US20150030826A1 - Method for creating a textured bond coat surface - Google Patents

Method for creating a textured bond coat surface Download PDF

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Publication number
US20150030826A1
US20150030826A1 US13/951,542 US201313951542A US2015030826A1 US 20150030826 A1 US20150030826 A1 US 20150030826A1 US 201313951542 A US201313951542 A US 201313951542A US 2015030826 A1 US2015030826 A1 US 2015030826A1
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US
United States
Prior art keywords
layer
particles
depositing
bond coat
powder
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
US13/951,542
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English (en)
Inventor
Ahmed Kamel
Gary B. Merrill
Anand A. Kulkarni
Gerald J. Bruck
Dhafer Jouini
Jonathan E. Shipper, JR.
Sachin R. Shinde
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.)
Siemens Energy Inc
Original Assignee
Siemens Energy Inc
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 Siemens Energy Inc filed Critical Siemens Energy Inc
Priority to US13/951,542 priority Critical patent/US20150030826A1/en
Assigned to SIEMENS ENERGY, INC reassignment SIEMENS ENERGY, INC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KULKARNI, ANAND A., SHINDE, SACHIN R., SHIPPER, JONATHAN E., JR., JOUINI, DHAFER, KAMEL, AHMED, BRUCK, GERALD J., MERRILL, GARY B.
Priority to US14/016,501 priority patent/US20150030871A1/en
Priority to KR1020167003956A priority patent/KR20160036572A/ko
Priority to PCT/US2014/044830 priority patent/WO2015013007A1/en
Priority to PCT/US2014/044816 priority patent/WO2015013005A2/en
Priority to DE112014003460.6T priority patent/DE112014003460T5/de
Priority to DE112014003451.7T priority patent/DE112014003451T5/de
Priority to CN201480039754.6A priority patent/CN105392920A/zh
Priority to KR1020167004533A priority patent/KR20160036583A/ko
Priority to CN201480039752.7A priority patent/CN105378147A/zh
Publication of US20150030826A1 publication Critical patent/US20150030826A1/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
    • 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
    • C23C28/40—Coatings including alternating layers following a pattern, a periodic or defined repetition
    • 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
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
    • C23C24/103—Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides
    • C23C24/106—Coating with metal alloys or metal elements only
    • 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
    • F01D11/00—Preventing or minimising internal leakage of working-fluid, e.g. between stages
    • F01D11/08—Preventing or minimising internal leakage of working-fluid, e.g. between stages for sealing space between rotor blade tips and stator
    • F01D11/14—Adjusting or regulating tip-clearance, i.e. distance between rotor-blade tips and stator casing
    • F01D11/16—Adjusting or regulating tip-clearance, i.e. distance between rotor-blade tips and stator casing by self-adjusting means
    • F01D11/18—Adjusting or regulating tip-clearance, i.e. distance between rotor-blade tips and stator casing by self-adjusting means using stator or rotor components with predetermined thermal response, e.g. selective insulation, thermal inertia, differential expansion
    • 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
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
    • Y10T428/24917—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including metal layer

