particular to a method for repairing monocrystalline materials which are often used for components subject to high temperatures, such as, for example, the blades of stationary gas turbines or aircraft turbines.
- Out EP 2631324 A1 is a process for coating a single-crystal substrate surface of a component made of a nickel superalloy, in which a powder material similar to the material of the component is applied by means of vacuum plasma spraying.
- the substrate is heated to 600 ° C and a mixture of argon and hydrogen is used as the working gas.
- EP 2110449 A1 reports on the production of coated superalloys, in which a rod made of a single crystal alloy is cast in a vacuum and solidified by a heat treatment. The surface of the substrate produced in this way is polished before the actual coating.
- EP 1001055 A1 discloses a method in which a protective coating is applied by means of laser cladding to protect a gas turbine component made of a superalloy base material with a monocrystalline structure, and in which the protective coating is grown epitaxially on the base material and the coating is grown with a completely monocrystalline structure.
- US 5,732,467 A1 describes a method for repairing cracks in the outer surfaces of components which have a superalloy with a directional microstructure.
- the process described there coats and seals the outer surfaces of directionally solidified and monocrystalline structures by coating the defective area using a high-speed oxy-fuel process (also referred to herein as HVOF), followed by hot isostatic pressing of the corresponding component.
- HVOF high-speed oxy-fuel process
- a crack-free, repaired area should be created without adversely affecting the single-crystal microstructure of the rest of the component.
- a polycrystalline microstructure is produced in the repair area, which has the aforementioned disadvantages.
- the break point must be suitable to be welded and at the same time to enable an orientation direction of the newly applied material which has the same orientation as the rest of the material. This requires a temperature gradient that supports the orientation alignment.
- the laser build-up welding described here is, due to its specific process parameters, such as small local energy input and controlled material input, in principle a suitable method for welding such break points accordingly.
- the challenges with this process are to achieve a perfect, single-crystal, crack-free area, since only polycrystalline areas can be generated regularly due to a low unstable energy distribution.
- a welding process is also proposed to repair damage to monocrystalline materials, such as those found in the blades or blades of gas turbines [3] .
- LMF laser metal forming
- laser cladding it is in principle possible to create monocrystalline structures on a monocrystalline substrate. This method is characterized by minimal heat input into the component during construction, so that further cracks or recrystallization of the monocrystalline material are prevented.
- the orientation of the monocrystalline starting material can also be maintained up to the interface in the newly applied material.
- Optimized process parameters can also lead to a matching epitaxial growth on a monocrystalline substrate, for example in which the ratio between the temperature gradient in the welding zone and the solidification rate is higher than a material-dependent threshold value.
- the object of the invention is achieved by a method for repairing single-crystal materials according to the main claim.
- the vacuum plasma spraying method can be used to generate epitaxial growth on a monocrystalline material (substrate).
- the material to be repaired typically comprises a metallic alloy, in particular a nickel-based alloy or also a cobalt-based alloy.
- plasma spraying is understood to mean a coating process which is carried out with the aid of a plasma and is not based on plasma polymerisation.
- vacuum plasma spraying is understood to mean a coating process which is carried out in a vacuum chamber at a pressure of 1 to 200 mbar to avoid oxidation of the coating material by atmospheric oxygen.
- the same material as the substrate material is used as the coating material. Since the components to be repaired, such as blades of stationary gas turbines and / or aircraft turbine blades, are usually materials exposed to high temperatures, all metallic high-temperature alloys or superalloys are particularly suitable as coating materials.
- the known high-temperature alloys currently predominantly include solid and high-strength nickel-based alloys or also cobalt-based alloys.
- metallic materials of complex composition iron, nickel, platinum, chromium or cobalt-based with additions of the elements Co, Ni, Fe, Cr, Mo, W, Re, Ru, Ta, Nb, Al, Ti, Mn
- superalloys Zr, C and B
- They are mostly scale and high temperature resistant. They can be manufactured using either melt metallurgy or powder metallurgy.
