EP1327703A1 - Coating system with a porous layer - Google Patents

Coating system with a porous layer Download PDF

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Publication number
EP1327703A1
EP1327703A1 EP02000874A EP02000874A EP1327703A1 EP 1327703 A1 EP1327703 A1 EP 1327703A1 EP 02000874 A EP02000874 A EP 02000874A EP 02000874 A EP02000874 A EP 02000874A EP 1327703 A1 EP1327703 A1 EP 1327703A1
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EP
European Patent Office
Prior art keywords
layer
ceramic
porous layer
substrate
porous
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Withdrawn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
EP02000874A
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German (de)
French (fr)
Inventor
Uwe Dr. Paul
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.)
Siemens AG
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Siemens AG
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Filing date
Publication date
Application filed by Siemens AG filed Critical Siemens AG
Priority to EP02000874A priority Critical patent/EP1327703A1/en
Priority to EP02787907A priority patent/EP1466036B1/en
Priority to DE50210249T priority patent/DE50210249D1/en
Priority to PCT/EP2002/013752 priority patent/WO2003060195A1/en
Priority to JP2003560272A priority patent/JP2005514526A/en
Publication of EP1327703A1 publication Critical patent/EP1327703A1/en
Priority to US10/641,996 priority patent/US7070853B2/en
Withdrawn legal-status Critical Current

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    • 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
    • C23C28/324—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 matrix material layer comprising a mixture of at least two metals or metal phases or a metal-matrix material with hard embedded particles, e.g. WC-Me
    • 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
    • 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
    • C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
    • 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
    • Y10T428/12479—Porous [e.g., foamed, spongy, cracked, etc.]
    • 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
    • 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
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24149—Honeycomb-like
    • 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
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24149—Honeycomb-like
    • Y10T428/24157—Filled honeycomb cells [e.g., solid substance in cavities, etc.]
    • 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
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • 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
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249955—Void-containing component partially impregnated with adjacent component
    • 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
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249955—Void-containing component partially impregnated with adjacent component
    • Y10T428/249956—Void-containing component is inorganic
    • Y10T428/249957—Inorganic impregnant

