JP2012527538A - Pt−Al−Hf/Zrコーティング及びコーティング方法 - Google Patents
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Abstract
【選択図】 図6
Description
本発明は、ガスタービンエンジン翼及び部品に対するPt-Al-Hf/Zrアルミナイドコーティング、及び合金の表面領域へ合金化元素を導入する方法に関するものである。
タービンエンジン性能の向上は、タービン合金、冷却スキーム、及びコーティングの改良を通じて成し遂げられてきた。コーティングの最大の改良は、冷却されたタービン部品に熱遮へいコーティング(Thermal Barrier Coating;TBC)を施すことによってなされた。タービン翼の場合、最も効果的なTBCは、電子ビーム物理気相成長法(Physical Vapor Deposition;PVD)によって施される。従来の技術として、NiCoCrAlY、アルミナイド及び白金−アルミナイドのボンドコートがある。これらボンドコートに対する進化的な改良は、表面仕上げを改良するための最適な処理、又はS(硫黄)等の混入による重大な影響を低減するための清浄化処理を行うことで実現されてきた。しかしながら、タービンの設計者達の予測寿命は、高温のタービン温度における部品の設計寿命に適合しないか、又は既存の温度におけるTBC寿命に信頼性がないため、TBCを十分に利用していない。そのため、信頼性がより多く、より長寿命のTBCに対する必要性が存在する。
本発明は、Pt-Al-Xアルミナイドコーティング(Xは、Hf及び/又はZrである)を提供するもので、TBCの下に用いられることができ、高温でのTBC破砕寿命を向上させる。本発明の一実施例において、Pt-Al-Xアルミナイドコーティングは、準安定(遷移)X-Pt/Pd-Ni相を含み、XはHf 及び/又はZrであり、Pt/PdはPt又はPd又はその両方が相に存在することを意味し、Niは、コーティングのβ(Ni,Pt)Alの外側相に単独で、又は他の合金化元素と共に存在する。簡潔化のために、三元又は四元以上のX-Pt/Pd-Ni相を、"μ相"と称する。準安定μ相は、コーティング発達の初期形成段階に存在することが観察されることができる。μ相は、成膜された状態のコーティング、例えば、用いられるパラメータに応じてCVD蒸着された状態のコーティングの中に観察されることができる。
破損= (R-0.3)/(N+0.4)* 100
R = 破損ランク (1, 2, 3, 4, ... )
N =破損の総数
X軸は、破損の対応するランクに対する破損時の破砕サイクル数である。
Claims (39)
- X-Pt/Pd-Ni相を含むアルミナイドコーティングであって、
前記相は、Hf及び/又はZrであるXと、Pt/Pdの内の一方又は両方と、Niとを含み、
X-Pt/Pd-Ni相は、前記コーティングのβ(Ni,Pt)Al相に存在する、アルミナイドコーティング。 - X-Pt/Pd-Ni相は、成膜された状態のコーティングに存在し観察されることができる、請求項1のコーティング。
- 前記相は、CVDで蒸着された状態のボンドコーティングに存在し観察されることができる、請求項1のコーティング。
- 前記相はX2Pt3Nix を含み、xは5以下である、請求項1のコーティング。
- 前記相はXPdNix を含み、xは4以下である、請求項1のコーティング。
- X2Pt3NiX相の一方の側から他方の側にわたるコーティング厚さ領域におけるPt濃度は約18原子%である、請求項4のコーティング。
- X2Pt3NiX相の一方の側から他方の側にわたる同じ厚さ領域におけるAl濃度は約31〜約40原子%である、請求項6のコーティング。
- X2Pt3NiX相の一方の側から他方の側にわたる同じ厚さ領域におけるAl濃度は約35〜約40原子%である、請求項7のコーティング。
- Hf2Pt3NiX相の一方の側から他方の側にわたる同じ厚さ領域におけるHf濃度は約0.25〜約1.0原子%である、請求項4のコーティング。
- Hfは、約0.5〜約1.0原子%である、請求項9のコーティング。
- Pt-Al-X(XはHf及び/又はZr)アルミナイドコーティングであって、
外側コーティング面を含み、該コーティング面は、Pt含有量が約2〜約16原子%、Al含有量が約31〜約40原子%であって、Hf及び/又はZrを有しており、
コーティング厚さは、約25〜約45ミクロンであり、
コーティングの全体厚さは、拡散ゾーンと追加領域とを含んでいる、アルミナイドコーティング。 - 全体厚さは、約30ミクロン〜約40ミクロンである、請求項11のコーティング。
- Pt含有量は約10〜約16原子%である、請求項11のコーティング。
- Al含有量は約35〜約40原子%である、請求項11のコーティング。
- 外側コーティング面の近傍にHf及び/又はZrを0.25原子%〜1.0原子%含んでいる、請求項11のコーティング。
- Hfは約0.5〜1.0原子%である、請求項15のコーティング。
- 中間元素を、他の合金化元素に対して溶解性の低い合金基材の表面領域上又は表面領域内に導入した後、前記中間元素及び前記他の元素が富化された表面領域を基材に形成できる成膜条件下で、前記他の合金化元素を中間元素内に導入することを含んでいる、方法。
