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EP1657322B1 - Appareil de pulvérisation à plasma - Google Patents

Appareil de pulvérisation à plasma Download PDF

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Publication number
EP1657322B1
EP1657322B1 EP20050256848 EP05256848A EP1657322B1 EP 1657322 B1 EP1657322 B1 EP 1657322B1 EP 20050256848 EP20050256848 EP 20050256848 EP 05256848 A EP05256848 A EP 05256848A EP 1657322 B1 EP1657322 B1 EP 1657322B1
Authority
EP
European Patent Office
Prior art keywords
plasma
spray apparatus
plasma spray
cathode
gas
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.)
Expired - Lifetime
Application number
EP20050256848
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German (de)
English (en)
Other versions
EP1657322A2 (fr
EP1657322A3 (fr
Inventor
Donn Blankenship
Paul H. Zajchowski
Gary C. Shubert
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.)
RTX Corp
Original Assignee
United Technologies 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 US10/982,041 external-priority patent/US20060091117A1/en
Priority claimed from US11/190,136 external-priority patent/US20070023402A1/en
Priority claimed from US11/253,868 external-priority patent/US20070087129A1/en
Application filed by United Technologies Corp filed Critical United Technologies Corp
Publication of EP1657322A2 publication Critical patent/EP1657322A2/fr
Publication of EP1657322A3 publication Critical patent/EP1657322A3/fr
Application granted granted Critical
Publication of EP1657322B1 publication Critical patent/EP1657322B1/fr
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
    • B05B7/16—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed
    • B05B7/22—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc
    • B05B7/222—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc using an arc
    • B05B7/226—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc using an arc the material being originally a particulate material

