EP0906964B1 - Thermal barrier coating and process for its manufacture - Google Patents

Thermal barrier coating and process for its manufacture Download PDF

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Publication number
EP0906964B1
EP0906964B1 EP98118456A EP98118456A EP0906964B1 EP 0906964 B1 EP0906964 B1 EP 0906964B1 EP 98118456 A EP98118456 A EP 98118456A EP 98118456 A EP98118456 A EP 98118456A EP 0906964 B1 EP0906964 B1 EP 0906964B1
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EP
European Patent Office
Prior art keywords
thermal barrier
barrier coating
ceramic
particles
thermal
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.)
Expired - Lifetime
Application number
EP98118456A
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German (de)
French (fr)
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EP0906964A3 (en
EP0906964A2 (en
Inventor
Joachim Dr. Bamberg
Peter Dr. Adam
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.)
MTU Aero Engines AG
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MTU Aero Engines GmbH
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Publication date
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Publication of EP0906964A2 publication Critical patent/EP0906964A2/en
Publication of EP0906964A3 publication Critical patent/EP0906964A3/en
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Publication of EP0906964B1 publication Critical patent/EP0906964B1/en
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Expired - Lifetime legal-status Critical Current

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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
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • 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
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/18—After-treatment

Definitions

  • the invention relates to a thermal barrier coating, which is applied by thermal spraying on a metallic component, is ceramic and has a porous structure, and a method for their preparation.
  • thermal barrier coatings In engine and turbine construction, highly stressed metallic components are provided with ceramic thermal barrier coatings to protect against high temperatures.
  • the thermal barrier coatings can be most inexpensively and effectively achieved by thermal spray techniques, e.g. Plasma spraying, apply to the metallic components.
  • the ceramic thermal barrier coatings thus produced have a porous microcracked structure which has a lower modulus of elasticity. As a result, the thermal barrier coating can withstand the damage occurring in operation due to thermo-mechanical stress on an unbounded scale.
  • the thermal barrier coatings in the high temperature range > 900 ° C
  • the ceramic changes. There are sintering effects that result in an increasing modulus of elasticity.
  • the heat-insulating layer is therefore less strain-tolerant, so that the thermomechanical loads lead to so-called segmentation cracks, through which the thermal barrier coating segments into individual clods.
  • a method for the surface treatment of components by means of shot peening is known in which first a metallic MCrAlY layer as an oxidation and hot gas corrosion layer on the component surface and then the layer is shot peened to achieve a smoothing of the rough layer surface and to densify the layer.
  • a metallic layer is homogeneous and fundamentally different from a ceramic thermal barrier coating having grains and grain boundaries.
  • the US 5,277,936 discloses a method for coating a Ni or Co based alloy component by applying a metal powder and oxides to form a metallic oxidation protection and adhesive layer for a thermal barrier coating by plasma spraying.
  • the oxidation protection and adhesive layer is blasted for densification.
  • the ceramic thermal barrier coating should not be blasted.
  • EP 0 455 996 A1 discloses a method for producing a cermet layer in which drop-shaped metal and ceramic particles are sprayed together onto a metallic substrate in such a way that the surface is rough but has no cracks.
  • Out JP 62 274062 A is a thermally sprayed layer is known in which after the application microcracks are generated on the surface by means of a laser treatment.
  • the invention has the object to improve a thermal barrier coating of the type described above so that it is thermomechanically stable as possible even in the high temperature range. Furthermore, a method be created to produce a thermomechanically stable as possible thermal barrier coating.
  • the solution of the problem relating to the method according to the invention is characterized in that the heat-insulating layer is blasted with particles during and / or after the application process (thermal spraying) in such a way that near-surface cracks occur. ;
  • the thermal barrier coating is blasted with spherical particles, which may preferably consist of metal, ceramic or glass.
  • the solution relating to the Wäremdämm Anlagen is inventively characterized in that the heat-insulating layer formed by blasting with particles, near-surface cracks.
  • the advantage is that the occurrence of unfavorable clod sizes is avoided by the thermal barrier coating is defined by the blasting with particles predamaged. Due to the high kinetic energy of the particles, numerous small shallow cracks in the thermal barrier coating occur on impact. In addition, so-called. Micro contact surfaces, which accelerate the sintering process, broken. In this way, both the sintering effects are reduced in thermomechanical stress, and the formation of subcritical, small clods in the segmentation due to the many crack starters promoted.
  • thermal barrier coatings so as not to damage the ceramic.
  • the latter applies to vapor-deposited thermal barrier coatings.
  • the surprising effect according to the present invention occurs in particular in heat-insulating layers produced by thermal spraying, which have numerous microcracks. As a result of the blasting according to the invention, such a layer is not compacted but loosened overall in order to avoid the sintering problem.
  • thermal barrier coating is applied to a metallic engine component.
  • a thermally highly stressed, metallic engine component such as a turbine blade
  • the thermal barrier coating is applied by plasma spraying onto the metallic component and has a porous structure, which is traversed by microcracks.
  • the ceramic thermal barrier coating during or immediately after the manufacturing process by means of plasma spraying, ie the application of the ceramic thermal barrier coating to the metallic component, predamaged by metal shot blasting. Due to the high kinetic energy of the metal balls, many small shallow cracks occur when they impact the thermal barrier coating. The layer is loosened overall. In addition, so-called. Micro contact surfaces, which accelerate the sintering process, broken. The blasting may begin during the application of the thermal barrier coating and then continue or even begin immediately after application.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)

