US20180305824A1 - Method for producing a corrosion protection layer for thermal insulation layers made of hollow aluminum oxide balls and glass layer and component as well as material mixture - Google Patents

Method for producing a corrosion protection layer for thermal insulation layers made of hollow aluminum oxide balls and glass layer and component as well as material mixture Download PDF

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Publication number
US20180305824A1
US20180305824A1 US15/771,103 US201615771103A US2018305824A1 US 20180305824 A1 US20180305824 A1 US 20180305824A1 US 201615771103 A US201615771103 A US 201615771103A US 2018305824 A1 US2018305824 A1 US 2018305824A1
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Prior art keywords
layer
corrosion protection
aluminum
protection layer
ceramic
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US15/771,103
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Inventor
Mathias Galetz
Xabier Montero
Werner Stamm
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Dechema-Forschungsinstitut Stiftung Buergerlichen Rechts
Siemens Energy Global GmbH and Co KG
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Siemens AG
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Assigned to DECHEMA-FORSCHUNGSINSTITUT STIFTUNG BÜRGERLICHEN RECHTS reassignment DECHEMA-FORSCHUNGSINSTITUT STIFTUNG BÜRGERLICHEN RECHTS ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: GALETZ, Mathias, MONTERO, Xabier
Assigned to SIEMENS AKTIENGESELLSCHAFT reassignment SIEMENS AKTIENGESELLSCHAFT ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: STAMM, WERNER
Publication of US20180305824A1 publication Critical patent/US20180305824A1/en
Assigned to Siemens Energy Global GmbH & Co. KG reassignment Siemens Energy Global GmbH & Co. KG ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SIEMENS AKTIENGESELLSCHAFT
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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
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    • 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
    • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/34—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates
    • C23C28/345—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer
    • C23C28/3455—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer with a refractory ceramic layer, e.g. refractory metal oxide, ZrO2, rare earth oxides or a thermal barrier system comprising at least one refractory oxide layer
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    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/043—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B18/00—Layered products essentially comprising ceramics, e.g. refractory products
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    • C23C10/26—Solid state diffusion of only metal elements or silicon into metallic material surfaces using liquids, e.g. salt baths, liquid suspensions more than one element being diffused
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    • C—CHEMISTRY; METALLURGY
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    • 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
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    • C—CHEMISTRY; METALLURGY
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    • 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
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    • Y10T428/12771—Transition metal-base component
    • Y10T428/12785—Group IIB metal-base component
    • 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
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12771—Transition metal-base component
    • Y10T428/12806—Refractory [Group IVB, VB, or VIB] metal-base component
    • 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
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12771—Transition metal-base component
    • Y10T428/12861—Group VIII or IB metal-base component
    • 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.]
    • Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
    • Y10T428/2495—Thickness [relative or absolute]

