WO2015099880A1 - Articles protégés contre la corrosion à chaud et procédés de fabrication - Google Patents

Articles protégés contre la corrosion à chaud et procédés de fabrication Download PDF

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Publication number
WO2015099880A1
WO2015099880A1 PCT/US2014/062554 US2014062554W WO2015099880A1 WO 2015099880 A1 WO2015099880 A1 WO 2015099880A1 US 2014062554 W US2014062554 W US 2014062554W WO 2015099880 A1 WO2015099880 A1 WO 2015099880A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
substrate
micrometers
coated article
nickel
Prior art date
Application number
PCT/US2014/062554
Other languages
English (en)
Inventor
Michael N. TASK
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
Priority to EP14874522.7A priority Critical patent/EP3090075B1/fr
Priority to US15/036,929 priority patent/US10266958B2/en
Publication of WO2015099880A1 publication Critical patent/WO2015099880A1/fr

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
    • 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
    • C23C28/02—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 only coatings only including layers of metallic material
    • C23C28/023—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 only coatings only including layers of metallic material only coatings of metal elements only
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
    • C25D5/10—Electroplating with more than one layer of the same or of different metals
    • C25D5/12—Electroplating with more than one layer of the same or of different metals at least one layer being of nickel or chromium
    • C25D5/14—Electroplating with more than one layer of the same or of different metals at least one layer being of nickel or chromium two or more layers being of nickel or chromium, e.g. duplex or triplex layers
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
    • C25D5/60—Electroplating characterised by the structure or texture of the layers
    • C25D5/605—Surface topography of the layers, e.g. rough, dendritic or nodular layers
    • C25D5/611—Smooth layers
    • 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
    • F01D5/02—Blade-carrying members, e.g. rotors
    • 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
    • F05D2230/00—Manufacture
    • F05D2230/20—Manufacture essentially without removing material
    • F05D2230/22—Manufacture essentially without removing material by sintering
    • 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
    • F05D2230/00—Manufacture
    • F05D2230/90—Coating; Surface treatment
    • 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
    • F05D2260/95—Preventing corrosion
    • 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
    • F05D2300/10—Metals, alloys or intermetallic compounds
    • F05D2300/13—Refractory metals, i.e. Ti, V, Cr, Zr, Nb, Mo, Hf, Ta, W
    • F05D2300/132—Chromium
    • 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
    • F05D2300/10—Metals, alloys or intermetallic compounds
    • F05D2300/17—Alloys
    • F05D2300/175—Superalloys

