EP3202946B1 - Forming aluminide coating using metal alloy gravel - Google Patents
Forming aluminide coating using metal alloy gravel Download PDFInfo
- Publication number
- EP3202946B1 EP3202946B1 EP17153434.0A EP17153434A EP3202946B1 EP 3202946 B1 EP3202946 B1 EP 3202946B1 EP 17153434 A EP17153434 A EP 17153434A EP 3202946 B1 EP3202946 B1 EP 3202946B1
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- EP
- European Patent Office
- Prior art keywords
- component
- coating
- metal alloy
- gravel
- aluminide coating
- 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.)
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- 238000000576 coating method Methods 0.000 title claims description 77
- 239000011248 coating agent Substances 0.000 title claims description 76
- 229910000951 Aluminide Inorganic materials 0.000 title claims description 34
- 229910001092 metal group alloy Inorganic materials 0.000 title claims description 29
- 239000000463 material Substances 0.000 claims description 46
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 24
- 229910052782 aluminium Inorganic materials 0.000 claims description 23
- 238000000034 method Methods 0.000 claims description 22
- 238000009792 diffusion process Methods 0.000 claims description 18
- 239000002245 particle Substances 0.000 claims description 15
- 239000012190 activator Substances 0.000 claims description 7
- 150000004820 halides Chemical class 0.000 claims description 4
- 238000010438 heat treatment Methods 0.000 claims description 4
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 3
- 230000000873 masking effect Effects 0.000 claims description 3
- 229910000990 Ni alloy Inorganic materials 0.000 claims description 2
- BLJNPOIVYYWHMA-UHFFFAOYSA-N alumane;cobalt Chemical compound [AlH3].[Co] BLJNPOIVYYWHMA-UHFFFAOYSA-N 0.000 claims description 2
- 238000010586 diagram Methods 0.000 description 12
- 239000000956 alloy Substances 0.000 description 7
- 239000000654 additive Substances 0.000 description 4
- 230000000996 additive effect Effects 0.000 description 4
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 3
- 229910045601 alloy Inorganic materials 0.000 description 3
- 238000002485 combustion reaction Methods 0.000 description 3
- -1 for example Chemical compound 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 239000000446 fuel Substances 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 230000002093 peripheral effect Effects 0.000 description 2
- 239000010936 titanium Substances 0.000 description 2
- 229910000531 Co alloy Inorganic materials 0.000 description 1
- 229910002515 CoAl Inorganic materials 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 230000004913 activation Effects 0.000 description 1
- 230000002776 aggregation Effects 0.000 description 1
- 238000004220 aggregation Methods 0.000 description 1
- 239000003245 coal Substances 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000010248 power generation Methods 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- 238000011144 upstream manufacturing Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C10/00—Solid state diffusion of only metal elements or silicon into metallic material surfaces
- C23C10/28—Solid state diffusion of only metal elements or silicon into metallic material surfaces using solids, e.g. powders, pastes
- C23C10/34—Embedding in a powder mixture, i.e. pack cementation
- C23C10/36—Embedding in a powder mixture, i.e. pack cementation only one element being diffused
- C23C10/48—Aluminising
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C10/00—Solid state diffusion of only metal elements or silicon into metallic material surfaces
- C23C10/04—Diffusion into selected surface areas, e.g. using masks
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C10/00—Solid state diffusion of only metal elements or silicon into metallic material surfaces
- C23C10/28—Solid state diffusion of only metal elements or silicon into metallic material surfaces using solids, e.g. powders, pastes
- C23C10/34—Embedding in a powder mixture, i.e. pack cementation
- C23C10/52—Embedding in a powder mixture, i.e. pack cementation more than one element being diffused in one step
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C10/00—Solid state diffusion of only metal elements or silicon into metallic material surfaces
- C23C10/28—Solid state diffusion of only metal elements or silicon into metallic material surfaces using solids, e.g. powders, pastes
- C23C10/34—Embedding in a powder mixture, i.e. pack cementation
- C23C10/52—Embedding in a powder mixture, i.e. pack cementation more than one element being diffused in one step
- C23C10/54—Diffusion of at least chromium
- C23C10/56—Diffusion of at least chromium and at least aluminium
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C10/00—Solid state diffusion of only metal elements or silicon into metallic material surfaces
- C23C10/60—After-treatment
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
Definitions
- This disclosure relates to forming an aluminide coating on a component.
- aluminide coatings on a component Various methods are known for forming aluminide coatings on a component.
- a pack cementation method for example, aluminum from an aluminum powder surrounding the component can be heated and diffused into a base material of that component.
