US20150284834A1 - Method for applying a high-temperature stable coating layer on the surface of a component and component with such a coating layer - Google Patents

Method for applying a high-temperature stable coating layer on the surface of a component and component with such a coating layer Download PDF

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Publication number
US20150284834A1
US20150284834A1 US14/474,564 US201414474564A US2015284834A1 US 20150284834 A1 US20150284834 A1 US 20150284834A1 US 201414474564 A US201414474564 A US 201414474564A US 2015284834 A1 US2015284834 A1 US 2015284834A1
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United States
Prior art keywords
coating layer
micron
component
sub
powder
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Abandoned
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US14/474,564
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English (en)
Inventor
Sophie Betty Claire Duval
Piero-Daniele Grasso
Sven Olliges
Alexander Stankowski
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Ansaldo Energia Switzerland AG
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Alstom Technology AG
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Assigned to ALSTOM TECHNOLOGY LTD reassignment ALSTOM TECHNOLOGY LTD ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: Olliges, Sven, Duval, Sophie Betty Claire, GRASSO, PIERO-DANIELE, STANKOWSKI, ALEXANDER
Publication of US20150284834A1 publication Critical patent/US20150284834A1/en
Assigned to GENERAL ELECTRIC TECHNOLOGY GMBH reassignment GENERAL ELECTRIC TECHNOLOGY GMBH CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: ALSTOM TECHNOLOGY LTD
Assigned to Ansaldo Energia Switzerland AG reassignment Ansaldo Energia Switzerland AG ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: GENERAL ELECTRIC TECHNOLOGY GMBH
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
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • 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
    • C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
    • 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
    • C23C4/073—Metallic material containing MCrAl or MCrAlY alloys, where M is nickel, cobalt or iron, with or without non-metal elements
    • 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
    • C23C4/08—Metallic material containing only metal elements
    • C23C4/085—
    • 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
    • C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
    • C23C4/105—
    • 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
    • C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
    • C23C4/11—Oxides
    • C23C4/127—
    • 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
    • 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
    • Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
    • Y10T428/256—Heavy metal or aluminum or compound thereof