- the polycrystallinity of thermally sprayed metallic layers can be suppressed by spraying an alloy of at least the same type as the monocrystalline substrate material has on the heated and polished substrate surface at greatly reduced pressure and in an argon atmosphere .
- the term “identical” is understood to mean that the proportion of alloying elements of substrate and layer differ only slightly and that these have an almost identical microstructure after a heat treatment.
- the temperature ranges of the substrate are so high that the solidification rate of the melted powder particles is greatly reduced, but the melting temperature of the substrate is not reached.
- substrate temperatures between 700 ° C. and temperatures just below the melting temperature of the substrate used, ie. H. for example 50 ° C below the melting temperature of the substrate, set.
- the disadvantage of this process is that the solidification rate cannot be measured exactly, but it should preferably be less than 100 mm / s.
- nucleation does not take place anywhere within the applied layer, but advantageously directly on the substrate surface, where it is aligned with the predetermined orientation of the single crystal of the substrate.
- An epitaxial growth of the applied layer on the substrate is thus possible.
- the area of the substrate to be repaired is preferably heated by a meandering movement of a plasma torch without conveying powder over the surface of the substrate.
- the entire substrate is heated.
- the substrate can be heated in different ways: electrically, inductively or by electromagnetic radiation.
- the entire substrate is advantageously heated to at least 700 ° C., advantageously to at least 800 ° C., preferably even to approx. 1100 ° C., depending on the alloy.
- the substrate itself is heated, but not up to temperatures at which the substrate melts.
- the powder melted in the plasma theoretically hits a solid, polished substrate surface, nucleates there and can therefore advantageously solidify in the same crystal orientation.
- local melting of the surface of the substrate by a few ⁇ m cannot be ruled out.
- This process step must be clearly distinguished from repair processes known to date, such as welding processes using a laser, in which the substrate itself is often also melted at least on the surface to be repaired.
- argon-containing plasma gas When it comes to the composition of the plasma gas, it is important that it contains hydrogen. Hydrogen causes reducing conditions which regularly suppress the oxidation of the substrate material during the heating process.
- a suitable argon-containing plasma gas could thus have a minimum of 5 NLPM and a maximum of 25 NLMP hydrogen at 50 NLPM argon.
- a vacuum plasma spray system with a powder delivery system and a device for heating a substrate (component) to temperatures of approx. 700 ° C. up to 1300 ° C. are preferably required.
- the area to be repaired on the component should preferably be polished.
- the repair process of the damaged component usually begins with the removal of the bondcoat and topcoat of the thermal insulation layer using hydrofluoric acid, also known as stripping, if there are any on the substrate material.
- hydrofluoric acid also known as stripping
- the critical damage is identified and regularly removed, ground and polished using a machining process.
- Sanding can be done with 320, 640, 1200 and 4000 grit sandpaper, for example.
- the subsequent polishing can be done with a diamond suspension on a soft cloth, for example first a suspension with diamond particles with an average particle size of approx. 3 ⁇ m and then a suspension with diamond particles with an average particle size of approx. 1 ⁇ m is used.
- a light microscope is suitable for checking the polished substrate surface.
- the treated substrate surface should be free of scratches.
- the undamaged areas of the substrate are masked.
- the removed area can now be rebuilt using the method according to the invention.
- Layer thicknesses of approx. 10 ⁇ m up to several mm can be achieved.
- the layer thickness when driving over / spraying the plasma torch once can be set individually and results from the robot speed in connection with the powder feed rate.
- the entire layer thickness is regularly implemented by repeatedly driving over / spraying.
- a single transition results in a layer thickness of approx. 25 ⁇ m.
- the layer can be built up as thick as you want.
- an application rate that is too high in the case of a single transition should not take place, since otherwise this can disadvantageously lead to increased pore formation. It is not necessary to polish between the individual transitions.
- the application of several layers is also possible according to the invention, provided that the corresponding surface is polished between the applications of the layers. This can be necessary, for example, if a further repair appears to be necessary after an initial repair and inspection of an area. In this respect, the repaired substrate can then be polished again and used for a further repair.
- the applied layer is generally very low in tension due to the high application temperature, there is no physical limit to a maximum layer thickness that can be applied using the method according to the invention.
