US20140017511A1 - Thermal barrier coating for industrial gas turbine blade, and industrial gas turbine using the same - Google Patents

Thermal barrier coating for industrial gas turbine blade, and industrial gas turbine using the same Download PDF

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Publication number
US20140017511A1
US20140017511A1 US13/937,881 US201313937881A US2014017511A1 US 20140017511 A1 US20140017511 A1 US 20140017511A1 US 201313937881 A US201313937881 A US 201313937881A US 2014017511 A1 US2014017511 A1 US 2014017511A1
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Prior art keywords
diffusion barrier
barrier layer
gas turbine
industrial gas
multilayer
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US13/937,881
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English (en)
Inventor
Takeshi Izumi
Hideyuki Arikawa
Yoshitaka Kojima
Akira Mebata
Tadashi Kasuya
Toshio Narita
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Hokkaido University NUC
Mitsubishi Power Ltd
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Hokkaido University NUC
Hitachi Ltd
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Assigned to HITACHI, LTD., NATIONAL UNIVERSITY CORPORATION HOKKAIDO UNIVERSITY reassignment HITACHI, LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ARIKAWA, HIDEYUKI, IZUMI, TAKESHI, KASUYA, TADASHI, KOJIMA, YOSHITAKA, MEBATA, AKIRA, NARITA, TOSHIO
Publication of US20140017511A1 publication Critical patent/US20140017511A1/en
Assigned to MITSUBISHI HITACHI POWER SYSTEMS, LTD. reassignment MITSUBISHI HITACHI POWER SYSTEMS, LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HITACHI, LTD.
Abandoned legal-status Critical Current

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/288—Protective coatings for blades
    • 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
    • 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
    • C23C10/02—Pretreatment of the material to be coated
    • 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
    • C23C10/28—Solid state diffusion of only metal elements or silicon into metallic material surfaces using solids, e.g. powders, pastes
    • C23C10/34—Embedding in a powder mixture, i.e. pack cementation
    • C23C10/36—Embedding in a powder mixture, i.e. pack cementation only one element being diffused
    • C23C10/38—Chromising
    • 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
    • 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
    • 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
    • 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
    • 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
    • C23C28/40—Coatings including alternating layers following a pattern, a periodic or defined repetition
    • C23C28/42—Coatings including alternating layers following a pattern, a periodic or defined repetition characterized by the composition of the alternating layers
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00—Aeronautics or air transport
    • Y02T50/60—Efficient propulsion technologies, e.g. for aircraft
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12535—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.] with additional, spatially distinct nonmetal component
    • Y10T428/12611—Oxide-containing component
    • Y10T428/12618—Plural oxides

Definitions

  • the present invention relates to a thermal barrier coating structure preferable for, for example, turbine blades for an industrial gas turbine.
  • the TBC is configured from a top coat as a thermal barrier, and a bond coat for providing oxidation resistance and corrosion resistance.
  • Oxides of low coefficient of thermal conductivity are used for the top coat, and yttria stabilized zirconia (YSZ), in which the crystalline structure is made stable by addition of yttria is widely used.
  • YSZ yttria stabilized zirconia
  • MCrAlY alloys M is at least one of Ni, Co, and Fe
  • aluminides such as Ni—Al, and Ni—Al—Pt are used.
  • the bond coat forms a thermal grown oxide (TGO) on the surface, and protects the substrate from oxidative and corrosive environment. Because alumina is preferably used for the TGO, the bond coat typically has a higher Al concentration than the substrate. On the other hand, diffusion of Al from the bond coat to the substrate is promoted, and formation of an altered layer which is called a secondary reaction zone (SRZ) in the substrate surface has become apparent along with the increasing trend for higher combustion temperatures. In the SRZ, a precipitated phase is generated in abundance, and the structure greatly differs from the original alloy structure. These are detrimental to mechanical property important for gas turbine blades such as creep strength and fatigue strength.
