CN1278873A - 在燃气涡轮叶片上形成磨料叶尖的方法 - Google Patents

在燃气涡轮叶片上形成磨料叶尖的方法 Download PDF

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CN1278873A
CN1278873A CN98810895A CN98810895A CN1278873A CN 1278873 A CN1278873 A CN 1278873A CN 98810895 A CN98810895 A CN 98810895A CN 98810895 A CN98810895 A CN 98810895A CN 1278873 A CN1278873 A CN 1278873A
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K·P·内诺夫
R·芬顿
J·A·福吉尼
P·霍瓦德
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Abstract

一种在底金属(14)的表面上形成磨料涂覆层的工艺方法,包含如下步骤:采用低压等离子喷涂法在底金属表面涂敷一层连接层(15);通过电镀将磨料颗粒(17)固定在连接层(15)上;和通过填充式电镀使上述的磨料颗粒(17)埋入一种抗氧化的基体内。

Description

在燃气涡轮叶片上形成磨料叶尖的方法
在燃气涡轮发动机工作过程中，希望在其涡轮叶片的尖部与相应的密封件之间保持最小的间隙，如果该间隙大，就会降低涡轮的效率，因为含高能量的气体漏泄了。相反地，叶片与相应密封件之间的摩擦又会引起零件过度磨损并浪费能量。由于航空涡轮在工作过程中要经历周期性变化的机械负荷和热负荷，所以在工作循环的不同阶段它们的零件几何形状会发生变化。因此在装配时不能调定所需的最小间隙。当前，通过活动地控制间隙并采用带磨料的叶片尖部，以便在工作过程中形成并保持最佳的间隙。采用带磨料的叶尖可使叶片在发动机最初的几个工作循环中切出它们自己的密封运行轨迹，最好是，这些叶尖在许多工作循环中保持它们的切割行为，以补偿涡轮几何形状的任何渐进变化。上述的叶片尖部通常含有埋入一种合适的抗氧化的合金基体如MCrALY(其中M代表Ni和Co中的一种或两种)内的磨料粒相例如CBN(立方氮化硼)、带涂层的Sic(碳化硅)或其他的硬陶瓷相。
在现有技术中已有各种对底金属涂敷磨料层的方法。美国专利No．4249913公开了一种在通过扩散焊、液相焊或钎焊与涡轮叶片尖部连接的合金中弥散分布的涂覆氧化铝的碳化硅磨料粒。美国专利No．4610698公开了一种综合采用烧结、等离子弧喷涂、热等静压和化学蚀刻工艺形成的磨料表面。美国专利No．4227703公开了一种工艺，该工艺是先将一种不连续的成形合金连接在叶尖上，然后在该合金上夹带磨料颗粒，再通过电沉积法涂敷一层含Cr、Co和Ni的基体。
最近，美国专利No．5076897公开了一种方法，其特征在于，先通过电沉积法涂敷一层MCrALY连接层，再通过复合电沉积法将磨料颗粒固定在连接层上，然后在磨料颗粒周围电镀沉积一种充填物。该方法的诱人之处是其成本低且制造简单，但是，这种带磨料的叶尖的问题在于机械强度低，这主要是由于电镀的基体以及该基体与叶片本体合金的界面比较薄弱之故。
因此，本发明的目的是提供一种涂敷耐久的磨料层的低成本的方法，该方法可使底金属与磨料层之间具有高的连接强度。
本说明书的附图如下：