Definitions

  • the invention relates to a layer system with a ceramic Share in the shift.
  • Layer systems consist of a substrate and at least a layer lying on the substrate. Substrates need for example, in gas turbine construction from too high temperatures and / or corrosive attacks are protected. For example by making a sheet on the substrate is applied with a honeycomb structure, the honeycomb are filled with a ceramic. The ceramics take over essentially the protective function. The sheet of the honeycomb structure serves to mechanically stabilize the ceramic. However, the mechanical connection between the ceramics and the inner surfaces of the honeycomb structure, so that the ceramics come off again and again.
  • US Pat. No. 5,720,597 shows a blade for a gas turbine, the inside is at least partially a foam-like area having.
  • US Pat. No. 6,299,935 discloses a method of manufacture a layer in which on the surface of a substrate a suspension of foam and a metallic powder is applied becomes.
  • the object of the invention is therefore to show a layer system, that the mechanical strength between metal and Ceramics improved.
  • the object is achieved according to the invention by a layer system which consists of a substrate, followed by a porous layer with a pore content of at least 30 percent by volume, a ceramic in the form of a coating or as ceramic particles being at least partially introduced into the porous layer.
  • a layer system which consists of a substrate, followed by a porous layer with a pore content of at least 30 percent by volume, a ceramic in the form of a coating or as ceramic particles being at least partially introduced into the porous layer.
  • the ceramic that is applied to the porous layer and in this is at least partially introduced, a Mix to form different ceramic materials select the desired properties.
  • the porous layer can be ceramic at least in some areas be filled out that they are almost in these areas is tight, so that an almost dense ceramic layer in the porous layer is achieved to take advantage of ceramics regarding heat resistance.
  • another ceramic layer Protective layer such as from the thermal insulation layers of Gas turbine blades are known to be applied through another coating the ceramic in the porous layer to protect against oxidation.
  • FIG. 1a shows a substrate 1, for example made of metal, in particular of a superalloy for a gas turbine blade, on which a porous layer 4 is applied.
  • the porous layer 4 can be made of metal or ceramic.
  • the porous structure is represented schematically by the lines that are intended to represent the individual walls that surround the pores in the porous layer 4.
  • the pore fraction is at least thirty (30) percent by volume.
  • an open pore structure is advantageous, ie there are connection paths from the outer surface of the porous layer 4 to its underside, which faces the substrate 1, as is the case, for. B. is known when using filter systems.
  • a ceramic can be introduced particularly well into the porous layer.
  • Figure 1b shows a layer system according to the invention, in which A ceramic 7 is present in the porous layer 4.
  • the Ceramic 7 can be made from a single ceramic material or from a mixture of different ceramic materials exist, for example, in the form of ceramic particles. Metallic Additions or coatings are also possible.
  • Figure 2a shows a further embodiment of an inventive Layer system 20 in which no individual ceramic Particles 7 can be seen (Fig. 2a) because of the pore walls 13 of the porous layer 4 with a ceramic Layer 16 are coated (Fig. 2b). So are the inner surfaces the pores of the porous layer 4, for example, entirely with a Ceramic 16 covered.
  • Figure 3 shows a further embodiment of an invention trained layer system 20.
  • a porous layer 4 is applied, the pores of which Ceramic 7 are filled so that a dense layer is reached becomes.
  • Figure 4 shows that between substrate 1 and the porous Layer 4 has at least one additional intermediate layer 10 can be.
  • FIG. 5 shows a further application example for an inventive one Layer system 20.
  • the layer system 20 forms part of a gas turbine housing 23, for example Turbine blades 26 that surrounds one in a gas turbine Burners are connected downstream.
  • the axis of rotation of the turbine blade 26 is indicated with 29.
  • the layer system according to the invention 20 forms a seal between the gas turbine housing 23 and turbine blade 26 and replaces the one described above Honeycomb structure. Further application examples can be found for gas turbine blades and heat shield elements.
  • Figure 6a, b shows the manufacturing steps for manufacturing of a layer system 20 according to the invention.
  • the substrate 1 is carried out with an already prefabricated porous component 4 a connection technology connected to each other (Fig. 6b). This can for example by welding, diffusion welding or Diffusion soldering is done. Other joining techniques are possible.
  • Figure 7 shows a further method for producing an inventive Layer system 20.
  • a suspension 32 applied, for example, by treatment at a temperature T in a porous layer 4 converts.
  • suspension 32 contains a metal powder and an activator, which gasifies during the heat treatment and the suspension foams with the metal, then at elevated temperature the metal particles, for example, sinter together and so form the porous layer 4, while at the same time a good one Connection to the substrate 1 takes place.
  • Other manufacturing methods for the production of porous, especially foam-like Structures can be used here, e.g. the Investment casting process.
  • Figure 8 shows a further embodiment for the production of a layer system 20 according to the invention.
  • This can for example, in a casting process the material for the substrate 1 is cast first and then continuously without interruption a metal or an alloy is cast, which have a porous structure or a mixture of metal and ceramic, so that on the Substrate 1 forms a porous metallic layer 4, which may is densely filled with ceramics. From a blank 38 can a substrate 1 and form a porous layer 4.
  • the ceramic 7 In order to ultimately manufacture the layer system 20 according to the invention, it is often still necessary to insert the ceramic 7 into the porous one Layer 4 to bring.
  • This can be done by a coating device 35 (Fig. 9a), for example by plasma spraying so that a ceramic coating 16 is produced in the porous layer 4.
  • the coating process can be continued so that not only the walls 13 of the porous layer are coated, but also still the pore structure is at least partially closed in order to to achieve a dense layer.
  • a ceramic nozzle can also be sprayed through a spray nozzle 35 (FIG. 9a) Suspension with ceramic particles in the porous layer 4 introduced, in particular injected.
  • the carrier of the suspension evaporates so that the ceramic particles 7 remain and after a heat treatment with the metallic ones Connect walls 13 of the porous layer 4.
  • the porous layer 4 can also only be in an upper region 11 the pores must be completely filled with the ceramic 7 (Fig. 9b).
  • the porous layer 4 is advantageously made of a ceramic 7 padded, the good mechanical properties at high Has temperatures and serves as a thermal barrier. Around however, this ceramic and also the metallic walls of the porous Layer 4 before oxidation and / or corrosion and / or To protect heat can be applied to the porous layer 4 (Fig. 10a) or over the ceramic particles 7 or the ceramic Layer 16 within the porous layer 7 (Fig. 10b) still a further ceramic protective layer 41 can be applied.

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

Abstract

Layer system (20) comprises: a substrate (1); an outer porous layer (4) having a pore volume of at least 30 vol.% arranged on the substrate; and a ceramic (7) partially arranged in the porous layer. Preferred Features: The porous layer has an open pore structure. The ceramic is a mixture of various ceramic materials. The porous layer is partially filled with the ceramic. The porous layer is a foam-like material or a metal. The substrate is made from a cobalt/nickel super alloy.

