EP3810829A1 - Method for manufacturing an abradable layer - Google Patents
Method for manufacturing an abradable layerInfo
- Publication number
- EP3810829A1 EP3810829A1 EP19745695.7A EP19745695A EP3810829A1 EP 3810829 A1 EP3810829 A1 EP 3810829A1 EP 19745695 A EP19745695 A EP 19745695A EP 3810829 A1 EP3810829 A1 EP 3810829A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- substrate
- ceramic particles
- abradable layer
- pulverulent composition
- micrometric
- 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
Links
- 238000000034 method Methods 0.000 title claims abstract description 40
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 13
- 239000002245 particle Substances 0.000 claims abstract description 82
- 239000000203 mixture Substances 0.000 claims abstract description 64
- 239000000919 ceramic Substances 0.000 claims abstract description 52
- 238000005245 sintering Methods 0.000 claims abstract description 46
- 239000000843 powder Substances 0.000 claims abstract description 7
- 239000000758 substrate Substances 0.000 claims description 54
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims description 30
- 230000006835 compression Effects 0.000 claims description 22
- 238000007906 compression Methods 0.000 claims description 22
- 230000015572 biosynthetic process Effects 0.000 claims description 5
- 238000000151 deposition Methods 0.000 claims description 4
- 229910052761 rare earth metal Inorganic materials 0.000 claims description 4
- 230000008021 deposition Effects 0.000 claims description 3
- 238000005304 joining Methods 0.000 claims description 3
- -1 rare earth silicate Chemical class 0.000 claims description 3
- 239000011159 matrix material Substances 0.000 claims description 2
- 239000002131 composite material Substances 0.000 claims 1
- BDERNNFJNOPAEC-UHFFFAOYSA-N propan-1-ol Chemical compound CCCO BDERNNFJNOPAEC-UHFFFAOYSA-N 0.000 description 15
- 230000003628 erosive effect Effects 0.000 description 9
- 239000000463 material Substances 0.000 description 9
- 238000012360 testing method Methods 0.000 description 7
- RUDFQVOCFDJEEF-UHFFFAOYSA-N yttrium(III) oxide Inorganic materials [O-2].[O-2].[O-2].[Y+3].[Y+3] RUDFQVOCFDJEEF-UHFFFAOYSA-N 0.000 description 7
- 230000008569 process Effects 0.000 description 6
- 230000004888 barrier function Effects 0.000 description 5
- 229910045601 alloy Inorganic materials 0.000 description 3
- 239000000956 alloy Substances 0.000 description 3
- 238000005259 measurement Methods 0.000 description 3
- 238000002156 mixing Methods 0.000 description 3
- 238000002490 spark plasma sintering Methods 0.000 description 3
- YRKCREAYFQTBPV-UHFFFAOYSA-N acetylacetone Chemical compound CC(=O)CC(C)=O YRKCREAYFQTBPV-UHFFFAOYSA-N 0.000 description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 2
- 239000011153 ceramic matrix composite Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 239000000835 fiber Substances 0.000 description 2
- 239000007769 metal material Substances 0.000 description 2
- 230000002829 reductive effect Effects 0.000 description 2
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 2
- 229910010271 silicon carbide Inorganic materials 0.000 description 2
- 230000003068 static effect Effects 0.000 description 2
- 238000003756 stirring Methods 0.000 description 2
- 229910001233 yttria-stabilized zirconia Inorganic materials 0.000 description 2
- 229910052727 yttrium Inorganic materials 0.000 description 2
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 description 2
- NGDQQLAVJWUYSF-UHFFFAOYSA-N 4-methyl-2-phenyl-1,3-thiazole-5-sulfonyl chloride Chemical compound S1C(S(Cl)(=O)=O)=C(C)N=C1C1=CC=CC=C1 NGDQQLAVJWUYSF-UHFFFAOYSA-N 0.000 description 1
- 229920000049 Carbon (fiber) Polymers 0.000 description 1
- 238000005219 brazing Methods 0.000 description 1
- 239000004917 carbon fiber Substances 0.000 description 1
- 238000005524 ceramic coating Methods 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 230000005669 field effect Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052863 mullite Inorganic materials 0.000 description 1
- 230000036961 partial effect Effects 0.000 description 1
- 229910002077 partially stabilized zirconia Inorganic materials 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 238000007750 plasma spraying Methods 0.000 description 1
- XPGAWFIWCWKDDL-UHFFFAOYSA-N propan-1-olate;zirconium(4+) Chemical compound [Zr+4].CCC[O-].CCC[O-].CCC[O-].CCC[O-] XPGAWFIWCWKDDL-UHFFFAOYSA-N 0.000 description 1
- 239000011253 protective coating Substances 0.000 description 1
- 150000002910 rare earth metals Chemical class 0.000 description 1
- 239000003870 refractory metal Substances 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 230000008439 repair process Effects 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 229910000601 superalloy Inorganic materials 0.000 description 1
- 238000003786 synthesis reaction Methods 0.000 description 1