Definitions

  • the present disclosure generally relates to a plasma spray coating apparatus, such as a microplasma spray coating apparatus.
  • Plasma coating methods and apparatus are known. For example, one such method and apparatus for plasma flame spray coating material onto a substrate by means of passing a plasma forming gas through a nozzle electrode, and passing an arc forming current between the nozzle electrode and a rear electrode to form a plasma effluent.
  • the method includes introducing coating material into the plasma effluent, passing the plasma effluent axially through a wall shroud extending from the exit of said nozzle electrode, and forming a flame shroud for the plasma effluent. The coating is thereby applied to the substrate.
  • RU 2039613-C1 discloses a plasma spraying apparatus for depositing coatings made from the powder of refractory material.
  • JP 61-210170 discloses an apparatus for applying a ceramic film to a component.
  • EP-A-0342388 discloses a plasma spray apparatus having an electrode with a frustoconical tip.
  • the blade roots of compressor blades can be coated with material to meet dimensional tolerance requirements for sealing the compressor blade with the compressor wheel and the like.
  • Metallic coatings consisting of copper-nickel, aluminium-copper, and other similar composition materials have been applied in this regard using various conventional plasma spray coating processes.
  • the coating process requires the workpiece to be masked in areas where the material transfer is not required and/or not desired.
  • the workpiece is typically coated in a dedicated facility such as a gas turbine engine manufacturing plant or repair shop.
  • a plasma spray apparatus as claimed in claim 1.
  • the apparatus can be used for coating at least a portion of a workpiece such as a gas turbine compressor blade
  • the electrode extending from a cathode housing and terminating at a tip includes a substantially circular cross section along at least a portion of a lengthwise axis.
  • the angled surface extending from the tip toward the cathode housing is formed on the electrode.
  • a substantially flat edge having a predetermined height defines a forward edge of the tip.
  • the plasma spray apparatus 10 includes a plasma gun 12 having an arc gas emitter 14, an anode 16, and a cathode 18.
  • An electric arc 20 is generated between the anode 16 and cathode 18.
  • a plasma stream 21 is formed when arc gas is injected from the arc gas emitter 14 and passes through the arc 20.
  • a powdered material injector 22 dispenses powdered material into the plasma stream which transports the powdered material to the workpiece 24 to form a coating thereon.
  • the size of the plasma stream 21 created by the device and/or the power used by the device determines whether the device is considered a microplasma spray apparatus. When the plasma stream 21 is small and/or the power used by the device is low, the device is considered a microplasma spray device.
  • Fig. 1 displays a microplasma spray device.
  • the powdered material can form a solid coating with a thickness of approximately 0.0015 to 0.006 inches (0.038 mm to 0.152 mm) in a desired location on the workpiece 24.
  • the coating material may be virtually any metallic, non-metallic or intermetallic powder, including the materials described above and ceramic-based materials.
  • an electric arc 20 is generated between the anode 16 and cathode 18 of the plasma gun 12.
  • Arc gas such as, but not limited to argon, is emitted into the electric arc 20 formed between the anode 16 and the cathode 18. It should be understood that in practice the arc gas can be emitted prior to generating the electric arc.
  • the electric arc 20 ionizes the gas to create the plasma gas stream 21. The ionization process removes electrons from the arc gas, causing the arc gas to become temporarily unstable.
  • the arc gas heats up to approximately 20,000°F to 30,000°F (11097°C to 16426°C) as it re-stabilizes.
  • the plasma stream cools rapidly after passing through the electric arc.
  • FIG. 2 an exploded view of such a plasma spray apparatus is again referred to by reference numeral 10.
  • the plasma spray apparatus 10 is operable for coating a workpiece, including, but not limited to at least a portion of a compressor blade 72 in a gas turbine engine (not shown).
  • a gas turbine engine not shown
  • teachings of disclosure can be used to coat myriad other surfaces, including those on aircraft, land-based vehicles, weapons, sea-faring vessels and the like.
  • the plasma spray apparatus 10 includes the aforementioned plasma gun 12 having an anode 16 and a cathode 18.
  • the cathode 18 is further depicted to include an insulated body 26 with an electrode 28 extending therefrom.
  • the cathode 18 can also include threads 30 for threadingly engaging the plasma gun 12.
  • the cathode 18 can also include an O-ring seal 32 to seal the leak path that is created at the interface between the cathode 18 and the plasma gun 12.
  • a powdered material injector 22 injects powdered material 34 into the plasma gas stream 21.
  • the powdered material 34 is heated and super plasticized in the plasma stream 21 and is deposited on the compressor blade 72 (see Fig. 4 ) where it cools and re-solidifies to form the coating.
  • the powdered material injector 22 includes a powder hopper 36 for holding and feeding the powdered material 34 into the plasma stream 21.
  • the hopper 36 can be connected to the plasma gun 12 through a conduit 38 such as a flexible hose or the like.
  • the conduit 38 can be connected via a threaded fitting 39 to a powder injector nozzle 40.
  • the powder injector nozzle 40 can extend through an aperture 42 formed in the anode 16.
  • the powder injector nozzle 40 can threadingly connect to the anode 16 via threads 43.
  • anodes are typically formed from a copper-tungsten alloy and provide very limited service life of approximately 10 to 20 minutes in a plasma spray apparatus 10. Copper and other similar metals have melting temperatures that are lower than the anode operating temperature. These metals can melt and cause the edge of the anode 16 to become molten and initiate cavitation erosion along an upper edge of the anode. In order to produce high quality coatings, the edge of the anode must remain relatively sharp. To achieve this, a commercially pure sintered tungsten material has been developed to produce a more robust anode. Test results using anodes made from sintered tungsten material has shown marked improvements in the erosion resistance over prior art anodes. Utilizing commercially pure tungsten in the anode 16 has increased the service life of the anode 16 to approximately between 10 and 20 hours.
  • a nozzle shroud 46 positioned on a forward wall 48 of the plasma gun 12 holds a nozzle insert 50 and permits the electrode 28 to extend through a center aperture 52 formed in the nozzle shroud 46.
  • the nozzle insert 50 can be threadingly attached to an end of the nozzle shroud 46.
  • a shield gas cap 54 is positioned over the nozzle shroud 46.