Definitions

  • This invention relates generally to the field of materials technology, and more particularly to a method for creating a textured surface in a bond coat of a thermal barrier coating system.
  • Ceramic thermal barrier coating systems are used on gas turbine engine hot gas path components to protect the underlying metal alloy substrate from combustion gas temperatures that exceed the safe operating temperature of the alloy.
  • a typical thermal barrier coating system may include a bond coat, such as an MCrAlY material, deposited onto the substrate alloy and a ceramic topcoat, such as yttria stabilized zirconia, deposited onto the bond coat. It is known that strong adhesion between the layers of such systems is critical for proper functioning and long life of the coating system, and that a degree of surface roughness in the interface between the layers provides a beneficial mechanical interlock in that regard.
  • Bond coat material is often deposited by a spray process, such as High Velocity Oxy-Fuel (HVOF) or Air Plasma Spray (APS). It is known to control spray parameters when depositing a bond coat layer in order to achieve a degree of surface roughness in the deposited coating. However, the degree of roughness and the shape of the surface features in the deposited coating that are created by controlling the spray parameters are limited.
  • HVOF High Velocity Oxy-Fuel
  • APS Air Plasma Spray
  • FIGS. 1-5 illustrate sequential steps for depositing a coating onto a substrate with a surface texture including geometric features having protruding undercuts.
  • FIG. 6 illustrates a layer of thermal barrier coating material deposited over a textured surface of a bond coat material.
  • FIG. 7 illustrates a layer of bond coat material deposited over a textured surface of a superalloy component with an overlying layer of ceramic thermal barrier coating material.
  • the present inventors have recognized that known bond coat texturing processes that rely upon material removal are inherently inefficient because unwanted material is first deposited and is then removed.
  • the methods of the present invention cause material to be initially deposited in a way that creates the desired texture pattern. Furthermore, because the methods of the present invention create a textured surface by depositing a plurality of layers of material, a wide range of surface feature geometries, including undercuts, are made possible.
  • FIG. 1 is a partial cross-sectional view of a gas turbine component 10 having a relatively smooth surface 12 to which it is desired to add a textured surface geometry.
  • the surface 12 may be a surface of an existing bond coat material layer that is to be textured, or it may be the surface of a superalloy substrate over which a layer of bond coat material is to be applied.
  • a layer of powder 14 is deposited onto the surface 12 .
  • the layer of powder 14 includes particles of a metal alloy 16 and particles of a flux material 18 .
  • the metal alloy 16 may be superalloy material for the embodiment where the surface of the superalloy substrate is to be textured, or it may be a bond coat material for the embodiment where the surface of a bond coat is to be textured.
  • the flux material 18 is applied to provide cleansing and atmospheric protection functions during a subsequent melting step. Accordingly, the particles of metal alloy 16 and particles of flux material 18 may be mixed together and applied as a single layer in one embodiment, or mixed and applied simultaneously by directing a spray of metal alloy particles and a spray of flux material particles simultaneously toward the surface. Alternatively, the particles of metal alloy 16 may be applied to the surface 12 first and then covered by the particles of flux material 18 in another embodiment.
  • FIG. 2 illustrates the layer of powder 14 being exposed to a pattern of energy 20 to melt selected regions of the layer of powder 14 to form a pattern of the metal alloy 16 ′ covered by slag 22 on the surface 12 .
  • the slag 22 and excess powder 14 are removed to reveal the component 10 with a textured surface 12 ′, as illustrated in FIG. 3 .
  • FIGS. 1 and 2 may then be repeated, as illustrated in FIG. 4 to add a further layer of metal alloy 16 ′′.
  • the pattern of energy 20 ′ in FIG. 4 is somewhat different than the pattern of energy 20 in FIG. 2 , and as a result, the second layer of deposited metal alloy 16 ′′ has a region 24 that is indexed from and somewhat cantilevered beyond the first layer of deposited metal alloy 16 ′.
  • the heat input of the energy 20 is selected such that the region of melting does not extend to a full depth of the layer of powder 14 in the cantilevered region 24 .
  • Such indexing of the pattern of energy 20 between layers can be repeated for additional layers as desired to create a desired final textured surface 12 ′′ having geometric features 26 including protruding undercuts 28 , as illustrated in FIG. 5 .
  • any surface geometric feature will provide a degree of mechanical interlocking with a subsequently applied overcoat layer (i.e. bond coat or thermal barrier coating), and that a feature 26 with a protruding undercut 28 may be especially beneficial in that regard.
  • FIG. 6 illustrates the component 10 after the further deposit of a layer of material 31 over the surface 12 ′′ having the layer of geometric features 26 .
  • the surface 12 ′′ is bond coat material and the layer of material 31 is a ceramic thermal barrier coating material wherein the protruding undercuts 28 function to mechanically anchor the ceramic material 31 .
  • the bond coat material may be deposited onto a superalloy substrate that is not illustrated in this view.
  • FIG. 7 is a partial cross-sectional illustration of a gas turbine component 34 wherein a layer of bond coat material 36 is deposited over a textured surface 38 of a superalloy substrate 40 with an overlying layer of ceramic thermal barrier coating material 42 to form a thermal barrier coating system 44 .
  • the surface 38 is textured by the addition of geometric features 46 that were deposited by the process described above. Note that the texturing of surface 38 is reflected in a more subtle but still effective texturing of the surface 48 of the bond coat material 36 .
  • the process described herein facilitates the joining of additional superalloy material to form the geometric features 46 with a greatly reduced risk of cracking and higher degree of geometric precision that could otherwise be achieved by using a welding additive process, as more fully described below.
  • the layer of powder 14 may be one to several millimeters in thickness in some embodiments rather than the fraction of a millimeter typical with known selective laser melting and sintering processes.
  • Typical powdered prior art flux materials have particle sizes ranging from 0.5-2 mm, for example.
  • the powdered alloy material 16 may have a particle size range (mesh size range) of from 0.02-0.04 mm or 0.02-0.08 mm or other sub-range therein.
  • This difference in mesh size range may work well in the embodiment where the materials constitute separate layers; however, in the embodiment where the particles are mixed together before being applied to the surface 12 , it may be advantageous for the powdered alloy material 38 and the powdered flux material 40 to have overlapping mesh size ranges, or to have the same mesh size range in order to facilitate mixing and feeding of the powders and to provide improved flux coverage during the melting process.
  • the flux material 18 and resultant layer of slag 22 provide a number of functions that are beneficial during the melting process. First, they function to shield both the region of molten material and the solidified (but still hot) alloy material 16 ′ from the atmosphere as the material cools. The slag floats to the surface to separate the molten or hot metal from the atmosphere, and the flux may be formulated to produce a shielding gas in some embodiments, thereby avoiding or minimizing the use of expensive inert gas. Second, the slag 22 acts as a blanket that allows the solidified alloy material 16 ′ to cool slowly and evenly, thereby reducing residual stresses that can contribute to cracking. Third, the slag 22 helps to shape the pool of molten alloy 16 ′.
  • the flux material 18 provides a cleansing effect for removing trace impurities such as sulfur and phosphorous that contribute to cracking. Such cleansing includes de-oxidation of the metal alloy powder 16 . Because the flux powder 18 is in intimate contact with the alloy powder 16 , it is especially effective in accomplishing this function. Furthermore, the flux material 18 may provide energy absorption and trapping functions to more effectively convert the beam energy 20 into heat energy, thus facilitating a precise control of heat input, such as within 1-2%, and a resultant tight control of material temperature during the process. Finally, the flux may be formulated to compensate for loss of volatized elements during processing or to actively contribute elements to the deposit that are not otherwise provided by the alloy powder itself.
  • the patterned energy beam 20 may be produced by a diode laser 30 having a generally rectangular cross-sectional shape, although other known types of energy beams may be used, such as electron beam, plasma beam, one or more circular laser beams, a scanned laser beam (scanned one, two or three dimensionally), an integrated laser beam, etc.
  • the rectangular shape may be particularly advantageous for embodiments having a relatively large area to be textured.
  • the broad area beam produced by a diode laser helps to reduce weld heat input, heat affected zone, dilution from the substrate and residual stresses, all of which reduce the tendency for the cracking effects normally associated with superalloy repair.
  • the laser energy may be patterned by any known beam shaping optics, such as a cartridge filter 32 having pre-determine openings.
  • Optical conditions and hardware optics used to generate a broad area laser exposure may include but are not limited to: defocusing of the laser beam; use of diode lasers that generate rectangular energy sources at focus; use of integrating optics such as segmented mirrors to generate rectangular energy sources at focus; scanning (rastering) of the laser beam in one or more dimensions; and the use of focusing optics of variable beam diameter (e.g. 0.5 mm at focus for fine detailed work varied to 2.0 mm at focus for less detailed work).
  • the motion of the optics and/or substrate may be programmed as in a selective laser melting or sintering process to build a custom shape layer deposit.
  • Advantages of this process over known laser melting or sintering processes include: high deposition rates and thick deposit in each processing layer; improved shielding that extends over the hot deposited metal without the need for inert gas; flux will enhance cleansing of the deposit of constituents that otherwise may lead to cracking; flux will enhance laser beam absorption and minimize reflection back to processing equipment; slag formation will shape and support the deposit, preserve heat and slow the cooling rate, thereby reducing residual stresses; flux may compensate for elemental losses or add alloying elements, and powder and flux pre-placement or feeding can efficiently be conducted selectively because the thickness of the deposit greatly reduces the time involved in total part building.
  • Flux materials which could be used include commercially available fluxes such as those sold under the names Lincolnweld P2007, Bohler Soudokay NiCrW-412, ESAB OK 10.16 or 10.90, Special Metals NT100, Oerlikon OP76, Sandvik 50SW or SAS1.
  • the flux particles may be ground to a desired smaller mesh size range before use. Any available structural alloy, superalloy or bond coat material that is appropriate for thermal barrier coating systems may be used.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • General Engineering & Computer Science (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Laser Beam Processing (AREA)
US13/951,542 2013-07-26 2013-07-26 Method for creating a textured bond coat surface Abandoned US20150030826A1 (en)