Definitions

  • the following relates to protection of a thermal barrier coating against corrosion, which comprises hollow aluminum oxide spheres and can further comprise a glass-like outer protective layer.
  • Components which are, in order to lower the metal temperature, coated with thermal barrier coatings composed of partially stabilized zirconia or gadolinium zirconate are present in the hot gas path.
  • the present-day surface temperatures of the ceramics in combination with impurities such as CMAS lead to chemical attacks on the ceramics and also to intrusion of liquid phases into the pores of the ceramic.
  • the abrasion of compressor abradables can leave one-off nickel deposits on the layers. This, too, leads to TBC spalling as a result of reduced thermal expansion. There has hitherto not been any system to protect against this multiple attack in the long term.
  • FIG. 1 depicts a schematic view of a first layer system having a corrosion protection layer, in accordance with embodiments of the present invention
  • FIG. 2 depicts a schematic view of a second layer system having a corrosion protection layer, in accordance with embodiments of the present invention.
  • FIG. 3 depicts a schematic view of a third layer system having a corrosion protection layer, in accordance with embodiments of the present invention.
  • the inventive step is application of a layer composed of aluminum particles, in particular by means of a slip.
  • the aluminum particles/zirconium oxide particles can have a diameter in the range from 1 to 125 ⁇ m, but particles in a smaller diameter range (2-40 ⁇ m) are desirable in most cases.
  • the thickness of the applied particle layer can be in the range from 5 to 150 ⁇ m. This layer is optimally applied as slip. However, other methods are also possible.
  • Hollow alumina spheres which comprise the further oxides as composite structure and due to this structure have good ductility in operation are formed from the aluminum particles by means of a suitable heat treatment (matched to the respective coating system consisting of base material, bonding layer and TBC).
  • a suitable heat treatment matched to the respective coating system consisting of base material, bonding layer and TBC.
  • the addition of boron, silicon and/or germanium increases the diffusion activity of the elements and ultimately leads to increased adhesion of the additional protective layer.
  • the titanium group oxides increase the mechanical compatibility and the resistance to CMAS attack.
  • a second optional layer has the composition of a low-melting, viscous glass whose melting point is preferably lower than or in the region of the melting point of the diffusing metal in the underlying layer.
  • the glass comprises, in particular, essentially SiO 2 and preferably contains accompanying elements such as magnesium (Mg), calcium (Ca) or else boron (B) and/or sodium (Na) which are relevant for setting the melting point.
  • the glass can also be formed only during the heat treatment in an oxygen-containing atmosphere from a silazane, siloxane or silicone polymer as precursor.
  • This precursor can contain inorganic fillers in order to set the shrinkage and degradation behavior and the resistance to CMAS attack.
  • oxidation of the aluminum particles can be carried out by means of the additional layer of the glass without pure aluminum particles which run along the surface of the system blocking holes in the component during the heat treatment.
  • the “migration” of aluminum/titanium group metal particles (which can lead to blocking of the cooling air holes) on the surface of the thermal barrier coating during the heat treatment can be prevented by two processes. Firstly, this occurrence can be prevented by polymer masking of the holes or else by application of SiO 2 to the particle layer.
  • the SiO 2 layer has, only in the initial state, the task of assisting the formation of alumina/zirconia layers and preventing such particles from running about. The SiO 2 layer will then largely delaminate during operation because of the brittleness and the actual protective layer can take over the protective action.
  • the inventive step lies in the composition and the application of the aluminum/titanium group metal particles in combination with semimetal additions and in the application of a further supplementary layer of SiO 2 .
  • Relatively high contents of Zr of >20% also lead to lower adhesion of the layers.
  • oxidation of the aluminum/zirconium particles can be carried out without the pure aluminum particles which run along the surface of the system blocking the cooling air holes during the heat treatment.
  • the use of polymer masking can also be carried out as an alternative. Boron strengthens the chemical bonding-on of the supplementary layer.
  • FIG. 1 shows a layer system 1 according to embodiments of the invention which comprises a substrate 4 .
  • the substrate 4 is, in particular, metallic and in particular comprises a nickel- or cobalt-based superalloy.
  • An optional metallic bonding layer 7 is present on the substrate 4 .
  • This is in particular a coating layer, in particular a coating layer based on NiCoCrAlY.