- a layer thickness range of a few ⁇ m up to approx. 5 mm can be achieved with the process.
- a new thermal insulation layer can be applied and, if necessary, new cooling holes can be drilled.
- the method according to the invention therefore advantageously offers the possibility of restoring defective and discarded monocrystalline blades to a new condition.
- the optimal process parameters can be determined by a specialist by means of a few preliminary tests. Depending on the material, CET models and / or microstructure diagrams already existed, such as for CMSX-4® [5] (see Figure 1 ) that can be accessed.
- the method according to the invention it is important to first heat the entire substrate or the entire component externally to temperatures just below the melting temperature of the substrate.
- the temperature to be set is alloy-specific.
- the additional further heating by the plasma jet is necessary to suppress oxidation of the surface.
- the hydrogen contained in the plasma jet creates reducing conditions.
- the desired temperatures should be as high as possible, so a temperature of 50 K below the melting temperature is desirable.
- the temperature difference to the rest of the substrate / component should be as small as possible, since the area to be repaired should advantageously have a temperature distribution that is as homogeneous as possible.
- a high substrate temperature usually has a beneficial effect on the formation of internal stresses. Residual stresses can disadvantageously lead to the previously applied layer flaking off. The higher the substrate temperature, the lower the resulting internal stresses.
- An inhomogeneous temperature distribution of the component during the injection molding process would increase the susceptibility to internal stresses in the entire component.
- the main difference in the method according to the invention is the additional external heating of the substrate. Only with this is it possible to achieve the desired microstructure with the outstanding mechanical properties of the monocrystalline alloys and to achieve minimal residual stresses. In contrast, heating up the component solely through the energy introduced by the plasma would not be sufficient.
- a CET diagram (Columnar to Equiaxed Transition (CET)) shows the effects of the solidification rate and the temperature gradient prevailing at the point on the resulting microstructure of the solidified material.
- the Figure 2 shows schematically a solidification model for the method described.
- the molten powder particles hit the heated surface of the sample with the velocity v p.
- the temperature near the substrate is below the melting temperature.
- There the dendrites and the interdendritic area have already solidified. Above this is a transition area in which the solidification front lies and the dendrites form.
- the interdentric area has not yet solidified.
- the melted particles hit the substrate.
- the temperature is above the melting temperature.
- the figure in the substrate shows the large dendrite arm spacing ⁇ 1 substrate, which is created by a very low solidification rate v and a low temperature gradient G (see CET diagram) during the production of the single-crystal substrates.
- CMSX-4® is a registered trademark for a single crystal (SC) alloy from Cannon-Muskegon, MI (USA).
- ERBO / 1 is a single crystal nickel-based superalloy of the second generation from Doncasters Precision Casting, Bochum (Germany).
- Table 1 Element [wt .-%] Al Cr Co Hf Mon re Ti Ta W.
- Ni CMSX-4® powder 6.0 6.4 9.5 0.1 0.6 2.9 0.9 8.5 8.1 rest ERBO-1® substrate 5.7 6.5 9.6 0.1 0.6 2.9 1.0 6.5 6.4 rest
- substrate samples with the dimensions 32 mm x 20 mm x 2.5 mm and a hole with a diameter of 1.1 mm and a length of 10 mm are produced by means of spark erosion from ERBO-1 plates.
- the Figure 3 shows the sample geometry used here.
- the substrate samples are ground and polished.
- the surface was first treated with 320, 640, 1200 grit sandpaper and finally with 4000 grit sandpaper.
- the subsequent polishing was carried out using a soft cloth soaked in a diamond suspension.
- a cloth with a suspension with diamond particles with an average particle size of approx. 3 ⁇ m was used and the surface was polished to a circular shape.
- Another cloth with a suspension with diamond particles with an average particle size of approx. 1 ⁇ m was then used and the surface was polished again.
- the substrate surface treated and polished in this way was checked using a light microscope. No scratches could be detected on the substrate surface.
