WO1994015000A1 - Revetement ceramique colonnaire formant une barriere thermique et a adherence amelioree - Google Patents

Revetement ceramique colonnaire formant une barriere thermique et a adherence amelioree Download PDF

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Publication number
WO1994015000A1
WO1994015000A1 PCT/US1993/010860 US9310860W WO9415000A1 WO 1994015000 A1 WO1994015000 A1 WO 1994015000A1 US 9310860 W US9310860 W US 9310860W WO 9415000 A1 WO9415000 A1 WO 9415000A1
Authority
WO
WIPO (PCT)
Prior art keywords
ceramic
coating
columnar
mcraly
layer
Prior art date
Application number
PCT/US1993/010860
Other languages
English (en)
Inventor
Dinesh K. Gupta
Original Assignee
United Technologies Corporation
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 United Technologies Corporation filed Critical United Technologies Corporation
Publication of WO1994015000A1 publication Critical patent/WO1994015000A1/fr

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Classifications

    • 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
    • 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
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2260/00—Function
    • F05D2260/20—Heat transfer, e.g. cooling
    • F05D2260/231—Preventing heat transfer
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/20—Oxide or non-oxide ceramics
    • F05D2300/21—Oxide ceramics

Definitions

  • the present invention relates to the field of ceramic coated metal substrates. More particularly, the present invention is concerned with metal substrates having columnar grain ceramic thermal barrier coatings suitable for use at elevated temperatures.
  • a most successful type ceramic thermal barrier coatings is one which is called a columnar ceramic thermal barrier coatings.
  • the ceramic coating comprises a multiplicity of thin columnar constituents, which is separated from each other by thin cracks. Each constituent is firmly bonded to the substrate at one end.
  • the advantage provided by the cracks is that the substrate expansion and contraction can be a accommodated in the coating by simply allowing for a very limited expansion of the existing cracks. Thus, in a sense, by providing a controlled precracked coating enhanced durability results.
  • the metallic substrate typically a nickel base superalloy
  • M is a metal chosen from the group the group consisting of iron, nickel and cobalt.
  • This columnar ceramic thermal barrier coatings is supplied by vapor deposition under controlled conditions.
  • An important feature of this type of coating is the existence of an alumina layer firmly bonded to the MCrAlY bond coat and simultaneously bonded to the fixed ends of the columnar ceramic segments.
  • U.S. Patent Nos. 4,880,614 and 4,916,022 also deal with the subject of columnar ceramic thermal barrier coatings.
  • U.S. Patent No. 4,880,614 suggests that improved durability can result by the provision of a high purity alumina interfacial layer between the bond coat and the ceramic coat.
  • an aluminizing step be performed on the bond coat prior to the application of the ceramic thermal barrier coatings layer.
  • U.S. Patent No. 4,916,022 suggests that a compositional modification of the ceramic thermal barrier coatings layer can improve enhanced durability.
  • titania to that portion columnar ceramic thermal barrier coatings which is adjacent to the bond.
  • the figure shows a schematic of a coating according to the present invention. Disclosure of Invention
  • the present invention arises from the discovery that the substitution of an MCrAlY bond coat containing both hafnium and silicon into existing columnar grain ceramic thermal barrier coatings as taught in U.S.
  • Patent Nos. 4,321,310, 4,401,697, 4,405,659, 4,405,660 and 4,414,249 can substantially enhance the long-term durability of this type of columnar grain ceramic thermal barrier coatings.
  • the invention includes a composite coating system which protects metallic articles from environmental damage especially under conditions of high temperature.
  • the coating will generally be applied to a superalloy substrate.
  • Table 1 lists examples of common superalloy materials to which the invention coating can be applied.
  • the article to be protected is supplied with a uniform adherent MCrAlY+Hf+Si layer. On this MCrAlY+Hf+Si layer, there is applied a columnar ceramic coating.
  • the metallic layer is comprised of a MCrAlY+Hf+Si alloy which has a broad composition of 5 to 40% chromium, 8 to 35% aluminum, 1 to 2.0% yttrium, .1-7% silica, .1-2.0% hafnium and the balance ("M") selected from the group consisting of iron, cobalt, nickel and mixtures thereof.
  • this MCrAlY+Hf+Si layer be applied by vapor deposition.
  • Such a deposition process in combination with (optional but preferred) peening and heat treating (4 hours at 1975°F) provides a dense adherent layer of relatively uniform thickness which is basically free from defects. A thickness of 1-10 mils is suitable.
