US20090246008A1 - Layer System - Google Patents
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- US20090246008A1 US20090246008A1 US12/481,093 US48109309A US2009246008A1 US 20090246008 A1 US20090246008 A1 US 20090246008A1 US 48109309 A US48109309 A US 48109309A US 2009246008 A1 US2009246008 A1 US 2009246008A1
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- Prior art keywords
- layer
- ceramic layer
- substrate
- vane
- yttrium
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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
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
- C23C28/32—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer
- C23C28/321—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer with at least one metal alloy layer
- C23C28/3215—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer with at least one metal alloy layer at least one MCrAlX layer
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- 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
- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
-
- 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
- B32B18/00—Layered products essentially comprising ceramics, e.g. refractory products
-
- 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
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
- C23C28/34—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates
- C23C28/345—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
- C23C28/34—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates
- C23C28/345—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer
- C23C28/3455—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer with a refractory ceramic layer, e.g. refractory metal oxide, ZrO2, rare earth oxides or a thermal barrier system comprising at least one refractory oxide layer
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- 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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T50/00—Aeronautics or air transport
- Y02T50/60—Efficient propulsion technologies, e.g. for aircraft
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
- Y10T428/12535—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.] with additional, spatially distinct nonmetal component
- Y10T428/12542—More than one such component
- Y10T428/12549—Adjacent to each other
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
- Y10T428/12535—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.] with additional, spatially distinct nonmetal component
- Y10T428/12611—Oxide-containing component
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
- Y10T428/12771—Transition metal-base component
- Y10T428/12806—Refractory [Group IVB, VB, or VIB] metal-base component
- Y10T428/12826—Group VIB metal-base component
- Y10T428/12847—Cr-base component
- Y10T428/12854—Next to Co-, Fe-, or Ni-base component
Definitions
- the invention relates to a layer system as described in the claims.
- a layer system of this type has a substrate comprising a metal alloy based on nickel, cobalt or iron.
- Products of this type are used in particular as components of a gas turbine, in particular as gas turbine blades or vanes or heat shields.
- the components are exposed to a hot-gas stream of aggressive combustion gases, and consequently they have to be able to withstand high thermal stresses. Furthermore, it is necessary for these components to be resistant to oxidation and corrosion. Furthermore, mechanical demands are imposed in particular on moving components, for example gas turbine blades or vanes, but also on static parts.
- the power and efficiency of a gas turbine in which components that can be exposed to hot gases are used rise with an increasing operating temperature.
- components of the gas turbines which are subject to particularly high stresses from the high temperatures are coated with a ceramic material. This ceramic material acts as a thermal barrier coating between the hot-gas stream and the metallic substrate.
- the metallic base body is protected from the aggressive hot-gas stream by coatings.
- Modern components generally have a plurality of coatings which each perform specific tasks. Therefore, a multilayer system is present.
- EP 0 944 746 B 1 discloses the use of pyrochlores as thermal barrier coating.
- thermal barrier coating it is necessary for materials not only to have good thermal barrier properties but also good bonding to the substrate.
- EP 0 992 603 A1 discloses a thermal barrier coating system comprising gadolinium oxide and zirconium oxide, which is not supposed to have a pyrochlore structure.
- the invention is based on the discovery that the entire system has to be considered as a single unit, rather than regarding and optimizing individual layers or combinations of individual layers in isolation, with a view to achieving a long service life.
- FIG. 1 shows a layer system according to the invention
- FIG. 2 shows a turbine blade or vane
- FIG. 3 shows a gas turbine
- FIG. 1 shows a layer system 1 according to the invention.
- the layer system 1 comprises a metallic substrate 4 , which in particular for components used at high temperatures consists of a nickel-base or cobalt-base superalloy.
- a metallic bonding layer 7 which consists either of 11-13 wt % cobalt, 20-22 wt % chromium, 10.5-11.5 wt % aluminum, 0.3-0.5 wt % yttrium, 1.5-2.5 wt % rhenium, remainder nickel, or 24-26 wt % cobalt, 16-18 wt % chromium, 9.5-11 wt % aluminum, 0.3-0.5 wt % yttrium, 0.5-2 wt % rhenium, remainder nickel.
