EP2636763B1 - Method for applying a high-temperature stable coating layer on the surface of a component and component with such a coating layer - Google Patents
Method for applying a high-temperature stable coating layer on the surface of a component and component with such a coating layer Download PDFInfo
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- EP2636763B1 EP2636763B1 EP12158129.2A EP12158129A EP2636763B1 EP 2636763 B1 EP2636763 B1 EP 2636763B1 EP 12158129 A EP12158129 A EP 12158129A EP 2636763 B1 EP2636763 B1 EP 2636763B1
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- 239000011247 coating layer Substances 0.000 title claims description 42
- 238000000034 method Methods 0.000 title claims description 42
- 239000000843 powder Substances 0.000 claims description 83
- 239000002245 particle Substances 0.000 claims description 46
- 238000000576 coating method Methods 0.000 claims description 43
- 239000011248 coating agent Substances 0.000 claims description 39
- 239000000463 material Substances 0.000 claims description 30
- 238000007254 oxidation reaction Methods 0.000 claims description 20
- 230000003647 oxidation Effects 0.000 claims description 19
- 238000005507 spraying Methods 0.000 claims description 10
- 229910052759 nickel Inorganic materials 0.000 claims description 8
- 239000000725 suspension Substances 0.000 claims description 7
- 230000001590 oxidative effect Effects 0.000 claims description 6
- 238000007750 plasma spraying Methods 0.000 claims description 6
- 238000010438 heat treatment Methods 0.000 claims description 5
- 238000007751 thermal spraying Methods 0.000 claims description 5
- 238000007749 high velocity oxygen fuel spraying Methods 0.000 claims description 3
- 239000010410 layer Substances 0.000 description 16
- 239000007921 spray Substances 0.000 description 15
- 239000012720 thermal barrier coating Substances 0.000 description 14
- PXHVJJICTQNCMI-UHFFFAOYSA-N nickel Substances [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 12
- 239000000203 mixture Substances 0.000 description 9
- 238000005336 cracking Methods 0.000 description 8
- 239000007789 gas Substances 0.000 description 8
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- 230000007797 corrosion Effects 0.000 description 7
- 238000005260 corrosion Methods 0.000 description 7
- 239000000446 fuel Substances 0.000 description 7
- 230000000694 effects Effects 0.000 description 6
- 239000010953 base metal Substances 0.000 description 5
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 4
- 230000008901 benefit Effects 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 4
- 239000011651 chromium Substances 0.000 description 4
- 229910052760 oxygen Inorganic materials 0.000 description 4
- 239000001301 oxygen Substances 0.000 description 4
- 230000036961 partial effect Effects 0.000 description 4
- 230000008569 process Effects 0.000 description 4
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 3
- 239000000919 ceramic Substances 0.000 description 3
- 238000009792 diffusion process Methods 0.000 description 3
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- 230000007246 mechanism Effects 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 229910052593 corundum Inorganic materials 0.000 description 2
- QDOXWKRWXJOMAK-UHFFFAOYSA-N dichromium trioxide Chemical compound O=[Cr]O[Cr]=O QDOXWKRWXJOMAK-UHFFFAOYSA-N 0.000 description 2
- 230000035876 healing Effects 0.000 description 2
- 230000000977 initiatory effect Effects 0.000 description 2
- 239000011159 matrix material Substances 0.000 description 2
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- 239000007800 oxidant agent Substances 0.000 description 2
- 229910000601 superalloy Inorganic materials 0.000 description 2
- 230000032258 transport Effects 0.000 description 2
- 229910001845 yogo sapphire Inorganic materials 0.000 description 2
- RUDFQVOCFDJEEF-UHFFFAOYSA-N yttrium(III) oxide Inorganic materials [O-2].[O-2].[O-2].[Y+3].[Y+3] RUDFQVOCFDJEEF-UHFFFAOYSA-N 0.000 description 2
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
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- 238000004364 calculation method Methods 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
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- 229910052751 metal Inorganic materials 0.000 description 1
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- 229910052717 sulfur Inorganic materials 0.000 description 1
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- 230000000930 thermomechanical effect Effects 0.000 description 1
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Images
Classifications
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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
- 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
- C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
-
- 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
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
- C23C4/073—Metallic material containing MCrAl or MCrAlY alloys, where M is nickel, cobalt or iron, with or without non-metal elements
-
- 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
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
- C23C4/08—Metallic material containing only metal elements
-
- 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
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
-
- 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
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
- C23C4/11—Oxides
-
- 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
- C23C4/134—Plasma spraying
-
- 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
- Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
- Y10T428/256—Heavy metal or aluminum or compound thereof
Definitions
- the present invention relates to thermally loaded components of thermal machines, especially gas turbines. It refers to a method for applying a high-temperature stable coating layer on the surface of a component. It further refers to a component with such a coating layer.