- An insulated SiN flat heater 2 with a power of 1000 W enables the sample 4 to be heated to up to 1100 ° C. in a vacuum, preferably at 1 to 200 mbar.
- a SiC heating plate 3 On the heater 2 is a SiC heating plate 3, which ensures a more constant temperature of the sample.
- the heater 2, the thermally conductive plate (SiC) 3 and the sample 4 are surrounded by a prepared insulation 1, 5 which reduces convection.
- the sprayed layer or layers are applied via an opening in the diaphragm 6.
- the temperature is regulated by a controller and by measuring the temperature in the sample with a thermocouple. Both the cables of the thermocouple and the power cables of the heater are laid separately in the vacuum chamber by means of a feedthrough.
- the Sulzer Metco Powder Feeder Twin-120-V is filled with CMSX-4® powder with spherical particles with a mean geometric particle diameter of 25 - 60 ⁇ m.
- the mean particle size was determined by means of laser diffraction using the Horiba LA-950V2 device from Retsch.
- the D 10 value was 27.70 ⁇ m
- the D 50 value was 39.77 ⁇ m
- the D 90 value was 55.27 ⁇ m.
- the powder had previously been stored at 150 ° C. for 2 hours. This step is to remove any water in the powder.
- the sample heater When the heating process is initiated, the sample heater is activated first. From a temperature of approx. 300 ° C, the plasma flame of the F4 - VB from Oerlinkon Metco supports the heating of the substrate surface until the coating temperature of approx. 900 ° C is reached.
- the hydrogen contained in the argon-containing plasma gas (plasma gas: 50 NLPM argon and 9 NLPM hydrogen) ensures reducing conditions. In this way, the oxygen contained in argon can be oxidized in a targeted manner without it reacting with the substrate surface and disadvantageously forming an oxide layer.
- Table 2 Argon [NLPM] 50.0 ⁇ 6.1 Hydrogen [NLPM] 9.0 ⁇ 0.6 Sample temperature [° C] 900 ⁇ 10 Spray distance [mm]: 275 ⁇ 0.1 Robot speed [mm / s]: 440 ⁇ 5 Process pressure [mbar]: 60 ⁇ 1 Powder feed rate in% based on the maximum feed rate 15 ⁇ 0.5 Powder feed rate (absolute) 47.7 g / min.
- a heat treatment is usually an advantage.
- solution heat treatment SHT may be necessary in order to reduce any inhomogeneities that may be present in the structure of the coating.
- the aforementioned heat treatment can advantageously be carried out with the aid of pressure using a hot isostatic press (HIP).
- HIP hot isostatic press
- the pressure-assisted heat treatment regularly reduces pores in the structure.
- the regular arrangement of the y'-precipitates within the ⁇ -matrix takes place regularly by precipitation annealing.
- the y 'precipitations are largely responsible for the very good mechanical properties in the high temperature range.
- Figures 5a and 5b Scanning electron microscope images of cross-sections of the samples treated in this way are shown, showing the directional solidification on the monocrystalline substrate.
- Figure 5a shows the single crystal substrate onto which the repair layer was sprayed.
- the columnar structure of the grains in the polycrystalline layer is an indication of directional solidification.
- At the transition between substrate and layer there is an area with a gray color similar to that of the substrate. Due to the crystal orientation contrast in the backscattered electron image of the scanning electron microscope, this means the same crystal orientation for substrate and layer in this same-colored area.
- Figure 5b represents a higher enlargement of this area.
- the dark y 'precipitations in the ⁇ matrix can be seen in the substrate.
- FIGS. 6a and 6b show scanning electron microscope images of cross-sections of the same sample which, after coating with the parameters listed above, was first solution annealed and then precipitation annealed.
- Figure 6a shows the transition area from the monocrystalline substrate to the repair layer.
- the white dashed line marks the former interface.
- the grains nucleated on the monocrystalline substrate grow into the polycrystalline layer at the expense of the small grains.
- a monocrystalline structure is created with the same crystal orientation as the substrate.
- the repair layer only has a slightly increased pore density, which would disappear through a pressure-assisted heat treatment using HIP.
