EP4461847A1 - Dvc-coating with fully and partially stabilized zirconia - Google Patents

Dvc-coating with fully and partially stabilized zirconia Download PDF

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Publication number
EP4461847A1
EP4461847A1 EP24188396.6A EP24188396A EP4461847A1 EP 4461847 A1 EP4461847 A1 EP 4461847A1 EP 24188396 A EP24188396 A EP 24188396A EP 4461847 A1 EP4461847 A1 EP 4461847A1
Authority
EP
European Patent Office
Prior art keywords
stabilized zirconia
layer
coating
dvc
partially stabilized
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
EP24188396.6A
Other languages
German (de)
French (fr)
Inventor
Arturo Flores Renteria
Neil Hitchman
Werner Stamm
Dimitrios Zois
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.)
Siemens Energy Global GmbH and Co KG
Original Assignee
Siemens Energy Global GmbH and Co KG
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 Siemens Energy Global GmbH and Co KG filed Critical Siemens Energy Global GmbH and Co KG
Publication of EP4461847A1 publication Critical patent/EP4461847A1/en
Pending legal-status Critical Current

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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
    • 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
    • C23C28/32—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
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/288—Protective coatings for blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/284—Selection of ceramic materials
    • 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
    • F05D2250/00—Geometry
    • F05D2250/20—Three-dimensional
    • F05D2250/29—Three-dimensional machined; miscellaneous
    • F05D2250/294—Three-dimensional machined; miscellaneous grooved
    • 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 invention relates to a ceramic layer-system with partially and fully stabilized zirconia which has also a dense vertical cracked microstructure (DVC).
  • DVC dense vertical cracked microstructure
  • TBC Thermal Barrier Coatings
  • the task of the invention is therefore to solve the problems given above.
  • DVC Dense Vertical Cracked
  • the system consists of partially stabilized zirconia, especially 8YSZ as the high fracture toughness lower layer to accommodate the CTE mismatch with bond coat and TGO and a lower toughness upper layer of fully stabilized zirconia, especially 48YSZ to provide the high temperature capability.
  • partially stabilized zirconia especially 8YSZ as the high fracture toughness lower layer to accommodate the CTE mismatch with bond coat and TGO
  • a lower toughness upper layer of fully stabilized zirconia especially 48YSZ to provide the high temperature capability.
  • the similar chemistry between the two coatings enhances their bonding.
  • DVC PSZ Appropriate preheating of the DVC PSZ will prepare its surface to receive the fully molten particles of FSZ and due to the high local temperatures during spraying allow diffusion between the two similar materials. Ideally a number of the vertical cracks will progress from one coating to the other demonstrating the continuity between the two coatings. In this manner the interface which has shown to be the weakest link in other bi-layer systems will be reinforced.
  • the figure shows a layer system 1.
  • the layer system 1 comprises a substrate 4 which is preferably metallic and very preferably made of a nickel or cobalt based super alloy.
  • a bond coat especially a metallic bond coat 7 and very especially a NiCoCrAlY-based bond coat 7 is applied on.
  • TGO thermally grown oxide
  • first zirconia layer 10 made of a Yttria partially stabilized zirconia.
  • the thickness of the partially stabilized zirconia layer 10 is preferable between 75um - 800um.
  • the porosity of the partially stabilized zirconia 10 is preferably lower than 5% and very preferably lower than 3%.
  • a fully stabilized zirconia layer 13 which is especially the outer most layer of the layer system 1.
  • the porosity of the fully stabilized zirconia 13 is lower than 5% and preferably lower than 3%.
  • the thickness of the fully stabilized zirconia 13 is between 50um - 800um.
  • the stabilization in this zirconia based system can be reached by yttria or by any other rare earth element as known by the state of the art or by a combination of that.
  • yttrium is used for stabilization.

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

Abstract

A dense vertical cracked microstructure in a ceramic layer system made of an underline partially stabilized zirconia layer and an above laying fully stabilized zirconia layer show good erosion resistance and long life time.

