JP2002361166A - Method for forming heat insulating layer having artificial defect - Google Patents
Method for forming heat insulating layer having artificial defectInfo
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- JP2002361166A JP2002361166A JP2001177410A JP2001177410A JP2002361166A JP 2002361166 A JP2002361166 A JP 2002361166A JP 2001177410 A JP2001177410 A JP 2001177410A JP 2001177410 A JP2001177410 A JP 2001177410A JP 2002361166 A JP2002361166 A JP 2002361166A
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- Japan
- Prior art keywords
- forming
- artificial defect
- layer
- top coat
- coat layer
- Prior art date
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Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は人工欠陥を有した遮
熱層の形成方法に関し、詳しくは産業用ガスタービン、
ジェットエンジンなどの高温部品である動翼等に形成さ
れる遮熱層の欠陥検出限界を求めるのに適用されるもの
である。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for forming a heat shield layer having artificial defects, and more particularly, to an industrial gas turbine,
The present invention is applied to obtain a defect detection limit of a heat shield layer formed on a rotor blade or the like which is a high-temperature component such as a jet engine.
【０００２】[0002]
【従来の技術】周知の如く、ガスタービン等に使用され
る動翼（タービン翼）としては、図２に示す構成のもの
が知られている。ところで、こうしたタービン翼は高温
で長時間使用されるため、その表面には遮熱コーティン
グ（ＴＢＣ）が施されている。ここで、ＴＢＣのトップ
コート層にはセラミックが使用されているが、その耐久
性、信頼性及び健全性の評価が重要である。2. Description of the Related Art As is well known, a blade shown in FIG. 2 is known as a moving blade (turbine blade) used in a gas turbine or the like. By the way, since these turbine blades are used for a long time at a high temperature, their surfaces are provided with a thermal barrier coating (TBC). Here, ceramic is used for the top coat layer of the TBC, but evaluation of its durability, reliability, and soundness is important.
【０００３】ところで、ＴＢＣでは、一般にアンダーコ
ート層に近いトップコート層内で剥離が生じることが知
られている。現在、ＴＢＣの剥離検出には、赤外線サー
モグラフィー法が検討されているが、このＴＢＣのトッ
プコート層の剥離に関して、欠陥を人工的に製作するこ
とは難しく、トップコート層の欠陥検出限界を求めるこ
とができなかった。[0003] In TBC, it is generally known that peeling occurs in a top coat layer close to an undercoat layer. At present, an infrared thermography method is being studied for detecting the peeling of the TBC. However, it is difficult to artificially produce a defect regarding the peeling of the top coat layer of the TBC, and it is necessary to find a defect detection limit of the top coat layer. Could not.
【０００４】図３は、図２に示すタービン翼１の剥離部
Ｘの断面図を示す。図３に示すように、トップコート層
２は、母材３上にアンダーコート層４を介して形成され
ている。前記剥離部１は、初期には全く発生しないが、
長時間運転するにつれてアンダーコート層２に近いトッ
プコート層２内にき裂５が生じ、これに起因して剥離へ
と進む。図５は、母材３、アンダーコート層４及びトッ
プコート層２の初期状態の断面を顕微鏡（×１００倍）
で撮影した金属組織の写真を示す。FIG. 3 is a sectional view of a separated portion X of the turbine blade 1 shown in FIG. As shown in FIG. 3, the top coat layer 2 is formed on the base material 3 via the undercoat layer 4. The peeling portion 1 does not occur at all in the initial stage,
As the operation is performed for a long time, cracks 5 are formed in the top coat layer 2 close to the undercoat layer 2, and due to this, the process proceeds to peeling. FIG. 5 shows a cross section of the initial state of the base material 3, the undercoat layer 4, and the top coat layer 2 under a microscope (× 100).
2 shows a photograph of the metal structure taken in Step 2.