- Such a method may be susceptible to cracking and/or trenching.
- the aluminum source may be chrome aluminum and/or cobalt aluminum.
- Activator material may be disposed with the metal alloy gravel.
- the activator material may be configured as or otherwise include halide material.
- the method may include a further step of heat treating the aluminide coating to provide a heat treated diffusion coating.
- the aluminide coating may be a green state coating.
- the heat treated diffusion coating may be a three-zone aluminide coating.
- the component may be laid on top of the metal alloy gravel.
- the component may be partially submersed in the metal alloy gravel.
- the component may be completely submersed in the metal alloy gravel.
- the method may include a step of masking a portion of the component such that the masked portion of the component is not coated with the aluminide coating.
- the component may be configured from or otherwise include a nickel alloy.
- the component may be configured as a part of a gas turbine engine.
- the component may be configured as an airfoil.
- FIG. 1 is a block diagram illustration of a system 20 for coating a component 22.
- FIG. 2 is a flow diagram of a method 200 for coating a component (e.g., 22) using a system such as, for example, the system 20 of FIG. 1 .
- the component 22 may be configured for an item of rotational equipment such as a gas turbine engine.
- This gas turbine engine may be configured in an aircraft propulsion system.
- the gas turbine engine may be configured in an auxiliary power unit for the aircraft.
- the methods and apparatuses of the present disclosure are not limited to such aircraft applications.
- the gas turbine engine may be configured as an industrial gas turbine engine in a power generation system.
- the item of rotational equipment may alternatively be configured as a wind turbine, a water turbine or any other item of rotational equipment which includes a component with a coating as described below.
- the component 22 is described below as a component of a gas turbine engine.
- the component 22, for example, may be configured as or include an airfoil as described below.
- Examples of such a component include, but are not limited to, a fan blade, a compressor blade, a turbine blade, a guide vane, a compressor vane, a turbine vane and a propeller.
- the component 22 of the present disclosure is not limited to the foregoing exemplary component configurations, or to rotational equipment applications.
- the component 22 has a metal component body 24; e.g., base material.
- This component body 24 provides the component 22 with its structure and general geometry; e.g., shape and dimensions.
- the component body 24 is constructed from metal, which is the base material.
- suitable metals include, but are not limited to, nickel (Ni), titanium (Ti) or an alloy of one or more of the foregoing materials.
- suitable metal alloy include, but are not limited to, airfoil and various hot section turbine components.
- the component body 24 of the present disclosure is not limited to the foregoing exemplary component body materials.
- source material 26 is provided for coating the component 22 and, more particularly, its body 24.
- the source material 26, for example, may be disposed in an open container 27 to provide a bed of the source material 26 as shown in FIG. 1 .
- This source material 26 includes metal alloy gravel.
- the source material 26 may also include activator material, which may be homogeneously or heterogeneously mixed with some or all of the metal alloy gravel.
- the metal alloy gravel includes a loose aggregation of small particles of metal alloy material. This metal alloy gravel is different from a quantity of metal alloy dust or powder.
- the metal alloy gravel of the present invention has an average particle size of at least about 0.125 inches (3.18 mm).
- the particle size may be a measure of a particle's diameter where that particle is generally spherical.
- the particle size may alternatively be a measure of a particle's length, width or height where that particle is non-spherical; e.g., globular cluster, cubic, ellipsoidal, etc.
- the average particle size of that particle may be the average of the particle's length, width and height.
- the average particle size of the metal alloy gravel may be calculated as an average of the particle sizes of the particles in the metal alloy gravel.
- the metal alloy material is a metal alloy which includes aluminum.
- the metal alloy material may be an alloy of cobalt (Co) and aluminum such as, for example, CoAl.
- the metal alloy material may be an alloy of chrome (Cr) and aluminum such as, for example, CrAl.
- the present disclosure is not limited to the foregoing exemplary alloys.
- the activator material is selected to promote diffusion of the aluminum from the metal alloy gravel into the component 22 and its body 24 to form an aluminide coating 28 (see FIG. 6 ).
- An example of such an activation material is a halide material; e.g., chloride halide.
- the present disclosure is not limited to the foregoing exemplary halide or activator material.
- the component 22 is disposed with the source material 26.
- the component 22, for example, may be partially submersed (e.g., covered) within the bed of the source material 26 as shown in FIGS. 1 and 3 . In this manner, the component 22 projects into the bed of the source material 26 such as that the source material 26 contacts multiple exterior surfaces 30-32 of the component body 24.