  • MCrAlY+Hf+Si layer may be produced by oxidation of the MCrAlY+Hf+Si layer. Oxidation may be in air or even commercially pure hydrogen. This oxide layer is relatively thin (0.01-0.1 mil) , uniform and adherent. Adherence of the oxide layer is greatly improved in MCrAlY+Hf+Si alloys compared to that of similar alloys which do not contain the combination of yttrium, hafnium and silcon.
  • the final component of the thermal barrier coating is a columnar grained ceramic surface coating which is tightly bonded to the alumina layer.
  • the columnar grains are oriented substantially perpendicular to the surface of the substrate with free surfaces between the individual columns extending down to the aluminum oxide layer.
  • the columnar nature of the surface layer circumvents the difference in the coefficients of thermal expansion between the substrate and the coating which is believed responsible for failure in prior art ceramic thermal barrier coatings.
  • the substrate expands at a greater rate than the ceramic surface coating and the columnar boundaries between the individual ceramic columns open to accommodate mismatch strains. This limits the stress at the interface between the substrate and the columnar ceramic to a level below that which will produce a fracture of a columnar surface layer.
  • the columns have dimensions on the order of 0.1 mil in cross section.
  • the columnar surface layer may be any of many ceramic compositions. Most of the experimental work to date has been performed with a ceramic composed of zirconium oxide stabilized by the addition of either 20 or 35% yttria to ensure a cubic structure at all temperatures of interest.
  • the columnar grain ceramic surface layer reduces the temperature of the underlying substrate and coating layers. Because of the nature of many ceramics and the existence of the open boundaries between the columns, the ceramic surface layer is relatively transparent to oxygen and does not play a major role in reducing the oxidation of the underlying layers except to the extent that the reduction in the temperature of the underlying layers reduces the rate of oxidation. Preliminary indications are that a 5 mil thick ZrO_ base coating can reduce substrate temperatures by from 50° to 200°F under conditions typical of those found in current gas turbine engines with cooled blades.
  • the Figure shows a cross sectional line drawing of a coating according to the present invention.
  • the substrate material 1 is coated with an MCrAlY+Hf+Si layer 2.
  • On this layer 2 there is formed an adherent alumina layer 3.
  • a columnar ceramic layer 4 adheres to the alumina layer 3.
  • the initial step is the preparation of the surface to be coated.
  • the surface must be clean of all dirt, grease, oxides and the like.
  • the cleaning method I has used is vapor honing in which an aqueous abrasive slurry is propelled against the surface to be cleaned with sufficient force to remove all extraneous material from the surface.
  • the surface is preferably vapor degreased. While this is a satisfactory cleaning process, numerous alternative processes are possible.
  • the MCrAlY+Hf+Si layer is applied. It is preferred that this MCrAlY+Hf+Si layer be applied by vapor deposition.
  • the deposition process is performed by holding the surface to be coated over a pool of molten MCrAlY+Hf+Si material in a vacuum chamber.
  • the heat source used to keep the MCrAlY+Hf+Si molten is usually an electron beam.
  • the surface to be coated is preferably maintained at a temperature of about 1600°-1800°F during the MCrAlY+Hf+Si deposition process.
  • the MCrAlY+Hf+Si layer have a thickness of about 1 to about 10 mils. MCrAlY+Hf+Si thicknesses below about 1 mil do not provide adequate protection to the surface and thicknesses in excess of about 10 mils are prone to rippling during repeated thermal cycling.
  • the coatings are dry glass bead peened to density any voids and to improve the coating structure. Such peening is preferred, but has not been found essential.
  • the coating is then preferably heat treated at 1975°F in hydrogen, however neither the time nor temperature is particularly critical. I have used a 4-hour treatment to improve the adherence of the coating to the substrate.
  • this hydrogen heat treatment also serves to develop the desired alumina layer.
  • This ' oxidation occurs as a result of oxygen impurities in the hydrogen.
  • the columnar grained ceramic surface layer is applied by a vapor deposition process.
  • the ceramic to be deposited is melted and maintained as a molten pool or evaporation source.
  • the substrate to be coated is positioned over the evaporation source and is manipulated to produce a uniform coating thickness and to enhance the production of a columnar structure.
  • the ceramic coating thickness may range from about 1 to abut 50 mils.
  • a columnar grain thermal barrier coating on a NiCoCrAlY bond coat (without Si or Hf) lasted about 100 hours (a range of 85-136 hours) .
  • a similar sample on a NiCoCrAlY+Hf+Si bond coat according to the invention lasted about 300 hours (220-500 hour range) .