  • an oxide layer (TGO), which is not shown in more detail here, forms on this bonding layer 7 .
  • a ceramic thermal barrier coating 10 is present on this thermally grown oxide layer (TGO) or on the metallic bonding layer 7 .
  • This ceramic thermal barrier coating can be made up of a single layer, in particular of zirconium oxide, or of two layers comprising zirconium oxide and a pyrochlore or “DVC” layers.
  • an outer ceramic corrosion protection layer 13 ′ composed of aluminum oxide, in particular hollow aluminum oxide spheres 14 is present on the ceramic thermal barrier coating 10 ( FIG. 1 ); however, a viscous glass has optionally been applied as outermost layer 16 . ( FIG. 2 ).
  • a layer of aluminum particles in particular having particle sizes of from 1 ⁇ m to 50 ⁇ m, is applied to the ceramic thermal barrier coating 10 , in particular by means of a slip, vapor deposition, sputtering, etc.
  • This layer can have a layer thickness in the range from a few microns up to 300 ⁇ m, in particular not more than 200 ⁇ m, very particularly preferably not more than 100 ⁇ m.
  • Additions of aluminum (Al) are preferred: in particular at least one element Z selected from the group I boron (B), gallium (Ga) and/or germanium (Ge) and/or, in addition to aluminum (Al), at least one element selected from the group II zirconium (Zr), titanium (Ti), tantalum (Ta), niobium (Nb) and/or hafnium (Hf) is applied as mixture of materials and/or oxidized or has been oxidized for the corrosion layer ( 13 ′, 13 ′′, 13 ′′′).
  • Zr zirconium
  • Ti titanium
  • Ta tantalum
  • Nb niobium
  • Hf hafnium
  • silicon (Si) and/or magnesium (Mg) can be concomitantly applied and/or be present in the mixture of materials.
  • Ge/Ga means: germanium and/or gallium, i.e. Ge, Ga or Ge+Ga.
  • Elements of the group I and II can in each case be present and be used as mixtures of two, three, . . . or all elements of the groups I, II.
  • This layer is intended to prevent the intrusion of the CMAS (CMAF) layer and also react with the CMAS (CMAF).
  • CMAF CMAS
  • CMAF CMAS
  • aluminum oxide and a reaction layer between thermal barrier coating and aluminum layer are formed.
  • the alumina applied in this way has a lower coefficient of expansion and in combination with the nickel (Ni), which originates from the compressor abradable, part of the aluminum oxide flakes off. The remaining layer then protects against the intrusion of liquid deposits.
  • the inventive step also lies in the application of the different particle sizes of the aluminum oxide which firstly provides protection against Ni deposits and also against CMAS. Since the deposits of nickel (Ni) occur only briefly and at the beginning of the operating time, a layer which has a short-term effect here and a layer having a long-term action against CMAS or similar attacks are present.
  • the layer of the aluminum oxide or the oxidation and/or optionally glass is in each case at least 20% thinner than the ceramic layer system 10 .
  • the glass can be, in particular, silicon oxide, in particular SiO 2 .
  • Al aluminum
  • Zr zirconium
  • Zirconium (Zr) improves the adhesion of the protective layer to the thermal barrier coating.
  • zirconium (Zr) reduces the viscosity of the CMAS and prevents or slows the infiltration of the CMAS and thus increases the life of the layer system.
  • At least one element from the group consisting of boron (B), gallium (Ga) and/or germanium (Ge) and optionally silicon (Si) is additionally present.
  • a glass layer as described above can also be or have been applied on top of the layer of aluminum oxide/zirconium oxide or on top of the metallic aluminum/zirconium or on top of aluminum and an element Z.
  • the heat treatment to form aluminum oxide or aluminum oxide/zirconium oxide or aluminum oxide and oxide of the element Z can be carried out by means of a first use of the component or by means of preceding heat treatment before first use or after it has been installed in a machine for high-temperature use.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Ceramic Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Laminated Bodies (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
US15/771,103 2015-11-05 2016-10-11 Method for producing a corrosion protection layer for thermal insulation layers made of hollow aluminum oxide balls and glass layer and component as well as material mixture Abandoned US20180305824A1 (en)

Applications Claiming Priority (3)

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DE102015221751.5 2015-11-05
DE102015221751.5A DE102015221751A1 (de) 2015-11-05 2015-11-05 Verfahren zur Herstellung einer Korrosionsschutzschicht für Wärmedämmschichten aus hohlen Aluminiumoxidkugeln und äußerster Glasschicht und Bauteil sowie Materialmischung
PCT/EP2016/074278 WO2017076583A1 (de) 2015-11-05 2016-10-11 Verfahren zur herstellung einer korrosionsschutzschicht für wärmedämmschichten aus hohlen aluminiumoxidkugeln und äusserster glasschicht und bauteil sowie materialmischung

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KR20180077254A (ko) 2018-07-06
KR102161752B1 (ko) 2020-10-05

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