WO2013144022A1 - Procédé pour retirer une céramique - Google Patents
Procédé pour retirer une céramique Download PDFInfo
- Publication number
- WO2013144022A1 WO2013144022A1 PCT/EP2013/056097 EP2013056097W WO2013144022A1 WO 2013144022 A1 WO2013144022 A1 WO 2013144022A1 EP 2013056097 W EP2013056097 W EP 2013056097W WO 2013144022 A1 WO2013144022 A1 WO 2013144022A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- ceramic
- coating
- metallic
- halogen
- gaseous process
- Prior art date
Links
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
- C23G—CLEANING OR DE-GREASING OF METALLIC MATERIAL BY CHEMICAL METHODS OTHER THAN ELECTROLYSIS
- C23G5/00—Cleaning or de-greasing metallic material by other methods; Apparatus for cleaning or de-greasing metallic material with organic solvents
-
- 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
- F01D5/005—Repairing methods or devices
-
- 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
- F01D5/284—Selection of ceramic materials
Definitions
- the present invention relates to the technology of technical ceramics, essentially with regard to gas turbines. It refers to a method for removing a ceramic.
- the reconditioning scope for gas turbine components depends on the degree of deterioration. In many cases only the ceramic coating needs to be replaced, or the metallic coating needs a re-loading with Al/Cr. Even if the parts just require a heat treatment, the ceramic coating needs to be replaced, since it can deteriorate during a heat treatment, and may have a shorter lifetime than the metallic coating also due to sintering. For all cases removal of the ceramic coating and a clean surface of the underlying metallic coating is required, without damaging the metallic coating.
- the ceramic coating is removed by grit blasting, taking advantage of the difference in brittleness between the ceramic and the metallic coating (see for example WO 201 1 /135526 A1 or US 7,805,822 B2 or US 6,908,657 B2).
- grit blasting is a very labor-intensive single piece process, which can only remove ceramic coating from line-of-sight location and not, e.g. coating residues in cooling air holes.
- EP10761 14B1 proposes a gaseous process that attacks the interface of the ceramic coating with the underlying metal part. Specifically, the interface needs to be exposed first to the gas. In addition, the interface has to comprise either Al, Ti, Cr, Zr or their oxides in order for the removal process to attack the bond to the ceramic. Thus, this process is limited to specific interfaces and may be rather slow, because the gas has to propagate along the interface rather than being able to attack on the entire surface simultaneously.
- hydrohalogen gas According to a preferred embodiment a mixture of 6-14 wt. -% hydrogen fluoride gas (HF) as reactive gas with the balance hydrogen gas is used. While such high concentrations of HF are for sure efficient in cleaning they also attack as a disadvantage the underlying metal, e.g. by depletion of Al, Ti.
- HF hydrogen fluoride gas
- the ceramic layer is removed from the part by a thermochemical treatment under fluorine- containing gas.
- the thermochemical attack is performed at a temperature close to 1000 °C using HF diluted to 10 % inH2.
- This relative high HF concentration has the same disadvantage, which has been already described (see above).
- EP 1 275 753 A1 that the fluorine-containing halogen gas penetrates into the ceramic via its pores, attacks the yttria of the ceramic and increases thereby the porosity, encouraging further penetration of the fluorine-containing halogen gas.
- Another problem is related to cleaning of complicated geometries. Every cooling air structure of a component, e.g. cooling air holes, channels or the like, is prone to contamination or even clogging by dirt/particles/contaminations carried with the cooling air. The severity of the contamination depends on the location of the gas turbine (sea, desert etc.), the maintenance of the air inlet filter system (in case of clogged filters, the filters are by-passed) and the geometry of the cooling air distribution system (channel diameter, length and curvature). Depending on the circumstances drastic contamination can be found.