附图简述
图1示出固定在模子内的燃气涡轮叶片；
图2示出安置在夹具底座上的一组叶片；
图3示出点固磨料用的夹具及其阳极组；
图4示出填充式电镀用的夹具；
图5简单示出附着在底金属表面的磨料层在最终热处理前的组织结构；
图6简单示出磨料层最终热处理后的组织结构。
                     发明概述
简要地说，本发明提出一种在底金属表面上形成一种磨料层的工艺，该工艺包含：先用纸压等离子喷涂法在底金属的表面上涂敷一层连接层；再用电镀法将磨料粒固定到上述连接层上；然后用填充式电镀法使上述磨料粒埋入一种抗氧化的金属基体内。更具体地说，在底金属上形成磨料层的方法是：先用纸压等离子喷涂法在底金属表面上喷涂一层M1CrAlX1连接层，其中M1是Ni和Co中的一种或两种，X1是Hf和Y中的一种或两种；再用电镀法从电镀槽中含有磨料粒的电镀液将磨料粒固定到上述连接层上；然后用填充式电镀法从电镀槽中含有CrAlX2或M2CrAlX2粉末的电镀液使CrAlX2或M2CrAlX2粉末填充在磨料粒周围，其中M2是Ni和Co中的一种或两种，X2是Hf和Y中的一种或两种。本发明公开了一种改进的电镀工艺和一种改进的磨料涂覆的底金属。
                     发明详述
本发明的方法引入了几项主要的改进：(ⅰ)低压等离子喷涂(LLPS)，用于沉积一层用作本体合金与电镀的尖部基体之间的过渡层并显著提高尖部的机械强度的底层，该底层还可以在磨料完全磨损后对叶片提供最后的保护；(ⅱ)一种电镀装置，该装置具有一套可在电镀时使粉末以均匀的状态有效地悬浮在每个叶片周围的独立的电镀格栅；(ⅲ)借助于化学表面活性剂悬浮在电镀槽内的高浓度的金属粉末；(ⅳ)叶片仅仅部分地浸入少量的电镀液中，从而避免了不希望有的有关溶液进入叶片内通道的问题；(ⅴ)高频换向-脉冲电镀，此法可以在比现有技术高得多的速度下稠密而均匀地填充高体积百分数的粉末。
本发明提出一种改进的通过LPPS法和填充式电镀法(entrapment plating)在燃气涡轮叶片上涂敷磨料尖部的方法。一般说来。由本发明的方法形成的叶尖含有一层厚度为0．002-0．003英寸的抗氧化的McrAlHf或MCrAlY的LPPS底层，和一层厚度为0．006英寸的含有埋入完全致密的NiCrAlHf或NiCoCrAlHf抗氧化金属基体内的CBN磨料粒的磨料层。上述叶尖的机械强度与现有技术喷涂的磨料叶尖(见U．S．P 4610698)的机械强度相当，但是制造较为简单且成本较低，而且比现有技术制成的沉积电镀叶尖(见U．S．P 5076897)的强度高得多。
首先用LPPS法在底金属表面例如涡轮叶片的叶尖上喷涂一层连接层。这就形成了一层基本上没有氧化物或污染物的致密而均匀的涂层。喷涂之后通过扩散热处理提高涂层对底金属表面的附着力。一种适合于在底金属表面与连接层之间以及在连接层与叶尖镀上的磨料部分之间形成强的附着力，同时又可保护底金属表面使之抗磨损、抗氧化和抗腐蚀的连接层是M1CrAlX1连接层，其中M1是N1和Co中的一种或两种，X1是Hf和Y中的一种或两种。一种典型的连接层是NiCoCrAlY层，其成分是(wt)：32％Ni，21％Cr，8％Al，0．5％Y，余Co。
