EP2964808B1 - Revêtement abradable en aluminium résistant à la fatigue thermomécanique - Google Patents

Revêtement abradable en aluminium résistant à la fatigue thermomécanique Download PDF

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Publication number
EP2964808B1
EP2964808B1 EP13877283.5A EP13877283A EP2964808B1 EP 2964808 B1 EP2964808 B1 EP 2964808B1 EP 13877283 A EP13877283 A EP 13877283A EP 2964808 B1 EP2964808 B1 EP 2964808B1
Authority
EP
European Patent Office
Prior art keywords
aluminum
particles
coating
boride
titanium
Prior art date
Legal status (The legal status 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 status listed.)
Active
Application number
EP13877283.5A
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German (de)
English (en)
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EP2964808A1 (fr
EP2964808A4 (fr
Inventor
Christopher W. Strock
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
RTX Corp
Original Assignee
United Technologies Corp
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Classifications

    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
    • B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/10—Alloys containing non-metals
    • C22C1/1036—Alloys containing non-metals starting from a melt
    • C22C1/1042—Alloys containing non-metals starting from a melt by atomising
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
    • C22C32/0047—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
    • C22C32/0047—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents
    • C22C32/0073—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents only borides
    • 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
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/06—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
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/18—After-treatment

Definitions

  • thermo-mechanical fatigue (TMF) resistant aluminum abradable coating which has particular utility as an outer air seal.
  • Compressor efficiency is related to blade tip clearance and outer air seal roughness. Coatings for the fan and the low pressure compressor are typically applied on titanium or iron based parts. The coefficient of thermal expansion (CTE) mismatch between the aluminum coating and the base metal (the titanium or iron) is almost a factor of two. This may lead to high compressive stresses in the coating during elevated temperature operation. With many thermal cycles from room temperature and back, the result is thermo-mechanical fatigue cracking and coating spallation.
  • CTE coefficient of thermal expansion
  • Blades that mate with an aluminum seal may be titanium- or iron-based. During rub interaction, under certain conditions, metal is transferred to the blade tips. This may cause localized wear of the seal in what is known as record groove patterns. The result is increased average tip clearance and increased roughness in the air flow direction.
  • EP 1 801 248 A discloses in an example a sealing composition made from a composite powder comprising 45 mass % boron nitride and 65 mass % of titanium diboride and having an average particle size of 15 - 30 ⁇ m.
  • the powder is mixed with a fine powder of aluminum containing 12 mass % of silicon.
  • An organic binder is mixed in with the metal and composite powder to form a slurry.
  • the mixture is heated to about 150 °C and stir blended until the material is dried and an agglomerated powder is formed.
  • the powder is then screened a size of 40 to 210 ⁇ m.
  • the powder is sprayed with a plasma gun onto a substrate to a coating of 30 ⁇ m thickness.
  • the invention is defined by an aluminum coating comprising an aluminum alloy matrix as claimed in claim 1, a process of applying the coating as claimed in claim 8, and a process of forming the aluminum alloy matrix as claimed in claim 12.
  • Preferred embodiments are defined in dependent claims 2 to 7, and 9 to 11.
  • thermo-mechanical fatigue resistant aluminum abradable coating are set forth in the following detailed description.
  • an aluminum coating which has a coefficient of thermal expansion which more closely matches the coefficient of thermal expansion of the substrate to which the aluminum coating is applied.
  • the substrate to which the aluminum coating described herein may be applied may be formed from a titanium alloy or from an iron based alloy.
  • the substrate may be a fan casing or a casing for a compressor section of gas turbine engine.
  • the aluminum coating has an aluminum matrix formed from an aluminum alloy such as an aluminum-silicon alloy.
  • the aluminum coating further includes fine particles in the range of 20 nm to 5 ⁇ m mean particle diameter of a low coefficient of thermal expansion (cte) material, which is defined as having a cte that is lower than that of the aluminum matrix, which are incorporated into the aluminum matrix.
  • the fine particles may be in the range of from 20 nm to 2 ⁇ m in mean particle size.
  • the inclusion of the fine particles of a low coefficient of thermal expansion material results in hardening, strengthening and coefficient of thermal expansion reduction.
  • the fine particles to be incorporated into the aluminum coating are boride particles. Only those particles which bond sufficiently well to the aluminum alloy matrix material and are capable of carrying a portion of the mechanical load and which act as a composite material are used in the aluminum coating described herein, such as aluminum boride particles and titanium boride particles.
  • Aluminum boride particles form high aspect ratio platelets when precipitated at a temperature of below about 650 degrees Centigrade.
  • the technique used to manufacture the aluminum coatings must contain sufficient heating of the alloy constituents to fully dissolve any AlB 12 which tends to form at temperatures between 650 degrees Centigrade and 1550 degrees Centigrade depending on boron concentration.
