WO2017084771A1 - 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
WO2017084771A1
WO2017084771A1 PCT/EP2016/063465 EP2016063465W WO2017084771A1 WO 2017084771 A1 WO2017084771 A1 WO 2017084771A1 EP 2016063465 W EP2016063465 W EP 2016063465W WO 2017084771 A1 WO2017084771 A1 WO 2017084771A1
Authority
WO
WIPO (PCT)
Prior art keywords
stabilized zirconia
ceramic layer
bond coat
layer system
fully
Prior art date
Application number
PCT/EP2016/063465
Other languages
French (fr)
Inventor
Cora HITCHMAN
Johannes Richter
Dimitrios Thomaidis
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 WO2017084771A1 publication Critical patent/WO2017084771A1/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
    • C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
    • 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
    • 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 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
  • 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 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 comprises 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 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 7 especially a metallic bond coat 7 and very especially a NiCoCrAlY-based bond coat 7 is applied on.
  • the bond coat 7 reveals an engineered surface, here in the form of bumps 24.
  • the engineered surface or bumps 24 are yielded during coating by additional means or machining the bond coat 7 after having fully coated the bond coat 7 and can have any geometry.
  • the bumps 24 are not caused by the roughness of the bond coat 7.
  • the bumps 24 can also be caused by an engineered or machined surface of the substrate on which the bond coat 7 is applied on .
  • TGO thermally grown oxide layer
  • 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.
  • 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 or mix ⁇ tures as known by the state of the art.
  • yttrium Y
  • Y yttrium
  • the engravings 16 are especially made by a laser.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Ceramic Engineering (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Compositions Of Oxide Ceramics (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 sprayed porous coatings do not demonstrate 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 engraved coatings.
1) Erosion. Such thermal barrier coatings have shown signifi- cantly lower rates compared to their porous counterparts.
2) Such 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 sub- strate or hot previously deposited splats which promotes a good intimate bonding to develop between them. Improved adhe¬ sion requires 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) 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 comprises 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. The advantages that arise are:
1) The low fracture toughness of the FSZ with the adoption of engravings 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 7, especially a metallic bond coat 7 and very especially a NiCoCrAlY-based bond coat 7 is applied on.
The bond coat 7 reveals an engineered surface, here in the form of bumps 24.
The engineered surface or bumps 24 are yielded during coating by additional means or machining the bond coat 7 after having fully coated the bond coat 7 and can have any geometry.
The bumps 24 are not caused by the roughness of the bond coat 7.
The bumps 24 can also be caused by an engineered or machined surface of the substrate on which the bond coat 7 is applied on .
Examples of engineered surface for the substrate 4 or bond coat 7 are given in WO 2015/130526 A2, especially in figures 13 to 25, 27 to 47.
On this bond coat 7 there is a thermally grown oxide layer (TGO, not shown) which is formed during further application of following 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.
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 or mix¬ tures as known by the state of the art.
Preferably yttrium (Y) is used for stabilization.
In this layers 10, 13 there are engravings 16 present, which are mostly present in the outer most layer 13 and preferably some of them are present in both layers 10, 13 and very pref¬ erably all engravings 16 are in both layers 10, 13.
The engravings 16 are especially made by a laser.