- a thermal barrier coating TBC
- a bond coat may be provided between the base material of the component and the TBC.
- the hot-section stationary components mainly combustors, transition pieces, and vanes
- TBCs thermal barrier coatings
- M metallic MCrAlY
- YPSZ Yttria partially stabilized zirconia
- the document further asserts that the full potential of the YPSZ TBCs is yet to be realized due mainly to the cracking problem that occurs along or near the bond coat/top coat interface after a limited number of cycles of engine operation.
- This interfacial cracking often leading to premature coating failure by debonding (spallation) of the top coat from the bond coat, has been amply demonstrated from microstructural evidence that was obtained from in-service degradation of deposited coatings as well as from laboratory experiments that have been conducted.
- the thin oxide layer that grows on top of the bond coat, at the bond coat/top coat interface plays a critical role in the interface cracking. It is quite evident that this cracking problem negatively impacts the coating performance by reducing both the engine efficiency (because the engine operating temperature is kept below its optimum temperature) and the lifetime of the engine components. In turn, this greatly affects the reliability and the efficiency of the entire engine system.
- the bond coat surface, onto which the YPSZ top coat is disposed has a thin oxide layer that consists mostly of various oxides (NiO, Ni(Cr,Al) 2 O 4 , Cr 2 O 3 , Y 2 O 3 , Al 2 O 3 ).
- This thin oxide layer plays an important role in the adhesion (bonding) between the metallic bond coat and the ceramic top coat.
- another oxide layer forms in addition to the native oxide.
- This second layer also mostly alumina, is commonly referred to as the thermally grown oxide (TGO) and slowly grows during exposure to elevated temperatures.
- TGO thermally grown oxide
- Interfacial oxides, in particular the TGO layer play a pivotal role in the cracking process. It is believed that the growth of the TGO layer leads to the build up of stresses at the interface region between the TGO layer and top coat.
- document US 7,361,386 B2 proposes to modify the microstructure of the MCrAlY bond coat (in a thermal barrier coating) in a controlled way prior to exposure to high temperatures, in order to control the subsequent changes during high temperature exposure. More specifically, the structure, composition, and growth rate of the thermally grown oxide (TGO) is controlled to ultimately improve the performance of TBCs.
- a nanostructure is provided in the bond coat and, consequently, nanocrystalline dispersoids are introduced into the structure. The purpose of the dispersoids is to stabilize the nanocrystalline structure and to nucleate the desirable [alpha]-Al 2 O 3 in the TGO.
- US 2010/032619 A1 discloses a method for applying a high-temperature stable coating layer on the surface of a component.
- a spraying technique is used for production of particle cores.
- the method according to the invention for applying a high-temperature stable coating layer on the surface of a component comprises the steps of:
- said powder material is applied to the surface of the component by means of a thermal spraying technique.
- the thermal spraying technique used is one of High Velocity Oxygen Fuel Spraying (HVOF), Low Pressure Plasma Spraying (LPPS), Air Plasma Spraying (APS) or Suspension Plasma Spraying (SPS).
- HVOF High Velocity Oxygen Fuel Spraying
- LPPS Low Pressure Plasma Spraying
- APS Air Plasma Spraying
- SPS Suspension Plasma Spraying
- said powder material has the form of agglomerates.
- said powder material has the form of a suspension.
- the powder material contains powder particles of micron size and/or larger agglomerates, and that the sub-micron powder particles are in said coating layer distributed around the surface of said powder particles of micron size and/or said larger agglomerates.
- the sub-micron powder particles are pre-oxidized before being incorporated into said coating layer.
- the pre-oxidation takes place in-flight during spraying.
- the pre-oxidation is done by an oxidative pre heat treatment of the powder material.
- the coating layer is a bond coat or an overlay coating.
- said coating layer further comprises powder particles of micron size and/or larger agglomerates.
- said sub-micron powder particles are in said coating layer distributed around the surface of said powder particles of micron size and/or said larger agglomerates.
- the coating layer is a bond coat.
- the present invention discloses a specific type of sub-micron structured coating. Due to a sub-micron scale oxide network and fine grain microstructure, the invention aims to reduce the LCF/TMF cracking.
- Another aspect of the invention is the retardant effect for the oxidation and the corrosion. Due to the nano-scale oxide network of the bond coat/overlay coating, the impact by oxidation and corrosion is slowed down.