【０００５】また、図６は、母材３、アンダーコート層
４及びトップコート層２の剥離直前の断面を顕微鏡（×
１００倍）で撮影した金属組織の写真を示す。図４及び
図５より、初期では発生しない剥離が、タービン翼の長
時間運転につれて発生することが確認された。FIG. 6 shows a cross section of the base material 3, the undercoat layer 4 and the top coat layer 2 immediately before peeling off by a microscope (×
10 shows a photograph of the metal structure taken at 100 ×). 4 and 5, it has been confirmed that the separation that does not occur in the initial stage occurs as the turbine blades operate for a long time.
【０００６】[0006]
【発明が解決しようとする課題】本発明は上記事情を考
慮してなされたもので、母材上にアンダーコート層、薄
いトップコート層を順次形成し、人工欠陥形成予定部を
除く前記トップコート層上にマスク材を形成し、マスク
材から露出する前記トップコート層上に人工欠陥形成部
材を形成し、マスク材を除去した後全面に厚い再度トッ
プコート層を形成した後、人工欠陥形成部材を消失させ
てトップコート層に人工欠陥を形成する構成とすること
により、実機の場合にきわめて近い人工欠陥を厚さや形
状を変えて製作でき、実機における欠陥検出限界を求め
ることができる人工欠陥を有した遮熱層の形成方法を提
供することを目的とする。SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and has an undercoat layer and a thin top coat layer formed sequentially on a base material, and the top coat except for a portion where an artificial defect is to be formed is formed. Forming a mask material on the layer, forming an artificial defect forming member on the top coat layer exposed from the mask material, forming a thick top coat layer again on the entire surface after removing the mask material, and then forming the artificial defect forming member. The artificial defect that can be produced by changing the thickness and shape of the artificial defect, which is very close to that of the actual device, can be obtained by changing the thickness and shape of the artificial defect. An object of the present invention is to provide a method for forming a heat shield layer having the same.
【０００７】[0007]
【課題を解決するための手段】本発明は、母材上にアン
ダーコート層を形成する工程と、このアンダーコート層
上にトップコート層を形成する工程と、人工欠陥形成予
定部を除く前記トップコート層上にマスク材を形成する
工程と、マスク材から露出する前記トップコート層上に
人工欠陥形成部材を形成する工程と、前記マスク材を除
去した後、全面に再度トップコート層を形成する工程
と、前記人工欠陥形成部材を消失させてトップコート層
に人工欠陥を形成する工程とを具備することを特徴とす
る人工欠陥を有した遮熱層の形成方法である。SUMMARY OF THE INVENTION The present invention comprises a step of forming an undercoat layer on a base material, a step of forming a top coat layer on the undercoat layer, and A step of forming a mask material on the coat layer, a step of forming an artificial defect forming member on the top coat layer exposed from the mask material, and forming the top coat layer again on the entire surface after removing the mask material A method of forming an artificial defect in the top coat layer by removing the artificial defect forming member from the artificial defect forming member.
【０００８】[0008]
【発明の実施の形態】以下、本発明について更に詳細に
説明する。本発明において、人工欠陥の形成手段として
は、 １）人工欠陥形成箇所に人工欠陥形成部材（例えばＡ
ｌ）を選択的に蒸着又は溶射により堆積し、かつトップ
コート層の形成後に水酸化ナトリウムで堆積したＡｌを
溶解することにより形成方法（実施例１参照）、 ２）人工欠陥形成箇所に人工欠陥形成部材（例えばカー
ボン）を選択的に塗布し、かつトップコート層の形成後
に大気中で前記カーボンを焼くことにより形成する方法
（実施例２参照）、 ３）人工欠陥形成箇所に人工欠陥形成部材（例えば樹
脂）を選択的に塗布又は溶射し、かつトップコート層の
形成後に大気中で前記樹脂を焼くことにより形成する方
法（実施例３参照）、が挙げられる。BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the present invention will be described in more detail. In the present invention, the means for forming an artificial defect include: 1) an artificial defect forming member (for example, A
l) is selectively deposited by vapor deposition or thermal spraying, and is formed by dissolving Al deposited with sodium hydroxide after formation of the top coat layer (see Example 1). A method of selectively applying a forming member (for example, carbon) and baking the carbon in the air after forming a top coat layer (see Example 2); 3) an artificial defect forming member at an artificial defect forming portion (For example, a resin) is selectively applied or sprayed, and the resin is formed by baking the resin in the air after the formation of the top coat layer (see Example 3).