  • the formation of AlB 12 during cooling may be suppressed by quenching to below 650 degrees Centigrade. This can bed one by rapid cooling of the melt or passively as one of the characteristics of thermal spray coating in which molten particles are quench cooled upon impact with a surface. If desired, the thermal spray coating may be subsequently heat treated to a temperature of up to 650 degrees Centigrade.
  • Aluminum boride is a desirable candidate due to its low cost, high thermal conductivity, low coefficient of thermal expansion, and good adhesion to the matrix. Aluminum boride at 20 vol% has been shown to increase the strength of aluminum by 80%.
  • Titanium boride is also a desirable candidate for the aluminum coating.
  • the titanium boride particles may be incorporated into the aluminum matrix by precipitation from a quenched metastable solid solution.
  • the titanium boride may have a ratio of titanium to boron which ranges from 1:1 to 1:4. It is also possible to include the titanium boride particles by mechanical alloying, agglomeration with the matrix alloy in a thermal spray feed stock powder, pressed and sintered.
  • the borides, such as titanium boride or aluminum boride, used as the fine particles may be present in a range of from 1.0 vol% to 33 vol%, balance aluminum matrix. In another non-limiting embodiment, the boride particles may be present in an amount from 10 to 25 vol%. In still another non-limiting embodiment, the boride particles may be present in an amount from 15 to 20 vol%.
  • the borides are dissolved in melt atomization to form a spray powder.
  • Melt atomization of a boride containing aluminum alloy that quenches during atomization forms particles of a metastable solid solution. This allows deposition of solid or semi-solid particles and subsequent precipitation. The precipitation of undesirable phases may be suppressed as a result of rapid cooling rates.
  • other powder manufacturing routes that result in powder with undesirable phases may be melted and solutionized during the spray coating operation. Either way, molten or softened particles may then be quench cooled during deposition.
  • titanium boride precipitates from a metastable quenched structure to form precipitates in the 20nm to 2.0 micron size range, depending on subsequent heat treat temperature.
  • the heat treatment could be heating the aluminum coating at 625 to 650 degrees Centigrade for 2.0 hours.
  • the aluminum alloy matrix with fine particles is formed into a powder so that it can be applied on the substrate by a spray process such as thermal spraying.
  • the fine particles may be included in the particles forming the aluminum alloy matrix material by agglomeration, alloying and precipitation, or ball milling and cold working.
  • the amount of fine particles is a function of the desired coefficient of thermal expansion for the aluminum coating. Also, considerations of through thickness thermal gradient may be taken into account.
  • the aluminum coating is applied to the substrate by thermally spraying the matrix material with the incorporated fine particles.
  • Hexagonal boron nitride as a pore making fugitive or soft filler material is added to the matrix material while it is being sprayed.
  • the fugitive or soft filler material does not affect the coefficient of thermal expansion of the aluminum coating.
  • the filler material would have to both bond with the aluminum matrix and have sufficient elastic modulus to at least partially elastically constrain the aluminum matrix.
  • the elastic modulus of the filler material may be higher than that of aluminum.
  • Fugitives and fillers like hexagonal boron nitride, polyester, and Lucite ® are candidates for affecting the abradability of the aluminum coating and may be used to offset the strengthening of the matrix material by the fine particles.
  • the coating is made from an aluminum alloy containing 70.4 wt% aluminum, 13.8 wt% titanium, 9.6 wt% silicon, and 6.2 wt% boron and hexagonal boron nitride to produce a coating of 40 volume % aluminum alloy, 50 volume % hBN and 10% porosity.
  • the titanium boride particles may be precipitated from a quenched metal alloy with heat treatment at 625 to 650 degrees Centigrade for 2.0 hours.
  • the sprayed particles may be quenced by conduction of heat to the coating and substrate cooling the particles. After quenching, the substrate with the sprayed particles may be subjected to a heat treatment in the range of from 625 to 650 degrees Centigrade for 2.0 hours.
  • the benefits of the abradable coating described herein include reduced coefficient of thermal expansion and thermo-mechanical fatigue. This results in a more stable part shape with temperature change and improved coating durability.
  • the filler material also helps to reduce metal transfer to blades during low interaction rate sliding contact wear and result in tighter tip clearance and a smoother coating.
  • the technique described herein does not increase the incipient melting point of the coating. With regard to the alloy mentioned above, this is because the titanium and boride constituents fully precipitate as a high melting point phase. As a result, the blade tip temperature, particularly of a titanium blade tip, during rub is still limited to the melting point of aluminum. This helps reduce the risk of a titanium fire.
  • the coatings described herein have good adhesion between the fine particles and the matrix.
  • thermo-mechanical fatigue resistant aluminum abradable coating There has been described herein a thermo-mechanical fatigue resistant aluminum abradable coating. While the coating has been described in the context of specific embodiments thereof, other unforeseeable alternatives, modifications, and variations may become apparent to those skilled in the art having read the foregoing description. Accordingly, it is intended to embrace those alternatives, modifications, and variations as fall within the broad scope of the appended claims.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)

