WO2016202495A1 - Dvc-coating with fully and partially stabilized zirconia - Google Patents

Dvc-coating with fully and partially stabilized zirconia Download PDF

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Publication number
WO2016202495A1
WO2016202495A1 PCT/EP2016/059828 EP2016059828W WO2016202495A1 WO 2016202495 A1 WO2016202495 A1 WO 2016202495A1 EP 2016059828 W EP2016059828 W EP 2016059828W WO 2016202495 A1 WO2016202495 A1 WO 2016202495A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
stabilized zirconia
fully
ceramic layer
ceramic
Prior art date
Application number
PCT/EP2016/059828
Other languages
French (fr)
Inventor
Arturo Flores Renteria
Neil Hitchman
Werner Stamm
Dimitrios Zois
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
Priority to EP16722589.5A priority Critical patent/EP3283667A1/en
Priority to US15/736,340 priority patent/US20180179645A1/en
Publication of WO2016202495A1 publication Critical patent/WO2016202495A1/en

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
    • C23C28/30—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
    • 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
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/288—Protective coatings for blades
    • 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
    • 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
    • F05D2250/00—Geometry
    • F05D2250/20—Three-dimensional
    • F05D2250/29—Three-dimensional machined; miscellaneous
    • F05D2250/294—Three-dimensional machined; miscellaneous grooved
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/20—Oxide or non-oxide ceramics
    • F05D2300/21—Oxide ceramics
    • F05D2300/2118—Zirconium oxides

Definitions

  • the invention relates to a ceramic layer-system with par- tially and fully stabilized zirconia which has also a dense vertical cracked microstructure (DVC) .
  • DVC dense vertical cracked microstructure
  • TBC Thermal Barrier Coatings
  • Coating life Thermal Spray porous coatings do not demon ⁇ strate at the same level the high strain tolerance along the coating thickness which can be seen in other coating types such as EB-PVD.
  • the thermal barrier coatings porosity has been increased to improve strain tolerance. However as mentioned above, that can reduce the spray ability process window and influence negatively the cohesion and erosion resistance of the coat ⁇ ings . 4) YSZ for TBC chemistries are currently limited to 1528K maximum temperature due to phase transformation issues.
  • New chemistries have been adopted that present phase stabil ⁇ ity in higher temperatures. However they show significantly lower fracture toughness compared to the partially stabilized zirconia and it is certain that their erosion resistance will be even less.
  • the task of the invention is therefore to solve the problems given above .
  • DVC Dense Vertical Cracked
  • DVC coatings have increased cohesion and adhesion compared to the typical porous coatings. The reason is that a very high ratio of fully molten particles deposit on hot substrate or hot previously deposited splats which promotes a good in ⁇ timate bonding to develop between them. Improved adhesion re- quires high energy for a horizontal crack to propagate so that guarantees a lower delamination .
  • the system consists of partially stabilized zirconia, espe ⁇ cially 8YSZ as the high fracture toughness lower layer to ac ⁇ commodate the CTE mismatch with bond coat and TGO and a lower toughness upper layer of fully stabilized zirconia, espe ⁇ cially 48YSZ to provide the high temperature capability.
  • the similar chemistry between the two coatings enhances their bonding.
  • Appropriate preheating of the DVC PSZ will prepare its sur ⁇ face to receive the fully molten particles of FSZ and due to the high local temperatures during spraying allow diffusion between the two similar materials.
  • a number of the vertical cracks will progress from one coating to the other demonstrating the continuity between the two coatings. In this manner the interface which has shown to be the weakest link in other bi-layer systems will be reinforced.
  • the figure shows a layer system 1.
  • the layer system 1 comprises a substrate 4 which is prefera- bly metallic and very preferably made of a nickel or cobalt based super alloy.
  • a bond coat especially a metallic bond coat 7 and very especially a NiCoCrAlY-based bond coat 7 is applied on.
  • TGO thermally grown oxide
  • first zirconia layer 10 made of a partially stabilized zirconia.
  • the thickness of the partially stabilized zirconia layer 10 is preferable between 75ym - 800ym.
  • the porosity of the partially stabilized zirconia 10 is pref ⁇ erably lower than 5% and very preferably lower than 3%.
  • a fully stabilized zirconia layer 13 which is especially the outer most layer of the layer system 1.
  • This outer layer can also be made of a pyrochlore ceramic, such as gadolinium zirconate (GZO) , which partially or fully replaces the fully stabilized zirconia (FSZ) .
  • GZO gadolinium zirconate
  • the porosity of the fully stabilized zirconia 13 is lower than 5% and preferably lower than 3%.
  • the thickness of the fully stabilized zirconia 13 is prefera ⁇ ble between 50ym - 800ym.
  • the stabilization in this zirconia based system can be reached by yttria or by any other rare earth element as known by the state of the art or by a combination of that.
  • yttrium is used for stabilization.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Inorganic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Ceramic Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Coating By Spraying Or Casting (AREA)