Description

  • The invention relates to a ceramic layer-system with partially and fully stabilized zirconia which has also a dense vertical cracked microstructure (DVC).
  • Field feedback has shown that the current Thermal Barrier Coatings (TBC) of turbines suffer from issues related to:
    1. 1) Erosion: turbine blades with high porosity coatings containing a large number of unmolten or semimolten particles show low erosion resistance.
      The development during the last years has pushed thermal spray coatings porosity upwards. However, that has caused the shrinkage of the spray ability window that allows coatings to receive high porosity and good cohesion. As a result, erosion has started manifesting itself as a major issue for coatings in specific parts and engines.
    2. 2) Drilling damage: High porosity coatings contain less intimate contacts between splats or splat and substrate and thus the required energy for a crack to propagate is relatively low.
      This problem has been addressed by drilling before the coating deposition and reopening of the holes after coating deposition. This approach minimizes the interaction between coating and laser and that reduces significantly the coating delamination around the drilled holes. However, since each part has to be processed twice, this solution is associated with longer drilling times that are reflected as increased cost.
    3. 3) Coating life: Thermal Spray porous coatings do not demonstrate at the same level the high strain tolerance along the coating thickness which can be seen in other coating types such as EB-PVD.
      The thermal barrier coatings porosity has been increased to improve strain tolerance. However as mentioned above, that can reduce the spray ability process window and influence negatively the cohesion and erosion resistance of the coatings.
    4. 4) YSZ for TBC chemistries are currently limited to 1528K maximum temperature due to phase transformation issues.
      New chemistries have been adopted that present phase stability in higher temperatures. However they show significantly lower fracture toughness compared to the partially stabilized zirconia and it is certain that their erosion resistance will be even less.
  • The task of the invention is therefore to solve the problems given above.
  • The problem is solved by a ceramic layer system according to claim 1.
  • In the subclaims further advantages are given which can be abitrality combined with each other to yield additional advantages.
  • The figure and the description show only examples of the invention.
  • The problems named under point 1 are addressed by adopting Dense Vertical Cracked (DVC) coatings.
    1. 1) Erosion. DVC thermal barrier coatings have shown significantly lower rates compared to their porous counterparts. That means for the same chemistry a porous coating will show more than 3x the erosion rate compared to the DVC one.
    2. 2) DVC coatings have increased cohesion and adhesion compared to the typical porous coatings. The reason is that a very high ratio of fully molten particles deposit on hot substrate or hot previously deposited splats which promotes a good intimate bonding to develop between them. Improved adhesion requires high energy for a horizontal crack to propagate so that guarantees a lower delamination.
    3. 3) Coating life. Due to the intimate contact between splats, the DVC coatings show high fracture toughness along the parallel to the substrate plane. That, combined with their ability to accommodate thermal strain along the coating thickness due to their columnar microstructure ensures a high TBC life.
    4. 4) DVC microstructures can be adopted on the new coating chemistries. That will create a bilayer DVC with partially stabilized zirconia as a lower layer and fully stabilized zirconia as the upper layer. The lower layer will accommodate CTE mismatch with the bond coat and the TGO while the upper layer will provide the higher temperature capability.
  • The system consists of partially stabilized zirconia, especially 8YSZ as the high fracture toughness lower layer to accommodate the CTE mismatch with bond coat and TGO and a lower toughness upper layer of fully stabilized zirconia, especially 48YSZ to provide the high temperature capability. Unlike other possible bilayer coating approaches, the similar chemistry between the two coatings enhances their bonding.
  • Appropriate preheating of the DVC PSZ will prepare its surface to receive the fully molten particles of FSZ and due to the high local temperatures during spraying allow diffusion between the two similar materials. Ideally a number of the vertical cracks will progress from one coating to the other demonstrating the continuity between the two coatings. In this manner the interface which has shown to be the weakest link in other bi-layer systems will be reinforced.
  • The advantages that arise are:
    1. 1) The low fracture toughness of the FSZ with the adoption of a DVC microstructure will significantly increase. That will improve the erosion resistance of the coating.
    2. 2) A good bonding between the two layers and as well with the bond coat will increase the drilling damage tolerance. Less delamination will be observed compared to other bilayer coating systems which have suffered in the past from drilling.
    3. 3) The columnar microstructure along the bilayer coating thickness will allow improved strain tolerance, thus increased coating life.
    4. 4) Higher temperature capability compared to single layer DVC coatings.
  • The figure shows a layer system 1.
  • The layer system 1 comprises a substrate 4 which is preferably metallic and very preferably made of a nickel or cobalt based super alloy.
  • On the substrate 4 a bond coat especially a metallic bond coat 7 and very especially a NiCoCrAlY-based bond coat 7 is applied on.
  • On this bond coat 7 there is a thermally grown oxide (TGO, not shown) layer which is formed during further application of the ceramic layers or by an additional oxidation step or at least during use of the layer system 1.
  • On the bond coat 7 there is applied a first zirconia layer 10 made of a Yttria partially stabilized zirconia.
  • The thickness of the partially stabilized zirconia layer 10 is preferable between 75um - 800um.
  • The porosity of the partially stabilized zirconia 10 is preferably lower than 5% and very preferably lower than 3%.
  • As an outer ceramic layer there is applied a fully stabilized zirconia layer 13, which is especially the outer most layer of the layer system 1.
  • The porosity of the fully stabilized zirconia 13 is lower than 5% and preferably lower than 3%.
  • The thickness of the fully stabilized zirconia 13 is between 50um - 800um.
  • The same parameters for thickness and porosity are also valid for the pyrochlore layer or pyrochlore/FSZ layer.
  • The stabilization in this zirconia based system can be reached by yttria or by any other rare earth element as known by the state of the art or by a combination of that.
  • Preferably yttrium is used for stabilization.
  • In this layers 10, 13 there are cracks 16 present, which 19 are mostly present in the outer most layer 13 and preferably some of them 21 are present in both layers 10, 13.

