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CN108699916A - 具有分级纤维增强陶瓷基底的陶瓷基复合材料涡轮机部件 - Google Patents

具有分级纤维增强陶瓷基底的陶瓷基复合材料涡轮机部件 Download PDF

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Publication number
CN108699916A
CN108699916A CN201680081909.1A CN201680081909A CN108699916A CN 108699916 A CN108699916 A CN 108699916A CN 201680081909 A CN201680081909 A CN 201680081909A CN 108699916 A CN108699916 A CN 108699916A
Authority
CN
China
Prior art keywords
fiber
tbc
layer
ceramic
fibers
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.)
Pending
Application number
CN201680081909.1A
Other languages
English (en)
Inventor
拉梅什·苏布拉马尼亚
克里斯蒂安·沙维尔·坎贝尔
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Siemens Corp
Original Assignee
Siemens Corp
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
Priority claimed from US14/188,941 external-priority patent/US8939706B1/en
Priority claimed from US14/188,958 external-priority patent/US9151175B2/en
Priority claimed from PCT/US2016/018224 external-priority patent/WO2016133990A1/en
Application filed by Siemens Corp filed Critical Siemens Corp
Priority claimed from PCT/US2016/031607 external-priority patent/WO2017142572A1/en
Publication of CN108699916A publication Critical patent/CN108699916A/zh
Pending legal-status Critical Current

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Classifications

    • 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
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
    • B22C7/02—Lost patterns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/22—Moulds for peculiarly-shaped castings
    • B22C9/24—Moulds for peculiarly-shaped castings for hollow articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D25/00—Special casting characterised by the nature of the product
    • B22D25/02—Special casting characterised by the nature of the product by its peculiarity of shape; of works of art
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D29/00—Removing castings from moulds, not restricted to casting processes covered by a single main group; Removing cores; Handling ingots
    • B22D29/001—Removing cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/04—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers
    • B28B11/048—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers by spraying or projecting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/0015—Machines or methods for applying the material to surfaces to form a permanent layer thereon on multilayered articles
    • 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
    • B32B15/14—Layered products comprising a layer of metal next to a fibrous or filamentary layer
    • 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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/71—Ceramic products containing macroscopic reinforcing agents
    • C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
    • C04B35/80—Fibres, filaments, whiskers, platelets, or the like
    • 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
    • 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
    • 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