- 230000002194 synthesizing effect Effects 0.000 description 1
- 238000007751 thermal spraying Methods 0.000 description 1
- 238000011144 upstream manufacturing Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- 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
-
- 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
- C23C24/085—Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/02—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/0018—Coating or impregnating "in situ", e.g. impregnating of artificial stone by subsequent melting of a compound added to the artificial stone composition
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/0072—Heat treatment
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/4505—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements characterised by the method of application
- C04B41/4545—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements characterised by the method of application applied as a powdery material
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/4505—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements characterised by the method of application
- C04B41/4545—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements characterised by the method of application applied as a powdery material
- C04B41/4547—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements characterised by the method of application applied as a powdery material characterised by the grain distribution
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/4596—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with fibrous materials or whiskers
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
- C04B41/81—Coating or impregnation
- C04B41/85—Coating or impregnation with inorganic materials
- C04B41/87—Ceramics
-
- 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
- C23C26/00—Coating not provided for in groups C23C2/00 - C23C24/00
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/002—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B82—NANOTECHNOLOGY
- B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
- B82Y40/00—Manufacture or treatment of nanostructures
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
- C04B2111/00982—Uses not provided for elsewhere in C04B2111/00 as construction elements for space vehicles or aeroplanes
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- 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
- F01D11/00—Preventing or minimising internal leakage of working-fluid, e.g. between stages
- F01D11/08—Preventing or minimising internal leakage of working-fluid, e.g. between stages for sealing space between rotor blade tips and stator
- F01D11/12—Preventing or minimising internal leakage of working-fluid, e.g. between stages for sealing space between rotor blade tips and stator using a rubstrip, e.g. erodible. deformable or resiliently-biased part
- F01D11/122—Preventing or minimising internal leakage of working-fluid, e.g. between stages for sealing space between rotor blade tips and stator using a rubstrip, e.g. erodible. deformable or resiliently-biased part with erodable or abradable material
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- 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
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- 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
- F05D2240/00—Components
- F05D2240/55—Seals
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- 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
- F05D2300/00—Materials; Properties thereof
- F05D2300/10—Metals, alloys or intermetallic compounds
- F05D2300/15—Rare earth metals, i.e. Sc, Y, lanthanides
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- 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
- F05D2300/00—Materials; Properties thereof
- F05D2300/20—Oxide or non-oxide ceramics
- F05D2300/21—Oxide ceramics
- F05D2300/211—Silica
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- 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
- F05D2300/00—Materials; Properties thereof
- F05D2300/20—Oxide or non-oxide ceramics
- F05D2300/21—Oxide ceramics
- F05D2300/2118—Zirconium oxides
Definitions
- the present invention relates to a method of manufacturing an abradable layer and a substrate coated with this abradable layer.
- Abradable layers are currently used in gas turbines to minimize the functional clearance, and therefore leaks, between the rotating parts and the static parts.
- the abradable seals are deposited on ring sectors attached to the casing. When the turbine blades come into contact with the abradable material, the latter should wear out first, which would maintain the aerodynamic performance of the engine.
- a ceramic coating or based on refractory metals is usually formed by thermal spraying on the static parts that are the ring sectors, to form a protective coating of thermal barrier type.
