JP2021519386A - Cmas耐性、高歪み許容性及び低熱伝導率の遮熱コーティング及び溶射コーティング方法 - Google Patents
Cmas耐性、高歪み許容性及び低熱伝導率の遮熱コーティング及び溶射コーティング方法 Download PDFInfo
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- 239000012720 thermal barrier coating Substances 0.000 title claims description 57
- 238000005507 spraying Methods 0.000 title description 6
- 239000010410 layer Substances 0.000 claims abstract description 80
- 238000000576 coating method Methods 0.000 claims abstract description 73
- 239000011247 coating layer Substances 0.000 claims abstract description 72
- 239000011248 coating agent Substances 0.000 claims abstract description 66
- 230000003628 erosive effect Effects 0.000 claims abstract description 63
- 239000000758 substrate Substances 0.000 claims abstract description 25
- 229910052759 nickel Inorganic materials 0.000 claims abstract description 6
- -1 rare earth silicate Chemical class 0.000 claims description 29
- 229910052761 rare earth metal Inorganic materials 0.000 claims description 28
- 239000000203 mixture Substances 0.000 claims description 27
- 238000007750 plasma spraying Methods 0.000 claims description 17
- 239000000463 material Substances 0.000 claims description 14
- 229910001404 rare earth metal oxide Inorganic materials 0.000 claims description 10
- 229910052688 Gadolinium Inorganic materials 0.000 claims description 8
- 229910000272 alkali metal oxide Inorganic materials 0.000 claims description 8
- 239000002585 base Substances 0.000 claims description 8
- UIWYJDYFSGRHKR-UHFFFAOYSA-N gadolinium atom Chemical compound [Gd] UIWYJDYFSGRHKR-UHFFFAOYSA-N 0.000 claims description 8
- 238000005240 physical vapour deposition Methods 0.000 claims description 8
- 239000000725 suspension Substances 0.000 claims description 8
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 claims description 7
- 238000000034 method Methods 0.000 claims description 7
- 229910000601 superalloy Inorganic materials 0.000 claims description 7
- 238000005524 ceramic coating Methods 0.000 claims description 6
- 230000000116 mitigating effect Effects 0.000 claims description 4
- 238000000151 deposition Methods 0.000 claims description 3
- 238000005260 corrosion Methods 0.000 claims 1
- 230000007797 corrosion Effects 0.000 claims 1
- 239000000126 substance Substances 0.000 description 6
- 229910001233 yttria-stabilized zirconia Inorganic materials 0.000 description 6
- MRELNEQAGSRDBK-UHFFFAOYSA-N lanthanum(3+);oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[La+3].[La+3] MRELNEQAGSRDBK-UHFFFAOYSA-N 0.000 description 4