Claims (5)

  1. Ceramic layer system,
    at least comprising:
    a metallic substrate (4),
    a metallic bond coat (7) on the substrate (4),
    an inner partially stabilized zirconia layer (10) and
    on it (10) a fully stabilized zirconia layer (13),
    wherein vertical cracks (16, 19, 21) are present,
    wherein cracks (19) are mostly present in the outer most layer 13,
    wherein the cracks (21) are present in both ceramic layers (10, 13),
    wherein the porosity of the fully stabilized zirconia layer (13) is lower than 50,
    which is dense vertically cracked,
    wherein the porosity of the partially stabilized zirconia layer is lower than 50,
    which is dense vertically cracked.
  2. Ceramic layer system according to any of the preceding claims,
    wherein the thickness of the partially stabilized zirconia layer (10) is between 75um - 800um.
  3. Ceramic layer system according to any of the preceding claims,
    wherein the thickness of the fully stabilized zirconia layer (13) is between 50um - 800um.
  4. Ceramic layer system according to any of the preceding claims,
    wherein the zirconia or the zirconia layers (10, 13) are stabilized by yttria.
  5. Ceramic layer system according to any of the preceding claims,
    wherein the partially stabilized zirconia is stabilized by yttria.
EP24188396.6A 2015-06-19 2016-05-03 Dvc-coating with fully and partially stabilized zirconia Pending EP4461847A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
EP15172884.7A EP3106541A1 (en) 2015-06-19 2015-06-19 Dvc-coating with fully and partially stabilized zirconia
PCT/EP2016/059828 WO2016202495A1 (en) 2015-06-19 2016-05-03 Dvc-coating with fully and partially stabilized zirconia
EP16722589.5A EP3283667A1 (en) 2015-06-19 2016-05-03 Dvc-coating with fully and partially stabilized zirconia

Related Parent Applications (1)

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EP16722589.5A Division EP3283667A1 (en) 2015-06-19 2016-05-03 Dvc-coating with fully and partially stabilized zirconia

Publications (1)

