EP3404127B1 - Revêtement de barrière environnementale à gradient fonctionnel - Google Patents

Revêtement de barrière environnementale à gradient fonctionnel

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Publication number
EP3404127B1
EP3404127B1 EP18171307.4A EP18171307A EP3404127B1 EP 3404127 B1 EP3404127 B1 EP 3404127B1 EP 18171307 A EP18171307 A EP 18171307A EP 3404127 B1 EP3404127 B1 EP 3404127B1
Authority
EP
European Patent Office
Prior art keywords
substrate
powders
ebc
layer
environmental barrier
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.)
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Application number
EP18171307.4A
Other languages
German (de)
English (en)
Other versions
EP3404127A1 (fr
Inventor
Aaron T. Nardi
Thomas J. Martin
Alexander Staroselsky
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
RTX Corp
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Publication of EP3404127A1 publication Critical patent/EP3404127A1/fr
Application granted granted Critical
Publication of EP3404127B1 publication Critical patent/EP3404127B1/fr
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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
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/02—Coating starting from inorganic powder by application of pressure only
    • C23C24/04—Impact or kinetic deposition of particles
    • 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
    • C23C28/32—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer
    • C23C28/325—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer with layers graded in composition or in physical properties
    • 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 present invention relates generally to environmental barrier coatings (EBCs) and more particularly to a process for forming functionally graded EBCs.
  • EBCs environmental barrier coatings
  • EBCs are used to protect components from environmental attack. EBCs are particularly useful in protecting superalloy components of gas turbine engines exposed to high temperature and corrosive environments.
  • EBCs can consist of intermetallic compounds, such as MCrAlY compounds (where M can be nickel, cobalt, iron, or a mixture thereof).
  • MCrAlY compounds can serve as an aluminum or chromium reservoir to form oxide scales-typically alumina (Al 2 O 3 ) or chromia (Cr 2 O 3 ) at lower temperatures-which act as oxide barriers to protect the metal substrate against oxidation.
  • oxide scales typically alumina (Al 2 O 3 ) or chromia (Cr 2 O 3 )
  • TGO thermally grown oxide layer
  • oxides would be formed with aluminum or chromium in the substrate, causing degradation of the component over time.
  • interdiffusion between the EBC and substrate can improve adherence of the EBC to the substrate.
  • a thermal barrier coating (TBC) ceramic topcoat can be deposited on top of the EBC to provide thermal insulation for the metal substrate.
  • TBC ceramic topcoats typically consist of yttria, zirconia, gadolinium, and other elements (e.g., yttria-stabilized zirconia (YSZ)), which have a high melting temperature and low thermal conductivity.
  • the EBC serves as a bond coat, providing the interface between the TBC ceramic topcoat and the metal substrate.
  • the EBC will share elements with the ceramic topcoat and the metal substrate (e.g., aluminum and yttrium) to form a high strength bond at each interface.
  • TBC is resistant to oxidation and corrosion
  • the TBC allows diffusion of oxygen; therefore, when placed in an oxygen environment, oxygen freely diffuses through the TBC to the EBC where it combines with available aluminum or chromium to form oxides, which develop into the TGO between the EBC and TBC layers.
  • EP 2,617,869 A prior art environmental barrier coating and process for forming an environmental barrier coating having the features of the preamble to claim 1 is disclosed in EP 2,617,869 .
  • Another prior art environmental barrier coating and process for forming the same is disclosed in EP 1,382,707 .
  • the present invention provides an environmental barrier coating in accordance with claim 1.
  • the present invention provides a process for forming an environmental barrier coating in accordance with claim 7.
  • the present invention combines cold spray material deposition with heat treatment to produce a functionally graded EBC.
  • the EBC can be functionally graded to increase resistance to erosion and provide thermal protection.
  • the EBC can be functionally graded to increase strength with a reduction of thermal strain misfit between the substrate and TBC.
