EP2000557B1 - Barrière contre l'érosion pour revêtements de barrière thermique - Google Patents

Barrière contre l'érosion pour revêtements de barrière thermique Download PDF

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Publication number
EP2000557B1
EP2000557B1 EP20070252248 EP07252248A EP2000557B1 EP 2000557 B1 EP2000557 B1 EP 2000557B1 EP 20070252248 EP20070252248 EP 20070252248 EP 07252248 A EP07252248 A EP 07252248A EP 2000557 B1 EP2000557 B1 EP 2000557B1
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EP
European Patent Office
Prior art keywords
suspension
range
workpiece
step comprises
barrier coating
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Ceased
Application number
EP20070252248
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German (de)
English (en)
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EP2000557A1 (fr
Inventor
Joshua E. Persky
David L. Lambert
David A. Litton
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RTX Corp
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United Technologies Corp
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Publication of EP2000557A1 publication Critical patent/EP2000557A1/fr
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    • 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
    • C23C28/04—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 of inorganic non-metallic material
    • 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
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D13/00—Electrophoretic coating characterised by the process
    • C25D13/02—Electrophoretic coating characterised by the process with inorganic material
    • 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
    • F01D5/286—Particular treatment of blades, e.g. to increase durability or resistance against corrosion or erosion
    • 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
    • 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
    • F05D2230/80—Repairing, retrofitting or upgrading methods