Publication Number Publication Date
EP4461847A1 true EP4461847A1 (en) 2024-11-13

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EP15172884.7A Withdrawn EP3106541A1 (en) 2015-06-19 2015-06-19 Dvc-coating with fully and partially stabilized zirconia
EP24188396.6A Pending EP4461847A1 (en) 2015-06-19 2016-05-03 Dvc-coating with fully and partially stabilized zirconia
EP16722589.5A Ceased EP3283667A1 (en) 2015-06-19 2016-05-03 Dvc-coating with fully and partially stabilized zirconia

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EP15172884.7A Withdrawn EP3106541A1 (en) 2015-06-19 2015-06-19 Dvc-coating with fully and partially stabilized zirconia

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EP16722589.5A Ceased EP3283667A1 (en) 2015-06-19 2016-05-03 Dvc-coating with fully and partially stabilized zirconia

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US (1) US20180179645A1 (en)
EP (3) EP3106541A1 (en)
WO (1) WO2016202495A1 (en)

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102017206063A1 (en) * 2017-04-10 2018-10-11 Siemens Aktiengesellschaft Partially and fully stabilized zirconium oxide powder as a ceramic layer
US10550462B1 (en) * 2017-09-08 2020-02-04 United Technologies Corporation Coating with dense columns separated by gaps
WO2020131929A1 (en) * 2018-12-18 2020-06-25 Oerlikon Metco (Us) Inc. Coating for protecting ebc and cmc layers and thermal spray coating method thereof
EP3712379A1 (en) 2019-03-22 2020-09-23 Siemens Aktiengesellschaft Fully stabilized zirconia in a seal system
WO2021067979A1 (en) * 2019-10-04 2021-04-08 Siemens Aktiengesellschaft Composite layer system having an additively manufactured substrate and a thermal protection system
US12227464B2 (en) * 2021-05-18 2025-02-18 Rolls-Royce Corporation CMAS-resistant environmental barrier coating system

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US20050170200A1 (en) * 2004-02-03 2005-08-04 General Electric Company Thermal barrier coating system
EP1674663A2 (en) * 2004-12-14 2006-06-28 Mitsubishi Heavy Industries, Ltd. Thermal barrier coating material, thermal barrier member, and member coated with thermal barrier and method for manufacturing the same
EP1908856A2 (en) * 2006-10-05 2008-04-09 United Technologies Corporation Segmented abradable coatings and process(es) for applying the same

Patent Citations (3)

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Publication number Priority date Publication date Assignee Title
US20050170200A1 (en) * 2004-02-03 2005-08-04 General Electric Company Thermal barrier coating system
EP1674663A2 (en) * 2004-12-14 2006-06-28 Mitsubishi Heavy Industries, Ltd. Thermal barrier coating material, thermal barrier member, and member coated with thermal barrier and method for manufacturing the same
EP1908856A2 (en) * 2006-10-05 2008-04-09 United Technologies Corporation Segmented abradable coatings and process(es) for applying the same

Non-Patent Citations (2)

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Title
CANAN U. HARDWICKE ET AL: "Advances in Thermal Spray Coatings for Gas Turbines and Energy Generation: A Review", JOURNAL OF THERMAL SPRAY TECHNOLOGY., vol. 22, no. 5, 28 February 2013 (2013-02-28), US, pages 564 - 576, XP055221532, ISSN: 1059-9630, DOI: 10.1007/s11666-013-9904-0 *
KARGER M ET AL: "Atmospheric plasma sprayed thermal barrier coatings with high segmentation crack densities: Spraying process, microstructure and thermal cycling behavior", SURFACE AND COATINGS TECHNOLOGY, ELSEVIER, NL, vol. 206, no. 1, 18 June 2011 (2011-06-18), pages 16 - 23, XP028261462, ISSN: 0257-8972, [retrieved on 20110625], DOI: 10.1016/J.SURFCOAT.2011.06.032 *

Also Published As

Publication number Publication date
EP3283667A1 (en) 2018-02-21
WO2016202495A1 (en) 2016-12-22
EP3106541A1 (en) 2016-12-21
US20180179645A1 (en) 2018-06-28

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