- the method for removing a partially or fully stabilized ceramic is characterized in that said ceramic is put into a halogenising/reducing or halogenising/inert atmosphere, containing at least one halogen with an halogen content of 2 vol. -% in maximum, and that at least one element or phase of said ceramic is converted, for example dissolved or disintegrated, to a gaseous species (phase change) in a gaseous process at elevated temperatures in said
- halogen content being sufficient to reduce the content of the stabilizing element or phase of the ceramic below the stability limit of the ceramic.
- the halogen content (for example the amount of HF in the reactor) is just enough to reduce the stabilizing element or phase of the partially or fully stabilized ceramic below the minimum necessary to stabilize the ceramic.
- the ceramic undergoes a phase change.
- the volume change associated with this phase change leads to disintegration of the entire ceramic, even if only parts of the ceramic are destabilized. Therefore, the ceramic spalls very easily.
- said ceramic is a partially or fully stabilized oxide ceramic.
- said partially or fully stabilized oxide ceramic is zirconia stabilized with a rare earth or an alkaline earth element or combinations thereof.
- said rare earth or alkaline earth element is one of Sc, Y, Sm, Mg, Ca, Ce, Ta or Sr.
- said ceramic is one of an alkali silicate, alkali borosilicate, earth alkali silicate or earth alkali borosilicate ceramic, or any of those compounds with the addition of a semimetal or metalloid, especially Al or Pb.
- said halogen has a higher electronegativity than oxygen, on either Pauling Scale, Mulliken Scale or Allred- Rochow Scale.
- said halogen is F.
- HF content is 1 vol. -% or less. According to a further embodiment of the invention, HF content is 0.5 vol. - % or less.
- the ceramic is put into H 2 or Ar or N 2 and as reactive halogen F is added as HF gas.
- the advantage of using an inert atmosphere (Ar or N 2 ) is that there is no risk of explosion when oxygen is released from the ceramic.
- said elevated temperatures are above 850 °C, preferably between 1000°C and 1 150°C.
- said halogen may be CI.
- said gaseous process takes place in a reactor, which is operated in a pulsed mode through several cycles, whereby in each cycle reaction products of the process are removed from the reactor by pumping out said reducing atmosphere and fresh gas is supplied afterwards.
- said gaseous process is run as a batch process, whereby several articles comprising said ceramic are processed at the same time.
- said gaseous process is used to separate a ceramic from a metal or underlying ceramic coating layers or substrate.
- said gaseous process is used to separate a ceramic coating from a metallic or ceramic body or surface.
- said gaseous process is further used to simultaneously clean the surface of said metallic body or said metallic surface or ceramic surface such that said metallic body or said metallic surface can be brazed without further cleaning or oxide removal and, in case no rework is required, is immediately ready for receiving a fresh ceramic coating.
- said gaseous process is used to remove a thermal barrier coating, especially consisting of yttria stabilized zirconia (YSZ) from a component and clean the underlying metallic coating, thereby removing thermally grown oxide and any other oxide scales.
- a thermal barrier coating especially consisting of yttria stabilized zirconia (YSZ) from a component and clean the underlying metallic coating, thereby removing thermally grown oxide and any other oxide scales.
- said gaseous process is used to remove an abradable coating consisting of alkali silicate from a component and clean the underlying metallic coating.
- said gaseous process is used to remove ceramic tiles attached to a base metal by an alkali silicate or yttria stabilized zirconia (YSZ) from a component and clean the underlying metallic coating.
- YSZ yttria stabilized zirconia
- said gaseous process is used to remove a ceramic coating that is connected to a metallic surface by means of rivets, without damaging the delicate riveted structure of the underlying surface.
- said gaseous process is used to remove only the outermost layer from a component coated with a multilayer metallic/ceramic coating.
- said gaseous process is used to remove a contamination, e.g. sand, earth alkali silicates, from effusion- or transpiration-cooled parts, which have a structure exhibiting open porosity.
- said gaseous process is used to remove an environmental barrier coating from a ceramic matrix composite (CMC) component.