【０００９】本発明において、トップコート層の厚みは
１０〜５０μｍであることが好ましい。これは、実機に
おけるき裂などの欠陥が一般に上記範囲で形成されるか
らである。これにより、より実機の欠陥により近い供試
体を得ることができる。In the present invention, the thickness of the top coat layer is preferably from 10 to 50 μm. This is because defects such as cracks in the actual machine are generally formed in the above range. As a result, a specimen closer to the defect of the actual machine can be obtained.
【００１０】本発明によれば、例えば図４に示すよう
に、母材１１にアンダーコート層１２を介して該アンダ
ーコート層１２近傍に空洞部（人工欠陥）１６を有した
トップコート層１３を形成された供試体を得ることがで
きる。なお、人工欠陥１６の厚さ（高さ）や形状は図示
されたものに限らず、人工欠陥形成部材の堆積状況によ
り種々の形状の人工欠陥を形成することができる。According to the present invention, for example, as shown in FIG. 4, a top coat layer 13 having a cavity (artificial defect) 16 near an undercoat layer 12 is provided on a base material 11 with an undercoat layer 12 interposed therebetween. The formed specimen can be obtained. The thickness (height) and shape of the artificial defect 16 are not limited to those shown in the figure, and artificial defects having various shapes can be formed depending on the state of deposition of the artificial defect forming member.
【００１１】[0011]
【実施例】以下、本発明の実施例に係る人工欠陥を有し
た遮熱層の形成方法について図面を参照して説明する。
なお、下記実施例で述べる各部材の材料、数値等は一例
を示すもので、本発明の権利範囲を特定するものではな
い。DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A method for forming a heat shielding layer having an artificial defect according to an embodiment of the present invention will be described below with reference to the drawings.
Note that the materials, numerical values, and the like of each member described in the following examples are merely examples, and do not specify the scope of rights of the present invention.
【００１２】（実施例１）図１（Ａ）〜（Ｄ）を参照す
る。まず、Ｎｉ系合金からなる母材１１上に、例えばＭ
ＣｒＡｌＹ（Ｎｉ又はＣｏの少なくとも一方を含む合
金）からなる極薄いアンダーコート層（厚さ約１００μ
ｍ）１２を形成した。次に、前記アンダーコート層１２
上にＺｒＯ２からなるトップコート層（厚さ約１０μｍ
程度）１３ａを形成した。つづいて、人工欠陥形成予定
部を除く前記トップコート層１３ａ上に例えば樹脂から
なるマスク材１４を形成した（図１（Ａ）参照）。次い
で、全面に人工欠陥形成部材例えばＡｌを蒸着し、Ａｌ
層１５を形成した(図１（Ｂ）)参照）。Embodiment 1 Referring to FIGS. 1A to 1D. First, for example, on a base material 11 made of a Ni-based alloy, M
An extremely thin undercoat layer (thickness of about 100 μm) made of CrAlY (an alloy containing at least one of Ni and Co)
m) was formed. Next, the undercoat layer 12
A top coat layer made of ZrO 2 (about 10 μm thick)
Degree) 13a was formed. Subsequently, a mask material 14 made of, for example, a resin was formed on the top coat layer 13a except for a portion where an artificial defect was to be formed (see FIG. 1A). Next, an artificial defect forming member such as Al is deposited on the entire surface,
The layer 15 was formed (see FIG. 1B).
【００１３】次に、前記マスク材１４を除去した後、全
面に再度厚いトップコート層（厚さ３００μｍ）１３ｂ
を形成した（図１（Ｃ）参照）。ここで、前記トップコ
ート層１３ａ，１３ｂを総称してトップコート層１３と
呼ぶ。つづいて、ＮａＯＨ中に浸漬し化学反応により前
記Ａｌ層１５を溶解して消失させ、アンダーコート層１
２との近傍のトップコート層１３に空洞部（平面形状が
円形の人工欠陥）１６を形成した（図１（Ｄ）参照）。Next, after the mask material 14 is removed, a thick top coat layer (thickness: 300 μm) 13b is formed on the entire surface again.
