WO2003068673A2 - Procede pour la production d'un composant a resistance thermique elevee, revetu d'une couche de protection thermique - Google Patents

Procede pour la production d'un composant a resistance thermique elevee, revetu d'une couche de protection thermique Download PDF

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Publication number
WO2003068673A2
WO2003068673A2 PCT/CH2003/000100 CH0300100W WO03068673A2 WO 2003068673 A2 WO2003068673 A2 WO 2003068673A2 CH 0300100 W CH0300100 W CH 0300100W WO 03068673 A2 WO03068673 A2 WO 03068673A2
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WO
WIPO (PCT)
Prior art keywords
layer
adhesive layer
component
heat
nanocrystalline
Prior art date
Application number
PCT/CH2003/000100
Other languages
German (de)
English (en)
Other versions
WO2003068673A3 (fr
Inventor
Valery Shklover
Paul Bowen
Karima Belaroui
Heinrich Hofmann
Maxim Konter
Original Assignee
Alstom Technology Ltd
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 Alstom Technology Ltd filed Critical Alstom Technology Ltd
Priority to AU2003202402A priority Critical patent/AU2003202402A1/en
Publication of WO2003068673A2 publication Critical patent/WO2003068673A2/fr
Publication of WO2003068673A3 publication Critical patent/WO2003068673A3/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
    • 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
    • C23C28/32—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer
    • C23C28/321—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer with at least one metal alloy layer
    • C23C28/3215—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer with at least one metal alloy layer at least one MCrAlX layer
    • 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
    • C23C28/30—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
    • 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
    • C23C28/30—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