- the component 22 may be laid on top of the bed of the source material 26 as shown in FIG. 4 . In this manner, only the bottom surface 30 of the component body 24 contacts the source material 26.
- the component 22 may be completely submersed within (e.g., covered and surrounded by) the source material 26 as shown in FIG. 5 . In this manner, the source material 26 contacts all exterior surfaces (e.g., 30-33) of the component body 24 of FIG. 5 .
- the aluminide coating 28 is formed on the component 22 (see FIG. 6 ).
- a heating vessel 34 e.g., oven
- at least an outer peripheral portion of the component 22 as well as the source material 26 is heated to an elevated temperature using a heater 36 (see FIG. 1 ).
- the aluminum from the metal alloy gravel diffuses into material in an outer peripheral region of the component body 24 and thereby forms the aluminide coating 28 (see FIG. 6 ).
- the elevated temperature may be selected such that the aluminide coating 28 is generally (or more of) an inward diffusion coating rather than an outward diffusion coating.
- inward diffusion coating may describe a coating formed by diffusing material into a base material; i.e., the material being coated. Generally speaking, such an inward diffusion coating does not substantially change the exterior dimensions of the original base material.
- outward diffusion coating may describe a coating formed by the diffusion of a base material outward into surrounding material; i.e., coating material. Generally speaking, such an outward diffusion coating increases the exterior dimensions of the original base material.
- the elevated temperature is selected to be between fourteen-hundred degrees Fahrenheit (1400°F or 760°C) and sixteen-hundred degrees Fahrenheit (1600°F or 871°C).
- an exterior of the component body 24 of FIG. 6 is completely (partially in FIG. 10 ) coated with the aluminide coating 28; e.g., an inward diffusion aluminide coating.
- This aluminide coating 28 may be referred to as a green state coating.
- the term "green state coating” may describe a coating with a relatively high weight percentage and a relatively high atomic percentage of aluminum.
- the aluminide coating 28, for example may have a weight percentage of aluminum of about forty percent (40%) to about sixty percent (60%).
- the aluminide coating 28 may have an atomic percentage of aluminum of about sixty percent (60%) to about seventy percent (70%).
- Such a green state coating may be relatively brittle.
- the aluminide coating 28 formed in the coating step 206 is not limited to the foregoing exemplary weight and atomic percentages of aluminum.
- the coated component 22 and, more particularly, the aluminide coating 28 is heat treated to provide a heat treated aluminide coating 28' (see FIG. 7 ).
- the environment within the heating vessel 34 of FIG. 1 (or another heating vessel or system) and, as a result, the aluminide coating 28 is heated to another elevated temperature.
- the relatively brittle green state coating may be transformed into a less brittle diffused state coating.
- the term "diffused state coating” may describe a coating with a relatively low weight percentage and a relatively low atomic percentage of aluminum.
- the heat treated aluminide coating 28' may have a weight percentage of aluminum of about twenty-five percent (25%) to about thirty-two percent (32%).
- the heat treated aluminide coating 28' may have an atomic percentage of aluminum of about forty percent (40%) to about fifty percent (50%).
- the heat treated aluminide coating 28' formed in the heat treating step 208 is not limited to the foregoing exemplary weight and atomic percentages of aluminum.
- the heat treated aluminide coating 28' may be a three-zone aluminide coating as shown in FIG. 7 .
- Such a three-zone aluminide coating may include a diffusion zone 38, an intermediate zone 40 and an additive zone 42.
- the diffusion zone 38 is between the base material of the component body 24 and the intermediate zone 40.
- This zone 38 includes a relatively low atomic percentage of aluminum which has diffused into the base material of the component body 24.
- the intermediate zone 40 is between the diffusion zone 38 and the additive zone 42.
- This zone 40 includes a higher atomic percentage of aluminum than the diffusion zone 38, in which aluminum is also diffused to a lesser degree into the base material of the component body 24.
- the additive zone 42 is the outermost zone and includes the highest atomic percentage of aluminum, where the base material of the component body 24 may have diffused outward to form an additive portion.
- one or more portions of the component body 24 may be masked to prevent coating those portions with the aluminide coating 28, 28' described above.
- a mask 44 e.g., masking putty
- the masked off component 22 may then undergo the coating step 206 as shown in FIG. 9 .
- the mask 44 may be removed from the now coated component body 24 to reveal an uncoated (e.g., bare) surface 46 of the component body 24 as shown in FIG. 10 where the mask was removed.
- FIG. 11 illustrates one such type and configuration of the rotational equipment - a geared turbofan gas turbine engine 70.