Was formed (see FIG. 1C). Here, the top coat layers 13a and 13b are collectively referred to as a top coat layer 13. Subsequently, the Al layer 15 was dissolved in NaOH to dissolve and disappear by a chemical reaction.
A cavity portion (artificial defect having a circular planar shape) 16 was formed in the top coat layer 13 near 2 (see FIG. 1D).
【００１４】このように実施例１では、母材１１上にア
ンダーコート層１２、約１０μｍ程度の極薄いトップコ
ート層１３ａを順次形成し、人工欠陥形成予定部を除く
前記トップコート層１３ａ上にマスク材１４を形成した
後、全面にＡｌを蒸着してＡｌ層１５を形成し、更にマ
スク材１４を除去した後、全面に再度トップコート層１
３ｂを形成してトップコート層１３とし、ＮａＯＨ中で
前記Ａｌ層１５を溶解して消失させるため、アンダーコ
ート層１２との近傍のトップコート層１３に人工欠陥１
６を形成することができる。従って、ＴＢＣの人工欠陥
を厚さや形状を変えて製作でき、欠陥検出限界を求める
ことができる。As described above, in the first embodiment, the undercoat layer 12 and the very thin top coat layer 13a of about 10 μm are sequentially formed on the base material 11, and the undercoat layer 12 is formed on the top coat layer 13a except for the portion where the artificial defect is to be formed. After forming the mask material 14, Al is vapor-deposited on the entire surface to form an Al layer 15, and after removing the mask material 14, the top coat layer 1 is again formed on the entire surface.
3b to form a top coat layer 13 and dissolve the Al layer 15 in NaOH and dissipate it, so that an artificial defect 1 is formed in the top coat layer 13 near the undercoat layer 12.
6 can be formed. Therefore, an artificial defect of TBC can be manufactured by changing the thickness and the shape, and the defect detection limit can be obtained.
【００１５】事実、Ａｌ蒸着、ＮａＯＨによる溶解で試
作した供試体の断面ミクロ組織は、図７（顕微鏡写真の
模式図、目標欠陥サイズ：φ１０ｍｍ）に示すようにな
った。なお、図７中の端部における厚みは、アンダーコ
ート層：２０μｍ（Ｔ１）、人工欠陥：１２５μｍ（Ｔ
２）、トップコート層：２８０μｍ（Ｔ３）であった。In fact, the cross-sectional microstructure of a test sample produced by Al deposition and dissolution with NaOH was as shown in FIG. 7 (a schematic diagram of a micrograph, target defect size: φ10 mm). The thickness at the end in FIG. 7 is 20 μm (T 1 ) for the undercoat layer and 125 μm (T
2 ), Top coat layer: 280 μm (T 3 ).
【００１６】なお、上記実施例１では、マスク材を介し
てＡｌを蒸着する場合について述べたがこれに限らず、
溶射してもよい。また、マスク材も樹脂に限らず、ステ
レンレス等でもよい。In the first embodiment, the case where Al is deposited through the mask material has been described. However, the present invention is not limited to this.
It may be sprayed. Further, the mask material is not limited to resin, but may be stellenless or the like.
【００１７】（実施例２）本実施例２は、実施例１と比
べ、Ａｌ蒸着の代わりにカーボンを塗布すること、及び
再度厚いトップコート層１３ｂを形成した後例えば５０
０℃、大気中でカーボンを焼いて空洞部とすることを除
いて、実施例１と同様な工程で人工欠陥を作ることを特
徴とする。実施例２によれば、実施例１と同様な効果を
有する。(Embodiment 2) In Embodiment 2, compared with Embodiment 1, carbon is applied instead of Al vapor deposition, and after forming a thick top coat layer 13b again, for example, 50
An artificial defect is produced in the same process as in Example 1, except that carbon is burned in the air at 0 ° C. to form a cavity. According to the second embodiment, the same effects as in the first embodiment are obtained.