  • TGO thermal grown oxide
  • SRZ secondary reaction zone
  • Patent Document 1 discloses a method for suppressing element diffusion into a substrate during high-temperature use with the use of a multilayer alloy coating configured from a stabilizing layer, and a diffusion barrier layer formed of a Re-containing alloy.
  • the diffusion barrier layer is deposited by plating and heat treatment, and this is followed by a solution heat treatment and an aging treatment to control structure of the substrate, and to stabilize structure of the multilayer alloy coating.
  • the diffusion barrier layer is described as being desirably formed as a continuous layer in the producing process of Patent Document 1.
  • Patent Document 2 describes a Ni-based single crystal alloy consisting essentially of 0.06 to 0.08% of C, 0.016 to 0.035% of B, 0.2 to 0.3% of Hf, 6.9 to 7.3% of Cr, 0.7 to 1.0% of Mo, 7.0 to 9.0% of W, 1.2 to 1.6% of Re, 8.5 to 9.5% of Ta, 0.6 to 1.0% of Nb, 4.9 to 5.2% of Al, 0.8 to 1.2% of Co, and the balance being Ni and incidental impurities by weight.
  • a turbine blade for an industrial gas turbine of the present invention includes an Ni-based single crystal alloy which is prepared by adding grain boundary enhancing elements such as C, B, and Hf, and having a large acceptable crystal orientation difference for heterocrystals of different orientations from single crystals.
  • the present invention can prevent element diffusion into the substrate with the use of the diffusion barrier layer, and improve durability against thermal fatigue due to thermal cycles and durability against mechanical fatigue.
  • the present invention makes it possible to improve the strength reliability of the turbine blade for industrial gas turbine, and increase the lifetime of the turbine blade for industrial gas turbine.
  • FIG. 1 is a flowchart showing procedures of a multilayer alloy coating deposition method of Example.
  • FIG. 2A is a cross sectional view schematically illustrating a TBC including diffusion barrier layers of Example.
  • FIG. 2B is a cross sectional view schematically illustrating a TBC including diffusion barrier layers of Example.
  • FIG. 3 is a SEM image showing a cross section of a barrier layer of a TBC including diffusion barrier layers of an Example.
  • FIG. 4 is a SEM image showing a cross section of the TBC including diffusion barrier layers of the Example after a heat testing.
  • FIG. 5 is a SEM image showing a cross section of the TBC including diffusion barrier layers of the Example after a thermal cycle testing.
  • FIG. 6 is a SEM image showing a cross section of a TBC including a multilayer alloy coating of a Comparative Example after the thermal cycle testing.
  • FIG. 7A is a partial cross sectional view illustrating a turbine blade for industrial gas turbine.
  • FIG. 7B is a partially enlarged cross sectional view illustrating details of portion A of FIG. 7A .
  • Turbine blades for industrial gas turbine experience thermal fatigue caused by fluctuations of thermal stress due to thermal cycles during operation and upon shutdown.
  • the present inventors conducted an element test for a test piece, and confirmed that a multilayer alloy coating deposited by using the method described in Patent Document 1 undergoes horizontal cracking in its brittle diffusion barrier layer and at the interface of the diffusion barrier layer under thermal cycle conditions.
  • a problem of the continuous diffusion barrier layer, then, is the rapid propagation of cracking.
  • turbine blades for industrial gas turbine require more long-term durability than turbine blades for aircraft, and it is important to maintain the alloy structure over a long lifetime, and to prevent generation of heterocrystals, particularly in single-crystal gas turbine blades.
  • the Ni-based single crystal alloy described in Patent Document 2 is materially suited as the material of a large single-crystal blade, the alloy being prepared by adding grain boundary enhancing elements such as C, B, and Hf, and having a large acceptable crystal orientation difference for heterocrystals of different orientations from single crystals.
  • grain boundary enhancing elements such as C, B, and Hf
  • such an alloy will be referred to as a single crystal alloy for use in the present invention.