Description

Die Erfindung betrifft ein Schichtsystem mit einem keramischen Anteil in der Schicht.The invention relates to a layer system with a ceramic Share in the shift.

Schichtsysteme bestehen aus einem Substrat und zumindest einer auf dem Substrat liegenden Schicht. Substrate müssen beispielsweise im Gasturbinenbau vor zu hohen Temperaturen und/oder korrosiven Attacken geschützt werden. Dies kann beispielsweise dadurch erfolgen, dass auf dem Substrat ein Blech mit einer Honigwabenstruktur aufgebracht ist, wobei die Waben mit einer Keramik gefüllt sind. Die Keramik übernimmt dabei im wesentlichen die Schutzfunktion. Das Blech der Honigwabenstruktur dient zur mechanischen Stabilisierung der Keramik. Jedoch ist die mechanische Verbindung zwischen der Keramik und den inneren Oberflächen der Honigwabenstruktur nicht gut, so dass es immer wieder zu Ablösungen der Keramik kommt.Layer systems consist of a substrate and at least a layer lying on the substrate. Substrates need for example, in gas turbine construction from too high temperatures and / or corrosive attacks are protected. For example by making a sheet on the substrate is applied with a honeycomb structure, the honeycomb are filled with a ceramic. The ceramics take over essentially the protective function. The sheet of the honeycomb structure serves to mechanically stabilize the ceramic. However, the mechanical connection between the ceramics and the inner surfaces of the honeycomb structure, so that the ceramics come off again and again.

Aus der US-PS 5,634,189 ist eine Vorrichtung bekannt, die im Inneren eine poröse Struktur aufweist, die durch Kügelchen verschiedenen Durchmessers gebildet ist, wobei dieses poröse Innere von einer äußeren dichten Hülle umgeben ist. Die äußere Hülle dient nicht zum Schutz. Das poröse Innere dient zum Auffüllen des Hohlraums, um eine gewisse mechanische Stabilität zu erreichen, wobei die Dichte des porösen Inneren jedoch geringer ist als die der Hülle, um dadurch Gewicht zu sparen.From US-PS 5,634,189 a device is known which in Inside has a porous structure created by beads Different diameter is formed, this being porous Interior is surrounded by an outer dense shell. The outer shell is not for protection. The porous interior serves to fill the cavity to some mechanical Achieve stability while maintaining the density of the porous interior however, is less than that of the sheath, thereby adding weight save up.

Die US-PS 5,720,597 zeigt eine Schaufel für eine Gasturbine, die im Inneren zumindest teilweise einen schaumartigen Bereich aufweist.US Pat. No. 5,720,597 shows a blade for a gas turbine, the inside is at least partially a foam-like area having.

Die US-PS 6,299,935 offenbart eine Methode zur Herstellung einer Schicht, bei dem auf die Oberfläche eines Substrats eine Suspension aus Schaum und einem metallischen Pulver aufgebracht wird.US Pat. No. 6,299,935 discloses a method of manufacture a layer in which on the surface of a substrate a suspension of foam and a metallic powder is applied becomes.

Alle bekannten Vorrichtungen oder Verfahren haben jedoch den Nachteil, dass die mechanische Verbindung zwischen Metall und Keramik nicht ausreichend ist.However, all known devices or methods have the Disadvantage that the mechanical connection between metal and Ceramic is not sufficient.

Aufgabe der Erfindung ist es daher, ein Schichtsystem aufzuzeigen, das die mechanische Festigkeit zwischen Metall und Keramik verbessert.The object of the invention is therefore to show a layer system, that the mechanical strength between metal and Ceramics improved.

Die Aufgabe wird erfindungsgemäß durch ein Schichtsystem gelöst, das aus einem Substrat besteht, auf dem eine poröse Schicht mit einem Porenanteil von mindestens 30 Volumenprozent folgt, wobei eine Keramik in Form einer Beschichtung oder als keramische Teilchen zumindest teilweise in die poröse Schicht eingebracht ist.
Gegenüber einer glattflächigen Kontaktfläche bei der Wabenstruktur mit der metallischen Oberfläche und der darauf aufgebrachten Keramik sind hier viele kleine gekrümmte Oberflächen vorhanden, die den mechanischen Verbund zwischen Metall und Keramik durch Vergrößerung der spezifischen Oberfläche und mechanisches Verhaken verbessern.The object is achieved according to the invention by a layer system which consists of a substrate, followed by a porous layer with a pore content of at least 30 percent by volume, a ceramic in the form of a coating or as ceramic particles being at least partially introduced into the porous layer.
Compared to a smooth surface contact surface in the honeycomb structure with the metallic surface and the ceramic applied thereon, there are many small curved surfaces which improve the mechanical bond between metal and ceramic by increasing the specific surface area and mechanical interlocking.