  • the EBC can have a graded elastic modulus through a thickness, which can reduce a thermal expansion mismatch between the TBC, EBC, and the substrate. Additionally, a controlled distribution of components of the EBC can reduce thermal cyclic stresses during operation, provide additional structural reinforcement, improve EBC adherence to the substrate, arrest crack propagation, and ultimately enhance the EBC's durability under thermal and structural load cycling.
  • Cold spraying also known as “cold gas dynamic spraying” has been used to form bond coats or EBCs on substrates. Unlike conventional thermal spray processes, cold spraying avoids exposing the substrate to high temperatures. In the cold spray process, solid state powder particles are accelerated toward a substrate at a velocity sufficient to cause the particles to plastically deform upon impact and cold weld or bond to the substrate or a previously deposited layer of powder particles. The particles are not metallurgically transformed in the cold spray process.
  • Conventional cold sprayed EBCs particularly those designed to serve as bond coats for TBCs, are formed from pre-alloyed powders, such as MCrAlY compounds. Any functional grading is accomplished by varying the chemical composition of the alloyed particles during deposition.
  • the present invention uses the cold spray process to deposit precursor elemental powders, alone or in combination with pre-alloyed powders or powders of other morphologies, which can form a functionally graded EBC upon subsequent diffusion heat treatment.
  • the combination of cold spray and diffusion heat treatment can be used to narrowly control both chemical composition and porosity through a thickness of the EBC to reduce thermal expansion mismatch, improve bond strength, and enhance overall durability and function of the EBC.
  • FIGS. 1 and 2 illustrate an EBC of the present invention and a process for forming the EBC.
  • FIG. 1 shows a schematic illustration of EBC 10, having multiple functionally graded layers 10a-10n, substrate 12, TGO 14, and TBC 16.
  • EBC can provide the interface between substrate 12 and TBC 16.
  • EBC 10 can be applied to substrate 12 without the addition of TBC 16.
  • Substrate 12 can be a prefabricated component, including but not limited to components intended to operate within high temperature, thermally cycling, and oxidizing environments. Examples of substrate 12 include a turbine airfoil, combustor liner, and blade outer air seal in a gas turbine engine. Substrate 12 can be made of a superalloy material, including but not limited to a nickel superalloy. In some embodiments, substrate 12 can be a single-crystal nickel-aluminum superalloy formed by investment casting, directional solidification, equiax direct build, forging, additive manufacturing, or other processes known in the art.
  • EBC 10 and the process of forming EBC 10 disclosed in the present invention can be used for a variety of material substrates and applications. While the present disclosure is directed to an example of the production of an ECB for use on a component within a hot section of a gas turbine engine, the disclosed ECB and process of formation can be adapted for use on a variety of components and within a variety of environments.
  • EBC 10 can be formed from the cold spray deposition of multiple layers 10a-10n of solid powder particles, generally including but not limited to metals, intermetallics, or alloys.
  • EBC 10 can generally consist of an intermetallic compound, such as an MCrAlY (where M is nickel, cobalt, iron, or mixtures thereof) or platinum aluminide.
  • an MCrAlY where M is nickel, cobalt, iron, or mixtures thereof
  • platinum aluminide platinum aluminide.
  • functionally graded EBC 10 can generally include three to five layers 10a-10n, forming a coating having a thickness between 75 ⁇ m and 200 ⁇ m with each layer 10a-10n having a thickness of approximately 25 ⁇ m.
  • EBC 10 can be functionally graded by modifying the cold spray process and feedstock material layer-by-layer. In embodiments requiring narrow functional grading, EBC 10 can have more than five layers 10a-10n and, in some cases, can have more than 20 layers 10a-10n. It will be understood by one of ordinary skill in the art that the thickness of each layer 10a-10n and number of layers 10a-10n can be changed by modifying spray parameters and material feedstock (e.g., nozzle traverse speed, powder feed rate, powder size, etc.).