为了采用LPPS法涂敷连接层，首先对底金属表面进行LPPS沉积前的准备，例如用机械方法清理叶尖表面。通常用氧化铝磨粒吹砂来清理底金属表面。然后，在低压室内采用氩-氦等离子弧喷涂法涂上一层例如325目(按U．S筛网系列)的粉末。在喷涂过程中，喷涂室的压力保持在40托左右。叶片底金属置于等离子弧的对面，使要喷涂的叶尖横截面垂直于熔融粒子射出的方向。对叶片的***加以合适的防护，以使杂乱的喷射粒子不会沉积在叶片的侧面。将叶尖预热到例如约1300°F，然后喷涂连接层，其厚度要能有效地起到连接层的作用，并可保护底金属表面。对于M1CrAlX1连接层来说，其典型的厚度厚达0．010英寸左右，最好约为0．002-0．003英寸。
LPPS之后，对喷涂的连接涂层进行喷丸处理和热处理，以使连接层与底金属之间进行互扩散，并去除涂层中的任何孔隙，同时，清除零散的粉粒，降低表面粗糙度，并释放涂层中的残余应力。NiCoCrAlY连接层的热处理通常是在真空或非氧化气氛下加热到1975°F保温2-4h。
然后对连接层进行电镀前的准备。通过例如吹砂(氧化铝)的方法去除表面氧化物，然后用例如碱性清洗剂进行清洗以去除有机物残渣，再在酸液槽中对表面进行腐蚀。然后进入含Ni或Co的触击电镀槽液中以形成适于电镀的高活性的金属表面层，例如，通过两分钟的氨基磺酸镍的触击电镀，以便形成0．0001英寸厚的镍层而使清理过的表面激活。在进行清理和随后的电镀操作时，对叶片加以屏蔽。最好是，如图1所示，将叶片1安置在通常是橡胶或塑料制的模子2内，该模子2包住叶片1仅让要涂层的叶尖3露出来，这种模子2与图2所示的夹具底座4做成整体。它有助于保护不需要电镀和清理的区域，使之不受电镀和清理，并有助于使叶片固紧在夹具底座4中。
准备好连接层的表面后，采用点固式电镀法将磨料粒固定在连接层上。这是通过在盛装含有磨料粒的电镀溶液的电镀槽中进行电镀而实现的。上述磨料粒最好与叶夹直接而稳定地接触，然后用电镀法在磨粒周围包上一薄层的Ni或Co。磨料粒一般是坚硬的陶瓷颗粒，而且可以是例如带有或不带有金属包覆层的CBN或SiC。用于燃气涡轮叶片尖部的磨料粒的最佳颗粒尺寸通常约为4-7密耳。例如使用一层从含Ni量约80g／l的氨基磺酸镍电镀液中沉积出的0．0004英寸厚的镍层可以固定80-100目的不带包覆层的CBN颗粒。
通过在如图2所示夹具底座4的上部安置一个如图3所示的点因磨料的夹具5来进行磨料的点固电镀。将点固磨料的夹具5的锥形槽6套在涡轮叶片叶尖3周围，起到导引磨料进入延伸至叶尖3的集料口中，并在点固电镀时保持磨料粒与叶尖直接接触的作用。阳极盖板7与点固磨料的夹具5相连接，并置于叶尖3的上方，这样，在点固磨料的电镀过程中，在每个叶尖3上方的每个锥形槽6内便有一个阳极8。为了在叶尖上固定磨料粒，在组装好的点固磨料的夹具中注入电镀液，并将磨料粒导入所有的锥形槽6内。然后接通电镀电流，使点固夹具5在高频低振幅下振动数秒钟，以使磨料粒均匀分布在叶尖表面。通常需要有约0．0003-0．0005英寸厚的电镀层以使磨料粒点固到连接层上。
点固电镀之后，采用填充式电镀法从电镀槽中含有金属粉末的镍或钴的电镀液电镀一层金属合金粉末充填磨料粒之间而使上述磨料粒埋入金属基体中。上述的金属合金粉末最好是CrAlX2或M2CrAlX2粉末，其中，M2是Ni和Co中的一种，X2是Hf和Y中的一种。细的CrAlX2或M2CrAlX2粉末尺寸最好为10μm或更细，电镀液的浓度最好为500-2000克／升。例如，在一种氨基磺酸镍溶液中填充电镀CoCrAlHf粉末(99％是小于10μm的)。最好用一种表面活化剂使粉末弥散在电镀液中，以便使电镀液具有高浓度的粉末而不积集或者说沉淀。