- the coatings thus obtained may not have very high abradability, which can lead to wear of the tips of the blades in operation, leading to complex and costly repairs.
- the invention relates to a method for manufacturing an abradable layer, comprising the following steps:
- a pulverulent composition comprising at least micrometric ceramic particles having a number-average form factor greater than or equal to 3, the mass content of said micrometric ceramic particles in the pulverulent composition being greater than or equal to 85%, and
- the number average form factor corresponds to the number average value of the following ratio R calculated for each particle of a given set of particles, with R denoting the ratio [largest dimension of the particle] / [more large transverse dimension of the particle].
- the use of the pulverulent composition defined above and of a pressure sintering technique advantageously makes it possible to obtain a layer having both good abradability and good resistance to erosion.
- the inventors have found that the abradable layers formed by pressure sintering have a better resistance to erosion compared to the layers formed by plasma spraying at equal porosity rate or, even in certain cases, if the porosity rate is superior.
- the pulverulent composition further comprises nanometric ceramic particles having a number form factor of between 0.7 and 1.3, preferably between 1.0 and 1.3, the mass content of said particles nanometric ceramics in the pulverulent composition being less than or equal to 15%.
- nanometric ceramic particles in the contents indicated advantageously makes it possible to further improve the resistance to erosion of the abradable layer obtained without affecting the abradability.
- the mass content of said nanometric ceramic particles in the pulverulent composition can be between 1% and 10%.
- the presence of nanometric ceramic particles is however not compulsory insofar as, according to a variant, the pulverulent composition consists essentially of said micrometric ceramic particles.
- the mass content of said micrometric ceramic particles in the pulverulent composition is greater than or equal to 90%.
- said micrometric ceramic particles comprise at least acicular particles having a number-average form factor of between 3 and 5.
- said micrometric ceramic particles comprise at least fibrous particles having a factor of medium form in number strictly greater than 5.
- the volume porosity rate of the abradable layer is greater than or equal to 20%.
- volume porosity rate is understood to mean the ratio between the volume of the interstitial spaces separating the grains of the material considered and the overall volume of said material.
- Such a porosity rate is advantageous in order to further improve the abradability of the layer formed.
- a compression pressure of between 12.5 MPa and 100 MPa is applied to the pulverulent composition during sintering.
- Such values for the compression pressure participate in optimizing the porosity rate of the abradable layer, and in optimizing the abradability / erosion resistance compromise.
- the duration of the sintering is between 1 minute and 10 minutes.
- Such values for the duration of sintering participate in optimizing the porosity rate of the abradable layer, and in optimizing the abradability / erosion resistance compromise.
- the temperature imposed during sintering is between 900 ° C and 1150 ° C.
- the pulverulent composition is sintered by flash sintering technique ("Spark Plasma Sintering";
- the invention also relates to a method of manufacturing a substrate coated with an abradable layer, the substrate being a part of a turbomachine and the method comprising:
- This variant relates to the case where the pulverulent composition is first deposited on the substrate, then where the abradable layer is formed directly on the substrate by pressure sintering of the pulverulent composition deposited.
- the invention also relates to a method of manufacturing a substrate coated with an abradable layer, the substrate being a part of a turbomachine and the method comprising:
- This variant relates to the case where the abradable layer is first formed, then this abradable layer is deposited on the substrate and then secured to the latter.
- the substrate is metallic, and said micrometric ceramic particles, as well as said nanometric ceramic particles which may be present, comprise at least zirconia, for example yttria zirconia ("Yttria Stabilized Zirconia”; “YSZ”) or partially zirconia stabilized with yttrium (“Yttria-Partially Stabilized Zirconia”; “YSPZ”) or a mixture of zirconia and alumina, or
- the substrate is made of a ceramic matrix composite material (“Ceramic Matrix Composite”; “CMC”), and said particles micrometric ceramics, as well as said nanometric ceramic particles which may be present, are made of rare earth silicate.
- CMC Ceramic Matrix Composite
- the substrate is a sector of a turbine or compressor ring.
