EP4056738A2 - Systèmes et procédés d'élimination de revêtement de diffusion à partir d'aubages - Google Patents

Systèmes et procédés d'élimination de revêtement de diffusion à partir d'aubages Download PDF

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Publication number
EP4056738A2
EP4056738A2 EP22159930.1A EP22159930A EP4056738A2 EP 4056738 A2 EP4056738 A2 EP 4056738A2 EP 22159930 A EP22159930 A EP 22159930A EP 4056738 A2 EP4056738 A2 EP 4056738A2
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EP
European Patent Office
Prior art keywords
gas turbine
turbine engine
engine component
vol
diffusion coating
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.)
Withdrawn
Application number
EP22159930.1A
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German (de)
English (en)
Other versions
EP4056738A3 (fr
Inventor
Michael Minor
Eric STRATTON
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
Raytheon Technologies Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Raytheon Technologies Corp filed Critical Raytheon Technologies Corp
Publication of EP4056738A2 publication Critical patent/EP4056738A2/fr
Publication of EP4056738A3 publication Critical patent/EP4056738A3/fr
Withdrawn legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25F—PROCESSES FOR THE ELECTROLYTIC REMOVAL OF MATERIALS FROM OBJECTS; APPARATUS THEREFOR
    • C25F5/00—Electrolytic stripping of metallic layers or coatings
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25F—PROCESSES FOR THE ELECTROLYTIC REMOVAL OF MATERIALS FROM OBJECTS; APPARATUS THEREFOR
    • C25F3/00—Electrolytic etching or polishing
    • C25F3/02—Etching
    • 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
    • C23C10/00—Solid state diffusion of only metal elements or silicon into metallic material surfaces
    • C23C10/60—After-treatment
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25F—PROCESSES FOR THE ELECTROLYTIC REMOVAL OF MATERIALS FROM OBJECTS; APPARATUS THEREFOR
    • C25F7/00—Constructional parts, or assemblies thereof, of cells for electrolytic removal of material from objects; Servicing or operating
    • 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
    • C23F—NON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
    • C23F1/00—Etching metallic material by chemical means
    • C23F1/44—Compositions for etching metallic material from a metallic material substrate of different composition