【００１８】(実施例３)本実施例３は、実施例１と比
べ、Ａｌ蒸着の代わりにポリエステル等の樹脂を塗布
（又は溶射）すること、及び再度厚いトップコート層１
３ｂを形成した後例えば５００℃、大気中でカーボンを
焼いて空洞部とすることを除いて、実施例１と同様な工
程で人工欠陥を作ることを特徴とする。実施例３によれ
ば、実施例１と同様な効果を有する。(Embodiment 3) This embodiment 3 is different from the embodiment 1 in that a resin such as polyester is applied (or sprayed) instead of Al vapor deposition, and a thick top coat layer 1 is formed again.
After the formation of 3b, an artificial defect is formed in the same process as in Example 1 except that carbon is burned in air at, for example, 500 ° C. to form a cavity. According to the third embodiment, the same effects as in the first embodiment are obtained.
【００１９】[0019]
【発明の効果】以上詳述したように本発明によれば、実
機の場合にきわめて近い人工欠陥を厚さや形状を変えて
製作でき、実機における欠陥検出限界を求めることがで
きる人工欠陥を有した遮熱層の形成方法を提供できる。As described above in detail, according to the present invention, an artificial defect which is very close to that of the actual machine can be manufactured by changing the thickness and shape, and the artificial defect which can determine the defect detection limit in the actual machine is provided. A method for forming a heat shielding layer can be provided.
【図１】本発明の実施例１に係る人工欠陥を有した遮熱
層の形成方法を工程順に示す説明図。FIG. 1 is an explanatory view showing a method of forming a heat shielding layer having an artificial defect according to a first embodiment of the present invention in the order of steps.
【図２】タービン翼の説明図。FIG. 2 is an explanatory diagram of a turbine blade.
【図３】図２のＸ部の断面図。FIG. 3 is a sectional view of a portion X in FIG. 2;
【図４】本発明による人工欠陥を有した遮熱層の説明
図。FIG. 4 is an explanatory view of a heat shield layer having an artificial defect according to the present invention.
【図５】ＴＢＣ等の初期状態の断面を顕微鏡（×１００
倍）で撮影した金属組織の写真。FIG. 5 shows a cross section of an initial state such as TBC by a microscope (× 100
Photograph of the metallographic structure taken at x).
【図６】ＴＢＣ等の剥離直前の断面を顕微鏡（×１００
倍）で撮影した金属組織の写真。FIG. 6 shows a cross section immediately before peeling of TBC or the like under a microscope (× 100).
Photograph of the metallographic structure taken at x).
【図７】本発明の実施例１に係るＴＢＣの人工欠陥の状
態を示す模式図。FIG. 7 is a schematic view showing a state of an artificial defect of the TBC according to the first embodiment of the present invention.
１１…母材、 １２…アンダーコート層、 １３ａ，１３ｂ，１３…トップコート層、 １４…マスク材、 １５…Ａｌ層、 １６…空洞部（人工欠陥）。 11: Base material, 12: Undercoat layer, 13a, 13b, 13: Top coat layer, 14: Mask material, 15: Al layer, 16: Cavity (artificial defect).
