EP3090075B1 - Heisskorrosionsgeschützter artikel und dessen herstellungsverfahren - Google Patents

Heisskorrosionsgeschützter artikel und dessen herstellungsverfahren Download PDF

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Publication number
EP3090075B1
EP3090075B1 EP14874522.7A EP14874522A EP3090075B1 EP 3090075 B1 EP3090075 B1 EP 3090075B1 EP 14874522 A EP14874522 A EP 14874522A EP 3090075 B1 EP3090075 B1 EP 3090075B1
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EP
European Patent Office
Prior art keywords
layer
micrometers
substrate
coated article
nickel
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Active
Application number
EP14874522.7A
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English (en)
French (fr)
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EP3090075A4 (de
EP3090075A1 (de
Inventor
Michael N. TASK
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
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United Technologies Corp
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Publication date
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Publication of EP3090075A4 publication Critical patent/EP3090075A4/de
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Classifications

    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/02—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material
    • C23C28/023—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material only coatings of metal elements only
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
    • C25D5/10—Electroplating with more than one layer of the same or of different metals
    • C25D5/12—Electroplating with more than one layer of the same or of different metals at least one layer being of nickel or chromium
    • C25D5/14—Electroplating with more than one layer of the same or of different metals at least one layer being of nickel or chromium two or more layers being of nickel or chromium, e.g. duplex or triplex layers
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
    • C25D5/60—Electroplating characterised by the structure or texture of the layers
    • C25D5/605—Surface topography of the layers, e.g. rough, dendritic or nodular layers
    • C25D5/611—Smooth layers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/02—Blade-carrying members, e.g. rotors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/20—Manufacture essentially without removing material
    • F05D2230/22—Manufacture essentially without removing material by sintering
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/90—Coating; Surface treatment
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2260/00—Function
    • F05D2260/95—Preventing corrosion
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/10—Metals, alloys or intermetallic compounds
    • F05D2300/13—Refractory metals, i.e. Ti, V, Cr, Zr, Nb, Mo, Hf, Ta, W
    • F05D2300/132—Chromium
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/10—Metals, alloys or intermetallic compounds
    • F05D2300/17—Alloys
    • F05D2300/175—Superalloys