- FIG. 1 is a sectional plan of a turbomachine
- FIG. 2 is a partial perspective and schematic view of an example of a substrate coated by the method according to the invention
- FIGS. 3A and 3B schematically illustrate several successive stages of an example of a method according to the invention
- FIGS. 4A to 4C are photographs using a scanning electron microscope of particles that can be used in the pulverulent composition in the context of the invention.
- FIGS. 5A and 5B illustrate an example of evolution of the temperature and of the compression pressure which can be implemented within the framework of a method according to the invention
- FIG. 6 is a photograph illustrating the result obtained within the framework of an abradability test for a layer formed within the framework of the invention
- FIG. 7 is a photograph illustrating the state of the tips of the blades obtained following the abradability test of FIG. 6,
- FIG. 8 is a photograph illustrating the result obtained within the framework of an abradability test for a layer formed within the framework of a process outside the invention
- FIG. 9 is a photograph illustrating the state of the tips of the blades obtained following the abradability test in FIG. 8.
- Figure 1 shows, in section along a vertical plane passing through its main axis A, a turbofan engine 1. It comprises, from upstream to downstream according to the circulation of the air flow, a blower 2, a low pressure compressor 3, a high pressure compressor 4, a combustion chamber 5, a high pressure turbine 6, and a low pressure turbine 7.
- the high pressure turbine 6 comprises a plurality of vanes 6a rotating with the rotor and rectifiers 6b mounted on the stator.
- the stator of the turbine 6 comprises a plurality of stator rings arranged opposite the movable blades 6a of the turbine 6.
- FIG. 2 illustrates a stator ring, which is divided into several sectors each comprising a substrate 10 coated with an abradable layer 12. The movable vanes 6a of the rotor rub on the abradable layer 12 in the event of a radial incursion of the rotor.
- FIGS. 3A and 3B schematically illustrate the implementation of an example of a method according to the invention.
- the substrate 10 to be coated is placed in the cavity of a mold 20.
- the pulverulent composition 30 is then deposited on a surface S of the substrate 10.
- the mold 20 is then closed.
- a bearing face of its cover 25 is applied against the layer of pulverulent composition 30 so as to compress the latter on the substrate 10.
- the compression pressure applied to the pulverulent composition 30 may be a uniaxial pressure.
- the thickness of the layer of powder composition 30 is thus reduced due to the compression between the substrate 10 and the cover 25.
- the powder composition 30 undergoing the compression pressure is then sintered.
- the abradable layer 12 is obtained at the end of this sintering step.
- the particles forming the pulverulent composition 30 can be made of a thermal barrier material, such as yttria zirconia, zirconia partially stabilized with yttrium, in a mixture comprising zirconia and alumina or a rare earth silicate, for example a mono-silicate or a rare earth disilicate.
- a flash sintering technique can be used to produce the abradable layer 12.
- the abradable layer 12 obtained has a substantially uniform density.
- the abradable layer 12 is first possible to form the abradable layer 12 on a support separate from the substrate by implementing the pressure sintering method which has been described above.
- the abradable layer 12 thus formed is then separated from the support to be positioned on the surface S of the substrate 10.
- This abradable layer 12 thus positioned is then secured to the surface S of the substrate 10 in order to obtain the coated substrate.
- This joining can be carried out by brazing, sintering or using added elements (bolting for example).
- the abradable layer 12 formed is particularly suitable for equipping high or low pressure turbine rings or compressor rings, for example in the aeronautical field, and very particularly in aircraft turbojets.
- the substrate 10 can be a part for a turbomachine.
- the substrate 10 can be made of metallic material, for example superalloy.
- the substrate 10 can for example be formed by one of the following materials: AMI alloy, C263 alloy or M509 alloy.
- the substrate 10 can be made of CMC material.
- the substrate 10 may comprise a woven fibrous reinforcement, formed of carbon fibers or silicon carbide, densified by a ceramic matrix, comprising for example silicon carbide.
- a woven fibrous reinforcement formed of carbon fibers or silicon carbide, densified by a ceramic matrix, comprising for example silicon carbide.
- the substrate 10 can be coated with a bonding layer (not shown) which the abradable layer 12 is intended to coat.
