US20080317622A1 - Thermal barrier deposited directly on monocrystalline superalloys - Google Patents

Thermal barrier deposited directly on monocrystalline superalloys Download PDF

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Publication number
US20080317622A1
US20080317622A1 US12/053,901 US5390108A US2008317622A1 US 20080317622 A1 US20080317622 A1 US 20080317622A1 US 5390108 A US5390108 A US 5390108A US 2008317622 A1 US2008317622 A1 US 2008317622A1
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oxide
superalloy
zirconia
constituted
stabilized
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US12/053,901
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Inventor
Florent Didier Andre Bourlier
Kristell Le Biavant
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Safran Aircraft Engines SAS
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SNECMA SAS
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C19/00—Alloys based on nickel or cobalt
    • C22C19/03—Alloys based on nickel or cobalt based on nickel
    • C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
    • C22C19/051—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W
    • C22C19/057—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being less 10%
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C19/00—Alloys based on nickel or cobalt
    • C22C19/03—Alloys based on nickel or cobalt based on nickel
    • C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
    • C22C19/058—Alloys based on nickel or cobalt based on nickel with chromium without Mo and W
    • 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
    • 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
    • C23C28/04—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 only coatings of inorganic non-metallic material
    • C23C28/042—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 only coatings of inorganic non-metallic material including a refractory ceramic layer, e.g. refractory metal oxides, ZrO2, rare earth oxides
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00—Aeronautics or air transport
    • Y02T50/60—Efficient propulsion technologies, e.g. for aircraft

