WO2002097150A2 - Procede permettant de traiter mecaniquement une surface metallique - Google Patents

Procede permettant de traiter mecaniquement une surface metallique Download PDF

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Publication number
WO2002097150A2
WO2002097150A2 PCT/EP2002/005577 EP0205577W WO02097150A2 WO 2002097150 A2 WO2002097150 A2 WO 2002097150A2 EP 0205577 W EP0205577 W EP 0205577W WO 02097150 A2 WO02097150 A2 WO 02097150A2
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WO
WIPO (PCT)
Prior art keywords
particles
layer
metallic
manufacture
article
Prior art date
Application number
PCT/EP2002/005577
Other languages
English (en)
Other versions
WO2002097150A3 (fr
Inventor
Thomas Jansing
Helge Reymann
Original Assignee
Siemens Aktiengesellschaft
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 Aktiengesellschaft filed Critical Siemens Aktiengesellschaft
Publication of WO2002097150A2 publication Critical patent/WO2002097150A2/fr
Publication of WO2002097150A3 publication Critical patent/WO2002097150A3/fr

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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
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/58—After-treatment
    • C23C14/5873—Removal of material
    • C23C14/588—Removal of material by mechanical treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
    • B24C11/00—Selection of abrasive materials or additives for abrasive blasts
    • 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
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/02—Pretreatment of the material to be coated
    • C23C14/028—Physical treatment to alter the texture of the substrate surface, e.g. grinding, polishing
    • 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

