WO2021204596A1 - Surface treatment before applying tbc - Google Patents

Surface treatment before applying tbc Download PDF

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Publication number
WO2021204596A1
WO2021204596A1 PCT/EP2021/058304 EP2021058304W WO2021204596A1 WO 2021204596 A1 WO2021204596 A1 WO 2021204596A1 EP 2021058304 W EP2021058304 W EP 2021058304W WO 2021204596 A1 WO2021204596 A1 WO 2021204596A1
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WO
WIPO (PCT)
Prior art keywords
carried out
shot
grit blasting
tbc
coating
Prior art date
Application number
PCT/EP2021/058304
Other languages
French (fr)
Inventor
Xin-hai LI
Mohit Gupta
Nicolaie Markocsan
Snezana Djordjevic
Original Assignee
Siemens Aktiengesellschaft
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Siemens Aktiengesellschaft filed Critical Siemens Aktiengesellschaft
Publication of WO2021204596A1 publication Critical patent/WO2021204596A1/en

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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
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
    • B24C1/00—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods
    • B24C1/08—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods for polishing surfaces, e.g. smoothing a surface by making use of liquid-borne abrasives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
    • B24C1/00—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods
    • B24C1/10—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods for compacting surfaces, e.g. shot-peening
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/005—Repairing methods or devices
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/284—Selection of ceramic materials
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/288—Protective coatings for blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/90—Coating; Surface treatment

Definitions

  • the invention relates to a surface treatment of a substrate or metallic coating before applying a ceramic coating on top.
  • the APS TBC's contain a laminar structure and are much less strain tolerant as compared to the ones with a columnar structure and therefore have a short cyclic life.
  • the EB-PVD TBC's contain a columnar structure and therefore a good cyclic life. However, they have some disadvantages as high thermal conductivity, thickness is limited to maximum 350pm, high investment costs, and component size limitation since using vacuum chamber is necessary.
  • TBCs with a long life and a low conductivity are needed to solve the problem.
  • a new spraying process called suspension plasma spraying comprises spraying fine TBC powders on top of a metal lic bond coat, especially of MCrAlY bond coats, applied by thermal spraying methods for gas turbine hot components.
  • SPS TBC's have been discovered to possess not only a co lumnar structure like EB-PVD does, but also a high desired microporosity .
  • the intention to develop a SPS TBC is to offer both high cynch life and a low thermal conductivity to replace both APS and EB-PVD TBC's.
  • the test results of coating were not repeatable and the process has not been sta bilized to create a controllable coating quality, although a huge effort has been made by many research groups to optimize the SPS TBC spraying parameters.
  • the problem is solved by a method of a surface treatment of claim 1, by a substrate of claim 10 and by a method to apply a ceramic coating according to claim 11.
  • the three figures show the surface morphology and the result ing SPS TBC.
  • This invention is to introduce some key surface treatments on the metallic bond coat or a substrate, like especially MCrAlY bond coats prior to a SPS top coat application.
  • the inventive surface treatment includes first a shot peening and then a light grit blasting.
  • Cleaning steps can preferably be performed before, between and finally.
  • the shot peening should be carried out with a shot size of 0,2 mm -0,5 mm in diameter of shot media, preferably made of cast steels, metal cut wires, glass beans, or ceramic beans, preferably a pressure of 0,5-5 bars, preferably a surface coverage 100% - 400%.
  • the following grit blasting should be carried out preferably with
  • Alumina grit of 80-270 mesh preferably a pressure of 0,5-5 bars, preferably nozzle diameter 5 mm - 20 mm, preferably at an angle of 30° - 80° to the surface.
  • the unique surface roughness created by this procedure results in formation of thin columnar topcoat microstructure.
  • SPS TBCs have a lower thermal conductivity and/or longer life, especially cyclic life than that of the currently used APS and EBPVD TBC. These advantages allow an increase in lifetime of gas turbine components and the turbine efficien cy.
  • Figure 1 shows the morphology of an as-spayed surface 4' of a metallic bond coat on substrate 4 on the left and on the right side the columnar microstructure of a SPS TBC 7' as in the state of the art.
  • FIG 2 shows the morphology of a surface 4’’ of a metallic bond coat on a substrate 4 on the left, which was shot peened (starting from Figure 1) creating a smoother bond coat sur face than the as-sprayed bond coat 4' and on the right side the columnar microstructure of a SPS TBC 1’’.
  • TBC ⁇ ’’ contains smaller columns and its outer surface is smoother than the SPS TBC 7' in figure 1.
  • Figure 3 shows the inventive morphology of a surface 4''' of a metallic bond coat on a substrate 4 on the left, which was shot peened according to figure 2 and finally grit blasting, starting from figure 2 and on the right side the resulting microstructure of a SPS TBC ⁇ '''.
  • the bond coat sur face 4''' is smooth but contains small and frequent peaks so called micro-roughness.
  • This inventive surface morphology leads to the SPS TBC 1’’’ in figure 3 containing much smaller or thinner columns with a high column density as compared to the SPS TBC 1’’ in figure 2.
  • the SPS TBC ⁇ ’’’ surface is as least as smooth as that 1’’ in figure 2.