Abstract

A dense vertical cracked microstructure in a ceramic layer system made of an underline partially stabilized zirconia layer and an above laying fully stabilized zirconia layer show good erosion resistance and long life time.

Description

DVC-Coating with fully and partially stabilized zirconia
The invention relates to a ceramic layer-system with par- tially and fully stabilized zirconia which has also a dense vertical cracked microstructure (DVC) .
Field feedback has shown that the current Thermal Barrier Coatings (TBC) of turbines suffer from issues related to:
1) Erosion: turbine blades with high porosity coatings con¬ taining a large number of unmolten or semimolten particles show low erosion resistance.
The development during the last years has pushed thermal spray coatings porosity upwards. However, that has caused the shrinkage of the spray ability window that allows coatings to receive high porosity and good cohesion. As a result, erosion has started manifesting itself as a major issue for coatings in specific parts and engines.
2) Drilling damage: High porosity coatings contain less inti¬ mate contacts between splats or splat and substrate and thus the required energy for a crack to propagate is relatively low .
This problem has been addressed by drilling before the coat¬ ing deposition and reopening of the holes after coating deposition. This approach minimizes the interaction between coating and laser and that reduces significantly the coating de- lamination around the drilled holes. However, since each part has to be processed twice, this solution is associated with longer drilling times that are reflected as increased cost.
3) Coating life: Thermal Spray porous coatings do not demon¬ strate at the same level the high strain tolerance along the coating thickness which can be seen in other coating types such as EB-PVD.
The thermal barrier coatings porosity has been increased to improve strain tolerance. However as mentioned above, that can reduce the spray ability process window and influence negatively the cohesion and erosion resistance of the coat¬ ings . 4) YSZ for TBC chemistries are currently limited to 1528K maximum temperature due to phase transformation issues.
New chemistries have been adopted that present phase stabil¬ ity in higher temperatures. However they show significantly lower fracture toughness compared to the partially stabilized zirconia and it is certain that their erosion resistance will be even less.
The task of the invention is therefore to solve the problems given above .
The problem is solved by a ceramic layer system according to claim 1.
In the subclaims further advantages are given which can be abitrality combined with each other to yield additional ad¬ vantages .
The figure and the description show only examples of the in¬ vention .
The problems named under point 1 are addressed by adopting Dense Vertical Cracked (DVC) coatings.
1) Erosion. DVC thermal barrier coatings have shown signifi- cantly lower rates compared to their porous counterparts.
That means for the same chemistry a porous coating will show more than 3x the erosion rate compared to the DVC one.
2) DVC coatings have increased cohesion and adhesion compared to the typical porous coatings. The reason is that a very high ratio of fully molten particles deposit on hot substrate or hot previously deposited splats which promotes a good in¬ timate bonding to develop between them. Improved adhesion re- quires high energy for a horizontal crack to propagate so that guarantees a lower delamination .