Definitions

  • the invention relates to a method for a mechanical treatment of a surface of a metallic substrate of an article of manufacture, in particular for an article of manufacture to be exposed to a hot temperature and to be coated with a protective coating, wherein the surface is treated with abrasive particles.
  • a protective coating for protecting a component, in particular a gas turbine blade, from corrosion and oxidation at a high temperature and from excessive thermal stress is disclosed.
  • This coating has a heat insulation layer including a ceramic material and an adhesion-promoting layer including a rhenium containing metal alloy.
  • the metal alloy belongs to the alloys covered by the general term MCrAlY, where M represents cobalt and/or nickel and Y represents yttrium and/or at least one equivalent metal from the group including scandium and the rare earth elements.
  • smoothing of the adhesion-promoting layer to a maximum roughness of 2 ⁇ m is darned out by vibratory grinding, before which, if required, blasting can be effected using glass beads or sand.
  • a thermal barrier coating is described in which a bond layer is polished to have an average surface roughness R a of at most about two micrometers, as measured in accordance with standardised measurement procedures, with a preferred surface roughness being at most about one micrometer R a with out indicating which method may be used to achieve such a surface roughness.
  • R a average surface roughness
  • EP 1 016 735 Al a method for coating a component of a gas turbine is described. On this component an adhesion metallic layer is bound, whereby on this adhesion layer a ceramic thermal barrier layer is bonded. Prior to applying the thermal barrier layer the metallic layer is grit blasted with abrasive materials consisting of the same material as the ceramic thermal barrier layer, wherein the ceramic thermal barrier layer consists of zirconia.
  • a multi-layer thermal barrier coating for a superalloy article comprises a platinum enriched superalloy layer, an MCrAlY bond coating on the platinum enriched superalloy layer, a platinum enriched MCrAlY layer on the MCrAlY bond coating, a platinum aluminide coating on the platinum enriched MCrAlY layer, an oxide layer on the platinum aluminide coating and a ceramic thermal barrier coating on the oxide layer.
  • the surface of the bond coating is grit blasted with dry alumina powder to remove any diffusion residues.
  • the ceramic thermal barrier coating is then applied by EBPVD, to produce a thin oxide layer on the platinum aluminide coating with a platinum enriched gamma phase layer there between.
  • a method for a mechanical treatment of a surface of a metallic substrate of an article of manufacture comprising the step of treating the surface with abrasive particles, which particles comprise a metallic nitride and/or a silicon nitride.
  • a method for treating the surface of a metallic substrate is provided, which assures- a predefined surface roughness' and an activation of the surface.
  • the surface treated in this manner achieves a good bonding of layers deposited on the substrate by for example conventional spraying methods.
  • the layers may equally be ceramic layers or metallic layers, in particular metallic adhesion layers.
  • Known methods use for example particles consisting of aluminium (A1 2 0 3 ) , which is quite inexpensive, or silicon carbide (SiC) and lead to a smoothing and roughening of a surface of a substrate.
  • the resulting surface structure is influenced to some extent by the pressure and the duration during which the particles hit the surface.
  • such particles blasting grains
  • a substantial contamination of the substrate with broken particles remaining on the surface or being enclosed in the surface is to be observed.
  • Mechanical treatment of the surface using aluminium may therefor lead to a contamination of the surface between 5 and up to over 10%.
  • metallic nitride an/or silicon containing nitrides according to the invention having a higher fracture toughness of the particles leads to a lower brittleness and therefor less particles break in parts when hitting the surface.
  • the process parameters can vary in a wider process windows, for example resulting in a higher blasting pressure and a reduced blasting duration. allows the use of more coarse-grained blasting material.
  • the choice of nitrides furthermore possibility to achieve a higher roughness of the surface with a reduced contamination of the surface .
  • a method for mechanical treatment of a surface of a metallic substrate of an article of manufacture comprising the step of treating the surface with abrasive particles which particles have on average a fracture toughness between 5.5MPa*m 0 ' 5 and 10.0 MPa*m 0 - 5
  • the particles comprise aluminium nitride (A1N) , titan nitride (TiN) , silicon nitride (Si 3 N 4 ) or a mixture thereof.
  • the particles used for the mechanical treatment essentially consist of one of the nitrides mentioned or a mixture thereof.
  • the particles substantially consist of a sintered silicon nitride (SSN) .
  • SSN sintered silicon nitride
  • Sintered silicon nitride has a fracture toughness from about 6MPa*m 0 - 5 to 8.5 MPa*m 0 ' 5 in particular about 7MPa*m 0 ' 5 .
  • the particles substantially consist of a hot pressed silicon nitride (HPSN) .
  • Hot pressed silicon nitride has a fractuted toughness of about 6 MPa*m 0,5 to 8.5MPa*m 0 " 5 in particular about 6 MPa*m 0 - 5 .
  • the particles have on average a diameter between 150 micrometers to 600 micrometers in particular over 450 micrometers.
  • the average diameter is chosen as one of the process parameters applied according to the surface roughness to be obtained. Further process parameters are blasting pressure, the choice of material for the particles and blasting duration as well as other parameters, for example the material of the substrate and the material of the coating layer.