Definitions

  • the present invention relates to the field of thermal machines. It relates to a method for producing a thermally highly resilient component coated with a heat protection layer according to the preamble of claim 1.
  • Such a method is e.g. known from US-A-5,759,640.
  • the adhesive layer is typically formed from an aluminum-containing, oxidation-resistant alloy of the type MCrAIY (M stands for iron, cobalt and / or nickel) (see US Pat. No. 5,759,640).
  • the two most important functions of the MCrAlY adhesive layer of a heat protection layer arrangement are (1) the compensation of the thermal mismatch between the heat protection layer (Y-stabilized Zr0) and the superalloy and (2) the provision of a protective Al 2 0 3 layer, which is due to the oxidation the adhesive layer is formed at high temperatures and leads to the formation of a thermally grown oxide layer (Thermally Grown Oxide TGO).
  • the AI 2 ⁇ 3 layer serves as oxidation protection for the system made of adhesive layer and super alloy.
  • FIG. 1 a shows the initial situation for a component 13 made of a superalloy, which is provided with a coating structure 10 consisting of an adhesive layer 12 and an overlying heat protection layer 11. Becomes If the component 13 is exposed to high temperatures from the side of the heat protection layer 11 in a heat treatment, an oxide layer 14 forms on the hot side of the adhesive layer 12 (sub-figure 1b).
  • the actual composition of the thermally grown oxide layer 14 is, however, very complex, because various other oxides (Cr 2 0 3 , NiO, Y 2 0 3 and others) also form at the high temperatures due to interdiffusion of the metals and subsequent interactions between the Oxides (e.g. AI 2 ⁇ 3 / Zr0 2 ) take place.
  • These solid-state chemical high-temperature processes are heterogeneous, take place with a significant change in volume, lead to the formation of mixed oxides with no protective effect and are ultimately responsible for micro-crack formation and the chipping of the heat protection layer.
  • microstructural changes e.g. by directional microcrystallization (using kinetic factors), such as, for example, an in-situ change of the surface of an EB-PVD NiCoCrAlY coating supported by argon plasma at 900 ° C.
  • kinetic factors such as, for example, an in-situ change of the surface of an EB-PVD NiCoCrAlY coating supported by argon plasma at 900 ° C.
  • microstructural change is the growth of a thin (0.1 to 2 ⁇ m) layer of a "naturally" grown oxide by treating the pre-cleaned surface of the adhesive layer with laser energy (UV laser) to form a diffusion barrier in the form of an aluminum oxide layer to produce with controlled thickness (see also the already mentioned US-A-5,759,640).
  • UV laser laser energy
  • Nanotechnology now offers new possibilities for changing a thermally grown oxide layer (TGO) by varying the synthesis methods or process conditions.
  • TGO thermally grown oxide layer
  • a nanocrystalline MCrAlY adhesive layer produced using "cryo milling” has been used in order to obtain a uniform, fine structure of the TGO layer with improved protective properties (V. Provenzano, GE Kim, EJ Lavernja, JM Schoenung and EV Barrera Abstr. Conf. "Novel Synthesis and Processing of Nanostructural Coatings for Protection against Degradation” August 12-17, 2001 Davos, Switzerland).
  • the tailoring of material properties by nanocrystallization has also been proposed elsewhere (US Pat. No. 5,994,164).
  • the growth of selected phases of nanocrystalline materials (aluminum oxide, titanium dioxide) with dimensions of less than 20 nm by controlling the oxidizing atmosphere is also known (US-A-5, 128,081).
  • the crystallization behavior and the phase transitions do not necessarily have to follow the conventional paths of the phase transitions.
  • the explanation of this unusual crystallization behavior can lie in the high surface energy of the nanocrystals.
  • TBCs thermal protection layers
  • the previously proposed methods for improving the service life of thermal protection layers (TBCs) on components that are subjected to high thermal loads have various disadvantages: For example, the service life of a TBC system which has been modified by a pre-oxidation process is limited to only a few thousand hours or less (MF Stroosnijder, R. Mevrel and MJ Bennet Mater. High Temp., 12, 53 (1994)).
  • the improvement in the protective function of the chemically modified adhesive layer is limited by the exhaustion of the reactive elements, the concentration of which must be limited in order to prevent the formation of undesired mixed oxide phases.
  • the fine-grained TGO Layers obtained from a nanostructured MCrAlY adhesive layer V.
  • the object is achieved by the entirety of the features of claim 1.
  • the essence of the invention is to bring about a preferred formation of ⁇ -Al 2 O 3 phases by introducing a special auxiliary layer at the boundary between the adhesive layer and the heat protection layer during the subsequent oxidation of the adhesive layer, so that the oxide layer formed predominantly contains the stable ⁇ -Al 2 0 3 phase.
  • the special auxiliary layer consists of nanocrystalline ⁇ -Al 2 0 3 .
  • the auxiliary layer made of nanocrystalline ⁇ -Al 2 O 3 can be deposited directly on the surface of the adhesive layer.
  • the thickness of the auxiliary layer is approximately 10 ⁇ m.
  • FIG. 1 shows a schematic representation of the layer system of a thermally highly resilient component provided with a heat protection layer in the conventional manner before the heat treatment (FIG. 1 a) and after the heat treatment (FIG. 1 b);
  • FIG. 2 shows the layer system according to an exemplary embodiment of the invention in an illustration analogous to FIG. 1 before the heat treatment (FIG. 2a) and after the heat treatment (FIG. 2b);
  • FIG. 2 shows the layer system according to an exemplary embodiment of the invention before the heat treatment (FIG. 2a) and after the heat treatment (FIG. 2b) in an illustration analogous to FIG. 1.
  • a thin, preferably about 10 ⁇ m thick, auxiliary layer 24 is then produced on the surface of the adhesive layer 22 and consists of nanocrystalline ⁇ -Al 2 O 3 .
  • auxiliary layer is deposited 24 of nanocrystalline ⁇ -Al 2 0 3 on the surface of the adhesive layer 22, or by first komgrössenstabilinstrumentes for forming the auxiliary layer 24 nanocrystalline ⁇ -Al 2 0 3 on the Surface of the adhesive layer 22 is deposited, and that the ⁇ -Al 2 0 3 is then converted to ⁇ -Al 2 0 3 by heating to 1080 ° C in a vacuum.
  • the actual heat protection layer 21 is deposited thereon, which preferably consists of Y-stabilized zirconium dioxide.
  • the coating structure 20 then has the inner structure shown in FIG. 2a. If the component 23 coated in this way is then subjected to a heat treatment in the presence of 0 2 , an oxide layer 25 is again formed on the hot side of the adhesive layer 22 (FIG. 2 b).
  • the nanocrystalline ⁇ -Al 2 0 3 auxiliary layer 24 has the effect that predominantly -AI 2 0 3 phase forms in the thermally grown oxide layer 25.
  • the predominant content of ⁇ -AI 2 0 3 phase and the associated lack of a complex mixture of stable and metastable Al 2 0 3 phase reduces the number of phase transitions and the associated volume changes in the TGO layer during operation. This increases the stability of the coating and significantly extends its service life.
  • Step 1 Polished MK-4 material was coated with a thin layer (thickness d) of nanocrystalline ⁇ -Al 2 0 3 and oxidized at temperatures of 950 and 1050 ° C. The resulting TGO layer was then subjected to a phase analysis. The results were compared to those for a MK-4 sample oxidized without a nano-layer.
  • Step 2 The procedure was the same as in step 1, with the difference that the size-stabilized ⁇ -AI 2 0 3 was used to start the nano-coating and then converted to ⁇ -AI 2 0 3 by heating to 1080 ° C in a vacuum ,
  • Step 3 The procedure was the same as in step 1, with the difference that the nanocoating was applied to an MCrAlY adhesive layer (SV-20) on an MK-4 substrate.
  • Step 4 The procedure was the same as in step 2, with the difference that the nanocoating was applied to an MCrAlY adhesive layer (SV-20) on an MK-4 substrate.
  • Step 5 The procedure was the same as in step 3, with the difference that an upper TBC layer was applied and a possible change in the flaking behavior was analyzed.
  • Step 6 The procedure was the same as in step 3, with the difference that an upper TBC layer was applied and a possible change in the flaking behavior was analyzed.
  • Examples of the morphology of the layers of nanocrystalline Al 2 O 3 produced with different binder concentrations and sintered in two steps at 1200 ° C. and 1140 ° C. on a base made of polycrystalline Ni-based superalloy are shown in FIG. 3 on the basis of their SEM pattern and 4 reproduced. Nanocrystalline ⁇ -Al 2 0 3 powder with a 3% proportion of ⁇ -Al 2 0 3 was used for the coating.
  • the cross sections of FIGS. 3 and 4 show that the particle size varies within a wide range of 50-200 nm and 50-100 nm, depending on the binder concentration. The sintering leads to a certain increase in the grain size and to an improvement in the adhesion of the coating to the substrate.