  • the present invention has been completed over the foregoing problems, and it is an object of the present invention to provide a thermal barrier coating structure that includes a diffusion barrier layer and for use in single-crystal turbine blades for industrial gas turbine formed of a single crystal alloy for use in the present invention, and that can suppress the growth of the secondary reaction zone due to element diffusion into the substrate, and can provide durability against thermal fatigue due to thermal cycles, and durability against mechanical fatigue.
  • the present inventors conducted intensive studies to solve the foregoing problems, and found that the problems can be solved by forming a discontinuous multilayer diffusion barrier layer.
  • the present invention was completed on the basis of this finding.
  • a turbine blade for industrial gas turbine of an embodiment of the present invention has a structure that includes a diffusion barrier layer-containing multilayer alloy coating, a bond coat, and a top coat directly and sequentially laminated on a surface of a blade substrate formed of a single crystal alloy which consists essentially of 0.06 to 0.08% of C, 0.016 to 0.035% of B, 0.2 to 0.3% of Hf, 6.9 to 7.3% of Cr, 0.7 to 1.0% of Mo, 7.0 to 9.0% of W, 1.2 to 1.6% of Re, 8.5 to 9.5% of Ta, 0.6 to 1.0% of Nb, 4.9 to 5.2% of Al, 0.8 to 1.2% of Co, and the balance being Ni and incidental impurities by weight, in which the diffusion barrier layer is a multilayer and a discontinuous layer.
  • the diffusion barrier layer is preferably an alloy that contains Re, Cr, and Ni.
  • 0.06% or more to 0.08% or less has the same meaning as “0.06% or more and 0.08% or less”, and can also be recited as “0.06 to 0.08%”. The same applies to all the other numerical ranges recited herein.
  • the step of forming the diffusion barrier layer-containing multilayer alloy coating and the TBC on the single crystal alloy for use in the present invention in a diffusion barrier deposition method of an embodiment of the present invention is performed according to the following procedures, as shown in FIG. 1 .
  • the substrate is subjected to a solution heat treatment (solution heat treatment step).
  • the substrate is processed into a blade shape (shaping step).
  • the multilayer alloy coating deposition step includes a plating step and a Cr cementation step.
  • the multilayer alloy coating deposition step is also referred to as a “barrier deposition step”.
  • the substrate is aged with the diffusion barrier layer-containing multilayer alloy coating and the bond coat deposited thereon (aging step).
  • top coat is deposited on the bond coat (top coat deposition step).
  • the steps (4) to (6) are also collectively referred to as a “TBC deposition step”.
  • the diffusion barrier-containing multilayer alloy coating of the embodiment of the present invention includes a diffusion barrier layer and an interlayer, the diffusion barrier layer being directly in contact with the substrate surface of the single crystal alloy for use in the present invention.
  • a protective layer may be inserted to protect the diffusion barrier layer from the impact of thermal spray.
  • a metal coating of Ni, Re—Ni, and Ni—W is formed on the blade substrate surface, using electrolytic plating and nonelectrolytic plating.
  • the diffusion barrier layer is a Re-containing alloy, and contains Cr as another metallic element.
  • a Cr cementation process is performed to cause the Cr to react with the metal coating deposited on the blade substrate surface, depositing the multilayer alloy coating that contains the diffusion barrier layer of a Re-containing alloy.
  • the multilayer alloy coating deposition method described in Patent Document 1 teaches a Cr cementation process performed at about 1,300° C. to make the diffusion barrier layer continuous, and to smooth the interface.
  • the publication also describes a solution heat treatment and an aging treatment preferably performed after the deposition of the multilayer alloy coating to control the substrate structure, reduce defects in the multilayer alloy coating, and smooth the layer interface.
  • the Cr cementation process temperature is set at or below the substrate aging temperature to discontinuously form the diffusion barrier layer in a form reflecting the discontinuous portion (discontinuous area) that occurs in the Re—Ni metal coating deposited by plating.
  • discontinuous area refers to portions where the interlayer component has entered the diffusion barrier layer.