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/06—Metallic material
    • C23C4/073—Metallic material containing MCrAl or MCrAlY alloys, where M is nickel, cobalt or iron, with or without non-metal elements
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/18—After-treatment
    • 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
    • F01D11/00—Preventing or minimising internal leakage of working-fluid, e.g. between stages
    • F01D11/08—Preventing or minimising internal leakage of working-fluid, e.g. between stages for sealing space between rotor blade tips and stator
    • 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
    • F01D11/00—Preventing or minimising internal leakage of working-fluid, e.g. between stages
    • F01D11/08—Preventing or minimising internal leakage of working-fluid, e.g. between stages for sealing space between rotor blade tips and stator
    • F01D11/12—Preventing or minimising internal leakage of working-fluid, e.g. between stages for sealing space between rotor blade tips and stator using a rubstrip, e.g. erodible. deformable or resiliently-biased part
    • 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
    • F01D11/00—Preventing or minimising internal leakage of working-fluid, e.g. between stages
    • F01D11/08—Preventing or minimising internal leakage of working-fluid, e.g. between stages for sealing space between rotor blade tips and stator
    • F01D11/12—Preventing or minimising internal leakage of working-fluid, e.g. between stages for sealing space between rotor blade tips and stator using a rubstrip, e.g. erodible. deformable or resiliently-biased part
    • F01D11/122—Preventing or minimising internal leakage of working-fluid, e.g. between stages for sealing space between rotor blade tips and stator using a rubstrip, e.g. erodible. deformable or resiliently-biased part with erodable or abradable material
    • 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
    • F01D11/00—Preventing or minimising internal leakage of working-fluid, e.g. between stages
    • F01D11/08—Preventing or minimising internal leakage of working-fluid, e.g. between stages for sealing space between rotor blade tips and stator
    • F01D11/12—Preventing or minimising internal leakage of working-fluid, e.g. between stages for sealing space between rotor blade tips and stator using a rubstrip, e.g. erodible. deformable or resiliently-biased part
    • F01D11/127—Preventing or minimising internal leakage of working-fluid, e.g. between stages for sealing space between rotor blade tips and stator using a rubstrip, e.g. erodible. deformable or resiliently-biased part with a deformable or crushable structure, e.g. honeycomb
    • 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
    • F01D5/14—Form or construction
    • F01D5/18—Hollow blades, i.e. blades with cooling or heating channels or cavities; Heating, heat-insulating or cooling means on blades
    • 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
    • F01D5/14—Form or construction
    • F01D5/18—Hollow blades, i.e. blades with cooling or heating channels or cavities; Heating, heat-insulating or cooling means on blades