Es ist vorteilhaft, eine offene Porenstruktur zu verwenden, weil dadurch die Eindringtiefe von Keramik in die poröse Schicht verbessert wird, so dass die Haftung der Schicht noch weiter erhöht wird.It is advantageous to use an open pore structure because it allows the depth of penetration of ceramic into the porous one Layer is improved so that the adhesion of the layer is still is further increased.

Die Keramik, die auf die poröse Schicht aufgebracht und in diese zumindest teilweise eingebracht wird, kann auch eine Mischung aus verschiedenen keramischen Materialien bilden, um gewünschte Eigenschaften gezielt einzustellen.The ceramic that is applied to the porous layer and in this is at least partially introduced, a Mix to form different ceramic materials select the desired properties.

Die poröse Schicht kann zumindest bereichsweise so mit Keramik ausgefüllt sein, dass sie in diesen Bereichen nahezu dicht ist, so dass eine nahezu dichte Keramikschicht in der porösen Schicht erreicht wird, um die Vorteile der Keramik bzgl. Hitzebeständigkeit auszunutzen.The porous layer can be ceramic at least in some areas be filled out that they are almost in these areas is tight, so that an almost dense ceramic layer in the porous layer is achieved to take advantage of ceramics regarding heat resistance.

Auf die Keramik in der porösen Schicht oder oberhalb der porösen Schicht kann beispielsweise eine weitere keramische Schutzschicht, wie sie bspw. von den Wärmedämmschichten von Gasturbinenschaufeln bekannt ist, aufgebracht sein, um durch eine weitere Beschichtung die Keramik in der porösen Schicht vor Oxidation zu schützen.On the ceramic in the porous layer or above the porous For example, another ceramic layer Protective layer, such as from the thermal insulation layers of Gas turbine blades are known to be applied through another coating the ceramic in the porous layer to protect against oxidation.

Ausführungsbeispiele sind in den Figuren 1 bis 7 näher erläutert.Exemplary embodiments are explained in more detail in FIGS. 1 to 7.

Es zeigen

  • Figur 1a, b ein Substrat mit einer porösen Schicht und einer Keramik in der porösen Schicht,
  • Figur 2a ein Substrat mit einer porösen Schicht, wobei die poröse Schicht an ihren inneren Oberflächen mit einer keramischen Schicht beschichtet ist (Fig. 2b),
  • Figur 3 ein Substrat mit einer porösen Schicht, die durch die Keramik nahezu dicht geworden ist,
  • Figur 4 ein weiteres Ausführungsbeispiel der Erfindung,
  • Figur 5 ein Anwendungsbeispiel eines solchen Schichtsystems,
  • Figur 6a, b Herstellungsschritte zur Herstellung eines erfindungsgemäßen Schichtsystems,
  • Figur 7, 8, 9a, b weitere Ausführungsbeispiele zur Herstellung eines erfindungsgemäßen Schichtsystems, und
  • Figur 10a, b weitere Ausführungsbeispiele der Erfindung.
    • Show it
  • 1a, b a substrate with a porous layer and a ceramic in the porous layer,
  • 2a shows a substrate with a porous layer, the porous layer being coated on its inner surfaces with a ceramic layer (FIG. 2b),
  • FIG. 3 shows a substrate with a porous layer that has become almost dense due to the ceramic,
  • FIG. 4 shows a further exemplary embodiment of the invention,
  • FIG. 5 shows an application example of such a layer system,
  • 6a, b production steps for producing a layer system according to the invention,
  • 7, 8, 9a, b further exemplary embodiments for producing a layer system according to the invention, and
  • Figure 10a, b further embodiments of the invention.

