EP4281595A1 - Système de revêtement de barrière thermique transplanté - Google Patents

Système de revêtement de barrière thermique transplanté

Info

Publication number
EP4281595A1
EP4281595A1 EP22702901.4A EP22702901A EP4281595A1 EP 4281595 A1 EP4281595 A1 EP 4281595A1 EP 22702901 A EP22702901 A EP 22702901A EP 4281595 A1 EP4281595 A1 EP 4281595A1
Authority
EP
European Patent Office
Prior art keywords
layer
tbc
sand core
based polymer
microns
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
EP22702901.4A
Other languages
German (de)
English (en)
Inventor
Arifovic HALIL
Frantisek ZAHALKA
James William GIRGULIS
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.)
Oerlikon Metco AG
Original Assignee
Oerlikon Metco AG
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 Oerlikon Metco AG filed Critical Oerlikon Metco AG
Publication of EP4281595A1 publication Critical patent/EP4281595A1/fr
Pending legal-status Critical Current

Links

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
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D15/00—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C3/00—Selection of compositions for coating the surfaces of moulds, cores, or patterns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/10—Cores; Manufacture or installation of cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/12—Treating moulds or cores, e.g. drying, hardening
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/18—Finishing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D15/00—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor
    • B22D15/02—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor of cylinders, pistons, bearing shells or like thin-walled objects
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • 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
    • 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
    • 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
    • C23C28/34—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates
    • C23C28/345—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer
    • C23C28/3455—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer with a refractory ceramic layer, e.g. refractory metal oxide, ZrO2, rare earth oxides or a thermal barrier system comprising at least one refractory oxide 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
    • C23C28/36—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including layers graded in composition or physical properties
    • 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
    • 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
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
    • C23C4/11—Oxides
    • 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