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Metallurgy (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Ceramic Engineering (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)

Abstract

This invention is to introduce some key surface treatments on the metallic bond coats, like especially MCrAlY bond coats prior to SPS top coat application. The surface treatments include a shot peening first and then a light grit blasting.

Description

Description
Surface treatment before applying TBC
The invention relates to a surface treatment of a substrate or metallic coating before applying a ceramic coating on top.
With increased demands in high gas temperature and long ser vice life, especially in cyclic life for industrial gas tur bines, the conventional Air Plasma Sprayed (APS) and Electron Beam Physical Vapour Deposited(EB-PVD) of 7%Y203 partially stabilized Zr02 (7YPSZ) thermal barrier coatings (TBC's) can not meet the higher challenges.
The APS TBC's contain a laminar structure and are much less strain tolerant as compared to the ones with a columnar structure and therefore have a short cyclic life.
The EB-PVD TBC's contain a columnar structure and therefore a good cyclic life. However, they have some disadvantages as high thermal conductivity, thickness is limited to maximum 350pm, high investment costs, and component size limitation since using vacuum chamber is necessary.
These disadvantages create problems to satisfy the increased market demands.
Therefore, turbine efficiency and availability are limited and less competitive.
TBCs with a long life and a low conductivity are needed to solve the problem.
A new spraying process called suspension plasma spraying (SPS) comprises spraying fine TBC powders on top of a metal lic bond coat, especially of MCrAlY bond coats, applied by thermal spraying methods for gas turbine hot components.
Such SPS TBC's have been discovered to possess not only a co lumnar structure like EB-PVD does, but also a high desired microporosity . The intention to develop a SPS TBC is to offer both high cy clic life and a low thermal conductivity to replace both APS and EB-PVD TBC's. However, up to now the test results of coating were not repeatable and the process has not been sta bilized to create a controllable coating quality, although a huge effort has been made by many research groups to optimize the SPS TBC spraying parameters.
It is the aim of the invention to improve a columnar TBC microstructure .
The problem is solved by a method of a surface treatment of claim 1, by a substrate of claim 10 and by a method to apply a ceramic coating according to claim 11.
In the dependent claims further advantages are listed which can be arbitrarily combined with each other to yield further advantages.
The three figures show the surface morphology and the result ing SPS TBC.
This invention is to introduce some key surface treatments on the metallic bond coat or a substrate, like especially MCrAlY bond coats prior to a SPS top coat application.
The inventive surface treatment includes first a shot peening and then a light grit blasting.
Cleaning steps can preferably be performed before, between and finally.
Preferably the shot peening should be carried out with a shot size of 0,2 mm -0,5 mm in diameter of shot media, preferably made of cast steels, metal cut wires, glass beans, or ceramic beans, preferably a pressure of 0,5-5 bars, preferably a surface coverage 100% - 400%. The following grit blasting should be carried out preferably with
Alumina grit of 80-270 mesh, preferably a pressure of 0,5-5 bars, preferably nozzle diameter 5 mm - 20 mm, preferably at an angle of 30° - 80° to the surface.
The resulting surface, here of the bond coat surface has a roughness value of Ra = 1pm - 5pm with a micro-roughness cre ated due to the light grit blasting with fine grit media. The unique surface roughness created by this procedure results in formation of thin columnar topcoat microstructure.
The surface treatment parameters depend on the method of coating the substrate or the MCrAlY bond coats (M= Ni, Co,
Fe).
Now SPS TBCs have a lower thermal conductivity and/or longer life, especially cyclic life than that of the currently used APS and EBPVD TBC. These advantages allow an increase in lifetime of gas turbine components and the turbine efficien cy.
Figure 1 shows the morphology of an as-spayed surface 4' of a metallic bond coat on substrate 4 on the left and on the right side the columnar microstructure of a SPS TBC 7' as in the state of the art.
Without any post surface treatment, the as-spayed bond coat surface 4' is very roughness more than Ra= 6pm and the micro structure of SPS TBC 7' sprayed on this bond coat surface 4' contains very large columns, i.e. very low column density and the TBC 7' surface is also very rough.
Figure 2 shows the morphology of a surface 4’’ of a metallic bond coat on a substrate 4 on the left, which was shot peened (starting from Figure 1) creating a smoother bond coat sur face than the as-sprayed bond coat 4' and on the right side the columnar microstructure of a SPS TBC 1’’. On top of the shot peened bond coat 4'', TBC Ί’’ contains smaller columns and its outer surface is smoother than the SPS TBC 7' in figure 1. Figure 3 shows the inventive morphology of a surface 4''' of a metallic bond coat on a substrate 4 on the left, which was shot peened according to figure 2 and finally grit blasting, starting from figure 2 and on the right side the resulting microstructure of a SPS TBC Ί'''. With both shot peening and grit blasting, the bond coat sur face 4''' is smooth but contains small and frequent peaks so called micro-roughness. This inventive surface morphology leads to the SPS TBC 1’’’ in figure 3 containing much smaller or thinner columns with a high column density as compared to the SPS TBC 1’’ in figure 2. The SPS TBC Ί’’’ surface is as least as smooth as that 1’’ in figure 2.