    • F01D5/186—Film cooling
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
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    • 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
    • F01D9/00—Stators
    • F01D9/02—Nozzles; Nozzle boxes; Stator blades; Guide conduits, e.g. individual nozzles
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/40—Casings; Connections of working fluid
    • F04D29/52—Casings; Connections of working fluid for axial pumps
    • F04D29/522—Casings; Connections of working fluid for axial pumps especially adapted for elastic fluid pumps
    • F04D29/526—Details of the casing section radially opposing blade tips
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
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    • F04D29/66—Combating cavitation, whirls, noise, vibration or the like; Balancing
    • F04D29/68—Combating cavitation, whirls, noise, vibration or the like; Balancing by influencing boundary layers
    • F04D29/681—Combating cavitation, whirls, noise, vibration or the like; Balancing by influencing boundary layers especially adapted for elastic fluid pumps
    • F04D29/685—Inducing localised fluid recirculation in the stator-rotor interface
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    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
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    • B32B2260/023—Two or more layers
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Abstract

一种陶瓷基复合材料(“CMC”)部件、比如用于燃气涡轮发动机(20)的涡轮叶片(80)，该陶瓷基复合材料部件具有纤维增强的固化的陶瓷基底(88)。基底(88)具有用于使部件(80)的结构强度增强的内纤维层(100)。在外纤维层(120)中限定有空隙(126)。热障涂层(“TBC”)(90)被应用在外纤维层(120)上并且联接至外纤维层(120)，从而填充空隙(126)。空隙(126)提供了增大的表面面积并且与TBC(90)机械地互锁，从而提高了纤维增强陶瓷基底(88)与TBC之间的附着。

Description

具有分级纤维增强陶瓷基底的陶瓷基复合材料涡轮机部件
相关申请的交叉引用
本申请要求于2016年2月17日提交的、题目为“CERAMIC MATRIX COMPOSITETURBINE COMPONENT WITH ENGINEERED SURFACE FEATURES RETAINING A THERMALBARRIER COAT(具有保持热障涂层的专设表面特征的陶瓷基复合材料涡轮机部件)”的国际申请No.PCT/US16/18224的优先权，国际申请No.PCT/US16/18224要求于2015年2月18日提交的、题目为“TURBINE COMPONENT THERMAL BARRIER COATING WITH CRACK ISOLATINGENGINEERED GROOVE FEATURES(具有裂纹隔离专设槽特征的涡轮机部件热障涂层)”的国际申请No.PCT/US15/16318的优先权和效益，上述申请的整体内容通过参引并入本文。
技术领域
本发明涉及用于燃气涡轮发动机的具有陶瓷基复合材料(“CMC”)结构的部件以及用于制造这些部件的方法，其中，陶瓷基复合材料(“CMC”)结构又通过热障涂层(“TBC”)被进行隔热。更特别地，本发明涉及用于燃气涡轮发动机的具有陶瓷基复合材料(“CMC”)结构的发动机部件，其中，陶瓷基复合材料(“CMC”)结构具有分级纤维增强的陶瓷基底。内纤维层图案为部件提供结构支撑，并且外纤维层图案将TBC锚固至CMC结构。
背景技术
CMC结构包括固化的陶瓷基底，在该固化的陶瓷基底中嵌入有陶瓷纤维。与没有结合嵌入纤维的陶瓷结构相比，CMC的陶瓷基底内的嵌入的陶瓷纤维提高了抗延伸断裂性、断裂韧性、耐热冲击性和动态载荷能力。CMC嵌入的纤维取向还有助于部件的结构性能的选择性各向异性的改变。CMC结构通过将陶瓷纤维、也被称为“粗纱”铺设到或者以其他方式定向到织物、纤维缠绕物、纤维束或编织物中来制造。用于CMC的纤维增强陶瓷基底制造可以比得上形成用于飞行器机翼或船体的纤维增强的聚合物结构部件。除非陶瓷纤维用包含陶瓷材料的树脂预浸渍，否则陶瓷纤维随后通过比如气相沉积、熔融浸润、预陶瓷聚合物热解、化学反应、烧结或陶瓷粉末的电泳沉积的这些技术被陶瓷材料浸渍，从而形成具有嵌入的定向陶瓷纤维的实体陶瓷结构。
陶瓷基复合材料(“CMC”)结构作为诸如绝缘衬套、机叶和涡轮叶片之类的这些部件的绝缘层和/或结构元件被结合到燃气涡轮发动机部件中。这些CMC对于氧化物基陶瓷基复合材料而言在约1150摄氏度(“C”)的范围内提供了更好的抗氧化性和更高的温度能力，并且对于碳化硅纤维-碳化硅芯(“SiC-SiC”)基陶瓷基复合材料而言在达约1350C的情况下提供了更好的抗氧化性和更高的温度能力，而镍基或钴基超合金在发动机内的类似的运行条件下通常被限制在约950摄氏度至1000摄氏度。尽管1150C(对于SiC-SiC基CMC而言为1350C)的运行能力是对传统的超合金的温度极限的改进，但CMC的机械强度(例如，承载能力)还受限于晶粒生长、与基体的反应过程和/或1150C/1350C及更高温度的环境。在所需的燃气涡轮发动机的燃烧温度高达1600C至1700C的情况下，CMC需要在其自身与燃烧气体之间置入另外的隔热保护，以将CMC的温度保持在1150C/1350C以下。