3) Coating life. Due to the intimate contact between splats, the DVC coatings show high fracture toughness along the par¬ allel to the substrate plane. That, combined with their abil¬ ity to accommodate thermal strain along the coating thickness due to their columnar microstructure ensures a high TBC life. 4) DVC microstructures can be adopted on the new coating chemistries. That will create a bilayer DVC with partially stabilized zirconia as a lower layer and fully stabilized zirconia as the upper layer. The lower layer will accommodate CTE mismatch with the bond coat and the TGO while the upper layer will provide the higher temperature capability.
The system consists of partially stabilized zirconia, espe¬ cially 8YSZ as the high fracture toughness lower layer to ac¬ commodate the CTE mismatch with bond coat and TGO and a lower toughness upper layer of fully stabilized zirconia, espe¬ cially 48YSZ to provide the high temperature capability.
Unlike other possible bilayer coating approaches, the similar chemistry between the two coatings enhances their bonding. Appropriate preheating of the DVC PSZ will prepare its sur¬ face to receive the fully molten particles of FSZ and due to the high local temperatures during spraying allow diffusion between the two similar materials. Ideally a number of the vertical cracks will progress from one coating to the other demonstrating the continuity between the two coatings. In this manner the interface which has shown to be the weakest link in other bi-layer systems will be reinforced.
The advantages that arise are: 1) The low fracture toughness of the FSZ with the adoption of a DVC microstructure will significantly increase. That will improve the erosion resistance of the coating. 2) A good bonding between the two layers and as well with the bond coat will increase the drilling damage tolerance. Less delamination will be observed compared to other bilayer coating systems which have suffered in the past from drilling. 3) The columnar microstructure along the bilayer coating thickness will allow improved strain tolerance, thus in¬ creased coating life.
4) Higher temperature capability compared to single layer DVC coatings.
The figure shows a layer system 1.
The layer system 1 comprises a substrate 4 which is prefera- bly metallic and very preferably made of a nickel or cobalt based super alloy.
On the substrate 4 a bond coat especially a metallic bond coat 7 and very especially a NiCoCrAlY-based bond coat 7 is applied on.
On this bond coat 7 there is a thermally grown oxide (TGO, not shown) layer which is formed during further application of the ceramic layers or by an additional oxidation step or at least during use of the layer system 1.
On the bond coat 7 there is applied a first zirconia layer 10 made of a partially stabilized zirconia.
The thickness of the partially stabilized zirconia layer 10 is preferable between 75ym - 800ym.
The porosity of the partially stabilized zirconia 10 is pref¬ erably lower than 5% and very preferably lower than 3%. As an outer ceramic layer there is applied a fully stabilized zirconia layer 13, which is especially the outer most layer of the layer system 1. This outer layer can also be made of a pyrochlore ceramic, such as gadolinium zirconate (GZO) , which partially or fully replaces the fully stabilized zirconia (FSZ) .
The porosity of the fully stabilized zirconia 13 is lower than 5% and preferably lower than 3%.
The thickness of the fully stabilized zirconia 13 is prefera¬ ble between 50ym - 800ym.
The same parameters for thickness and porosity are also valid for the pyrochlore layer or pyrochlore/FSZ layer.
The stabilization in this zirconia based system can be reached by yttria or by any other rare earth element as known by the state of the art or by a combination of that. Preferably yttrium is used for stabilization.
In this layers 10, 13 there are cracks 16 present, which 19 are mostly present in the outer most layer 13 and preferably some of them 21 are present in both layers 10, 13.