Description

Die Erfindung betrifft eine Wärmedämmschicht, die durch thermisches Spritzen auf eine metallische Komponente aufgebracht ist, keramisch ist und eine poröse Struktur aufweist, sowie ein Verfahren zu Ihrer Herstellung.The invention relates to a thermal barrier coating, which is applied by thermal spraying on a metallic component, is ceramic and has a porous structure, and a method for their preparation.

Im Motoren- und Turbinenbau werden hochbelastete metallische Komponenten zum Schutz vor hohen Temperaturen mit keramischen Wärmedämmschichten versehen. Die Wärmedämmschichten lassen sich am kostengünstigsten und effektivsten durch thermische Spritzverfahren, wie z.B. Plasmaspritzen, auf die metallischen Komponenten aufbringen. Die so hergestellten keramischen Wärmedämmschichten besitzen eine poröse, von Mikrorissen durchzogene Struktur, die einen niedrigeren Elastizitätsmodul aufweist. Infolgedessen kann die Wärmedämmschicht die im Betrieb infolge thermomechanischer Belastung stets auftretenden Verformungen in bergrenztem Umfang schadlos aushalten. Beim Einsatz der Wärmedämmschichten im Hochtemperaturbereich (> 900 °C) verändert sich jedoch die Keramik. Es treten Sintereffekte auf, die ein ansteigendes Elastizitätsmodul zur Folge haben. Die Wärmedämmschicht ist mithin weniger dehnungstolerant, so daß die thermomechanischen Belastungen zu sog. Segmentierungsrissen führen, durch welche die Wärmedämmschicht zu einzelnen Schollen segmentiert.In engine and turbine construction, highly stressed metallic components are provided with ceramic thermal barrier coatings to protect against high temperatures. The thermal barrier coatings can be most inexpensively and effectively achieved by thermal spray techniques, e.g. Plasma spraying, apply to the metallic components. The ceramic thermal barrier coatings thus produced have a porous microcracked structure which has a lower modulus of elasticity. As a result, the thermal barrier coating can withstand the damage occurring in operation due to thermo-mechanical stress on an unbounded scale. When using the thermal barrier coatings in the high temperature range (> 900 ° C), however, the ceramic changes. There are sintering effects that result in an increasing modulus of elasticity. The heat-insulating layer is therefore less strain-tolerant, so that the thermomechanical loads lead to so-called segmentation cracks, through which the thermal barrier coating segments into individual clods.