  • An insulator 56 is positioned between the shield gas cap 54 and the nozzle shroud 46 to electrically isolate the shield gas cap 54 from the nozzle shroud 46.
  • the shield gas cap 54 can be pressed fit onto the nozzle shroud 46 and over the insulator 56.
  • the shield gas cap 54 includes a plurality of through apertures 58 for permitting shield gas to flow therethrough and shield the arc gas from ambient atmosphere.
  • a center aperture 60 formed in the shield gas cap 54 permits high velocity arc gas to pass through and into the electric arc.
  • Cooling fluid such as water or the like, can be utilized to cool the plasma gun 12.
  • the cooling fluid is delivered to the plasma gun 12 via a cooling fluid hose 62.
  • the cooling fluid traverses through internal passages (not shown) in the plasma gun 12 and flows through an inlet passage 64, into an anode holder 66 and back through an outlet passage 68.
  • the cooling fluid reduces the temperature of the anode 16 during operation of the plasma gun 12.
  • the cooling flow rate may be approximately 0.1 to 1.0 gallons per minute.
  • a second conduit 70 can be connected to the plasma gun 12.
  • the second conduit may be operable for providing electrical power, arc gas, and/or shield gas to the plasma gun 12.
  • the electrode 28 of the cathode 18 is shown in an enlarged view.
  • the electrode 28 can have a circular cross-section, for example, of approximately 1/16 th inch (1.59 mm) in diameter, although other dimensions are certainly possible.
  • the electrode 28 includes a tip 65 that is tapered, for example, by machining at an angle A, to form a substantially flat upper surface 67.
  • the angle A can range between 0 and 90 degrees, but in one embodiment the angle A ranges between approximately 8 and 10 degrees.
  • a distal end of the tip 65 can then be machined flat to a desired height B. In one embodiment the height B can range from .008 to .010 inches (0.2 mm to 0.25 mm).
  • the height B can be defined as approximately between 10% and 20% of a diameter or a width of the electrode.
  • the electrode can be formed from any electrically conductive material such as a copper alloy, but has been found to be advantageously formed from thoriated tungsten.
  • a localized area of the compressor blade 72 can be spray coated with powdered material 34.
  • the plasma gas stream 21 is directed toward the portion of the compressor blade 72 to be coated.
  • the plasma gun 12 is operated at a relatively low power range of between approximately 0.5 Kilowatts and 4 Kilowatts.
  • the low power output of the plasma gun 12 significantly reduces the heat flow into the compressor blade 72 over that of conventional coating methods.
  • the maximum surface temperature of the compressor blade 72 caused by the coating process is approximately 200°F (93°C).
  • Such low power output and resulting low temperature on blade 72 allows the plasma gun 12 to apply powdered material 34 to a thin wall area of the compressor blade 72 without distorting the compressor blade 72 because the localized stresses caused by high thermal gradients do not exist.
  • the plasma gun 12 can apply coating material in narrow strips of, for example, about 0.5 to about 5 mm in width. This permits accurate surface coating even with a hand held device.
  • the narrow strips of coating substantially eliminate the need for masking or otherwise covering the compressor blade.72 in areas where the coating is unwanted.
  • the narrow spray pattern is controlled by the nozzle opening size.
  • the hand held version of the plasma gun 12 can spray coatings on components even while they remain in an installed condition, such as in an engine or the like.
  • the arc gas flow rate of the plasma apparatus 10 may be between approximately0.5 and 3 liters per minute, although other rates are certain possible.
  • the arc gas and shield gas are typically argon, but any suitable inert gas can be utilized as is known to those skilled in the art.
  • the shield gas flow rate could range between approximately 2 and 8 liters per minute for a typical application.
  • the powder hopper 36 holds the powdered material 34 prior to being injected into the plasma gas stream 21 by the powder injector 22. Powdered material 34 can be transferred to the workpiece from between approximately 1 to 30 grams per minute.
  • the plasma gun 12 can typically apply the coating from distances ranging from approximately 1.5 inches to 8 inches (38 mmto 203 mm) to the workpiece, but can vary depending on the coating application requirements.
  • the plasma spray gun 12 provides unlimited angles of orientation relative to the workpiece because the pressurized powder feed system uses carrier gas to entrain and deliver the powdered material 34 to the plasma stream 21 and does not rely on gravitation as prior art systems did.
  • Compressed carrier gas such as an inert gas flows through the powder injector 22.
  • Powdered material 34 can be entrained with the carrier gas as is known to those skilled in the art.
  • the carrier gas will flow through the powder injector 22 at any angle of orientation and thus does not rely on gravitational forces to deliver powdered material 34 to the plasma stream 21.
  • the plasma stream 21 provides a venturi effect with respect to the powder injector 22.
  • the high velocity flow rate of the plasma stream 21 across the powder injector 22 generates a low pressure region which augments the flow rate of the carrier gas and the powdered material 34 through the powder injector 22.
  • the plasma spray gun 12 generates a relatively low noise level that ranges from between 40 and 70 decibels due to the low power output, thereby making the apparatus 10 suitable for hand held application.
  • Current U.S. government regulations require hearing protection when environmental noise reaches 85 decibels.
  • the plasma spray apparatus 10 can be hand held or alternatively held in a fixture (not shown) such as one that is computer controlled.
  • a residual amount of electric current is transmitted from the anode 16 to the powder injector 22.
  • This residual current can cause preheating of the powdered material 34 to occur which facilitates softening of the powdered material 34 prior to entering the plasma stream 21.
  • a block diagram generally describing the operation of the plasma spray apparatus 10 and the plasma spray coating process is illustrated.
  • arc gas is emitted from the nozzle insert 50.
  • An electric potential is generated between the anode 16 and the cathode 18 of the plasma spray gun 12 and is directed through the arc gas, as described in block 82.
  • Arc gas is directed through the electric potential to create the plasma stream 21.
  • powdered material 34 is injected into the plasma stream 21.
  • the plasma stream heats the powdered material 34 to a "super plasticized" condition such that the powdered material 34 is malleable when it is applied to a workpiece.
  • the powdered material 34 is applied to an unmasked substrate. The powdered material 34 then cools and solidifies as a hard coating on the substrate.