Claims (12)

  1. Revêtement en aluminium qui doit être déposé sur un substrat ayant un premier coefficient de dilatation thermique, ledit revêtement en aluminium comprenant une matrice en alliage d'aluminium et des particules de borure ayant un faible coefficient de dilatation thermique incorporées dans ladite matrice ;
    caractérisé en ce que ledit revêtement est composé d'un alliage d'aluminium contenant 70,4 % en poids d'aluminium, 13,8 % en poids de titane, 9,6 % en poids de silicium et 6,2 % en poids de bore et de nitrure de bore hexagonal (hBN) pour produire un revêtement de
    (i) 40 % en volume d'alliage d'aluminium ;
    (ii) 50 % en volume de nitrure de bore hexagonal (hBN) ; et
    (iii) 10 % en volume de porosité.
  2. Revêtement en aluminium selon la revendication 1, dans lequel lesdites particules sont des particules de borure d'aluminium.
  3. Revêtement en aluminium selon la revendication 1, dans lequel lesdites particules sont des particules de borure de titane.
  4. Revêtement en aluminium selon la revendication 3, dans lequel lesdites particules de borure de titane ont un rapport de titane sur bore dans la plage de 1:1 à 1:4.
  5. Revêtement en aluminium selon une quelconque revendication précédente, dans lequel lesdites particules sont présentes dans une quantité de 1,0 à 33 % en volume.
  6. Revêtement en aluminium selon l'une quelconque des revendications 1 à 4, dans lequel lesdites particules sont présentes dans une quantité de 10 à 25 % en volume.
  7. Revêtement en aluminium selon l'une quelconque des revendications 1 à 4, dans lequel lesdites particules sont présentes dans une quantité de 15 à 20 % en volume.
  8. Procédé pour appliquer un revêtement en aluminium selon une quelconque revendication précédente à une pièce comprenant les étapes suivantes :
    la fourniture d'une pièce ;
    la formation d'une poudre contenant ladite matrice en alliage d'aluminium et des particules de borure ayant un faible coefficient de dilatation thermique liées à ladite matrice en aluminium ; et
    la pulvérisation thermique de ladite poudre sur ladite pièce.
  9. Procédé selon la revendication 8, dans lequel ladite étape de fourniture de pièce comprend la fourniture d'une pièce formée à partir d'un alliage à base de titane ou d'un alliage à base de fer.
  10. Procédé selon la revendication 8 ou 9, dans lequel ladite étape de formation de poudre comprend l'atomisation à chaud d'un alliage d'aluminium contenant du borure et le refroidissement de l'alliage d'aluminium contenant du borure au cours de l'atomisation pour former les particules d'une solution solide métastable.
  11. Procédé selon la revendication 8, 9 ou 10, comprenant en outre le fait de soumettre ledit revêtement en aluminium à un traitement thermique dans la plage de 625 à 650 degrés centigrades pendant 2,0 heures.
  12. Procédé pour former une matrice en alliage d'aluminium contenant de fines particules de borure comprenant les étapes suivantes :
    atomisation à chaud d'un alliage d'aluminium contenant du borure, contenant 70,4 % en poids d'aluminium, 13,8 % en poids de titane, 9,6 % en poids de silicium et 6,2 % en poids de bore; et
    refroidissement de l'alliage d'aluminium contenant du borure au cours de l'atomisation pour former des particules d'une solution solide métastable.
EP13877283.5A 2013-03-06 2013-12-30 Revêtement abradable en aluminium résistant à la fatigue thermomécanique Active EP2964808B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201361773344P 2013-03-06 2013-03-06
PCT/US2013/078183 WO2014137464A1 (fr) 2013-03-06 2013-12-30 Revêtement abradable en aluminium résistant à la fatigue thermomécanique

