US20040159552A1 - Method of depositing a local MCrAIY-coating - Google Patents

Method of depositing a local MCrAIY-coating Download PDF

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Publication number
US20040159552A1
US20040159552A1 US10/726,593 US72659303A US2004159552A1 US 20040159552 A1 US20040159552 A1 US 20040159552A1 US 72659303 A US72659303 A US 72659303A US 2004159552 A1 US2004159552 A1 US 2004159552A1
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Prior art keywords
coating
mcraly
coatings
pat
article
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Abandoned
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US10/726,593
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English (en)
Inventor
Abdus Khan
Thomas Duda
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General Electric Technology GmbH
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Alstom Technology AG
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Assigned to ALSTOM TECHNOLOGY LTD reassignment ALSTOM TECHNOLOGY LTD ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: DUDA, THOMAS, KHAN, ABDUS SUTTAR
Publication of US20040159552A1 publication Critical patent/US20040159552A1/en
Abandoned legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
    • C25D5/02—Electroplating of selected surface areas
    • C25D5/022—Electroplating of selected surface areas using masking means
    • 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
    • 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
    • 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
    • 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
    • F05D2230/80—Repairing, retrofitting or upgrading methods

Definitions

  • This invention relates according to claim 1 to a method of depositing a MCrAlY-coating.
  • MCrAlY overlay coatings are used for protection of turbine blades and vanes.
  • MCrAlY protective overlay coatings are widely known in the prior art. They are a family of high temperature coatings, wherein M is selected from one or a combination of iron, nickel and cobalt.
  • U.S. Pat. No. 3,528,861 or U.S. Pat. No. 4,585,481 are disclosing such kind of oxidation resistant coatings.
  • U.S. Pat. No. 4,152,223 as well discloses such method of coating and the coating itself.
  • ⁇ / ⁇ -MCrAlY-coating there is another class of overlay MCrAlY coatings which are based on a ⁇ / ⁇ ′-gamma/gamma prime-structure, which is for example disclosed in U.S. Pat. No. 4,546,052 or U.S. Pat. No. 4,973,445.
  • ⁇ / ⁇ ′-coatings have a negligible thermal expansion mismatch with alloy of the underlying turbine article and are likely to have a better thermal mechanical properties.
  • U.S. Pat. No. 4,313,760 discloses a superalloy coating composition with good oxidation, corrosion and fatigue resistance. Additional examples MCrAlY coatings are known from U.S. Pat. No. 6,280,857, U.S. Pat. No. 6,221,181, U.S. Pat. No. 5,455,119, U.S. Pat. No. 5,154,885, U.S. Pat. No. 5,035,958 or U.S. Pat. No. 6,207,297. They all deal primarily with improving the oxidation resistance of MCrAlY coatings.
  • Thermal barrier coatings are used to provide thermal insulation of the components in various types of engines e.g. in turbine engines.
  • Thermal Barrier Coatings are known from different patents.
  • U.S. Pat. No. 4,055,705, U.S. Pat. No. 4,248,940, U.S. Pat. No. 4,321,311 or U.S. Pat. No. 4,676,994 disclose a TBC-coating for the use in the turbine blades and vanes.
  • the ceramics used are yttria stabilized zirconia and applied by plasma spray (U.S. Pat. No. 4,055,705, U.S. Pat. No. 4,248,940) or by electron beam process (U.S. Pat. No. 4,321,311, U.S. Pat. No. 4,676,994) on top of the MCrAlY bond coat.
  • One approach of improving the fatigue resistance of coatings is by modification of the composition of the coatings and secondly by the use of a thin coating or possibly a combination of both.
  • U.S. Pat. No. 4,346,137 and U.S. Pat. No. 4,758,480 described a method of improving the fatigue resistance of overlay coatings by a modification of composition.
  • the platinum was added to MCrAlY coatings, which reduces the thermal expansion mismatch between the coatings and the substrate, hence also reduces the propensity of the coatings to cracking. This results in a significant improvement of the TMF life of the coatings.
  • the U.S. Pat. No. 4,758,480 discloses a class of protected coatings for superalloys in which the coating compositions are based on the composition of the underlying substrate. By tailoring the coatings to the substrate composition, diffusional stability results and other mechanical properties of the coating such as coefficient of thermal expansion and modulas, are brought closer to the substrate. The coatings thus obtained showed both increased oxidation and TMF resistance.
  • U.S. Pat. No. 5,558,758, U.S. Pat. No. 5,824,205 and U.S. Pat. No. 5,833,829 described the deposition of MCrAlY coatings by electroplated process.
  • the process involves a deposition of the coating precursor, CrAlM2 powder in a M1 bath where M2 is one or more of Si, Ti, Hf, Ga, Nb, Mn, Pt and rare earth elements and M1 consists of Ni, Co, Fe alone or in combination.
  • the as-deposited coating is heat-treated to obtain the final coating structure.
  • the stress strain distribution and thermal-mechanical loading are different area to area.
  • some local area i.e. zone in an airfoil may be sensitive to oxidation or corrosion or thermal mechanical fatigue, or possibly a combination of one or more of degradation mode.
  • a local coating with appropriate set of properties could be potentially beneficial in increasing the lifetime of airfoils.
  • the plasma spray process generally used for manufacturing of coating is not ideal for local coating—it has a line of sight limitation and cannot coat effectively many ‘difficult to coat area’ such as platform to airfoil transition area with good thickness control.
  • EP-B1-0 139 396 disclosed a process of local coating of turbine blade by plasma spraying of MCrAlY coatings.
  • local coatings for repair or refurbish of components degraded by oxidation or corrosion For example, U.S. Pat. No. 6,203,847 provided a method of repairing by first plating the affected areas with Pt or noble metals then aluminising the surfaces.
