KR20180026532A - 가스 터빈의 압축기 부품에 대한 외형 윤곽을 따른 보호 코팅 - Google Patents

가스 터빈의 압축기 부품에 대한 외형 윤곽을 따른 보호 코팅 Download PDF

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KR20180026532A
KR20180026532A KR1020187003555A KR20187003555A KR20180026532A KR 20180026532 A KR20180026532 A KR 20180026532A KR 1020187003555 A KR1020187003555 A KR 1020187003555A KR 20187003555 A KR20187003555 A KR 20187003555A KR 20180026532 A KR20180026532 A KR 20180026532A
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South Korea
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layer
coating system
substrate
gas turbine
layers
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KR1020187003555A
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KR102568312B1 (ko
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미카엘 안넨
요켄 바르니켈
렌테리아 알투로 플로레스
안드레이 그히코브
사스카 헤셀
토르스텐 네드데메이어
위르겐 람
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오를리콘 서피스 솔루션스 아크티엔게젤샤프트, 페피콘
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    • 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
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    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
    • C23C14/24—Vacuum evaporation
    • C23C14/32—Vacuum evaporation by explosion; by evaporation and subsequent ionisation of the vapours, e.g. ion-plating
    • C23C14/325—Electric arc evaporation
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    • 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
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    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
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    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/02—Pretreatment of the material to be coated
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    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
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    • C23C14/08—Oxides
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    • 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
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    • C23C14/08—Oxides
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    • C23C14/14—Metallic material, boron or silicon
    • C23C14/16—Metallic material, boron or silicon on metallic substrates or on substrates of boron or silicon
    • C—CHEMISTRY; METALLURGY
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    • 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
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    • 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
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    • C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
    • 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
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    • F01D5/286—Particular treatment of blades, e.g. to increase durability or resistance against corrosion or erosion
    • 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
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    • F01D5/288—Protective coatings for blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/02—Selection of particular materials
    • F04D29/023—Selection of particular materials especially adapted for elastic fluid pumps
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/26—Rotors specially for elastic fluids
    • F04D29/32—Rotors specially for elastic fluids for axial flow pumps
    • F04D29/321—Rotors specially for elastic fluids for axial flow pumps for axial flow compressors
    • F04D29/324—Blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/26—Rotors specially for elastic fluids
    • F04D29/32—Rotors specially for elastic fluids for axial flow pumps
    • F04D29/38—Blades
    • F04D29/388—Blades characterised by construction
    • 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
    • F05D2230/00—Manufacture
    • F05D2230/30—Manufacture with deposition of material
    • F05D2230/31—Layer deposition
    • F05D2230/311—Layer deposition by torch or flame spraying
    • 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
    • F05D2230/00—Manufacture
    • F05D2230/30—Manufacture with deposition of material
    • F05D2230/31—Layer deposition
    • F05D2230/312—Layer deposition by plasma spraying
    • 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
    • F05D2230/00—Manufacture
    • F05D2230/30—Manufacture with deposition of material
    • F05D2230/31—Layer deposition
    • F05D2230/313—Layer deposition by physical vapour deposition

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Abstract

본 발명은 기재를 위한 코팅 시스템에 관한 것이며, 상기 코팅 시스템은 적어도 제1 층, 제2 층 및 제3 층을 포함한다. 상기 코팅 시스템에서, 제1 층은 부착 촉진층으로서 설계되며, 제2 층은 주상 조직을 갖는 연성 금속층이고, 맨 위의 제3 층은 높은 경도 값을 가진 세라믹 산화물 층이다. 이상적으로는, 기재는 고정식 가스 터빈의 압축기 부품의 구성 요소이다. 또한, 본 발명은 상기 코팅 시스템의 제조 방법에 관한 것이다.