Landscapes

  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Nozzles (AREA)
  • Coating By Spraying Or Casting (AREA)

Claims (23)

  1. Appareil de pulvérisation à plasma servant à revêtir une pièce de travail, comprenant :
    une anode (16), une cathode (18) et un générateur d'arc produisant un arc électrique (20) entre l'anode (16) et la cathode (18) ;
    une buse destinée à envoyer du gaz d'arc dans l'arc électrique (20), l'arc électrique servant à ioniser le gaz pour créer un flot de gaz plasma (21) ; et
    un dispositif d'alimentation fournissant une matière pulvérulente (34) dans le flot de gaz plasma (21) ;
    dans lequel la cathode (18) inclut une électrode (28) s'étendant à partir d'un logement de cathode et se terminant au niveau d'une pointe (65) qui inclut un bord avant sensiblement plat, l'électrode (28) servant à conduire un courant électrique ;
    caractérisé en ce que :
    l'électrode (28) inclut une surface supérieure (67) formant un angle sensiblement plat s'étendant à partir de la pointe (65) vers le logement de cathode ; en ce qu'elle comprend en outre un capot de cathode (46) entourant une partie de la cathode (18) et un capuchon de gaz de protection (54) englobant sensiblement le capot (46), le capuchon de gaz de protection servant à fournir un gaz de protection en tant que barrière entre le gaz d'arc et une atmosphère ambiante.
  2. Appareil de pulvérisation à plasma selon la revendication 1, dans lequel l'angle de la surface (67) fait entre 8 et 10 degrés.
  3. Appareil de pulvérisation à plasma selon la revendication 2, dans lequel l'angle de la surface (67) fait 10 degrés.
  4. Appareil de pulvérisation à plasma selon l'une quelconque des revendications précédentes, dans lequel le bord avant sensiblement plat a une hauteur comprise entre 10 % et 20 % d'une largeur de l'électrode.
  5. Appareil de pulvérisation à plasma selon l'une quelconque des revendications précédentes, dans lequel l'électrode (28) comprend une section transversale sensiblement circulaire le long d'au moins une partie d'un axe longitudinal.
  6. Appareil de pulvérisation à plasma selon l'une quelconque des revendications précédentes, dans lequel l'appareil de pulvérisation à plasma (10) est un appareil de pulvérisation à microplasma.
  7. Appareil de pulvérisation à plasma selon l'une quelconque des revendications précédentes, dans lequel le dispositif d'alimentation est configuré pour utiliser un gaz porteur servant à entraîner la matière pulvérulente (34) à travers l'anode (16).
  8. Appareil de pulvérisation à plasma selon l'une quelconque des revendications précédentes, incluant en outre une trémie à poudre (36) servant à contenir la matière pulvérulente (34) avant l'injection de la matière pulvérulente dans le flot de gaz plasma (21).
  9. Appareil de pulvérisation à plasma selon la revendication 8, dans lequel la trémie à poudre (36) et le dispositif d'alimentation sont combinés en un seul appareil.
  10. Appareil de pulvérisation à plasma selon l'une quelconque des revendications précédentes, incluant en outre une buse d'injection de poudre reliée au dispositif d'alimentation, la buse d'injection de poudre s'étendant à travers l'anode (16) et injectant de la matière pulvérulente dans le flot de gaz plasma (21).
  11. Appareil de pulvérisation à plasma selon l'une quelconque des revendications précédentes, dans lequel l'appareil à plasma fonctionne à une puissance comprise dans une plage de 0,5 kilowatt et 4 kilowatts.
  12. Appareil de pulvérisation à plasma selon l'une quelconque des revendications précédentes, dans lequel la température maximale de surface de la pièce de travail provoquée par le processus de revêtement est de 200 °F (93 °C).
  13. Appareil de pulvérisation à plasma selon l'une quelconque des revendications précédentes, dans lequel l'appareil à plasma est agencé pour appliquer la matière de revêtement sur la pièce de travail dans des largeurs de 0,5 mm à 5 mm.
  14. Appareil de pulvérisation à plasma selon l'une quelconque des revendications précédentes, dans lequel la matière pulvérulente (34) est un alliage métallique.
  15. Appareil de pulvérisation à plasma selon l'une quelconque des revendications 1 à 13, dans lequel la matière pulvérulente (34) est un revêtement à base de céramique.
  16. Appareil de pulvérisation à plasma selon l'une quelconque des revendications précédentes, incluant en outre un système de refroidissement destiné à refroidir l'appareil à plasma.
  17. Appareil de pulvérisation à plasma selon l'une quelconque des revendications précédentes, dans lequel l'appareil à plasma sert au revêtement par pulvérisation d'une pièce de travail sous n'importe quel angle d'orientation.
  18. Appareil de pulvérisation à plasma selon l'une quelconque des revendications précédentes, dans lequel l'appareil à plasma produit un niveau sonore compris entre 40 et 70 décibels.
  19. Appareil de pulvérisation à plasma selon l'une quelconque des revendications précédentes, dans lequel la buse est placée dans une ouverture de réception formée dans le capot de cathode (46).
  20. Appareil de pulvérisation à plasma selon l'une quelconque des revendications précédentes, incluant en outre un isolant de capuchon de protection (56) placé entre le capuchon de gaz de protection (54) et le capot de cathode (46).
  21. Appareil de pulvérisation à plasma selon l'une quelconque des revendications précédentes, dans lequel l'anode (16) est formée à partir d'une matière de tungstène commercialement pur.
  22. Appareil de pulvérisation à plasma selon l'une quelconque des revendications précédentes, dans lequel l'anode (16) est formée à partir de matière de tungstène fritté.
  23. Appareil de pulvérisation à plasma selon l'une quelconque des revendications 1 à 20, dans lequel l'électrode (28) est formée à partir de tungstène au thorium.
EP20050256848 2004-11-04 2005-11-04 Appareil de pulvérisation à plasma Expired - Lifetime EP1657322B1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US10/982,041 US20060091117A1 (en) 2004-11-04 2004-11-04 Plasma spray apparatus
US11/190,136 US20070023402A1 (en) 2005-07-26 2005-07-26 Methods for repairing workpieces using microplasma spray coating
US11/253,868 US20070087129A1 (en) 2005-10-19 2005-10-19 Methods for repairing a workpiece