- an aluminum oxide layer has formed on this metallic bonding layer 7 , or an aluminum oxide layer of this type is formed during operation.
- a fully or partially stabilized zirconium oxide layer is present as inner ceramic layer 10 on the metallic bonding layer 7 or on the aluminum oxide layer (not shown). It is preferable to use yttrium-stabilized zirconium oxide. It is also possible to use calcium oxide, cerium oxide or hafnium oxide to stabilize zirconium oxide.
- the zirconium oxide is preferably applied as a plasma-spray layer, but also may be applied as a columnar structure by means of electron beam physical vapor deposition.
- An outer ceramic layer 13 which mostly comprises a pyrochlore phase, i.e. is made up to an extent of at least 80 wt % of the pyrochlore phase and comprises Gd 2 Hf 2 O 7 or Gd 2 Zr 2 O 7 , has been applied to the stabilized zirconium oxide layer 10 . It is preferable for the outer layer 13 to consist of 100 wt % of one of the two pyrochlore phases.
- Amorphous phases or pure GdO 2 or pure ZrO 2 or pure HfO 2 have been disregarded. Mixed phases of GdO 2 and ZrO 2 and/or HfO 2 which do not comprise the pyrochlore phase are undesirable and should be minimized.
- the crucial factor in the invention is the discovery that not only does the interaction between the outer ceramic layer 13 and an inner ceramic layer 10 need to be optimized, but also the metallic bonding layer 7 has a significant influence on the service life and function of the outer ceramic layer 13 of this two-layer ceramic structure.
- FIG. 2 shows a perspective view of a rotor blade 120 or guide vane 130 of a turbomachine, which extends along a longitudinal axis 121 .
- the turbomachine may be a gas turbine of an aircraft or of a power plant for generating electricity, a steam turbine or a compressor.
- the blade or vane 120 , 130 has, in succession along the longitudinal axis 121 , a securing region 400 , an adjoining blade or vane platform 403 and a main blade or vane part 406 .
- the vane 130 may have a further platform (not shown) at its vane tip 415 .
- a blade or vane root 183 which is used to secure the rotor blades 120 , 130 to a shaft or a disk (not shown), is formed in the securing region 400 .
- the blade or vane root 183 is designed, for example, in hammerhead form. Other configurations as a fir-tree root or dovetail root are possible.
- the blade or vane 120 , 130 has a leading edge 409 and a trailing edge 412 for a medium which flows past the main blade or vane part 406 .
- the blade or vane 120 , 130 may in this case be produced by a casting process, also by means of directional solidification, by a forging process, by a milling process or combinations thereof.
- Workpieces with a single-crystal structure or structures are used as components for machines which, in operation, are exposed to high mechanical, thermal and/or chemical stresses.
- Single-crystal workpieces of this type are produced, for example, by directional solidification from the melt. This involves casting processes in which the liquid metallic alloy solidifies to form the single-crystal structure, i.e. the single-crystal workpiece, or solidifies directionally.
- dendritic crystals are oriented along the direction of heat flow and form either a columnar crystalline grain structure (i.e. grains which run over the entire length of the workpiece and are referred to here, in accordance with the language customarily used, as directionally solidified) or a single-crystal structure, i.e. the entire workpiece consists of one single crystal.
- a transition to globular (polycrystalline) solidification needs to be avoided, since non-directional growth inevitably forms transverse and longitudinal grain boundaries, which negate the favorable properties of the directionally solidified or single-crystal component.
- directionally solidified microstructures refers in general terms to directionally solidified microstructures, this is to be understood as meaning both single crystals, which do not have any grain boundaries or at most have small-angle grain boundaries, and columnar crystal structures, which do have grain boundaries running in the longitudinal direction but do not have any transverse grain boundaries.
- This second form of crystalline structures is also described as directionally solidified microstructures (directionally solidified structures).