- the invention should enable a longer service life and/or assure reconditionability with less scrap parts and/or decreased operation risks, such as crack formation in critical area of the component due to mechanical/thermal load, and/or oxidation/corrosion and/or FOD (Foreign Objects Damage) events.
- the invention enables:
- the novelty of the invention is the use of a sub-micron powder (at least to a certain percentage of the total powder mixture) and the way to process it (preparation and thermal spray application) to reach the mentioned improved coating properties.
- the improved coating behavior is particularly based on a reduced TMF/LCF effect of the coating with (at least partial) sub-micron structure.
- the invention is based on:
- Fig. 1 shows a typical thermal spray configuration 10, which can be used to apply the sub-micron powder coating layer according to the invention.
- the thermal spray configuration 10 comprises a spray gun 13, which is supplied with the sub-micron powder 15, a fuel 16 and an oxidant 17. By burning the fuel 16, a flame 14 is generated, which transports the powder particles to the surface of a component 11, thereby building the coating layer 12.
- the sub-micron powder particles 18 undergo a reaction, as can be seen in Fig. 2 , such that they are transformed into particles having a (metallic) core 19 surrounded by an oxide shell 20.
- those oxidized sub-micron particles build up an interconnected structure with a sub-micron oxide network 22.
- the resulting coating layer 12a comprises those agglomerates or micron powder particles 21 being surrounded by oxidized sub-micron powder particles 18.
- the initiation and propagation of damages within coatings exhibiting an at least partial sub-micron scale structure is retarded compared to conventional coating microstructures.
- the "sub-micron effect" is retained over extended lifetime periods, also due to the (at least partial) oxide network.
- Such aspects of the invention give to the coating a so-called self healing characteristic.
- the fine grain sized coating allows a diffusion heat treatment with a reduced number of heat treatment cycles.
- a nano coating as top layer improves the TMF and oxidation resistance, which results in an improved overall coating lifetime.
Description
- The present invention relates to thermally loaded components of thermal machines, especially gas turbines. It refers to a method for applying a high-temperature stable coating layer on the surface of a component. It further refers to a component with such a coating layer.
- In order to protect thermally loaded components against hot gases they are coated with various protective layers, for example a thermal barrier coating (TBC). To bond such a layer firmly to the body of the component, a bond coat may be provided between the base material of the component and the TBC. A well-known bond coat material for a component made of a Ni base superalloy or the like, is of the type MCrAlY, where M stand for a metal, e.g. Ni.
- During service life, cracks might form in the bond coat and propagate into the base metal of components, which are part of gas turbine or other thermal machine, and which are exposed to high operating temperatures. Especially, low cycle fatigue (LCF)/thermo-mechanical fatique (TMF) cracking is a limiting factor for the lifetime and the reconditionability of such components.
- In the current situation, lifetime and reconditionability limits for the state of the art design and engine operation mode are specified based on calculation and experience. No solution is currently commercially available with the standard MCrAlY composition of the bond coat/overlay coat in order to extend these limits (both oxidation life and mechanical life at the same time). A self healing system would be a solution to extend them.
- A different approach using nano-structured coating is presented in document
US 7,361,386 B2 . - According to this document, in order to increase the efficiency of gas turbine engines, the hot-section stationary components (mainly combustors, transition pieces, and vanes) are protected with thermal barrier coatings (TBCs). In addition to providing the thermal insulation to the nickel-based superalloy components, TBCs also provide protection against high temperature oxidation and hot corrosion attack. The conventional TBCs that are used in naval (diesel) engines, in military and commercial aircraft, and in land-based gas turbine engine components, consist of a duplex structure made up of a metallic MCrAlY (M stands for either Co, Ni and/or Fe) bond coat and Yttria partially stabilized zirconia (YPSZ) ceramic top coat.
- The document further asserts that the full potential of the YPSZ TBCs is yet to be realized due mainly to the cracking problem that occurs along or near the bond coat/top coat interface after a limited number of cycles of engine operation. This interfacial cracking, often leading to premature coating failure by debonding (spallation) of the top coat from the bond coat, has been amply demonstrated from microstructural evidence that was obtained from in-service degradation of deposited coatings as well as from laboratory experiments that have been conducted. The thin oxide layer that grows on top of the bond coat, at the bond coat/top coat interface, plays a critical role in the interface cracking. It is quite evident that this cracking problem negatively impacts the coating performance by reducing both the engine efficiency (because the engine operating temperature is kept below its optimum temperature) and the lifetime of the engine components. In turn, this greatly affects the reliability and the efficiency of the entire engine system.