Publications (3)

Publication Number Publication Date
EP1657322A2 EP1657322A2 (fr) 2006-05-17
EP1657322A3 EP1657322A3 (fr) 2008-02-27
EP1657322B1 true EP1657322B1 (fr) 2013-10-30

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Application Number Title Priority Date Filing Date
EP20050256848 Expired - Lifetime EP1657322B1 (fr) 2004-11-04 2005-11-04 Appareil de pulvérisation à plasma

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Family Cites Families (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL7600738A (nl) * 1976-01-23 1977-07-26 Plasmainvent Ag Inrichting voor het plasma-spuiten.
JPS61210170A (ja) 1985-03-14 1986-09-18 Hitachi Zosen Corp セラミツク粉体の溶射方法
US4841114A (en) 1987-03-11 1989-06-20 Browning James A High-velocity controlled-temperature plasma spray method and apparatus
US5233153A (en) * 1992-01-10 1993-08-03 Edo Corporation Method of plasma spraying of polymer compositions onto a target surface
RU2039613C1 (ru) 1992-07-01 1995-07-20 Сибирская аэрокосмическая академия Плазмотрон для напыления преимущественно тугоплавких материалов
EP0727504A3 (fr) * 1995-02-14 1996-10-23 Gen Electric Procédé de revêtement pour plasma pour améliorer la liaison de revêtements sur des substrats
DE10023303A1 (de) * 2000-05-15 2002-04-18 Euromat Ges Fuer Werkstofftech Verfahren zum Aufbringen einer Schicht aus Edelmetall und/oder einer Edelmetallegierung sowie deren Verwendung
US7026009B2 (en) * 2002-03-27 2006-04-11 Applied Materials, Inc. Evaluation of chamber components having textured coatings
JP2006131999A (ja) * 2004-10-29 2006-05-25 United Technol Corp <Utc> マイクロプラズマ溶射を用いたワークピースを修復する方法

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EP1657322A2 (fr) 2006-05-17
EP1657322A3 (fr) 2008-02-27

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