Definitions

  • the disclosure relates to gas turbines. More particularly, the disclosure relates to protective coatings for hot section components.
  • An exemplary gas turbine is discussed in the context of a gas turbine engine used for aircraft propulsion.
  • Such an engine has a core gaspath passing sequentially through one or more compressor sections for compressing ingested air, a combustor section for combusting the compressed air and an introduced fuel to generate high pressure/temperature combustion gases, and one or more turbine sections for extracting work from the combustion gases to drive the compressor sections.
  • the turbine sections also drive a fan which, in turn drives air along a flowpath bypassing the core flowpath.
  • Exemplary turbine sections are axial turbines wherein flow passes through one or more stages of rotating blades interspersed with stationary vanes or counter-rotating blades.
  • the blades of a given stage may be unitarily formed with or mounted to the periphery of a disk.
  • the disks of each section may be mounted to co-rotate with each other and any compressor section driven thereby.
  • Exemplary compressor sections are also axial, although centrifugal compressors and turbines are also known.
  • Engine components e.g., combustor panels, vanes, blades, disks, air seals, and the like
  • Engine components e.g., combustor panels, vanes, blades, disks, air seals, and the like
  • Engine components are particularly subject to corrosion and erosion. Additionally, due to temperature increase with sequential stages of compression, the higher pressure portions of the compressor sections may be subject to significant operational heating.
  • Exemplary substrate materials include a number of cast or powdermetallurgical (PM) forged nickel-based superalloys and/or cobalt-based superalloys.
  • PM cast or powdermetallurgical
  • the centrifugal loading to which disks are exposed makes disks a particular area of concern for substrate materials.
  • Thermal barrier coating (TBC) systems have been developed for hot section components.
  • Typical such systems have one or more insulative ceramic layers (e.g., zirconia-based such as yttria-stabilized zirconia (YSZ) and/or gadolinia-stabilized zirconia (GSZ)).
  • YSZ yttria-stabilized zirconia
  • GSZ gadolinia-stabilized zirconia
  • Such coatings may be used in combination with metallic bondcoats.
  • temperatures may be sufficiently lower than directly in the gaspath (e.g., to which airfoils are exposed) that the insulative benefit of ceramic TBC may be traded for improved hot corrosion protection of a metallic coating system.
  • EP 1930467 describes an environmental coating suitable for use on turbine components such as turbine disks and turbine seal elements, formed of alloys susceptible to oxidation and hot corrosion.
  • US 2005/058848 describes a zinc-diffused nickel alloy coating for corrosion and heat protection and to a method for forming such a coating.
  • One aspect of the disclosure involves a coated article comprising a nickel-based superalloy substrate and a coating system atop the substrate.
  • the coating system has a nickel-based first layer and a chromium-based second layer atop the first layer, wherein the first layer is essentially pure nickel and the second layer is essentially pure chromium.
  • a further embodiment may additionally and/or alternatively include the substrate being a powder metallurgical substrate.
  • a further embodiment may additionally and/or alternatively include the coated article being a turbine engine disk.
  • a further embodiment may additionally and/or alternatively include the first layer having a characteristic thickness T 1 of 13 micrometers to 51 micrometers and the second layer having a characteristic thickness T 2 of 13 micrometers to 51 micrometers.
  • a further embodiment may additionally and/or alternatively include the coating system consisting of said first layer and said second layer.
  • a further embodiment may additionally and/or alternatively include the coating system lacking a ceramic layer.
  • a further embodiment includes a method for manufacturing the coated article comprising a nickel-based superalloy substrate; and a coating system atop the substrate and comprising a nickel-based first layer; and a chromium-based second layer atop the first layer.
  • the method comprises: plating the first layer; and electroplating the second layer, wherein the plating of the first layer is plating of nickel; and electroplating of the second layer is electroplating of chromium.
  • a further embodiment may additionally and/or alternatively include the first layer plating being electroplating.
  • a further embodiment may additionally and/or alternatively include forming the substrate by forging of a powder metallurgical material.
  • a further embodiment includes a method for using the coated article.
  • the method comprises: installing the article in a gas turbine engine; and running the gas turbine engine to heat the article.
  • FIG. 1 shows a gas turbine engine disk assembly 20 including a disk 22 and a plurality of blades 24.
  • the disk is generally annular, extending from an inboard bore or hub 26 at a central aperture to an outboard rim 28.
  • a relatively thin web 30 is radially between the bore 26 and rim 28.
  • the periphery of the rim 28 has a circumferential array of engagement features 32 (e.g., dovetail slots) for engaging complementary features 34 of the blades 24.
  • the disk and blades may be a unitary structure (e.g., so-called "integrally bladed" rotors or disks).
  • the disk 22 may be formed by a powder metallurgical forging process (e.g., as is disclosed in U.S. Pat. No. 6,521,175 ).
  • the elemental components of the alloy are mixed (e.g., as individual components of refined purity or alloys thereof).
  • the mixture is melted sufficiently to eliminate component segregation.
  • the melted mixture is atomized to form droplets of molten metal.
  • the atomized droplets are cooled to solidify into powder particles.
  • the powder may be screened to restrict the ranges of powder particle sizes allowed.
  • the powder is put into a container.
  • the container of powder is consolidated in a multi-step process involving compression and heating.
  • the resulting consolidated powder then has essentially the full density of the alloy without the chemical segregation typical of larger castings.
  • a blank of the consolidated powder may be forged at appropriate temperatures and deformation constraints to provide a forging with the basic disk profile.
  • the forging is then heat treated in a multi-step process involving high temperature heating followed by a rapid cooling process or quench.
  • the quench for the heat treatment may also form strengthening precipitates (e.g., gamma prime and eta phases) of a desired distribution of sizes and desired volume percentages.
  • Subsequent heat treatments are used to modify these distributions to produce the requisite mechanical properties of the manufactured forging.
  • the increased grain size is associated with good high-temperature creep-resistance and decreased rate of crack growth during the service of the manufactured forging.
  • the heat treated forging is then subject to machining of the final profile and the slots.
  • FIG. 2 schematically shows a section of the disk (e.g., along a rim portion such as an outer diameter (OD) surface or a front surface or a rear surface).
  • the disk has a forged PM substrate 100 as discussed above.
  • a coating system 102 lies atop the substrate and has an overall thickness T.
  • the exemplary coating system comprises a lower or inner/inboard first layer 104 (e.g., atop a surface 106 of the substrate) and an upper or outer/outboard second layer 108 (e.g., atop a surface 110 of the first layer).
  • the respective first and second layers have thicknesses T 1 and T 2 .
  • An exemplary surface 112 of the second layer is exposed and, thus, it does not bear any further coating layer (namely, a ceramic TBC).
  • Exemplary T 1 is 6.0 micrometers to 50 micrometers, more narrowly 6.0 micrometers to 25 micrometers or 6.0 micrometers to 15.0 micrometers.
  • Exemplary T 2 is 6.0 micrometers to 50 micrometers, more narrowly 6.0 micrometers to 25 micrometers or 10.0 micrometers to 20.0 micrometers.
  • the second layer provides corrosion resistance.
  • the second layer consists essentially of chromium (e.g., offering equivalent performance to pure chromium).
  • the first layer With a second layer material that is relatively brittle, the first layer provides a relatively ductile interface with the substrate to prevent cracks in the second layer from propagating into the substrate.
  • the first layer consists essentially of nickel (e.g., offering equivalent performance to pure nickel).
  • one or both layers may be pure or relatively pure chromium and nickel, respectively but may be subject to some diffusion with each other or the substrate.
  • An exemplary process for depositing the first layer is plating (e.g., electroless or electroplating). This may be applied directly to the machined substrate to build to the thickness T 1 .
  • plating e.g., electroless or electroplating
  • the second layer is deposited by electroplating. This is applied directly to the first layer (e.g., after any washing) to build to the thickness T 2 .
  • Exemplary electroplating is disclosed in US Patent Application Publication 2013/0220819 entitled "Electrodeposition of Chromium from Trivalent Chromium Using Modulated Electric Fields". Such use of a trivalent chromium bath avoids toxicity concerns of hexavalent chromium.
  • FIG. 3 is a micrograph of an exemplary such two layer coating system 102.
  • the lower layer 104 is directly atop the substrate and is thinner than the upper layer 104 (e.g. about 15% to 33% of the upper layer thickness).
  • FIG. 4 shows a baseline MCrAlY.
  • a dark boundary 122 is seen between the two layers. This is a very thin gap that appears to have been created during the sectioning/mounting process for generating the micrograph. Also, it is seen that, compared to the MCrAlY, there is a lower degree of apparent interdiffusion with the substrate. Finally, it is seen that, compared to the MCrAlY, there is a lower degree of apparent surface roughness of the exposed coating surface.