- According to document
US 7,361,386 B2 , the bond coat surface, onto which the YPSZ top coat is disposed, has a thin oxide layer that consists mostly of various oxides (NiO, Ni(Cr,Al)2O4, Cr2O3, Y2O3, Al2O3). The presence of this thin oxide layer plays an important role in the adhesion (bonding) between the metallic bond coat and the ceramic top coat. However, during engine operation, another oxide layer forms in addition to the native oxide. This second layer, also mostly alumina, is commonly referred to as the thermally grown oxide (TGO) and slowly grows during exposure to elevated temperatures. Interfacial oxides, in particular the TGO layer, play a pivotal role in the cracking process. It is believed that the growth of the TGO layer leads to the build up of stresses at the interface region between the TGO layer and top coat. - To solve these problems, document
US 7,361,386 B2 proposes to modify the microstructure of the MCrAlY bond coat (in a thermal barrier coating) in a controlled way prior to exposure to high temperatures, in order to control the subsequent changes during high temperature exposure. More specifically, the structure, composition, and growth rate of the thermally grown oxide (TGO) is controlled to ultimately improve the performance of TBCs. According toUS 7,361,386 B2 , a nanostructure is provided in the bond coat and, consequently, nanocrystalline dispersoids are introduced into the structure. The purpose of the dispersoids is to stabilize the nanocrystalline structure and to nucleate the desirable [alpha]-Al2O3 in the TGO. - Other prior art documents, Ajdelsztajn et al. in Surf. & Coat. Tech. 201 (2007) 9462-9467 and Funk et al. in Met. Mat. Trans. A 42 [8] (2011) 2233-2241), show that such a nano- structured bond coat has several advantages like for e.g. improved mechanical properties. Such benefit is due to the presence of ultrafine dispersoids of γ and β phases.
-
US 2010/032619 A1 discloses a method for applying a high-temperature stable coating layer on the surface of a component. The method comprises: providing a component with a surface to be coated and providing a powder material containing at least a fraction of sub-micron powder particles, the powder material being of the MCrAlY type with M = Fe, Ni, Co or combinations thereof. A spraying technique is used for production of particle cores. - It is an object of the present invention to provide a method for applying an improved high-temperature stable coating layer on the surface of a component and a component being used in a high-temperature environment, which is coated with such coating layer.
- This object is obtained by a method according to claim 1 and a component according to
claim 11. - The method according to the invention for applying a high-temperature stable coating layer on the surface of a component, comprises the steps of:
- a) providing a component with a surface to be coated;
- b) providing a powder material containing at least a fraction of sub-micron powder particles, the powder material being of the MCrAlY type with M = Fe, Ni, Co or combinations thereof;
- c) applying said powder material to the surface of the component by means of a spraying technique to build up a coating layer, whereby
- d) said sub-micron powder particles are each at least partially surrounded by an oxide shell and establish with their oxide shells an at least partially interconnected sub-micron oxide network within said coating layer.
- According to an embodiment of the inventive method said powder material is applied to the surface of the component by means of a thermal spraying technique.
- Especially, the thermal spraying technique used is one of High Velocity Oxygen Fuel Spraying (HVOF), Low Pressure Plasma Spraying (LPPS), Air Plasma Spraying (APS) or Suspension Plasma Spraying (SPS).
- According to another embodiment of the inventive method said powder material has the form of agglomerates.
- According to a further embodiment of the inventive method said powder material has the form of a suspension.
- According to another embodiment of the inventive method the powder material contains powder particles of micron size and/or larger agglomerates, and that the sub-micron powder particles are in said coating layer distributed around the surface of said powder particles of micron size and/or said larger agglomerates.
- According to just another embodiment of the inventive method the sub-micron powder particles are pre-oxidized before being incorporated into said coating layer.
- Preferably, the pre-oxidation takes place in-flight during spraying.
- Alternatively, the pre-oxidation is done by an oxidative pre heat treatment of the powder material.
- According to just another embodiment of the inventive method the coating layer is a bond coat or an overlay coating.
- According to the invention, said component having a surface, which is coated with a coating layer is characterized in that said coating layer comprises sub-micron powder particles, which are each at least partially surrounded by an oxide shell and establish with their oxide shells an at least partially interconnected sub-micron oxide network within said coating layer, wherein the powder material is of the MCrAlY type with M = Ni, Co, Fe or combinations thereof.
- According to an embodiment of the invention, said coating layer further comprises powder particles of micron size and/or larger agglomerates.