- a bonding layer (not shown) which the abradable layer 12 is intended to coat.
- a metallic substrate it is possible, for example, to use an MCrAlY bonding layer, for example a CoNiCrAlY bonding layer.
- a CMC substrate it is possible to use a bonding layer of mullite, for example.
- the mass content of the micrometric ceramic particles having an average form factor in number greater than or equal to 3 in this composition is greater than or equal to 85%. This mass content may be greater than or equal to 90%, preferably greater than or equal to 95%.
- the micrometric ceramic particles may comprise needle-like particles having a number average form factor of between 3 and 5, fibrous particles having a number average form factor greater than 5 or a mixture of such particles.
- the number-average form factor of the fibrous particles can, in particular, be between 15 and 25.
- all of the micrometric ceramic particles can consist of the fibrous particles. According to another particular variant, all of the micrometric ceramic particles can be constituted by the needle-like particles. According to yet another particular variant, all of the micrometric ceramic particles can be constituted by a mixture of needle-like particles and fibrous particles.
- the needle-like particles may have an average diameter in the non-agglomerated state (or average width) greater than or equal to 15 ⁇ m, for example between 15 ⁇ m and 35 ⁇ m.
- the needle-like particles can have an average length greater than or equal to 55 ⁇ m, for example between 55 ⁇ m and 75 ⁇ m.
- the mean diameter and mean length can be measured using a field effect scanning electron microscope ("SEM-FEG").
- the average diameter and the average length correspond to number averages.
- the needle-like particles which can be used in the context of the invention can be obtained by the sol-gel route under the conditions described in the following article: C. Viazzi & al., 2006, Solid State Sciences 8 1023-1028, “Synthesis of Yttria StabiHzed Zirconia by soi-gei route: Influence of experimental parameters and large scaie production ”.
- the fibrous particles can have an average diameter in the non-agglomerated state (or average width) greater than or equal to 6 ⁇ m, for example between 6 ⁇ m and 8 ⁇ m.
- the fibrous particles may have an average length greater than or equal to 125 ⁇ m, for example between 125 ⁇ m and 215 ⁇ m.
- fibrous particles which can be used in the context of the invention, mention may be made of the particles sold under the reference ZYBF-5 (CF010) by the company Zircar.
- the pulverulent composition may comprise nanometric ceramic particles having a number-average form factor of between 0.7 and 1.3, preferably between 1.0 and 1.3, and present in a limited amount, so as not to degrade the abradability of the layer obtained.
- the mass content of the nanometric ceramic particles in the pulverulent composition is preferably less than or equal to 10%, preferably less than or equal to 5%.
- the mass content of the nanometric ceramic particles in the pulverulent composition can, for example, be between 1% and 15%, for example between 5% and 15%, for example between 5% and 10% or between 10% and 15%.
- the mass content of the nanometric ceramic particles in the pulverulent composition can, for example, be between 1% and 10%, for example between 1% and 5%.
- the nanometric ceramic particles may have an average diameter in the non-agglomerated state less than or equal to 70 nm, for example between 30 nm and 70 nm.
- the nanometric ceramic particles can have a number-average form factor of between 0.9 and 1.1, preferably between 1.0 and 1.1, for example substantially equal to 1.
- the nanometric ceramic particles can thus have a shape substantially spherical.
- the pulverulent composition 30 can consist essentially of the micrometric ceramic particles, and the nanometric ceramic particles which may be present.
- FIGS. 4A to 4C photographs of particles usable in the context of the invention are provided in FIGS. 4A to 4C.
- FIG. 4A is a photograph of nanometric ceramic particles having a substantially spherical shape and a form factor substantially equal to 1.
- FIG. 4B is a photograph of acicular micrometric ceramic particles having a number form factor between 3 and 5.
- FIG. 4C is a photograph of micrometric fibrous ceramic particles having a number form factor strictly greater than 5.
- the volume porosity rate of the abradable layer can be greater than or equal to 20%, for example 30%, for example greater than or equal to 35%. This volume porosity rate can be between 20% and 50%, for example between 30% and 50%, for example between 35% and 50%.