  • Functional grading can be accomplished by selecting precursor powders for each layer 10a-10n to provide a gradual transition in the microstructure between each layer 10a-10n and between substrate 12 and optional TBC 16 following subsequent diffusion heat treatment.
  • Precursor powders can vary widely in chemical composition, morphology, and particle size, with a typical size ranging from 5 ⁇ m to 70 ⁇ m.
  • Precursor powders can be pre-mixed at engineered compositions and delivered to the spray gun from a single storage container (e.g., hopper) or can be individually fed as homogeneous compositions or elemental powders from separate storage containers.
  • Powders can be simultaneously fed to the spray gun from multiple storage containers at the same or differing powder feed rate, as set to optimize mixing, or can be fed from multiple storage containers on an alternating basis (e.g., alternating with each layer 10a-10n).
  • the precursor powders can be delivered through a powder feeder to the cold spray gun where the powder converges with a compressed gas stream, is accelerated, and is delivered to substrate 14 or a previously deposited layer 10a-10n.
  • each layer 10a-10n of EBC 10 By finely selecting and controlling the deposition of precursor powders layer-by-layer, graduated mixing regions can be developed between and within each layer 10a-10n of EBC 10 to optimize functional gradation of EBC 10 through the thickness of EBC 10 extending from substrate 12 to optional TBC 16 upon diffusion heat treatment.
  • the microstructure and chemical composition of each layer 10a-10n can be finely controlled. For instance, a porosity (illustrated by reference numbers 18 (varying in pore quantity) and 20 (varying in pore size) in FIG.
  • EBC 10 can be tailored to provide a graded elastic modulus and thermal expansion coefficient through the thickness of EBC 10 thereby reducing the thermal strains between the substrate 12, EBC 10, and TBC 16; while a varying content of oxide-forming elements (e.g., aluminum) can be tailored to control TGO growth.
  • oxide-forming elements e.g., aluminum
  • Areas of highest stress are generally located at the interface between EBC 10 and TBC 16, as the thermal expansion coefficient of EBC 10 can be typically be two times greater than the thermal expansion coefficient of TBC 16.
  • the thermal expansion coefficient and elastic modulus of EBC 10, and particularly outermost layer 10n can be reduced to more closely match that of TBC 16.
  • a reduction in the elastic modulus can generally be achieved by increasing the porosity of the layer 10a-10n.
  • the porosity can be created and tailored, with regard to both volume and pore size, through the thickness of EBC 10 (layers 10a-10n) by controlling the proportion of pre-alloyed versus elemental powder deposited and/or by controlling the powder morphology.
  • a diffusing species can cause the formation of pores in the microstructure.
  • aluminum which has a relatively low melting point, can diffuse at lower temperatures than some other metals. When combined with nickel in a controlled thermal process, aluminum will diffuse into the nickel leaving a pore where the aluminum was.
  • the size and location of the primary diffusing species, as well as diffusion time, are critical to the formation and extent of the porosity. Porosity can be increased in each layer 10a-10n by increasing the amount of elemental aluminum or other diffusing species deposited. As shown in FIG. 1 , porosity can increase through the thickness of EBC 10, extending from substrate 12 to TBC 16.
  • innermost layer 10a can have essentially no porosity or a porosity of less than two percent, which is consistent with the porosity of substrate 12, while outermost later 10n can have a porosity greater than 10 percent and, in some embodiments, between 20 and 50 percent nearest TBC 16 and thereby reduce the strain caused by thermal coefficient mismatch between EBC 10 and TBC 16.
  • the size and shape of the pores can also be tailored by controlling the size and shape of the diffusing species, which can be accomplished through the selection of powder morphology, powder constituents, and spray parameters.
  • a layer 10a-10n formed by the deposition of a blend of pre-alloyed NiCrAlY powders and elemental aluminum can result in the formation of thin pores following diffusion heat treatment.