  • the aging temperature for the single crystal alloy for use in the present invention ranges from 800° C. to 1,150° C., and can suppress deterioration of the substrate structure.
  • the thickness of the diffusion barrier layer is not particularly limited, and is desirably 1 to 5 microns ( ⁇ m) to enable the diffusion barrier layer of a Re-containing alloy of a high melting point to be easily formed at a temperature not greater than the substrate aging temperature, and to make the diffusion barrier layer more discontinuous. With a thickness of 5 microns or more, the diffusion barrier layer tends to become continuous, whereas the effect of suppressing diffusion becomes insufficient with a thickness of 1 micron or less.
  • the discontinuous portion of the diffusion barrier layer occurs at 5 to 100 micron intervals, particularly 10 to 60 micron intervals. It was found in an element test conducted for a test piece by the present inventors that intervals of 5 microns or less increase the occurrence of the discontinuous portion, and are insufficient for suppressing diffusion. It was also found in a thermal cycle test that intervals of 100 microns or more cause rapid propagation of the cracking generated in the diffusion barrier layer.
  • the horizontal width of the discontinuous portion is desirably 0.5 to 5 microns, particularly desirably 1 to 3 microns. With a discontinuous portion width of 0.5 microns or less, the cracking generated in the diffusion barrier layer easily propagates into the adjacent diffusion barrier in a thermal cycle test. On the other hand, a discontinuous portion width of 5 microns or more is insufficient in terms of the effect of suppressing diffusion.
  • the number of diffusion barrier layers is not particularly limited, as long as more than one layer is provided to obtain the diffusion suppressing effect. However, 2 to 10 layers, particularly 3 to 5 layers are desirable for maintaining the effect over extended time periods even with the discontinuous diffusion barrier layers.
  • the bond coat is deposited on the diffusion barrier layer-containing multilayer alloy coating after the deposition of the multilayer alloy coating.
  • MCrAlY that exhibits excellent corrosion resistance and oxidation resistance is used as the bond coat.
  • the thickness of the bond coat is not particularly limited, and is typically about 100 to 200 microns.
  • Specific examples of the deposition method include low pressure plasma spray (LPPS), and high velocity oxy-fuel frame-spraying (HVOF).
  • the top coat is deposited on the bond coat deposited as above.
  • yttria stabilized zirconia (YSZ ZrO2-6 to 8Y2O3) of low coefficient of thermal conductivity is typically used for the top coat, and the thickness of the top coat is typically about 300 to 500 microns.
  • the top coat is normally deposited by using, for example, air plasma spray (APS) under atmospheric pressure.
  • FIGS. 2A and 2B are schematic views representing the TBC that contains the diffusion barrier layer of the embodiment of the present invention.
  • FIG. 2A represents a configuration in which the multilayer alloy coating includes a diffusion barrier layer and an interlayer.
  • FIG. 2B represents a configuration in which the multilayer alloy coating includes the diffusion barrier layer, the interlayer, and a protective layer.
  • an alloy coating 5 containing diffusion barrier layers 2 (multilayer alloy coating), a bond coating 6 , and a top coating 7 are formed in order on a surface of a substrate 1 .
  • the alloy coating 5 is a laminate in which the diffusion barrier layers 2 and interlayers 3 are alternately disposed.
  • the diffusion barrier layers 2 include a discontinuous area 8 .
  • the discontinuous area 8 is configured from the component of the interlayer 3 .
  • a protective layer 4 is provided in a portion of the alloy coating 5 in contact with the bond coat 6 .
  • a single crystal alloy for use in the present invention preferred for a gas turbine member was cast into a rod shape, and was subjected to a solution heat treatment in a vacuum atmosphere under the following multi-stage heating conditions.
  • the rod-shaped casting material after the solution heat treatment was processed into a test piece (diameter 1 inch; thickness 3 mm) to obtain a substrate.