- the blades or vanes 120 , 130 may also have coatings protecting against corrosion or oxidation, e.g. (MCrAlX; M is at least one element selected from the group consisting of iron (Fe), cobalt (Co), nickel (Ni), X is an active element and stands for yttrium (Y) and/or silicon and/or at least one rare earth element, or hafnium (Hf)). Alloys of this type are known from EP 0 486 489 B1, EP 0 786 017 B1, EP 0 412 397 B1 or EP 1 306 454 A1, which are intended to form part of the present disclosure with regard to the chemical composition of the alloy.
- MrAlX M is at least one element selected from the group consisting of iron (Fe), cobalt (Co), nickel (Ni)
- X is an active element and stands for yttrium (Y) and/or silicon and/or at least one rare earth element, or hafnium (Hf)). Alloys
- thermal barrier coating consisting, for example, of ZrO 2 , Y 2 O 4 —ZrO 3 , i.e. unstabilized, partially stabilized or fully stabilized by yttrium oxide and/or calcium oxide and/or magnesium oxide, on the MCrAlX.
- Columnar grains are produced in the thermal barrier coating by suitable coating processes, such as for example electron beam physical vapor deposition (EB-PVD).
- EB-PVD electron beam physical vapor deposition
- Refurbishment means that after they have been used, protective layers may have to be removed from components 120 , 130 (e.g. by sand-blasting). Then, the corrosion and/or oxidation layers and products are removed. If appropriate, cracks in the component 120 , 130 are also repaired. This is followed by recoating of the component 120 , 130 , after which the component 120 , 130 can be reused.
- the blade or vane 120 , 130 may be hollow or solid in form. If the blade or vane 120 , 130 is to be cooled, it is hollow and may also have film-cooling holes 418 (illustrated in dashed lines).
- FIG. 3 shows, by way of example, a partial longitudinal section through a gas turbine 100 .
- the gas turbine 100 has a rotor 103 which is mounted such that it can rotate about an axis of rotation 102 and has a shaft 101 and is also referred to as the turbine rotor.
- the annular combustion chamber 110 is in communication with a, for example, annular hot-gas passage 111 , where, by way of example, four successive turbine stages 112 form the turbine 108 .
- Each turbine stage 112 is formed, for example, from two blade or vane rings. As seen in the direction of flow of a working medium 113 , in the hot-gas passage 111 a row of guide vanes 115 is followed by a row 125 formed from rotor blades 120 .
- the guide vanes 130 are secured to an inner housing 138 of a stator 143 , whereas the rotor blades 120 of a row 125 are fitted to the rotor 103 for example by means of a turbine disk 133 .
- a generator (not shown) is coupled to the rotor 103 .
- the compressor 105 While the gas turbine 100 is operating, the compressor 105 sucks in air 135 through the intake housing 104 and compresses it. The compressed air provided at the turbine-side end of the compressor 105 is passed to the burners 107 , where it is mixed with a fuel. The mix is then burnt in the combustion chamber 110 , forming the working medium 113 . From there, the working medium 113 flows along the hot-gas passage 111 past the guide vanes 130 and the rotor blades 120 . The working medium 113 is expanded at the rotor blades 120 , transferring its momentum, so that the rotor blades 120 drive the rotor 103 and the latter in turn drives the generator coupled to it.
- Substrates of the components may likewise have a directional structure, i.e. they are in single-crystal form (SX structure) or have only longitudinally oriented grains (DS structure).
- SX structure single-crystal form
- DS structure longitudinally oriented grains
- iron-base, nickel-base or cobalt-base superalloys are used as material for the components, in particular for the turbine blade or vane 120 , 130 and components of the combustion chamber 110 .
- the blades or vanes 120 , 130 may also have coatings which protect against corrosion (MCrAlX; M is at least one element selected from the group consisting of iron (Fe), cobalt (Co), nickel (Ni), X is an active element and represents yttrium (Y) and/or silicon and/or at least one rare earth element and/or hafnium).