填充电镀金属合金的粉末最好在一组独立的电镀栅格内进行，通过将图4所示的填充电镀用的夹具9安置在图2所示的夹具底座4的上部而使叶片固定在每个格子内。上述电镀栅格可含有任意数目的格子，对于航空涡轮叶片来说。通常是每组栅格具有20-40个格子。图2示出的是一组有25个叶片。在夹具底座4中的每个叶片的尖部3配入图4所示的填充电镀栅格夹具9的相应的电镀格子10内。各个阳极11固定在接近每个格子11之顶部的塑料垫板上，在格子10注入电镀液时，阳极11完全浸入电镀液中。每个格子顶部的通气孔可以排出注液时积集的空气。夹具底座4与电镀夹具9组装好之后，每个叶片尖部3就封闭在各自独立的格子内。在电镀时，含有粉末的电镀液在每个独立的封闭的电镀格子之底部通过位于夹具底座4上的入口12和出口13形成的封闭回路中重复循环。通过机电振动器使上述的夹具以30-35Hz的频率振动。振动的频率控制着粉末颗粒与叶尖表面保持接触的时间长短，并控制涂层中被沉积的粉末的百分数，振动还有助于使镀上的粉末颗粒均匀分布。另外，对于进行合适的电镀来说电镀的电流密度和波形是重要的。波形最好含有短时的高振幅换向脉冲，它有助于去除松散地附着的粉粒，防止界面层上贫镍或贫钴，改善涂层均匀性，并增大溶液的推动力。上述的换向电流脉冲通常是每秒至少重复一次，最好是每0．1秒重复一次成系列的换向电流脉冲。
电镀之后，对涂层过的叶片进行热处理，以使CrAlX2或M2CrAlX2粉末的成分扩散进入电镀金属基体中，为磨料粒形成一种致密而均匀的基体。典型的热处理是在约1975°F保温4h。涂覆磨料的叶尖的其他处理包括施加涂层例如扩散铝化物涂层，以进一步提高涂覆磨料的叶尖的抗氧化性。
图5示出按本发明方法制成的在最终热处理前的涂覆磨料的表面层的示意图。在底金属表面14上有一层LPPS的连接层15，该连接层15上有一层镍层16和附着在该镍层16上的磨料粒17，所有的磨料粒17均包围在充填物(即CrAlX2或M2CrAlX2)18中。在热处理后，如图6所示，CrAlX2或M2CrAlX2粉末充填物和镀镍层变成一种包围着磨料粒17的均匀的相19。
本发明方法中使用LPPS连接层的主要优点是它所提供的机械强度和整体性。LPPS连接层用作电镀的基体与涡轮叶片底金属之间的一个过渡区，起到一种顺从的夹层的作用，承受与电镀沉积有关的应力和尺寸变化、更重要的是承受与发动机工作有关的变化。这种连接层还具有微观粗糙表面，这就使连接层与电镀的基体之间有更大的界面。增大表面积和所增强的互扩散使涂覆磨料的叶尖具有更高的连接强度。另外，连接层具有与填充基体的成分较接近的相容性。这种涂层也提高抗氧化性和抗热腐蚀性。连接层还对叶尖提供环境保护，因为当叶尖的磨料部分磨损和退化时，它仍然与叶尖连在一起。本发明的工艺和涂层还具有成分上的灵活性。连接层的成分可以很容易调整，以便长时间地使本体材料的适应性、蠕度强度、抗氧化和／或抗热腐蚀性能最佳化。连接层内还可以掺加入那些可通过互扩散而提高沉积的基体的环境抗力的元素如Hf、Y、Pt、Al。
实例Ⅰ
将燃气涡轮叶片的叶尖进行加工，以准备进行LPPS沉积。采用低压等离子喷涂法沉积一层0．0025英寸厚的NiCoCrALY层。LPPS喷涂后，对沉积物进行喷丸处理，并在1975°F扩散处理两小时。
然后将LPPS喷涂的叶尖磨光，并对叶片进行屏蔽，然后将叶片置入电镀夹具底座的模子内。组装好夹具后，对叶尖进行电镀前的清理(碱液和酸液处理)。再通过两分钟的氨基磺酸镍电镀液的触击电镀(温度90°F，电流密度50安／英尺2)使清理过的表面活化。