Priority Applications (10)

Application Number Priority Date Filing Date Title
US13/951,542 US20150030826A1 (en) 2013-07-26 2013-07-26 Method for creating a textured bond coat surface
US14/016,501 US20150030871A1 (en) 2013-07-26 2013-09-03 Functionally graded thermal barrier coating system
CN201480039752.7A CN105378147A (zh) 2013-07-26 2014-06-30 用于创建纹理粘结涂层表面的方法
PCT/US2014/044816 WO2015013005A2 (en) 2013-07-26 2014-06-30 Functionally graded thermal barrier coating system
PCT/US2014/044830 WO2015013007A1 (en) 2013-07-26 2014-06-30 Method for creating a textured bond coat surface
KR1020167003956A KR20160036572A (ko) 2013-07-26 2014-06-30 경사기능 열차폐 코팅 시스템
DE112014003460.6T DE112014003460T5 (de) 2013-07-26 2014-06-30 Verfahren zur Erzeugung einer strukturierten Haftschichtoberfläche
DE112014003451.7T DE112014003451T5 (de) 2013-07-26 2014-06-30 Funktional gradiertes Wärmedämmschichtsystem
CN201480039754.6A CN105392920A (zh) 2013-07-26 2014-06-30 功能性梯度热障涂层系统
KR1020167004533A KR20160036583A (ko) 2013-07-26 2014-06-30 텍스처링된 본드 코트 표면을 생성하기 위한 방법