Definitions

  • the present invention relates to a method of depositing a thermal barrier on a monocrystalline superalloy.
  • High pressure turbine blades in turbomachines need to conserve their mechanical properties, their resistance to corrosion, and their resistance to oxidation in the aggressive environment of gas at very high temperature (more than 1000° C.) ejected at high speed.
  • the superalloys that presently provide the best high temperature performance ideally monocrystalline superalloys
  • a superalloy commonly in use is the alloy known as AM1, which is a nickel-based superalloy in accordance with U.S. Pat. No.
  • 4,639,280 having the following composition by weight: 5% to 8% Co, 6.5% to 10% Cr, 0.5% to 2.5% Mo, 5% to 9% W, 6% to 9% Ta, 4.5% to 5.8% Al, 1% to 2% Ti, 0 to 1.5% Nb, and C, Zr, B each less than 0.01%.
  • the thermal barriers presently in use are typically made by depositing a ceramic layer on the superalloy.
  • the ceramic layer is typically based on zirconia (zirconium oxide).
  • the ceramic layer provides the superalloy with thermal insulation, and enables the surface of the superalloy to be maintained at temperatures for which its mechanical performance and lifetime are acceptable.
  • the underlayer that is thus interposed between the superalloy and the ceramic is normally an intermetallic compound, e.g. a compound of the MCrAlY type (where “M” designates Ni, Co, or a combination thereof), or a platinum-modified nickel aluminide (e.g. NiAlPt).
  • the platinum is typically deposited on the superalloy by electrolysis, which operation is typically followed by vapor phase aluminization.
  • This underlayer also serves to protect the superalloy against the phenomenon of high temperature oxidation.
  • the oxidation layer forms at the surface of the underlayer and not at the surface of the superalloy.
  • the oxide constituting said layer is typically alumina (aluminum oxide) that is formed by oxidizing the aluminum contained in the underlayer.
  • the use of such an underlayer presents several drawbacks. Depositing the underlayer leads to additional material and process cost. In addition, it makes the overall method of fabricating the part coated in the thermal barrier more complex. In such situations, the underlayer must be deposited before drilling the holes that are included in the superalloy part, otherwise the electrolytic deposition of the underlayer runs the risk of obstructing holes of small diameter. Deposition must therefore be performed after the superalloy part has been machined, but before drilling holes in that part. This involves additional trips for the part between machining/drilling stations and the station for depositing the underlayer. These trips are undesirable since they increase the risk of the surface of the part being contaminated by foreign elements that can reduce the bonding capacity of the ceramic that is subsequently deposited on said surface.
  • EBPVD electron beam physical vapor deposition
  • the layer of alumina (oxidation layer) tends to undulate so as to follow deformations in the underlayer, thereby leading to regions where the ceramic is held by the alumina in spots only and from which the ceramic becomes detached prematurely.
  • This localized detachment of the ceramic layer from the underlayer (or other surface on which it is bonded) is referred to as spalling. Once the ceramic has begun to spall, the part deteriorates rapidly and is no longer capable of providing the required performance.
  • the invention seeks to provide a method that makes it possible to increase the lifetime of a superalloy coated in a thermal barrier, while simplifying the fabrication flow-process for said assembly and reducing its fabrication cost.
  • the superalloy has following composition by weight: 3.5% to 7.5% Cr, 0 to 1.5% Mo, 1.5% to 5.5% Re, 2.5% to 5.5% Ru, 3.5% to 8.5% W, 5% to 6.5% Al, 0 to 2.5% Ti, 4.5% to 9% Ta, 0.08% to 0.12% Hf, 0.08% to 0.12% Si, the balance to 100% being constituted by Ni and any impurities, and in that a stabilized zirconia is deposited directly on said superalloy, the zirconia being stabilized with at least one oxide of an element selected from the group constituted by rare earths, or with a combination of a tantalum oxide and at least one rare earth oxide, or with a combination of a niobium oxide and at least one rare earth oxide.
  • MCNG superalloys which term is used in the description below.
  • the fabrication flow process for the thermal barrier is simplified. Firstly there is no need to deposit the underlayer since the zirconia is deposited directly on the superalloy without any underlayer. Secondly it is possible to drill holes immediately after the MCNG superalloy part has been machined, where those two operations (drilling and machining) are preferably performed in the same workshop. The risks of the surface of the superalloy being contaminated are thus minimized. After the drilling operation, the part is taken directly to the workshop for depositing the final ceramic layer.
  • the lifetime of a superalloy having a thermal barrier deposited thereon by the method of the present invention is lengthened. This is due in particular to the fact that the zirconia-based ceramic deposited on an MCNG superalloy is less sensitive to the above-described phenomenon of the alumina layer undulating. Tests have shown that oxidation at the interface between the zirconia and the MCNG superalloy takes place in more uniform and rectilinear manner than oxidation of a conventional underlayer. The physical bonding between the alumina and the ceramic thus occupies a larger area than with AM1.
  • the superalloy has the following composition by weight: 3.5% to 5.5% Cr, 0 to 1.5% Mo, 4.5% to 5.5% Re, 2.5% to 5.5% Ru, 4.5% to 6.5% W, 5% to 6.5% Al, 0 to 1.5% Ti, 5% to 6.2% Ta, 0.08% to 0.12% Hf, 0.08% to 0.12% Si, the balance to 100% being constituted by Ni and any impurities.