触击电镀之后，将点固磨料的夹具安装在电镀夹具底座上，并注入氨基磺酸镍电镀液。将80／100目的CBN磨料引入每个叶片上方的锥形槽内，并使阳极配置盖板固定在点固磨料的夹具上。将组装好的夹具在高频低振幅下振动一段短的时间(100Hz／10秒)，以便使CBN磨粒均匀分布在叶尖顶上。在电流密度30安／英尺2条件下进行CBN磨料点固电镀15分钟，形成一层0．0004英寸厚的镍粘结层。将上述的组装好的夹具倒置，并通过一个过滤器排出电镀液，回收多余的CBN磨料。喷水冲洗叶片去除松散地粘附着的CBN磨料。
卸下点固磨料用的夹具，并将填充电镀用的夹具安装在夹具底座上，使电镀格子置于每个叶尖的顶上。将组装好的夹具置于振动架上，并在33Hz频率下开始振动，接通脉冲整流器，并通过泵将电镀槽从贮存／溢流箱引入电镀格栅中，上述的电镀槽盛装着添加有0．67％(Vol．)表面活化剂和500g／l的超细CrAlHf或CoCrAlHf粉末(100％-15μm，99％-10μm)的氨基磺酸镍电镀液。该电镀液通过底部入口孔进入电镀栅格中。为了完全去除任何吸附的空气，使填充电镀液通过通气孔和贮液箱重复循环几分钟，而底部出口孔保持关闭，或仅部分打开。然后打开格栅底部的出口孔并关闭空气导流孔，在随后的工序中，电镀液在封闭回路中重复循环，其流动速度是保持整个***之最小速度30cm／s所需的速度。重复循环电镀液的总体积取决于所镀叶片的数目和尺寸，通常是每20-40片叶片为1-2加仑。电镀液的温度保持在120°F。填充电镀在30安／英尺2当量直流的电流密度的电流控制条件下进行210分钟，所用的脉冲循环是：在47安／英寸2条件下向前电流80ms(兆秒)，然后是5次的1ms／140安／英尺2反脉冲，再3ms设有电流。采用此方法沉积的粉末百分数是填充电镀层体积的40％。
将叶片从夹具中取下，并去除屏蔽，然后置于真空炉内在1975°F扩散处理4h。本工艺过程结束时，CrAlHf或CoCrAlHf粉末颗粒完全溶解在镍的基体中，从而形成一种在100％致密的NiCrAlHf或NiCoCrAlHf合金中埋入CBN颗粒的金属基复合材料。
实例Ⅱ
将按照实例Ⅰ所说明的本发明工艺制备的涂覆磨料的叶尖进行拉伸强度试验，并与按美国专利5076897制备的带有磨料层的叶尖进行对比，后者是通过电沉积法涂敷一层MCrAlY连接层，然后电沉积磨料粒，再用MCrAlY填充在磨料粒周围，最后进行扩散处理。
拉伸强度试验设备是Instron 60 Kpf拉伸试验机。按实例Ⅰ的方法制备的叶尖和按美国专利5076897的方法制备的叶尖用环氧树脂粘到或者钎焊(Au-Ni)到1英寸直径的钢拉力棒上。试验在室温下进行，恒定应变速率为0．05英寸／分钟。
拉伸试验结果：按美国专利No．5076897的方法制备的叶尖的强度为4．7千磅／英寸2，其断裂部分附着在填充电镀的基体内，并粘结有叶尖本体合金与电镀的基体之间的界面的分层。按本实例Ⅰ的方法制备的叶尖的强度为27千磅／英寸2，其断裂部位粘着LPPS层与填充电镀的基体之间的界面的分层。

Claims (27)

1．一种在底金属表面上制成磨料层的工艺方法，包含如下步骤：
采用低压等离子喷涂法在底金属表面涂敷一层连接层；
通过填充式电镀将上述连接层上的磨料颗粒固定到金属基体内。
2．根据权利要求1的工艺方法，其特征在于，采用低压等离子喷涂法涂敷一种M1CrAlX1连接层，其中，M1代表Ni和Co中的一种或两种，X1是Y和Hf中的一种或两种。
通过点固电镀法将磨料颗粒固定到连接层上；
从电镀槽中含有CrAlX2或M2CrAlX2颗粒的电镀液槽中将CrA1X2或M2CrAlX2填充粉末电镀到上述磨料颗粒周围，其中M2是Ni和Co中的一种或两种，X2是Y和Hf中的一种或两种。