- This turbine engine 70 includes various types and configurations of rotor blade airfoils as described below as well as stator vane airfoils, where the component 22 can be configured as anyone of the foregoing airfoils, or other structures not mentioned herein.
- the turbine engine 70 extends along an axial centerline 76 between an upstream airflow inlet 78 and a downstream airflow exhaust 80.
- the turbine engine 70 includes a fan section 82, a compressor section 83, a combustor section 84 and a turbine section 85.
- the compressor section 83 includes a low pressure compressor (LPC) section 83A and a high pressure compressor (HPC) section 83B.
- the turbine section 85 includes a high pressure turbine (HPT) section 85A and a low pressure turbine (LPT) section 85B.
- the engine sections 82-85 are arranged sequentially along the centerline 76 within an engine housing 86.
- This housing 86 includes an inner case 88 (e.g., a core case) and an outer case 90 (e.g., a fan case).
- the inner case 88 may house one or more of the engine sections 83-85; e.g., an engine core.
- the outer case 90 may house at least the fan section 82.
- Each of the engine sections 82, 83A, 83B, 85A and 85B includes a respective rotor 92-96.
- Each of these rotors 92-96 includes a plurality of rotor blades with airfoils arranged circumferentially around and connected to one or more respective rotor disks.
- the rotor blades may be formed integral with or mechanically fastened, welded, brazed, adhered and/or otherwise attached to the respective rotor disk(s).
- the fan rotor 92 is connected to a gear train 98, for example, through a fan shaft 100.
- the gear train 98 and the LPC rotor 93 are connected to and driven by the LPT rotor 96 through a low speed shaft 101.
- the HPC rotor 94 is connected to and driven by the HPT rotor 95 through a high speed shaft 102.
- the shafts 100-102 are rotatably supported by a plurality of bearings 104. Each of these bearings 104 is connected to the engine housing 86 by at least one stationary structure such as, for example, an annular support strut.
- This air is directed through the fan section 82 and into a core gas path 106 and a bypass gas path 108.
- the core gas path 106 flows sequentially through the engine sections 83-85.
- the bypass gas path 108 flows away from the fan section 82 through a bypass duct, which circumscribes and bypasses the engine core.
- the air within the core gas path 106 may be referred to as "core air”.
- the air within the bypass gas path 108 may be referred to as "bypass air”.
- the core air is compressed by the compressor rotors 93 and 94 and directed into a combustion chamber 110 of a combustor in the combustor section 84.
- Fuel is injected into the combustion chamber 110 and mixed with the compressed core air to provide a fuel-air mixture.
- This fuel air mixture is ignited and combustion products thereof flow through and sequentially cause the turbine rotors 95 and 96 to rotate.
- the rotation of the turbine rotors 95 and 96 respectively drive rotation of the compressor rotors 94 and 93 and, thus, compression of the air received from a core airflow inlet.
- the rotation of the turbine rotor 96 also drives rotation of the fan rotor 92, which propels bypass air through and out of the bypass gas path 108.
- the propulsion of the bypass air may account for a majority of thrust generated by the turbine engine 70, e.g., more than seventy-five percent (75%) of engine thrust.
- the turbine engine 70 of the present disclosure is not limited to the foregoing exemplary thrust ratio.
- the component 22 may be included in various aircraft and industrial turbine engines other than the one described above as well as in other types of rotational equipment and non-rotating equipment.
- the component 22 may be included in a geared turbine engine where a gear train connects one or more shafts to one or more rotors in a fan section, a compressor section and/or any other engine section.
- the component 22 may be included in a turbine engine configured without a gear train.
- the component 22 may be included in a geared or non-geared turbine engine configured with a single spool, with two spools (e.g., see FIG. 11 ), or with more than two spools.
- the turbine engine may be configured as a turbofan engine, a turbojet engine, a propfan engine, a pusher fan engine or any other type of turbine engine.
- the present invention is not limited to any particular types or configurations of turbine engines or rotational equipment.
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- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Physics & Mathematics (AREA)
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Description
- This disclosure relates to forming an aluminide coating on a component.
- Various methods are known for forming aluminide coatings on a component. During a pack cementation method, for example, aluminum from an aluminum powder surrounding the component can be heated and diffused into a base material of that component. Such a method, however, may be susceptible to cracking and/or trenching. There is a need in the art therefore for improved methods for forming an aluminide coating on a component.
-
US 2011/074113 discloses features of the preamble of claim 1. - According to the present disclosure, a method is provided for coating a component as claimed in claim 1.