- the modification of the temperature imposed during sintering, of the duration of sintering and / or of the compression pressure applied makes it possible to vary the volume porosity rate of the abradable layer 12 obtained. Increasing the temperature, the duration of sintering and / or the compression pressure thus makes it possible to reduce the volume porosity rate of the abradable layer 12.
- FIGS. 5A and 5B show a possible example of changes in the compression pressure and the temperature during the manufacture of the abradable layer 12.
- the whole of the substrate 10 and of the pulverulent composition 30 is initially brought to a first temperature T if for example greater than or equal to 600 ° C. While the assembly is brought to this first temperature Ti, the compression pressure increases until reaching, at a first instant ti, a plateau at a value Pc which corresponds to the compression pressure which will be applied during the sintering of the powder composition 30.
- the compression pressure Pc imposed on the pulverulent composition 30 during sintering can be less than or equal to 100 MPa, for example less than or equal to 50 MPa.
- This compression pressure Pc can be between 12.5 MPa and 100 MPa, for example between 25 MPa and 100 MPa, for example between 25 MPa and 50 MPa or between 50 MPa and 100 MPa.
- the compression pressure Pc is maintained throughout the duration of the sintering of the pulverulent composition 30.
- the temperature imposed on the substrate 10 and on the pulverulent composition 30 is increased up to the sintering temperature T f .
- the temperature reaches the sintering temperature T f at a second instant t 2 and is then maintained at this value.
- the sintering temperature T f depends on the nature of the pulverulent composition used. This sintering temperature T f can be between 900 ° C and 1150 ° C, for example between 1050 ° C and 1150 ° C.
- the sintering temperature T f and the compression pressure Pc are maintained until the third instant t 3 .
- the sintering time (t 3 -t 2 ) may be greater than or equal to 1 minute, for example between 1 minute and 10 minutes, for example between 1 minute and 6 minutes.
- a first temperature rise speed is imposed between the first temperature Ti and a second higher temperature T2 reached at the intermediate instant t , then a second temperature rise speed, lower than the first speed temperature rise, between the second temperature T 2 and the sintering temperature T f .
- the first temperature rise speed may be greater than or equal to 100 ° C./minute and the second temperature rise speed may be less than or equal to 50 ° C./minute.
- the second temperature T 2 may be greater than or equal to 1000 ° C. It is not, however, outside the scope of the invention when the rate of temperature rise is constant between the first temperature Ti and the sintering temperature T f .
- a pulverulent composition formed at 100% by mass of micrometric fibers of yttria zirconia marketed under the reference ZYBF-5 (CFO 10) by the company Zircar was formed by flash sintering by imposing the following conditions:
- the layer obtained had a volume porosity rate of approximately 50%.
- a pulverulent composition comprising the following mixture was sintered by flash sintering:
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Abstract
Description
Claims
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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FR1855682A FR3082765B1 (en) | 2018-06-25 | 2018-06-25 | PROCESS FOR MANUFACTURING AN ABRADABLE LAYER |
PCT/FR2019/051510 WO2020002799A1 (en) | 2018-06-25 | 2019-06-20 | Method for manufacturing an abradable layer |
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EP3810829A1 true EP3810829A1 (en) | 2021-04-28 |
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EP19745695.7A Pending EP3810829A1 (en) | 2018-06-25 | 2019-06-20 | Method for manufacturing an abradable layer |