  • Embodiments are directed to applying a thermal barrier coating system to a sand core in a molding process.
  • Regeneration is a process used, e.g., in diesel engine manifolds, to remove accumulated soot from filters, such as diesel particulate filters. Regeneration can be performed passively, e.g., from exhaust heat or by adding a catalyst to the filter, or by actively adding heat into the exhaust system.
  • These manifolds which can be produced, e.g., by a die casting and/or injection molding process, can be exposed to heat extremes, e.g., about 760°C, that can result in thermo-mechanical fatigue, e.g., cracking, in the part, which can allow gases and heat to escape.
  • Figure 7 shows critical areas in the exhaust manifold and turbo manifold in which this cracking is likely to occur. The existence of these cracks prevent the exhaust and/or turbo manifolds from keeping heat inside the manifold, which prevents the regeneration process from adequately removing accumulated soot.
  • TBCs Thermal barrier coatings
  • components such as combustors, high-pressure turbine blades, vanes, shrouds, and the like.
  • TBCs are applied to components to increase the operating temperature of hot gas path components which can result in higher energy output and improved engine efficiencies.
  • TBCs provide thermal insulation that enables TBC coated components to survive at higher operating temperatures, to increase component durability and to improve engine reliability.
  • TBCs when TBCs are applied to manifolds, the following advantages have been attained: SUMMARY
  • Embodiments are directed to molding products using sand cores.
  • the molded products can be parts specially designed to retain high heat, e.g., in an engine, but which avoid the formation of cracks.
  • a transplanted thermal barrier coating (TBC) system is applied to a sand core prior to the casting or molding process.
  • the TBC system can include a ceramic layer as a top coat applied on the sand core and a metallic layer as a bond coat applied on the top coat.
  • the TBC system can also include an abradable layer as an adhesion coat applied on the sand core and the top coat is then applied on the adhesion layer.
  • the TBC can be applied to the sand core using a thermal spraying process.
  • the same thermal spray process is used for each component of the TBC system.
  • Embodiments are directed to a method for forming a molded part that includes applying a thermal barrier coating (TBC) system to a sand core; inserting the TBC coated sand core into a mold; and forming a cast iron part in the mold with the inserted TBC coated sand core.
  • TBC thermal barrier coating
  • the TBC system may include a ceramic layer and a metallic layer.
  • the method can further include applying the ceramic layer over the sand core with an air plasma spray thermal spray process; and applying the metallic layer onto the ceramic layer with the air plasma spray thermal spray process.
  • the ceramic layer can include yttria stabilized zirconia and the metallic layer can comprise a low-alloyed carbon steel that forms a bond coat for the cast iron.
  • the method further may also include preheating the sand core with the air plasma spray thermal spray process.
  • the TBC system can further include an adhesion layer.
  • the method can also include applying the adhesion layer onto the sand core with an air plasma spray thermal spray process, wherein the ceramic layer is applied onto the adhesion layer.
  • the adhesion layer can include NiC (Nickel Graphite) or mixtures of metal and polymer, such as metal-based polymer composites, in particular an Al based polymer, preferably at least one of a MCrAlY based polymer (wherein M for example equals Co, Ni or Co/Ni), a NiCrAl based polymer, a NiAl based polymer, an Al -bronze based polymer or an Al Si polyester.
  • the polymer in the adhesion layer includes a thermoplastic polymer such as Polytetrafluoroethylene (PFTE).
  • the sand core can include one of silica sand, chromite sand, or zircon sand; bentonite; water; and inert sludge.
  • the sand core can also include anthracite.
  • the one of silica sand, chromite sand or zircon sand may further include olivine, staurolite, or graphite.
  • Embodiments are directed to a molded part that includes a cast iron body; and a TBC system integrally molded with an interior surface of the cast iron body.
  • the TBC system is applied according to the method for forming the molded part.
  • the TBC system comprises a ceramic layer and a metallic layer.
  • the ceramic layer can include yttria stabilized zirconia and the metallic layer can comprise a low-alloyed carbon steel.
  • the TBC system may further include an adhesion layer, and the adhesion layer can comprise NiC (Nickel Graphite) or mixtures of metal and polymer, such as metal-based polymer composites, preferably an Al based polymer, more preferably at least one of a MCrAlY based polymer (wherein M for example equals Co, Ni or Co/Ni), a NiCrAl based polymer, a NiAl based polymer, an Al- bronze based polymer or an Al Si polyester.
  • NiC Nickel Graphite
  • M MCrAlY based polymer
  • FIG. 1 shows a sand core for an exemplary embodiment
  • FIGs 2A - 2F illustrate a process by which a transplanted TBC system is applied to the sand core
  • Figs 3 A - 3E illustrate an alternative to the process depicted in Figs. 2A - 2F to by which a transplanted TBC system is applied to the sand core without a bond coat
  • FIGs 4A - 4G illustrate another process by which a transplanted TBC system is applied to the sand core
  • FIGs 5 A - 5F illustrate an alternative to the process depicted in Figs. 4A - 4G to by which a transplanted TBC system is applied to the sand core without a bond coat;
  • FIG. 6 shows a cross-section of the sand core with transplanted TBC system in a mold
  • Fig. 7 shows critical areas for cracks in known engine manifolds.
  • Cores are used for producing interior surfaces of a component, in particular a component with complex shapes, in a die casting and/or injection molding process.