    • Figur 1a zeigt ein Substrat 1, beispielsweise aus Metall, insbesondere aus einer Superlegierung für eine Gasturbinenschaufel, auf dem eine poröse Schicht 4 aufgebracht ist. Die poröse Schicht 4 kann aus Metall oder Keramik sein.
    Die poröse Struktur ist schematisch dargestellt durch die Striche, die die einzelnen Wände darstellen sollen, die die Poren in der porösen Schicht 4 umgeben. Der Porenanteil beträgt mindestens dreissig (30) Volumenprozent. Insbesondere ist eine offene Porenstruktur von Vorteil, d.h. es bestehen Verbindungswege von der äusseren Oberfläche der porösen Schicht 4 zu seiner Unterseite, die dem Substrat 1 zugewandt ist, wie sie z. B. bei der Anwendung von Filtersystemen bekannt ist. Dabei kann eine Keramik besonders gut in die poröse Schicht eingebracht werden.    FIG. 1a shows a substrate 1, for example made of metal, in particular of a superalloy for a gas turbine blade, on which a porous layer 4 is applied. The porous layer 4 can be made of metal or ceramic.
    The porous structure is represented schematically by the lines that are intended to represent the individual walls that surround the pores in the porous layer 4. The pore fraction is at least thirty (30) percent by volume. In particular, an open pore structure is advantageous, ie there are connection paths from the outer surface of the porous layer 4 to its underside, which faces the substrate 1, as is the case, for. B. is known when using filter systems. A ceramic can be introduced particularly well into the porous layer.

    Figur 1b zeigt ein erfindungsgemäßes Schichtsystem, bei dem in der porösen Schicht 4 eine Keramik 7 vorhanden ist. Die Keramik 7 kann aus einem einzigen keramischen Material oder aus einer Mischung von verschiedenen keramischen Materialien bspw. in Form von keramischen Teilchen bestehen. Metallische Beimischungen oder Beschichtungen sind ebenfalls möglich.Figure 1b shows a layer system according to the invention, in which A ceramic 7 is present in the porous layer 4. The Ceramic 7 can be made from a single ceramic material or from a mixture of different ceramic materials exist, for example, in the form of ceramic particles. Metallic Additions or coatings are also possible.

    Figur 2a zeigt ein weiteres Ausführungsbeispiel eines erfindungsgemäßen Schichtsystems 20, bei dem keine einzelnen keramischen Teilchen 7 zu erkennen sind (Fig. 2a), weil die Porenwände 13 der porösen Schicht 4 mit einer keramischen Schicht 16 beschichtet sind (Fig. 2b). So sind die Innenoberflächen der Poren der porösen Schicht 4 bspw. ganz mit einer Keramik 16 bedeckt.Figure 2a shows a further embodiment of an inventive Layer system 20 in which no individual ceramic Particles 7 can be seen (Fig. 2a) because of the pore walls 13 of the porous layer 4 with a ceramic Layer 16 are coated (Fig. 2b). So are the inner surfaces the pores of the porous layer 4, for example, entirely with a Ceramic 16 covered.

    Figur 3 zeigt ein weiteres Ausführungsbeispiel eines erfindungsgemäß ausgebildeten Schichtsystems 20. Auf dem Substrat 1 ist eine poröse Schicht 4 aufgebracht, deren Poren mit der Keramik 7 aufgefüllt sind, so dass eine dichte Schicht erreicht wird.Figure 3 shows a further embodiment of an invention trained layer system 20. On the substrate 1, a porous layer 4 is applied, the pores of which Ceramic 7 are filled so that a dense layer is reached becomes.

    Figur 4 zeigt, dass zwischen Substrat 1 und der porösen Schicht 4 zumindest eine weitere Zwischenschicht 10 vorhanden sein kann.Figure 4 shows that between substrate 1 and the porous Layer 4 has at least one additional intermediate layer 10 can be.

    Figur 5 zeigt ein weiteres Anwendungsbeispiel für ein erfindungsgemäßes Schichtsystem 20. Das Schichtsystem 20 bildet einen Teil eines Gasturbinengehäuses 23, das beispielsweise Turbinenschaufeln 26 umgibt, die in einer Gasturbine einem Brenner nachgeschaltet sind. Die Drehachse der Turbinenschaufel 26 ist mit 29 angezeigt. Das erfindungsgemäße Schichtsystem 20 bildet eine Dichtung zwischen Gasturbihengehäuse 23 und Turbinenschaufel 26 und ersetzt die oben beschriebene Honigwabenstruktur. Weitere Anwendungsbeispiele finden sich für Gasturbinenschaufeln und Hitzeschildelemente.FIG. 5 shows a further application example for an inventive one Layer system 20. The layer system 20 forms part of a gas turbine housing 23, for example Turbine blades 26 that surrounds one in a gas turbine Burners are connected downstream. The axis of rotation of the turbine blade 26 is indicated with 29. The layer system according to the invention 20 forms a seal between the gas turbine housing 23 and turbine blade 26 and replaces the one described above Honeycomb structure. Further application examples can be found for gas turbine blades and heat shield elements.