- PLDDOISOJJCEMH-UHFFFAOYSA-N neodymium(3+);oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[Nd+3].[Nd+3] PLDDOISOJJCEMH-UHFFFAOYSA-N 0.000 description 4
- 229940126062 Compound A Drugs 0.000 description 3
- NLDMNSXOCDLTTB-UHFFFAOYSA-N Heterophylliin A Natural products O1C2COC(=O)C3=CC(O)=C(O)C(O)=C3C3=C(O)C(O)=C(O)C=C3C(=O)OC2C(OC(=O)C=2C=C(O)C(O)=C(O)C=2)C(O)C1OC(=O)C1=CC(O)=C(O)C(O)=C1 NLDMNSXOCDLTTB-UHFFFAOYSA-N 0.000 description 3
- 230000004888 barrier function Effects 0.000 description 3
- 230000006866 deterioration Effects 0.000 description 3
- 229910000420 cerium oxide Inorganic materials 0.000 description 2
- VQCBHWLJZDBHOS-UHFFFAOYSA-N erbium(iii) oxide Chemical compound O=[Er]O[Er]=O VQCBHWLJZDBHOS-UHFFFAOYSA-N 0.000 description 2
- 229910001940 europium oxide Inorganic materials 0.000 description 2
- 229940075616 europium oxide Drugs 0.000 description 2
- AEBZCFFCDTZXHP-UHFFFAOYSA-N europium(3+);oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[Eu+3].[Eu+3] AEBZCFFCDTZXHP-UHFFFAOYSA-N 0.000 description 2
- 238000010285 flame spraying Methods 0.000 description 2
- 239000000446 fuel Substances 0.000 description 2
- 229910001938 gadolinium oxide Inorganic materials 0.000 description 2
- 229940075613 gadolinium oxide Drugs 0.000 description 2
- CMIHHWBVHJVIGI-UHFFFAOYSA-N gadolinium(iii) oxide Chemical compound [O-2].[O-2].[O-2].[Gd+3].[Gd+3] CMIHHWBVHJVIGI-UHFFFAOYSA-N 0.000 description 2
- 238000010286 high velocity air fuel Methods 0.000 description 2
- 238000007749 high velocity oxygen fuel spraying Methods 0.000 description 2
- 229910003443 lutetium oxide Inorganic materials 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000003647 oxidation Effects 0.000 description 2
- 238000007254 oxidation reaction Methods 0.000 description 2
- BMMGVYCKOGBVEV-UHFFFAOYSA-N oxo(oxoceriooxy)cerium Chemical compound [Ce]=O.O=[Ce]=O BMMGVYCKOGBVEV-UHFFFAOYSA-N 0.000 description 2
- MPARYNQUYZOBJM-UHFFFAOYSA-N oxo(oxolutetiooxy)lutetium Chemical compound O=[Lu]O[Lu]=O MPARYNQUYZOBJM-UHFFFAOYSA-N 0.000 description 2
- 230000035515 penetration Effects 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 229910001954 samarium oxide Inorganic materials 0.000 description 2
- 229940075630 samarium oxide Drugs 0.000 description 2
- FKTOIHSPIPYAPE-UHFFFAOYSA-N samarium(iii) oxide Chemical compound [O-2].[O-2].[O-2].[Sm+3].[Sm+3] FKTOIHSPIPYAPE-UHFFFAOYSA-N 0.000 description 2
- HYXGAEYDKFCVMU-UHFFFAOYSA-N scandium oxide Chemical compound O=[Sc]O[Sc]=O HYXGAEYDKFCVMU-UHFFFAOYSA-N 0.000 description 2
- 229910003451 terbium oxide Inorganic materials 0.000 description 2