Description

가스 터빈의 압축기 부품에 대한 외형 윤곽을 따른 보호 코팅
본 발명은 부식성 부하를 받는 기재를 위한 다층 코팅 시스템에 관한 것이다.
가스 터빈의 부품들은 부식 매질에 노출된다. 이 부품들을 부식으로부터 보호하기 위해 코팅이 적용된다. 따라서, 가스 터빈, 특히 고정식 가스 터빈의 압축기 부품을 위해 알루미늄 입자를 함유하는 고온 래커가 사용된다. 그러나, 이러한 유형의 코팅들은 낮은 통합 경도(대략 50 HV)를 갖는다. 결과적으로, 내식성(예를 들어, 입자 침식 또는 낙하 충돌 침식에 대한 내식성)이 또한 비교적 낮다. 낮은 통합 경도는 특히 코팅의 연질 알루미늄 입자에 기인한 것일 수 있다. 낮은 내식성으로 인해, 특정 시간 간격 후에 부품에 대해 침식 검사를 하는 것이 필수적이며, 필요하다면 탈막하고, 검사하며 동일한 코팅으로 재코팅해야 한다. 이러한 절차는 시간이 많이 걸리고 노동 집약적이다.
따라서, 본 발명의 목적은 가스 터빈의 부품들의 내식성을 향상시키는 것이다.
이러한 목적은 청구범위 제1항의 특징을 갖는 코팅 시스템에 의해 달성된다. 본 발명의 다른 바람직한 실시예들은 추가의 독립항들과 종속항들, 도면 및 예시적인 실시예로부터 분명해질 것이다.
본 발명의 제1 양태는 표면을 갖고 있으며 부식성 부하를 받는 기재(substrate)를 위한 코팅 시스템에 관한 것이며, 상기 코팅 시스템은 적어도 제1 층, 제2 층 및 제3 층을 포함하며,
- 기재의 표면과 제2 층 사이에 배치되는 제1 층은 부착 촉진층으로서 설계되며,
- 제2 층은 주상 조직(columnar structure)을 갖는 연성 금속층이고,
- 기재로부터 멀어지는 쪽을 향하는 제2 층의 표면에 배치되는 제3 층은 적어도 20 GPa의 경도를 갖는 세라믹 산화물 층이다.
본 발명에 따른 코팅 시스템은 종래의 코팅과 비교하여 유지 관리가 덜 필요하고 유지 관리 및 보수 간격이 더욱 관대하게 선택될 수 있기 때문에 유리하다. 결과적으로, 유지하기 위하여 소모해야 하는 시간을 줄이고 비용을 낮추기 때문에 상기 코팅 시스템은 경제적으로 더욱 효과적이다. 증가한 내식성 이외에, 본 발명에 따른 코팅은 알루미늄 입자를 함유하는 고온 래커와 적어도 유사한 부식 피로 균열 성질을 나타낸다.
단위 GPa로 나타낸 경도는 코팅이 물체의 침투에 대항하여 제공할 수 있는 압력을 의미한다.
부착 촉진층으로서 형성된 제1 층은 기재와 코팅 시스템의 제2 층 사이에 더욱 강한 부착을 보장한다. 바람직하게는, 코팅 시스템의 제1 층은 크롬 또는 크롬 질화물을 포함한다.
제2 층은 희생 양극으로서의 기능을 통해 유리하게 음극으로 기재를 보호한다. 연성의 제2 층은 유리하게는 진동 하중의 경우에 층에서 발생하는 균열없이 연신에 저항하는 역할을 한다. 제2 층의 주상 조직은 제3 층에 의해 야기되는 잔류 응력을 유리하게 보상하는 역할을 한다. 바람직하게, 제2 층의 주상 조직은 알루미늄 함유 합금, 예를 들어 알루미늄과 크롬을 포함하는 합금으로 이루어진다.
본 발명에 따른 코팅 시스템의 제3 층은 바람직하게는 고용체 조직에 알루미늄 산화물 및/또는 크롬 산화물 및/또는 알루미늄/크롬 산화물을 포함한다. 또한 제3 층은 이 산화물들로만 구성될 수도 있다. 산화물에 의해서, 제3 층은 이미 적어도 하나의 산화물로 이루어지므로 산화에 대한 저항성이 있으며, 따라서 고온에서 사용될 수 있다. 제3 층은 매우 조밀한 조직이다. 제3 층은 특히 제2 층에 대한 부식 방지층으로서 유리하게 작용한다. 또한, 제3 층은 그 세라믹 특성으로 인해 절연 작용을 나타내며, 결과적으로 갈바닉 효과가 유리하게 방지된다. 또한, 제3 층은 기재보다 현저히 단단하며, 따라서 하부 층들 및 기재에 대한 침식, 특히 낙하 충돌 침식 및 입자 침식에 대한 보호층으로서 유리하게 작용한다. 바람직하게는, 제3 층의 경도는 약 25 GPa 이다.
바람직하게는, 3 개의 층들이 적용되는 기재는 가스 터빈의 압축기 부품의 구성 요소이다. 특히 바람직하게는, 기재는 고정식 가스 터빈의 압축기 부품의 구성 요소이다. 예를 들어, 압축기 부품은 압축기 블레이드 일 수 있다.
본 발명의 제2 양태는 본 발명에 따른 코팅 시스템을 갖는 가스 터빈의 압축기 부품에 관한 것이다. 환언하면, 본 발명에 따른 가스 터빈의 압축기 부품은 표면을 갖고 있으며 부식성 부하를 받는 기재를 위한 코팅 시스템을 포함하고, 상기 코팅 시스템은 적어도 제1 층, 제2 층 및 제3 층을 포함하며, 기재의 표면과 제2 층 사이에 배치되는 상기 제1 층은 부착 촉진층으로서 설계되고, 상기 제2 층은 주상 조직을 갖는 연성 금속층이며, 기재로부터 멀어지는 쪽을 향하는 제2 층의 표면에 배치되는 상기 제3 층은 적어도 20 GPa의 경도를 갖는 세라믹 산화물 층이다. 이 경우에 가스 터빈은 바람직하게는 고정식 가스 터빈이다.