    Figur 6a, b zeigt die Fertigungsschritte zur Herstellung eines erfindungsgemäßen Schichtsystems 20. Das Substrat 1 wird mit einem bereits vorgefertigten porösen Bauteil 4 durch eine Verbindungstechnik miteinander verbunden (Fig. 6b). Dies kann beispielsweise durch Schweißen, Diffusionsschweißen oder Diffusionslöten erfolgen. Weitere Verbindungstechniken sind möglich.Figure 6a, b shows the manufacturing steps for manufacturing of a layer system 20 according to the invention. The substrate 1 is carried out with an already prefabricated porous component 4 a connection technology connected to each other (Fig. 6b). This can for example by welding, diffusion welding or Diffusion soldering is done. Other joining techniques are possible.

    Figur 7 zeigt eine weitere Methode zur Herstellung eines erfindungsgemäßen Schichtsystems 20. Auf das Substrat 1 wird eine Suspension 32 aufgebracht, die sich beispielsweise durch eine Behandlung bei einer Temperatur T in eine poröse Schicht 4 umwandelt. Dies kann bekanntermassen dadurch erfolgen, dass die Suspension 32 ein Metallpulver enthält und einen Aktivator, der bei der Wärmebehandlung vergast und die Suspension mit dem Metall aufschäumt, wobei dann bei erhöhter Temperatur die Metallteilchen beispielsweise miteinander versintern und so die poröse Schicht 4 bilden, wobei gleichzeitig eine gute Anbindung an das Substrat 1 erfolgt. Weitere Herstellungsmethoden zur Herstellung von porösen, insbesondere schaumartigen Strukturen, können hier angewendet werden, wie z.B. das Feingussverfahren.Figure 7 shows a further method for producing an inventive Layer system 20. On the substrate 1 is a suspension 32 applied, for example, by treatment at a temperature T in a porous layer 4 converts. As is known, this can be done in that suspension 32 contains a metal powder and an activator, which gasifies during the heat treatment and the suspension foams with the metal, then at elevated temperature the metal particles, for example, sinter together and so form the porous layer 4, while at the same time a good one Connection to the substrate 1 takes place. Other manufacturing methods for the production of porous, especially foam-like Structures can be used here, e.g. the Investment casting process.

    Figur 8 zeigt ein weiteres Ausführungsbeispiel zur Herstellung eines erfindungsgemäßen Schichtsystems 20. Dies kann beispielsweise dadurch erfolgen, dass in einem Gießprozess zuerst das Material für das Substrat 1 gegossen wird und dann kontinuierlich ohne Unterbrechung ein Metall oder eine Legierung gegossen wird, die eine poröse Struktur aufweisen oder eine Mischung aus Metall und Keramik, so dass sich auf dem Substrat 1 eine poröse metallische Schicht 4 bildet, die ggf. dicht mit Keramik ausgefüllt ist. Aus einem Rohling 38 kann sich auch durch eine Zwischenbehandlung ein Substrat 1 und eine poröse Schicht 4 ausbilden.Figure 8 shows a further embodiment for the production of a layer system 20 according to the invention. This can for example, in a casting process the material for the substrate 1 is cast first and then continuously without interruption a metal or an alloy is cast, which have a porous structure or a mixture of metal and ceramic, so that on the Substrate 1 forms a porous metallic layer 4, which may is densely filled with ceramics. From a blank 38 can a substrate 1 and form a porous layer 4.

    Um das erfindungsgemäße Schichtsystem 20 letztendlich herzustellen, ist es oft noch notwendig, die Keramik 7 in die poröse Schicht 4 einzubringen. Dies kann durch eine Beschichtungsvorrichtung 35 (Fig. 9a) erfolgen, beispielsweise durch das Plasmaspritzen, so dass eine keramische Beschichtung 16 in der porösen Schicht 4 erzeugt wird. Das Beschichtungsverfahren kann so fortgeführt werden, dass nicht nur die Wände 13 der porösen Schicht beschichtet werden, sondern auch noch die Porenstruktur zumindest teilweise geschlossen wird, um eine dichte Schicht zu erreichen.In order to ultimately manufacture the layer system 20 according to the invention, it is often still necessary to insert the ceramic 7 into the porous one Layer 4 to bring. This can be done by a coating device 35 (Fig. 9a), for example by plasma spraying so that a ceramic coating 16 is produced in the porous layer 4. The coating process can be continued so that not only the walls 13 of the porous layer are coated, but also still the pore structure is at least partially closed in order to to achieve a dense layer.