  • the superalloy has the following composition by weight: 3.5% to 5.5% Cr, 0 to 1.5% Mo, 3.5% to 4.5% Re, 3.5% to 5.5% Ru, 4.5% to 6.5% W, 5.5% to 6.5% Al, 0 to 1% Ti, 4.5% to 5.5% Ta, 0.08% to 0.12% Hf, 0.08% to 0.12% Si, the balance to 100% being constituted by Ni and any impurities.
  • Bare MCNG alloys (having no thermal barrier) of those compositions present longer lifetime than other bare MCNG alloys throughout the temperature range 950° C. to 1150° C. The same conclusion is thus true for superalloys of these compositions on which a thermal barrier is deposited using the method of the present invention compared with other MCNG alloys on which a thermal barrier is deposited using the method of the present invention.
  • the invention also provides a part which, according to the invention, is constituted by a monocrystalline superalloy having the following composition by weight: 3.5% to 7.5% Cr, 0 to 1.5% Mo, 1.5% to 5.5% Re, 2.5% to 5.5% Ru, 3.5% to 8.5% W, 5% to 6.5% Al, 0 to 2.5% Ti, 4.5% to 9% Ta, 0.08% to 0.12% Hf, 0.08% to 0.12% Si, the balance to 100% being constituted by Ni and any impurities, and in that at least a portion of its surface is in direct contact with a zirconia stabilized with at least one oxide of an element selected from the group constituted by rare earths, or with a combination of a tantalum oxide and at least one rare earth oxide, or with a combination of a niobium oxide and at least one rare earth oxide, said zirconia acting as a thermal barrier.
  • the stabilized zirconia is in direct contact with a portion of the surface of the superalloy.
  • the term “direct” is used to mean that there is no underlayer between the zirconia and the surface of the superalloy. It should be observed that during deposition of the ceramic and then once the part is in working condition, an oxide layer develops at the interface between the superalloy and the zirconia. Even in the presence of this oxide layer, it is considered that the zirconia is in direct contact with the superalloy.
  • a monocrystalline superalloy 10 of the MCNG type is covered in a ceramic that is a zirconia partially or completed stabilized with at least one rare earth oxide, or else a combination of a tantalum oxide and at least one rare earth oxide, or even with a combination of a niobium oxide and at least one rare earth oxide.
  • the rare earth group is constituted by cerium, dysprosium, erbium, europium, gadolinium, holmium, lanthanum, lutetium, neodymium, praseodymium, promethium, samarium, scandium, terbium, thulium, ytterbium, and yttrium.
  • the zirconia can be stabilized with at least one oxide of an element selected from the group constituted by dysprosium, erbium, europium, gadolinium, samarium, ytterbium, yttrium, or with a combination of a tantalum oxide and at least one oxide of an element in this group, or with a combination of a niobium oxide and at least one oxide of an element in this group.
  • the zirconia is stabilized with an yttrium oxide.
  • the ceramic is deposited by the electron beam physical vapor deposition (EBPVD) method.
  • the ceramic is supplied in the form of a powder that, once vaporized by the electron beam, condenses on the MCNG superalloy to form a ceramic layer 20 . Because an electron beam is used, it is necessary to maintain a primary vacuum in the enclosure containing the electron beam, the ceramic for deposition, and the MCNG superalloy substrate.
  • the ceramic layer 20 deposited by the EBPVD method presents a structure in the form of adjacent columns 22 that are substantially perpendicular to the surface of the superalloy 10.
  • the MCNG superalloy part 10 covered in ceramic 20 may be constituted, for example, by a high pressure turbine blade for a turbomachine.
  • a high pressure turbine blade for a turbomachine In operation, i.e. when such a blade is in the aggressive environment of very high temperature gas (higher than 1500° C.) ejected at high speed, the surface of the superalloy oxidizes progressively.
  • An oxide layer 15 is thus created constituted by oxides of aluminum (alumina) at the interface between the superalloy 10 and the ceramic layer 20 , as shown in the sole Figure.
  • Comparative tests have also been performed between the same AM1 monocrystalline superalloy coated with an underlayer of NiAlPt (nickel-aluminum-platinum) and then a zirconia layer stabilized with dysprosium oxide deposited by EBPVD, and the same MCNG superalloy coated with a zirconia layer stabilized with dysprosium oxide deposited by EBPVD.
  • the tests consisted in oxidizing cylindrical test pieces (thickness 2 millimeters (mm), diameter 25 mm) in a cycle comprising being maintained in an oven at 1100° C. in air followed by cooling under pulsed air for 15 minutes.
  • the rare earth oxide mass contents in the zirconia were respectively 6.8% Y 2 O 3 and 27.3% Dy 2 O 3 .
  • zirconia stabilized by an oxide other than yttrium oxide has required deposition in two layers: a layer having a thickness of a few tens of micrometers of zirconia stabilized with yttrium oxide, on which the desired ceramic is then deposited.
  • Attempts at depositing zirconia stabilized by an oxide other than yttrium oxide directly on any nickel-based superalloy coated in an NiAlPt type underlayer were found to be disappointing in terms of ability to withstand cycled oxidation.
  • zirconia stabilized with yttrium oxide withstands those stresses.
  • the MCNG superalloy part covered in a layer of zirconia stabilized in accordance with the invention can be used in a terrestrial or aviation turbomachine.
  • the part can be used in airplane turbojets. It can also be used in any machine where its high temperature mechanical performance is necessary.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Ceramic Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
  • Physical Vapour Deposition (AREA)
US12/053,901 2007-03-30 2008-03-24 Thermal barrier deposited directly on monocrystalline superalloys Abandoned US20080317622A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR0754156A FR2914319B1 (fr) 2007-03-30 2007-03-30 Barriere thermique deposee directement sur superalliages monocristallins.
FR0754156 2007-03-30