본 발명의 제3 양태는 본 발명에 따른 코팅 시스템에 상응하는 3 개의 층을 포함하는, 부식성 부하를 받는 기재를 위한 코팅 시스템을 제조하는 방법에 관한 것이며, 모든 층의 물질은 물리적 기상 증착(PVD)에 의해서 적용된다. 이 방법은 종래의 층들의 적용 중에 실행해야만 했던 열처리가 필요하지 않기 때문에 유리하다. 또한, 물리적 기상 증착에 의해 적용된 층은 양호한 공기 역학적 특성을 초래하는 유리한 표면 조도를 갖는다. 또한, 물리적 기상 증착법은 층의 두께가 10 ㎛ 이하일 수 있기 때문에 코팅에 유리하며, 따라서 코팅되는 부품은 정확한 외형 윤곽으로 재현될 수 있다. 즉, 부가적인 마스킹이 필요하지 않다.
코팅 시스템의 층들은 바람직하게는 음극 아크 증착 및/또는 스퍼터링에 의해 적용된다. 바꾸어 말하면, 층들은 전술한 방법들 중 하나 또는 두 방법의 조합에 의해서 적용될 수 있다.
본 발명은 도면을 참조하여 더욱 상세히 설명될 것이다.
도 1은 코팅 시스템의 실시예를 도시한 도면이다.
도 2는 도 1에 도시된 실시예의 전자 현미경 이미지를 도시한 도면이다.
도 3은 본 발명에 따른 방법의 실시예의 흐름도를 도시한 도면이다.
도 1에 도시된 실시예에서, 코팅 시스템(1)은 표면(2a)을 가진 기재(2), 제1 층(3), 제2 층(4) 및 제3 층(5)을 갖고 있다. 기재(2)는 적어도 하나의 금속을 포함하며 금속 합금일 수 있다. 부식 조건 하에서, 기재(2)는 부식에 민감할 수 있다.
제1 층(3)은 표면(2a) 상에 배치되고 대략 100 nm의 두께를 갖는다. 제1 층은 바람직하게는 크롬 또는 크롬 질화물로 이루어지지만, 그 특성상 부착 촉진층으로서 다른 금속을 포함하거나 예를 들어 MCrAlY 유형의 다른 조성물을 또한 가질 수 있다.
제2 층(4)은 제1 층(3) 상에 배치되고 0.5 내지 5.0 ㎛, 바람직하게는 1.0 내지 3.0 ㎛의 범위의 두께를 갖는다. 제2 층(4)은 알루미늄 합금으로 이루어진 주상 조직을 갖는 연성 금속층이다. 예를 들어, 제2 층(4)은 알루미늄 및 크롬을 포함하는 합금으로 구성되지만, 대안적으로, 상기 합금은 추가적인 금속 또는 크롬 이외의 다른 금속을 또한 함유할 수 있다.
제3 층(5)은 제2 층(4) 상에 배치되고 0.5 내지 10.0 ㎛, 바람직하게는 1.0 내지 5.0 ㎛의 범위의 두께를 갖는다. 제3 층(5)은 매우 조밀한 조직을 갖는 경질 세라믹 산화물 층이다. 제3 층(5)의 재료는 크롬 산화물과 알루미늄 산화물의 혼합물, 바람직하게는 알루미늄/크롬 산화물의 고용체 화합물과 추가적인 Al-Cr 금속 간 화합물의 혼합물이다. 추가의 산화물 및 다른 화합물 또는 원소가 제3 층(5)에 또한 존재할 수 있다. 제3 층(5)은 이미 산화물로 구성되어 있기 때문에 내식성이 있다. 결과적으로, 제3 층(5)은 기재(2) 및 다른 층들을 부식으로부터 보호한다. 세라믹 성분은 제3 층(5)에 일반적으로 최대 25 GPa의 높은 경도를 부여한다. 따라서, 제3 층(5)은 기재(2) 및 다른 층보다 상당히 단단하다. 높은 경도는 침식, 특히 낙하 충돌 침식 및 입자 침식에 대해 효과적이다.
전체적으로 코팅 시스템의 두께는 최대 20 ㎛일 수 있습니다. 이 경우, 개개의 층들, 특히 제2 층(4) 및 제3 층(5)은 전술한 것보다 더 큰 두께를 가질 수도 있다. 금속 조직 조사를 위한 도 2에 도시된 매립 화합물(6)이 제3 층(5)에 적용된다. 매립 층은 무기 산화물을 포함한다. 도 2는 코팅 시스템(1)의 주사 전자 현미경 이미지의 도면인데, 제1 층(3)은 그 작은 두께로 인해 거의 보이지 않는다.
기재(2)는 바람직하게는 압축기 부품, 바람직하게는 고정식 가스 터빈의 압축기 블레이드에 속한다. 그러나, 기재는 고정식 가스 터빈 또는 다른 가스 터빈의 다른 부품에 속할 수도 있다.
설명한 코팅 시스템(1)을 제조하기 위해, 도 3에 나타낸 방법의 실시예에서, 표면(2a)을 가진 기재(2)가 제1 단계(S1)에서 제공된다. 제2 단계(S2)에서, 제1 층(3)의 물질이 물리적 기상 증착(PVD)에 의해 적용된다. 제3 단계(S3)에서, 제2 층(4)의 물질은 마찬가지로 물리적 기상 증착에 의해 적용된다. 제4 단계(S4)에서, 제3 층(5)의 물질은 마찬가지로 물리적 기상 증착에 의해 적용된다.
이 경우에, 물리적 기상 증착의 바람직한 방법으로서 음극 아크 증착이 실행된다. 또한 바람직한 방법은 스퍼터링이다. 두 가지 방법이 서로 조합되는 경우에도 마찬가지로 바람직하다. 대안적으로 및/또는 전술한 방법과 조합하여 사용될 수 있는 유용한 다른 방법들은 열 증착, 전자 빔 증착, 레이저 빔 증착 또는 아크 증착이다.
당업자에게 자명한 본 발명의 변형 및 변경은 특허청구범위의 보호 범위에 포함된다.