Claims

Patent claims
1. Ceramic layer system,
at least comprising:
a substrate ( 4 ) ,
especially a metallic substrate (4),
very especially made of a nickel or cobalt based super al¬ loy,
optionally a metallic bond coat (7) on the substrate (4), which is especially metallic and
very especially made of a NiCoCrAlY-based alloy,
an inner partially stabilized zirconia layer (10) and on it (10) a fully stabilized zirconia layer (13),
wherein vertical cracks (16, 19, 21) are present.
2. Ceramic layer system according to claim 1,
wherein the fully stabilized zirconia layer (13) is re- placed partially or fully by a layer comprising or consist¬ ing of a pyrochlore material,
especially by gadolinium zirconate.
3. Ceramic layer system according to claim 1 or 2,
wherein the cracks (19) are only present in the fully sta¬ bilized zirconia layer (13) or the outer layer with the pyrochlore material.
4. Ceramic layer system according to any of the claims 1, 2 or 3 ,
wherein the cracks (21) are present in both ceramic layers (10, 13) .
Ceramic layer according to any of the preceding claims, wherein the porosity of the fully stabilized zirconia laye (13) or the layer with the pyrochlore material is lower than 5%,
especially lower than 3%.
Ceramic layer system according to any of the preceding claims ,
wherein the thickness of the partially stabilized zirconia layer (10) is between 75ym - 800ym.
7. Ceramic layer system according to any of the preceding claims ,
wherein the thickness of the fully stabilized zirconia layer (13) or the layer with the pyrochlore material is be tween 50ym - 800ym.
Ceramic layer system according to any of the preceding claims ,
wherein the zirconia or the zirconia layers (10, 13) are stabilized by yttria,
especially only by yttria.
Ceramic layer system according to any of the preceding claims ,
wherein the porosity of the partially stabilized zirconia layer is lower than 5%,
especially lower than 3%.
10. Ceramic layer system according to any of the preceding claims ,
wherein the partially stabilized zirconia is stabilized by yttria,
especially is 8YPSZ .
PCT/EP2016/059828 2015-06-19 2016-05-03 Dvc-coating with fully and partially stabilized zirconia WO2016202495A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP16722589.5A EP3283667A1 (en) 2015-06-19 2016-05-03 Dvc-coating with fully and partially stabilized zirconia
US15/736,340 US20180179645A1 (en) 2015-06-19 2016-05-03 Dvc-coating with fully and partially stabilized zirconia

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP15172884.7 2015-06-19
EP15172884.7A EP3106541A1 (en) 2015-06-19 2015-06-19 Dvc-coating with fully and partially stabilized zirconia

Publications (1)

Publication Number Publication Date
WO2016202495A1 true WO2016202495A1 (en) 2016-12-22

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PCT/EP2016/059828 WO2016202495A1 (en) 2015-06-19 2016-05-03 Dvc-coating with fully and partially stabilized zirconia

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US (1) US20180179645A1 (en)
EP (2) EP3106541A1 (en)
WO (1) WO2016202495A1 (en)

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102017206063A1 (en) * 2017-04-10 2018-10-11 Siemens Aktiengesellschaft Partially and fully stabilized zirconium oxide powder as a ceramic layer
US10550462B1 (en) 2017-09-08 2020-02-04 United Technologies Corporation Coating with dense columns separated by gaps
JP2022514483A (en) * 2018-12-18 2022-02-14 エリコン メテコ（ユーエス）インコーポレイテッド Coating for protecting EBC layer and CMC layer and spray coating method thereof
EP3712379A1 (en) * 2019-03-22 2020-09-23 Siemens Aktiengesellschaft Fully stabilized zirconia in a seal system
WO2021067978A1 (en) * 2019-10-04 2021-04-08 Siemens Aktiengesellschaft High temperature capable additively manufactured turbine component design
US20220371967A1 (en) * 2021-05-18 2022-11-24 Rolls-Royce Corporation Cmas-resistant environmental barrier coating system

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050170200A1 (en) * 2004-02-03 2005-08-04 General Electric Company Thermal barrier coating system
EP1674663A2 (en) * 2004-12-14 2006-06-28 Mitsubishi Heavy Industries, Ltd. Thermal barrier coating material, thermal barrier member, and member coated with thermal barrier and method for manufacturing the same

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050170200A1 (en) * 2004-02-03 2005-08-04 General Electric Company Thermal barrier coating system
EP1674663A2 (en) * 2004-12-14 2006-06-28 Mitsubishi Heavy Industries, Ltd. Thermal barrier coating material, thermal barrier member, and member coated with thermal barrier and method for manufacturing the same

Also Published As

Publication number Publication date
EP3106541A1 (en) 2016-12-21
EP3283667A1 (en) 2018-02-21
US20180179645A1 (en) 2018-06-28

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