    Durch eine Spritzdüse 35 (Fig. 9a) kann auch eine keramische Suspension mit keramischen Partikeln in die poröse Schicht 4 eingebracht, insbesondere eingespritzt, werden. In einem weiteren Herstellungsschritt wird das Trägermittel der Suspension verdampft, so dass die keramischen Partikel 7 zurückbleiben und sich nach einer Wärmebehandlung mit den metallischen Wänden 13 der porösen Schicht 4 verbinden.A ceramic nozzle can also be sprayed through a spray nozzle 35 (FIG. 9a) Suspension with ceramic particles in the porous layer 4 introduced, in particular injected. In another The manufacturing step becomes the carrier of the suspension evaporates so that the ceramic particles 7 remain and after a heat treatment with the metallic ones Connect walls 13 of the porous layer 4.

    Die poröse Schicht 4 kann auch nur in einem oberen Bereich 11 die Poren vollständig mit der Keramik 7 ausgefüllt sein (Fig. 9b).The porous layer 4 can also only be in an upper region 11 the pores must be completely filled with the ceramic 7 (Fig. 9b).

    Die poröse Schicht 4 ist vorteilhafterweise mit einer Keramik 7 aufgefüllt, die gute mechanische Eigenschaften bei hohen Temperaturen aufweist und als thermische Barriere dient. Um jedoch diese Keramik und auch die metallischen Wände der porösen Schicht 4 vor Oxidation und/oder Korrosion und/oder Wärme zu schützen, kann auf die poröse Schicht 4 (Fig. 10a) oder über den keramischen Teilchen 7 oder der keramischen Schicht 16 innerhalb der porösen Schicht 7 (Fig. 10b) noch eine weitere keramische Schutzschicht 41 aufgebracht werden.The porous layer 4 is advantageously made of a ceramic 7 padded, the good mechanical properties at high Has temperatures and serves as a thermal barrier. Around however, this ceramic and also the metallic walls of the porous Layer 4 before oxidation and / or corrosion and / or To protect heat can be applied to the porous layer 4 (Fig. 10a) or over the ceramic particles 7 or the ceramic Layer 16 within the porous layer 7 (Fig. 10b) still a further ceramic protective layer 41 can be applied.

    Claims (15)