Claims (10)

  1. 표면(2a)을 갖고 있으며 부식성 부하를 받는 기재(2)를 위한 코팅 시스템(1)에 있어서, 상기 코팅 시스템은 적어도 제1 층(3), 제2 층(4) 및 제3 층(5)을 포함하며,
    - 기재의 표면(2a)과 제2 층(4) 사이에 배치되는 상기 제1 층(3)은 부착 촉진층으로서 설계되며,
    - 상기 제2 층(4)은 주상 조직을 갖는 연성 금속층이고,
    - 기재(2)로부터 멀어지는 쪽을 향하는 제2 층의 표면에 배치되는 상기 제3 층(5)은 적어도 20 GPa의 경도를 갖는 세라믹 산화물 층인 것을 특징으로 하는 코팅 시스템(1).
  2. 제1항에 있어서,
    상기 제1 층(3)은 크롬 또는 크롬 질화물을 포함하는 것을 특징으로 하는 코팅 시스템(1).
  3. 제1항 또는 제2항에 있어서,
    상기 제2 층(4)의 주상 조직은 알루미늄 함유 합금으로 이루어지는 것을 특징으로 하는 코팅 시스템(1).
  4. 선행항들 중 하나의 항에 있어서,
    상기 제3 층(5)은 고용체 조직에 알루미늄 산화물 및/또는 크롬 산화물, 및/또는 알루미늄/크롬 산화물을 포함하는 것을 특징으로 하는 코팅 시스템(1).
  5. 선행항들 중 하나의 항에 있어서,
    상기 제3 층(5)의 경도는 약 25 GPa인 것을 특징으로 하는 코팅 시스템(1).
  6. 선행항들 중 하나의 항에 있어서,
    상기 기재(2)는 가스 터빈의 압축기 부품의 구성 요소인 것을 특징으로 하는 코팅 시스템(1).
  7. 제6항에 있어서,
    상기 기재(2)는 고정식 가스 터빈의 압축기 부품의 구성 요소인 것을 특징으로 하는 코팅 시스템(1).
  8. 제1항 내지 제7항 중 하나의 항에 따른 코팅 시스템을 갖는 가스 터빈의 압축기 부품.
  9. 부식성 부하를 받는 기재를 위한 코팅 시스템을 제조하는 방법으로서,
    제1항 내지 제7항 중 하나의 항에 따른 코팅 시스템의 3 개의 층을 포함하며, 모든 층들의 물질은 물리적 기상 증착에 의해서 적용되는 것을 특징으로 하는 코팅 시스템 제조 방법.
  10. 제9항에 있어서,
    상기 층들의 물질은 음극 아크 증착 및/또는 스퍼터링에 의해 적용되는 것을 특징으로 하는 코팅 시스템 제조 방법.
KR1020187003555A 2015-07-06 2016-06-14 가스 터빈의 압축기 부품에 대한 외형 윤곽을 따른 보호 코팅 KR102568312B1 (ko)

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