Definitions

  • the disclosure relates to gas turbines. More
  • An exemplary gas turbine is discussed in the context of a gas turbine engine used for aircraft propulsion. Such an engine has a core gaspath passing sequentially through one or more compressor sections for compressing ingested air, a combustor section for combusting the compressed air and an introduced fuel to generate high pressure/temperature
  • combustion gases combustion gases
  • turbine sections for generating combustion gases
  • compressor sections With an exemplary turbofan engine, the turbine sections also drive a fan which, in turn drives air along a flowpath bypassing the core flowpath.
  • Exemplary turbine sections are axial turbines wherein flow passes through one or more stages of rotating blades interspersed with stationary vanes or counter-rotating blades. The blades of a given stage may be unitarily formed with or mounted to the periphery of a disk. The disks of each section may be mounted to co-rotate with each other and any compressor section driven thereby.
  • Exemplary compressor sections are also axial, although centrifugal compressors and turbines are also known . [0004] Engine components (e.g., combustor panels, vanes, blades, disks, air seals, and the like) exposed to the
  • combustion gases and heat are particularly subject to
  • Exemplary substrate materials include a number of cast or
  • TBC Thermal barrier coating
  • zirconia-based such as yttria-stabilzed zirconia (YSZ) and/or gadolinia-stabilized zirconia (GSZ) ) .
  • YSZ yttria-stabilzed zirconia
  • GSZ gadolinia-stabilized zirconia
  • Such coatings may be used in combination with metallic bondcoats.
  • temperatures may be sufficiently lower than directly in the gaspath (e.g., to which airfoils are exposed) that the
  • insulative benefit of ceramic TBC may be traded for improved hot corrosion protection of a metallic coating system.
  • Hot corrosion is most severe in geographic regions which have elevated levels of airborne particulate matter and gaseous pollution, man-made or otherwise. [0010] There are also substantial problems when aircraft operate in coastal regions, because ingested sea salt can also result in severe hot corrosion attack.
  • the polycrystalline Ni-base superalloys of typical turbine and compressor disks do not have sufficient hot corrosion resistance. Thus there is an increasing need for disks (and certain legacy components) to have hot corrosion-resistant coatings in order to meet life requirements.
  • hot corrosion-resistant coatings in order to meet life requirements.
  • these coatings are advantageously designed such that debits to low cycle fatigue are minimal. This can be accomplished by developing coatings that are either ductile or only loosely adherent to the superalloy substrate.
  • Fabricating Coated Components and Coated Turbine Disks discloses use of sequential diffusion coating of chromium and noble metal on such a superalloy disk.
  • One aspect of the disclosure involves a coated article comprising a substrate and a coating system atop the
  • the coating system has a nickel-based first layer and a chromium-based second layer atop the first layer.
  • a further embodiment may additionally and/or
  • a further embodiment may additionally and/or alternatively include the first layer being essentially pure nickel and the second layer is essentially pure chromium.
  • a further embodiment may additionally and/or
  • the substrate being a powder
  • a further embodiment may additionally and/or
  • coated article being a turbine engine disk.
  • a further embodiment may additionally and/or
  • a further embodiment may additionally and/or
  • a further embodiment may additionally and/or
  • a further embodiment may additionally and/or
  • a further embodiment may additionally and/or alternatively include the first layer plating being
  • a further embodiment may additionally and/or
  • a further embodiment may additionally and/or
  • a further embodiment may additionally and/or
  • the method comprises: installing the article in a gas turbine engine; and running the gas turbine engine to heat the
  • FIG. 1 is an exploded partial view of a gas turbine engine turbine disk assembly.
  • FIG. 2 is a schematic sectional view of a surface region of the disk showing a substrate and coating.
  • FIG. 3 is a photomicrograph of a section of the
  • FIG. 4 is a photomicrograph of a section of a substrate and a prior art MCrAlY overlay coating.
  • FIG. 1 shows a gas turbine engine disk assembly 20 including a disk 22 and a plurality of blades 24.
  • the disk is generally annular, extending from an inboard bore or hub 26 at a central aperture to an outboard rim 28.
  • a relatively thin web 30 is radially between the bore 26 and rim 28.
  • periphery of the rim 28 has a circumferential array of