Simulationsrechnungen und Versuche haben gezeigt, daß bei den so segmentierten, keramischen Wärmedämmschichten bei weiterer thermomechanischer Belastung ein Rißfortschritt an der Grenzfläche zur metallischen Komponente (Metallsubstrat) auftritt. Dieser Rißfortschritt führt zum Abplatzen und damit zum völligen Versagen der Wärmedämmschicht.Simulation calculations and experiments have shown that in the case of the segmented, ceramic thermal barrier coatings, further cracking occurs at the interface with the metallic component (metal substrate) during further thermomechanical loading. This crack progress leads to flaking and thus to the complete failure of the thermal barrier coating.

Aus der DE 40 41 103 A1 ist ein Verfahren zur Oberflächenbehandlung von Bauteilen mittels Kugelstrahlen bekannt, bei dem zunächst eine metallische MCrAlY-Schicht als Oxidations- und Heißgaskorrosionsschicht auf die Bauteiloberfläche aufgebracht und anschließend die Schicht kugelgestrahlt wird, um eine Glättung der rauhen Schichtoberfläche zu erzielen und die Schicht zu verdichten. Eine solche metallische Schicht ist homogen und unterscheidet sich grundlegend von einer keramischen Wärmedämmschicht, die Körner und Korngrenzen aufweist.From the DE 40 41 103 A1 a method for the surface treatment of components by means of shot peening is known in which first a metallic MCrAlY layer as an oxidation and hot gas corrosion layer on the component surface and then the layer is shot peened to achieve a smoothing of the rough layer surface and to densify the layer. Such a metallic layer is homogeneous and fundamentally different from a ceramic thermal barrier coating having grains and grain boundaries.

Die US 5,277,936 offenbart ein Verfahren zum Beschichten eines Bauteils aus einer Ni- oder Co-Basislegierung, bei dem ein Metallpulver und Oxide zur Herstellung einer metallischen Oxidationsschutz- und Haftschicht für eine Wärmedämmschicht durch Plasmaspritzen aufgebracht werden. Die Oxidationsschutz- und Haftschicht wird zur Verdichtung gestrahlt. Dabei soll die keramische Wärmedämmschicht gerade nicht gestrahlt werden.The US 5,277,936 discloses a method for coating a Ni or Co based alloy component by applying a metal powder and oxides to form a metallic oxidation protection and adhesive layer for a thermal barrier coating by plasma spraying. The oxidation protection and adhesive layer is blasted for densification. At the same time, the ceramic thermal barrier coating should not be blasted.

EP 0 455 996 A1 offenbart ein Verfahren zur Herstellung einer Cermet-Schicht, bei dem tropfenförmige Metall- und Keramikpartikel derart zusammen auf ein metallisches Substrat gespritzt werden, dass die Oberfläche zwar rauh ist, jedoch keine Risse aufweist. EP 0 455 996 A1 discloses a method for producing a cermet layer in which drop-shaped metal and ceramic particles are sprayed together onto a metallic substrate in such a way that the surface is rough but has no cracks.

Aus JP 62 274062 A ist eine thermisch gespritzte Schicht bekannt, bei der nach dem Aufbringvorgang Mikrorisse an der Oberfläche mittels einer Laser behandlung erzeugt werden.Out JP 62 274062 A is a thermally sprayed layer is known in which after the application microcracks are generated on the surface by means of a laser treatment.

Beim Verfahren zur Herstellung einer porösen keramischen Wärmedämmschicht nach EP 0 897 019 A1 werden beim thermischen Spritzen kugelförmige Polymerpartikel gleichzeitig mit dem Schichtmaterial aufgebracht. Eine anschließende Herauslösung der Polymerpartikel führt dann zur Erzeugung der gewünschten Porosität.In the process for producing a porous ceramic thermal barrier coating according to EP 0 897 019 A1 During thermal spraying, spherical polymer particles are applied simultaneously with the layer material. Subsequent dissolution of the polymer particles then leads to the generation of the desired porosity.

Der Erfindung liegt die Aufgabe zugrunde, eine Wärmedämmschicht der eingangs beschriebenen Gattung so zu verbessern, daß sie auch im Hochtemperaturbereich thermomechanisch möglichst beständig ist. Ferner soll ein Verfahren zur Herstellung einer thermomechanisch möglichst beständigen Wärmedämmschicht geschaffen werden.The invention has the object to improve a thermal barrier coating of the type described above so that it is thermomechanically stable as possible even in the high temperature range. Furthermore, a method be created to produce a thermomechanically stable as possible thermal barrier coating.

