US20100104440A1 - Coating material and method of manufacturing same, coating method, and moving blade with shroud - Google Patents

Coating material and method of manufacturing same, coating method, and moving blade with shroud Download PDF

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Publication number
US20100104440A1
US20100104440A1 US12/532,585 US53258509A US2010104440A1 US 20100104440 A1 US20100104440 A1 US 20100104440A1 US 53258509 A US53258509 A US 53258509A US 2010104440 A1 US2010104440 A1 US 2010104440A1
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US
United States
Prior art keywords
mass
less
shroud
coating
coating film
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
US12/532,585
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English (en)
Inventor
Taiji Torigoe
Tomoaki Yunomura
Ikuo Okada
Zhi-Gang Yang
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Tsinghua University
Mitsubishi Heavy Industries Ltd
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Tsinghua University
Mitsubishi Heavy Industries Ltd
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.)
Filing date
Publication date
Application filed by Tsinghua University, Mitsubishi Heavy Industries Ltd filed Critical Tsinghua University
Assigned to MITSUBISHI HEAVY INDUSTRIES, LTD., TSINGHUA UNIVERSITY reassignment MITSUBISHI HEAVY INDUSTRIES, LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: OKADA, IKUO, TORIGOE, TAIJI, YANG, ZHI-GANG, YUNOMURA, TOMOAKI
Publication of US20100104440A1 publication Critical patent/US20100104440A1/en
Abandoned legal-status Critical Current

