JP2021501830A - タービンブレードおよびその他の構成要素の耐水滴浸食性コーティング材 - Google Patents
タービンブレードおよびその他の構成要素の耐水滴浸食性コーティング材 Download PDFInfo
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- JP2021501830A JP2021501830A JP2020524456A JP2020524456A JP2021501830A JP 2021501830 A JP2021501830 A JP 2021501830A JP 2020524456 A JP2020524456 A JP 2020524456A JP 2020524456 A JP2020524456 A JP 2020524456A JP 2021501830 A JP2021501830 A JP 2021501830A
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Classifications
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/01—Layered products comprising a layer of metal all layers being exclusively metallic
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/01—Layered products comprising a layer of metal all layers being exclusively metallic
- B32B15/013—Layered products comprising a layer of metal all layers being exclusively metallic one layer being formed of an iron alloy or steel, another layer being formed of a metal other than iron or aluminium
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C19/00—Alloys based on nickel or cobalt
- C22C19/07—Alloys based on nickel or cobalt based on cobalt
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C27/00—Alloys based on rhenium or a refractory metal not mentioned in groups C22C14/00 or C22C16/00
- C22C27/04—Alloys based on tungsten or molybdenum
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
- C22C29/02—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides
- C22C29/06—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds
- C22C29/08—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds based on tungsten carbide
-
- C—CHEMISTRY; METALLURGY
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- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
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- F04D29/00—Details, component parts, or accessories
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- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
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- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
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- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
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Abstract