- the smaller black dots indicate Al 2 O 3 inclusions that have arisen as a result of slight oxidation of the spray material.
- Figure 6b shows an enlarged section. At the former interface, an Al 2 O 3 pore fringe indicates this.
- the precipitation annealing reduces the size of the y 'precipitates in the ⁇ matrix and these are arranged in a cubic manner. This arrangement ensures for the best possible mechanical properties of the alloy.
- the orientation of the precipitates shows, in addition to the same crystal orientation contrast, that the monocrystallinity of the substrate was continued in the repair layer.
- the applied coating can then be recognized by its red color, the red color indicating the (001) crystal plane in which the substrate material is also oriented. It can thus be proven that in the application according to the invention the applied, sprayed layer solidifies at least in wide areas in the same orientation as the single-crystal substrate material.
- the porosity in the sprayed layer is determined by the application rate, which results from the powder feed rate and the robot speed. As the application rate decreases, the quality of the layer is also reduced. It was also found that the size of the solidified grains depends on the powder size used. The size of the directionally solidified grains increases with larger particle diameters.
- the quality of the argon with regard to the oxygen content should be improved.
- Another reason for the formation of an oxide layer could be an awkward robot movement during the spraying process. This should preferably be adjusted so that the sample does not leave the area of influence of the plasma torch. If there is no nucleation on the polished surface of the area to be repaired, although there is no oxide layer, the temperature of the workpiece to be repaired must be increased.
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Coating By Spraying Or Casting (AREA)
- Turbine Rotor Nozzle Sealing (AREA)
- Other Surface Treatments For Metallic Materials (AREA)
- Crystals, And After-Treatments Of Crystals (AREA)
Claims (8)
- Procédé de réparation pour le revêtement d'une surface de substrat métallique monocristallin d'une pièce, comprenant un alliage monocristallin, d'une matière de revêtement, comprenant les stades :- on polit la surface à revêtir,- on transfert le substrat dans une chambre sous vide,- on porte tout le substrat à des températures qui correspondent au moins à la moitié du point de fusion du substrat en °C, mais qui sont en dessous du point de fusion du substrat,- on dépose la matière de revêtement sous forme pulvérulente au moyen d'une projection au plasma sous vide sur la surface à revêtir,- dans lequel on utilise une poudre d'une granulométrie moyenne dans la plage de 10 à 200 µm, et- dans lequel la matière de revêtement comprend un alliage du même type que celui du matériau du substrat monocristallin,- dans lequel on règle une pression comprise entre 1 et 200 mbar, et- dans lequel on utilise comme gaz de travail une atmosphère d'argon ayant une proportion d'hydrogène de 10 à 50 % en volume,- grâce à quoi, on produit directement à la surface limite de la matière de revêtement et de la surface du substrat polie, au moins une région, qui a la même direction d'orientation monocristalline que le substrat sous-jacent.
- Procédé de réparation suivant la revendication 1,
dans lequel on utilise comme matière de revêtement une matière qui est pareille à la matière du substrat. - Procédé de réparation suivant l'une des revendications 1 à 2, dans lequel on utilise comme substrat et comme matière de revêtement respectivement un alliage à base de nickel ou un alliage à base de cobalt monocristallin.
- Procédé de réparation suivant l'une des revendications 1 à 3, dans lequel on porte tout le substrat à au moins 700°C, de préférence à au moins 800°C.
- Procédé de réparation suivant l'une des revendications 1 à 4, dans lequel on effectue le chauffage de tout le substrat électriquement inductivement ou par un rayonnement électromagnétique.
- Procédé de réparation suivant l'une des revendications 1 à 5, dans lequel on effectue le chauffage de la surface du substrat par la torche à plasma sans apport de poudre.
- Procédé de réparation suivant l'une des revendications 1 à 6, dans lequel on soumet le substrat revêtu après le revêtement à un recuit de mise en solution et/ou à un recuit de précipitation et/ou à un traitement thermique assisté par la pression.
- Procédé de réparation suivant l'une des revendications 1 à 7, dans lequel on utilise un substrat ayant au moins un trou de refroidissement.