- Especially, said sub-micron powder particles are in said coating layer distributed around the surface of said powder particles of micron size and/or said larger agglomerates.
- According to another embodiment of the invention the coating layer is a bond coat.
- The present invention is now to be explained more closely by means of different embodiments and with reference to the attached drawings.
- Fig. 1
- shows in a simplified schematic diagram a thermal spray configuration, which can be used for the present invention;
- Fig. 2
- shows the creation of a coating layer with an internal oxide network by in-flight oxidation of sprayed sub-micron powder particles according to an embodiment of the invention;
- Fig. 3
- shows - similar to
Fig. 2 - the embedding of micron particles or agglomerates in said sub-micron powder particle oxide network; and - Fig. 4
- shows schematically a graded coating layer in accordance with an embodiment of the invention.
- The present invention discloses a specific type of sub-micron structured coating. Due to a sub-micron scale oxide network and fine grain microstructure, the invention aims to reduce the LCF/TMF cracking.
- Another aspect of the invention is the retardant effect for the oxidation and the corrosion. Due to the nano-scale oxide network of the bond coat/overlay coating, the impact by oxidation and corrosion is slowed down.
- In consequence, the invention should enable a longer service life and/or assure reconditionability with less scrap parts and/or decreased operation risks, such as crack formation in critical area of the component due to mechanical/thermal load, and/or oxidation/corrosion and/or FOD (Foreign Objects Damage) events.
- The invention enables:
- the preservation of a sub-micron structure during application of the coating by thermal spraying techniques and during turbomachine operation (at least for an extended operation period compared to the state-of-the art nano-structured coatings);
- additional improvements of coating properties.
- The novelty of the invention is the use of a sub-micron powder (at least to a certain percentage of the total powder mixture) and the way to process it (preparation and thermal spray application) to reach the mentioned improved coating properties. The improved coating behavior is particularly based on a reduced TMF/LCF effect of the coating with (at least partial) sub-micron structure.
- The invention is based on:
- (1) The use of powder with sub-micron size or a powder containing at least a portion of such sub-micron powder:
- either in form of agglomerates, consisting of at least a portion of such sub-micron powder, processed by thermal spray techniques like HVOF, LPPS or APS, for example (see
Fig. 1 ); - or in form of a suspension including at least a portion of such sub-micron powder, when applied by thermal spray techniques like suspension plasma spray (SPS).
Such powder is MCrAlY with M= Ni, Co, Fe or combinations thereof.
In-flight oxidation during spraying (seeFig. 2 ) has the effect of pre-oxidizing the sub-micron powder of the agglomerate or suspension. Pre-oxidation can also be achieved by oxidative pre heat treatment of the powder mixture. When only a portion of the powder exhibits a sub-micron scale, it is preferable to have the sub-micron particles distributed around the surface of the micron and/or agglomerated spray powder particles. - either in form of agglomerates, consisting of at least a portion of such sub-micron powder, processed by thermal spray techniques like HVOF, LPPS or APS, for example (see
- (2) The application of the powder on a component of a turbo machine by thermal spray methods (HVOF, LPPS, APS, SPS etc.) in order to form a (at least partially) sub-micron structured coating with (at least a partially) oxide network. Air gun spray technologies can also be used. The use of pre-oxidized spray powder is preferred. A homogeneous or a graded coating can be applied (see the graded
coating layer 12b inFig. 4 ). For example, the gradedlayer 12b can have an oxide content, which increases or decreases with the distance from the surface of the base metal to the top surface of the coating. In a different example the oxide content could have a minimum in the middle of the coating thickness. - (3) The function of such a coating can be as bond coat, overlay coating or a thermal barrier coating system for turbo machine components like gas turbine blades or vanes. The coating of the invention can be used alone or in combination with other standard coatings. The coating of the invention can be used on newly made components or reconditioned components and can also locally be applied for the partial (surface) repair of components.
- (4) The component with such a coating, benefits during operation from:
- Oxidation protection:
Due to the presence of an oxide shell (20) around the particles, the losses of reactive elements (for example Y, Al and C) during the thermal spray process are reduced. In consequence, a more stable thermally grown oxide (TGO) can be formed during service by diffusion mechanism, slowing down the oxidation mechanism during operation compared to conventional metallic coating systems. In parallel, the oxide network (22) formed by the connecting oxide shells (20) allows to reduce the build-up of the depletion zone in the coating (top and interface to the base metal) by slowing down the diffusion mechanism. - Corrosion protection:
With the current invention, Chromium is finely dispersed in the coating. This enables a faster gattering of sulfur and a slowing down of the corresponding corrosion process(es). - Mechanical lifetime:
The mechanical lifetime is improved compared to conventional coating systems, due to several effects:- 1) The improved coating oxidation properties enable to reduce the overall coating thickness. As a consequence, the risk of crack formation due to TMF and LCF is also reduced. This effect implies the slowing down of formation and propagation of respective damages, such as cracks.