  • the particles are transported to the surface in a jet of a pressurised gaseous transport medium.
  • a pressurised gaseous transport medium is preferably pressurised air.
  • a direct-type blasting apparatus whereby the transport medium is pressurised to a pressure between 0.5 bar and 4 bar.
  • the pressure of the gaseous transport medium which preferably is compressed air, lies between 2.5bar and 4bar .
  • an injector-type blasting apparatus is used, whereby the transport medium is pressurised to a pressure between 0.5bar and 7bar. In particular the pressure lies between 3bar and 6bar.
  • the particles are ejected from a blasting apparatus a distance of between 10cm and 50cm away from the surface of the substrate.
  • the distance hereby is defined as the distance between the location, in particular a nozzle of the apparatus, where the particles leave the apparatus and the location where they hit the surface .
  • the article of manufacture comprises a body, on which a metallic layer is placed and where the surface to be mechanically treated is the surface of the metallic layer opposite to the boundary with the substrate.
  • the metallic layer itself maybe bounded on the surface of the body, which surface has been mechanically treated according to the method described herein.
  • the surface of the body maybe mechanically treated in a process using the same process parameters as for the treatment of the metallic layer, like diameter of the particles, material of the particles, distance between apparatus and surface, blasting pressure, blasting duration.
  • the process parameters could also be different with respect to the different materials of the substrate of the metallic layer and a further layer to be placed on the metallic layer, which further layer could be a ceramic layer.
  • the metallic layer substantially consists of an alloy or an intermetallic compound.
  • a metallic layer may itself serve as a corrosion protective coating or an oxidation protection coating.
  • the metallic layer is a metallic anchoring layer (or also called adhesion layer), for bonding a thermal barrier layer.
  • the thermal barrier layer preferably contains zirconia (Zro 2 ) which, due to its relatively high and therefor metal-like expansion coefficient, is particularly suitable for providing the adhesion-promotion layer with a thermal barrier coating.
  • Zro 2 zirconia
  • a zirconium layer is preferably partially stabilised by adding 5wt-% to 10wt-% of yttrium oxide.
  • thermal barrier layer Other ceramic material for the thermal barrier layer are also possible which are for example metal ceramic oxides, in particular having a perofskite structure (for example Lathanaluminate) , a pyrochloride structure (for example Lathanhafnate) or a spinell structure, for example MgAl 2 0 4 .
  • the thickness of the thermal barrier coating is preferably above 500 micrometers, in particular above 200 micrometers.
  • the thermal barrier layer could be applied by any suitable method in particular atmospheric plasma spray (APS) or physical vapour deposition (PVD) .
  • the anchoring layer substantially consist of a MCrAlY alloy.
  • This alloy is widely known in particular in the field of coating of components to be exposed to high temperatures from above 500°C to about 1200°C, in particular components of combustion turbines, furnaces etc.
  • MCrAlY M represents at least one of the elements from the group including iron, cobalt and nickel .
  • Cr stands for chromium and Al for aluminium.
  • Y stands for yttrium or a metal which is selected from the group including scandium, rhenium and the rare earth elements which are equivalent to yttrium.
  • the metallic layer in particular an adhesion layer and more particular a MCrAlY alloy layer is preferably applied to the surface of the substrate by using thermal spraying in particular atmospheric plasma spray (APS) , vacuum plasma spraying (VPS) , low pressure plasma spraying (LPPS) or physical vapour deposition (PVD) .
  • APS atmospheric plasma spray
  • VPS vacuum plasma spraying
  • LPPS low pressure plasma spraying
  • PVD physical vapour deposition
  • the article of manufacture is a component to be exposed to high temperatures, in particular above 500°C.
  • the article of manufacture is a component of a combustion turbine.
  • a component is for example a heat shield element used in a combustion turbine, a turbine blade, a turbine vane, a shroud element attached to the 10 wall structure of a gas turbine or any other component used in a combustion chamber.
  • Components of a combustion turbine which are in contact with the hot exhaust gas resulting from the burning of fuel in the combustion chamber may be exposed to temperatures of about 900°C to over 1300°C. Therefor it is essential for the trouble-free operation of a combustion turbine, that coatings applied to articles of manufactures used in a combustion turbine are firmly bonded to the article of manufacture. An efficient and contamination free treatment of the surface of the article of manufacture prior to coating is essential for this, which is achieved with the method described herein.
  • FIG 1 shows a fractional cross-sectional view through a portion of a body of an article of manufacture
  • FIG 2 shows a fractional cross-sectional view through a portion of a body of an article of manufacture having a metallic coating layer
  • FIG 3 shows a fractional cross-sectional view through a portion of a body of an article of manufacture having a coating layer structure
  • FIG 4 shows a perspective view of a turbine blade
  • FIG 5 shows a perspective view of a heat shield element.
  • the article of manufacture 1 (see for example figures 4 and 5) has a body 2 consisting of a base material, which may be in particular, a nickel super alloy or a cobalt super alloy.