Claims

Patent claims
1. Method to produce an uniform surface roughness, especially on a metallic coating for bonding a ceramic coating, wherein the surface treatment comprises first a shot peening and finally a grit blasting, especially consists of these two steps of mechanical im pact.
2. Method according to claim 1, wherein the shot peening with a shot media is carried out with a shot size of 0,2 mm - 0,5 mm.
3. Method according to one or both claims 1 or 2, wherein the shot peening with a shot media is carried out with a pressure of 0,5 bar - 5 bar.
4. Method according to one or more of the claims 1, 2 or 3, wherein the shot peening is carried out with a surface cov erage 100% - 400%.
5. Method according to one or more of the claims 1, 2, 3 or
4, wherein the shot media comprises, especially consists of, cast steel, metal cut wires, glass beans and/or ceramic beans.
6. Method according to one or more of the claims 1, 2, 3, 4 or 5, wherein the grit blasting is carried out with ceramic particles, especially with alumina grit.
7. Method according to one or more of the claims 1, 2, 3,
4, 5 or 6, wherein the grit blasting is carried out with a particle size of 80 mesh - 270 mesh.
8. Method according to one or more of the claims 1, 2, 3,
4, 5, 6 or 7, wherein the grit blasting is carried out with a pressure of 0,5 bar - 5 bar.
9. Method according to one or more of the claims 1, 2, 3,
4, 5, 6, 7, or 8, wherein the grit blasting is carried out with a nozzle di ameter 5 mm - 20 mm, and especially with at an angle of 30° - 80° to the bond coat surface.
10. Substrate (4) with a metallic coating, especially produced by a method of any of the preceding claims 1 to 9, wherein coating surface (4, , f) has an uniform roughness value of Ra = lpm - 5pm.
11. Method to apply a ceramic coating, wherein a ceramic coating is applied via SPS on a metallic coating 4, , , produced by a method of any of the claims 1 to 9, or on a substrate (4) according to claim 10.
12. Method according to claim 11, wherein yttria stabilized zirconia is applied, especially 7YSZ.
PCT/EP2021/058304 2020-04-07 2021-03-30 Surface treatment before applying tbc WO2021204596A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP20168495.8A EP3892750A1 (en) 2020-04-07 2020-04-07 Surface treatment before applying tbc
EP20168495.8 2020-04-07

Publications (1)

Publication Number Publication Date
WO2021204596A1 true WO2021204596A1 (en) 2021-10-14

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EP (1) EP3892750A1 (en)
WO (1) WO2021204596A1 (en)

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0937787A1 (en) * 1998-02-19 1999-08-25 United Technologies Corporation Method of applying an overcoat to a thermal barrier coating and coated article
EP1013795A1 (en) * 1998-12-15 2000-06-28 United Technologies Corporation Method for applying improved durability thermal barrier coatings
EP1217089A2 (en) * 2000-12-22 2002-06-26 United Technologies Corporation Enhanced surface preparation process for application of ceramic coatings
US20030041927A1 (en) * 2001-08-31 2003-03-06 Irene Spitsberg Fabrication of an article having a protective coating with a flattened, pre-oxidized protective-coating surface

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0937787A1 (en) * 1998-02-19 1999-08-25 United Technologies Corporation Method of applying an overcoat to a thermal barrier coating and coated article
EP1013795A1 (en) * 1998-12-15 2000-06-28 United Technologies Corporation Method for applying improved durability thermal barrier coatings
EP1217089A2 (en) * 2000-12-22 2002-06-26 United Technologies Corporation Enhanced surface preparation process for application of ceramic coatings
US20030041927A1 (en) * 2001-08-31 2003-03-06 Irene Spitsberg Fabrication of an article having a protective coating with a flattened, pre-oxidized protective-coating surface

Also Published As

Publication number Publication date
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