- 2) Due to the 3D-oxide network (22), the mechanical load is more homogeneously distributed along the oxide network, which reduces the risks of sudden facture.
- 3) The depletion zone in the coating is reduced due to less interdiffusion with the base metal and the atmosphere (environment). In consequence, the risk of brittle phase precipitation (potential sites for crack initiation) in the base metal/coating is reduced.
- 4) The oxide shell slows down the grain coarsening in the coating microstructure and with this another root cause for crack formation.
- 5) When the oxide-network is disrupted due to cracking, the metallic core of sub-micron particles can diffuse into the metallic coating matrix. By subsequent local oxidation, potential cracks can be filled up.
- 6) The metallic matrix ductility is increased due to the fine grain structure, which is also beneficial for the overall coating lifetime.
- Oxidation protection:
-
Fig. 1 shows a typicalthermal spray configuration 10, which can be used to apply the sub-micron powder coating layer according to the invention. Thethermal spray configuration 10 comprises aspray gun 13, which is supplied with thesub-micron powder 15, afuel 16 and anoxidant 17. By burning thefuel 16, aflame 14 is generated, which transports the powder particles to the surface of acomponent 11, thereby building thecoating layer 12. - During the transport in the
flame 14 thesub-micron powder particles 18 undergo a reaction, as can be seen inFig. 2 , such that they are transformed into particles having a (metallic)core 19 surrounded by anoxide shell 20. Within thecoating layer 12, those oxidized sub-micron particles build up an interconnected structure with asub-micron oxide network 22. - When the powder material is a mixture of
sub-micron particles 18 and micron powder particles oragglomerates 21, as shown inFig. 3 , the resultingcoating layer 12a comprises those agglomerates ormicron powder particles 21 being surrounded by oxidizedsub-micron powder particles 18. - One additional embodiment of the invention is a manufacturing process for an improved thermal barrier coating system of highly thermally and especially cyclically liner segment of a gas turbine by
- a) providing an homogeneous metallic powder material made of NiCrAlY type with Ni = balancing element, Cr = 25 wt%, AI=5 wt%, Y=0.7 wt%, containing 30 wt% of pre-oxidised sub-micron powder particles agglomerated with microsized powder particles (20-50 micron) of same chemical composition,
- b) said sub-micron powder particles (<1 micron) are each surrounded by an oxide shell (50-100 nm) and establish with their oxide shells an at least partially interconnected 3D sub-micron oxide network in the final coating layer application,
- c) applying said powder material to the surface of the vane by means of High Velocity Oxygen Fuel (HVOF) spraying technique to build up a homogeneous bondcoating layer with a thickness of 250 micron, and
- d) the bondcoat layer is subsequently over coated with a ceramic thermal barrier coating (300-600 micron).
- The result is a bondcoat / thermal barrier coating system with improved TMF and oxidation resistance with the capability of forming stable TGO scales, leading to an improved overall coating lifetime.
- A further embodiment of the invention is a manufacturing process for a graded metallic overlay coating system of highly thermally and especially cyclically loaded turbine vane of a gas turbine by
- a) providing a first homogeneous metallic powder material and a second homogeneous metallic powder material, each of them have a chemical composition of NiCrAlY type with Ni = balancing element, Cr = 26 wt%, AI=6 wt%, Y=0.8 wt%,
- b) wherein the first powder blend contains 25 wt% of pre-oxidised sub-micron (<1 micron; 50-100 nm oxide shell) powder particles agglomerated (average 80 micron) with microsized powder particles (20-50 micron) of same chemical composition,
- c) and wherein the second powder containing microsize powder particles (20-50 micron),
- d) applying the first powder material to the surface of the liner segment by means of High Velocity Oxygen Fuel (HVOF) spraying technique to build up a homogeneous first coating layer with a thickness 80 micron,
- e) applying the second powder material to the surface of the first coating layer by means of High Velocity Oxygen Fuel (HVOF) spraying technique (250 micron),
- f) applying another layer of first powder material on top of the second layer by means of High Velocity Oxygen Fuel (HVOF) spraying technique (80 micron),
- g) the first and third layer contains each at least a partially interconnected 3D submicron oxide network.