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US20080317622A1 true US20080317622A1 (en) 2008-12-25

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US (1) US20080317622A1 (fr)
EP (1) EP1975261B1 (fr)
JP (1) JP2008255485A (fr)
BR (1) BRPI0800973A2 (fr)
CA (1) CA2626908C (fr)
FR (1) FR2914319B1 (fr)
RU (1) RU2464351C2 (fr)

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2962447B1 (fr) * 2010-07-06 2013-09-20 Snecma Barriere thermique pour aube de turbine, a structure colonnaire avec des colonnes espacees
RU2615099C1 (ru) * 2015-10-26 2017-04-03 Федеральное государственное бюджетное учреждение "Национальный исследовательский центр "Курчатовский институт" Способ выращивания эпитаксиальной пленки дисилицида европия на кремнии
FR3052463B1 (fr) * 2016-06-10 2020-05-08 Safran Procede de fabrication d'une piece en superalliage a base de nickel contenant de l'hafnium
FR3057880B1 (fr) 2016-10-25 2018-11-23 Safran Superalliage a base de nickel, aube monocristalline et turbomachine
CN111321384A (zh) * 2020-04-21 2020-06-23 南京信息工程大学 一种在镍基合金上制备二氧化锆薄膜的方法
CN117802351B (zh) * 2024-02-29 2024-06-04 成都先进金属材料产业技术研究院股份有限公司 高强耐蚀钛合金管材及其制备方法

Citations (2)

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Publication number Priority date Publication date Assignee Title
US5538796A (en) * 1992-10-13 1996-07-23 General Electric Company Thermal barrier coating system having no bond coat
US20060078750A1 (en) * 2001-01-22 2006-04-13 Dongming Zhu Low conductivity and sintering-resistant thermal barrier coatings

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FR2557598B1 (fr) 1983-12-29 1986-11-28 Armines Alliage monocristallin a matrice a base de nickel
US5514482A (en) 1984-04-25 1996-05-07 Alliedsignal Inc. Thermal barrier coating system for superalloy components
US5262245A (en) 1988-08-12 1993-11-16 United Technologies Corporation Advanced thermal barrier coated superalloy components
RU2065505C1 (ru) * 1992-09-10 1996-08-20 Акционерное общество "Моторостроитель" Лопатка турбины и способ ее изготовления
EP0786017B1 (fr) * 1994-10-14 1999-03-24 Siemens Aktiengesellschaft Couche de protection de pieces contre la corrosion, l'oxydation et les contraintes thermiques excessives, et son procede de production
FR2780982B1 (fr) * 1998-07-07 2000-09-08 Onera (Off Nat Aerospatiale) Superalliage monocristallin a base de nickel a haut solvus
FR2780983B1 (fr) * 1998-07-09 2000-08-04 Snecma Superalliage monocristallin a base de nickel a resistance accrue a haute temperature
JP2002167636A (ja) * 2000-10-30 2002-06-11 United Technol Corp <Utc> 接合被覆なしに断熱被覆を保持できる低密度耐酸化性超合金材料
EP1295969A1 (fr) * 2001-09-22 2003-03-26 ALSTOM (Switzerland) Ltd Procédé pour la croissance d'un revêtement de MCrAlY ainsi qu'un objet revêtu de cet alliage
US6974637B2 (en) * 2003-12-19 2005-12-13 General Electric Company Ni-base superalloy having a thermal barrier coating system
RU2260071C1 (ru) * 2004-09-30 2005-09-10 Балдаев Лев Христофорович Способ нанесения теплозащитного эрозионно стойкого покрытия

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5538796A (en) * 1992-10-13 1996-07-23 General Electric Company Thermal barrier coating system having no bond coat
US20060078750A1 (en) * 2001-01-22 2006-04-13 Dongming Zhu Low conductivity and sintering-resistant thermal barrier coatings

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Publication number Publication date
FR2914319A1 (fr) 2008-10-03
FR2914319B1 (fr) 2009-06-26
RU2008112052A (ru) 2009-10-10
EP1975261B1 (fr) 2016-11-09
CA2626908C (fr) 2015-08-11
CA2626908A1 (fr) 2008-09-30
RU2464351C2 (ru) 2012-10-20
EP1975261A1 (fr) 2008-10-01
JP2008255485A (ja) 2008-10-23
BRPI0800973A2 (pt) 2009-07-14

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