- M is at least one element selected from the group consisting of iron (Fe), cobalt (Co), nickel (Ni)
- X is an active element and represents yttrium (Y) and/or silicon and/or at least one rare earth element and/or hafnium).
- EP 0 486 489 B1 EP 0 786 017 B1, EP 0 412 397 B1 or EP 1 306 454 A1, which are intended to form part of the present disclosure with regard to the chemical composition.
- a thermal barrier coating may also be present on the MCrAlX, consisting, for example, of ZrO 2 , Y 2 O 3 —ZrO 2 , i.e. unstabilized, partially stabilized or fully stabilized by yttrium oxide and/or calcium oxide and/or magnesium oxide.
- Columnar grains are produced in the thermal barrier coating by suitable coating processes, such as for example electron beam physical vapor deposition (EB-PVD).
- EB-PVD electron beam physical vapor deposition
- the guide vane 130 has a guide vane root (not shown here) facing the inner housing 138 of the turbine 108 and a guide vane head at the opposite end from the guide vane root.
- the guide vane head faces the rotor 103 and is fixed to a securing ring 140 of the stator 143 .
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- Inorganic Chemistry (AREA)
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- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Ceramic Engineering (AREA)
- Turbine Rotor Nozzle Sealing (AREA)
- Other Surface Treatments For Metallic Materials (AREA)
- Coating By Spraying Or Casting (AREA)
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Abstract
Thermal barrier coating layer systems, in addition to good thermal barrier properties, also have to have a long service life of the thermal barrier coating. The layer system according to the invention comprises a specially adapted layer sequence of metallic bonding layer, inner ceramic layer and outer ceramic layer.
Description
- This application is a continuation of U.S. application Ser. No. 11/396,419 filed Mar. 31, 2006 and is incorporated by reference herein in its entirety. This application claims the benefits of European Patent application No. 05007225.5 filed Apr. 1, 2005 and is incorporated by reference herein in its entirety.
- The invention relates to a layer system as described in the claims.
- A layer system of this type has a substrate comprising a metal alloy based on nickel, cobalt or iron. Products of this type are used in particular as components of a gas turbine, in particular as gas turbine blades or vanes or heat shields. The components are exposed to a hot-gas stream of aggressive combustion gases, and consequently they have to be able to withstand high thermal stresses. Furthermore, it is necessary for these components to be resistant to oxidation and corrosion. Furthermore, mechanical demands are imposed in particular on moving components, for example gas turbine blades or vanes, but also on static parts. The power and efficiency of a gas turbine in which components that can be exposed to hot gases are used rise with an increasing operating temperature. To achieve a high efficiency and a high power, components of the gas turbines which are subject to particularly high stresses from the high temperatures are coated with a ceramic material. This ceramic material acts as a thermal barrier coating between the hot-gas stream and the metallic substrate.
- The metallic base body is protected from the aggressive hot-gas stream by coatings. Modern components generally have a plurality of coatings which each perform specific tasks. Therefore, a multilayer system is present.
- Since power and efficiency of gas turbines rise with increasing operating temperature, constant attempts have been made to achieve a higher gas turbine performance by improving the coating system.
- EP 0 944 746
B 1 discloses the use of pyrochlores as thermal barrier coating. - However, to be used as material for a thermal barrier coating, it is necessary for materials not only to have good thermal barrier properties but also good bonding to the substrate.
- EP 0 992 603 A1 discloses a thermal barrier coating system comprising gadolinium oxide and zirconium oxide, which is not supposed to have a pyrochlore structure.
- Therefore, it is an object of the invention to provide a layer system which has good thermal barrier properties and good bonding to the substrate and therefore provides a long service life of the overall layer system.
- The invention is based on the discovery that the entire system has to be considered as a single unit, rather than regarding and optimizing individual layers or combinations of individual layers in isolation, with a view to achieving a long service life.
- The object is achieved by the layer system as claimed in the claims.
- The subclaims list further advantageous measures which can be combined in any desired, advantageous way.