  • the thin pores are caused by the flattening of the elemental aluminum during deposition. Because the particle velocity required to deposit pre-alloyed NiCrAlY powder onto substrate 12 is greater than the velocity required to deposit elemental aluminum, the increased particle velocity causes the aluminum to flatten upon impact.
  • the elemental aluminum diffuses leaving behind a flattened pore in the shape of the originally deposited elemental aluminum powder.
  • a layer 10a-10n formed by the deposition of nickel clad aluminum powders can result in the formation of spherical or semi-spherical pores, resultant of reduced particle deformation.
  • the nickel clad aluminum particles can require a particle velocity similar to that of NiCrAlY particles for deposition, however, the elemental aluminum can largely be protected from deformation by the outer nickel layer upon impact.
  • the aluminum can diffuse into the nickel leaving behind a hollow nickel aluminum structure, which can have an inner pore shape and size approximately equal to that of the aluminum in the precursor powder.
  • the plurality of nickel clad aluminum powders can form a closed cell foam structure upon diffusion heat treatment.
  • the size of the pores obtained with clad composite, such as nickel clad aluminum, can be significantly larger than those obtained with blended powders that include elemental aluminum.
  • the aluminum in typical nickel clad aluminum powders has a minimum diameter of around 30 ⁇ m as compared to 1-2 ⁇ m for elemental aluminum powders.
  • the size of the pores can be tailored to increase in outermost layer 10n.
  • an increase in pore size at outmost layer 10n can increase surface roughness and improve bonding between EBC 10 and TBC 16.
  • the blended powders can include a variety of alloys and elemental powders not limited to NiCrAlY and elemental aluminum.
  • clad composites are not limited to nickel clad aluminum, although the benefits of elemental aluminum in a functionally graded bond coat-as a diffusing species and an oxide-forming element-will be recognized.
  • FIG. 1 illustrates increasing porosity through layers 10a-10n by both increasing a quantity of similarly sized pores 18 (illustrated by reference number 18) and increasing a size of pores (illustrated by reference number 20), it will be understood that either or both increased quantity and size can be suitable for producing a graded elastic modulus through the thickness of EBC 10 for reducing thermal expansion mismatch.
  • the chemical composition of EBC 10 can also be varied to control TGO formation and growth and to enhance EBC 10 strength.
  • the content of oxide-forming elements, such as aluminum can be increased by weight percent in outermost layer 10n to provide a reservoir of aluminum available for TGO growth.
  • Aluminum content can also be decreased in innermost layer 10a and other layers near substrate 12 to minimize inward diffusion of aluminum, which can damage substrate 12.
  • aluminum content in innermost layer 10a can approximately match an aluminum content in substrate 12 to limit aluminum diffusion in either direction between substrate 12 and EBC 10.
  • EBC 10 particularly when used in the absence of TBC 16, can be functionally graded to increase resistance to erosion due to particle impact and to provide thermal protection.
  • the cold spray plus diffusion heat treatment process can be used to optimize the chemical composition and functionality of EBC 10 to produce an EBC 10 capable of providing thermal protection to substrate 12 without a TBC 16 topcoat.
  • the cold spray deposition of elemental particles and metal clad ceramics can provide for tailored alloy formation and optimized interspersion of ceramic material upon diffusion heat treatment.
  • EBC 10 can be finely adapted to accommodate the needs of varying applications and that it is the combination of finely controlled particle deposition and diffusion through heat treatment that can optimize the function of EBC 10.
  • the disclosed process can be extended to other common EBCs, such as yttrium silicate, which includes a reaction silicon barrier and a silicon carbide bond coat.
  • TBC 16 can be applied over EBC 10.
  • TBC 16 can be a ceramic topcoat, such as YSZ or similar high temperature ceramic capable of providing thermal or environmental barrier protection. Suitable ceramics can include but are not limited to zirconia, alumina, gadolinium zirconia, silica, titania, yttria, boron nitride, carbon nitride, silicon nitride, silicon carbide, tantalum carbide, and tungsten carbide.