- CMC ceramic matrix composite
- Fig. 1 shows different steps in a method for removing the thermal barrier coating and cleaning the underlying surface according to an embodiment of the invention
- Fig. 2 shows different steps in a method for removing the ceramic layer from a metallic body in a pulsed process in a reactor according to another embodiment of the invention.
- Fig. 3 shows the removal of a ceramic layer from a "riveted" metallic body without damaging the rivets according to another
- the invention is related to a gaseous process at elevated temperatures in a halogenising/reducing or halogenising /inert atmosphere containing halogens as reactive species to selectively dissolve and remove partially or fully stabilized ceramics.
- the stabilizing phase is removed from the ceramic. As soon as the content of the stabilizing phase decreases below the stability limit, the entire ceramic de-stabilizes and is readily removed or spalls of during the cooling-down phase. Especially, said process may be applied to partially or fully stabilized oxide ceramics. During the process the stabilizing phase is removed (by phase change) from the oxide ceramic. As soon as the content of the stabilizing phase decreases below the stability limit, the entire oxide ceramic de-stabilizes and is readily removed or spalls of.
- said process may be applied to an alkali silicate, alkali borosilicate, earth alkali silicate, earth alkali borosilicate or any of those compounds with the addition of a semimetal or metalloid (e.g. Al, Pb.).
- a semimetal or metalloid e.g. Al, Pb.
- Said halogen may be F or CI.
- Said partially or fully stabilized oxide ceramic may be zirconia stabilized with a rare earth or an alkaline earth element or
- rare earth or alkaline earth element may be Sc, Y, Sm, Mg, Ca, Ce, Ta or Sr.
- Fig. 1 shows different steps in a method for removing the thermal barrier coating and cleaning the underlying surface according to an embodiment of the invention.
- the respective process starts (Fig. 1 (a)) with a component 10, which comprises a metallic body, or metallic coating on a component, 1 1 covered with a thermal barrier coating TBC 13.
- Fig. 1 shows an exemplary cooling air hole 25 crossing the layer body and being covered at its inner wall with a contamination 26.
- the component 10 is put into a reducing, halogen containing atmosphere 14 and heated to temperatures of several hundred °C. Said
- atmosphere 14 destabilizes the ceramic of the thermal barrier coating 13 and at the same time reduces and finally removes contamination 26 within the cooling air hole 25.
- the body, or metallic coating on a component, 1 1 itself remains with a cleaned surface, which is ready to be coated again, and a cleaned cooling air hole 25, which is ready to guide cooling air without obstruction.
- the simultaneous cleaning of the metal part allows the metal part to be brazed without further cleaning or oxide removal, and in case no rework of the metal part is required, the part is immediately ready for receiving a fresh ceramic coating. So the process offers a time efficient one step process for coating removal, cleaning, preparation for repair and recoating.
- F as a halogen is a strong oxidizing agent and can thus also dissolve many contaminations.
- the invented process is preferably a batch process, not a single piece process, which allows economic ceramic removal for entire sets in very short time.
- Fig. 2 shows different steps in a method for removing the ceramic layer from a metallic body in a pulsed process in a reactor according to another embodiment of the invention.
- the process starts with a component 20, which comprises a body 21 with ceramic layer 22 on its upper surface (Fig. 2(a)).
- the component 20 is put into a reactor 15, which can be heated by means of a heater 17 (Fig. 2(b)).
- the inner space 16 of the reactor 15 can be filled with one or more gases through a gas supply line 18, which can be closed by means of valve 23.
- the inner space 16 can be pumped out or evacuated by means of pump 24 through a pump line 19.
- the reactor 15 When the process begins at a low temperature T1 (e.g. room temperature), the reactor 15 is heated up to a temperature T2, which is substantially higher than the temperature T1 (Fig. 2(c)).
- T1 e.g. room temperature
- a first atmosphere A1 containing hydrogen is therefore established in the inner space 16 of the reactor by introducing an inert/-reducing gas through the supply line 18 and the valve 23 into the reactor (Fig. 2(d)).