- SCRZPWWVSXWCMC-UHFFFAOYSA-N terbium(iii) oxide Chemical compound [O-2].[O-2].[O-2].[Tb+3].[Tb+3] SCRZPWWVSXWCMC-UHFFFAOYSA-N 0.000 description 2
- 230000007704 transition Effects 0.000 description 2
- 229910052691 Erbium Inorganic materials 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- OYINIGQXPJKPOM-UHFFFAOYSA-N aluminum calcium magnesium silicate Chemical compound [Si]([O-])([O-])([O-])[O-].[Al+3].[Mg+2].[Ca+2] OYINIGQXPJKPOM-UHFFFAOYSA-N 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000007795 chemical reaction product Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- UYAHIZSMUZPPFV-UHFFFAOYSA-N erbium Chemical compound [Er] UYAHIZSMUZPPFV-UHFFFAOYSA-N 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000037361 pathway Effects 0.000 description 1
- 150000002910 rare earth metals Chemical class 0.000 description 1
- 230000009257 reactivity Effects 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
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- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
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Abstract
Description
本出願は、2018年4月9日に提出された米国仮特許出願第62/654,985号の35 U.S.C.§119(e)に基づく優先権を主張するものであり、その開示全体を参照により本明細書に明示的に組み込む。
適用不可
RE安定化ZrO2若しくはHfO2(RE=希土類酸化物)
希土類酸化物とのRE安定化ZrO2若しくはHfO2混合物、又は
希土類シリケートとのRE安定化ZrO2若しくはHfO2混合物、又は
希土類アルミネートとのRE安定化ZrO2若しくはHfO2混合物、又は
希土類アルミネートシリケート(Rare earth Aluminate Silicate)とのRE安定化ZrO2若しくはHfO2混合物、又は
アルカリ酸化物とのRE安定化ZrO2若しくはHfO2混合物、又は
ジルコン酸ガドリニウムとのRE安定化ZrO2若しくはHfO2混合物、又は
上記の任意の組合せを含む。
RE安定化ZrO2若しくはHfO2
希土類酸化物とのRE安定化ZrO2若しくはHfO2混合物、又は
希土類シリケートとのRE安定化ZrO2若しくはHfO2混合物、又は
希土類アルミネートとのRE安定化ZrO2若しくはHfO2混合物、又は
希土類アルミネートシリケートとのRE安定化ZrO2若しくはHfO2混合物、又は
アルカリ酸化物とのRE安定化ZrO2若しくはHfO2混合物、又は
ジルコン酸ガドリニウムとのRE安定化ZrO2若しくはHfO2混合物、又は
上記の任意の組合せを含む。
Claims (31)
- MCrAlY(MはNi、Co又はそれらの組合せを表す)の層を含む遮熱コーティング(TBC)上に配置された低熱伝導率を提供する少なくとも1つの多孔質縦割れ(PVC)コーティング層;及び
前記少なくとも1つのPVCコーティング層上に堆積された少なくとも1つの緻密縦割れ(DVC)耐侵食性CMAS耐性コーティング層
を含む耐侵食性CMAS耐性コーティング。 - 前記少なくとも1つのDVC層が最上層である、請求項1に記載のコーティング。
- 前記TBCと基材との間に配置された少なくとも1つのボンドコーティング層をさらに含む、請求項1に記載のコーティング。
- 前記基材が超合金基材である、請求項1に記載のコーティング。
- 前記少なくとも1つの緻密縦割れ(DVC)耐侵食性CMAS耐性コーティング層が、希土類酸化物と混合されたRe安定化ZrO2又はHfO2を含む、請求項1に記載のコーティング。
- 前記少なくとも1つの緻密縦割れ(DVC)耐侵食性CMAS耐性コーティング層が、希土類シリケートと混合されたRe安定化ZrO2又はHfO2を含む、請求項1に記載のコーティング。
- 前記少なくとも1つの緻密縦割れ(DVC)耐侵食性CMAS耐性コーティング層が、希土類アルミネートと混合されたRe安定化ZrO2又はHfO2を含む、請求項1に記載のコーティング。
- 前記少なくとも1つの緻密縦割れ(DVC)耐侵食性CMAS耐性コーティング層が、希土類アルミネート若しくはシリケートと混合されたRe安定化ZrO2又はHfO2を含む、請求項1に記載のコーティング。
- 前記少なくとも1つの緻密縦割れ(DVC)耐侵食性CMAS耐性コーティング層が、アルカリ酸化物と混合されたRe安定化ZrO2又はHfO2を含む、請求項1に記載のコーティング。
- 前記少なくとも1つの緻密縦割れ(DVC)耐侵食性CMAS耐性コーティング層が、ジルコン酸ガドリニウムと混合されたRe安定化ZrO2又はHfO2を含む、請求項1に記載のコーティング。