Definitions

  • the present invention relates to an erosion barrier for thermal barrier coatings and to processes for forming the erosion barrier.
  • thermal barrier coating to protect the underlying substrate.
  • High velocity particles in the gas path of an engine cause considerable erosion damage to the thermal barrier coating.
  • the erosion of the thermal barrier coating leads to premature failure of the coated turbine engine part.
  • EP 0783043 discloses a thermal barrier coating having an erosion-resistant composition dispersed within or overlaying a ceramic layer
  • EP 1788122 discloses a process for forming a protective deposit over a ceramic thermal barrier layer.
  • the present invention provides a process for forming an erosion barrier for protecting a thermal barrier coating on a workpiece as claimed in claim 1.
  • a hard exterior shell is formed that is strongly bonded to the thermal barrier coating.
  • the erosion barrier may be formed from aluminum oxide, silicon carbide, silicon nitride, and molybdenum disilicide.
  • the present invention involves forming a hard shell exterior coating which acts as an erosion barrier on a thermal barrier coating applied to a substrate such as a turbine engine component.
  • the exterior coating erosion barrier is formed by electrophoretic deposition.
  • the workpiece 50 such as a turbine engine component or part, forming the substrate is immersed in a suspension 10 and electrically connected to one terminal of a voltage source 12.
  • a thermal barrier coating 52 such as a zirconia based thermal barrier coating, is applied to the turbine engine component 50.
  • the thermal barrier coating 52 may be applied to the turbine engine component using any suitable technique known in the art.
  • the suspension 10 consists of very fine ceramic particles ranging in size from about 0.02 microns to 0.2 microns in sol form. Preferably, the ceramic particles have a size in the range of from about 0.02 to 0.05 microns.
  • the ceramic particles may be suspended in a solvent such as water, alcohols including, but not limited to, ethanol or methanol, and water-alcohol mixtures.
  • a solvent such as water, alcohols including, but not limited to, ethanol or methanol, and water-alcohol mixtures.
  • organic solvents such as tricholoethane, however, such use may be prohibited by health and environmental issues.
  • an aluminum oxide (alumina) sol is put in suspension in water, alcohol, or mixtures thereof, and stabilized by the addition of sufficient acid to keep the pH of the solution below 4.25. This results in a positive charge on the alumina particles, such that they repel each other, avoiding agglomeration and sedimentation of the particles out of solution.
  • Candidates for acids to be added to the solution include, but is not limited to, nitric acid, hydrochloric acid, acetic acid, and stearic acid. Reducing the pH of the solution as low as 2.0 is possible, but low pHs could result in acid attack of any exposed metal on the parts or components to be coated in the suspension.
  • the preferred pH for alumina sol suspensions in water and/or alcohol is from 3.0 to 4.5.
  • the part or component 50 to be coated may be strongly biased with a negative DC voltage to accelerate the suspended particles in the suspension toward the thermal barrier coated surface of the part or component 50.
  • Typical negative biasing voltages range from about 50 to 2000V, preferably from about 900 to 1100V. Higher voltages lead to higher deposition rates, but are potentially hazardous by increasing the system's potential energy to a level that can compromise workplace safety.
  • alumina sol in suspension In addition to alumina sol in suspension, other hard ceramic materials that would be suitable include silicon nitride sol, silicon carbide sol, and molybdenum disilicide sol.
  • the suitable pH range required to produce a stable suspension varies with the composition of the fine ceramic particles in the suspension. This is due to surface chemistry variations which lead to different buildups of charge on the surfaces of the particles as a function of the pH of the suspension. At low pH, surfaces are positively charged, and at high pH, surfaces are negatively charged. Thus, there exists a pH level that corresponds to zero surface charge on the particles, which is known as the isoelectric point or pHiep.
  • Alumina has a pHiep of 4.5, while silicon nitride has a pHiep of 9.0, silicon nitride has a pHiep of 5.4, and molybdenum disilicide has a pHiep of 2.2.
  • the present invention may be used to form hard shell materials deposited on zirconia based thermal barrier coatings, it may also be advantageous to operate in a pH range that results in negative charge on the zirconia based coatings. This can be done by operating above the pHiep of zirconia which is 4.0. With regard to alumina particles in a suspension, the biasing of the zirconia coating would supply plenty of negative charge to the zirconia surface, thereby extending the useable pH lower limit downwards to 3.0.
  • silicon nitride may have an advantage over the other coatings since its pHiep is high at 9.0. This system has the additional advantage of being able to be deposited at neutral pH, which has health and safety advantages.
  • the pH level at which the electrophoretic deposition is carried out may be raised by modifying the surface chemistry of the sols prior to putting them into suspension. For example, nitriding alumina sols, or aluminizing molybdenum disilicide sols may raise the operating pH level, minimizing damage to parts or components 50.
