US20060216429A1 - Method of depositing an anti-wear coating by thermal spraying - Google Patents

Method of depositing an anti-wear coating by thermal spraying Download PDF

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Publication number
US20060216429A1
US20060216429A1 US11/385,734 US38573406A US2006216429A1 US 20060216429 A1 US20060216429 A1 US 20060216429A1 US 38573406 A US38573406 A US 38573406A US 2006216429 A1 US2006216429 A1 US 2006216429A1
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US
United States
Prior art keywords
coating
spraying
weight
hvaf
cuniin
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US11/385,734
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English (en)
Inventor
Per Bengtsson
Laurent Dudon
Gerard Gueldry
Michel Hacala
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PLASMATEC
Safran Aircraft Engines SAS
Original Assignee
PLASMATEC
SNECMA SAS
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date
Application filed by PLASMATEC, SNECMA SAS filed Critical PLASMATEC
Assigned to SNECMA, PLASMATEC reassignment SNECMA ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BENGTSSON, PER, DUDON, LAURENT PAUL, GUELDRY, GERARD MICHEL ROLAND, HACALA, MICHEL
Publication of US20060216429A1 publication Critical patent/US20060216429A1/en
Abandoned legal-status Critical Current

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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
    • 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
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/06—Metallic material
    • 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
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • 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
    • F05D2230/30—Manufacture with deposition of material
    • F05D2230/31—Layer deposition
    • 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
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/10—Metals, alloys or intermetallic compounds
    • F05D2300/17—Alloys
    • F05D2300/172—Copper alloys
    • F05D2300/1723—Nickel-Copper alloy, e.g. Monel