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  • Chemical & Material Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Ceramic Engineering (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention concerne un procédé pour la production d'un composant (23) à résistance thermique élevée, revêtu d'une couche de protection thermique (21). Selon le procédé de l'invention, on dépose d'abord une couche adhésive (22) contenant de l'aluminium sur la surface du composant (23), puis on dépose la couche de protection thermique (21) sur la couche adhésive (22). Selon un tel procédé, on obtient une longévité accrue du revêtement en produisant, avant le dépôt de la couche de protection thermique (21) sur la surface de la couche adhésive (22), une mince couche auxiliaire (24) constituée d'alumine alpha nanocristalline.
PCT/CH2003/000100 2002-02-15 2003-02-11 Procede pour la production d'un composant a resistance thermique elevee, revetu d'une couche de protection thermique WO2003068673A2 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2003202402A AU2003202402A1 (en) 2002-02-15 2003-02-11 Method for producing a component having a high thermal loading capacity and coated with a heat-protective layer

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CH2672002 2002-02-15
CH267/02 2002-02-15

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WO2003068673A2 true WO2003068673A2 (fr) 2003-08-21
WO2003068673A3 WO2003068673A3 (fr) 2003-10-16

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Cited By (2)

* 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

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EP0700879A1 (fr) * 1994-09-10 1996-03-13 Bayerische Motoren Werke Aktiengesellschaft Revêtement en oxyde d'aluminium résistant aux rayures sur un substrat en verre et procédé pour sa production
US5516588A (en) * 1991-03-27 1996-05-14 Widia Gmbh Composite body, its use and a process for its production
EP0780484A1 (fr) * 1995-12-22 1997-06-25 General Electric Company Articles avec revêtement de barrière thermique et procédé de revêtement
US5683761A (en) * 1995-05-25 1997-11-04 General Electric Company Alpha alumina protective coatings for bond-coated substrates and their preparation
EP0937786A2 (fr) * 1998-02-21 1999-08-25 DLR Deutsches Zentrum für Luft- und Raumfahrt e.V. Système de revêtement de barrière thermique avec une couche d'alumine intégrée
JP2000017458A (ja) * 1998-06-29 2000-01-18 Mitsubishi Heavy Ind Ltd 高温部材およびその製造方法
EP1127959A1 (fr) * 2000-02-23 2001-08-29 Howmet Research Corporation Revêtement de barrière thermique et article

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US5516588A (en) * 1991-03-27 1996-05-14 Widia Gmbh Composite body, its use and a process for its production
EP0700879A1 (fr) * 1994-09-10 1996-03-13 Bayerische Motoren Werke Aktiengesellschaft Revêtement en oxyde d'aluminium résistant aux rayures sur un substrat en verre et procédé pour sa production
US5683761A (en) * 1995-05-25 1997-11-04 General Electric Company Alpha alumina protective coatings for bond-coated substrates and their preparation
EP0780484A1 (fr) * 1995-12-22 1997-06-25 General Electric Company Articles avec revêtement de barrière thermique et procédé de revêtement
EP0937786A2 (fr) * 1998-02-21 1999-08-25 DLR Deutsches Zentrum für Luft- und Raumfahrt e.V. Système de revêtement de barrière thermique avec une couche d'alumine intégrée
JP2000017458A (ja) * 1998-06-29 2000-01-18 Mitsubishi Heavy Ind Ltd 高温部材およびその製造方法
EP1127959A1 (fr) * 2000-02-23 2001-08-29 Howmet Research Corporation Revêtement de barrière thermique et article

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GUOFENG CHEN: "THE EFFECT OF NANOCRYSTALLIZATION ON THE OXIDATION RESISTANCE OF NI-5CR-5AL ALLOY" SCRIPTA MATERIA, Bd. 41, Nr. 8, - 1999 Seiten 883-887, XP004325825 ELSEVIER SCIENCE *
LEONARDO AJDELSTAJN: "OXIDATION BEHAVIOR OF HVOF SPRAYED NANOCRYSTALLINE NICRALY POWDER" MATERIALS SCIENCE AND ENGINEERING, Bd. A338, - 2002 Seiten 33-43, XP001148280 *
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Cited By (2)

* 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

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WO2003068673A3 (fr) 2003-10-16
AU2003202402A8 (en) 2003-09-04
AU2003202402A1 (en) 2003-09-04

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