- The aluminum source may be chrome aluminum and/or cobalt aluminum.
- Activator material may be disposed with the metal alloy gravel.
- The activator material may be configured as or otherwise include halide material.
- The method may include a further step of heat treating the aluminide coating to provide a heat treated diffusion coating.
- The aluminide coating may be a green state coating. In addition or alternatively, the heat treated diffusion coating may be a three-zone aluminide coating.
- The component may be laid on top of the metal alloy gravel.
- The component may be partially submersed in the metal alloy gravel.
- The component may be completely submersed in the metal alloy gravel.
- The method may include a step of masking a portion of the component such that the masked portion of the component is not coated with the aluminide coating.
- The component may be configured from or otherwise include a nickel alloy.
- The component may be configured as a part of a gas turbine engine.
- The component may be configured as an airfoil.
- The foregoing features and the operation of the invention will become more apparent in light of the following description and the accompanying drawings.
-
-
FIG. 1 is a block diagram illustration of a system for coating a component. -
FIG. 2 is a flow diagram of a method for coating a component using a system. -
FIG. 3 is a block diagram of a component disposed partially in material used in coating that component. -
FIG. 4 is a block diagram of a component disposed on material used in coating that component. -
FIG. 5 is a block diagram of a component disposed completely within material used in coating that component. -
FIG. 6 is a sectional block diagram of a coated component. -
FIG. 7 is a sectional block diagram of a portion of another coated component. -
FIG. 8 is a block diagram of a masked component prior to being coating. -
FIG. 9 is a block diagram of the masked component during the coating. -
FIG. 10 is a block diagram of the component after the coating and unmasked. -
FIG. 11 is a side cutaway illustration of a gas turbine engine. -
FIG. 1 is a block diagram illustration of asystem 20 for coating acomponent 22.FIG. 2 is a flow diagram of amethod 200 for coating a component (e.g., 22) using a system such as, for example, thesystem 20 ofFIG. 1 . - The
component 22 may be configured for an item of rotational equipment such as a gas turbine engine. This gas turbine engine may be configured in an aircraft propulsion system. Alternatively, the gas turbine engine may be configured in an auxiliary power unit for the aircraft. The methods and apparatuses of the present disclosure, however, are not limited to such aircraft applications. In other embodiments, for example, the gas turbine engine may be configured as an industrial gas turbine engine in a power generation system. In still other embodiments, the item of rotational equipment may alternatively be configured as a wind turbine, a water turbine or any other item of rotational equipment which includes a component with a coating as described below. - For ease of description, the
component 22 is described below as a component of a gas turbine engine. Thecomponent 22, for example, may be configured as or include an airfoil as described below. Examples of such a component include, but are not limited to, a fan blade, a compressor blade, a turbine blade, a guide vane, a compressor vane, a turbine vane and a propeller. Thecomponent 22 of the present disclosure, however, is not limited to the foregoing exemplary component configurations, or to rotational equipment applications. - The
component 22 has ametal component body 24; e.g., base material. Thiscomponent body 24 provides thecomponent 22 with its structure and general geometry; e.g., shape and dimensions. Thecomponent body 24 is constructed from metal, which is the base material. Examples of suitable metals include, but are not limited to, nickel (Ni), titanium (Ti) or an alloy of one or more of the foregoing materials. Examples of a component body metal alloy include, but are not limited to, airfoil and various hot section turbine components. Thecomponent body 24 of the present disclosure, however, is not limited to the foregoing exemplary component body materials. - In
step 202,source material 26 is provided for coating thecomponent 22 and, more particularly, itsbody 24. Thesource material 26, for example, may be disposed in anopen container 27 to provide a bed of thesource material 26 as shown inFIG. 1 . Thissource material 26 includes metal alloy gravel. Thesource material 26 may also include activator material, which may be homogeneously or heterogeneously mixed with some or all of the metal alloy gravel. - The metal alloy gravel includes a loose aggregation of small particles of metal alloy material. This metal alloy gravel is different from a quantity of metal alloy dust or powder. The metal alloy gravel of the present invention has an average particle size of at least about 0.125 inches (3.18 mm).
- The particle size may be a measure of a particle's diameter where that particle is generally spherical. The particle size may alternatively be a measure of a particle's length, width or height where that particle is non-spherical; e.g., globular cluster, cubic, ellipsoidal, etc. In such a case, the average particle size of that particle may be the average of the particle's length, width and height. In turn, the average particle size of the metal alloy gravel may be calculated as an average of the particle sizes of the particles in the metal alloy gravel.