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Classifications

    • 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
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C19/00—Alloys based on nickel or cobalt
    • C22C19/07—Alloys based on nickel or cobalt based on cobalt
    • 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
    • C23C4/129—Flame spraying
    • 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
    • C23C4/134—Plasma spraying
    • 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
    • C23C4/18—After-treatment
    • 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
    • F01D5/22—Blade-to-blade connections, e.g. for damping vibrations
    • F01D5/225—Blade-to-blade connections, e.g. for damping vibrations by shrouding
    • 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 coating material, a method of manufacturing the coating material, a coating method, and a moving blade fitted with a shroud.
  • FIG. 1 is a partial perspective view illustrating a moving blade fitted with a shroud.
  • a Z-type shroud 2 is formed that prevents fluid leakage and restrains torsion of the moving blade 1 , and the shroud 2 has a contact surface 3 that contacts the shroud 2 of the adjacent moving blade 1 .
  • the contact surface 3 of the shroud 2 is typically subjected to an abrasion resistance treatment, conventionally by applying a coating film of Tribaloy 800 (T-800: a cobalt-based abrasion resistance material) by an APS (Atmospheric Plasma Spraying) process.
  • T-800 Tribaloy 800
  • APS Admospheric Plasma Spraying
  • Patent Citation 1 discloses a coating method in which the Tribaloy coating film is formed on a shroud contact surface 3 of a turbine moving blade 1 by High Velocity Oxy-Fuel (HVOF) spraying, Low Pressure Plasma Spraying (LPPS) or atmospheric plasma spraying, and is then subjected to a diffusion heat treatment.
  • HVOF High Velocity Oxy-Fuel
  • LPPS Low Pressure Plasma Spraying
  • Patent Citation 1
  • the T-800 coating film has excellent ductility and high abrasion resistance
  • the metal temperature at the tips of the three-stage moving blades reaches 750° C. or higher, causing significant oxidative loss and a deterioration in the function of the abrasion-resistant coating film.
  • the present invention has been developed in light of the above circumstances, and has an object of providing a coating material, a method of manufacturing the coating material, and a coating method using the coating material that are capable of forming a coating film that retains high abrasion resistance while offering improved oxidation resistance at high temperatures, as well as providing a moving blade fitted with a shroud.
  • the present invention provides the following aspects.
  • the present invention provides a coating material, which comprises not less than 14% by mass and not more than 30% by mass of molybdenum (Mo), not less than 13% by mass and not more than 20% by mass of chromium (Cr), and not less than 0.5% by mass and not more than 4% by mass of silicon (Si), which may comprise not more than 1.5% by mass of nickel (Ni), not more than 1.5% by mass of iron (Fe), and not more than 0.08% by mass of carbon (C), and which comprises a balance of cobalt (Co) and unavoidable impurities, wherein the coating material further comprises at least one added component selected from the group consisting of not less than 0.01% by mass and not more than 3% by mass of yttrium (Y), not less than 0.01% by mass and not more than 10% by mass of aluminum (Al), and not less than 0.1% by mass and not more than 10% by mass of Fe.
  • Mo molybdenum
  • Cr chromium
  • Si silicon
  • Si silicon
  • Ni
  • the coating material of the present invention is used for depositing a coating film that achieves a combination of high abrasion resistance, and high oxidation resistance at high temperatures.
  • the added component may be not less than 0.01% by mass and not more than 3% by mass of Y.
  • the oxidation resistance of the coating film can be improved.
  • the added component may be not less than 0.1% by mass and not more than 10% by mass of Fe.
  • the added component may be not less than 0.01% by mass and not more than 10% by mass of Al, and not less than 0.1% by mass and not more than 10% by mass of Fe.
  • the added component may be not less than 0.01% by mass and not more than 10% by mass of Al, and not less than 0.01% by mass and not more than 3% by mass of Y.
  • the added component may be not less than 0.01% by mass and not more than 10% by mass of Al, not less than 0.1% by mass and not more than 10% by mass of Fe, and not less than 0.01% by mass and not more than 3% by mass of Y.
  • the oxidation resistance of the coating film at high temperatures can be improved even further.
  • a coating film is formed on a substrate surface by high-velocity flame spraying, using a spray powder composed of any of the coating materials described above.
  • the coating method of the present invention can be used to deposit a dense coating film that provides a combination of high abrasion resistance and high oxidation resistance at high temperatures.
  • a coating film is formed on a substrate surface by low pressure plasma spraying or atmospheric plasma spraying, using a spray powder composed of any of the coating materials described above.
  • This coating method can be used to deposit a dense coating film that provides a combination of high abrasion resistance and high oxidation resistance at high temperatures.
  • a diffusion heat treatment is preferably performed after the coating film is formed.
  • the film quality of the coating film is enhanced, and the adhesion between the coating film and the base material is further improved.
  • a shroud is provided at the tip of a moving blade of a turbine, wherein the shroud comprises a contact surface that contacts another shroud provided at a tip of an adjacently positioned moving blade when the moving blade is in use, and this contact surface comprises a coating film formed by any of the coating methods described above.
  • the moving blade fitted with a shroud of the present invention has a dense coating film at the contact surface that provides a combination of high abrasion resistance and high oxidation resistance at high temperatures, the contact surface of the shroud suffers little oxidative loss, and has a long lifespan.
  • Y has a so-called pegging effect that prevents generated oxide scales from flaking off, and therefore improves the oxidation resistance of the coating film. This effect is not realized if the added quantity of Y is less than 0.01% by mass, whereas if the quantity exceeds 3%, then significant segregation occurs within the coating film, adversely affecting the mechanical characteristics of the coating film such as the ductility.
  • the added quantity of Y is preferably not less than 0.1% and not more than 2%, and is most preferably not less than 0.3% and not more than 1.0%.
  • Al contributes to improved stability of the Cr 2 O 3 that acts as the protective oxide film, thereby improving the oxidation resistance of the coating film.
  • This effect of enhancing the oxidation resistance of the coating film is not realized if the added quantity of aluminum is less than 0.01%, whereas if the quantity exceeds 10%, then although the oxidation resistance and abrasion resistance of the coating film improve, the resulting coating film is extremely hard and tends to crack more easily.
  • the added quantity of Al is preferably not less than 1% and not more than 7%, and is most preferably not less than 3% and not more than 5%.
  • the present invention is able to provide a coating material, a method of manufacturing the coating material and a coating method using the coating material that are capable of forming a coating film that retains high abrasion resistance while offering improved oxidation resistance at high temperatures, as well as a moving blade fitted with a shroud.