如以往的关于超合金部件所做的那样，CMC通过应用热障涂层或涂覆层(“TBC”)的上覆层来接受额外的隔热保护。然而，TBC在CMC或超合金基底上的应用带来了新的和不同的热膨胀失配及附着的挑战。在燃气涡轮发动机运行期间，超合金、CMC和TBC材料都具有不同的热膨胀性能。在超合金基底上应用TBC的情况下，超合金材料比位于该超合金基底上方的TBC材料膨胀的程度更大，这在极端情况下会导致在TBC层中形成裂纹，从而导致TBC层与超合金表面的分层。除了热失配的挑战之外，还存在金属基底/TBC接合面附着的挑战。尽管TBC材料通常很好地附着至最初的金属超合金基底上，或者很好地附着在位于该超合金基底上方的金属结合涂层(“BC”)基底中，但是金属会产生氧化物表面层，该氧化表面层随后在相应的层接合面处降低了对TBC的附着。
TBC/金属基底接合面的一体性通过使用如下申请中的方案来保持：题目为“TURBINE COMPONENT THERMAL BARRIER COATING WITH CRACK ISOLATING ENGINEEREDGROOVE FEATURES(具有裂纹隔离专设槽特征的涡轮机部件热障涂层)”的国际申请No.PCT/US15/16318；以及题目为“TURBINE COMPONENT THERMAL BARRIER COATING WITH CRACKISOLATING ENGINEERED SURFACE FEATURES(具有裂纹隔离专设表面特征的涡轮机部件热障涂层”的国际申请No.PCT/US15/16331，这两个申请都在本申请的优先权限内并且在国家阶段审查期间在允许这样的并入的管辖区内被参引并入。在这些优先权申请中描述的一些实施方式在金属超合金基底的基底表面上或在位于该基层表面上方的金属结合涂层中(“BC”)或这两种金属表面的组合中都结合有专设的表面特征(“ESF”)。金属表面/TBC层接合面的ESF机械地锚固TBC材料，以抑制分层或至少限制对由相邻的ESF限定的边界的分层损害。优先权申请中的其他实施方式在TBC层外表面上结合有专设的槽特征(“EGF”)，以控制表面裂纹扩展。这些申请中的另外的实施方式结合有ESF和EGF两者。因此，当金属材料在发动机运行期间变热(形成表面氧化物)并且膨胀时，尽管层间附着降低，但更少膨胀的TBC材料与金属机械地互锁。
回到CMC/TBC热膨胀失配和通常的层间附着挑战，相对层的膨胀与超合金/TBC部件所经历的相反。TBC材料往往比位于TBC材料下方的CMC材料膨胀更多。随着TBC变热，其趋于失去与CMC表面的附着并且与CMC表面分层。许多CMC材料在固化的陶瓷芯和CMC材料所嵌入的陶瓷纤维中已经包含有氧化物，这对CMC/TBC接合面处的层间附着有不利的影响。在SiC-SiC复合材料的情况下，热障涂层可以与位于热障涂层下方的硅基基体反应形成比基体或涂层更脆的新化合物。因此，将TBC应用在部件的CMC表面上而不随后在发动机运行期间分层是困难的。根据预制件中嵌入的陶瓷纤维的局部宏观粗糙度以及将预制件嵌入到固化的陶瓷芯中的陶瓷材料的浸润特性，TBC涂层的附着通常比TBC涂层在金属的基质上的附着差。TBC/CMC的附着在陶瓷基底的嵌入纤维被定向成平行于部件表面的情况下是特别差的。TBC层的厚度被限制至下述厚度：尽管TBC具有较高的热膨胀率，但所述厚度的TBC仍能保持与CMC表面结合。换句话说，TBC层厚度在已经相对受限的TBC/CMC材料附着能力界限内被保持在使TBC/CMC热膨胀分层加速的阈值以下。不幸的是，限制TBC层的厚度不利地限制了TBC的隔热性能。通常，较厚的TBC层会比较薄的TBC层向位于TBC层下方的CMC基底/层提供更多的隔热保护。
发明内容
文中描述示例性实施方式通过利用嵌入在CMC陶瓷基底内的不同区域中的分级纤维或分级图案的织物而提高TBC在燃气涡轮发动机中的CMC部件上的保持。在陶瓷基底的更面向内的区域中的内纤维比沿着基底外表面的与TBC的内表面接合的外纤维提供了部件的更大结构强度。外纤维图案具有在纤维之间和/或纤维束之间的用于在TBC层被应用至陶瓷芯时保持且锚固TBC层的锚固空隙。在一些实施方式中，外纤维图案具有带纹理表面，以用于将TBC层锚固在形成于织物组织中的峰部和谷部空隙内，该带纹理表面在一些实施方式中包括三维纹理表面。其他实施方式包括从外织物组织图案突出的纤维股或纤维环，以用于附加TBC层锚固。外织物组织空隙和/或带纹理表面特征使CMC结构、并且特别是纤维与TBC机械地互锁，并且为层间附着提供了增大的表面面积和另外的互锁。可选地，正如通过参引而并入的于2016年2月17日提交的、题目为“CERAMIC MATRIX COMPOSITE TURBINECOMPONENT WITH ENGINEERED SURFACE FEATURES RETAINING A THERMAL BARRIER COAT(具有保持热障涂层的专设表面特征的陶瓷基复合材料涡轮机部件)”的优先权文件PCT/US16/18224中所描述的，专设表面特征(“ESF”)被切入到陶瓷芯的外表面和预制件的纤维中。热喷涂的、或者汽相沉积的、或者溶液/悬浮液等离子体喷涂的TBC被应用并且联接在纤维增强陶瓷基底的外表面和任何切割的ESF上。由外纤维图案的空隙和/或突出物提供的加强的附着能力有助于将较厚的TBC层应用至部件，这增大了对位于TBC层下方的CMC结构/层的隔热保护。相应材料的增大的附着表面面积和增加的机械互锁促使在没有TBC分层的风险的情况下将更大TBC层厚度应用于CMC基底。更大TBC层厚度又为CMC结构提供了更多的热隔离，以用于更高的可能的发动机运行温度和效率。在一些实施方式中，CMC部件覆盖位于CMC部件下方的基底、比如超合金金属基底。在其他实施方式中，CMC部件是金属基底上的衬套。在其他实施方式中，CMC部件不具有下层的金属基底，而是在纤维增强陶瓷基底内提供其自身的内部结构支撑。在另外的实施方式中，多个CMC部件结合在一起以形成较大的复合CMC部件，比如层压的涡轮叶片或机叶。在其他实施方式中，CMC部件是单一结构的、非层压的涡轮叶片或机叶。
CMC部件通过将陶瓷纤维铺设成层状结构制成，该层状结构具有用于结构支撑的内层和用于锚固TBC的外层。如果铺设的织物结构在它们铺设之前没有用陶瓷材料预浸渍，则非预浸渍的纤维随后会用陶瓷材料浸润，从而形成固化的陶瓷芯。TBC然后被应用至芯的外表面。外织物层的空隙和突出物有助于将TBC层锚固至陶瓷基底的外表面，以用于抵抗前述氧化物层和用于燃气涡轮发动机的CMC/TBC部件中的所固有的热膨胀引起的分层挑战。
示例性实施方式的特征在于用于燃气涡轮发动机的陶瓷基复合材料(“CMC”)部件，陶瓷基复合材料(“CMC”)部件具有固化的陶瓷基底，陶瓷基底具有嵌入在其中的陶瓷纤维。纤维增强陶瓷基底具有用于使部件的结构强度增强的内纤维层。基底还具有在内层的外部的外纤维层，在外纤维层中限定有空隙。热喷涂的、或者汽相沉积的、或者溶液/悬浮液等离子体喷涂的热障涂层(“TBC”)被应用在基底的外纤维层上并且联接至基底的外纤维层，从而填充空隙。空隙提供了增大的表面面积并且与TBC机械地互锁，从而提高了纤维增强陶瓷基底与TBC之间的附着。TBC外表面适于在被安装在运行的燃气涡轮发动机中时暴露至燃烧气体。