- The metal alloy material is a metal alloy which includes aluminum. The metal alloy material, for example, may be an alloy of cobalt (Co) and aluminum such as, for example, CoAl. In another example, the metal alloy material may be an alloy of chrome (Cr) and aluminum such as, for example, CrAl. The present disclosure, however, is not limited to the foregoing exemplary alloys.
- The activator material is selected to promote diffusion of the aluminum from the metal alloy gravel into the
component 22 and itsbody 24 to form an aluminide coating 28 (seeFIG. 6 ). An example of such an activation material is a halide material; e.g., chloride halide. The present disclosure, however, is not limited to the foregoing exemplary halide or activator material. - In
step 204, thecomponent 22 is disposed with thesource material 26. Thecomponent 22, for example, may be partially submersed (e.g., covered) within the bed of thesource material 26 as shown inFIGS. 1 and3 . In this manner, thecomponent 22 projects into the bed of thesource material 26 such as that the source material 26 contacts multiple exterior surfaces 30-32 of thecomponent body 24. Alternatively, thecomponent 22 may be laid on top of the bed of thesource material 26 as shown inFIG. 4 . In this manner, only thebottom surface 30 of thecomponent body 24 contacts thesource material 26. Still alternatively, thecomponent 22 may be completely submersed within (e.g., covered and surrounded by) thesource material 26 as shown inFIG. 5 . In this manner, the source material 26 contacts all exterior surfaces (e.g., 30-33) of thecomponent body 24 ofFIG. 5 . - In
step 206, thealuminide coating 28 is formed on the component 22 (seeFIG. 6 ). In particular, an environment within a heating vessel 34 (e.g., oven) and, as a result, at least an outer peripheral portion of thecomponent 22 as well as thesource material 26 is heated to an elevated temperature using a heater 36 (seeFIG. 1 ). At this elevated temperature, the aluminum from the metal alloy gravel diffuses into material in an outer peripheral region of thecomponent body 24 and thereby forms the aluminide coating 28 (seeFIG. 6 ). - The elevated temperature may be selected such that the
aluminide coating 28 is generally (or more of) an inward diffusion coating rather than an outward diffusion coating. The term "inward diffusion coating" may describe a coating formed by diffusing material into a base material; i.e., the material being coated. Generally speaking, such an inward diffusion coating does not substantially change the exterior dimensions of the original base material. In contrast, the term "outward diffusion coating" may describe a coating formed by the diffusion of a base material outward into surrounding material; i.e., coating material. Generally speaking, such an outward diffusion coating increases the exterior dimensions of the original base material. - To form an inward diffusion coating, the elevated temperature is selected to be between fourteen-hundred degrees Fahrenheit (1400°F or 760°C) and sixteen-hundred degrees Fahrenheit (1600°F or 871°C).
- Upon completion of the
coating step 206, an exterior of thecomponent body 24 ofFIG. 6 is completely (partially inFIG. 10 ) coated with thealuminide coating 28; e.g., an inward diffusion aluminide coating. Thisaluminide coating 28 may be referred to as a green state coating. Herein, the term "green state coating" may describe a coating with a relatively high weight percentage and a relatively high atomic percentage of aluminum. Thealuminide coating 28, for example, may have a weight percentage of aluminum of about forty percent (40%) to about sixty percent (60%). Thealuminide coating 28 may have an atomic percentage of aluminum of about sixty percent (60%) to about seventy percent (70%). Such a green state coating may be relatively brittle. Thealuminide coating 28 formed in thecoating step 206, however, is not limited to the foregoing exemplary weight and atomic percentages of aluminum. - In
step 208, thecoated component 22 and, more particularly, thealuminide coating 28 is heat treated to provide a heat treated aluminide coating 28' (seeFIG. 7 ). In particular, the environment within theheating vessel 34 ofFIG. 1 (or another heating vessel or system) and, as a result, thealuminide coating 28 is heated to another elevated temperature. At this elevated temperature, the relatively brittle green state coating may be transformed into a less brittle diffused state coating. Herein, the term "diffused state coating" may describe a coating with a relatively low weight percentage and a relatively low atomic percentage of aluminum. The heat treated aluminide coating 28', for example, may have a weight percentage of aluminum of about twenty-five percent (25%) to about thirty-two percent (32%). The heat treated aluminide coating 28' may have an atomic percentage of aluminum of about forty percent (40%) to about fifty percent (50%). The heat treated aluminide coating 28' formed in theheat treating step 208, however, is not limited to the foregoing exemplary weight and atomic percentages of aluminum. - The heat treated aluminide coating 28' may be a three-zone aluminide coating as shown in