Priority Applications (1)
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PL18796582T PL3701060T3 (pl) | 2017-10-26 | 2018-10-04 | Sposób naprawiania materiałów monokrystalicznych |
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DE102017009948.0A DE102017009948A1 (de) | 2017-10-26 | 2017-10-26 | Verfahren zur Reparatur einkristalliner Werkstoffe |
PCT/DE2018/000281 WO2019080951A1 (fr) | 2017-10-26 | 2018-10-04 | Procédé de réparation d'un matériau monocristallin |
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EP3701060A1 EP3701060A1 (fr) | 2020-09-02 |
EP3701060B1 true EP3701060B1 (fr) | 2021-06-09 |
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EP18796582.7A Active EP3701060B1 (fr) | 2017-10-26 | 2018-10-04 | Procédé de réparation d'un matériau monocristallin |
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US (1) | US20200216942A1 (fr) |
EP (1) | EP3701060B1 (fr) |
CN (1) | CN111373068A (fr) |
DE (1) | DE102017009948A1 (fr) |
ES (1) | ES2886226T3 (fr) |
PL (1) | PL3701060T3 (fr) |
WO (1) | WO2019080951A1 (fr) |
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CN115537810B (zh) * | 2022-10-14 | 2024-06-25 | 中国兵器装备集团西南技术工程研究所 | 基于等离子喷涂-激光熔覆制备复合构件的方法 |
Family Cites Families (9)
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US3493415A (en) * | 1967-11-16 | 1970-02-03 | Nasa | Method of making a diffusion bonded refractory coating |
CA2030427A1 (fr) * | 1989-12-19 | 1991-06-20 | Jonathan S. Stinson | Methode d'amelioration de l'integration structurale des joints de liaison d'articles moules en grappe |
US5232522A (en) * | 1991-10-17 | 1993-08-03 | The Dow Chemical Company | Rapid omnidirectional compaction process for producing metal nitride, carbide, or carbonitride coating on ceramic substrate |
US5732467A (en) | 1996-11-14 | 1998-03-31 | General Electric Company | Method of repairing directionally solidified and single crystal alloy parts |
DE69821945T2 (de) * | 1998-11-10 | 2005-07-14 | Alstom Technology Ltd | Gasturbineteil |
US7157151B2 (en) * | 2002-09-11 | 2007-01-02 | Rolls-Royce Corporation | Corrosion-resistant layered coatings |
JP5334017B2 (ja) * | 2006-09-13 | 2013-11-06 | 独立行政法人物質・材料研究機構 | 耐熱部材 |
CH699930A1 (de) * | 2008-11-26 | 2010-05-31 | Alstom Technology Ltd | Hochtemperatur- und oxidationsbeständiges Material. |
EP2631324A4 (fr) * | 2010-10-19 | 2014-04-16 | Nat Inst For Materials Science | Élément en un superalliage à base de ni contenant une couche d'accrochage résistante à la chaleur |
-
2017
- 2017-10-26 DE DE102017009948.0A patent/DE102017009948A1/de not_active Withdrawn
-
2018
- 2018-10-04 WO PCT/DE2018/000281 patent/WO2019080951A1/fr unknown
- 2018-10-04 PL PL18796582T patent/PL3701060T3/pl unknown
- 2018-10-04 CN CN201880062701.4A patent/CN111373068A/zh active Pending
- 2018-10-04 EP EP18796582.7A patent/EP3701060B1/fr active Active
- 2018-10-04 ES ES18796582T patent/ES2886226T3/es active Active
- 2018-10-04 US US16/649,994 patent/US20200216942A1/en not_active Abandoned
Also Published As
Publication number | Publication date |
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EP3701060A1 (fr) | 2020-09-02 |
PL3701060T3 (pl) | 2021-12-20 |
US20200216942A1 (en) | 2020-07-09 |
WO2019080951A1 (fr) | 2019-05-02 |
DE102017009948A1 (de) | 2019-05-02 |
CN111373068A (zh) | 2020-07-03 |
ES2886226T3 (es) | 2021-12-16 |
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