- a reactive halogen e.g. F
- a second reducing atmosphere A2 is established, which begins to destabilize the ceramic layer 22 of the component 20 (Fig. 2(e)).
- the reactor 15 is operated in a pulsed mode, i.e. the reaction products are removed from the reactor 15 by pumping out the gas with pump 24 (Fig. 2(f)) and supplying fresh gas afterwards through gas supply line 18 (Fig. 2(g)).
- Several of such cycles (Fig. 2(f) -> Fig. 2(g) -> Fig. 2(f) -> Fig. 2(g) ) are done, until the ceramic layer 22 is completely removed and the surface of body 21 cleaned (Fig. 2(h)).
- Aim remove a thermal barrier coating 13 consisting of YSZ (yttria stabilized zirconia) from a component 10 and clean the underlying metallic coating
- the YSZ 13 readily disintegrates and detaches from the component, any thermally grown oxides 12 at the ceramic/metallic interface are dissolved as well, and the surface of the metallic coating is cleaned.
- Process the parts are put in a reactor 15, which is heated to more than 850 °C, preferably to more than 1000°C, but not more than 1 150°C. To achieve a reducing atmosphere the reactor is flooded with H 2 . As reactive halogen, F is introduced as HF gas. The gas mixture has a halogen content of max. 2 vol. -%.
- the reactor 15 is operated in a pulsed mode, i.e. the reaction products are removed from the reactor 15 by pumping out the gas and supplying fresh gas afterwards. Several such cycles are done.
- Aim remove ceramic tiles attached to a base metal by an alkali silicate from a component and clean the underlying metallic coating;
- Process the parts are put in a reactor 15, which is heated to more than 850 ⁇ 0, preferably to more than 1000°C but not more than 1 150°C. To achieve a reducing atmosphere the reactor 15 is flooded with H 2 . As reactive halogen, F is introduced as HF gas. The reactor 15 is operated in a pulsed mode, i.e. the reaction products are removed from the reactor by pumping out the gas and supplying fresh gas afterwards. Several such cycles are done.
- Aim removing only the outermost layer (e.g. an YSZ for thermal protection) from a component coated with a multilayer coating (as disclosed for example in US 2005/01 12381 A1 ).
- Process the parts are put in a reactor 15, which is heated to more than 850 °C, preferably to more than 1000°C but not more than 1 150°C. To achieve a reducing atmosphere the reactor 15 is flooded with H 2 . As reactive halogen, F is introduced as HF gas. The reactor 15 is operated in a pulsed mode, i.e. the reaction products are removed from the reactor by pumping out the gas and supplying fresh gas afterwards. Several such cycles are done.
- the YSZ coating which formed the outermost thermal protection layer TBC, is readily disintegrated by the gaseous process.
- the underlying environmental coating based essentially on tantalum oxide and alloyed with lanthanum oxide, is not harmed.
- ⁇ Aim remove the worn abradable coating from a ceramic component. Due to the brittle nature of the ceramic component, an abrasive process cannot be used;
- Process the parts are put in a reactor 15, which is heated to more than 850 °C, preferably to more than 1000°C but not more than 1 150°C. To achieve a reducing atmosphere the reactor 15 is flooded with H 2 . As reactive halogen, F is introduced as HF gas. The reactor 15 is operated in a pulsed mode, i.e. the reaction products are removed from the reactor by pumping out the gas and supplying fresh gas afterwards. Several such cycles are done.
- the alkali silicate based abradable coating is preferably attacked, whereas the attack on the dense (SiN) component is too slow to damage the part.