FIG. 7 . Such a three-zone aluminide coating may include adiffusion zone 38, anintermediate zone 40 and anadditive zone 42. Thediffusion zone 38 is between the base material of thecomponent body 24 and theintermediate zone 40. Thiszone 38 includes a relatively low atomic percentage of aluminum which has diffused into the base material of thecomponent body 24. Theintermediate zone 40 is between thediffusion zone 38 and theadditive zone 42. Thiszone 40 includes a higher atomic percentage of aluminum than thediffusion zone 38, in which aluminum is also diffused to a lesser degree into the base material of thecomponent body 24. Theadditive zone 42 is the outermost zone and includes the highest atomic percentage of aluminum, where the base material of thecomponent body 24 may have diffused outward to form an additive portion. - In some embodiments, one or more portions of the
component body 24 may be masked to prevent coating those portions with thealuminide coating 28, 28' described above. For example, referring toFIG. 8 , a mask 44 (e.g., masking putty) may be applied to an exterior surface of thecomponent body 24. The masked offcomponent 22 may then undergo thecoating step 206 as shown inFIG. 9 . After thiscoating step 206, themask 44 may be removed from the now coatedcomponent body 24 to reveal an uncoated (e.g., bare)surface 46 of thecomponent body 24 as shown inFIG. 10 where the mask was removed. - As described above, the
component 22 of the present disclosure may be configured with various different types and configurations of rotational equipment, or other devices.FIG. 11 illustrates one such type and configuration of the rotational equipment - a geared turbofangas turbine engine 70. Thisturbine engine 70 includes various types and configurations of rotor blade airfoils as described below as well as stator vane airfoils, where thecomponent 22 can be configured as anyone of the foregoing airfoils, or other structures not mentioned herein. - Referring still to
FIG. 11 , theturbine engine 70 extends along anaxial centerline 76 between anupstream airflow inlet 78 and adownstream airflow exhaust 80. Theturbine engine 70 includes afan section 82, acompressor section 83, acombustor section 84 and aturbine section 85. Thecompressor section 83 includes a low pressure compressor (LPC)section 83A and a high pressure compressor (HPC)section 83B. Theturbine section 85 includes a high pressure turbine (HPT)section 85A and a low pressure turbine (LPT)section 85B. - The engine sections 82-85 are arranged sequentially along the
centerline 76 within anengine housing 86. Thishousing 86 includes an inner case 88 (e.g., a core case) and an outer case 90 (e.g., a fan case). Theinner case 88 may house one or more of the engine sections 83-85; e.g., an engine core. Theouter case 90 may house at least thefan section 82. - Each of the
engine sections - The
fan rotor 92 is connected to agear train 98, for example, through afan shaft 100. Thegear train 98 and theLPC rotor 93 are connected to and driven by theLPT rotor 96 through alow speed shaft 101. TheHPC rotor 94 is connected to and driven by theHPT rotor 95 through ahigh speed shaft 102. The shafts 100-102 are rotatably supported by a plurality ofbearings 104. Each of thesebearings 104 is connected to theengine housing 86 by at least one stationary structure such as, for example, an annular support strut. - During operation, air enters the
turbine engine 70 through theairflow inlet 78. This air is directed through thefan section 82 and into acore gas path 106 and abypass gas path 108. Thecore gas path 106 flows sequentially through the engine sections 83-85. Thebypass gas path 108 flows away from thefan section 82 through a bypass duct, which circumscribes and bypasses the engine core. The air within thecore gas path 106 may be referred to as "core air". The air within thebypass gas path 108 may be referred to as "bypass air". - The core air is compressed by the
compressor rotors combustion chamber 110 of a combustor in thecombustor section 84. Fuel is injected into thecombustion chamber 110 and mixed with the compressed core air to provide a fuel-air mixture. This fuel air mixture is ignited and combustion products thereof flow through and sequentially cause theturbine rotors turbine rotors compressor rotors turbine rotor 96 also drives rotation of thefan rotor 92, which propels bypass air through and out of thebypass gas path 108. The propulsion of the bypass air may account for a majority of thrust generated by theturbine engine 70, e.g., more than seventy-five percent (75%) of engine thrust. Theturbine engine 70 of the present disclosure, however, is not limited to the foregoing exemplary thrust ratio. - The
component 22 may be included in various aircraft and industrial turbine engines other than the one described above as well as in other types of rotational equipment and non-rotating equipment. Thecomponent 22 may be included in a geared turbine engine where a gear train connects one or more shafts to one or more rotors in a fan section, a compressor section and/or any other engine section. Alternatively, thecomponent 22 may be included in a turbine engine configured without a gear train. Thecomponent 22 may be included in a geared or non-geared turbine engine configured with a single spool, with two spools (e.g., seeFIG. 11 ), or with more than two spools. The turbine engine may be configured as a turbofan engine, a turbojet engine, a propfan engine, a pusher fan engine or any other type of turbine engine. The present invention, however, is not limited to any particular types or configurations of turbine engines or rotational equipment. - Accordingly, the present invention is not to be restricted except in light of the attached claims.