  • the body 2 has a surface 7.
  • Surface 7 is treated prior to applying a coating to the body 2 by exposing the surface 7 to a jet of abrasive particles 5.
  • the abrasive particles 5 are carried within a pressurised transport or carrier medium 8 in particular compressed air.
  • the jet of the transport medium 8 including the abrasive particles is generated in a blast apparatus 9.
  • the abrasive articles 5 by bouncing against the surface 7 lead to a smoothening of the roughness of the surface 7 and also to a cleaning and activating of the surface 7.
  • abrasive particles 5 particles which consist of aluminium nitride, titanium nitride, silicon nitride or a mixture thereof.
  • the jet of particles 5 is inclined under and angle oi to the surface 7. This angle a lies between 20° and 90°, in particular is about 60°.
  • This distance D lies preferably between 10cm and 50 cm.
  • FIG. 2 shows a body 2 , for example the body 2 as shown in figure 1, which is coated by a metallic layer 3.
  • the metallic layer 3 represents the substrate 6 which has the surface 7, which is to be mechanically treated.
  • the metallic coating layer 3 is preferably an adhesion or anchoring layer and has been applied by using a physical vapour deposition (PVD) process, in particular electron beam physical vapour deposition (EB-PVD) or by plasma spraying.
  • PVD physical vapour deposition
  • EB-PVD electron beam physical vapour deposition
  • - consists of an alloy widely known as MCrAlY or an aluminite for a corrosion protective coating.
  • the surface 7 of the metallic coating layer 3 is prepared and treated before bonding a further layer, in particular a ceramic thermal barrier layer , to the surface 7.
  • the surface 7 is grit-blasted with abrasive particles 5, which may consist of the same materials as discussed relating to figure 1, in particular a metallic nitride or silicon nitride.
  • Particles 5 may also have the same diameter on average, in particular between 150 and 600 microns, in particular between 450 and 600 microns and the client angle a of inclination also lies between 20 and 60°.
  • the angle a the material of the abrasive particles 5, the distance D between blast apparatus 9 and the location on the surface 7 at which the particles 5 hit the surface 7 as well as the duration during which particles hit the same location of the surface 7 as process parameters depend on the roughness of the surface 7 which has to be reached by the mechanical treatment.
  • the pressure to which the carrier medium 8 is pressurised also depends on the choice of material for the abrasive particles 5, the material of the coating layer 3 and the roughness to be reached.
  • the blast apparatus 9 shown in figure 2 may be the same one as shown in figure 1.
  • FIG 3 a fractional cross-section view of the particle of manufacture 1 which is obtained after applying a thermal barrier layer 4 to the body 2 after the mechanical treatment of a metallic bond layer 3.
  • an oxide layer 12 is formed between the metallic bond layer 3 and the ceramic thermal barrier layer 4 .
  • the ceramic thermal barrier layer 4 is - in particular for a component of a combustion turbine -made of a metal oxide or a mixture of different metal oxides, for example partially stabilised zirconia.
  • the oxide layer 12 includes aluminium or chromium oxide and is formed due to thermal oxidation (thermally grown oxide, TGO) .
  • the oxide layer 12 may also be created during an intermediate process step through oxidation of the metallic bond layer 3.
  • FIG. 4 shows a perspective view of an article of manufacture 1, which is a turbine blade of a combustion turbine.
  • Blade 1 has an active blade area 10, which is coated with a thermal barrier coating 4.
  • the active blade area 10 of the turbine blade 1 is exposed to a stream of hot exhaust gas 13, which is generated by burning fuel in a not shown combustion chamber.
  • Turbine blade 1 further comprises a fastening region 14 which is a blade root section having a fir-tree fastening profile. Opposite to the blade root 14 the active blade region 10 is bounded by a shroud 15, which serves to seal the stream of hot gas 13 off from other areas of a combustion turbine.
  • the thermal barrier layer 4 is bonded to the active blade region 10 after having treated the surface 7 of this active blade region 10 with the method as described above .
  • FIG 5 in a perspective view an article shield element of a not shown combustion of manufacture 1 is shown, which is a heat chamber of a combustion turbine.
  • the heat shield element 1 has a through hole 16 for a not shown fastening element.
  • a bolt guided through the through hole 16 is put into connection with a not shown wall structure for securing the heat shield element in a combustion chamber.
  • the surface of the heat shield element 1 is prior to coating with a thermal barrier layer 4 mechanically treated with the method described above. Due to this the thermal barrier layer 4 shows an improved bonding capability for withstanding high temperatures and for resisting against a hot aggressive gas flowing along the thermal barrier layer 4.
  • the invention is distinguished by a method of mechanical treating the surface of an article of manufacture with abrasive particles comprising metallic and/or silicon nitrides which leads to a very low contamination of the surface with the material of the particles, a cleaning and activating on the surface as well as an accurate adjustment of a predetermined surface roughness of the article of manufacture.
  • a surface, in particular metallic surface, mechanically treated in such a way leads to an improved bond between a metallic surface and a metallic coating as well as between a metallic surface and a ceramic coating, in particular a ceramic thermal barrier coating.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
  • Ceramic Products (AREA)