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

Claims (14)

  1. Beschichteter Artikel (22), umfassend:
    ein Superlegierungs-Substrat auf Nickelbasis (100); und
    ein Beschichtungssystem (102) auf dem Substrat und umfassend:
    eine erste Schicht auf Nickelbasis (104); und
    eine zweite Schicht auf Chrombasis (108) auf der ersten Schicht,
    wobei:
    die erste Schicht im Wesentlichen reines Nickel ist; und
    die zweite Schicht im Wesentlichen reines Chrom ist.
  2. Beschichteter Artikel nach Anspruch 1, wobei:
    das Substrat ein pulvermetallurgisches Substrat ist.
  3. Beschichteter Artikel nach Anspruch 1 oder Anspruch 2, wobei dieser eine Turbinentriebwerkscheibe ist.
  4. Beschichteter Artikel nach einem der vorstehenden Ansprüche, wobei:
    die erste Schicht eine charakteristische Dicke T1 von 13 Mikrometer bis 51 Mikrometer aufweist; und
    die zweite Schicht eine charakteristische Dicke T2 von 13 Mikrometer bis 51 Mikrometer aufweist.
  5. Beschichteter Artikel nach einem der vorstehenden Ansprüche, wobei:
    das Beschichtungssystem aus der ersten Schicht und der zweiten Schicht besteht.
  6. Beschichteter Artikel nach einem der Ansprüche 1 - 4, wobei:
    das Beschichtungssystem keine keramische Schicht aufweist.
  7. Verfahren zur Verwendung des beschichteten Artikels nach einem der Ansprüche 1 - 6, wobei das Verfahren Folgendes umfasst:
    Einbauen des Artikels in ein Gasturbinentriebwerk; und
    Laufenlassen des Gasturbinentriebwerks, um den Artikel zu erhitzen.
  8. Verfahren zur Herstellung eines beschichteten Artikels, umfassend:
    ein Superlegierungssubstrat auf Nickelbasis (100); und
    ein Beschichtungssystem (102) auf dem Substrat und umfassend:
    eine erste Schicht auf Nickelbasis (104); und
    eine zweite Schicht auf Chrombasis (108) auf der ersten Schicht,
    wobei das Verfahren Folgendes umfasst:
    Plattieren der ersten Schicht; und
    Elektroplattieren der zweiten Schicht,
    wobei das Plattieren der ersten Schicht das Plattieren von Nickel ist;
    und wobei das Elektroplattieren der zweiten Schicht das Elektroplattieren von Chrom ist.
  9. Verfahren nach Anspruch 8, wobei:
    das Plattieren der ersten Schicht Elektroplattieren ist.
  10. Verfahren nach Anspruch 8 oder Anspruch 9, weiter umfassend:
    Bilden des Substrats durch Schmieden eines pulvermetallurgischen Materials.
  11. Verfahren nach einem der Ansprüche 8 - 10, wobei:
    die erste Schicht eine charakteristische Dicke von 13 Mikrometer bis 51 Mikrometer aufweist; und
    die zweite Schicht eine charakteristische Dicke von 13 Mikrometer bis 51 Mikrometer aufweist.
  12. Verfahren nach einem der Ansprüche 8 - 11, wobei:
    das Beschichtungssystem aus der ersten Schicht und der zweiten Schicht besteht.
  13. Verfahren nach einem der Ansprüche 8 - 11, wobei das Beschichtungssystem des beschichteten Artikels keine keramische Schicht aufweist.
  14. Verfahren nach einem der Ansprüche 8 - 13, wobei der beschichtete Artikel eine Turbinentriebwerkscheibe ist.
EP14874522.7A 2013-12-24 2014-10-28 Heisskorrosionsgeschützter artikel und dessen herstellungsverfahren Active EP3090075B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201361920546P 2013-12-24 2013-12-24
PCT/US2014/062554 WO2015099880A1 (en) 2013-12-24 2014-10-28 Hot corrosion-protected articles and manufacture methods