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US13/951,542 US20150030826A1 (en) 2013-07-26 2013-07-26 Method for creating a textured bond coat surface

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US14/016,501 Continuation-In-Part US20150030871A1 (en) 2013-07-26 2013-09-03 Functionally graded thermal barrier coating system

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US20150030826A1 true US20150030826A1 (en) 2015-01-29

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US13/951,542 Abandoned US20150030826A1 (en) 2013-07-26 2013-07-26 Method for creating a textured bond coat surface

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US (1) US20150030826A1 (ko)
KR (1) KR20160036583A (ko)
CN (1) CN105378147A (ko)
DE (1) DE112014003460T5 (ko)
WO (1) WO2015013007A1 (ko)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3170918A1 (en) * 2015-11-19 2017-05-24 Siemens Aktiengesellschaft Dvc-coating with fully and partially stabilized zirconia
US9957598B2 (en) 2016-02-29 2018-05-01 General Electric Company Coated articles and coating methods
US11073029B2 (en) 2018-08-13 2021-07-27 Rolls-Royce Deutschland Ltd & Co Kg Construction element having a bond structure for a turbo engine, method for the production of a construction element having a bond structure for a turbo engine, and turbo engine having a construction element having a bond structure
US11136902B2 (en) * 2011-08-30 2021-10-05 Siemens Energy, Inc. Method of forming a thermal barrier coating system with engineered surface roughness

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112122797A (zh) * 2020-09-24 2020-12-25 松山湖材料实验室 激光加工熔渣去除方法、系统、计算机设备及可读存储介质

Citations (3)

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US7182580B2 (en) * 2003-10-02 2007-02-27 Siemens Aktiengesellschaft Layer system, and process for producing a layer system
US20120181255A1 (en) * 2011-01-13 2012-07-19 Bruck Gerald J Flux enhanced high energy density welding
US20130045093A1 (en) * 2011-08-17 2013-02-21 Rolls-Royce Deutschland Ltd & Co Kg Method for the manufacture of a component for high thermal loads, a component producible by this method and an aircraft engine provided with the component

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5723078A (en) 1996-05-24 1998-03-03 General Electric Company Method for repairing a thermal barrier coating
US20030101587A1 (en) * 2001-10-22 2003-06-05 Rigney Joseph David Method for replacing a damaged TBC ceramic layer
US9283593B2 (en) * 2011-01-13 2016-03-15 Siemens Energy, Inc. Selective laser melting / sintering using powdered flux
US8999226B2 (en) * 2011-08-30 2015-04-07 Siemens Energy, Inc. Method of forming a thermal barrier coating system with engineered surface roughness

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7182580B2 (en) * 2003-10-02 2007-02-27 Siemens Aktiengesellschaft Layer system, and process for producing a layer system
US20120181255A1 (en) * 2011-01-13 2012-07-19 Bruck Gerald J Flux enhanced high energy density welding
US20130045093A1 (en) * 2011-08-17 2013-02-21 Rolls-Royce Deutschland Ltd & Co Kg Method for the manufacture of a component for high thermal loads, a component producible by this method and an aircraft engine provided with the component

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11136902B2 (en) * 2011-08-30 2021-10-05 Siemens Energy, Inc. Method of forming a thermal barrier coating system with engineered surface roughness
EP3170918A1 (en) * 2015-11-19 2017-05-24 Siemens Aktiengesellschaft Dvc-coating with fully and partially stabilized zirconia
WO2017084771A1 (en) * 2015-11-19 2017-05-26 Siemens Aktiengesellschaft Dvc-coating with fully and partially stabilized zirconia
US9957598B2 (en) 2016-02-29 2018-05-01 General Electric Company Coated articles and coating methods
US11073029B2 (en) 2018-08-13 2021-07-27 Rolls-Royce Deutschland Ltd & Co Kg Construction element having a bond structure for a turbo engine, method for the production of a construction element having a bond structure for a turbo engine, and turbo engine having a construction element having a bond structure

Also Published As

Publication number Publication date
DE112014003460T5 (de) 2016-05-19
CN105378147A (zh) 2016-03-02
WO2015013007A1 (en) 2015-01-29
KR20160036583A (ko) 2016-04-04

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