  • the coating film obtained using the present invention can, for example, withstand continuous use at 850° C.
  • the life of the contact surface which is approximately 2 years when the coating surface is formed by depositing T-800, can be extended significantly to three years or longer, particularly in those cases where the coating film is used on the contact surfaces of the shroud of a three-stage moving blade in a high-temperature gas turbine.
  • FIG. 1 A partial perspective view illustrating a moving blade fitted with a shroud.
  • FIG. 2 A schematic cross-sectional view of a device used in a gas atomization method.
  • FIG. 3 A graph illustrating the results of oxidation tests performed on coating films according to examples and a comparative example.
  • FIG. 4 A graph illustrating the hardness on the Rockwell C scale of coating films according to the examples and the comparative example.
  • a coating material, a method of manufacturing the coating material, a coating method, and a moving blade fitted with a shroud according to a first embodiment of the present invention are described below in detail by way of examples with reference to the drawings. However, the present invention is in no way limited by the examples presented below.
  • Spray powders with the compositions of examples 1 to 7 shown in Table 1 were prepared by a gas atomization method using the device shown in FIG. 2 .
  • a predetermined alloy component was superheated and melted inside a levitation furnace 12 , and the molten matter was then drained through a nozzle hole of a spray nozzle 14 provided at the base of the tundish to create a thin flow of molten matter.
  • An inert jet fluid typically helium gas or the like
  • the downward flow of molten matter was broken up into liquid droplets, which were solidified as they fell to produce an alloy powder.
  • the alloy powder was separated from the exhaust gas by a cyclone 18 provided on the downstream side of the device, and was then collected in a powder collection vessel 20 provided beneath the cyclone.
  • the spray powder was supplied in a powdered state to a spray gun, melted by heating to a relatively low temperature (not higher than 1600° C.) by combusting oxygen and kerosene, and then sprayed at a high velocity (300 m/s or faster) onto the contact surface 3 , thereby forming a coating film on the contact surface 3 .
  • the flame velocity of the HVOF process is within a range from 300 m/s to 500 m/s at its slowest, and by this enables a dense coating film to be deposited by the spray material striking the contact surface 3 .
  • the film thickness of the coating film was approximately 0.2 mm.
  • Oxygen flow rate 54 m 3 /h
  • HVOF is conducted in the open atmosphere, and is therefore an advantageous deposition method due to factors such as its low cost and applicability to large components.
  • a diffusion heat treatment was performed in a vacuum furnace after film deposition in order to improve the film quality.
  • This heat treatment may be performed, for example, by first performing solution heat treatment at 1121° C. for 2.5 hours, subsequently cooling the coating film in nitrogen, and then performing an aging heat treatment at 850° C. for 24 hours, followed by cooling in nitrogen.
  • This heat treatment may be combined with a heat treatment of the base material.
  • This diffusion heat treatment can be performed as part of the heat treatment applied to the moving blade 1 itself.
  • the various structural moieties within the film derived from the base material, the coating film and the spray powder undergo diffusion and integration, enabling a coating film to be obtained that offers excellent adhesion to the base material of the contact surface 3 and does not peel easily.
  • FIG. 3 shows the results of isothermal oxidation tests of the coating film performed at 1000° C.
  • the isothermal oxidation tests were performed using a High Temperature Thermogravimeter TG 96 manufactured by Setaram Inc., by placing the samples in argon gas (flow rate: 1 L/hr), raising the temperature by 5° C./min. until the target temperature was reached, and then replacing the gas with dry air (at the same flow rate) while continuously measuring the mass change caused by oxidation.
  • oxidation resistance was greatly enhanced when compared with that of comparative example 1 described below, which used T-800 as the coating material.
  • the mass had increased by 14 mg/cm 2 after 50 hours of oxidation time at 1,000° C., whereas in each of the examples, oxidation was reduced to 1/10th of this amount or less.
  • FIG. 4 shows the hardness of the coating films on the Rockwell C scale. It is clear from the results that in all of the examples, the hardness of the coating film was retained when compared with that of comparative example 1 described below in which T-800 was used as the coating material.
  • a coating film was deposited on the contact surface 3 of the shroud 2 using the same method as that described for example 1.
  • FIG. 3 shows the results of an oxidation test of the coating film performed at 1000° C. The results show that the coating film deposited using the T-800 spray powder had poor oxidation resistance at high temperatures.
  • FIG. 4 shows the hardness of the coating film on the Rockwell C scale.
  • Deposition of the coating film may be performed using a HVAF (High Velocity Air Fuel) process instead of the HVOF process.
  • HVAF High Velocity Air Fuel
  • a dense coating film with minimal oxides can be obtained. This improves the adhesion between the coating film on the contact surface 3 and the base material.
  • Deposition of the coating film may be performed by a low pressure plasma spraying (LPPS) process instead of the HVOF process.
  • LPPS low pressure plasma spraying
  • the plasma working gas argon or a mixed gas of argon and nitrogen or the like may be used.
  • Table 2 shows an example under LPPS spray conditions (using a low-pressure spraying system manufactured by Sulzer Metco Ltd.).
  • the term “Clearing” in Table 2 refers to using a reversed polarity arc discharge to dislodge deposits from the surface of the target object.
  • the resulting film is dense and has excellent adhesion to the base material.
  • adhesion is improved even further.
  • a powder with a particle size distribution of not less than 10 ⁇ m and not more than 44 ⁇ m can be used.
  • Atmospheric plasma spraying may be used instead of low pressure plasma spraying.
  • Deposition of the coating film may be performed using an atmospheric plasma spraying (APS) process instead of the HVOF process.
  • APS atmospheric plasma spraying
  • a powder with a particle size distribution of not more than 103 ⁇ m can be used.
  • the coating material of the present invention is used to form a coating film on a contact surface of a shroud within a moving blade fitted with a shroud, but the present invention is not limited to such examples, and the coating film may also be applied to a turbine member having friction components that are exposed to high-temperature gases.
  • the coating material of the present invention is also useful for forming a coating film on a seal pin or the like.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Organic Chemistry (AREA)
  • Plasma & Fusion (AREA)
  • Physics & Mathematics (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Engineering & Computer Science (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Heat Treatment Of Articles (AREA)
US12/532,585 2007-03-29 2009-03-28 Coating material and method of manufacturing same, coating method, and moving blade with shroud Abandoned US20100104440A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
JP2007-088697 2007-03-29
JP2007088697A JP5529366B2 (ja) 2007-03-29 2007-03-29 コーティング材料及びその製造方法並びにコーティング方法並びにシュラウド付き動翼
PCT/JP2008/056097 WO2008123418A1 (ja) 2007-03-29 2008-03-28 コーティング材料及びその製造方法並びにコーティング方法並びにシュラウド付き動翼