  • U.S. Pat. No. 6,274,193 restored a protective coating in a local areas with a replacement aluminide coating.
  • the aim of the present invention is to find a MCrAlY-bond or overlay coating with good oxidation and fatigue resistance according to the requirements on local areas of a gas turbine component. Another aim is to find a method of depositing a MCrAlY-coating on a turbine component with uniformity. Yet another aim of the invention is to deposit a thin MCrAlY-coating on a large industrial gas turbine blade or vane with a good thickness control of the deposited layer.
  • the present invention individualized local or zone-coating by using an electroplated method. It is noted that the cost of the application of a coating by a galvanic process is with advantage a third of a conventional plasma spray coating.
  • the process of the invention has a thickness control of ⁇ 20 ⁇ m of the thickness of the deposited layer, where as conventional plasma spray coating processes have thickness scatters of ⁇ 75 ⁇ m or even more. Thus, a coating with a layer thickness in a range of 25-400 ⁇ m can be applied. A thinner coating increase the TMF life of the coating.
  • the used electroplated process has no line of sight limitation and can coat complex contour surfaces without any difficulty.
  • the coating/masking step can be repeated at different local areas on the surface of the article.
  • the different areas can be coated with different MCrAlY-coatings.
  • the MCrAlY-coatings are the selected according to the required properties in said areas in respect to one or a combination of oxidation, corrosion, thermal mechanical fatigue (TMF).
  • TMF thermal mechanical fatigue
  • Examples of electroplated ⁇ / ⁇ ′ and that of ⁇ / ⁇ -MCrAlY local coatings are Ni-24Cr-5Al-1Ta-1.2Si-0.3Y and Ni-23C0-18Cr-10Al.0.5Y, respectively, or known from the unpublished patent application with application no. EP02405881.0 (internal reference number B02/046-0), which has the same applicant as the present application.
  • FIG. 1 shows as an example such an article 1 as blades or vanes comprising a blade 2 against which hot combustion gases are directed during operation of the gas turbine engine, a cavity, not visible in FIG. 1, and cooling holes 4 , which are on the external surface 5 of the component 1 as well as on the platform 3 of the component. Through the cooling holes 4 cooling air is ducted during operation of the engine to cool the external surface 5 .
  • the external surface 5 is subjected to severe attack by oxidation, corrosion and erosion due to the hot combustion gases and more importantly TMF cracking due to thermal mechanical loading.
  • the article 1 consists of a nickel or cobalt base super alloy such as disclosed, by way of an example, in U.S. Pat. No. 5,759,301.
  • the article 1 can be single crystal (SX) or directionally solidified (DS). While the advantages of this invention is described with reference to a turbine blade or vane as shown in FIG. 1, the invention is generally applicable to any component on which a coating system may be used to protect the component from its environment.
  • the present invention individualized local or zone-coating 6 by using an electroplated method.
  • the TMF life of the electroplated coating 6 was at least 2 times higher than the life of the plasma sprayed coatings. It is noted that the cost of the application of a coating 6 by an electroplated process is with advantage a third of a conventional plasma spray coating.
  • the process of the invention has a thickness control of ⁇ 20 ⁇ m of the thickness of the deposited layer, where as conventional plasma spray coating processes have thickness scatters of ⁇ 75 ⁇ m or even more. Thus, a coating with a layer thickness in a range of 25-400 ⁇ m can be applied. A thinner coating 6 increase the TMF life of the coating 6 .
  • the used electroplated process has no line of sight limitation and can coat complex contour surfaces without any difficulty.
  • the target coatings 6 shall be selected from the MCrAlX family of coatings tailored for oxidation/corrosion or fatigue resistance according the requirements at the local zone.
  • the coatings 6 shall be applied in steps. Initially the areas not be coated are masked and the target area is coated by the electroplated method.
  • Another previously masked area is coated, whereas the other areas is previously masked.
  • To be able to coat the mask from the target area is removed and at the same time mask the previously coated area.
  • the process of masking and coating of target areas are repeated as often as necessary.
  • the surface will appear as if decorated with a series of ‘patch coatings’ each distinct from the other.
  • the different areas can be coated with different MCrAlY-coatings 6 .
  • the MCrAlY-coatings are the selected according to the required properties in said areas in respect to one or a combination of oxidation, corrosion, thermal mechanical fatigue (TMF).
  • TMF thermal mechanical fatigue
  • One example of localized coating could be the TMF resistant coating on the platform/airfoil transition area of gas turbine blades and vanes and a highly oxidation resistant coating provided on the upper airfoil—the tip section.
  • the masks used are wax and organic polymers. These masks can be applied and removed easily and do not leave any residue or chemical impurity behind on the surface.
  • the method can be used as a repair process for a used MCrAlY-coating 6 .
  • Examples of electroplated ⁇ / ⁇ ′ and that of ⁇ / ⁇ -MCrAlY local coatings are Ni-24Cr-5Al-1Ta-1.2Si-0.3Y and Ni-23C0-18Cr-10Al.0.5Y, respectively, or known from the unpublished patent application with application no. EP02405881.0 (internal reference number B02/046-0), which has the same applicant as the present application.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • General Engineering & Computer Science (AREA)
  • Electrochemistry (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Electroplating Methods And Accessories (AREA)
US10/726,593 2002-12-06 2003-12-04 Method of depositing a local MCrAIY-coating Abandoned US20040159552A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP02406066.7 2002-12-06
EP02406066A EP1428982B1 (fr) 2002-12-06 2002-12-06 Méthode pour déposer localement un revêtement de type MCrAlY