Definitions

  • the disclosure relates generally to airfoils in gas turbine engines and systems and methods for removing diffusion coatings from airfoils of gas turbine engines.
  • Removal of diffusion coatings from gas turbine engine airfoils may be performed during a repair process or during a manufacturing process for various reasons.
  • an airfoil may not meet a desired geometric dimension(s) and tolerancing for a respective application with an original diffusion coating, so the diffusion coating may be removed and re-applied to meet the desired specification of the airfoil.
  • an airfoil may be removed from service after a specified time on wing of an aircraft.
  • a diffusion coating may be removed, the airfoil restored, and a new diffusion coating re-applied prior to returning the airfoil to service.
  • Typical systems and methods for removing a diffusion coating from an airfoil include a high-temperature concentrated acid solution with heavy capital equipment investments. Additionally, typical systems and methods are susceptible to damaging the airfoil resulting in significant costs when an airfoil is scrapped due to excess removal of the component's base material.
  • a method of removing an aluminide diffusion coating from a gas turbine engine component having a nickel alloy base material is disclosed herein.
  • the method may comprise: disposing the gas turbine engine component in a solution, the solution including an acid between 5% and 15% vol./vol. and water between 85% and 95% vol./vol.; placing the gas turbine engine component in electrical contact with a graphite plate; and removing the aluminide diffusion coating from the gas turbine engine component in response to placing the gas turbine engine component in electrical contact with the graphite plate and disposing the gas turbine engine component in the solution.
  • the method may further comprise increasing a reaction rate of the solution in response to generating a voltage differential between the solution and the aluminide diffusion coating.
  • the method may further comprise reducing the reaction rate in response to the aluminide diffusion coating being removed and the solution contacting the nickel alloy base material.
  • the method may further comprise heating the solution between 80 °F (27 °C) and 140 °F (60 °C).
  • the gas turbine engine component may include an airfoil.
  • the method may further comprise placing the gas turbine engine component in direct contact with the graphite plate.
  • the method may further comprise electrically coupling the gas turbine engine component is electrically coupled to the graphite plate.
  • the acid may be a nitric acid.
  • a method of removing an aluminide diffusion coating from a gas turbine engine component having a nickel alloy base material via a coating removal system is disclosed herein.
  • the method may comprise: enhancing, via the coating removal system, a reaction rate of a diluted acid solution in response to generating a localized redox reaction between the aluminide diffusion coating and the diluted acid solution; removing, via the coating removal system, the aluminide diffusion coating from the nickel alloy base material in response to generating the localized redox reaction; and reducing, via the coating removal system, the reaction rate of the diluted acid solution in response to the aluminide diffusion coating being removed.
  • a first electromotive force produced during the enhancing the reaction rate of the diluted acid solution is greater than a second electromotive force produce during reducing the reaction rate of the diluted acid solution.
  • the diluted acid solution may be an acid between 5% and 15% vol./vol. and water between 85% and 95% vol./vol.
  • the diluted acid may be a solution with a temperature between 80 °F (27 °C) and 140 °F (60 °C).
  • the acid may be nitric acid.
  • the coating removal system may include a graphite plate in electrical communication with the gas turbine engine component. The graphite plate may be disposed in the diluted acid solution.
  • a system for removing an aluminide diffusion coating may comprise: a diluted nitric acid solution comprising nitric acid between 5% and 15% vol./vol. and water between 85% and 95% vol./vol; and a graphite plate disposed in the diluted nitric acid solution, the graphite plate configured to be in electrical communication with a gas turbine engine component during removal of the aluminide diffusion coating.
  • the system may further comprise a heater, wherein the heater is configured to heat the diluted nitric acid solution to a temperature between 80 °F (27 °C) and 140 °F (60 °C).
  • the system may further comprise the gas turbine engine component disposed in the diluted nitric acid solution, the gas turbine engine component comprising a base material and the aluminide diffusion coating, the base material comprising a nickel-based superalloy.
  • a reaction rate of the diluted nitric acid solution may be increased in response to an electromotive force generated from a voltage differential between the diluted nitric acid solution and the aluminide diffusion coating.
  • the reaction rate of the diluted nitric acid solution may be decreased in response to the aluminide diffusion coating being removed.
  • aluminide diffusion coating removal systems and methods are disclosed herein.
  • the systems and methods correspond to removal of an aluminide diffusion coating from a nickel-base, or cobalt-base, superalloy.
  • the methods and systems disclosed herein may reduce capital intensive equipment for diffusion coating removal, mitigate air permits, water sampling, outfall samplings, emissions, and discharge exposure to concentrated acids for diffusion coating removal, reduce an amount of base material removed from a gas turbine engine component during diffusion coating removal, enhance a life of a restored gas turbine engine component, and/or reduce a cost of the removal methods and system.
  • Gas turbine engine 100 (such as a turbofan gas turbine engine) is illustrated according to various embodiments.