  • Hardness of the hard shell materials at room temperature are:
  • the concentration of sols in the suspensions may range from about 0.001 wt% to 5.0 wt% solids. Preferably, the concentration of sols in the suspensions may be from about 0.005 to 0.05 wt% solids.
  • the part or component 50 After the part or component 50 is removed from the suspension after the erosion barrier coating has been deposited, it may be dried using any suitable drying technique known in the art. Drying may be carried out at a temperature in the range of from about room temperature to 650°F (20°C to 343°C). Drying times at room temperature may range from about 1.0 to 20 hours, preferably from about 3.0 to 10 hours. At drying temperatures in the range of 250°F to 650°F (121°C to 343°C), the drying times may be reduced from about 0.5 to 5.0 hours with a preferred drying time range of from about 1.0 to 2.0 hours.
  • the coated part or component may be subjected to a sintering operation to form strong bonds within the deposited erosion barrier coating and between the erosion barrier coating and the thermal barrier coating. Also, sintering reduces porosity in the erosion barrier coating which drives the hardness values toward the bulk hardness values discussed hereinbefore. Sintering may be carried out using any suitable technique known in the art. Sintering times may range from about 3.0 to 4.0 hours at a temperature in the range of from about 1950°F to 2000°F (1066°C to 1093°C).
  • one or more dispersants such as polymethyl methacrylate alcohol and ammonium stearate could be added to the suspension to avoid agglomeration and settling of particles.
  • the dispersant(s) may be present in a concentration from 0.01 to 1.0 wt%, preferably from 0.4 to 0.8 wt%.
  • polyvinyl alcohol can be added as a binder to the suspension to increase the strength of the hard shell prior to sintering if necessary.
  • the polyvinyl alcohol may be added in an amount from 0.1 to 3.0 wt%, preferably from 1.0 to 2.0 wt%.
  • the goal of the polyvinyl alcohol binder addition is to coat each particle of sol in the suspension with a monolayer of binder.
  • the processes of the present invention preferably yield a component or part 50 having a thermal barrier coating (TBC) 52 and a hard shell erosion barrier coating 54 deposited over the thermal barrier coating 52.
  • TBC thermal barrier coating
  • An infiltrated region 56 may be formed between the coating 54 and the coating 52.
  • the infiltrated region may constitute from 5.0 to 100% of the thickness of the TBC measured down from the surface of the TBC.
  • the thickness of the infiltrated region is from 10-20% of the TBC thickness.
  • the component or part 50 may be formed from any suitable metallic material known in the art such as a nickel based superalloy.
  • TBCs Erosion of TBCs tends to happen on specific areas of turbine engine components. For example, blade tips get eroded, especially on the suction side. Outer buttresses of vanes also get eroded due to centrifugal forces. Most particulates in the turbine gas stream are centrifuged out to the outer diameter of the turbine, where they do most of their damage. Any relatively steep contours on the turbine engine components get eroded, simply because steep contours increase the local pressure on the part surface by compressing the gas stream, which increases the frequency of collisions with both molecules and any particulates in the gas stream--thus increasing erosion. To minimize the weight added by the hard shell coating and to minimize any potential detrimental effects a hard shell coating might have on TBCs on any turbine engine component, such as reduction of strain tolerance, it would be beneficial to put the hard shell coating only on areas with known susceptibility to erosion.
  • a hard shell coating on only a portion of a turbine engine component may be done using a painting process, a dipping process, or an electrophoretic approach.
  • An organic maskant may be applied to all surfaces not intended to be coated.
  • the placement of the hard shell coating may be done by applying a UV curable resin, such as a commercially available resin known as PHOTORESIST, on the turbine engine component. Then one could apply a sheet metal mask to the areas onto which the deposition of the hard coating is desired. Thereafter, the resin-coated, masked component may be exposed to UV light for a time period from 1.0 to 10 minutes to cure all exposed resin. After curing, the sheet metal mask is removed. Any uncured resin may be washed off. Then one can proceed to the hard coating process. If photolithography is used, drying may be carried out at a temperature in the range of from 600°F to 900°F (316°C to 482°C) for a time in the range of from 2.0 to 4.0 hours to burn off the cured resin.
  • a UV curable resin such as a commercially available resin known as PHOTORESIST
  • the processes of the present invention may be used to form an erosion barrier coating on a wide variety of parts and components having a thermal barrier coating thereon.
  • the parts or components which may be treated include, but are not limited, any part having an airfoil, any part having a seal, airfoils, seals, and the like. Examples of such parts or components include blades, vanes, stators, mid-turbine frames, combustor panels, combustor cans, combustor bulkhead panels, disk side plates, and fuel nozzle guides.