    Schichtsystem (20),
    bestehend aus
    einem Substrat (1),
    einer äusseren porösen Schicht (4) mit einem Porenanteil von mindestens 30 Volumenprozent,
    die auf dem Substrat (1) angeordnet ist,
    und einer Keramik (7, 16), die zumindest teilweise in der porösen Schicht (4) angeordnet ist.    Layer system (20),
    consisting of
    a substrate (1),
    an outer porous layer (4) with a pore content of at least 30 percent by volume,
    which is arranged on the substrate (1),
    and a ceramic (7, 16) which is at least partially arranged in the porous layer (4).         Schichtsystem nach Anspruch 1,
    dadurch gekennzeichnet, dass
    die poröse Schicht (4) eine offene Porenstruktur aufweist.    Layer system according to claim 1,
    characterized in that
    the porous layer (4) has an open pore structure.         Schichtsystem nach Anspruch 1,
    dadurch gekennzeichnet, dass
    die Keramik (7) eine Mischung aus verschiedenen keramischen Materialien ist.    Layer system according to claim 1,
    characterized in that
    the ceramic (7) is a mixture of different ceramic materials.         Schichtsystem nach Anspruch 1,
    dadurch gekennzeichnet, dass
    die poröse Schicht (4) zumindest bereichsweise nahezu ganz ausgefüllt ist mit der Keramik (7).    Layer system according to claim 1,
    characterized in that
    the porous layer (4) is at least partially completely filled with the ceramic (7).         Schichtsystem nach Anspruch 1 oder 4,
    dadurch gekennzeichnet, dass
    auf der Keramik (7) in der porösen Schicht (4) eine weitere keramische Schicht (41) aufgebracht ist.    Layer system according to claim 1 or 4,
    characterized in that
    a further ceramic layer (41) is applied to the ceramic (7) in the porous layer (4).         Schichtsystem nach Anspruch 1,
    dadurch gekennzeichnet, dass
    die poröse Schicht (4) schaumartig ist.    Layer system according to claim 1,
    characterized in that
    the porous layer (4) is foam-like.         Schichtsystem nach Anspruch 1,
    dadurch gekennzeichnet, dass
    das Substrat (1) metallisch ist, insbesondere eine Cobalt/Nickelsuperlegierung.    Layer system according to claim 1,
    characterized in that
    the substrate (1) is metallic, in particular a cobalt / nickel super alloy.         Schichtsystem nach Anspruch 1,
    dadurch gekennzeichnet, dass die poröse Schicht (4) aus Metall ist.    Layer system according to claim 1,
    characterized in that the porous layer (4) is made of metal.         Schichtsystem (20),
    bestehend aus
    einem Substrat (1),
    einer äusseren porösen Schicht (4) mit einem Porenanteil von mindestens 30 Volumenprozent,
    die auf dem Substrat (1) angeordnet ist,
    und einer Keramik (7, 16),
    wobei die poröse Schicht (4) zumindest bereichsweise nahezu ganz ausgefüllt ist mit der Keramik (7).    Layer system (20),
    consisting of
    a substrate (1),
    an outer porous layer (4) with a pore content of at least 30 percent by volume,
    which is arranged on the substrate (1),
    and a ceramic (7, 16),
    wherein the porous layer (4) is almost completely filled with the ceramic (7) at least in some areas.         Schichtsystem nach Anspruch 1,
    dadurch gekennzeichnet, dass
    die poröse Schicht (4) eine offene Porenstruktur aufweist.    Layer system according to claim 1,
    characterized in that
    the porous layer (4) has an open pore structure.         Schichtsystem nach Anspruch 1,
       dadurch gekennzeichnet, dass
    die Keramik (7) eine Mischung aus verschiedenen keramischen Materialien ist.    Layer system according to claim 1,
    characterized in that
    the ceramic (7) is a mixture of different ceramic materials.         Schichtsystem nach Anspruch 1,
       dadurch gekennzeichnet, dass
    auf der Keramik (7) in der porösen Schicht (4) eine weitere keramische Schicht (41) aufgebracht ist.     Layer system according to claim 1,
    characterized in that
    a further ceramic layer (41) is applied to the ceramic (7) in the porous layer (4).         Schichtsystem nach Anspruch 1,
       dadurch gekennzeichnet, dass
    die poröse Schicht (4) schaumartig ist.    Layer system according to claim 1,
    characterized in that
    the porous layer (4) is foam-like.         Schichtsystem nach Anspruch 1,
       dadurch gekennzeichnet, dass
    das Substrat (1) metallisch ist, insbesondere eine Cobalt/Nickelsuperlegierung.    Layer system according to claim 1,
    characterized in that
    the substrate (1) is metallic, in particular a cobalt / nickel super alloy.         Schichtsystem nach Anspruch 1,
       dadurch gekennzeichnet, dass
    die poröse Schicht (4) aus Metall ist.    Layer system according to claim 1,
    characterized in that
    the porous layer (4) is made of metal.
    EP02000874A 2002-01-15 2002-01-15 Coating system with a porous layer Withdrawn EP1327703A1 (en)

    Priority Applications (6)

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    EP02000874A EP1327703A1 (en) 2002-01-15 2002-01-15 Coating system with a porous layer
    EP02787907A EP1466036B1 (en) 2002-01-15 2002-12-04 Layer system comprising a porous layer
    DE50210249T DE50210249D1 (en) 2002-01-15 2002-12-04 COATING SYSTEM WITH A POROUS LAYER
    PCT/EP2002/013752 WO2003060195A1 (en) 2002-01-15 2002-12-04 Layer system comprising a porous layer
    JP2003560272A JP2005514526A (en) 2002-01-15 2002-12-04 Layered structure consisting of porous layers
    US10/641,996 US7070853B2 (en) 2002-01-15 2003-08-15 Layer system comprising a substrate, and an outer porous layer

    Applications Claiming Priority (1)

    Application Number Priority Date Filing Date Title
    EP02000874A EP1327703A1 (en) 2002-01-15 2002-01-15 Coating system with a porous layer

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    JP2005514526A (en) 2005-05-19
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    EP1466036B1 (en) 2007-05-30
    WO2003060195A1 (en) 2003-07-24
    US20040058185A1 (en) 2004-03-25

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