  • Figure 1 shows an exemplary core 10 for an engine manifold, but it is understood that cores can be used for any number of casting and/or molding processes forming components for gasoline or diesel engines such as turbocharger parts and components, e.g., for automobiles, sport-utility vehicles, light-weight and heavy-duty trucks, farming equipment, marine vehicles, commercial and non-commercial vehicles, etc.
  • core 10 is made of a sand composition, in which the sand composition is a mixture of: 75 - 85 wt.
  • silica sand SiO2
  • chromite sand FeCr2O4
  • zircon sand ZrSiO4
  • the silica sand, chromite sand or zircon sand can include a proportion of olivine, staurolite, or graphite and/or the composition can include up to Iwt. % (> 0 - 1 wt. %) anthracite.
  • Casted and/or molded parts e.g., those parts utilized in an engine, can be exposed to heat extremes, e.g., about 760 °C, which can result in thermo-mechanical fatigue, e.g., cracking, in the part, which can allow gases and heat to escape.
  • heat extremes e.g., about 760 °C
  • thermo-mechanical fatigue e.g., cracking
  • components that are designed to keep or retain heat e.g., manifolds
  • it is desired that component is formed so that heat transfer through the component housing or walls is avoid to the greatest extent possible.
  • TBC thermal barrier coating
  • the TBC system can include plural layers or coatings formed by thermal spraying, e.g., plasma spraying, high velocity oxygen fuel (HVOF) spraying, or other suitable spraying processes, for depositing powder products to form at least a ceramic layer and a metallic layer.
  • thermal spraying e.g., plasma spraying, high velocity oxygen fuel (HVOF) spraying, or other suitable spraying processes, for depositing powder products to form at least a ceramic layer and a metallic layer.
  • FIGs 2A - 2F show an exemplary process for forming a transported TBC on a casted and/or molded part.
  • a sand core 20 such as the core shown in Fig. 1
  • a TBC 21 (or ceramic layer) is applied to sand core 20 via a thermal spraying process.
  • TBC 21 Prior to applying TBC 21, it can be advantageous to preheat sand core 20, particularly a sand core comprising bentonite, to avoid evaporation of water or binding chemicals in the sand during the TBC application, which can disadvantageously lead to poor adhesion, cracking and spallation.
  • the preheating of core 20 can be achieved with a plasma torch or plum without feeding powder, e.g., by air plasma spraying from a cascaded plasma torch such as the SINPLEXPRO-90 from OERLIKON METCO (US) INC.
  • a plasma torch or plum without feeding powder e.g., by air plasma spraying from a cascaded plasma torch such as the SINPLEXPRO-90 from OERLIKON METCO (US) INC.
  • Thermal barrier coating 21 functions to protect part to be produced from thermomechanical fatigue (cracking) and to keep heat inside the part.
  • the applied TBC 21 increases the heat management efficiency for fuel consumption reduction.
  • TBC 21 has a porosity lower than 15-25% to avoid penetration of liquid metal during the casting process, e.g., as discussed below with reference to Fig. 2E, which can result in the unintended creation of deposits inside the casted parts after solidification (scabbing effect).
  • the TBC 21 can be applied as a dual layer system with a porous TBC layer applied to sand core 20 and a non-porous (dense) TBC layer applied to the porous TBC layer, in particular the porous TBC layer having a porosity of 15-25% and the non-porous TBC layer having a porosity of 1% to lower than 15%, more preferably 5% to 10% in order to avoid penetration of liquid metal during the casting process.
  • the TBC 21 can be applied as a gradient layer with a porosity decreasing from the sand core 20 to avoid penetration of liquid metal during the casting process.
  • the coating parameters can be adjusted, i.e.
  • TBC 21 is formed by the thermal spraying of powder products, e.g., yttria stabilized zirconia (YSZ), such as METCO 204NS powders by OERLIKON METCO (US) INC., onto sand core 20 with a thickness between 100 and 1000 microns, preferably 200 - 800, and more preferably between 400 - 500 microns.
  • powder products e.g., yttria stabilized zirconia (YSZ), such as METCO 204NS powders by OERLIKON METCO (US) INC.
  • bond coat 22 ensures adhesion of TBC 21 to the casted part in Fig. 2E.
  • bond coat 22 can be a low-alloyed carbon steel applied to TBC 21 by thermal spraying of powder products, e.g., FeCrMnC (Fe 1.4-1.6Cr 1.4-1.6Mn 1.0-1.3C), such as METCO XPT 512 powder from OERLIKON METCO (US) INC.
  • CoCrAlY Co 29Cr 6A1 2Si 0.3 Y
  • AMDRY 920 CoCrAlY powder from OERLIKON METCO (US) INC.
  • a thicker bond coat 22 can be applied, having a thickness of up to 500 microns, preferably a thickness between about 100 and 500 microns, more preferably between about 100 and 350 microns.
  • bond coat 22 is applied in the same manner as used in applying TBC 21, i.e., air plasma spraying from a cascaded plasma torch such as the SINPLEXPRO-90 from OERLIKON METCO (US) INC.
  • Coated sand core 20 is then inserted into a mold 24, e.g., a sand mold, as shown in Fig. 2D, so that an opening 23 is formed within mold 24 to receive a casting material.
  • a casting material 25 suitable for the part to be cast e.g., gray cast iron, such as ferritic cast iron SiMo51, austenitic cast iron D5S and austenitic cast stainless steel HK30, is deposited into opening 23 to cast the part.
  • the transplanted TBC coated casted part is removed from sand mold 24 and sand core 20 is likewise removed.
  • the process can be performed without Fig 2C, i.e., without applying a bond coat after TBC 21.
  • this alternative embodiment which is illustrated in Figs, 3 A - 3E, after the application of TBC 31 in Fig. 3B, the coated sand core 30 is inserted to the mold 34 in Fig. 3C and casting material 35 is deposited into opening 33 of mold 34 in Fig. 3D.
  • the transplanted TBC coated casting part is removed from mold 34 and sand core 30 is likewise removed in Fig. 3E.