Die das Verfahren betreffende Lösung der Aufgabe ist erfindungsgemäß dadurch gekennzeichnet, daß die Wärmedämmschicht während und/oder nach dem Aufbringvorgang (thermisches Spritzen) derart mit Partikeln gestrahlt wird, dass oberflächennahe Risse entstehen. ;The solution of the problem relating to the method according to the invention is characterized in that the heat-insulating layer is blasted with particles during and / or after the application process (thermal spraying) in such a way that near-surface cracks occur. ;

In einer bevorzugten Ausgestaltung wird die Wärmedämmschicht mit kugelförmigen Partikeln gestrahlt, die bevorzugt aus Metall, Keramik oder Glas bestehen können.In a preferred embodiment, the thermal barrier coating is blasted with spherical particles, which may preferably consist of metal, ceramic or glass.

Die die Wäremdämmschicht betreffende Lösung ist erfindungsgemäß dadurch gekennzeichnet, daß die Wärmedämmschicht durch Strahlen mit Partikeln gebildete, oberflächennahe Risse aufweist.The solution relating to the Wäremdämmschicht is inventively characterized in that the heat-insulating layer formed by blasting with particles, near-surface cracks.

Der Vorteil besteht darin, daß das Auftreten ungünstiger Schollengrößen vermieden wird, indem die Wärmedämmschicht durch das Strahlen mit Partikeln definiert vorgeschädigt wird. Durch die hohe kinetische Energie der Partikel entstehen beim Aufprall zahlreiche kleine oberflächennahe Risse in der Wärmedämmschicht. Darüberhinaus werden sog. Mikrokontaktflächen, die den Sinterprozeß beschleunigen, aufgebrochen. Auf diese Weise werden bei thermomechanischer Belastung sowohl die Sintereffekte reduziert, als auch die Bildung unterkritischer, kleiner Schollen bei der Segmentierung infolge der vielen Rißstarter gefördert.The advantage is that the occurrence of unfavorable clod sizes is avoided by the thermal barrier coating is defined by the blasting with particles predamaged. Due to the high kinetic energy of the particles, numerous small shallow cracks in the thermal barrier coating occur on impact. In addition, so-called. Micro contact surfaces, which accelerate the sintering process, broken. In this way, both the sintering effects are reduced in thermomechanical stress, and the formation of subcritical, small clods in the segmentation due to the many crack starters promoted.

Anders als bei den metallischen Schichten, die durch Strahlen verdichtet werden, wurde das Strahlen bei Wärmedämmschichten stets vermieden, um die Keramik nicht zu beschädigen. Letzteres gilt für durch Aufdampfen hergestellter Wärmedämmschichten weiter. Der überraschende Effekt gemäß der vorliegenden Erfindung tritt insbesondere bei durch thermisches Spritzen hergestellten Wärmedämmschichten auf, welche zahlreiche Mikrorisse aufweisen. Durch das erfindungsgemäße Strahlen wird eine solche Schicht nicht verdichtet, sondern zur Vermeidung der Sinterproblematik insgesamt aufgelockert.Unlike the metallic layers, which are compacted by blasting, blasting has always been avoided in thermal barrier coatings so as not to damage the ceramic. The latter applies to vapor-deposited thermal barrier coatings. The surprising effect according to the present invention occurs in particular in heat-insulating layers produced by thermal spraying, which have numerous microcracks. As a result of the blasting according to the invention, such a layer is not compacted but loosened overall in order to avoid the sintering problem.

Im folgenden wird die Erfindung anhand eines Ausführungsbeispiels näher erläutert, bei dem die Wärmedämmschicht auf eine metallische Triebwerkskomponente aufgebracht wird.In the following the invention will be explained in more detail with reference to an embodiment in which the thermal barrier coating is applied to a metallic engine component.