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,
a metallic bond coat (7) on the substrate (4),
which is especially metallic and
very especially made of a NiCoCrAlY-based alloy,
wherein the metallic bond coat (7) has a structured surface with bumps (24),
an inner partially stabilized zirconia layer (10) on the metallic bond coat (7) and
on the inner partially stabilized zirconia layer (10) a fully stabilized zirconia layer (13),
wherein engravings (16) are present in the fully stabilized zirconia layer (13) .
2. Ceramic layer system according to claim 1,
wherein the engravings (16) are only present in the fully stabilized zirconia layer (13) .
3. Ceramic layer system according to claim 1,
wherein the engravings (16) are present in both layers (10, 13) .
4. Ceramic layer according to any of the preceding claims, wherein the porosity of the fully stabilized zirconia layer (13) is lower than 5%,
especially lower than 3%.
5. Ceramic layer system according to any of the preceding claims ,
wherein the thickness of the partially stabilized zirconia layer (10) is between 75ym - 800ym.
Ceramic layer system according to any of the preceding claims ,
wherein the thickness of the fully stabilized zirconia lay er (13) is between 50ym - 800ym.
7. Ceramic layer system according to any of the preceding claims ,
wherein the zirconia of the zirconia layers (10, 13) is stabilized by yttria,
especially only by yttria.
8. 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%.
9. Ceramic layer system according to any of the preceding claims ,
wherein the partially stabilized zirconia is stabilized by yttria,
especially is 8YPSZ .
10. Ceramic layer system according to any of the preceding claims ,
wherein the bumps (24) are yielded
during coating by additional means
or by machining the bond coat (7) after having fully coated the bond coat (7)
or
the bumps (24) are caused by an engineered or a machined surface of the substrate (4) on which the bond coat (7) is applied on.
11. Ceramic layer system according to any of the preceding claims 1 to 10,
wherein the bumps (24) are not caused by the roughness of the bond coat (7) .
PCT/EP2016/063465 2015-11-19 2016-06-13 Dvc-coating with fully and partially stabilized zirconia WO2017084771A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP15195270.2 2015-11-19
EP15195270.2A EP3170918A1 (en) 2015-11-19 2015-11-19 Dvc-coating with fully and partially stabilized zirconia

Publications (1)

Publication Number Publication Date
WO2017084771A1 true WO2017084771A1 (en) 2017-05-26

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Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102018203895A1 (en) * 2018-03-14 2019-09-19 Siemens Aktiengesellschaft Ceramic material, layer and layer system
WO2020131929A1 (en) * 2018-12-18 2020-06-25 Oerlikon Metco (Us) Inc. Coating for protecting ebc and cmc layers and thermal spray coating method thereof

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2001348655A (en) * 2000-06-09 2001-12-18 Mitsubishi Heavy Ind Ltd Thermal barrier coating material, gas turbine member applied with the same and gas turbine
US20050170200A1 (en) * 2004-02-03 2005-08-04 General Electric Company Thermal barrier coating system
EP1908856A2 (en) * 2006-10-05 2008-04-09 United Technologies Corporation Segmented abradable coatings and process(es) for applying the same
US20150030826A1 (en) * 2013-07-26 2015-01-29 Ahmed Kamel Method for creating a textured bond coat surface
WO2015130526A2 (en) 2014-02-25 2015-09-03 Siemens Aktiengesellschaft Turbine component thermal barrier coating with crack isolating engineered groove features

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2001348655A (en) * 2000-06-09 2001-12-18 Mitsubishi Heavy Ind Ltd Thermal barrier coating material, gas turbine member applied with the same and gas turbine
US20050170200A1 (en) * 2004-02-03 2005-08-04 General Electric Company Thermal barrier coating system
EP1908856A2 (en) * 2006-10-05 2008-04-09 United Technologies Corporation Segmented abradable coatings and process(es) for applying the same
US20150030826A1 (en) * 2013-07-26 2015-01-29 Ahmed Kamel Method for creating a textured bond coat surface
WO2015130526A2 (en) 2014-02-25 2015-09-03 Siemens Aktiengesellschaft Turbine component thermal barrier coating with crack isolating engineered groove features

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
C H PERRY ET AL: "Phase Characterization of Partially Stabilized Zirconia by Raman Spectroscopy", JOURNAL OF THE AMERICAN CERAMIC SOCIETY VOLUME 68, ISSUE 8, AUGUST 1985, 1 August 1985 (1985-08-01), pages C - 184, XP055267433, Retrieved from the Internet <URL:http://onlinelibrary.wiley.com/doi/10.1111/j.1151-2916.1985.tb10176.x/abstract> [retrieved on 20160421], DOI: 10.1111/j.1151-2916.1985.tb10176.x *

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