Description
i)タービンのより効率的な高温運転を可能にするためにホットゾーンブレードに施された遮熱コーティング、
ii)空気/ガスシールシステムを形成するようにアブレイダブルシュラウドを切断するためにブレード端に施されたアブレイシブコーティング、
iii)ブレードの腐食を防止するために施された耐腐食性コーティング、および
iv)耐浸食性コーティング。
i)強化された耐水滴浸食性;
ii)強化された耐固体粒子浸食性;
iii)腐食性流体の浸食から基体材料を絶縁するための腐食保護特性および低多孔度;
iv)コーティング後の研磨なしにエアフォイルブレードの3D形状を維持するように堆積されたコーティング厚さの良好な均一性;
v)金属ブレードに対するコーティングの強固な接着結合;
vi)水滴浸食に抵抗する十分な厚さ、適切な構造および機械的性質;
vii)コーティングは、亀裂の発生および伝播を防止し、その耐疲労特性を高めるために、好ましくは、圧縮残留応力下にあるべきである;
viii)コーティングの水平方向のひび割れや凝集破壊の原因になることから、圧縮応力が過大にならないようにする;
ix)機械的摩耗に抵抗するのに十分な硬度、また、機械的または熱的衝撃または複数の衝撃疲労条件下での脆性破壊および微小亀裂に対するコーティングを防止するための強化された靭性および延性;
x)「堆積した」状態でのコーティング表面は、粗さが低くあるべきであり、必要に応じて、典型的には0.2ミクロンRa前後(またはそれ未満)のタービンブレードに必要な表面仕上げまでの研磨に適しているべきである(タービンブレードまたはベーンの複雑な3Dエアフォイル形状がコーティング後の仕上げを複雑にするので、これは有利である)。
i)コーティングプロセス温度を320℃〜580℃の範囲に維持すること;
ii)1時間当たり3.5〜82μmの範囲、任意に1時間当たり4〜18μmの範囲のコーティング付着速度の維持;
iii)コーティング後の平均冷却速度を毎分0.12°C〜1.9°Cの範囲に維持すること;
iv)タービン部品の研磨、任意で他のコーティング後の仕上げ作業を行い、0.2ミクロンRa以下の表面仕上げ粗さを達成すること。
i)チャンバまたはガスシステムに空気が漏れないように、CVD反応チャンバおよびそのガスシステムを真空密閉させる;これは、真空密閉システム設計および構成要素を使用することによって、およびチャンバーフランジおよびシールおよびその他の構成要素の真空密閉性を反応器開放ごとにヘリウム漏れ検出器で試験することによって達成することができる。ヘリウム漏れ限界は、例えば、1×10−9mbar.l/sに設定することができる。この限界を超えた場合、反応器を開け、フランジとシールを洗浄し、反応器を閉じ、別のヘリウム漏れ試験を行い、限界が満たされていることを確認する。
ii)吸着した水および酸素を除去するために、例えば、チャンバを加熱し、オプションとして、チャンバの表面および装填された構成要素から吸着した酸素および/または水の痕跡を除去するために、指定された真空圧力までチャンバを真空排気する前に、不活性気体を指定された分圧まで反応チャンバに充填する一連のサイクルを任意に実行することによって、CVD反応チャンバおよび装填された構成要素をパージおよび脱気して、CVD反応チャンバおよび装填された構成要素を除去する。本出願人は、真空チャンバの内部に10m2以上の面積の内部ステンレス鋼表面を有する可能性のある大型CVD反応器が、チャンバを開いてCVD処理前に部品をロードするときに、かなりの量の水蒸気を吸着することを見出した。冷却された真空シール領域のような原子炉チャンバの水冷領域は、このような水の凝縮に特に曝されることが見出された。また、ステンレス鋼表面は酸素を吸着できることが分かっている。本出願人は、驚くべきことに、各CVDサイクルの前に真空チャンバを脱気し、より高純度のガス(特に水素還元ガス及びアルカンガス)を使用すると、機械的性質が著しく改善された実質的に無酸素コーティングが得られることを見出した。
iii)実質的に無酸素で水分のない前駆体及びプロセスガスを用いて、例えば、酸素量が10ppm以下で水分量が3ppm以下の反応性混合ガスを得る。工業グレードの水素は通常電解によって生成され、その結果、かなりの量の水蒸気としばしば微量の酸素を含むので、前駆体とプロセスガスの純度は、コーティングプロセスにおいて水素ガスを使用する場合に特に重要であることが見出された。
iv)コーティングされた材料を冷却させながら、コーティングプロセスの完了後に実質的に無酸素および無水の不活性気体でCVD反応チャンバを埋め戻すこと。
v)コーティングされた部品を200℃以下の温度まで冷却してから反応器チャンバを開放し、堆積コーティングの表面下酸化を低減する。
以下、添付の図面を参照して、本発明の実施形態をさらに説明する:
Claims (51)
- 基体上にコーティングされた耐浸食性耐腐食性材料であって、空気または水分に曝される表面部分以外において、実質的に酸素を含まない実質的に均一なナノ構造で炭素と合金化された金属タングステンを含み、前記材料が柱状の結晶微細構造を有する、材料。