Eine thermisch hochbelastete, metallische Triebwerkskomponente, wie eine Turbinenschaufel, wird mit einer keramischen Wärmedämmschicht versehen. Die Wärmedämmschicht wird durch Plasmaspritzen auf die metallische Komponente aufgebracht und weist eine poröse, von Mikrorissen durchzogene Struktur auf. Um das Auftreten ungünstiger Schollengrößen bei Sintereffekten während des Betriebs im Hochtemperaturbereich zu vermeiden, wird die keramische Wärmedämmschicht während oder unmittelbar nach dem Herstellprozeß mittels Plasmaspritzen, d.h. dem Aufbringen der keramischen Wärmedämmschicht auf die metallische Komponente, durch Metallkugelstrahlen definiert vorgeschädigt. Durch die hohe kinetische Energie der Metallkugeln entstehen beim Aufprall auf die Wärmedämmschicht viele kleine oberflächennahe Risse. Die Schicht wird insgesamt aufgelockert. Außerdem werden sog. Mikrokontaktflächen, die den Sinterprozeß beschleunigen, aufgebrochen. Das Strahlen kann während des Aufbringens der Wärmedämmschicht beginnen und sich danach fortsetzen oder auch erst unmittelbar nach dem Aufbringen beginnen.A thermally highly stressed, metallic engine component, such as a turbine blade, is provided with a ceramic thermal barrier coating. The thermal barrier coating is applied by plasma spraying onto the metallic component and has a porous structure, which is traversed by microcracks. In order to avoid the occurrence of unfavorable clod sizes in sintering effects during operation in the high temperature range, the ceramic thermal barrier coating during or immediately after the manufacturing process by means of plasma spraying, ie the application of the ceramic thermal barrier coating to the metallic component, predamaged by metal shot blasting. Due to the high kinetic energy of the metal balls, many small shallow cracks occur when they impact the thermal barrier coating. The layer is loosened overall. In addition, so-called. Micro contact surfaces, which accelerate the sintering process, broken. The blasting may begin during the application of the thermal barrier coating and then continue or even begin immediately after application.

Claims (4)

  1. Method for the production of a thermal barrier coating, wherein a ceramic thermal barrier coating is applied to a metallic component by thermal spraying, characterised in that the thermal barrier coating is, during and/or after the application process, shot-blasted with particles to produce near-surface cracks.
  2. Method according to claim 1, characterised in that the thermal barrier coating is shot-blasted with spherical particles.
  3. Method according to claim 1 or 2, characterised in that the particles are made of metal, a ceramic material or glass.
  4. Thermal barrier coating which is applied to a metallic component by thermal spraying, which is ceramic and has a porous structure, characterised in that the thermal barrier coating has near-surface cracks produced by shot-blasting with particles.
EP98118456A 1997-10-02 1998-09-30 Thermal barrier coating and process for its manufacture Expired - Lifetime EP0906964B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE19743579A DE19743579C2 (en) 1997-10-02 1997-10-02 Thermal barrier coating and process for its manufacture
DE19743579 1997-10-02

Publications (3)

Publication Number Publication Date
EP0906964A2 EP0906964A2 (en) 1999-04-07
EP0906964A3 EP0906964A3 (en) 2002-09-18
EP0906964B1 true EP0906964B1 (en) 2008-01-02

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EP98118456A Expired - Lifetime EP0906964B1 (en) 1997-10-02 1998-09-30 Thermal barrier coating and process for its manufacture

Country Status (5)

Country Link
US (1) US6214475B1 (en)
EP (1) EP0906964B1 (en)
JP (1) JP4603105B2 (en)
DE (1) DE19743579C2 (en)
ES (1) ES2297872T3 (en)

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DE102014222684A1 (en) * 2014-11-06 2016-05-12 Siemens Aktiengesellschaft Segmented thermal barrier coating made of fully stabilized zirconium oxide

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Publication number Priority date Publication date Assignee Title
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Also Published As

Publication number Publication date
EP0906964A3 (en) 2002-09-18
JP4603105B2 (en) 2010-12-22
ES2297872T3 (en) 2008-05-01
US6214475B1 (en) 2001-04-10
EP0906964A2 (en) 1999-04-07
DE19743579C2 (en) 2001-08-16
DE19743579A1 (en) 1999-04-15
JPH11158599A (en) 1999-06-15

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