Definitions

  • the invention relates to a method of depositing an anti-wear coating on a mechanical part by thermal spraying, and more particularly it relates to a gas turbine part made of titanium or titanium alloy such as a fan blade or a compressor blade of a turbomachine.
  • Fan or compressor blades constitute good examples of parts that are subjected to wear while a turbine is in operation. Such blades are held by their roots in slots of appropriate shape that are formed in the peripheries of rotary disks, referred to below as compressor disks or fan disks.
  • the blade roots move in said slots under the effects of centrifugal force and of vibration.
  • the roots of blades are shaped in a manner that matches the shapes of the slots so as to make such relative displacements possible.
  • the surfaces of blade roots that come to bear against the edges of said slots under the effect of centrifugal force are subjected to significant compression stresses (which are generally cyclical). These stresses in combination with vibratory movement damage and wear said surfaces. The wear that is observed is found to be even greater when the blade roots and the fan or compressor disks are made of titanium or titanium alloy. This is because the coefficient of friction of titanium on titanium is rather high.
  • anti-wear coatings that are constituted by copper nickel alloys (CuNi), copper aluminum alloys (CuAl), or indeed copper nickel indium alloys (CuNiIn). It is generally preferred to use a copper nickel indium type alloy (CuNiIn) since it presents better mechanical characteristics at high temperatures.
  • Plasma spraying In order to deposit these alloys on blade roots, it is common practice to use a thermal spraying technique known as plasma spraying. That technique can be implemented using a plasma gun such as that described in U.S. Pat. No. 3,145,287. Plasma spraying consists in bringing alloy powder to a plasma torch that is producing a jet of gas at very high temperature: greater than 2000° C. The speed at which the particles are sprayed lies in the range 100 meters per second (m/s) to 400 m/s.
  • the microstructure of the coating deposited by plasma spraying nevertheless presents very high porosity and oxidation, thereby affecting the mechanical properties of the coating.
  • the coating adheres poorly on titanium or titanium alloy.
  • a second type of thermal spraying is also used for depositing anti-wear coatings: this is known as high velocity oxy fuel (HVOF) spraying which consists in taking advantage of combustion between oxygen and a fuel gas such as propane, propylene, hydrogen, or propadiene methyl acetylene, in order to heat and propel molten grains of alloy powder at very high speed.
  • HVOF high velocity oxy fuel
  • the temperatures reached with that method lie in the range 1500° C. to 2000° C. and the spray speeds lie in the range 300 m/s to 700 m/s.
  • An example of depositing a nickel-based alloy using HVOF spraying is described in U.S. Pat. No. 5,518,683.
  • An object of the invention is to propose a novel method of deposition that makes it possible to deposit anti-wear coatings that are better at withstanding the stresses to which they are subjected than are the coatings obtained by existing methods.
  • the invention provides a method of depositing an alloy of copper, nickel, and indium by thermal spraying to constitute an anti-wear coating on a mechanical part, wherein said coating is deposited by thermal spraying of the activated combustion high velocity air fuel (AC-HVAF) type.
  • AC-HVAF activated combustion high velocity air fuel
  • Thermal spraying of the AC-HVAF type is a known technique that differs from the above-mentioned HVOF spraying mainly by using a mixture of air and a fuel gas such as propane (instead of a mixture of oxygen and gas) that is burnt in order to heat and propel an alloy powder at very high speed.
  • a fuel gas such as propane (instead of a mixture of oxygen and gas) that is burnt in order to heat and propel an alloy powder at very high speed.
  • the molten alloy particles are sprayed at a speed lying substantially in the range 600 m/s to 800 m/s, and the temperatures reached lie in the range 800° C. to 1500° C.
  • the temperatures reached during spraying of the AC-HVAF type are lower than those reached during spraying of the HVOF or plasma type. This serves to limit oxidation of the sprayed particles.
  • the spray speeds that can be obtained with the AC-HVAF method are higher than the speeds obtained by plasma or HVOF spraying.
  • the lapse of time between the moment when the particles are sprayed and the moment when they reach the part to be coated, during which time lapse the particles are particularly sensitive to oxidizing is itself shortened. This also contributes to reducing the extent to which the coating is oxidized.
  • the high kinetic energy of the particles sprayed onto the part for coating makes it possible firstly to achieve better bonding of the particles on the part, and secondly to obtain a coating that is more compact, presenting porosity that is less than that obtained with the methods that have been used in the past.
  • the structure of the resulting coating is unitary and not lamellar.
  • AC-HVAF thermal spraying is less expensive than plasma spraying.
  • said coating is constituted by a copper-based alloy containing 30% to 42% by weight of nickel and 2% to 8% by weight of indium.
  • said coating comprises a copper-based alloy comprising 34% to 38% by weight of nickel and 4% to 6% by weight of indium.
  • CuNiIn coatings are advantageous since they are mechanically very strong at high temperatures.
  • the Applicant company While undertaking research to improve the lifetime of anti-wear coatings of this type, the Applicant company has found that the melting temperatures of CuNiIn alloys are much lower than the temperatures reached during plasma spraying, and lower than those reached during a HVOF type spraying. In contrast, the temperatures reached during AC-HVAF spraying turn out to be of the same order as the melting temperatures of said CuNiIn alloy. It has thus been found that by using the AC-HVAF method, it is possible to melt a CuNiIn alloy while avoiding any useless oxidation associated with temperatures that are too high. The AC-HVAF method thus turns out to be particularly well suited to depositing CuNiIn coatings.
  • a lubricating varnish layer is deposited thereon, e.g. comprising molybdenum disulfide (MoS 2 ) and an organic resin.
  • MoS 2 molybdenum disulfide
  • CuNiIn coatings present high roughness and it is advisable to cover them in a layer of varnish having a low coefficient of friction in order to encourage sliding and limit wear.
  • the combined coating of CuNiIn and a layer of lubricant gives results that are entirely satisfactory in terms of protecting the part and in terms of the lifetime of the coating.
  • the method of the invention can be used for coating any type of part, regardless of whether it is made of titanium or a titanium alloy.
  • the method can be used for coating at least one part taken from any two gas turbine parts of any kind that are liable to come into contact with each other.
  • FIG. 1 is a comparative plot
  • FIG. 2 is a micrograph of a CuNiIn coating deposited by AC-HVAF spraying in accordance with the method of the invention
  • FIG. 3 is a micrograph of a CuNiIn coating deposited by plasma spraying
  • FIG. 4 is a diagram of a device enabling the stresses exerted on a fan blade root in operation to be simulated.
  • FIG. 5 is a graph showing a cycle in the variation of the traction force exerted on a fan blade root in operation, as a function of time.
  • the plot of FIG. 1 has spray speed in m/s plotted along the abscissa and spray temperature in ° C. plotted up the ordinate, as obtained when using various thermal spraying methods.
  • spray speed in m/s plotted along the abscissa and spray temperature in ° C. plotted up the ordinate, as obtained when using various thermal spraying methods.
  • outlines for temperature and spray speed ranges for plasma, HVAF, and AC-HVAF spraying Furthermore, the range of temperatures over which a copper-based alloy such as the CuNiIn alloy melts is also shown.
  • Composition CuNiIn alloy comprising 36% by weight Ni, 5% by weight In, with the balance being Cu;
  • Particle size 11 micrometers ( ⁇ m) to 45 ⁇ m;
  • Torch feed rate 8 kilograms per hour (kg/h);
  • Carrier gas nitrogen.
  • Coating deposition rate 45 ⁇ m per pass.
  • Preparation sandblasting with aluminum oxide particles having a mean size of 300 ⁇ m;
  • the thickness of the deposited coating was 165 ⁇ m, but greater thicknesses could have been obtained without any particular difficulty.
  • the measured porosity of the coating was less than 1%.
  • the micrograph of FIG. 2 was taken of the CuNiIn coating deposited using AC-HVAF in accordance with the invention, while the micrograph of FIG. 3 was taken using a CuNiIn coating obtained by plasma spraying.
  • the oxides and the pores appear in the form of black spots in the layer of coating 2 deposited on the substrate 1 .
  • the presence of oxides and pores in the coating of FIG. 2 is less than in the coating of FIG. 3 .
  • the coating of FIG. 2 presents a microstructure that is compact and unitary, whereas that of the coating of FIG. 3 is lamellar. Consequently, the coating deposited with the method of the invention is less subject to becoming delaminated (and thus to flaking) than is the coating obtained by plasma spraying. To sum up, the microstructure of the coating in FIG. 2 is mechanically stronger.
  • a device was used similar to that shown in FIG. 4 in which a mechanical part 10 representing the blade was mounted via its root 14 in a slot 15 defined between two uprights 16 a and 16 b, and it was held in position between two jaws 18 .
  • the assembly made in this way is analogous to a dovetail assembly.
  • the uprights 16 a and 16 b represented the fan disk.
  • the root 14 of the part 10 had two surfaces 14 a and 14 b that were in contact with the uprights 16 a and 16 b.
  • a cyclical traction force F was exerted on the part 10 . The way the force F varied as a function of time is shown in FIG. 5 .