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US (1) | US20210317584A1 (en) |
EP (1) | EP3810829A1 (en) |
CN (1) | CN112334601A (en) |
FR (1) | FR3082765B1 (en) |
WO (1) | WO2020002799A1 (en) |
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FR3123236B1 (en) | 2021-05-25 | 2023-10-27 | Safran Aircraft Engines | Process for manufacturing an abradable layer. |
DE102021211656A1 (en) * | 2021-10-15 | 2023-04-20 | Siemens Energy Global GmbH & Co. KG | Sealing area between rotating and stationary components, method of manufacture and machine |
FR3139488A1 (en) | 2022-09-13 | 2024-03-15 | Safran Aircraft Engines | Process for manufacturing an abradable coating, abradable coating and coated part |
Family Cites Families (17)
Publication number | Priority date | Publication date | Assignee | Title |
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US4851188A (en) * | 1987-12-21 | 1989-07-25 | United Technologies Corporation | Method for making a turbine blade having a wear resistant layer sintered to the blade tip surface |
US6641907B1 (en) * | 1999-12-20 | 2003-11-04 | Siemens Westinghouse Power Corporation | High temperature erosion resistant coating and material containing compacted hollow geometric shapes |
US6916529B2 (en) * | 2003-01-09 | 2005-07-12 | General Electric Company | High temperature, oxidation-resistant abradable coatings containing microballoons and method for applying same |
CA2585992C (en) * | 2006-06-08 | 2014-06-17 | Sulzer Metco (Us) Inc. | Dysprosia stabilized zirconia abradable |
US9725797B2 (en) * | 2008-04-30 | 2017-08-08 | United Technologies Corporation | Process for forming an improved durability thick ceramic coating |
EP2406466B1 (en) * | 2009-03-09 | 2012-11-07 | Snecma | Turbine ring assembly |
FR2972449B1 (en) * | 2011-03-07 | 2013-03-29 | Snecma | METHOD FOR PRODUCING A THERMAL BARRIER IN A MULTILAYER SYSTEM FOR PROTECTING A METAL PIECE AND PIECE EQUIPPED WITH SUCH A PROTECTION SYSTEM |
US9186866B2 (en) * | 2012-01-10 | 2015-11-17 | Siemens Aktiengesellschaft | Powder-based material system with stable porosity |
FR2994397B1 (en) * | 2012-08-07 | 2014-08-01 | Snecma | COATING IN ABRADABLE MATERIAL WITH LOW SURFACE ROUGHNESS |
FR2996477B1 (en) * | 2012-10-05 | 2015-02-13 | Snecma | PROCESS FOR MANUFACTURING A COVERED PART WITH AN ABRADABLE COATING |
FR2996474B1 (en) * | 2012-10-05 | 2014-12-12 | Snecma | METHOD FOR THE INTEGRATION OF ABRADABLE MATERIAL IN ISOSTATIC COMPRESSION HOUSING |
US9102015B2 (en) * | 2013-03-14 | 2015-08-11 | Siemens Energy, Inc | Method and apparatus for fabrication and repair of thermal barriers |
FR3044946B1 (en) * | 2015-12-14 | 2018-01-12 | Safran Aircraft Engines | ABRADABLE COATING WITH VARIABLE DENSITY |
FR3044945B1 (en) | 2015-12-14 | 2018-01-12 | Centre National De La Recherche Scientifique | ABRADABLE COATING WITH VARIABLE DENSITY |
FR3048629B1 (en) * | 2016-03-14 | 2018-04-06 | Centre National De La Recherche Scientifique | PROCESS FOR MANUFACTURING A TURBINE RING FOR TURBOMACHINE |
FR3048630B1 (en) * | 2016-03-14 | 2020-02-21 | Centre National De La Recherche Scientifique | PROCESS FOR MANUFACTURING AN ABRADABLE PLATE AND FOR REPAIRING A TURBINE RING |
FR3060556B1 (en) * | 2016-12-20 | 2022-03-04 | Norimat | PROCESS FOR MANUFACTURING A RED COLORED CERAMIC MATERIAL |
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2018
- 2018-06-25 FR FR1855682A patent/FR3082765B1/en active Active
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- 2019-06-20 EP EP19745695.7A patent/EP3810829A1/en active Pending
- 2019-06-20 US US17/255,232 patent/US20210317584A1/en active Pending
- 2019-06-20 CN CN201980040927.9A patent/CN112334601A/en active Pending
- 2019-06-20 WO PCT/FR2019/051510 patent/WO2020002799A1/en unknown
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WO2020002799A1 (en) | 2020-01-02 |
FR3082765A1 (en) | 2019-12-27 |
CN112334601A (en) | 2021-02-05 |
US20210317584A1 (en) | 2021-10-14 |
FR3082765B1 (en) | 2021-04-30 |
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