  • the barrier deposition was performed by using plating, and thus the surface was pretreated by being wet polished with a #600 wet abrasive paper, and degreased with acetone.
  • the multilayer plating film was deposited on the washed substrate surface in the following order.
  • Ni plating thickness, 2 microns
  • Ni—W plating thickness, 2 microns
  • Ni plating thickness, 10 microns
  • the plating deposition of the multilayer plating film on the substrate surface was followed by a Cr cementation process.
  • the test piece was buried in a processing powder (Al 2 O 3 -15Cr-5NH 4 Cl mass %) in an Ar atmosphere, and held for 4 hours at a heating temperature, for which the aging temperature 1,120° C. of the single crystal alloy for use in the present invention was selected.
  • the Ni plating film ( 1 ) was inserted to improve the adhesion between the single crystal substrate and the Re—Ni plating film ( 2 ), and reacts with the Re—Ni plating film ( 2 ) in the Cr cementation process, upon which the Ni plating film ( 1 ) becomes apart of the diffusion barrier layer and disappears.
  • the Ni plating film ( 7 ) reacts with the Re—Ni plating film ( 6 ), and becomes a part of the diffusion barrier layer.
  • the Ni plating film ( 7 ) becomes the protective layer for protecting the diffusion barrier layer from the impact.
  • the Cr cementation process forms a multilayer alloy coating structure in which two interlayers are interposed between three diffusion barrier layers.
  • the bond coat was thermal sprayed on the test piece of the single crystal alloy for use in the present invention.
  • blasting for improving adhesion was performed with alumina particles of grain size 24 under pressure of 5 kgf/cm 2 .
  • CoNiCrAlY Co-32Ni-21Cr-8Al-0.5Y mass %) powder was used for the bond coat.
  • various techniques can be used for the deposition method.
  • the bond coat was deposited on the multilayer alloy coating in about 150 microns by using high velocity oxy-fuel frame-spraying (HVOF) and low pressure plasma spray (LPPS).
  • HVOF high velocity oxy-fuel frame-spraying
  • LPPS low pressure plasma spray
  • the thermal spray of the bond coat was followed by a heat treatment, which was performed in a vacuum atmosphere under the following heating conditions to improve the adhesion of the bond coat.
  • the top coating was formed in about 300 microns by the atmospheric plasma spraying (APS) of commercially available yttria stabilized zirconia (YSZ).
  • APS atmospheric plasma spraying
  • YSZ yttria stabilized zirconia
  • FIG. 3 is a magnified view in the vicinity of the barrier layer of the TBC that includes the diffusion barrier layer-containing multilayer alloy coating of the embodiment of the present invention prepared as above.
  • an alloy coating 5 is present that includes two interlayers 3 and three diffusion barrier layers 2 .
  • the diffusion barrier layers 2 have the discontinuous area 8 .
  • the effect of the diffusion barrier layer obtained according to the embodiment of the present invention was investigated by conducting a heat test at 1,050° C. for 500 hours.
  • FIG. 4 is a SEM image of a cross sectional structure after the heat testing of the TBC that includes the diffusion barrier layer-containing multilayer alloy coating of the embodiment of the present invention.
  • the TBC having the diffusion barrier layer-containing multilayer alloy coating of the embodiment of the present invention had a confirmed effect as the barrier layer.
  • the TBC was further evaluated for durability by conducting a thermal cycle test that involved heating and cooling.
  • the thermal cycle test involved repeated heating and cooling between room temperature and 1,093° C., and was performed in 100 cycles, each cycle consisting of holding at room temperature for 15 min, and at 1,093° C. for 10 hours.
  • FIG. 5 is a SEM image of a cross sectional structure after the thermal cycle testing of the TBC having the diffusion barrier layer-containing multilayer alloy coating of the embodiment of the present invention.
  • the TBC with the multilayer alloy coating 5 containing the diffusion barrier layers 2 according to the embodiment of the present invention had partial decomposition in the diffusion barrier layers 2 after the prolonged heating.