───────────────────────────────────────────────────── フロントページの続き (72)発明者 岡田 郁生 兵庫県高砂市荒井町新浜２丁目１番１号 三菱重工業株式会社高砂製作所内 (72)発明者 高橋 孝二 兵庫県高砂市荒井町新浜２丁目１番１号 三菱重工業株式会社高砂製作所内 (72)発明者 大原 稔 兵庫県高砂市荒井町新浜２丁目１番１号 三菱重工業株式会社高砂製作所内 Ｆターム(参考） 2G052 AA14 EC09 EC12 EC14 FD06 JA09 4D075 AD11 AE04 AE27 BB28Z BB63Z BB77Z BB83Y BB85Y CA17 DA06 DB01 DC08 DC16 EB01 EB05 ──────────────────────────────────────────────────続 き Continuing from the front page (72) Inventor Ikuo Okada 2-1-1 Shinama, Araimachi, Takasago City, Hyogo Prefecture Inside the Takasago Works, Mitsubishi Heavy Industries, Ltd. (72) Inventor Koji Takahashi 2-1-1 Shinama, Araimachi, Takasago City, Hyogo Prefecture No. 1 Inside the Mitsubishi Heavy Industries, Ltd. Takasago Works (72) Inventor Minoru Ohara 2-1-1, Araimachi Shinhama, Takasago City, Hyogo Prefecture Inside the Takasago Works, Mitsubishi Heavy Industries, Ltd. F-term (reference) 2G052 AA14 EC09 EC12 EC14 FD06 JA09 4D075 AD11 AE04 AE27 BB28Z BB63Z BB77Z BB83Y BB85Y CA17 DA06 DB01 DC08 DC16 EB01 EB05
Claims (5)
程と、このアンダーコート層上にトップコート層を形成
する工程と、人工欠陥形成予定部を除く前記トップコー
ト層上にマスク材を形成する工程と、マスク材から露出
する前記トップコート層上に人工欠陥形成部材を形成す
る工程と、前記マスク材を除去した後、全面に再度トッ
プコート層を形成する工程と、前記人工欠陥形成部材を
消失させてトップコート層に人工欠陥を形成する工程と
を具備することを特徴とする人工欠陥を有した遮熱層の
形成方法。1. A step of forming an undercoat layer on a base material, a step of forming a topcoat layer on the undercoat layer, and forming a mask material on the topcoat layer excluding a portion where an artificial defect is to be formed. Performing the step of forming an artificial defect forming member on the top coat layer exposed from the mask material; removing the mask material; and then forming a top coat layer again on the entire surface after removing the mask material; And forming an artificial defect in the top coat layer by eliminating the defects.
溶射により堆積し、かつトップコート層の形成後に水酸
化ナトリウムで堆積したＡｌを溶解することにより人工
欠陥を形成することを特徴とする請求項１記載の人工欠
陥を有した遮熱層の形成方法。2. An artificial defect is formed by depositing Al as an artificial defect forming member by vapor deposition or thermal spraying and dissolving Al deposited with sodium hydroxide after forming a top coat layer. A method for forming a heat shielding layer having an artificial defect according to claim 1.
し、かつトップコート層の形成後に大気中で前記カーボ
ンを焼くことにより人工欠陥を形成することを特徴とす
る請求項１記載の人工欠陥を有した遮熱層の形成方法。3. An artificial defect according to claim 1, wherein said artificial defect is formed by applying carbon as an artificial defect forming member and baking said carbon in air after forming a top coat layer. Method of forming a heat shield layer.
溶射し、かつトップコート層の形成後に大気中で前記樹
脂を焼くことにより人工欠陥を形成することを特徴とす
る請求項１記載の人工欠陥を有した遮熱層の形成方法。4. The artificial defect according to claim 1, wherein the artificial defect is formed by applying or spraying a resin as an artificial defect forming member, and baking the resin in the air after forming a top coat layer. A method for forming a heat shield layer having
μｍであることを特徴とする請求項１〜４いずれか記載
の人工欠陥を有した遮熱層の形成方法。5. The thickness of the top coat layer is from 10 to 50.
The method for forming a thermal barrier layer having artificial defects according to any one of claims 1 to 4, wherein the thickness is μm.
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| JP2001177410A JP3950303B2 (en) | 2001-06-12 | 2001-06-12 | Method for forming a thermal barrier layer with artificial defects |
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|---|---|---|---|
| JP2001177410A JP3950303B2 (en) | 2001-06-12 | 2001-06-12 | Method for forming a thermal barrier layer with artificial defects |
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| JP3950303B2 JP3950303B2 (en) | 2007-08-01 |
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| CN104931320A (en) * | 2015-06-24 | 2015-09-23 | 桂林电子科技大学 | Sample piece with two material interfaces containing preset microcracks and production method of sample piece |
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- 2001-06-12 JP JP2001177410A patent/JP3950303B2/en not_active Expired - Fee Related
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104931320A (en) * | 2015-06-24 | 2015-09-23 | 桂林电子科技大学 | Sample piece with two material interfaces containing preset microcracks and production method of sample piece |
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| JP3950303B2 (en) | 2007-08-01 |
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