- 中間元素は、Pt又はPd又はその両方を含む、請求項17の方法。
- Ptが供給される量は、約2mg/cm2 〜約8mg/cm2 である、請求項17の方法。
- 前記他の合金化元素は、Hf又はZr又はその両方を含む、請求項17の方法。
- 前記他の合金化元素は、化学蒸着法を用いて中間元素に導入される、請求項17の方法。
- 基材の表面領域上にアルミナイドコーティングを生成する方法であって、
中間元素を、他の合金化元素に対して溶解性の低い基材の表面領域上又は表面領域内に層として成膜すること、
前記中間元素及び前記他の元素を含む表面領域に相を形成できる成膜条件下で、前記他の合金化元素を前記層に成膜すること、及び
拡散アルミナイドコーティングを形成できる条件下で基材をアルミナイジングすることを含んでいる、方法。 - 中間元素は、表面領域上の層として、Pt又はPd又はその両方を含む、請求項22の方法。
- Ptが成膜される量は、約2mg/cm2〜約8mg/cm2である、請求項23の方法。
- 前記他の合金化元素は、Hf又はZr又はその両方を含む、請求項22の方法。
- 前記他の合金化元素は、アルミニウムと共に表面領域上に成膜される、請求項22の方法。
- 前記他の合金化元素を前記表面領域に成膜し、次いでアルミニウムを単独又は前記他の合金化元素と共に成膜する、請求項22の方法。
- 前記他の合金化元素は、化学蒸着法を用いて前記層に蒸着され、前記相が形成される、請求項22の方法。
- 前記相は、Pt及び/又はPdと、Hf及び/又はZrと、Niとを含む、請求項22の方法。
- 前記相は、X2Pt3Nixを含み、xは5以下である、請求項29の方法。
- Ptが表面領域に成膜される量は、約2mg/cm2〜約8mg/cm2である、請求項22の方法。
- Ptが表面領域に成膜される量は、約4mg/cm2〜約6mg/cm2である、請求項31の方法。
- コーティングの微細組織内で相を維持する時間の経過後、アルミナイジングを中止することを含む、請求項22の方法。
- 前記相がコーティングの微細組織から消滅する間、アルミナイジングを継続することを含む、請求項22の方法。
- アルミナイドコーティングを基材表面領域上に施す方法であって、
Pt及び/又はPdを基材の表面領域上に層として成膜すること、
Pt及び/又はPdと、Hf及び/又はZrと、Niとを含む相を形成できる条件下で、Hf及び/又はZrを、前記層上又は前記層内に成膜すること、及び
化学蒸着法によるアルミナイジングによりアルミナイドコーティングを形成することを含んでいる、方法。 - Ptが表面領域に蒸着される量は、約2mg/cm2〜約8mg/cm2である、請求項35の方法。
- Ptが表面領域に成膜される量は、約4mg/cm2〜約6mg/cm2である、請求項36の方法。
- コーティングの微細組織内で相を維持する時間の経過後、アルミナイジングを中止することを含む、請求項35の方法。
- 前記相がコーティングの微細組織から消滅する間、アルミナイジングを継続することを含む、請求項35の方法。
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US20140134447A1 (en) | 2014-05-15 |
US20100297471A1 (en) | 2010-11-25 |
EP3006592A1 (en) | 2016-04-13 |
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CN102292465A (zh) | 2011-12-21 |
EP2432916A1 (en) | 2012-03-28 |
CN103921492A (zh) | 2014-07-16 |
WO2010134976A1 (en) | 2010-11-25 |
EP2432916A4 (en) | 2015-07-29 |
US9404372B2 (en) | 2016-08-02 |
CA2748304C (en) | 2017-07-04 |
HK1202278A1 (en) | 2015-09-25 |
JP2016074971A (ja) | 2016-05-12 |
CA2967670A1 (en) | 2010-11-25 |
CA2967670C (en) | 2019-12-24 |
JP6067071B2 (ja) | 2017-01-25 |
EP3006592B1 (en) | 2019-07-17 |
ES2704138T3 (es) | 2019-03-14 |
JP5791594B2 (ja) | 2015-10-07 |
CN102292465B (zh) | 2014-04-09 |
CN103921492B (zh) | 2017-05-10 |
EP2432916B1 (en) | 2018-10-03 |
CA2748304A1 (en) | 2010-11-25 |
PL2432916T3 (pl) | 2019-02-28 |
US9284846B2 (en) | 2016-03-15 |
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