Definitions

  • the present invention relates to thermally loaded components of thermal machines, especially gas turbines. It refers to a method for applying a high-temperature stable coating layer on the surface of a component. It further refers to a component with such a coating layer.
  • a thermal barrier coating TBC
  • a bond coat may be provided between the base material of the component and the TBC.
  • the hot-section stationary components mainly combustors, transition pieces, and vanes
  • TBCs thermal barrier coatings
  • M metallic MCrAlY
  • YPSZ Yttria partially stabilized zirconia
  • the document further asserts that the full potential of the YPSZ TBCs is yet to be realized due mainly to the cracking problem that occurs along or near the bond coat/top coat interface after a limited number of cycles of engine operation.
  • This interfacial cracking often leading to premature coating failure by debonding (spallation) of the top coat from the bond coat, has been amply demonstrated from microstructural evidence that was obtained from in-service degradation of deposited coatings as well as from laboratory experiments that have been conducted.
  • the thin oxide layer that grows on top of the bond coat, at the bond coat/top coat interface plays a critical role in the interface cracking. It is quite evident that this cracking problem negatively impacts the coating performance by reducing both the engine efficiency (because the engine operating temperature is kept below its optimum temperature) and the lifetime of the engine components. In turn, this greatly affects the reliability and the efficiency of the entire engine system.
  • the bond coat surface, onto which the YPSZ top coat is disposed has a thin oxide layer that consists mostly of various oxides (NiO, Ni(Cr,Al) 2 O 4 , Cr 2 O 3 , Y 2 O 3 , Al 2 O 3 ).
  • This thin oxide layer plays an important role in the adhesion (bonding) between the metallic bond coat and the ceramic top coat.
  • another oxide layer forms in addition to the native oxide.
  • This second layer also mostly alumina, is commonly referred to as the thermally grown oxide (TGO) and slowly grows during exposure to elevated temperatures.
  • TGO thermally grown oxide
  • Interfacial oxides, in particular the TGO layer play a pivotal role in the cracking process. It is believed that the growth of the TGO layer leads to the build up of stresses at the interface region between the TGO layer and top coat.
  • This object is obtained by a method according to claim 1 and a component according to claim 14 .
  • the method according to the invention for applying a high-temperature stable coating layer on the surface of a component comprises the steps of:
  • said powder material is applied to the surface of the component by means of a thermal spraying technique.
  • the thermal spraying technique used is one of High Velocity Oxygen Fuel Spraying (HVOF), Low Pressure Plasma Spraying (LPPS), Air Plasma Spraying (APS) or Suspension Plasma Spraying (SPS).
  • HVOF High Velocity Oxygen Fuel Spraying
  • LPPS Low Pressure Plasma Spraying
  • APS Air Plasma Spraying
  • SPS Suspension Plasma Spraying
  • said powder material has the form of agglomerates.
  • said powder material has the form of a suspension.
  • the powder material contains powder particles of micron size and/or larger agglomerates, and that the sub-micron powder particles are in said coating layer distributed around the surface of said powder particles of micron size and/or said larger agglomerates.
  • the sub-micron powder particles are pre-oxidized before being incorporated into said coating layer.
  • the pre-oxidation takes place in-flight during spraying.
  • the pre-oxidation is done by an oxidative pre heat treatment of the powder material.
  • the powder material is a metallic powder.
  • the coating layer is a bond coat or an overlay coating.
  • said component having a surface, which is coated with a coating layer is characterized in that said coating layer comprises sub-micron powder particles, which are each at least partially surrounded by an oxide shell and establish with their oxide shells an at least partially interconnected sub-micron oxide network within said coating layer.
  • said coating layer further comprises powder particles of micron size and/or larger agglomerates.
  • said sub-micron powder particles are in said coating layer distributed around the surface of said powder particles of micron size and/or said larger agglomerates.
  • FIG. 1 shows in a simplified schematic diagram a thermal spray configuration, which can be used for the present invention
  • FIG. 2 shows the creation of a coating layer with an internal oxide network by in-flight oxidation of sprayed sub-micron powder particles according to an embodiment of the invention
  • FIG. 3 shows—similar to FIG. 2 —the embedding of micron particles or agglomerates in said sub-micron powder particle oxide network
  • FIG. 4 shows schematically a graded coating layer in accordance with an embodiment of the invention.
  • the present invention discloses a specific type of sub-micron structured coating. Due to a sub-micron scale oxide network and fine grain microstructure, the invention aims to reduce the LCF/TMF cracking.
  • Another aspect of the invention is the retardant effect for the oxidation and the corrosion. Due to the nano-scale oxide network of the bond coat/overlay coating, the impact by oxidation and corrosion is slowed down.
  • the invention should enable a longer service life and/or assure reconditionability with less scrap parts and/or decreased operation risks, such as crack formation in critical area of the component due to mechanical/thermal load, and/or oxidation/corrosion and/or FOD (Foreign Objects Damage) events.
  • the invention enables:
  • the novelty of the invention is the use of a sub-micron powder (at least to a certain percentage of the total powder mixture) and the way to process it (preparation and thermal spray application) to reach the mentioned improved coating properties.
  • the improved coating behavior is particularly based on a reduced TMF/LCF effect of the coating with (at least partial) sub-micron structure.
  • the invention is based on:
  • FIG. 1 shows a typical thermal spray configuration 10 , which can be used to apply the sub-micron powder coating layer according to the invention.
  • the thermal spray configuration 10 comprises a spray gun 13 , which is supplied with the sub-micron powder 15 , a fuel 16 and an oxidant 17 . By burning the fuel 16 , a flame 14 is generated, which transports the powder particles to the surface of a component 11 , thereby building the coating layer 12 .
  • the sub-micron powder particles 18 undergo a reaction, as can be seen in FIG. 2 , such that they are transformed into particles having a (metallic) core 19 surrounded by an oxide shell 20 .
  • those oxidized sub-micron particles build up an interconnected structure with a sub-micron oxide network 22 .
  • the resulting coating layer 12 a comprises those agglomerates or micron powder particles 21 being surrounded by oxidized sub-micron powder particles 18 .
  • the initiation and propagation of damages within coatings exhibiting an at least partial sub-micron scale structure is retarded compared to conventional coating microstructures.
  • the “sub-micron effect” is retained over extended lifetime periods, also due to the (at least partial) oxide network.
  • Such aspects of the invention give to the coating a so-called self healing characteristic.
  • the fine grain sized coating allows a diffusion heat treatment with a reduced number of heat treatment cycles.
  • a nano coating as top layer improves the TMF and oxidation resistance, which results in an improved overall coating lifetime.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
US14/474,564 2012-03-05 2014-09-02 Method for applying a high-temperature stable coating layer on the surface of a component and component with such a coating layer Abandoned US20150284834A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
EP12158129.2A EP2636763B1 (fr) 2012-03-05 2012-03-05 Procédé pour appliquer une couche de revêtement stable à haute température sur la surface d'un composant et composant avec une telle couche de revêtement
EP12158129.2 2012-03-05
PCT/EP2013/054337 WO2013131874A1 (fr) 2012-03-05 2013-03-05 Procédé pour l'application d'une couche de revêtement stable à haute température sur la surface d'un composant et composant pourvu d'une telle couche de revêtement