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Plasma & Fusion (AREA)
  • Physics & Mathematics (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • General Engineering & Computer Science (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
US11/385,734 2005-03-23 2006-03-22 Method of depositing an anti-wear coating by thermal spraying Abandoned US20060216429A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR0502865A FR2883574B1 (fr) 2005-03-23 2005-03-23 "procede de depot par projection thermique d'un revetement anti-usure"
FR05002865 2005-03-23

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US (1) US20060216429A1 (fr)
EP (1) EP1705261A1 (fr)
JP (1) JP2006266264A (fr)
CN (1) CN1896312A (fr)
CA (1) CA2540266A1 (fr)
FR (1) FR2883574B1 (fr)

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110000308A1 (en) * 2008-02-25 2011-01-06 Snecma Device for testing the coating of a vane base
US20110138926A1 (en) * 2008-02-25 2011-06-16 Snecma Method for testing the coating of a vane base
US20160004744A1 (en) * 2013-03-07 2016-01-07 Brian Charles ERIKSSON Top-k search using selected pairwise comparisons
US9664201B2 (en) 2011-08-10 2017-05-30 Snecma Method of making protective reinforcement for the leading edge of a blade
US10029957B2 (en) * 2012-08-21 2018-07-24 Uop Llc Methane conversion apparatus and process using a supersonic flow reactor
US10160697B2 (en) * 2012-08-21 2018-12-25 Uop Llc Methane conversion apparatus and process using a supersonic flow reactor
US10166524B2 (en) * 2012-08-21 2019-01-01 Uop Llc Methane conversion apparatus and process using a supersonic flow reactor
US10195574B2 (en) * 2012-08-21 2019-02-05 Uop Llc Methane conversion apparatus and process using a supersonic flow reactor
US10214464B2 (en) * 2012-08-21 2019-02-26 Uop Llc Steady state high temperature reactor
US10982310B2 (en) 2018-04-09 2021-04-20 ResOps, LLC Corrosion resistant thermal spray alloy
US20220049611A1 (en) * 2020-08-14 2022-02-17 Raytheon Technologies Corporation Self-lubricating blade root/disk interface

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JP4692462B2 (ja) * 2006-10-12 2011-06-01 株式会社Ｉｈｉ 摺動構造体及び皮膜形成方法
DE202010018202U1 (de) * 2010-02-18 2014-09-09 Hydac Accessories Gmbh Verbindungsvorrichtung sowie Verwendung eines metallischen Werkstoffes
CN103276341B (zh) * 2013-05-08 2015-04-08 西安热工研究院有限公司 一种水轮机过流部件耐磨蚀涂层的喷涂方法
CN104775052B (zh) * 2015-04-24 2016-11-30 吴丽清 一种汽车用水泵
CN112267061A (zh) * 2020-10-13 2021-01-26 泗县金皖泵业有限公司 一种降低水泵运行中水力损失的水泵叶轮加工工艺
CN114703440B (zh) * 2022-04-02 2023-11-17 华东理工大学 一种纳米氧化物分散强化高熵合金粘结层及其制备方法和应用