Publications (3)

Publication Number Publication Date
EP3090075A1 EP3090075A1 (de) 2016-11-09
EP3090075A4 EP3090075A4 (de) 2017-08-23
EP3090075B1 true EP3090075B1 (de) 2018-12-05

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ID=53479486

Family Applications (1)

Application Number Title Priority Date Filing Date
EP14874522.7A Active EP3090075B1 (de) 2013-12-24 2014-10-28 Heisskorrosionsgeschützter artikel und dessen herstellungsverfahren

Country Status (2)

Country Link
EP (1) EP3090075B1 (de)
WO (1) WO2015099880A1 (de)

Family Cites Families (16)

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Publication number Priority date Publication date Assignee Title
US3625039A (en) * 1969-08-28 1971-12-07 Theo G Kubach Corrosion resistance of decorative chromium electroplated objects
US4346137A (en) 1979-12-19 1982-08-24 United Technologies Corporation High temperature fatigue oxidation resistant coating on superalloy substrate
US6521175B1 (en) 1998-02-09 2003-02-18 General Electric Co. Superalloy optimized for high-temperature performance in high-pressure turbine disks
US7150923B2 (en) * 2000-10-24 2006-12-19 Goodrich Technology Corporation Chrome coating composition
US6756134B2 (en) 2002-09-23 2004-06-29 United Technologies Corporation Zinc-diffused alloy coating for corrosion/heat protection
US6933058B2 (en) * 2003-12-01 2005-08-23 General Electric Company Beta-phase nickel aluminide coating
US20100008790A1 (en) 2005-03-30 2010-01-14 United Technologies Corporation Superalloy compositions, articles, and methods of manufacture
US20060222880A1 (en) * 2005-04-04 2006-10-05 United Technologies Corporation Nickel coating
US7364801B1 (en) * 2006-12-06 2008-04-29 General Electric Company Turbine component protected with environmental coating
US20080308425A1 (en) * 2007-06-12 2008-12-18 Honeywell International, Inc. Corrosion and wear resistant coating for magnetic steel
US8641963B2 (en) 2008-07-08 2014-02-04 United Technologies Corporation Economic oxidation and fatigue resistant metallic coating
US8124246B2 (en) 2008-11-19 2012-02-28 Honeywell International Inc. Coated components and methods of fabricating coated components and coated turbine disks
CN103796828B (zh) * 2011-09-12 2016-03-16 西门子公司 具有双层的MCrAlX金属层的层系统
US9752215B2 (en) 2012-02-14 2017-09-05 United Technologies Corporation Superalloy compositions, articles, and methods of manufacture
US9783873B2 (en) 2012-02-14 2017-10-10 United Technologies Corporation Superalloy compositions, articles, and methods of manufacture
US20130220819A1 (en) 2012-02-27 2013-08-29 Faraday Technology, Inc. Electrodeposition of chromium from trivalent chromium using modulated electric fields

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Publication number Publication date
EP3090075A4 (de) 2017-08-23
EP3090075A1 (de) 2016-11-09
WO2015099880A1 (en) 2015-07-02

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