  • engagement features 32 e.g., dovetail slots
  • complementary features 34 of the blades 24 e.g., dovetail slots
  • the disk and blades may be a unitary structure (e.g., so-called “integrally bladed” rotors or disks).
  • the disk 22 may be formed by a powder metallurgical forging process (e.g., as is disclosed in U.S. Pat. No.
  • the elemental components of the alloy are mixed (e.g., as individual components of refined purity or alloys thereof) .
  • the mixture is melted sufficiently to eliminate component segregation.
  • the melted mixture is atomized to form droplets of molten metal.
  • the atomized droplets are cooled to solidify into powder
  • the powder may be screened to restrict the ranges of powder particle sizes allowed.
  • the powder is put into a container.
  • the container of powder is consolidated in a multi-step process involving compression and heating.
  • the resulting consolidated powder then has essentially the full density of the alloy without the chemical segregation typical of larger castings.
  • a blank of the consolidated powder may be forged at appropriate temperatures and deformation constraints to provide a forging with the basic disk profile.
  • the forging is then heat treated in a multi-step process involving high temperature heating followed by a rapid cooling process or quench.
  • the quench for the heat treatment may also form strengthening precipitates (e.g., gamma prime and eta phases) of a desired distribution of sizes and desired volume percentages.
  • FIG. 2 schematically shows a section of the disk (e.g., along a rim portion such as an outer diameter (OD) surface or a front surface or a rear surface) .
  • the disk has a forged PM substrate 100 as discussed above.
  • a coating system 102 lies atop the substrate and has an overall thickness T.
  • exemplary coating system comprises a lower or inner/inboard first layer 104 (e.g., atop a surface 106 of the substrate) and an upper or outer/outboard second layer 108 (e.g., atop a surface 110 of the first layer) .
  • the respective first and second layers have thicknesses ⁇ and T 2 .
  • An exemplary surface 112 of the second layer is exposed and, thus, it does not bear any further coating layer (namely, a ceramic TBC) .
  • Exemplary Ti is 6.0 micrometers to 50 micrometers, more narrowly 6.0 micrometers to 25 micrometers or 6.0 micrometers to 15.0 micrometers) .
  • Exemplary T 2 is 6.0 micrometers to 50 micrometers, more narrowly 6.0 micrometers to 25 micrometers or 10.0 micrometers to 20.0 micrometers) .
  • the second layer provides corrosion resistance.
  • the second layer material is chromium-based (e.g., with chromium as a largest by-weight content, more
  • the first layer provides a relatively ductile interface with the substrate to prevent cracks in the second layer from propagating into the substrate.
  • the first layer material is nickel-based (e.g., nickel as a largest by-weight component, more particularly at least 50% nickel by weight, more particularly at least 80% and may consist essentially of nickel (e.g., offering equivalent performance to pure nickel and likely at least 95% nickel) .
  • nickel-based e.g., nickel as a largest by-weight component, more particularly at least 50% nickel by weight, more particularly at least 80% and may consist essentially of nickel (e.g., offering equivalent performance to pure nickel and likely at least 95% nickel
  • one or both layers may be pure or relatively pure chromium and nickel, respectively but may be subject to some diffusion with each other or the substrate.
  • An exemplary process for depositing the first layer is plating (e.g., electroless or electroplating). This may be applied directly to the machined substrate to build to the thickness ⁇ .
  • plating e.g., electroless or electroplating
  • An exemplary process for depositing the second layer is plating.
  • Exemplary plating is electroplating. This may be applied directly to the first layer (e.g., after any washing) to build to the thickness T 2 .
  • Exemplary electroplating is disclosed in US Patent Application Publication 2013/0220819 entitled "Electrodeposition of Chromium from Trivalent
  • Chromium Using Modulated Electric Fields the disclosure of which is incorporated by reference in its entirety herein as if set forth at length.
  • Such use of a trivalent chromium bath avoids toxicity concerns of hexavalent chromium.
  • FIG. 3 is a micrograph of an exemplary such two layer coating system 102.
  • the lower layer 104 is directly atop the substrate and is thinner than the upper layer 104 (e.g. about 15% to 33% of the upper layer thickness) .
  • FIG. 4 shows a baseline MCrAlY.
  • parenthetical ' s units are a conversion and should not imply a degree of precision not found in the English units.