其他示例性实施方式的特征在于用于燃气涡轮发动机的部件，该部件包括用于结构支撑的金属构件。金属构件由陶瓷基复合材料(“CMC”)包围使得内纤维层也包围金属构件。在一些实施方式中，CMC层还在具有或不具有另外的金属构件的情况下用作支撑基底。CMC层包括固化的陶瓷纤维增强基底，陶瓷纤维增强基底具有定形成符合并抵接金属构件的表面轮廓的基底内表面。在一些实施方式中，专设的表面特征(“ESF”)被切入到陶瓷基底的外表面以及陶瓷基底的外纤维层。热喷涂的、或者汽相沉积的、或者溶液/悬浮液等离子体喷涂的热障涂层(“TBC”)、包括TBC内表面，被应用在陶瓷基底的外表面上并且联接至陶瓷基底的外表面，并且通过外纤维层中的空隙被锚固。在一些实施方式中，外纤维层限定下述带纹理表面轮廓以增加大TBC内表面的接触表面面积，该带纹理表面轮廓具有比外纤维层中的任何单个纤维或纤维束的直径大的高度变化。在一些实施方式中，纤维股或纤维股环从第二层向外突出以增大与TBC内表面的接触表面面积。在其他实施方式中，在内纤维层与外纤维层之间置有中间纤维层。在一些实施方式中，中间层具有限定了比第一层的图案限定的密度和横截面面积小且比第二层的图案限定的密度和横截面面积大的密度和横截面面积的图案。
其他示例性实施方式的特征在于用于制造燃气涡轮发动机的CMC部件的方法。三维预制件是用陶瓷纤维制造的。陶瓷纤维被铺设成层状结构，层状结构包括用于部件的结构强度的内层。层状结构还具有在内层的外部的外纤维层，外纤维层具有在外纤维层中限定空隙的第二织物图案。在一些实施方式中，内纤维层和外纤维层在被铺设成层状结构之前用陶瓷材料预浸渍。如果没有用陶瓷材料预浸渍，则层状结构会用陶瓷材料浸润，从而形成固化的纤维增强的陶瓷基底，纤维增强的陶瓷基底限定基底的外表面。热喷涂的、或者汽相沉积的、或者溶液/悬浮液等离子体喷涂的热障涂层(“TBC”)被应用在基底的外表面和基底的外纤维层上并且联接至基底的外表面和基底的外纤维层，从而填充空隙。空隙提供了增大的表面面积并且与TBC机械地互锁，从而提高了陶瓷基底与TBC之间的附着。TBC外表面适于在被安装在运行的燃气涡轮发动机中时暴露至燃烧气体。在一些方法实施方式中，外纤维层具有下述带纹理表面轮廓以增大与TBC内表面的接触表面面积，该带纹理表面轮廓具有比外纤维层中的任何单个纤维或纤维束的直径大的高度变化。在其他实施方式中，外纤维层具有向外突出的纤维股或纤维环，以用于增大与TBC内表面的接触表面面积。在其他实施方式中，纤维增强陶瓷基底被制造成具有置于内纤维层与外纤维层之间的中间纤维层，中间纤维层具有限定了比内层织物图案的织物密度和横截面面积小且比外层织物图案的织物密度和横截面面积大的第三织物密度和横截面面积的第三织物图案。
文中描述的本发明的示例性实施方式的各个特征可以以任意组合或子组合的方式结合地或分开地应用。
附图说明
在以下结合附图的详细描述中进一步描述本发明的示例性实施方式，在附图中：
图1是气体或燃气涡轮发动机的局部轴向横截面视图，其中，该涡轮发动机包括根据本发明的示例性实施方式构造的一个或更多个CMC部件；
图2是根据本发明的示例性实施方式的用于燃气涡轮发动机的金属增强的CMC涡轮叶片部件的横截面正视图；
图3是图2的涡轮叶片的横截面平面图；
图4是用于燃气涡轮发动机的CMC涡轮叶片部件的另一实施方式的横截面视图，其中，该CMC涡轮叶片部件不具有内部金属增强；
图5是图4的涡轮叶片的横截面平面图；
图6是穿过图4和图5的涡轮叶片的侧壁的局部横截面正视图，其示出了嵌入在固化的纤维增强陶瓷基底内的分级纤维层；
图7是图6的叶片侧壁的内纤维层的在它们被结合到纤维增强陶瓷基底中之前或在应用TBC之前的正视图；
图8是图6的叶片侧壁的内纤维层的替代性的实施方式的在它们被结合到纤维增强陶瓷基底中之前或在应用TBC之前的正视图；
图9是图8的内纤维层的细节正视图；
图10是图6的叶片侧壁的中间纤维层的在它们被结合到纤维增强陶瓷基底中之前或在应用TBC之前的正视图；
图11是图6的叶片侧壁的外纤维层的在它们被结合到纤维增强陶瓷基底中之前或在应用TBC之前的正视图；
图12是图11的外纤维层的详细立体图；
图13是穿过图2和图3的涡轮叶片的侧壁的局部横截面正视图，其示出了叶片的金属支撑构件和嵌入在纤维增强陶瓷基底内的分级纤维；
图14是穿过涡轮叶片的另一实施方式的侧壁的局部横截面正视图，其示出了用于锚固TBC的从外纤维层向外突出的纤维股；以及
图15是穿过涡轮叶片的另一实施方式的侧壁的局部横截面视图，其示出了用于锚固TBC的从外纤维层向外突出的纤维环。
为了便于理解，在可能的情况下，已经使用相同的附图标记来指示附图中共有的相同元件。附图没有按比例绘制。
具体实施方式
本文中的示例性实施方式被应用在燃气涡轮发动机中。本发明的CMC部件的实施方式被组合以形成在结构上为自支撑的复合结构，比如涡轮叶片或机叶。在其他实施方式中，CMC部件覆盖其他结构元件，比如内部金属(例如，超合金金属)构件，所述其他结构元件包括例如结构加强肋件或其他类型的支撑件。在一些实施方式中，本发明的陶瓷基复合材料(“CMC”)部件被用作用于其他结构部件的隔热覆盖件或者衬套，所述其他结构部件比如是金属超合金部件或其他类型金属支撑构件。在其他实施方式中，CMC部件在结构上是完全自支撑的，这依赖于用以对CMC部件的纤维增强陶瓷基底提供附加的强度的内部嵌入的纤维。本发明的CMC部件的实施方式具有固化的纤维增强陶瓷基底，在固化的纤维增强陶瓷基底中嵌入有陶瓷纤维。纤维增强陶瓷基底利用嵌入在CMC基底内的不同区域中的分级纤维或分级的带图案织物。在陶瓷基底的更面向内的区域中的内纤维比沿着陶瓷芯的外表面的与TBC层的内表面接合的外纤维具有相对较高的纤维密度和横截面，以用于部件的更大的结构支撑。外纤维图案在纤维之间和/或纤维束之间具有空隙，以用于在TBC层被应用至纤维增强陶瓷基底时保持及锚固TBC层。在一些实施方式中，外纤维图案具有带纹理表面，以用于将TBC层锚固在形成于织物图案或织物中的峰部和谷部空隙或纤维间隔空隙内，所述带纹理表面在其他实施方式中包括带纹理的三维表面。其他实施方式包括用于附加TBC层锚固的纤维股和/或纤维环，所述纤维股和/或纤维环从外织物图案或组织(包括另一示例针织织物组织)突出。外织物空隙和表面特征使CMC结构、特别是纤维与TBC机械地互锁，并且为层间附着提供了增大的表面面积和附加的互锁。在一些实施方式中，专设的表面特征(“ESF”)被切入到纤维增强陶瓷基底的外表面中。热喷涂的、或者汽相沉积的、或者溶液/悬浮液等离子体喷涂的TBC被应用在纤维增强陶瓷基底的外表面和任何切割的ESF上并且联接至纤维增强陶瓷基底的外表面和所述任何切割的ESF。
外织物层空隙和表面特征提供了增大的表面面积，并且使TBC机械地互锁，从而改善了陶瓷纤维增强陶瓷基底与TBC之间的附着。由外织物层内的空隙和表面特征提供的机械互锁和改进的附着有助于0.5mm至2mm的相对较厚的TBC层的应用。由于厚的TBC的应用，本发明的CMC部件的实施方式能够在达1950摄氏度的燃烧环境中运行，其中，较厚的TBC将CMC陶瓷芯的温度限制成低于1150/1350摄氏度。
根据本发明的实施方式的方法，CMC部件通过将陶瓷纤维铺设成层状结构制成。如果陶瓷纤维在它们的铺设之前还没有用陶瓷材料预浸渍，则陶瓷纤维随后会用陶瓷材料浸润，从而形成固化的纤维增强陶瓷基底。在一些实施方式中，专设的表面特征(“ESF”)被切入到陶瓷基底的外表面以及陶瓷基底的外纤维层中。然后TBC被应用至陶瓷基底的外表面和任何的ESF。如果CMC部件在结构上是自支撑的，陶瓷基底的内织物层对诸如燃气涡轮发动机的叶片或机叶之类的部件提供结构的支撑。如果CMC部件是用于另一结构部件——比如金属构件、超合金基底——的隔热覆盖件，则部件定尺寸成覆盖或以其他方式包围金属构件。在一些应用中，CMC部件或多个CMC部件被构造为隔热衬套以覆盖金属构件。在一些实施方式中，在应用TBC之前，多个这样的衬套被堆叠起来并且侧向接合在金属构件或其他金属基底上。在其他实施方式中，CMC部件是用于燃气涡轮发动机的单一结构的自支撑的叶片或机叶。