- In the drawing:
-
FIG. 1 shows a layer system according to the invention, -
FIG. 2 shows a turbine blade or vane, -
FIG. 3 shows a gas turbine. -
FIG. 1 shows alayer system 1 according to the invention. - The
layer system 1 comprises ametallic substrate 4, which in particular for components used at high temperatures consists of a nickel-base or cobalt-base superalloy. - Directly on the
substrate 4 there is ametallic bonding layer 7, which consists either of 11-13 wt % cobalt, 20-22 wt % chromium, 10.5-11.5 wt % aluminum, 0.3-0.5 wt % yttrium, 1.5-2.5 wt % rhenium, remainder nickel, or 24-26 wt % cobalt, 16-18 wt % chromium, 9.5-11 wt % aluminum, 0.3-0.5 wt % yttrium, 0.5-2 wt % rhenium, remainder nickel. - Even before the application of further ceramic layers, an aluminum oxide layer has formed on this
metallic bonding layer 7, or an aluminum oxide layer of this type is formed during operation. - A fully or partially stabilized zirconium oxide layer is present as inner
ceramic layer 10 on themetallic bonding layer 7 or on the aluminum oxide layer (not shown). It is preferable to use yttrium-stabilized zirconium oxide. It is also possible to use calcium oxide, cerium oxide or hafnium oxide to stabilize zirconium oxide. - The zirconium oxide is preferably applied as a plasma-spray layer, but also may be applied as a columnar structure by means of electron beam physical vapor deposition.
- An outer
ceramic layer 13, which mostly comprises a pyrochlore phase, i.e. is made up to an extent of at least 80 wt % of the pyrochlore phase and comprises Gd2Hf2O7 or Gd2Zr2O7, has been applied to the stabilizedzirconium oxide layer 10. It is preferable for theouter layer 13 to consist of 100 wt % of one of the two pyrochlore phases. - Amorphous phases or pure GdO2 or pure ZrO2 or pure HfO2 have been disregarded. Mixed phases of GdO2 and ZrO2 and/or HfO2 which do not comprise the pyrochlore phase are undesirable and should be minimized.
- The crucial factor in the invention is the discovery that not only does the interaction between the outer
ceramic layer 13 and an innerceramic layer 10 need to be optimized, but also themetallic bonding layer 7 has a significant influence on the service life and function of the outerceramic layer 13 of this two-layer ceramic structure. -
FIG. 2 shows a perspective view of arotor blade 120 orguide vane 130 of a turbomachine, which extends along alongitudinal axis 121. - The turbomachine may be a gas turbine of an aircraft or of a power plant for generating electricity, a steam turbine or a compressor.
- The blade or
vane longitudinal axis 121, asecuring region 400, an adjoining blade orvane platform 403 and a main blade orvane part 406. - As a
guide vane 130, thevane 130 may have a further platform (not shown) at itsvane tip 415. - A blade or
vane root 183, which is used to secure therotor blades securing region 400. - The blade or
vane root 183 is designed, for example, in hammerhead form. Other configurations as a fir-tree root or dovetail root are possible. - The blade or
vane edge 409 and atrailing edge 412 for a medium which flows past the main blade orvane part 406. - In the case of conventional blades or
vanes regions vane - Superalloys of this type are known, for example, from
EP 1 204 776 B1,EP 1 306 454,EP 1 319 729 A1, WO 99/67435 or WO 00/44949; these documents form part of the disclosure with regard to the chemical composition of the alloy. - The blade or
vane - Workpieces with a single-crystal structure or structures are used as components for machines which, in operation, are exposed to high mechanical, thermal and/or chemical stresses.
- Single-crystal workpieces of this type are produced, for example, by directional solidification from the melt. This involves casting processes in which the liquid metallic alloy solidifies to form the single-crystal structure, i.e. the single-crystal workpiece, or solidifies directionally.