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
  • Physical Vapour Deposition (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)

Abstract

Article à revêtement et procédé de production de l'article. On applique sur ce dernier un revêtement céramique à grain colonnaire formant une barrière thermique efficace. Entre le substrat et le revêtement céramique se trouve une couche interne d'une composition spécifique qui confère à l'article une durabilité améliorée et une meilleure résistance à la détérioration.
PCT/US1993/010860 1992-12-22 1993-11-10 Revetement ceramique colonnaire formant une barriere thermique et a adherence amelioree WO1994015000A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US99531392A 1992-12-22 1992-12-22
US07/995,313 1992-12-22

Publications (1)

Publication Number Publication Date
WO1994015000A1 true WO1994015000A1 (fr) 1994-07-07

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Family Applications (1)

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Country Status (1)

Country Link
WO (1) WO1994015000A1 (fr)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5645893A (en) * 1994-12-24 1997-07-08 Rolls-Royce Plc Thermal barrier coating for a superalloy article and method of application
US5652044A (en) * 1992-03-05 1997-07-29 Rolls Royce Plc Coated article
US5667663A (en) * 1994-12-24 1997-09-16 Chromalloy United Kingdom Limited Method of applying a thermal barrier coating to a superalloy article and a thermal barrier coating
EP1318215A2 (fr) * 2001-12-06 2003-06-11 Siemens Westinghouse Power Corporation Oxides à taux de défauts élevés utilisables comme revêtement formant barrière thermique résistant à l'agglomération
CN113480337A (zh) * 2021-06-25 2021-10-08 中国航发北京航空材料研究院 一种陶瓷基复合材料用超疏水环境障涂层及其制备方法

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1992005298A1 (fr) * 1990-09-20 1992-04-02 United Technologies Corporation Enduit en ceramique a structure colonnaire destine a servir de barriere thermique et avec adherence amelioree

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1992005298A1 (fr) * 1990-09-20 1992-04-02 United Technologies Corporation Enduit en ceramique a structure colonnaire destine a servir de barriere thermique et avec adherence amelioree

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5652044A (en) * 1992-03-05 1997-07-29 Rolls Royce Plc Coated article
US5846605A (en) * 1992-03-05 1998-12-08 Rolls-Royce Plc Coated Article
US5645893A (en) * 1994-12-24 1997-07-08 Rolls-Royce Plc Thermal barrier coating for a superalloy article and method of application
US5667663A (en) * 1994-12-24 1997-09-16 Chromalloy United Kingdom Limited Method of applying a thermal barrier coating to a superalloy article and a thermal barrier coating
US5763107A (en) * 1994-12-24 1998-06-09 Rolls-Royce Plc Thermal barrier coating for a superalloy article
US5981091A (en) * 1994-12-24 1999-11-09 Rolls-Royce Plc Article including thermal barrier coated superalloy substrate
EP1318215A2 (fr) * 2001-12-06 2003-06-11 Siemens Westinghouse Power Corporation Oxides à taux de défauts élevés utilisables comme revêtement formant barrière thermique résistant à l'agglomération
EP1318215A3 (fr) * 2001-12-06 2003-07-09 Siemens Westinghouse Power Corporation Oxides à taux de défauts élevés utilisables comme revêtement formant barrière thermique résistant à l'agglomération
US6930066B2 (en) 2001-12-06 2005-08-16 Siemens Westinghouse Power Corporation Highly defective oxides as sinter resistant thermal barrier coating
CN113480337A (zh) * 2021-06-25 2021-10-08 中国航发北京航空材料研究院 一种陶瓷基复合材料用超疏水环境障涂层及其制备方法
CN113480337B (zh) * 2021-06-25 2022-09-20 中国航发北京航空材料研究院 一种陶瓷基复合材料用超疏水环境障涂层及其制备方法

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