图1示出了燃气涡轮发动机20，燃气涡轮发动机20具有燃气涡轮壳体22、多级压缩机部段24、燃烧部段26、多级涡轮部段28和转子30。多个火焰筒型燃烧室32中的一个燃烧室联接至下游过渡部段34，下游过渡部段34将来自燃烧室的燃烧气体引导至涡轮部段28。大气压力下的进气沿着涡轮发动机20的轴向长度大致在流动箭头F的方向上被吸入到压缩机部段24中。进气在压缩机部段24中由成排的旋转压缩机叶片50被逐渐加压，并且通过相配合的压缩机机叶52被引导至燃烧部段26，在燃烧部段26处，进气与燃料混合并被点燃。此时与最初的进气相比处于更高的压力和速度的点燃的燃料/气体混合物被引导穿过过渡部段34到达涡轮部段28中的相继的机叶56和成排的叶片50。发动机的转子30和轴保持多排的翼型横截面形状的涡轮叶片54。本文中描述的CMC部件的实施方式被设计成在达1950摄氏度的发动机温度环境下运行。在一些实施方式中，CMC部件是用于金属构件的隔热衬套或覆盖件，所述金属构件包括诸如燃烧室32内的子部件、过渡件34、叶片54或机叶56之类的金属基底的结构部件。在其他实施方式中，本发明的CMC部件在不需要金属构件或其他支撑的金属基底的情况下而在结构上是自支撑的。示例性的自支撑的CMC部件包括压缩机叶片50或机叶52(该部件不一定需要对TBC、压缩机32的内部子部件或者过渡件34进行隔热)。在一些实施方式中，整个涡轮部段28的叶片54或者机叶56的翼型件均为CMC结构件；其中，CMC结构件的纤维增强陶瓷基底的外表面通过使用分级织物具有表面纹理，该表面纹理与0.5mm至2mm的相对较厚的TBC层机械地互锁。
图2和图3示出了示例性发动机部件、即涡轮叶片60的示意性横截面图。涡轮叶片60具有用于固定至涡轮发动机的转子30的叶片根部62和远端叶片梢部64。叶片内部侧壁65包括金属构件，金属构件是金属加强肋66。肋66由CMC纤维增强陶瓷基底68覆盖或以其他方式包围。涡轮叶片60内的内芯的内部结构细节是已知的，并且为了简洁起见没有被详细示出或描述。陶瓷基底68包括嵌入在陶瓷基底68中的分级的陶瓷纤维，以下将详细描述分级的陶瓷纤维。热喷涂的、或者汽相沉积的、或者溶液/悬浮液等离子体喷涂的热障涂层(“TBC”)70围绕叶片侧壁的压力侧部72和叶片侧壁的吸入侧部74——包括前缘和后缘——被应用在基底68的外表面上并且联接至基底68的外表面。
图4和图5的涡轮叶片80的实施方式具有叶片根部82、叶片梢部84和自支撑的CMC纤维增强陶瓷基底88，这些部分形成叶片的翼型侧壁，其中包括内部侧壁85和其上应用了TBC 90的外部部分。涡轮叶片80没有内部金属肋或其他支撑结构以承载施加在叶片的压力侧部92或吸入侧部94上的载荷。自支撑的CMC纤维增强陶瓷基底88利用分级纤维用于执行局部结构功能。一些纤维主要结合用于CMC陶瓷基底内的结构强度，而其他纤维主要结合用于锚固TBC层90。在该实施方式中，形成CMC纤维增强陶瓷基底88的层状结构的纤维被结合到织物片中，在一些实施方式中，纤维片在叶片制造期间被堆叠成层或层片并且围绕叶片包绕、即在内部侧壁85的边界的外部包绕，这类似于雪茄外包物。通常，嵌入在纤维增强陶瓷基底88内的纤维结构内的纤维的取向结合一个或更多个织造纤维(二维或三维织物，包括针织织物)、编织纤维(包括编织纤维的丝束)和/或单轴纤维。
图6示意地示出了被结合到纤维增强陶瓷基底88的层状结构中的分级织物层。以下关于图6的描述同样能够适用于图13。关于图2和图3的叶片实施方式的图13的示意图结合了金属构件、即叶片加强肋件66，但是在其他方面与图6相同。为了简单起见，图6中示出了陶瓷芯88内的每个示例性类型的织物片的平面图。
参照图6和图7，内层的平行纤维、比如图6和图7中示出的织造织物纤维具有第一织物图案100，第一织物图案100限定了第一织物密度和横截面面积，从而为叶片部件80的部件陶瓷基底88提供结构强度。内纤维层的主要功能是为陶瓷基底88和整个叶片部件80提供结构上的支撑。示出的内层织物图案具有平行的竖向定向或轴向定向的纤维102，纤维102织造成束或丝束112，束或丝束112增强了叶片部件80的轴向拉伸强度和扭转拉伸强度。内层织物图案100还具有横向纤维104，横向纤维104保持竖向/轴向定向的纤维102的平行取向。竖向纤维102以在其之间没有刻意间隔的方式在图7的横向方向上紧密地布置。在图8和图9的替代性的实施方式中，内层织物100A具有紧密的、平坦的织物纤维图案，其中，该织物纤维图案具有分布和密度均匀的竖向纤维102A和横向纤维104A。用于内层织物组织的实施方式100和100A都具有相对平坦的表面轮廓。如前所述，这种平坦的织物轮廓不能促进与TBC覆盖层的良好结合，使得TBC易于在热膨胀期间与纤维增强陶瓷基底88分离或者使得在陶瓷基底88与TBC材料90之间具有相对较差的氧化物结合。因此，内纤维层织物的实施方式100和100A对于用在纤维增强陶瓷基底的最外层、比如涡轮叶片陶瓷基底88的最外层而言不是最理想的。然而，本文描述的实施方式在纤维增强陶瓷基底88中结合了分级纤维，分级纤维在基底内局部改变取向，并且针对分级纤维的结构和功能的适用性选择分级纤维。
参照图6和图10，纤维增强陶瓷基底88结合了中间纤维层、比如织造纤维织物110，织造纤维织物110在内层织造纤维100的外部。中间层110具有限定了比第一织物图案100限定的织物密度和横截面面积小的织物密度和横截面面积的织物图案。中间层包括具有侧向间隔距离S2的竖向纤维112(一个或更多个单独的或成束/丝束的纤维)和具有竖向间隔S1的横向纤维114(一个或更多个单独的或成束/丝束的纤维)。间隔开的纤维112和114之间形成有空隙116，从而有助于CMC陶瓷芯88内的结合和结构的完整性。
如图6、图11和图12中所示，外纤维层、比如织物组织纤维120在内层100和中间层110的外部定向在CMC部件的纤维增强陶瓷基底88中。在一些实施方式中，通常包含非织造熔融纤维的开放纤维网格的稀松织物用于形成外纤维层120。在图6、图11和图12的实施方式中，外纤维层120具有限定了比内层100的织物图案或中间层110的织物图案的织物密度和横截面面积小的织物密度和横截面面积的织物图案。外层120采用带纹理表面，带纹理表面包括具有侧向间隔距离S4的竖向纤维122(一个或更多个单独的或成束/丝束的纤维、或非织造的稀松型织物)和具有竖向间隔S3的横向纤维124(一个或更多个单独的或成束/丝束的纤维或稀松织物融合的纤维中的纤维)。在一些实施方式中，纤维之间的间隔S3或S4在0.1mm至8mm之间。网状排列的间隔开的纤维122和纤维124之间形成有空隙126，从而有助于CMC陶瓷芯88内的和TBC层90内的结合和结构的完整性。