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US5271965A (en) * 1991-01-16 1993-12-21 Browning James A Thermal spray method utilizing in-transit powder particle temperatures below their melting point
US5601933A (en) * 1994-03-17 1997-02-11 Sherritt Inc. Low friction cobalt based coatings for titanium alloys
US6245390B1 (en) * 1999-09-10 2001-06-12 Viatcheslav Baranovski High-velocity thermal spray apparatus and method of forming materials
US20010026845A1 (en) * 1997-08-11 2001-10-04 Drexel University Method of applying corrosion, oxidation and/or wear-resistant coatings
US20050112411A1 (en) * 2003-11-21 2005-05-26 Gray Dennis M. Erosion resistant coatings and methods thereof

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US3145287A (en) 1961-07-14 1964-08-18 Metco Inc Plasma flame generator and spray gun
US5312696A (en) * 1991-09-16 1994-05-17 United Technologies Corporation Method for reducing fretting wear between contacting surfaces
US5518683A (en) 1995-02-10 1996-05-21 General Electric Company High temperature anti-fretting wear coating combination
US5932293A (en) * 1996-03-29 1999-08-03 Metalspray U.S.A., Inc. Thermal spray systems
FR2836620B1 (fr) * 2002-02-28 2004-04-16 Snecma Services Instrument de projection thermique

Patent Citations (6)

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Publication number Priority date Publication date Assignee Title
US3793195A (en) * 1972-10-10 1974-02-19 Gen Electric Coated bearing surfaces
US5271965A (en) * 1991-01-16 1993-12-21 Browning James A Thermal spray method utilizing in-transit powder particle temperatures below their melting point
US5601933A (en) * 1994-03-17 1997-02-11 Sherritt Inc. Low friction cobalt based coatings for titanium alloys
US20010026845A1 (en) * 1997-08-11 2001-10-04 Drexel University Method of applying corrosion, oxidation and/or wear-resistant coatings
US6245390B1 (en) * 1999-09-10 2001-06-12 Viatcheslav Baranovski High-velocity thermal spray apparatus and method of forming materials
US20050112411A1 (en) * 2003-11-21 2005-05-26 Gray Dennis M. Erosion resistant coatings and methods thereof

Cited By (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110138926A1 (en) * 2008-02-25 2011-06-16 Snecma Method for testing the coating of a vane base
US8387467B2 (en) 2008-02-25 2013-03-05 Snecma Method for testing the coating of a vane base
US8408068B2 (en) 2008-02-25 2013-04-02 Snecma Device for testing the coating of a vane base
US20110000308A1 (en) * 2008-02-25 2011-01-06 Snecma Device for testing the coating of a vane base
US9664201B2 (en) 2011-08-10 2017-05-30 Snecma Method of making protective reinforcement for the leading edge of a blade
US10029957B2 (en) * 2012-08-21 2018-07-24 Uop Llc Methane conversion apparatus and process using a supersonic flow reactor
US10160697B2 (en) * 2012-08-21 2018-12-25 Uop Llc Methane conversion apparatus and process using a supersonic flow reactor
US10166524B2 (en) * 2012-08-21 2019-01-01 Uop Llc Methane conversion apparatus and process using a supersonic flow reactor
US10195574B2 (en) * 2012-08-21 2019-02-05 Uop Llc Methane conversion apparatus and process using a supersonic flow reactor
US10214464B2 (en) * 2012-08-21 2019-02-26 Uop Llc Steady state high temperature reactor
US20160004744A1 (en) * 2013-03-07 2016-01-07 Brian Charles ERIKSSON Top-k search using selected pairwise comparisons
US10982310B2 (en) 2018-04-09 2021-04-20 ResOps, LLC Corrosion resistant thermal spray alloy
US20220049611A1 (en) * 2020-08-14 2022-02-17 Raytheon Technologies Corporation Self-lubricating blade root/disk interface
US11952916B2 (en) * 2020-08-14 2024-04-09 Rtx Corporation Self-lubricating blade root/disk interface

Also Published As

Publication number Publication date
CA2540266A1 (fr) 2006-09-23
FR2883574A1 (fr) 2006-09-29
JP2006266264A (ja) 2006-10-05
EP1705261A1 (fr) 2006-09-27
FR2883574B1 (fr) 2008-01-18
CN1896312A (zh) 2007-01-17

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