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US20040159552A1 true US20040159552A1 (en) 2004-08-19

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US (1) US20040159552A1 (fr)
EP (1) EP1428982B1 (fr)
JP (1) JP2004190140A (fr)
DE (1) DE60231084D1 (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20040079648A1 (en) * 2002-10-15 2004-04-29 Alstom (Switzerland) Ltd. Method of depositing an oxidation and fatigue resistant MCrAIY-coating
US8728951B2 (en) 2012-07-31 2014-05-20 Varian Semiconductor Equipment Associates, Inc. Method and system for ion-assisted processing
US20160003074A1 (en) * 2013-03-14 2016-01-07 United Technologies Corporation Gas turbine engine stator vane platform cooling
US11395991B2 (en) * 2015-09-29 2022-07-26 Ketai (Beijing) Technology Co., Ltd. Metal-organic framework filter and preparation method thereof

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DE102006051813A1 (de) 2006-11-03 2008-05-08 Mtu Aero Engines Gmbh Schaufel für einen Verdichter oder eine Turbine eines Flugtriebwerks, Flugtriebwerk mit einer solchen Schaufel sowie Verfahren zum Beschichten einer Schaufel eines Flugtriebwerks
EP2157209B1 (fr) 2008-07-31 2014-10-22 Rohm and Haas Electronic Materials LLC Inhibition de placage d'arrière plan
JP6126852B2 (ja) * 2012-02-21 2017-05-10 ハウメット コーポレイションＨｏｗｍｅｔ Ｃｏｒｐｏｒａｔｉｏｎ ガスタービン部品のコーティング及びコーティング方法
CN104141157A (zh) * 2013-05-07 2014-11-12 景祥凯工业股份有限公司 手工具制造方法
WO2015077163A1 (fr) 2013-11-19 2015-05-28 United Technologies Corporation Article possédant un revêtement de composition variable
US9957629B2 (en) * 2014-08-27 2018-05-01 Praxair S.T. Technology, Inc. Electroplated coatings
KR102711268B1 (ko) * 2019-03-07 2024-09-26 오를리콘 메트코 (유에스) 아이엔씨. 열 사이클 피로 내성 및 황화부식 저항성이 향상된 tbc용 고도의 접합 코트 재료

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EP1428982A1 (fr) 2004-06-16
DE60231084D1 (de) 2009-03-19
EP1428982B1 (fr) 2009-02-04

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