  • TBC 16 can be deposited on EBC 10 using deposition processes known in the art, including but not limited to, thermal spray, chemical vapor deposition (CVD), and physical vapor deposition (PVD).
  • thermal spray deposition examples include air plasma spray (APS), suspension plasma spray (SPS), solution precursor plasma spray (SPPS), low pressure plasma spray (LPPS), and high velocity oxygen fuel (HVOF).
  • PVD examples include cathodic arc (Arc-PVD) and electron beam physical vapor deposition (EB-PVD).
  • TBC 16 can typically have a thickness ranging from 100 ⁇ m - 400 ⁇ m, but can be varied outside of this range depending on the application.
  • TBC 16 can have a variety of defining microstructures, including but not limited to elongated columnar grains (consistent with EB-PVD), columnar structures formed by preferential deposition (consistent with SPS, SPPS), lamellar structures (consistent with APS), and dense vertical cracked structures with columnar or equiaxed grains consistent with APS, SPS, SPPS). It will be understood by one of ordinary skill in the art to tailor EBC 10 in accordance with the microstructure of or deposition method used to form TBC 16 to optimize bond strength or other interfacial properties.
  • FIG. 2 illustrates the process for forming EBC 10, which includes cold spray deposition (step 28) followed by a controlled diffusion heat treatment process (step 30).
  • the cold spray deposition process includes selecting a precursor powder composition for each ECB layer 10a-10n (step 32) and depositing each EBC layer 10a-10n (step 34) in a layer-by-layer fashion using a cold spray technique as known in the art.
  • the steps of powder selection (step 32) and deposition (step 34) can repeat until all ECB layers 10a-10n have been deposited.
  • precursor powders can be premixed in a single hopper or can be fed from multiple hoppers with a controlled feed rate and mixed in the gas stream.
  • the powder particles can be accelerated to supersonic speeds by compressed gas, such as helium, nitrogen, other inert gases, or combinations thereof.
  • compressed gas such as helium, nitrogen, other inert gases, or combinations thereof.
  • Conventional cold sprayed MCrAlY coatings generally require helium to accelerate the particles to a velocity sufficient for deposition.
  • Nitrogen gas can be more cost effective, but is generally not capable of producing the requisite particle velocity for alloyed particles having high hardness. Nitrogen can be suited for the cold spray deposition of softer elemental powders and can be utilized for various embodiments of the present invention.
  • EBCs 10 produced from the blending of elemental powders or other soft particles can, therefore, reduce processing costs over conventional MCrAlY cold sprayed EBCs.
  • EBC 10 is exposed to the controlled diffusion heat treatment process (step 30).
  • Controlled heat treatment causes interdiffusion of elements in EBC layers 10a-10n and diffusion of elements of EBC 10 with elements of substrate 12.
  • the interdiffusion of elements within EBC layers 10a-10n can create the graded porosity through the thickness of EBC 10.
  • the diffusion of elements in EBC 10 with elements of substrate 12 can create a diffusion bond joint, which can enhance the bond between EBC 10 and substrate 12.
  • Heat treatment can be carried out using conventional heat treatment systems known in the art (e.g., high vacuum furnace or argon atmosphere furnace), in which the component including EBC 10 is heated.
  • the heat treatment process is divided into multiple steps of applying heat to EBC 10 (step 38) and holding EBC 10 at a preselected temperature (step 40) to control diffusion and porosity formation.
  • the steps of applying heat and holding at temperature can be repeated until a maximum holding temperature reaches (or exceeds) a minimum diffusion bonding temperature of the innermost EBC layer 10a. (e.g., approximately 1200 °C for a layer 10a formed from a NiCrAlY alloy), while remaining below a melting point of the EBC layer 10a-10n having the lowest melting point after chemistry homogenization to prevent incipient melting.
  • the lowest melting point can be determined by depositing each layer 10a-10n on a separate coupon, heat treating to form an alloy of the deposited powders, and analyzing each EBC layer 10a-10n using methods known in the art (e.g., differential scanning calorimetry) to determine the melting points.