如图12的实施方式所示，三维的带纹理织物除了以开放的间隔距离S3和S4形成在纤维之间的网状空隙126之外，还在纤维股122A、122B和122C之间产生具有径向距离或高度H的竖向间隙或空隙126。在一些实施方式中，外纤维层中的由外纤维层120中的具有带纹理表面轮廓高度H的各个纤维或纤维束之间的间隔所限定的竖向空隙在0.1mm至1.5mm之间变化。在该实施方式中，外纤维层120内的高度H比形成该层的任何单个纤维或纤维束的直径T都大。在TBC被应用至CMC部件的纤维增强陶瓷基底88时，竖向和横向空隙或间隙产生用于TBC的嵌入或锚固的空间。考虑到与内层110相比外织物层120的织物密度和横截面积较小，外织物层120为CMC涡轮叶片部件80及其陶瓷基底88提供了较小的结构强度，但外织物层120提供了用于锚固TBC层90的相对较大的表面面积和空隙。
热喷涂的、或者汽相沉积的、或者溶液/悬浮液等离子体喷涂的热障涂层(“TBC”)90被应用在CMC陶瓷基底88的外表面和CMC陶瓷基底88的外织物层120上并且联接至CMC陶瓷基底88的外表面和其外织物层120。TBC 90通过外织物层120的沿着结合区域的与相对平坦的平面结合区域相比相对较大的表面面积结合并锚固至外织物层120，其中，相对较大的表面面积以另外的方式由内织物层110的织物图案形成。经验显示TBC趋于与平坦的CMC外表面分层并脱离，尤其是在增强纤维、比如内织物层110的增强纤维平行于CMC陶瓷基底88的外表面定向的情况下，更是如此。本文中的实施方式中，空隙或间隙126、包括示例性的三维空隙和间隙，使纤维122和纤维124的取向相对于TBC层90倾斜，这产生邻接的接合面而非内织物层110的平行的接合面。可选的专设槽特征(EGF)91被切入到TBC外表面中。
参照图14和图15的部件实施方式，TBC对CMC部件的纤维增强陶瓷基底的附着通过TBC材料与从外织物层的外表面突出的纤维之间的结合被增强。在图14中，部件130的CMC部件的纤维增强陶瓷基底132具有外纤维层图案134，外纤维层图案134具有从该外层突出的纤维股136。在CMC部件的陶瓷基底132的外周区域的非结构承载的外织物层134中切割陶瓷纤维股不损害CMC部件130的结构完整性。纤维股136为TBC层140提供了附加的锚固。
参照图6和图13，可选的专设槽特征(“EGF”)71、91被切入到相应的TBC 70、90的外表面中，正如通过参引并入本文的于2016年2月17日提交的、题目为“CERAMIC MATRIXCOMPOSITE TURBINE COMPONENT WITH ENGINEERED SURFACE FEATURES RETAININGATHERMAL BARRIER COAT(具有保持热障涂层的专设表面特征的陶瓷基复合材料涡轮机部件)”的优先权国际申请No.PCT/US16/18224中描述的那样。在一些实施方式中，如优先权文件中描述的，EGF 71、79被切成图案阵列，该图案阵列包括与CMC陶瓷芯的专设表面特征(“ESF”)相交以增强剥落隔离的图案阵列。在优先权文件的实施方式中，CMC陶瓷基底的外表面和嵌入的陶瓷纤维通过将凹形或圆筒形的ESF阵列铣削到CMC陶瓷基底的外表面和嵌入的陶瓷纤维中而被切割。其他轮廓的ESF可选地通过选择性地改变陶瓷基底的外轮廓而对称或不对称地形成。
现在描述用于制造用于燃气涡轮发动机的陶瓷基复合材料(“CMC”)部件的示例性方法。这种部件包括图6和图13至图15的氧化纤维-氧化陶瓷芯CMC部件60、80、130和150。使用任何已知的技术将分级陶瓷纤维铺设成层状结构。示例性的层状结构是通过将陶瓷纤维定向成对称或非对称的图案而铺设的。在一些实施方式中，纤维已经被结合到准备铺设成层状结构的二维或三维织物组织中、或者各种织物束中、或者非织造的稀松织物内。在一些实施方式中，例如在最终的CMC部件要用作自支撑的或者部分自支撑的结构元件的情况下，纤维图案选择性地被改变以提供各向异性的结构性能，这与非结构隔热覆盖件覆于金属构件或者其他基底的情况相反。
CMC部件中的分级纤维层被选择成改变局部结构强度并且加强浸渍陶瓷悬浮液材料或TBC的锚固能力。层状织物的表面纹理(例如，在二维或三维织造图案织物或非织造稀松织物内)可以在层状织物的铺设期间或者在铺设之前通过选择具有期望的纤维图案的织物而被选择性地改变。在一些实施方式中，铺设的纤维表面纹理通过应用不同的稀松织物的纤维间隔和/或纤维厚度、或者织造织物内的织物/丝束图案而改变。这允许选择性地改变纤维增强陶瓷基底内的一些层或区域中的纤维取向和各向异性结构强度，并且用于在之后与陶瓷基底内的其他织物层或区域中的所应用的TBC的结合。例如，在一些实施方式中，铺设的层状结构内的织物层可以被改变以适应之后在已完成的纤维增强陶瓷基底中的纤维束之间或向外突出的突出物之间的切入的ESF取向。
在一些实施方式中，CMC-复合材料涡轮叶片80内的纤维增强陶瓷基底88由下述材料形成：(i)氧化物陶瓷纤维(例如，在商业上可用的商标为440、610和720的钇铝石榴石(“YAG”)纤维)，或者替代性地，氧化锆(“ZrO2”)；(ii)玻璃纤维或类玻璃纤维(例如，在商业上可用的商标为312、Fiberglass、E-glass)；或者(iii)非氧化物陶瓷纤维(碳化硅(“SiC”))，或者替代性地，碳氮化硅(“SiCN”)。氧化物陶瓷纤维复合材料通常使用氧化物陶瓷浆料、比如氧化铝、莫来石、氧化锆或氧化锆增韧氧化铝(“ZTA”)形成。玻璃纤维复合材料通常具有玻璃基质。非氧化物纤维陶瓷(通常为SiC，商业上可用的商标为)使用由陶瓷粉末、陶瓷前体(硅聚硼硅氮烷)、化学气相浸润或熔融浸润处理形成的非氧化物陶瓷基底(SiC，SiCN)而形成。
在一些实施方式中，用于铺设将被结合到纤维增强陶瓷基底88中的层状结构的纤维用陶瓷材料被预浸渍(“预浸料”纤维或织物)。在预浸料铺设完成后，其被固化成固化且硬化的纤维增强陶瓷基底88，纤维增强陶瓷基底88又被加工成最终的CMC部件、比如涡轮叶片80。在没有利用预浸料纤维的情况下，纤维被铺设成层状结构，层状结构随后在固化、凝固化和硬化成纤维增强陶瓷基底88之前用陶瓷材料浸渍。用来浸渍层状结构——层状结构用于随后固化成纤维增强陶瓷基底88——的示例性陶瓷材料包括硅酸铝、氧化铝氧化锆、氧化铝、氧化钇稳定的氧化锆、硅或碳化硅聚合物前体。后铺设浸润通过任何已知的技术执行，从而产生具有嵌入的、分级陶瓷纤维层100、120以及一些实施方式110中的实体的纤维增强陶瓷结构，这些已知技术包括气相沉积、熔体浸润、化学蒸气浸润、浆料浸润、预制陶瓷聚合物热分解、化学反应、烧结或陶瓷粉末的电泳沉积。
可选的专设表面特征(“ESF”)通过任何已知的切割技术被切入到纤维增强陶瓷基底的外表面中以及被切入到陶瓷基底的嵌入纤维120中，这些已知的切割技术包括机械加工、激光烧蚀或放电加工、网格喷砂或高压流体。尽管一般的CMC制造通常不太希望在预制件内切割纤维，因为会担心结构变弱，但是切割靠近纤维增强陶瓷基底的外表面的纤维、比如结合在图6和图13至图15的CMC部件60、80、130、150内的纤维并没有在结构上弱化这些部件。CMC部件60、80、130和150内的陶瓷基底的外表面的可选的ESF通过铣削进行机械切割或者通过激光烧蚀进行切割。