  • Gas turbine engine 100 is disposed about axial centerline axis 120, which may also be referred to as axis of rotation 120.
  • Gas turbine engine 100 may comprise a fan 140, compressor sections 150 and 160, a combustion section 180, and a turbine section 190. Air compressed in the compressor sections 150, 160 may be mixed with fuel and burned in combustion section 180 and expanded across turbine section 190.
  • Turbine section 190 may include high pressure rotors 192 and low pressure rotors 194, which rotate in response to the expansion.
  • Turbine section 190 may comprise alternating rows of rotary airfoils or blades 196 and static airfoils or vanes 198.
  • a plurality of bearings 115 may support spools in the gas turbine engine 100.
  • Any parts in gas turbine engine 100 may comprise a metallic diffusion or overlay coating to improve high temperature performance.
  • high pressure rotors 192, low pressure rotors 194, blades 196, or vanes 198 may be coated with an aluminum-based overlay or diffusion coating.
  • FIG. 1 provides a general understanding of the sections in a gas turbine engine and is not intended to limit the disclosure. The present disclosure may extend to all types of turbine engines, including turbofan gas turbine engines and turbojet engines, for all types of applications
  • Gas turbine engine components such as high pressure rotors 192, low pressure rotors 194, blades 196, or vanes 198 may be manufactured with a protective coating disposed thereon.
  • the protective coating is an aluminized diffusion coating. After an extended time on wing, a protective coating as disclosed herein may degrade to a point where the protective coating provides reduced protection to an airfoil of the gas turbine engine component. Thus, during a repair process, any remainder of the protective coating may be removed, and the gas turbine engine component may be re-coated.
  • the system includes a tank 202, a graphite plate 204, and a solution 206.
  • the graphite plate 204 and the solution 206 are both disposed in the tank 202.
  • the graphite plate 204 is a low Sulphur graphite plate (e.g., container Sulphur of less than 550 ppm).
  • the graphite plate 204 may be configured to be electrically coupled (i.e., either directly, or indirectly through a conductive path as discussed further herein) to a base material of a gas turbine engine component (e.g., high pressure rotors 192, low pressure rotors 194, blades 196, or vanes 198 from FIG. 1 ) having an aluminide diffusion coating disposed thereon.
  • a graphite plate 204 may be disposed proximate a bottom of tank 202 and be configured to receive a base material of a gas turbine engine component placed directly thereon.
  • system 250 for removing a diffusion coating may comprise graphite plates 208, 210 placed on sides of a tank 202 with electrical wires 212, 214 configured to electrically couple the graphite plates 208, 210 to a respective base material of a gas turbine engine component, in accordance with various embodiments.
  • An aluminide diffusion coating removal system may comprise solution 206 which is a highly diluted acidic solution comprising an acid diluted in water (e.g., between 5-15 % vol./vol. total acid), in accordance with various embodiments.
  • the acid base may include, but are not limited to, one or more organic acids of any molecular weight, one or more mineral acids (inorganic acids), and mixtures thereof.
  • Organic acids may include mono-carboxylic acids, di-carboxylic acids, or tri-carboxylic acids, and may be saturated or may have any degree of unsaturation.
  • organic acids for use in various embodiments of the composition in accordance to the present disclosure may include, but are not limited to, formic acid, carbonic acid, acetic acid, lactic acid, oxalic acid, propionic acid, valeric acid, enanthic acid, pelargonic acid, butyric acid, lauric acid, docosahexaenoic acid, eicosapentaenoic acid, pyruvic acid, acetoacetic acid, benzoic acid, salicylic acid, aldaric acid, fumaric acid, glutaconic acid, traumatic acid, muconic acid, malonic acid, malic acid, succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid, abietic acid, pimaric acid, sebacic acid, phthalic acid, isophthalic acid, terephthalic acid, maleic acid, citric acid, and combinations thereof.
  • mineral acids for use in various embodiments of the solution in accordance to the present disclosure may include, but are not limited to hydrochloric acid, phosphoric acid, sulfuric acid, nitric acid, and combinations thereof.
  • nitric acid is used as the only acid for the solution disclosed herein for base material (e.g., for high pressure rotors 192, low pressure rotors 194, blades 196, or vanes 198 from FIG. 1 ) having a nickel-base or cobalt-base superalloy.
  • the solution 206 comprises between 5 % and 15 % vol./vol. nitric acid with a remainder vol./vol. being water.
  • the total acidity may be significantly less than typical aluminide diffusion coating removal systems.
  • total acidity of typical systems may typically range from around 30% vol./vol. to 50 % vol./vol.
  • typical concentrated acids are used in the 30% vol./vol. to 50% vol./vol. range, after the diffusion coating is stripped off, the solution may begin to attack the base material.
  • typical concentrated acids are susceptible to removal of too much base material, especially for a thin walled gas turbine component, or the like, which may result in a gas turbine component having to be scrapped.
  • a reaction rate for removing a diffusion coating may be maintained or increased resulting in more consistent removal at a reduced cost.
  • the solution 206 of system 200 may be a heated solution.
  • the solution 206 may be heated to a temperature between 80 °F (27 °C) and 140 °F (60 °C), or between 95 °F (35 °C) and 140 °F (60 °C), or between 110 °F (43 °C) and 140 °F (60 °C).
  • a lowering of an acidic solution by 10 ° F (6 °C) may result in a doubling of a reaction rate (i.e., removal of the diffusion coating would be substantially longer for every 10 °F (6 °C) the temperature is lowered relative to a typical removal solution).