  • the diffusion barrier layers 2 did not show any damage such as cracking and exfoliation caused by stress that occurred during the temperature changes.
  • the substrate 1 did not show any SRZ, and the diffusion barrier function was maintained by the formation of the multiple layers, even though the barrier was discontinuous.
  • FIG. 6 is a photographic image showing a cross section after the thermal cycle testing of a TBC containing a multilayer alloy coating deposited by using the method described in Patent Document 1 (Comparative Example).
  • the relationship between the horizontal length of cracking and the number of thermal cycles, specifically the cracking propagation speed can be reduced to about 1 ⁇ 3 with the diffusion barrier layer-containing multilayer alloy coating of the embodiment of the present invention, as compared to the multilayer alloy coating deposited by using the method of Patent Document 1.
  • a turbine blade for industrial gas turbine formed of the single crystal alloy for use in the present invention used in Example 1 was coated with the coating of Example 1 to obtain a turbine blade for industrial gas turbine.
  • the coating was formed on the blade surface exposed to combustion gas.
  • FIG. 7A schematically shows the industrial gas turbine that uses the turbine blade for industrial gas turbine of the example.
  • the gas turbine is configured from an air intake portion 17 , a compressor 18 , a combustor 19 , a turbine section 20 (including blades and nozzles), and an exhaust unit 21 .
  • FIG. 7B is a magnified cross sectional view of portion A of FIG. 7A , illustrating details of the turbine section 20 that includes blades and nozzles.
  • the turbine section is configured from a turbine rotor 11 , a shroud 12 , a combustor 13 , a gas path 14 , nozzles 15 , and blades 16 .
  • the turbine blade for industrial gas turbine coated with the coating of the embodiment of the present invention had improvements in durability against thermal cycles and fatigue during operation and upon shutdown, and was able to maintain the strength reliability of the gas turbine blade, making it possible to extend the lifetime of the gas turbine.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • General Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
US13/937,881 2012-07-10 2013-07-09 Thermal barrier coating for industrial gas turbine blade, and industrial gas turbine using the same Abandoned US20140017511A1 (en)

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GB2607537A (en) * 2019-06-07 2022-12-07 Alloyed Ltd A nickel-based alloy
US11634792B2 (en) 2017-07-28 2023-04-25 Alloyed Limited Nickel-based alloy
CN117051347A (zh) * 2023-08-17 2023-11-14 北京北冶功能材料有限公司 一种长寿命燃气轮机热障涂层及其制备方法
GB2618754A (en) * 2019-06-07 2023-11-15 Alloyed Ltd A nickel-based alloy
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CN114752880A (zh) * 2021-01-08 2022-07-15 中国科学院上海硅酸盐研究所 一种用于dd5/dd6单晶高温合金和合金粘结层界面的扩散阻挡层

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US11634792B2 (en) 2017-07-28 2023-04-25 Alloyed Limited Nickel-based alloy
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GB2584654A (en) * 2019-06-07 2020-12-16 Oxmet Tech Limited A nickel-based alloy
GB2584654B (en) * 2019-06-07 2022-10-12 Alloyed Ltd A nickel-based alloy
GB2607537A (en) * 2019-06-07 2022-12-07 Alloyed Ltd A nickel-based alloy
GB2618754A (en) * 2019-06-07 2023-11-15 Alloyed Ltd A nickel-based alloy
GB2607537B (en) * 2019-06-07 2024-02-28 Alloyed Ltd A nickel-based alloy
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US12241144B2 (en) 2019-06-07 2025-03-04 Alloyed Limited Nickel-based alloy
US12319985B2 (en) 2019-10-02 2025-06-03 Alloyed Limited Nickel-based alloy
CN117051347A (zh) * 2023-08-17 2023-11-14 北京北冶功能材料有限公司 一种长寿命燃气轮机热障涂层及其制备方法

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EP2684976A2 (fr) 2014-01-15
EP2684976A3 (fr) 2014-11-26

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