  • the diffusion heat treatment process can be tailored based on the chemical constituents of EBC 10 and may require a slow increase in temperature to limit exothermic reactions between particular constituents (e.g., aluminum and nickel). Hold times and temperatures and ramp-up rates can vary depending on the chemical composition. Modeling or experimentation can be used to optimize the diffusion heat treatment process. In order to reduce the processing time, modeling or experimentation can be used to determine the temperature at which an exothermic reaction is observed, which indicates that diffusion is occurring too rapidly and can result in an unstable accelerated process. A hold temperature can generally be set 50-100 °C below the temperature at which an exothermic reaction will occur to allow optimal diffusion. After this point, it may be possible to heat to the final temperature.
  • EBC 10 (including substrate 12) was heated to 400 °C at a rate of 2 °C per minute and then held at 400 °C for two hours. Thereafter, the temperature was increased at a rate of 2 °C per minute and at held for period for two hours at 450 °C, 500 °C, 550 °C, 600 °C, 800 °C, and 1000 °C before being heated to a final temperature of 1200 °C.
  • Methods known in the art including differential scanning calorimetry or thermogravimetric analysis, can be used to monitor exothermic processes.
  • TBC 16 topcoat can be deposited on EBC 10 following heat treatment (step 44).
  • the TBC 16 can be deposited using any material deposition process known in the art, including but not limited to, thermal spray, CVD, and PVD methods. It will be understood by one of ordinary skill in the art to tailor EBC 10 in accordance with the microstructure of or deposition method used to form TBC 16 to optimize bond strength or other interfacial properties.
  • a surface of EBC 10 can be prepared for TBC 16 deposition. Surface preparation methods can include but are not limited to peening and grit blasting to provide a surface roughness optimized for deposition of TBC 16.
  • the combination of cold spray material deposition with diffusion heat treatment can be used to produce a functionally graded EBC having increased strength and resistance to erosion, thermal protection, and a reduction of thermal strain misfit between the substrate and a TBC topcoat.
  • the EBC can have a graded elastic modulus through a thickness, which can reduce a thermal expansion mismatch between the TBC, EBC, and the substrate. Additionally, a controlled distribution of components of the EBC can reduce thermal cyclic stresses during operation, provide additional structural reinforcement, improve EBC adherence to the substrate, arrest crack propagation, and ultimately enhance the EBC's durability under thermal and structural load cycling.
  • any relative terms or terms of degree used herein such as “substantially”, “essentially”, “generally”, “approximately” and the like, should be interpreted in accordance with and subject to any applicable definitions or limits expressly stated herein.
  • any relative terms or terms of degree used herein should be interpreted to broadly encompass any relevant disclosed embodiments as well as such ranges or variations as would be understood by a person of ordinary skill in the art in view of the entirety of the present disclosure, such as to encompass ordinary manufacturing tolerance variations, incidental alignment variations, transient alignment or shape variations induced by thermal, rotational or vibrational operational conditions, and the like.
  • any relative terms or terms of degree used herein should be interpreted to encompass a range that expressly includes the designated quality, characteristic, parameter or value, without variation, as if no qualifying relative term or term of degree were utilized in the given disclosure or recitation.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Ceramic Engineering (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)

Claims (12)

  1. Revêtement de barrière environnementale (10) déposé sur un substrat (12) par projection à froid, le revêtement de barrière environnementale (10) comprenant une microstructure ayant une porosité (18, 20) qui augmente à travers une dimension d'épaisseur se prolongeant du substrat (12) vers une couche externe (10n),
    caractérisé en ce que :
    la microstructure comprend des structures creuses en nickel-aluminium ou des pores minces formés à partir de poudre d'aluminium élémentaire aplatie et traitée thermiquement par diffusion.