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

Abstract

Un article revêtu (22) comprend un substrat (100) et un système de revêtement (102) situé sur le substrat. Le système de revêtement comporte une première couche (104) à base de nickel et une seconde couche (108) à base de chrome située sur la première couche.
PCT/US2014/062554 2013-12-24 2014-10-28 Articles protégés contre la corrosion à chaud et procédés de fabrication WO2015099880A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP14874522.7A EP3090075B1 (fr) 2013-12-24 2014-10-28 Article protégé contre la corrosion à chaud et procédé de fabrication
US15/036,929 US10266958B2 (en) 2013-12-24 2014-10-28 Hot corrosion-protected articles and manufacture methods

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201361920546P 2013-12-24 2013-12-24
US61/920,546 2013-12-24

Publications (1)

Publication Number Publication Date
WO2015099880A1 true WO2015099880A1 (fr) 2015-07-02

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Country Status (2)

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EP (1) EP3090075B1 (fr)
WO (1) WO2015099880A1 (fr)

Citations (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3625039A (en) * 1969-08-28 1971-12-07 Theo G Kubach Corrosion resistance of decorative chromium electroplated objects
US4346137A (en) 1979-12-19 1982-08-24 United Technologies Corporation High temperature fatigue oxidation resistant coating on superalloy substrate
US6521175B1 (en) 1998-02-09 2003-02-18 General Electric Co. Superalloy optimized for high-temperature performance in high-pressure turbine disks
US20050058848A1 (en) 2002-09-23 2005-03-17 Hodgens Henry M. Zinc-diffused alloy coating for corrosion/heat protection
US20050067273A1 (en) * 2000-10-24 2005-03-31 Goodrich Gary D. Chrome coating composition
US20050118453A1 (en) * 2003-12-01 2005-06-02 General Electric Company Beta-phase nickel aluminide coating
US7364801B1 (en) * 2006-12-06 2008-04-29 General Electric Company Turbine component protected with environmental coating
US20080124542A1 (en) * 2005-04-04 2008-05-29 United Technologies Corporation Nickel Coating
US20080308425A1 (en) * 2007-06-12 2008-12-18 Honeywell International, Inc. Corrosion and wear resistant coating for magnetic steel
US20100009092A1 (en) 2008-07-08 2010-01-14 United Technologies Corporation Economic oxidation and fatigue resistant metallic coating
US8124246B2 (en) 2008-11-19 2012-02-28 Honeywell International Inc. Coated components and methods of fabricating coated components and coated turbine disks
US8147749B2 (en) 2005-03-30 2012-04-03 United Technologies Corporation Superalloy compositions, articles, and methods of manufacture
US20130209266A1 (en) 2012-02-14 2013-08-15 Paul L. Reynolds Superalloy Compositions, Articles, and Methods of Manufacture
US20130209265A1 (en) 2012-02-14 2013-08-15 Paul L. Reynolds Superalloy Compositions, Articles, and Methods of Manufacture
US20130220819A1 (en) 2012-02-27 2013-08-29 Faraday Technology, Inc. Electrodeposition of chromium from trivalent chromium using modulated electric fields

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2729302A1 (fr) * 2011-09-12 2014-05-14 Siemens Aktiengesellschaft Système de revêtement comprenant une double couche métallique mcralx

Patent Citations (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3625039A (en) * 1969-08-28 1971-12-07 Theo G Kubach Corrosion resistance of decorative chromium electroplated objects
US4346137A (en) 1979-12-19 1982-08-24 United Technologies Corporation High temperature fatigue oxidation resistant coating on superalloy substrate
US6521175B1 (en) 1998-02-09 2003-02-18 General Electric Co. Superalloy optimized for high-temperature performance in high-pressure turbine disks
US20050067273A1 (en) * 2000-10-24 2005-03-31 Goodrich Gary D. Chrome coating composition
US20050058848A1 (en) 2002-09-23 2005-03-17 Hodgens Henry M. Zinc-diffused alloy coating for corrosion/heat protection
US20050118453A1 (en) * 2003-12-01 2005-06-02 General Electric Company Beta-phase nickel aluminide coating
US8147749B2 (en) 2005-03-30 2012-04-03 United Technologies Corporation Superalloy compositions, articles, and methods of manufacture
US20080124542A1 (en) * 2005-04-04 2008-05-29 United Technologies Corporation Nickel Coating
EP1930467A2 (fr) 2006-12-06 2008-06-11 General Electric Company Composant de turbine protégé par un revêtement contre les intempéries
US7364801B1 (en) * 2006-12-06 2008-04-29 General Electric Company Turbine component protected with environmental coating
US20080308425A1 (en) * 2007-06-12 2008-12-18 Honeywell International, Inc. Corrosion and wear resistant coating for magnetic steel
US20100009092A1 (en) 2008-07-08 2010-01-14 United Technologies Corporation Economic oxidation and fatigue resistant metallic coating
US8124246B2 (en) 2008-11-19 2012-02-28 Honeywell International Inc. Coated components and methods of fabricating coated components and coated turbine disks
US20130209266A1 (en) 2012-02-14 2013-08-15 Paul L. Reynolds Superalloy Compositions, Articles, and Methods of Manufacture
US20130209265A1 (en) 2012-02-14 2013-08-15 Paul L. Reynolds Superalloy Compositions, Articles, and Methods of Manufacture
US20130220819A1 (en) 2012-02-27 2013-08-29 Faraday Technology, Inc. Electrodeposition of chromium from trivalent chromium using modulated electric fields

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See also references of EP3090075A4 *

Also Published As

Publication number Publication date
EP3090075A4 (fr) 2017-08-23
EP3090075B1 (fr) 2018-12-05
EP3090075A1 (fr) 2016-11-09

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