  • typical heated solutions for removal of aluminide diffusion coatings are in excess of 160 °F (71 °C) to main a sufficient reaction rate.
  • a reaction rate at or above typical reaction rates of acidic solutions heated above 160 °F (71 °C) for removal of aluminide diffusion coatings may be maintained, and/or exceeded.
  • the methods disclosed herein may reduce removal of the base material during the removal process, reduce a cost of the removal process, mitigate air permits, water sampling, outfall sampling, emissions, and/or discharge exposures to concentrated acids, or the like, in accordance with various embodiments.
  • an airfoil element 300 is illustrated schematically in the form of a rotor blade 306 from a turbine section, such as, for example, one of high pressure rotors 192 or low pressure rotors 194 from FIG. 1 .
  • the rotor blade 306 includes an airfoil section 310, a root section 312 ( e.g ., a firtree root) and a blade tip 314.
  • a platform 316 may be disposed between the airfoil section 310 and the root section 312.
  • the airfoil section 310 typically extends in a spanwise direction between the platform 316 and the blade tip 314 and in a chordwise direction between a leading edge 318 and a trailing edge 320.
  • the airfoil section 310 typically defines a pressure side surface 322 and a suction side surface 324.
  • the rotor blade 306 includes an internal cooling passage system that includes a plurality of leading edge outlets 326, a plurality of trailing edge outlets 328, a plurality of pressure side surface outlets 330, a plurality of suction side surface outlets 332 and a plurality of blade tip outlets 334.
  • the various pluralities of outlets provide openings for a cooling fluid circulating through various internal passageways within the rotor blade 306 to exit.
  • airfoil element 300 includes a base material 350 and a diffusion coating 360.
  • the base material 350 may comprise a nickel-based superalloy (e.g., an austenitic nickel-chromium-based alloy such as that sold under the trademark Inconel ® which is available from Special Metals Corporation of New Hartford, New York, USA), a cobalt-based superalloy, or the like.
  • the diffusion coating 360 may comprise an aluminide diffusion coating. In various embodiments, the diffusion coating 360 may include a diffusion layer and an additive layer.
  • the diffusion coating 360 is disposed on an external surface 352 of the base material 350.
  • the diffusion coating 360 is configured to protect the base material 350 from the environment of the base material 350 during gas turbine engine operation. For example, during operation of the gas turbine engine 100 from FIG. 1 , hot combustion gases may be directed by the airfoil element 300 and subjected to severe attack by oxidation corrosion and erosion. In various embodiments, the diffusion coating 360 protects against these events and may erode overtime.
  • the method 400 comprises heating a diluted nitric acid solution to a predetermined temperature (step 402).
  • the diluted nitric acid solution may be in accordance with the solution 206 from FIGs. 2A-2B .
  • the diluted nitric acid solution may contain between 5% and 15 % vol./vol. nitric acid and between 85% and 95% vol./vol. water.
  • the diluted nitric acid solution may be significantly more diluted relative to typical diffusion coating removal processes.
  • the predetermined temperature is between 80 °F (27 °C) and 140 °F (60 °C), or between 95 °F (35 °C) and 140 °F (60 °C), or between 110 °F (43 °C) and 140 °F (60 °C).
  • the method 400 further comprises disposing a gas turbine engine component in the diluted nitric acid solution (step 404) and placing the gas turbine engine component in electrical contact with a graphite plate (step 406).
  • the gas turbine engine component may be in accordance with airfoil element 300 from FIGs. 3A and 3B .
  • the graphite plate is disposed in a tank in accordance with system 200 or system 250 from FIGs. 2A and 2B .
  • the graphite plate is placed in electrical contact with the base material of the gas turbine engine component.
  • the graphite plate is place in electrical contact.
  • a localized redox reaction occurs allowing for the chemical stripping of the aluminide diffusion coating in the heated solution from step 402.
  • the combination of the graphite plate 204 from FIGs. 2A-B , the base material (e.g., base material 350 from FIG. 3B ), the diffusion coating (e.g., diffusion coating 360 from FIG. 3B ), and the heated solution (e.g., solution 206 from FIGs. 2A-B ) essentially create an electrical circuit.
  • a voltage differential may be generated between the graphite plate and the coating that is significantly greater than a voltage created between the graphite plate and the base material.
  • the voltage created by electrically coupling the graphite plate to the gas turbine engine component essentially increases the reaction rate of the solution with respect to the coating and returns to a negligible, or nearly negligible effect once the coating is removed.
  • the graphite plate may act as an electrical contact point for the system that allows the redox reaction to take place.
  • a reaction rate of the solution towards the diffusion coating may be enhanced based on a voltage created due to the differential material (namely the aluminum in the coating and the nickel in the base material). Additionally, once the coating is removed, the voltage may become negligible and return the solution to a significantly lower reaction rate without the voltage differential.
  • the systems and methods disclosed herein may be configured to prevent additional base material from being removed during a diffusion coating removal process, in accordance with various embodiments. This may allow for gas turbine engine components with thinner walls to utilize the removal process without a high risk of creating a component that has to be scrapped due to not meeting specifications.
  • references to “one embodiment”, “an embodiment”, “an example embodiment”, etc. indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiment

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Electrochemistry (AREA)
  • Mechanical Engineering (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
EP22159930.1A 2021-03-12 2022-03-03 Systèmes et procédés d'élimination de revêtement de diffusion à partir d'aubages Withdrawn EP4056738A3 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US17/200,429 US20220290322A1 (en) 2021-03-12 2021-03-12 Systems, formulations, and methods for removal of diffusion coating from airfoils

Publications (2)

Publication Number Publication Date
EP4056738A2 true EP4056738A2 (fr) 2022-09-14
EP4056738A3 EP4056738A3 (fr) 2022-12-21

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EP22159930.1A Withdrawn EP4056738A3 (fr) 2021-03-12 2022-03-03 Systèmes et procédés d'élimination de revêtement de diffusion à partir d'aubages

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Family Cites Families (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4886552A (en) * 1988-09-09 1989-12-12 United Technologies Corporation Method for monitoring the removal of a metallic contaminant from the surface of a metallic article
US6176999B1 (en) * 1998-12-18 2001-01-23 United Technologies Corporation Feedback controlled stripping of airfoils
US6355116B1 (en) * 2000-03-24 2002-03-12 General Electric Company Method for renewing diffusion coatings on superalloy substrates
US8377324B2 (en) * 2005-06-10 2013-02-19 Acromet Technologies Inc. Methods for removing coatings from a metal component
EP2166125A1 (fr) * 2008-09-19 2010-03-24 ALSTOM Technology Ltd Procédé pour la configuration des services d'un réseau personnel
CN103088399B (zh) * 2011-10-31 2016-01-06 通用电气公司 多步骤电化学去金属涂层方法

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EP4056738A3 (fr) 2022-12-21
US20220290322A1 (en) 2022-09-15

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