- 前記少なくとも1つの緻密縦割れ(DVC)耐侵食性CMAS耐性コーティング層が、
希土類酸化物と混合されたRe安定化ZrO2又はHfO2、
希土類シリケートと混合されたRe安定化ZrO2又はHfO2、
希土類アルミネートと混合されたRe安定化ZrO2又はHfO2、
希土類アルミネート若しくはシリケートと混合されたRe安定化ZrO2又はHfO2、
アルカリ酸化物と混合されたRe安定化ZrO2又はHfO2、及び
ジルコン酸ガドリニウムと混合されたRe安定化ZrO2又はHfO2
のうちの2つ以上の混合物の混合物を含む、請求項1に記載のコーティング。 - 前記少なくとも1つの緻密縦割れ(DVC)耐侵食性CMAS耐性コーティング層が、全厚の垂直クラックを含む、請求項1に記載のコーティング。
- 前記少なくとも1つの多孔質縦割れ(PVC)コーティング層が、全厚の垂直クラックを含む、請求項1に記載のコーティング。
- TBCコーティングされた基材上に配置されたより低い熱伝導率を提供する少なくとも1つの多孔質縦割れ(PVC)遮熱コーティング層、及び
前記少なくとも1つのPVC遮熱コーティング層の上に堆積された緻密縦割れ(DVC)耐侵食性CMAS耐性コーティング材の最上層
を含む、前記TBCコーティングされた基材上に配置された耐侵食性CMAS耐性コーティング。 - 前記TBCと前記基材との間に配置された少なくとも1つのボンドコーティング層をさらに含む、請求項14に記載のコーティング。
- 前記TBCが、MCrAlYの少なくとも1つの層を含み、Mは、Ni、Co又はそれらの組合せを表す、請求項14に記載のコーティング。
- 前記少なくとも1つの緻密縦割れ(DVC)耐侵食性CMAS耐性コーティング層が、希土類酸化物と混合されたRe安定化ZrO2又はHfO2を含む、請求項14に記載のコーティング。
- 前記少なくとも1つの緻密縦割れ(DVC)耐侵食性CMAS耐性コーティング層が、希土類シリケートと混合されたRe安定化ZrO2又はHfO2を含む、請求項14に記載のコーティング。
- 前記少なくとも1つの緻密縦割れ(DVC)耐侵食性CMAS耐性コーティング層が、希土類アルミネートと混合されたRe安定化ZrO2又はHfO2を含む、請求項14に記載のコーティング。
- 前記少なくとも1つの緻密縦割れ(DVC)耐侵食性CMAS耐性コーティング層が、希土類アルミネート若しくはシリケートと混合されたRe安定化ZrO2又はHfO2を含む、請求項14に記載のコーティング。
- 前記少なくとも1つの緻密縦割れ(DVC)耐侵食性CMAS耐性コーティング層が、アルカリ酸化物と混合されたRe安定化ZrO2又はHfO2を含む、請求項14に記載のコーティング。
- 前記少なくとも1つの緻密縦割れ(DVC)耐侵食性CMAS耐性コーティング層が、ジルコン酸ガドリニウムと混合されたRe安定化ZrO2又はHfO2を含む、請求項14に記載のコーティング。
- 前記少なくとも1つの緻密縦割れ(DVC)耐侵食性CMAS耐性コーティング層が、
希土類酸化物と混合されたRe安定化ZrO2又はHfO2、
希土類シリケートと混合されたRe安定化ZrO2又はHfO2、
希土類アルミネートと混合されたRe安定化ZrO2又はHfO2、
希土類アルミネート若しくはシリケートと混合されたRe安定化ZrO2又はHfO2、
アルカリ酸化物と混合されたRe安定化ZrO2又はHfO2、及び
ジルコン酸ガドリニウムと混合されたRe安定化ZrO2又はHfO2
のうちの2つ以上の混合物を含む、請求項14に記載のコーティング。 - 前記緻密縦割れ(DVC)耐侵食性CMAS耐性コーティング層の最上層が、全厚の垂直クラックを含む、請求項14に記載のコーティング。
- 前記少なくとも1つの多孔質縦割れ(PVC)コーティング層が、全厚の垂直クラックを含む、請求項14に記載のコーティング。
- 超合金基材上に配置され、前記基材に結合されたMCrAlYのTBCコーティング層(ただし、Mは、Ni、Co又はそれらの組合せを表す)、
前記TBCコーティング層に直接堆積されたCTE緩和を提供する多孔質縦割れ(PVC)セラミックコーティング層、及び
前記PVCコーティング層に直接堆積された緻密縦割れ(DVC)耐侵食性CMAS耐性コーティング層
を含む、耐侵食性CMAS耐性セラミックコーティング。 - TBCコーティングされた基材上に耐侵食性CMAS耐性コーティングをプラズマ溶射する方法であって、
より低い熱伝導率を提供する少なくとも1つの多孔質縦割れ(PVC)遮熱コーティング層を前記TBCコーティングされた基材に堆積させること、及び
前記少なくとも1つのPVC遮熱コーティング層上に緻密縦割れ(DVC)耐侵食性CMAS耐性コーティング材を堆積させること
を含む方法。 - 前記TBCコーティングされた基材が、TBC層と前記基材との間に配置された少なくとも1つのボンドコーティング層を含む、請求項26に記載の方法。
- 前記プラズマ溶射が、
大気圧プラズマ溶射(APS)、
プラズマ溶射−物理蒸着(PS−PVD)又は
サスペンションプラズマ溶射(SPS)
のうちの1つを含む、請求項27に記載の方法。 - NiCrAlYの層を含む遮熱コーティング(TBC)上に配置された低熱伝導率を提供する少なくとも1つの多孔質縦割れ(PVC)コーティング層;及び
前記少なくとも1つのPVCコーティング層上に堆積された少なくとも1つの緻密縦割れ(DVC)耐侵食性CMAS耐性コーティング層
を含む耐侵食性CMAS耐性コーティング。 - CoCrAlYの層を含む遮熱コーティング(TBC)上に配置された低熱伝導率を提供する少なくとも1つの多孔質縦割れ(PVC)コーティング層;及び
前記少なくとも1つのPVCコーティング層上に堆積された少なくとも1つの緻密縦割れ(DVC)耐侵食性CMAS耐性コーティング層
を含む耐侵食性CMAS耐性コーティング。
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