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

Claims (21)

  1. Procédé de formation d'une barrière contre l'érosion servant à protéger un revêtement formant une barrière thermique (52) sur une pièce à usiner (50), ledit procédé comprenant les étapes suivantes :
    formation d'une suspension (10) de particules céramiques en suspension dans un solvant ; et
    dépôt de particules dans ladite suspension sur ledit revêtement formant une barrière thermique (52) ;
    caractérisé en ce que :
    ladite étape de formation de suspension comprend l'ajout d'un acide ou d'une base à ladite suspension (10) de sorte que ladite suspension a un pH inférieur à 9,0 ;
    ladite étape de dépôt comprend le dépôt par électrophorèse desdites particules dans ladite suspension (10) sur ledit revêtement formant une barrière thermique par polarisation de ladite pièce à usiner comportant ledit revêtement formant une barrière thermique (52) avec une tension continue suffisant à accélérer les particules en suspension dans ladite suspension (10) vers une surface de la pièce à usiner (50) ; et
    par séchage desdites particules déposées sur ledit revêtement formant une barrière thermique (52) de manière à former un revêtement formant une barrière contre l'érosion (54) qui a une dureté Vickers comprise entre 1 300 et 2 750 kgf/mm2 (12,8 à 27,0 GPa).
  2. Procédé selon la revendication 1, dans lequel ladite étape de formation de suspension comprend la formation d'une suspension à l'aide d'un solvant choisi dans l'ensemble constitué d'eau, d'alcool et de leurs mélanges.
  3. Procédé selon la revendication 1 ou 2, dans lequel ladite étape de formation de suspension comprend la formation d'une suspension (10) avec des particules céramiques choisies dans l'ensemble constitué d'oxyde d'aluminium, de nitrure de silicium, de carbure de silicium et de disiliciure de molybdène.
  4. Procédé selon l'une quelconque des revendications précédentes, dans lequel ladite étape de formation de suspension comprend la formation d'une suspension utilisant des particules céramiques dont la taille de particule est comprise entre 0,02 et 0,2 µm.
  5. Procédé selon l'une quelconque des revendications précédentes, comprenant en outre le maintien de ladite suspension (10) à une température comprise entre la température ambiante (68 °F) et 120 °F (20 °C à 49 °C).
  6. Procédé selon l'une quelconque des revendications précédentes, comprenant en outre la formation de ladite suspension (10) de sorte que lesdites particules céramiques soient présentes en une concentration comprise entre 0,001 et 5,0 % en poids.
  7. Procédé selon la revendication 6, comprenant la formation de ladite suspension (10) de sorte que lesdites particules céramiques soient présentes en une concentration comprise entre 0,005 et 0,05 % en poids.
  8. Procédé selon l'une quelconque des revendications précédentes, dans lequel ladite étape d'ajout d'acide comprend l'ajout d'un acide qui maintient le pH de ladite suspension soit (i) au-dessous de 4,25 ; soit (ii) dans l'intervalle allant de 2,0 à 4,25.
  9. Procédé selon la revendication 8, dans lequel ladite étape d'ajout d'acide comprend l'ajout d'un acide choisi dans l'ensemble constitué de l'acide nitrique, de l'acide chlorhydrique, de l'acide acétique et de l'acide stéarique.
  10. Procédé selon l'une quelconque des revendications 1 à 7, dans lequel ladite étape d'ajout de base comprend l'ajout d'une base choisie dans l'ensemble constitué d'hydroxyde d'aluminium et d'hydroxyde d'ammonium pour élever le pH de ladite suspension (10).
  11. Procédé selon l'une quelconque des revendications précédentes, comprenant en outre l'ajout de 0,01 à 1,0 % en poids d'un dispersant choisi dans l'ensemble constitué d'alcool de polyméthacrylate de méthyle et de stéarate d'ammonium à ladite suspension pour éviter l'agglomération et la décantation desdites particules.
  12. Procédé selon l'une quelconque des revendications précédentes, comprenant en outre l'ajout de 0,1 à 3,0 % en poids d'un liant à ladite suspension pour accroître la force d'une coque formée par ladite barrière contre l'érosion.
  13. Procédé selon la revendication 12, dans lequel ladite étape d'ajout de liant comprend l'ajout de 1,0 à 2,0 % en poids de polyalcool vinylique.
  14. Procédé selon l'une quelconque des revendications précédentes, dans lequel ladite étape de dépôt comprend l'application d'une tension comprise entre 50 et 2 000 V à ladite pièce à usiner (50).
  15. Procédé selon la revendication 14, dans lequel ladite étape de dépôt comprend l'application d'une tension comprise entre 900 et 1 100 V à ladite pièce à usiner (50).
  16. Procédé selon l'une quelconque des revendications précédentes, comprenant en outre l'élimination de ladite pièce à usiner (50) par lesdites particules déposées de ladite suspension et où ladite étape de séchage comprend le séchage de ladite pièce à usiner à une température comprise entre la température ambiante (68 °F) et 650 °F (20 °C à 343 °C) pendant une durée comprise entre 0,5 et 20 h.
  17. Procédé selon la revendication 16, dans lequel ladite étape de séchage comprend soit : (i) le séchage de ladite pièce à usiner à température ambiante pendant une durée comprise entre 1 et 20 h ; (ii) le séchage de ladite pièce à usiner à température ambiante pendant une durée comprise entre 3 et 10 h ; (iii) le séchage de ladite pièce à usiner à une température comprise entre 250 °F et 650 °F (121°C à 343 °C) pendant une durée comprise entre 0,5 et 5,0 h ; et (iv) le séchage de ladite pièce à usiner à une température comprise entre 250 °F et 650 °F (121 °C à 343 °C) pendant une durée comprise entre 1,0 et 2,0 h.
  18. Procédé selon l'une quelconque des revendications précédentes, comprenant en outre le frittage de ladite pièce à usiner (50) à une température comprise entre 1 950 °F et 2 000 °F (1 066 °C à 1 093 °C) pendant une durée comprise entre 3,0 et 4,0 h.
  19. Procédé selon l'une quelconque des revendications précédentes, dans lequel ledit revêtement formant une barrière thermique (52) comprend un revêtement formant une barrière thermique à base de zircone.
  20. Procédé selon l'une quelconque des revendications précédentes, dans lequel une région infiltrée (56) est formée entre ledit revêtement formant une barrière thermique (52) et ladite barrière contre l'érosion (54).
  21. Procédé selon l'une quelconque des revendications précédentes, dans lequel ladite pièce à usiner (50) comprend un composant de moteur de turbine.
EP20070252248 2007-06-04 2007-06-04 Barrière contre l'érosion pour revêtements de barrière thermique Ceased EP2000557B1 (fr)