Claims (12)
- A method for coating a component (22), comprising:disposing the component (22) with metal alloy gravel comprising aluminum;heating the metal alloy gravel adjacent the component (22) to a temperature between 1400 degrees Fahrenheit and 1600 degrees Fahrenheit (760 degrees Celsius and 871 degrees Celsius); andforming an aluminide coating (28) on the component (22), wherein the aluminum from the metal alloy gravel diffuses into the component (22) to form the aluminide coating (28),characterised in that the metal alloy gravel has an average particle size of at least 0.125 inches (3.18 mm).
- The method of claim 1, wherein the metal alloy gravel further comprises chrome aluminum and/or cobalt aluminum.
- The method of any preceding claim, wherein activator material is disposed with the metal alloy gravel.
- The method of claim 3, where the activator material comprises halide material.
- The method of any preceding claim, further comprising heat treating the aluminide coating (28) to provide a heat treated diffusion coating.
- The method of claim 5, wherein the aluminide coating (28) is a green state coating, and the heat treated diffusion coating is a three-zone aluminide coating.
- The method of any preceding claim, wherein the component (22) is laid on top of the metal alloy gravel.
- The method of any of claims 1 to 6, wherein the component (22) is partially or completely submersed in the metal alloy gravel.
- The method of any preceding claim, further comprising masking a portion of the component (22) such that the masked portion of the component (22) is not coated with the aluminide coating (28).
- The method of any preceding claim, wherein the component (22) comprises a nickel alloy.
- The method of any preceding claim, wherein the component (22) is configured as a part of a gas turbine engine (70).
- The method of claim 11, wherein the component (22) is an airfoil.
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US15/016,344 US20170226623A1 (en) | 2016-02-05 | 2016-02-05 | Forming aluminide coating using metal alloy gravel |
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EP3202946A1 EP3202946A1 (en) | 2017-08-09 |
EP3202946B1 true EP3202946B1 (en) | 2020-10-21 |
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EP17153434.0A Active EP3202946B1 (en) | 2016-02-05 | 2017-01-27 | Forming aluminide coating using metal alloy gravel |
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US (1) | US20170226623A1 (en) |
EP (1) | EP3202946B1 (en) |
Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20110074113A1 (en) * | 2009-09-30 | 2011-03-31 | General Electric Company | Method and composition for coating of honeycomb seals |
Family Cites Families (6)
Publication number | Priority date | Publication date | Assignee | Title |
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US3837901A (en) * | 1970-08-21 | 1974-09-24 | Gen Electric | Diffusion-coating of nickel-base superalloy articles |
EP0731187A1 (en) * | 1995-03-07 | 1996-09-11 | Turbine Components Corporation | Method of forming a protective diffusion layer on nickel, cobalt and iron based alloys |
US6224941B1 (en) * | 1998-12-22 | 2001-05-01 | General Electric Company | Pulsed-vapor phase aluminide process for high temperature oxidation-resistant coating applications |
US7371428B2 (en) * | 2005-11-28 | 2008-05-13 | Howmet Corporation | Duplex gas phase coating |
US20090035485A1 (en) * | 2007-08-02 | 2009-02-05 | United Technologies Corporation | Method for forming active-element aluminide diffusion coatings |
WO2010135144A1 (en) * | 2009-05-18 | 2010-11-25 | Sifco Industries, Inc. | Forming reactive element modified aluminide coatings with low reactive element content using vapor phase diffusion techniques |
-
2016
- 2016-02-05 US US15/016,344 patent/US20170226623A1/en not_active Abandoned
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2017
- 2017-01-27 EP EP17153434.0A patent/EP3202946B1/en active Active
Patent Citations (1)
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US20110074113A1 (en) * | 2009-09-30 | 2011-03-31 | General Electric Company | Method and composition for coating of honeycomb seals |
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US20170226623A1 (en) | 2017-08-10 |
EP3202946A1 (en) | 2017-08-09 |
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