Abstract

L'invention concerne un procédé permettant de traiter mécaniquement une surface (7) de substrat métallique (6) d'article manufacturé (1), qui consiste à traiter ladite surface (7) à l'aide de particules abrasives (5), ces particules (5) comprenant un nitrure métallique, en particulier un nitrure d'aluminium (A1N), un nitrure de titane (TiN), et/ou un nitrure de silicium (Si3N4) notamment un nitrure de silicium fritté (SSN). Lesdites particules abrasives (5) présentent, de préférence, une ténacité moyenne comprise entre 5,5 MPa*m1/2 et 10,0 MPa.*M1/2.
PCT/EP2002/005577 2001-05-26 2002-05-21 Procede permettant de traiter mecaniquement une surface metallique WO2002097150A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0112873.5 2001-05-26
GB0112873A GB2375725A (en) 2001-05-26 2001-05-26 Blasting metallic surfaces

Publications (2)

Publication Number Publication Date
WO2002097150A2 true WO2002097150A2 (fr) 2002-12-05
WO2002097150A3 WO2002097150A3 (fr) 2003-12-11

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GB (1) GB2375725A (fr)
WO (1) WO2002097150A2 (fr)

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US9074119B2 (en) 2012-12-31 2015-07-07 Saint-Gobain Ceramics & Plastics, Inc. Particulate materials and methods of forming same
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US9676980B2 (en) 2012-01-10 2017-06-13 Saint-Gobain Ceramics & Plastics, Inc. Abrasive particles having particular shapes and methods of forming such particles
US9707529B2 (en) 2014-12-23 2017-07-18 Saint-Gobain Ceramics & Plastics, Inc. Composite shaped abrasive particles and method of forming same
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US10106714B2 (en) 2012-06-29 2018-10-23 Saint-Gobain Ceramics & Plastics, Inc. Abrasive particles having particular shapes and methods of forming such particles
US10179391B2 (en) 2013-03-29 2019-01-15 Saint-Gobain Abrasives, Inc. Abrasive particles having particular shapes and methods of forming such particles
US10196551B2 (en) 2015-03-31 2019-02-05 Saint-Gobain Abrasives, Inc. Fixed abrasive articles and methods of forming same
US10280350B2 (en) 2011-12-30 2019-05-07 Saint-Gobain Ceramics & Plastics, Inc. Composite shaped abrasive particles and method of forming same
US10557067B2 (en) 2014-04-14 2020-02-11 Saint-Gobain Ceramics & Plastics, Inc. Abrasive article including shaped abrasive particles
US10563105B2 (en) 2017-01-31 2020-02-18 Saint-Gobain Ceramics & Plastics, Inc. Abrasive article including shaped abrasive particles
US10711171B2 (en) 2015-06-11 2020-07-14 Saint-Gobain Ceramics & Plastics, Inc. Abrasive article including shaped abrasive particles
US10759024B2 (en) 2017-01-31 2020-09-01 Saint-Gobain Ceramics & Plastics, Inc. Abrasive article including shaped abrasive particles
US10865148B2 (en) 2017-06-21 2020-12-15 Saint-Gobain Ceramics & Plastics, Inc. Particulate materials and methods of forming same
US11230653B2 (en) 2016-09-29 2022-01-25 Saint-Gobain Abrasives, Inc. Fixed abrasive articles and methods of forming same
US11718774B2 (en) 2016-05-10 2023-08-08 Saint-Gobain Ceramics & Plastics, Inc. Abrasive particles and methods of forming same
US11926019B2 (en) 2019-12-27 2024-03-12 Saint-Gobain Ceramics & Plastics, Inc. Abrasive articles and methods of forming same
US11959009B2 (en) 2016-05-10 2024-04-16 Saint-Gobain Ceramics & Plastics, Inc. Abrasive particles and methods of forming same
US12129422B2 (en) 2019-12-27 2024-10-29 Saint-Gobain Ceramics & Plastics, Inc. Abrasive articles and methods of forming same
US12338384B2 (en) 2019-12-27 2025-06-24 Saint-Gobain Ceramics & Plastics, Inc. Abrasive articles and methods of forming same
US12365822B2 (en) 2024-03-11 2025-07-22 Saint-Gobain Ceramics & Plastics, Inc. Composite shaped abrasive particles and method of forming same

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