  • the TBC and bond coat layers should be applied to all parts of the sand mold that will form inner surfaces of the part so that the liquid cast iron does not directly contact the sand mold.
  • spraying of functional areas of the sand mold e.g., areas for positioning the core in the mold or assembling the mold, should be avoided.
  • FIGS 4A - 4G show another exemplary process for forming a transported TBC on a casted and/or molded part.
  • a sand core 40 such as the core shown in Fig. 1
  • the TBC system additionally includes an adhesion (adhesive) layer 46 or abradable layer that is applied to sand core 40 via a thermal spraying process, e.g., air plasma spraying from a cascaded plasma torch such as the SINPLEXPRO-90 from OERLIKON METCO (US) INC.
  • a thermal spraying process e.g., air plasma spraying from a cascaded plasma torch such as the SINPLEXPRO-90 from OERLIKON METCO (US) INC.
  • Adhesion layer 46 which can be an aluminum silicate abradable layer that includes various polymers (Al SiPoly ester), is applied to sand core 40 by thermal spraying of powder products, e.g., METCO 1606, METCO 601, AMDRY 2010, AMDRY XPT 268, or AMDRY 2000, all from OERLIKON METCO (US) INC., to a thickness between 20 and 500 microns, preferably between about 100 to 400 microns, and more preferably between about 200 and 350 microns.
  • Applying adhesion layer 36 on sand core 40 ensures easy deposition as a first layer, as it has good affinity to sand core 46 and less sensitivity to heat effect.
  • preheating of sand core 40 is not required before applying adhesive layer 40 or subsequent layers.
  • a TBC 41 or ceramic layer is applied to adhesion layer 46 via a thermal spraying process, and preferably the same thermal spraying process utilized in applying adhesion layer 46, i.e., air plasma spraying from a cascaded plasma torch such as the SINPLEXPRO-90 from OERLIKON METCO (US) INC.
  • TBC 41 functions to protect the part to be produced from thermo-mechanical fatigue (cracking) and to keep heat inside the part.
  • TBC 41 preferably has a porosity lower than 15-25% to avoid penetration of liquid metal during the casting process, e.g., as discussed below with reference to Fig.
  • the TBC 41 can be deposited as the dual layer system or the gradient layer (with the porous TBC layer or TBC layer with the higher porosity applied to the adhesion layer 46).
  • TBC 41 is formed by applying the thermal spraying of powder products, e.g., yttria stabilized zirconia (YSZ), such as METCOTM 204NS powders by OERLIKON METCO (US) INC., onto sand core 40 with a thickness between 100 and 1000 microns, preferably 200 - 800, and more preferably between 400 - 500 microns.
  • YSZ yttria stabilized zirconia
  • US OERLIKON METCO
  • bond coat 42 ensures adhesion of TBC 41 to the casted part in Fig. 4F.
  • bond coat 42 can be a low-alloyed carbon steel applied to TBC 41 by thermally spraying, e.g., FeCrMnC (Fe 1.4-1.6Cr 1.4-1.6Mn 1.0-1.3C), such as METCO XPT 512 powder from OERLIKON METCO (US) INC. or CoCrAlY (Co 29Cr 6A1 2Si 0.3 Y), such as AMDRY 920) powder from OERLIKON METCO (US) INC. and can be applied up 100 microns, and preferably up to 50 microns, and more preferably between about 15 and 30 microns.
  • FeCrMnC Fe 1.4-1.6Cr 1.4-1.6Mn 1.0-1.3C
  • METCO XPT 512 powder from OERLIKON METCO (US) INC.
  • CoCrAlY Co 29Cr 6A1 2
  • bond coat 42 is preferably applied in the same manner as used in applying TBC 41, i.e., air plasma spraying from a cascaded plasma torch such as the SINPLEXPRO-90 from OERLIKON METCO (US) INC.
  • Coated sand core 40 is then inserted into a mold 43, e.g., a sand mold, as shown in Fig. 4E, so that an opening 44 is formed within mold 43 to receive a casting material.
  • a casting material 45 suitable for the part to be cast e.g., gray cast iron, such as ferritic cast iron SiMo51, austenitic cast iron D5S and austenitic cast stainless steel HK30 is deposited into opening 44 to cast the part.
  • gray cast iron such as ferritic cast iron SiMo51, austenitic cast iron D5S and austenitic cast stainless steel HK30 is deposited into opening 44 to cast the part.
  • the transplanted TBC coated casted part is removed from sand mold 44 and sand core 40 is likewise removed.
  • adhesion layer 46 functions to ensure integrity of TBC 41 during mechanical removal of the sand core 40 after the casting process by enhancing the breaking zone between sand core 40 and adhesion layer 46. Without adhesion layer 46, the risk of TBC 41 breaking is high.
  • the process can be performed without Fig. 4D, i.e., without applying a bond coat after TBC 41.
  • the coated sand core 50 is inserted to the mold 54 and casting material 55 is deposited into opening 53 of mold 54.
  • the transplanted TBC coated casting part is removed from mold 54 and sand core 50 is likewise removed.
  • the adhesion layer, TBC and bond coat layers should be applied to all parts of the sand mold that will form inner surfaces of the part so that the liquid cast iron does not directly contact the sand mold.
  • spraying of functional areas of the sand mold e.g., areas for positioning the core in the mold or assembling the mold, should be avoided.
  • pre-processing like grit blasting
  • core 20 provides a rough surface for coating
  • parts for coating are used in as-sprayed conditions, i.e., after processing, such as machining, is not necessary.
  • Figure 6 shows a cross-section of the part still in the mold.
  • adhesion coat 66 (abradable-based material layer) having a thickness between 264 and 300 microns is applied onto sand core 60
  • TBC 61 top coat - ceramic layer
  • bond coat 62 (metallic layer) having a thickness between 19 and 23 microns is applied onto TBC 61.
  • Casting material 65 is shown cast onto bond coat 62.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Plasma & Fusion (AREA)
  • Physics & Mathematics (AREA)
  • Inorganic Chemistry (AREA)
  • Ceramic Engineering (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Mold Materials And Core Materials (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Casting Devices For Molds (AREA)