- In this case, dendritic crystals are oriented along the direction of heat flow and form either a columnar crystalline grain structure (i.e. grains which run over the entire length of the workpiece and are referred to here, in accordance with the language customarily used, as directionally solidified) or a single-crystal structure, i.e. the entire workpiece consists of one single crystal. In these processes, a transition to globular (polycrystalline) solidification needs to be avoided, since non-directional growth inevitably forms transverse and longitudinal grain boundaries, which negate the favorable properties of the directionally solidified or single-crystal component.
- Where the text refers in general terms to directionally solidified microstructures, this is to be understood as meaning both single crystals, which do not have any grain boundaries or at most have small-angle grain boundaries, and columnar crystal structures, which do have grain boundaries running in the longitudinal direction but do not have any transverse grain boundaries. This second form of crystalline structures is also described as directionally solidified microstructures (directionally solidified structures).
- Processes of this type are known from U.S. Pat. No. 6,024,792 and EP 0 892 090 A1; these documents form part of the present disclosure.
- The blades or
vanes EP 1 306 454 A1, which are intended to form part of the present disclosure with regard to the chemical composition of the alloy. - There may also be a thermal barrier coating consisting, for example, of ZrO2, Y2O4—ZrO3, i.e. unstabilized, partially stabilized or fully stabilized by yttrium oxide and/or calcium oxide and/or magnesium oxide, on the MCrAlX. Columnar grains are produced in the thermal barrier coating by suitable coating processes, such as for example electron beam physical vapor deposition (EB-PVD).
- Refurbishment means that after they have been used, protective layers may have to be removed from
components 120, 130 (e.g. by sand-blasting). Then, the corrosion and/or oxidation layers and products are removed. If appropriate, cracks in thecomponent component component - The blade or
vane vane -
FIG. 3 shows, by way of example, a partial longitudinal section through agas turbine 100. - In the interior, the
gas turbine 100 has arotor 103 which is mounted such that it can rotate about an axis ofrotation 102 and has a shaft 101 and is also referred to as the turbine rotor. - An
intake housing 104, acompressor 105, a, for example,toroidal combustion chamber 110, in particular an annular combustion chamber, with a plurality of coaxially arrangedburners 107, aturbine 108 and the exhaust-gas housing 109 follow one another along therotor 103. - The
annular combustion chamber 110 is in communication with a, for example, annular hot-gas passage 111, where, by way of example, four successive turbine stages 112 form theturbine 108. - Each
turbine stage 112 is formed, for example, from two blade or vane rings. As seen in the direction of flow of a workingmedium 113, in the hot-gas passage 111 a row ofguide vanes 115 is followed by arow 125 formed fromrotor blades 120. - The guide vanes 130 are secured to an inner housing 138 of a stator 143, whereas the
rotor blades 120 of arow 125 are fitted to therotor 103 for example by means of aturbine disk 133. - A generator (not shown) is coupled to the
rotor 103. - While the
gas turbine 100 is operating, thecompressor 105 sucks inair 135 through theintake housing 104 and compresses it. The compressed air provided at the turbine-side end of thecompressor 105 is passed to theburners 107, where it is mixed with a fuel. The mix is then burnt in thecombustion chamber 110, forming the workingmedium 113. From there, the workingmedium 113 flows along the hot-gas passage 111 past theguide vanes 130 and therotor blades 120. The workingmedium 113 is expanded at therotor blades 120, transferring its momentum, so that therotor blades 120 drive therotor 103 and the latter in turn drives the generator coupled to it. - While the
gas turbine 100 is operating, the components which are exposed to the hot workingmedium 113 are subject to thermal stresses. The guide vanes 130 androtor blades 120 of thefirst turbine stage 112, as seen in the direction of flow of the workingmedium 113, together with the heat shield elements which line theannular combustion chamber 110, are subject to the highest thermal stresses. - To be able to withstand the temperatures which prevail there, they may be cooled by means of a coolant.
- Substrates of the components may likewise have a directional structure, i.e. they are in single-crystal form (SX structure) or have only longitudinally oriented grains (DS structure).