- The result is a graded metallic overlay coating system with improved TMF and oxidation resistance, leading to an improved overall coating lifetime.
- In general, the initiation and propagation of damages within coatings exhibiting an at least partial sub-micron scale structure is retarded compared to conventional coating microstructures. The "sub-micron effect" is retained over extended lifetime periods, also due to the (at least partial) oxide network. Such aspects of the invention give to the coating a so-called self healing characteristic.
- Therefore the following advantage are reached with the invention:
Longer service life and/or reduced amount of scrap parts during reconditioning and/or reduced operation risks and/or cost reduction related to crack restoration, oxidation and corrosion damage. In addition, the fine grain sized coating allows a diffusion heat treatment with a reduced number of heat treatment cycles. A nano coating as top layer improves the TMF and oxidation resistance, which results in an improved overall coating lifetime. -
- 10
- thermal spray configuration
- 11
- component
- 12,12a,12b
- coating layer (e.g. bond coat)
- 13
- spray gun
- 14
- flame
- 15
- powder
- 16
- fuel (e.g. gaseous)
- 17
- oxidant
- 18
- sub-micron powder particle
- 19
- metallic core
- 20
- oxide shell
- 21
- agglomerated or micron powder particle
- 22
- oxide network (sub-micron)
Claims (14)
- Method for applying a high-temperature stable coating layer (12, 12a, 12b) on the surface of a component (11), comprising the steps of:a) providing a component (11) with a surface to be coated;b) providing a powder material containing at least a fraction of sub-micron powder particles (18), the powder material being of the MCrAlY type with M = Fe, Ni, Co or combinations thereof;c) applying said powder material to the surface of the component (11) by means of a spraying technique to build up a coating layer (12, 12a, 12b), wherebyd) said sub-micron powder particles (18) are each at least partially surrounded by an oxide shell (20) and establish with their oxide shells (20) an at least partially interconnected sub-micron oxide network (22) within said coating layer (12, 12a, 12b).
- Method according to claim 1, characterized in that said powder material is applied to the surface of the component (11) by means of a thermal spraying technique.
- Method according to claim 2, characterized in that the thermal spraying technique used is one of High Velocity Oxygen Fuel Spraying (HVOF), Low Pressure Plasma Spraying (LPPS), Air Plasma Spraying (APS) or Suspension Plasma Spraying (SPS).
- Method according to one of the claims 1-3, characterized in that said powder material has the form of agglomerates.
- Method according to one of the claims 1-3, characterized in that said powder material has the form of a suspension.
- Method according to one of the claims 1-5, characterized in that the powder material contains powder particles (21) of micron size and/or larger agglomerates, and that the sub-micron particles powder particles (18) are in said coating layer (12, 12a, 12b) distributed around the surface of said powder particles (21) of micron size and/or said larger agglomerates.
- Method according to one of the claims 1-6, characterized in that the sub-micron powder particles (18) are pre-oxidized before being incorporated into said coating layer (12, 12a, 12b).
- Method according to claim 7, characterized in that the pre-oxidation takes place in-flight during spraying.
- Method according to claim 7, characterized in that the pre-oxidation is done by an oxidative pre heat treatment of the powder material.
- Method according to one of the claims 1-9, characterized in that the coating layer (12, 12a, 12b) is a bond coat or an overlay coating.
- Component (11) for being used in a high-temperature environment, said component (11) having a surface, which is coated with a coating layer (12, 12a, 12b), characterized in that said coating layer (12, 12a, 12b) comprises sub-micron powder particles (18), which are each at least partially surrounded by an oxide shell (20) and establish with their oxide shells (20) an at least partially interconnected sub-micron oxide network (22) within said coating layer (12, 12a, 12b), wherein the powder material is of the MCrAlY type with M = Ni, Co, Fe or combinations thereof.
- Component according to claim 11, characterized in that said coating layer (12, 12a, 12b) further comprises powder particles (21) of micron size and/or larger agglomerates.
- Component according to claim 12, characterized in that said sub-micron powder particles (18) are in said coating layer (12, 12a, 12b) distributed around the surface of said powder particles (21) of micron size and/or said larger agglomerates.
- Component according to one of the claims 11-13, characterized in that the coating layer (12, 12a, 12b) is a bond coat.