Abstract

L'invention concerne un procédé de formation d'une pièce moulée et la pièce moulée Le procédé comprend l'application d'un système de revêtement de barrière thermique (TBC) à un noyau de sable ; l'insertion du noyau de sable revêtu du revêtement TBC dans un moule ; et la formation d'une pièce de fonte dans le moule avec le noyau de sable revêtu du revêtement TBC inséré.
EP22702901.4A 2021-01-22 2022-01-21 Système de revêtement de barrière thermique transplanté Pending EP4281595A1 (fr)

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US202163140341P 2021-01-22 2021-01-22
PCT/EP2022/051388 WO2022157331A1 (fr) 2021-01-22 2022-01-21 Système de revêtement de barrière thermique transplanté

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EP (1) EP4281595A1 (fr)
JP (1) JP2024505622A (fr)
KR (1) KR20230132480A (fr)
CN (1) CN116848284A (fr)
MX (1) MX2023008491A (fr)
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WO2024077551A1 (fr) * 2022-10-13 2024-04-18 Wuxi Cummins Turbo Technologies Company Ltd. Procédé et appareil de coulée

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US3802482A (en) * 1972-03-09 1974-04-09 United Aircraft Corp Process for making directionally solidified castings
US6702886B2 (en) * 2001-11-20 2004-03-09 Alcoa Inc. Mold coating
US7055574B2 (en) * 2004-07-27 2006-06-06 Honeywell International Inc. Method of producing metal article having internal passage coated with a ceramic coating
DE102016123051A1 (de) * 2016-11-29 2018-05-30 HÜTTENES-ALBERTUS Chemische Werke Gesellschaft mit beschränkter Haftung Aminosäure enthaltende Formstoffmischung zur Herstellung von Formkörpern für die Gießereiindustrie
US20200164431A1 (en) * 2018-11-28 2020-05-28 GM Global Technology Operations LLC Methods for manufacturing cast components with integral thermal barrier coatings

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JP2024505622A (ja) 2024-02-07
US20240066589A1 (en) 2024-02-29
KR20230132480A (ko) 2023-09-15
MX2023008491A (es) 2023-07-26
CN116848284A (zh) 2023-10-03

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