- By way of example, iron-base, nickel-base or cobalt-base superalloys are used as material for the components, in particular for the turbine blade or
vane combustion chamber 110. - Superalloys of this type are known, for example, from
EP 1 204 776 B1,EP 1 306 454,EP 1 319 729 A1, WO 99/67435 or WO 00/44949; these documents form part of the disclosure with regard to the chemical composition of the alloys. - The blades or
vanes - Alloys of this type are known from EP 0 486 489 B1, EP 0 786 017 B1, EP 0 412 397 B1 or
EP 1 306 454 A1, which are intended to form part of the present disclosure with regard to the chemical composition. - A thermal barrier coating may also be present on the MCrAlX, consisting, for example, of ZrO2, Y2O3—ZrO2, i.e. unstabilized, partially stabilized or fully stabilized by yttrium oxide and/or calcium oxide and/or magnesium oxide.
- Columnar grains are produced in the thermal barrier coating by suitable coating processes, such as for example electron beam physical vapor deposition (EB-PVD).
- The
guide vane 130 has a guide vane root (not shown here) facing the inner housing 138 of theturbine 108 and a guide vane head at the opposite end from the guide vane root. The guide vane head faces therotor 103 and is fixed to a securingring 140 of the stator 143. -
-
- 1 Layer system
- Substrate
- Bonding layer
- Inner ceramic layer
- Outer ceramic layer
- Gas turbine
- Axis of rotation
- Rotor
- Intake housing
- Compressor
- Annular combustion chamber
- Burner
- Turbine
- Exhaust-gas housing
- Combustion chamber
- Hot-gas passage
- Turbine stage
- Working medium
- Row of guide vanes
- Rotor blade
- Longitudinal axis
- Row
- Guide vane
- Turbine disk
- Air
- Inner housing
- Securing ring
- Stator
- Combustion chamber wall
- Heat shield element
- Blade or vane root
- Securing region
- Blade or vane platform
- Main blade or vane part
- Leading edge
- Trailing edge
- Blade or vane tip
- Film-cooling holes
Claims (11)
1.-3. (canceled)
4. A layer system adapted for use in a high temperature environment, comprising:
a substrate;
a metallic bond layer arranged on the substrate comprising:
24-26 wt % cobalt,
16-18 wt % chromium,
9.5-11 wt % aluminum,
0.3-0.5 wt % yttrium,
0.5-2 wt % rhenium, and
remainder nickel;
a yttrium-stabilized zirconium oxide inner ceramic layer arranged on the bond layer; and
an outer ceramic layer arranged on the inner ceramic layer comprising:
80 wt % of a Gd2Zr2O7 pyrochlore.
5. The layer system as claimed in claim 4 , wherein the layer system consists essentially of: the substrate, the metallic bond layer, the inner ceramic layer and the outer ceramic layer.
6. The layer system as claimed in claim 4 , wherein the outer ceramic layer comprises 100 wt % of the Gd2Zr2O7 pyrochlore.
7. The turbine blade or vane claimed in claim 4 , wherein the substrate has a single crystal structure.
8. A high temperature coated turbine component, comprising:
a substrate formed from a nickel-based or cobalt-based super alloy;
a metallic bond layer arranged on the substrate comprising:
11-13 wt % cobalt,
20-22 wt % chromium,
10.5-11.5 wt % aluminum,
0.3-0.5 wt % yttrium,
1.5-2.5 wt % rhenium, and
remainder nickel.
a yttrium-stabilized zirconium oxide inner ceramic layer arranged on the bond layer; and
an outer ceramic layer arranged on the inner ceramic layer comprising:
80 wt % of a Gd2Hf2O7 pyrochlore.
9. The coated turbine component claimed in claim 8 , wherein the coated turbine component consists essentially of: the substrate, the metallic bond layer, the inner ceramic layer and the outer ceramic layer.
10. The coated turbine component claimed in claim 8 , wherein the outer ceramic layer comprises 100 wt % of the Gd2Hf2O7 pyrochlore.
11. The turbine blade or vane claimed in claim 8 , wherein the high temperature coated turbine component is a blade or vane.