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EP20070252248 EP2000557B1 (fr) 2007-06-04 2007-06-04 Barrière contre l'érosion pour revêtements de barrière thermique

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EP20070252248 EP2000557B1 (fr) 2007-06-04 2007-06-04 Barrière contre l'érosion pour revêtements de barrière thermique

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EP2000557B1 true EP2000557B1 (fr) 2015-04-29

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EP3707297B1 (fr) * 2017-11-21 2023-06-21 Safran Helicopter Engines Procede de fabrication d'une barriere thermique sur une piece d'une turbomachine

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US20090274850A1 (en) 2008-05-01 2009-11-05 United Technologies Corporation Low cost non-line-of -sight protective coatings
US8186946B2 (en) * 2009-04-17 2012-05-29 United Technologies Corporation Abrasive thermal coating
ITMI20090934A1 (it) * 2009-05-27 2010-11-28 Elettroplast Spa Procedimento elettroforetico di deposizione di rivestimenti
WO2011007019A1 (fr) * 2009-07-15 2011-01-20 Fundacion Cidetec Procédé pour l'obtention d'un revêtement céramique par dépôt électrophorétique
DE102011100724A1 (de) * 2011-05-06 2012-11-08 Li-Tec Battery Gmbh Elektrode für Lithiumionen-Batterien
CN106414813B (zh) 2014-01-29 2019-04-30 赛峰飞机发动机公司 局部修复受损隔热层的方法
JP6908973B2 (ja) * 2016-06-08 2021-07-28 三菱重工業株式会社 遮熱コーティング、タービン部材、ガスタービン、ならびに遮熱コーティングの製造方法
CN109913870A (zh) * 2019-04-30 2019-06-21 江苏理工学院 一种铌合金表面MoSi2涂层的制备方法

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JPH09511024A (ja) * 1994-03-29 1997-11-04 ユナイテッド テクノロジーズ コーポレイション ファイバ上に多層コーティングを堆積させるための電気泳動プロセス
US5683825A (en) 1996-01-02 1997-11-04 General Electric Company Thermal barrier coating resistant to erosion and impact by particulate matter
US6261643B1 (en) * 1997-04-08 2001-07-17 General Electric Company Protected thermal barrier coating composite with multiple coatings
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WO2005071141A1 (fr) * 2004-01-22 2005-08-04 The University Of Manchester Revetement de ceramique
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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3707297B1 (fr) * 2017-11-21 2023-06-21 Safran Helicopter Engines Procede de fabrication d'une barriere thermique sur une piece d'une turbomachine

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