  2. Revêtement de barrière environnementale (10) selon la revendication 1, dans lequel le revêtement de barrière environnementale (10) comprend une composition chimique comprenant un élément formant de l'oxyde augmentant en pourcentage en poids vers la couche externe (10n).
  3. Revêtement de barrière environnementale (10) selon la revendication 1 ou 2, dans lequel la microstructure est formée à partir :
    d'une poudre dont la morphologie est choisie dans le groupe constitué de particules composites plaquées, composites granulées, composites séchées par pulvérisation, mélangées et alliées mécaniquement ; ou
    d'une poudre d'aluminium élémentaire.
  4. Revêtement de barrière environnementale (10) selon une quelconque revendication précédente, dans lequel la porosité (18, 20) de la microstructure dans la couche externe (10n) est égale ou supérieure à 10 pour cent.
  5. Revêtement de barrière environnementale (10) selon une quelconque revendication précédente, dans lequel la porosité (18, 20) de la microstructure au niveau d'une couche interne (10a) adjacente au substrat (12) est égale ou inférieure à deux pour cent.
  6. Revêtement de barrière environnementale (10) selon une quelconque revendication précédente, dans lequel un module d'élasticité du revêtement augmente successivement couche par couche depuis le substrat (12) jusqu'à la couche externe (10n).
  7. Procédé de formation du revêtement de barrière environnementale (10) selon la revendication 1, le procédé comprenant les étapes suivantes :
    le dépôt séquentiel d'une pluralité de couches (10a-10n) de poudre solide sur un substrat (12) par projection à froid, dans lequel au moins deux des couches (10a-10n) comprennent des constituants de poudre différents ; et
    le traitement thermique de la pluralité de couches (10a-10n), dans lequel la projection à froid consistant à diriger les poudres solides vers le substrat (12) à une vitesse suffisante pour provoquer leur déformation plastique et leur adhésion au substrat (12) ou à la couche (10a-10n) préalablement déposée ; dans lequel le traitement thermique de la pluralité de couches (10a-10n) comprend :
    l'augmentation d'une température d'un four à un rythme sensiblement constant ; et
    le maintien de la température constante pendant une période de temps prédéterminée, dans lequel chacune de la température du four et de la température de maintien est déterminée sur la base d'un point de fusion de chaque constituant allié ou élémentaire dans la poudre, et la température de maintien maximale est égale ou supérieure à la température de liaison par diffusion minimale d'une couche de revêtement (10a) la plus proche du substrat (12) et est inférieure à un point de fusion d'une couche de revêtement (10a-10n) ayant l'homogénéisation chimique de couche de point de fusion le plus bas.
  8. Procédé selon la revendication 7, dans lequel les poudres solides sont choisies dans le groupe comprenant des poudres élémentaires, des poudres entièrement alliées, des poudres mélangées, des poudres composites plaquées, des poudres composites granulées, des poudres séchées par pulvérisation, des poudres alliées mécaniquement et des combinaisons de celles-ci.
  9. Procédé selon la revendication 7 ou 8, dans lequel le dépôt séquentiel de la pluralité de couches (10a-10n) comprend également l'augmentation successive d'une quantité d'un élément formant un oxyde dans la pluralité de couches (10a-10n).
  10. Procédé selon la revendication 7, 8 ou 9, dans lequel les poudres solides comprennent des poudres céramiques recouvertes de métal.
  11. Procédé selon une quelconque revendication précédente, dans lequel le traitement thermique comprend également la formation de pores (20) dans la couche externe (10a) du revêtement (10) ayant un diamètre plus grand que les pores (20) formés dans les couches internes (10a, 10b, 10c) du revêtement (10).
  12. Procédé selon une quelconque revendication précédente, dans lequel le traitement thermique comprend également la formation d'une microstructure ayant une porosité (18, 20) qui augmente à travers une dimension d'épaisseur du revêtement de barrière environnementale (10) se prolongeant du substrat (12) à une couche externe (12) du revêtement (10).
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