12. The coated turbine component claimed in claim 11 , wherein the superalloy substrate has a single crystal structure.
13. The coated turbine component claimed in claim 8 , wherein the yttrium-stabilized zirconium oxide inner ceramic layer is applied via a plasma-spray or an electron beam physical vapor deposition process.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/481,093 US20090246008A1 (en) | 2005-04-01 | 2009-06-09 | Layer System |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP05007225.5 | 2005-04-01 | ||
EP05007225A EP1707653B1 (en) | 2005-04-01 | 2005-04-01 | Coating system |
US11/396,419 US7592071B2 (en) | 2005-04-01 | 2006-03-31 | Layer system |
US12/481,093 US20090246008A1 (en) | 2005-04-01 | 2009-06-09 | Layer System |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/396,419 Continuation US7592071B2 (en) | 2005-04-01 | 2006-03-31 | Layer system |
Publications (1)
Publication Number | Publication Date |
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US20090246008A1 true US20090246008A1 (en) | 2009-10-01 |
Family
ID=35385702
Family Applications (2)
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US11/396,419 Active 2027-12-26 US7592071B2 (en) | 2005-04-01 | 2006-03-31 | Layer system |
US12/481,093 Abandoned US20090246008A1 (en) | 2005-04-01 | 2009-06-09 | Layer System |
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US11/396,419 Active 2027-12-26 US7592071B2 (en) | 2005-04-01 | 2006-03-31 | Layer system |
Country Status (11)
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US (2) | US7592071B2 (en) |
EP (1) | EP1707653B1 (en) |
JP (1) | JP2006281783A (en) |
KR (1) | KR20060105634A (en) |
CN (1) | CN1840329B (en) |
AT (1) | ATE471395T1 (en) |
BR (1) | BRPI0601049A (en) |
CA (1) | CA2541289A1 (en) |
DE (1) | DE502005009754D1 (en) |
ES (1) | ES2346228T3 (en) |
TW (1) | TW200643220A (en) |
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US20130004328A1 (en) * | 2011-06-30 | 2013-01-03 | United Technologies Corporation | Abrasive airfoil tip |
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FR2902693A1 (en) * | 2006-12-22 | 2007-12-28 | Siemens Ag | Laminate for gas turbine blades or thermal shield, comprises a substrate, an attachment layer, a zirconium oxide layer stabilized by yttrium, an inner ceramic layer on the metallic attachment layer, and an outer ceramic layer |
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DE102013223327A1 (en) * | 2013-11-15 | 2015-05-21 | Siemens Aktiengesellschaft | Porous ceramic coating system |
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DE102014225130A1 (en) * | 2014-12-08 | 2016-06-09 | Siemens Aktiengesellschaft | Thick thermal barrier coating system |
DE102015206321A1 (en) * | 2015-04-09 | 2016-10-13 | Siemens Aktiengesellschaft | Two-layer ceramic thermal barrier coating with transition zone |
EP3453779B1 (en) | 2017-09-08 | 2022-04-20 | Raytheon Technologies Corporation | Multi layer cmas resistant thermal barrier coating |
JP6967954B2 (en) * | 2017-12-05 | 2021-11-17 | 東京エレクトロン株式会社 | Exhaust device, processing device and exhaust method |
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Also Published As
Publication number | Publication date |
---|---|
TW200643220A (en) | 2006-12-16 |
DE502005009754D1 (en) | 2010-07-29 |
JP2006281783A (en) | 2006-10-19 |
ATE471395T1 (en) | 2010-07-15 |
CN1840329A (en) | 2006-10-04 |
EP1707653A1 (en) | 2006-10-04 |
BRPI0601049A (en) | 2006-12-05 |
US20060286401A1 (en) | 2006-12-21 |
CA2541289A1 (en) | 2006-10-01 |
US7592071B2 (en) | 2009-09-22 |
CN1840329B (en) | 2010-12-08 |
ES2346228T3 (en) | 2010-10-13 |
EP1707653B1 (en) | 2010-06-16 |
KR20060105634A (en) | 2006-10-11 |
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