- 基体上にコーティングされた耐水滴浸食性コーティング材料であって、空気または水分に曝される表面部分以外において、実質的に酸素を含まない実質的に均一なナノ構造で炭素と合金化された金属タングステンを含み、前記材料が柱状の結晶微細構造を有する、材料。
- 前記金属タングステンは、前記材料の総重量に基づいて、0.0001〜0.37wt%の量の炭素と合金化されており、任意に、前記材料の総重量に基づいて、0.0001〜0.21wt%の量の炭素と合金化されている、請求項1または2に記載の材料。
- 本質的に炭素と合金化された金属タングステンからなり、任意に、フッ素とさらに合金化された、請求項1から3のいずれか一項に記載の材料。
- 前記金属タングステンは、フッ素とさらに合金化されている、請求項1から4のいずれか一項に記載の材料。
- 前記金属タングステンは、前記材料の総重量に基づいて、0.0004〜0.31wt%の量のフッ素と合金化されており、任意に、前記材料の総重量に基づいて、0.0014〜0.19wt%の量のフッ素と合金化されている、請求項5に記載の材料。
- 前記材料は、オキシフルオライドを実質的に含まない、請求項5または6に記載の材料。
- 前記材料が、X線回折分析を受けたときにA15結晶構造を有する介在物に特徴的なピークを示さない、請求項1から7のいずれか一項に記載の材料。
- 前記材料が、X線回折分析を受けたときにA15結晶構造を有する炭化タングステンに特徴的なピークを示さない、請求項1から8のいずれか一項に記載の材料。
- 前記材料は、実質的に非多孔性である、請求項1から9のいずれか一項に記載の材料。
- 前記材料が0.5%体積未満の多孔度、任意に0.3%体積未満の多孔度、任意に0.2%体積未満の多孔度、任意に0.15%体積未満の多孔度を有する、請求項1〜9のいずれか一項に記載の材料。
- 97.60〜99.99wt%のタングステンの組成を有する、請求項1から11のいずれかに一項記載の材料。
- 4.4GPaから19GPa、任意で8GPaから16GPaの硬度を有する、請求項1から12のいずれか一項に記載の材料。
- 少なくとも9MPa.m1/2の破壊靭性を有する、請求項1から13のいずれか一項に記載の材料。
- 前記材料は、応力集中部として作用する多孔度、空隙および/または介在物を実質的に含まない、請求項1から14のいずれか一項に記載の材料。
- 前記いずれかの請求項に記載の基体上にコーティングされた化学蒸着材料。
- 前記材料が、520MPaから5.3GPa、任意で810MPaから2.63GPaの残留圧縮応力を有する、請求項16に記載の基体上にコーティングされた材料。
- 前記材料が、少なくとも15μm、任意で少なくとも50μmの厚さを有する、請求項16または17に記載の基体上にコーティングされた材料。
- 前記材料は、200μm以下の厚さを有し、任意に100μm以下である、請求項16から18のいずれか一項に記載の基体上にコーティングされた材料。
- 1μm Ra未満、任意に0.2μm Ra未満の表面粗さを有する、請求項16から19のいずれか一項に記載の基体上にコーティングされた材料。
- 化学蒸着によって堆積された材料が、堆積後に研磨を必要とせずに、基体の表面粗さよりも1μm以下の表面粗さRaを有する、請求項16から20のいずれか一項に記載の基体上にコーティングされた材料。
- 本質的に本質的にフッ素と随意的に合金化した金属タングステンからなる前記コーティングのより近い軟質層と、請求項1から15のいずれか一項の材料を含む前記コーティングのより硬質層とを少なくとも含む、請求項16から21のいずれか一項に記載の基体上にコーティングされた材料。
- 前記軟質層の前記金属タングステンは、前記軟質層の総重量に基づいて、0.0004〜0.31wt%の量のフッ素と合金化され、任意に、前記軟質層の総重量に基づいて、0.0014〜0.19wt%の量のフッ素と合金化される、請求項22に記載の基体上にコーティングされた材料。
- 前記軟質層と前記硬質層との間に遷移層をさらに含む、請求項22または23に記載の基体上にコーティングされた材料。
- 遷移層中の炭素の濃度が、より柔らかい層からより硬い層への方向に増加する、請求項24に記載の基体上にコーティングされた材料。
- 前記遷移層は、少なくとも0.01μm、任意で少なくとも0.1μmの厚さを有する、請求項24または25に記載の基体上にコーティングされた材料。
- 前記軟質層と前記硬質層との間の厚さの比が1:10〜10:1である、請求項22〜26のいずれか一項に記載の基体上にコーティングされた材料。
- 前記軟質層および硬質層、および任意に、前記遷移層の合計厚さは、1〜50μmである、請求項22から27のいずれか一項に記載の基体上にコーティングされた材料。
- 交互の層の多層構造を形成するように、より柔らかくより硬い層対を複数備える、請求項16から28のいずれか一項に記載の基体上にコーティングされた材料。
- 2〜100個のより柔らかくより硬い層対を含む、請求項29に記載の基体上にコーティングされた材料。
- 請求項1から15のいずれか一項に記載の材料で少なくとも部分的にコーティングされたタービンまたはコンプレッサのブレードまたはベーン。