Publications (3)

Publication Number Publication Date
EP2964808A1 EP2964808A1 (fr) 2016-01-13
EP2964808A4 EP2964808A4 (fr) 2016-10-26
EP2964808B1 true EP2964808B1 (fr) 2019-05-01

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EP13877283.5A Active EP2964808B1 (fr) 2013-03-06 2013-12-30 Revêtement abradable en aluminium résistant à la fatigue thermomécanique

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US (1) US20160017474A1 (fr)
EP (1) EP2964808B1 (fr)
WO (1) WO2014137464A1 (fr)

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10697464B2 (en) * 2016-07-29 2020-06-30 Raytheon Technologies Corporation Abradable material
US20190186281A1 (en) * 2017-12-20 2019-06-20 United Technologies Corporation Compressor abradable seal with improved solid lubricant retention
CN115852292A (zh) * 2022-11-08 2023-03-28 东莞城市学院 锅炉水冷壁电弧喷涂用铝基粉芯丝材的制备方法及应用

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4836982A (en) * 1984-10-19 1989-06-06 Martin Marietta Corporation Rapid solidification of metal-second phase composites
US5196471A (en) * 1990-11-19 1993-03-23 Sulzer Plasma Technik, Inc. Thermal spray powders for abradable coatings, abradable coatings containing solid lubricants and methods of fabricating abradable coatings
EP1247941A1 (fr) * 2001-04-03 2002-10-09 Siemens Aktiengesellschaft Aube de turbine à gaz
US8187720B2 (en) * 2005-11-14 2012-05-29 Lawrence Livermore National Security, Llc Corrosion resistant neutron absorbing coatings
US7754342B2 (en) * 2005-12-19 2010-07-13 General Electric Company Strain tolerant corrosion protecting coating and spray method of application
US8034153B2 (en) * 2005-12-22 2011-10-11 Momentive Performances Materials, Inc. Wear resistant low friction coating composition, coated components, and method for coating thereof
US8790789B2 (en) * 2008-05-29 2014-07-29 General Electric Company Erosion and corrosion resistant coatings, methods and articles

Non-Patent Citations (1)

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Title
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Also Published As

Publication number Publication date
WO2014137464A1 (fr) 2014-09-12
EP2964808A1 (fr) 2016-01-13
US20160017474A1 (en) 2016-01-21
EP2964808A4 (fr) 2016-10-26

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