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP12158129.2A EP2636763B1 (en) | 2012-03-05 | 2012-03-05 | Method for applying a high-temperature stable coating layer on the surface of a component and component with such a coating layer |
CA2864618A CA2864618A1 (en) | 2012-03-05 | 2013-03-05 | Method for applying a high-temperature stable coating layer on the surface of a component and component with such a coating layer |
CN201380012678.5A CN104160059B (en) | 2012-03-05 | 2013-03-05 | The method of high-temperature stable coating and the component with this coating are applied on the surface of component |
PCT/EP2013/054337 WO2013131874A1 (en) | 2012-03-05 | 2013-03-05 | Method for applying a high-temperature stable coating layer on the surface of a component and component with such a coating layer |
US14/474,564 US20150284834A1 (en) | 2012-03-05 | 2014-09-02 | Method for applying a high-temperature stable coating layer on the surface of a component and component with such a coating layer |
Applications Claiming Priority (1)
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EP12158129.2A EP2636763B1 (en) | 2012-03-05 | 2012-03-05 | Method for applying a high-temperature stable coating layer on the surface of a component and component with such a coating layer |
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EP2636763A1 EP2636763A1 (en) | 2013-09-11 |
EP2636763B1 true EP2636763B1 (en) | 2020-09-02 |
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EP12158129.2A Active EP2636763B1 (en) | 2012-03-05 | 2012-03-05 | Method for applying a high-temperature stable coating layer on the surface of a component and component with such a coating layer |
Country Status (5)
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US (1) | US20150284834A1 (en) |
EP (1) | EP2636763B1 (en) |
CN (1) | CN104160059B (en) |
CA (1) | CA2864618A1 (en) |
WO (1) | WO2013131874A1 (en) |
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CN104451520B (en) * | 2014-12-04 | 2017-08-01 | 中国船舶重工集团公司第十二研究所 | A kind of zirconia polycrystalline rolls into a ball the preparation method of ceramic coating |
EP3168204B1 (en) * | 2015-11-12 | 2019-02-27 | Ansaldo Energia IP UK Limited | Method for manufacturing a gas turbine part |
US10752999B2 (en) | 2016-04-18 | 2020-08-25 | Rolls-Royce Corporation | High strength aerospace components |
US10763715B2 (en) | 2017-12-27 | 2020-09-01 | Rolls Royce North American Technologies, Inc. | Nano-crystalline coating for magnet retention in a rotor assembly |
CN108004498A (en) * | 2017-12-29 | 2018-05-08 | 上海英佛曼纳米科技股份有限公司 | A kind of high temperature hot-rolled steel furnace roller with high temperature resistance dross oxidation and corrosion abrasion-resistant coatings |
US11317540B2 (en) | 2019-09-20 | 2022-04-26 | Samsung Electronics Co., Ltd. | Solid state drive apparatus and data storage apparatus including the same |
CN113881912B (en) * | 2021-10-09 | 2023-01-31 | 矿冶科技集团有限公司 | Nano oxide dispersion type MCrAlY anti-oxidation coating and preparation method thereof |
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DE3837782A1 (en) * | 1988-11-08 | 1990-05-10 | Starck Hermann C Fa | OXYGENOUS MOLYBDAEN METAL POWDER AND METHOD FOR THE PRODUCTION THEREOF |
US7361386B2 (en) | 2002-07-22 | 2008-04-22 | The Regents Of The University Of California | Functional coatings for the reduction of oxygen permeation and stress and method of forming the same |
ES2302907T3 (en) * | 2002-11-22 | 2008-08-01 | Sulzer Metco (Us) Inc. | PROJECTION POWDER FOR PRODUCTION BY THERMAL PROJECTION OF A THERMAL INSULATING LAYER RESISTANT TO HIGH TEMPERATURES. |
FR2877015B1 (en) * | 2004-10-21 | 2007-10-26 | Commissariat Energie Atomique | NANOSTRUCTURE COATING AND COATING PROCESS. |
WO2006078827A2 (en) * | 2005-01-21 | 2006-07-27 | Cabot Corporation | Controlling flame temperature in a flame spray reaction process |
GB2426010B (en) * | 2005-05-14 | 2011-04-06 | Jeffrey Boardman | semiconductor materials and methods of producing them |
WO2008031371A1 (en) * | 2006-09-14 | 2008-03-20 | Siemens Aktiengesellschaft | Method for producing a particle-containing functional layer and functional element comprising such a layer |
US20100080921A1 (en) * | 2008-09-30 | 2010-04-01 | Beardsley M Brad | Thermal spray coatings for reduced hexavalent and leachable chromuim byproducts |
US8313810B2 (en) * | 2011-04-07 | 2012-11-20 | General Electric Company | Methods for forming an oxide-dispersion strengthened coating |
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2012
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2013
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CN104160059B (en) | 2019-01-08 |
CN104160059A (en) | 2014-11-19 |
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