热喷涂的、或者汽相沉积的、或者溶液/悬浮液等离子体喷涂的热障涂层(“TBC”)被应用在纤维增强陶瓷基底88上。示例性的TBC复合材料包括单层的重量百分比为8的氧化钇稳定氧化锆(“8YSZ”)，或重量百分比为20的氧化钇稳定氧化锆(“20YSZ”)。对于包含热障涂层的烧绿石而言，需要底层的8YSZ形成双层8YSZ/重量百分比为59的钆稳定氧化锆(8YSZ/59GZO)涂层，或者双层的8YSZ/重量百分比为30至50的氧化钇稳定氧化锆(“30-50YSZ”)涂层，或者其组合。TBC附着至包括外纤维层120和任何可选的ESF的陶瓷基底的外表面。外纤维层120和任何可选的ESF增大了用于TBC对陶瓷基底的附着的表面面积，并且提供了材料的机械互锁。沿着可选的ESF的侧部切割的陶瓷纤维端部、以及图14的CMC部件130的纤维股136或CMC部件160的纤维环156附着至且抵接TBC材料，从而进一步增大了附着强度。可选地，粗糙表面的陶瓷结合涂层通过已知的沉积处理被应用在纤维增强陶瓷基底的外表面上、包括其外层织物和任意可选的ESF，从而进一步增强了TBC层对陶瓷基底的附着。在示例性的实施方式中，结合涂层材料是氧化铝或YAG，以能够在整个TBC从陶瓷基底外表面脱离的情况下实现氧化保护。
归因于增大的附着表面面积、机械互锁以及暴露的外层陶瓷纤维/TBC的附着所导致的增强的陶瓷基底/TBC的附着有助于0.5mm至2mm范围内的较厚的TBC层的应用，而0.5mm至2mm范围内的较厚的TBC层原本可能会从相比较的平坦表面TBC/陶瓷基底接合面分层。较厚的TBC提高了对CMC部件、比如用于燃气涡轮发动机的叶片或机叶的位于TBC下方的陶瓷基底和纤维的隔热保护。根据本文描述的实施方式制造的示例性模拟涡轮部件结构使TBC外层暴露于1950摄氏度的燃烧温度，而将位于TBC下方的纤维增强陶瓷基底和纤维增强陶瓷基底的嵌入纤维层的温度保持在1150摄氏度/1350摄氏度以下。如先前论述的，CMC部件内的位于TBC下方的纤维增强陶瓷基底和纤维增强陶瓷基底的嵌入纤维层暴露在燃气涡轮发动机内的1150C/1350C以上的温度会使这些部件热降解。
尽管本文已经详细地示出并描述了包括本发明的多种实施方式，但是其他人可以容易地设想出许多仍然包括所要求保护的本发明的其他被改变的实施方式。本发明就其应用而言不限于在说明书中陈述的或在附图中示出的部件的示例性实施方式的构造细节和布置细节。本发明能够具有其他实施方式并且能够以各种方式实践或执行。另外，应当理解到，本文使用的措辞和术语是为了描述的目的，而不应被视为限制。“包括”、“包含”或“具有”及其变体在本文中的使用意在包括其后所列出的项、这些项的等同替代以及附加的项。除非另有指定或限制，否则术语“安装”、“连接”、“支撑”和“联接”及其变体以广义使用，并且包括直接和间接地安装，连接、支撑和联接。此外，“连接”和“联接”不限于物理、机械或者电的连接或联接。

Claims (20)

1.一种用于燃气涡轮发动机的陶瓷基复合材料(“CMC”)部件，所述陶瓷基复合材料(“CMC”)部件包括：
纤维增强陶瓷基底，所述纤维增强陶瓷基底具有：
用于增强所述部件的结构强度的内纤维层，以及
在所述内纤维层的外部的外纤维层，在所述外纤维层中限定有空隙；以及
热喷涂的、或者汽相沉积的、或者溶液/悬浮液等离子体喷涂的热障涂层(“TBC”)，所述热障涂层包括TBC内表面和TBC外表面，所述TBC内表面被应用在所述外纤维层上并且被联接至所述外纤维层，从而填充所述外纤维层之间的所述空隙，所述TBC外表面用于暴露于燃烧气体。
2.根据权利要求1所述的发动机部件，所述外纤维层限定下述带纹理表面轮廓以增大与所述TBC内表面的接触表面面积，所述带纹理表面轮廓具有比所述外纤维层中的任何的单个纤维或纤维束的直径大的高度变化。
3.根据权利要求2所述的发动机部件，还包括远离由所述外纤维层限定的图案的外表面而向外突出的纤维股，以增大与所述TBC内表面的接触表面面积。
4.根据权利要求2所述的发动机部件，还包括远离由所述外纤维层限定的图案的外表面而向外突出的纤维股环，以增大与所述TBC内表面的接触表面面积。
5.根据权利要求2所述的发动机部件，所述TBC外表面具有专设槽特征(“EGF”)。
6.根据权利要求1所述的发动机部件，所述TBC的厚度在0.5mm至2mm之间。
7.根据权利要求2所述的发动机部件，所述外纤维层中的带纹理表面轮廓高度在0.1mm至1.5mm之间变化，其中，所述外纤维层中的空隙由各个纤维或纤维束之间的为0.1mm至8mm的间隔限定。
8.根据权利要求2所述的发动机部件，还包括置于所述内纤维层与所述外纤维层之间的中间纤维层，所述中间纤维层具有下述纤维图案：所述纤维图案限定了比所述内纤维层图案的密度和横截面面积小且比所述外纤维层的图案的密度和横截面面积大的密度和横截面面积。
9.根据权利要求1所述的发动机部件，还包括联接至纤维增强陶瓷基底并且被所述内纤维层所包围的金属构件。
10.根据权利要求1所述的发动机部件，还包括置于所述内纤维层与所述外纤维层之间的中间纤维层，所述中间纤维层具有下述纤维图案：所述纤维图案限定了比所述内纤维层图案的密度和横截面面积小且比所述外纤维层的图案的密度和横截面面积大的密度和横截面面积。
11.根据权利要求1所述的发动机部件，所述纤维增强陶瓷基底中的纤维包括：氧化陶瓷纤维、玻璃纤维或类玻璃纤维、或非氧化陶瓷纤维。
12.根据权利要求11所述的发送机部件，所述纤维增强陶瓷基底中的所述纤维选自包括氧化铝、莫来石、氧化铝和莫来石的混合物、以及氮化硅的组。
13.一种用于制造用于燃气涡轮发动机的陶瓷基复合材料(“CMC”)部件的方法，所述方法包括：
将陶瓷纤维铺设成层状结构，所述层状结构包括：
用于增强所述部件的结构强度的内层，以及
在所述内层的外部的外纤维层，在所述外纤维层中限定有空隙；
如果这些纤维在它们铺设之前没有用陶瓷材料预先浸渍，则用陶瓷浆料材料浸渍所述陶瓷纤维；
使浸渍的所述陶瓷纤维固化，从而形成固化的纤维增强陶瓷基底，所述固化的纤维增强陶瓷基底限定陶瓷基底外表面；以及
将热喷涂的、或者汽相沉积的、或者溶液/悬浮液等离子体喷涂的热障涂层(“TBC”)应用在所述陶瓷基底外表面上并且与所述陶瓷基底外表面联接。
14.根据权利要求13所述的方法，还包括将所述外纤维层铺设成限定下述带纹理表面轮廓以增大与所述TBC内表面的接触表面面积，所述带纹理表面轮廓具有比所述外纤维层中的任何的单个纤维或纤维束的直径大的高度变化。
15.根据权利要求14所述的方法，还包括将所述外纤维层铺设成限定远离由所述外纤维层限定的图案的外表面而向外突出的纤维股，以增大与所述TBC内表面的接触表面面积。
16.根据权利要求14所述的方法，还包括将所述外纤维层铺设成限定远离由所述外纤维层限定的图案的外表面而向外突出的纤维股环，以增大与所述TBC内表面的接触表面面积。
17.根据权利要求14所述的方法，还包括将所述TBC应用到0.5mm至2mm之间的厚度。
18.根据权利要求14所述的方法，还包括将所述外纤维层中的所述带纹理表面轮廓铺设成具有0.1mm至1.5mm的高度，并且在所述外纤维层中具有由各个纤维或纤维束之间的为0.1mm至8mm的间隔所限定的空隙。
19.根据权利要求14所述的方法，还包括铺设置于所述内纤维层与所述外纤维层之间的中间纤维层，所述中间纤维层具有下述纤维图案：所述纤维图案限定了比所述内纤维层图案的密度和横截面面积小且比所述外纤维层的图案的密度和横截面面积大的密度和横截面面积。
20.根据权利要求13所述的方法，还包括铺设置于所述内纤维层与所述外纤维层之间的中间纤维层，所述中间纤维层具有下述纤维图案：所述纤维图案限定了比所述内纤维层图案的密度和横截面面积小且比所述外纤维层的图案的密度和横截面面积大的密度和横截面面积。
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