3．根据权利要求2的工艺方法，其特征在于，上述的电镀是用含有Ni和Co中的一种或两种的电镀液实施的。
4．根据权利要求3的工艺方法，其特征在于，还包含对被电镀的填充底金属进行热处理，以便使CrAlX2或M2CrAlX2粉末跟Ni或Co电镀金属扩散。
5．根据权利要求3的工艺方法，其特征在于，用一种含有Ni和Co中的一种或两种的触击电镀清理上述连接层的表面，并使该表面活化以供电镀。
6．根据权利要求2的工艺方法，其特征在于，上述的底金属是镍基或钴基高温合金。
7．根据权利要求6的工艺方法，其特征在于，上述的底金属表面是燃气涡轮叶片的叶尖。
8．根据权利要求7的工艺方法，其特征在于，上述的电镀在一组独立的电镀栅格内进行，每个格子内固定一个叶片。
9．根据权利要求8的工艺方法，其特征在于，上述的CrAlX2或M2CrAlX2粉末扩散分布在电镀槽内含有表面活化剂的电镀液内。
10．根据权利要求9的工艺方法，其特征在于，在进行电镀时，只有燃气涡轮叶片的叶尖浸渍在电镀液内。
11．根据权利要求10的工艺方法，其特征在于，上述的电镀是在换向脉冲电流下进行。
12．根据权利要求7的工艺方法，其特征在于，上述的磨料颗粒是一种CBN(立方氮化硼)磨粒。
13．根据权利要求10的工艺方法，其特征在于，上述的叶片安置在一个模子内，只露出叶尖进行电镀。
14．根据权利要求9的工艺方法，其特征在于，上述的CrAlX2或M2CrAlX2粉末的颗粒尺寸为10μm或更小，在电镀液中的粉末浓度约为500-2000g／l。
15．按权利要求1、2、4、7或12中任一项的工艺方法制成的产品。
16．一种涂覆磨料的底金属，含有：
一种Ni或Co基高温合金底金属；
一层低压等离子喷涂的连接层；和
一层填充电镀在金属基体内的磨料粒。
17．根据权利要求16的底金属，其特征在于，上述的连接层是M1CrAlX1，其中M1是Ni和Co中的一种或两种，X1是Y和Hf中的一种或两种。
18．根据权利要求17的底金属，其特征在于上述的金属基体是M2CrAlX2，其中，M2是Ni和Co中的一种或两种，X2是Y和Hf中的一种或两种。
19．根据权利要求18的底金属，其特征在于，上述的磨料颗粒是CBN磨料颗粒。
20．根据权利要求18的底金属，其特征在于，上述的磨料涂覆底金属要经热处理，以使金属基体扩散。
21．一种填充电镀底金属表面使磨料颗粒固定到金属基体内的工艺方法，包含：
在一组独立的电镀栅格内用含有磨料颗粒的电镀液电镀底金属表面，在上述的每一个独立的格子内置入一个底金属表面。
22．根据权利要求21的工艺方法，其特征在于，上述的每个独立的格子具有供电镀液循环流动的入口和出口。
23．根据权利要求22的工艺方法，其特征在于，上述的电镀在换向脉冲电流下进行。
24．根据权利要求23的工艺方法，其特征在于，上述的电镀液含有表面活化剂，以使磨粒扩散分布。
25．根据权利要求24的工艺方法，其特征在于，在电镀过程中使上述底金属振动。
26．根据权利要求25的工艺方法，其特征在于，上述的底金属表面是燃气涡轮叶片的叶尖。
27．根据权利要求26的工艺方法，其特征在于，上述的颗粒是CrAlX2或M2CrAlX2粉末，其中M2是Ni和Co中的一种或两种，X2是Y和Hf中的一种或两种，而且电镀液含有Co和Ni中的一种或两种。
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