- Aim remove contamination (e.g. sand, earth alkali silicates) from effusion- or transpiration-cooled parts, which have a structure exhibiting open porosity (e.g. as disclosed in WO 2005/056220 A1 , EP 0 089 155 A2, US 7,402,335 B2, EP 1 155 760 B1 , EP 0 995 880 B1 );
- Process the parts are put in a reactor 15, which is heated to more than 850 °C, preferably to more than 1000°C but not more than 1 150°C. To achieve a reducing atmosphere the reactor 15 is flooded with H 2 . As reactive halogen, F is introduced as HF gas. The reactor 15 is operated in a pulsed mode, i.e. the reaction products are removed from the reactor by pumping out the gas and supplying fresh gas afterwards. Several such cycles are done.
- Process the parts are put in a reactor 15, which is heated to more than 850 °C, preferably to more than 1000°C but not more than 1 150°C. To achieve a reducing atmosphere the reactor 15 is flooded with H 2 . As reactive halogen, F is introduced as HF gas. The reactor 15 is operated in a pulsed mode, i.e. the reaction products are removed from the reactor by pumping out the gas and supplying fresh gas afterwards. Several such cycles are done.
- thermal barrier coating 13 made from YSZ from a component 10 • Aim: remove the thermal barrier coating from the component without attacking the underlying metal coating;
- the above-described process is a time-efficient, automatable, batch process that completely and selectively removes the ceramic without harming the underlying metallic coating, ceramic or substrate. Additionally, the surface is perfectly cleaned, allowing application of fresh coating right away.
- the inventive process furthermore provides an efficient way of dissolving contaminations in cooling air structures because the reactive species is in gaseous form and can therefore reach any location that is reached by the cooling air.
- TGO thermally grown oxide
- TBC thermal barrier coating
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- Chemical & Material Sciences (AREA)
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- General Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
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- General Chemical & Material Sciences (AREA)
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Abstract
L'invention concerne un procédé pour retirer une céramique (13), ladite céramique (13) étant placée dans une atmosphère (A2) d'halogénation/réduction ou d'halogénation/inerte, contenant au moins un halogène avec une teneur en halogène de 2% en volume au maximum, et au moins un élément ou une phase de ladite céramique (13) étant converti(e) en espèce gazeuse (de changement de phase) lors d'un processus gazeux mis en oeuvre à des températures élevées (T2) dans ladite atmosphère (A2).
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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EP12161873.0 | 2012-03-28 | ||
EP12161873 | 2012-03-28 |
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WO2013144022A1 true WO2013144022A1 (fr) | 2013-10-03 |
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PCT/EP2013/056097 WO2013144022A1 (fr) | 2012-03-28 | 2013-03-22 | Procédé pour retirer une céramique |
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Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11918172B2 (en) | 2016-10-28 | 2024-03-05 | Irobot Corporation | Mobile cleaning robot with a bin |
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EP0089155A2 (fr) | 1982-03-05 | 1983-09-21 | Rolls-Royce Plc | Articles composites et leur procédé de fabrication |
US4889589A (en) * | 1986-06-26 | 1989-12-26 | United Technologies Corporation | Gaseous removal of ceramic coatings |
US6074706A (en) | 1998-12-15 | 2000-06-13 | General Electric Company | Adhesion of a ceramic layer deposited on an article by casting features in the article surface |
DE10057187A1 (de) | 2000-11-17 | 2002-05-23 | Alstom Switzerland Ltd | Verfahren für die Herstellung von Verbundaufbauten zwischen metallischen und nichtmetallischen Materialien |
US6471881B1 (en) | 1999-11-23 | 2002-10-29 | United Technologies Corporation | Thermal barrier coating having improved durability and method of providing the coating |
US20020172799A1 (en) | 2001-05-16 | 2002-11-21 | Siemens Westinghouse Power Corporation | Honeycomb structure thermal barrier coating |
EP1275753A1 (fr) | 2001-07-12 | 2003-01-15 | Snecma Moteurs | Procédé de réparation globale d'une pièce revêtue d'une barrière thermique |
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Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11918172B2 (en) | 2016-10-28 | 2024-03-05 | Irobot Corporation | Mobile cleaning robot with a bin |
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