Related Parent Applications (1)

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PCT/EP2013/054337 Continuation WO2013131874A1 (fr) 2012-03-05 2013-03-05 Procédé pour l'application d'une couche de revêtement stable à haute température sur la surface d'un composant et composant pourvu d'une telle couche de revêtement

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US20150284834A1 true US20150284834A1 (en) 2015-10-08

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US14/474,564 Abandoned US20150284834A1 (en) 2012-03-05 2014-09-02 Method for applying a high-temperature stable coating layer on the surface of a component and component with such a coating layer

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US (1) US20150284834A1 (fr)
EP (1) EP2636763B1 (fr)
CN (1) CN104160059B (fr)
CA (1) CA2864618A1 (fr)
WO (1) WO2013131874A1 (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108004498A (zh) * 2017-12-29 2018-05-08 上海英佛曼纳米科技股份有限公司 一种具有抗高温结瘤抗氧化耐腐蚀耐磨损涂层的高温热轧钢炉辊
US10752999B2 (en) 2016-04-18 2020-08-25 Rolls-Royce Corporation High strength aerospace components
US10763715B2 (en) 2017-12-27 2020-09-01 Rolls Royce North American Technologies, Inc. Nano-crystalline coating for magnet retention in a rotor assembly
US11317540B2 (en) 2019-09-20 2022-04-26 Samsung Electronics Co., Ltd. Solid state drive apparatus and data storage apparatus including the same

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104451520B (zh) * 2014-12-04 2017-08-01 中国船舶重工集团公司第十二研究所 一种氧化锆多晶团陶瓷涂层的制备方法
EP3168204B1 (fr) * 2015-11-12 2019-02-27 Ansaldo Energia IP UK Limited Procédé de fabrication d'une pièce de turbine à gaz
CN113881912B (zh) * 2021-10-09 2023-01-31 矿冶科技集团有限公司 一种纳米氧化物弥散型MCrAlY抗氧化涂层及其制备方法

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US20040106015A1 (en) * 2002-11-22 2004-06-03 Sulzer Markets And Technology Ag Spray powder for the manufacture of a thermally insulating layer which remains resistant at high temperatures

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10752999B2 (en) 2016-04-18 2020-08-25 Rolls-Royce Corporation High strength aerospace components
US10763715B2 (en) 2017-12-27 2020-09-01 Rolls Royce North American Technologies, Inc. Nano-crystalline coating for magnet retention in a rotor assembly
CN108004498A (zh) * 2017-12-29 2018-05-08 上海英佛曼纳米科技股份有限公司 一种具有抗高温结瘤抗氧化耐腐蚀耐磨损涂层的高温热轧钢炉辊
US11317540B2 (en) 2019-09-20 2022-04-26 Samsung Electronics Co., Ltd. Solid state drive apparatus and data storage apparatus including the same

Also Published As

Publication number Publication date
CA2864618A1 (fr) 2013-09-12
WO2013131874A1 (fr) 2013-09-12
EP2636763A1 (fr) 2013-09-11
EP2636763B1 (fr) 2020-09-02
CN104160059B (zh) 2019-01-08
CN104160059A (zh) 2014-11-19

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