- 前記ブレードまたはベーンは、蒸気タービンまたは蒸気コンプレッサのブレードまたはベーンである、請求項31に記載のタービンまたはコンプレッサのブレードまたはベーン。
- 液体中でキャビテーションを受けるポンプインペラ、プロペラ、バルブ、または他の構成要素であって、少なくとも部分的に、請求項1乃至15のいずれかに記載の材料でコーティングされている、ポンプインペラ、プロペラ、バルブまたは他の構成要素。
- 水滴浸食に対する耐性を有するタービンまたはコンプレッサのブレードまたはベーンを提供する方法であって、化学蒸着によって前記ブレードまたはベーンを請求項1から30のいずれか一項の材料で少なくとも部分的にコーティングするステップを含む方法。
- 前記ブレードまたはベーンは、蒸気タービンまたは蒸気圧縮機のブレードまたはベーンである、請求項34に記載の方法。
- ポンプインペラ、プロペラ、バルブ、またはキャビテーションに対する耐性を有する他の構成要素を提供する方法であって、化学蒸着によって、請求項1から30のいずれか一項に記載の材料で構成要素を少なくとも部分的にコーティングすることを含む方法。
- WF6、水素及び少なくとも1つの炭化水素の混合物を含む気相、ならびに任意に不活性気体からなる化学気相からの化学気相堆積によって、酸素含有量が10ppm以下で水含有量が3ppm以下の前記気相を生成する、請求項1から15のいずれか一項に記載の材料の製造方法。
- 前記気相がイオン化されていない、請求項37に記載の方法。
- 前記気相は、前記堆積プロセス中に化学的に活性である、請求項37または38に記載の方法。
- WF6、水素及び少なくとも1つの炭化水素と、任意に不活性気体との気相混合物を0.1〜5kPaの圧力で少なくとも10分間、320〜580℃の温度で行う、請求項37から39のいずれか一項に記載の方法。
- 少なくとも1つの炭化水素が気体アルカンを含むか、またはそれからなる、請求項37〜40のいずれか一項に記載の方法。
- 前記少なくとも1つの炭化水素は、WF6および水素と混合する前に、500〜850℃の温度に加熱することによって熱活性化される、請求項37から41のいずれか一項に記載の方法。
- 前記化学蒸着が反応チャンバ内で行われる、請求項37から42のいずれか一項に記載の方法。
- 前記反応チャンバが、前記気相の導入前に真空中で加熱することによって脱気される、請求項43に記載の方法。
- 前記反応チャンバが不活性気体で満たされ、加熱され、次いで、前記気相の導入前に排気される、請求項43または44に記載の方法。
- 前記反応チャンバが、開かれた後、任意にヘリウム漏れ検出器を介して、閉じられるたびに真空試験される、請求項43乃至45のいずれか一項に記載の方法。
- 前記反応チャンバが開放される前に、前記材料が200℃以下に冷却される、請求項43から46のいずれか一項に記載の方法。
- 前記材料は、蒸着後、毎分0.12℃〜1.9℃の平均速度で冷却される、請求項37から47のいずれか一項に記載の方法
- 時速3.5〜82μm、任意に時速4〜18μmの速度で材料が堆積される、請求項37から48のいずれか一項に記載の方法。
- 請求項1から15のいずれか一項に記載の材料でブレードまたはベーンをコーティングすることを含む、タービンまたはコンプレッサのブレードまたはベーンの水滴浸食に抵抗する方法。
- 請求項1から15のいずれか一項に記載の材料で構成要素をコーティングすることを含む、ポンプインペラ、プロペラ、バルブまたは他の構成要素のキャビテーション壊食に抵抗する方法。
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JP2016517838A (ja) * | 2013-03-27 | 2016-06-20 | ハーダイド ピーエルシー | 保護接着剤被膜を有する超砥粒材料およびその被膜の製造方法 |
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WO2019086848A2 (en) | 2019-05-09 |
EP3684963A2 (en) | 2020-07-29 |
KR102607774B1 (ko) | 2023-11-29 |
CN111479951B (zh) | 2022-11-15 |
CA3081501A1 (en) | 2019-05-09 |
US11795830B2 (en) | 2023-10-24 |
RU2020118018A3 (ja) | 2022-04-06 |
US20200370440A1 (en) | 2020-11-26 |
RU2020118018A (ru) | 2021-12-02 |
GB2568063B (en) | 2019-10-30 |
WO2019086848A3 (en) | 2019-09-12 |
GB2568063A (en) | 2019-05-08 |
CN111479951A (zh) | 2020-07-31 |
GB201718191D0 (en) | 2017-12-20 |
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