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US20100104440A1 true US20100104440A1 (en) 2010-04-29

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US12/532,585 Abandoned US20100104440A1 (en) 2007-03-29 2009-03-28 Coating material and method of manufacturing same, coating method, and moving blade with shroud

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US (1) US20100104440A1 (de)
EP (1) EP2130933B1 (de)
JP (1) JP5529366B2 (de)
CA (1) CA2681866C (de)
WO (1) WO2008123418A1 (de)

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US20130149133A1 (en) * 2011-12-13 2013-06-13 Mark David Ring Stator vane shroud having an offset
US11155904B2 (en) 2019-07-11 2021-10-26 L.E. Jones Company Cobalt-rich wear resistant alloy and method of making and use thereof
CN114059002A (zh) * 2021-10-09 2022-02-18 厦门金鹭特种合金有限公司 一种控制通孔的金属陶瓷高温烧结用隔层及其制作方法
US20220064776A1 (en) * 2018-12-21 2022-03-03 Safran Method for manufacturing a core

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JP6698280B2 (ja) * 2015-05-15 2020-05-27 山陽特殊製鋼株式会社 合金粉末
FR3042563B1 (fr) * 2015-10-16 2017-10-27 Airbus Operations Sas Interface d'adaptation de friction entre deux pieces en nickel ou alliage de nickel ou cobalt chrome en mouvement relatif l'une contre l'autre a haute temperature
CN106222579A (zh) * 2016-08-19 2016-12-14 合肥东方节能科技股份有限公司 一种高速线材精轧机用导卫辊及其制备方法
CN107058807A (zh) * 2016-12-31 2017-08-18 天津滨海雷克斯激光科技发展有限公司 用于卷烟机烟枪的喷涂材料与喷涂方法及其应用
JP6698910B2 (ja) * 2019-04-09 2020-05-27 山陽特殊製鋼株式会社 合金粉末
WO2023277063A1 (ja) * 2021-06-30 2023-01-05 Ｊｆｅスチール株式会社 炉内構造物の被覆材料および表面被覆方法ならびに炉内構造物

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JP2008248280A (ja) 2008-10-16
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