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EP3572551B1 - Procédé de revêtement d'un substrat à l'aide d'une structure creuse - Google Patents

Procédé de revêtement d'un substrat à l'aide d'une structure creuse Download PDF

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Publication number
EP3572551B1
EP3572551B1 EP19174701.3A EP19174701A EP3572551B1 EP 3572551 B1 EP3572551 B1 EP 3572551B1 EP 19174701 A EP19174701 A EP 19174701A EP 3572551 B1 EP3572551 B1 EP 3572551B1
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EP
European Patent Office
Prior art keywords
substrate
gas flow
layer
diffusion layer
cavity structure
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.)
Active
Application number
EP19174701.3A
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German (de)
English (en)
Other versions
EP3572551A1 (fr
Inventor
Susanne Schrüfer
Tanja Wobst
Robert Vassen
Georg Mauer
Ralf Laufs
Karl-Heinz Rauwald
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.)
Forschungszentrum Juelich GmbH
Rolls Royce Deutschland Ltd and Co KG
Original Assignee
Forschungszentrum Juelich GmbH
Rolls Royce Deutschland Ltd and Co KG
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Publication of EP3572551A1 publication Critical patent/EP3572551A1/fr
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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
    • 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
    • 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
    • C23C10/00—Solid state diffusion of only metal elements or silicon into metallic material surfaces
    • C23C10/28—Solid state diffusion of only metal elements or silicon into metallic material surfaces using solids, e.g. powders, pastes
    • C23C10/34—Embedding in a powder mixture, i.e. pack cementation
    • C23C10/36—Embedding in a powder mixture, i.e. pack cementation only one element being diffused
    • C23C10/48—Aluminising
    • 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
    • C23C10/00—Solid state diffusion of only metal elements or silicon into metallic material surfaces
    • C23C10/60—After-treatment
    • 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
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    • 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
    • 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
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/01—Selective coating, e.g. pattern coating, without pre-treatment of the material to be coated
    • 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
    • C23C4/11—Oxides
    • 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
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/134—Plasma spraying
    • 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
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/137—Spraying in vacuum or in an inert atmosphere
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23R—GENERATING COMBUSTION PRODUCTS OF HIGH PRESSURE OR HIGH VELOCITY, e.g. GAS-TURBINE COMBUSTION CHAMBERS
    • F23R3/00—Continuous combustion chambers using liquid or gaseous fuel
    • F23R3/002—Wall structures
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F23R—GENERATING COMBUSTION PRODUCTS OF HIGH PRESSURE OR HIGH VELOCITY, e.g. GAS-TURBINE COMBUSTION CHAMBERS
    • F23R3/00—Continuous combustion chambers using liquid or gaseous fuel
    • F23R3/005—Combined with pressure or heat exchangers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
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    • F23R3/00—Continuous combustion chambers using liquid or gaseous fuel
    • F23R3/02—Continuous combustion chambers using liquid or gaseous fuel characterised by the air-flow or gas-flow configuration
    • F23R3/04—Air inlet arrangements
    • F23R3/06—Arrangement of apertures along the flame tube
    • 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
    • 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
    • F05D2220/00—Application
    • F05D2220/30—Application in turbines
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    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/30—Manufacture with deposition of material
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    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
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    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
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    • F05D2230/90—Coating; Surface treatment
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    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2240/00—Components
    • F05D2240/10—Stators
    • F05D2240/11—Shroud seal segments
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    • F05D2300/13—Refractory metals, i.e. Ti, V, Cr, Zr, Nb, Mo, Hf, Ta, W
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    • F05D2300/00—Materials; Properties thereof
    • F05D2300/10—Metals, alloys or intermetallic compounds
    • F05D2300/14—Noble metals, i.e. Ag, Au, platinum group metals
    • F05D2300/143—Platinum group metals, i.e. Os, Ir, Pt, Ru, Rh, Pd
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    • F23R2900/00—Special features of, or arrangements for continuous combustion chambers; Combustion processes therefor
    • F23R2900/00018—Manufacturing combustion chamber liners or subparts
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    • F23R2900/00—Special features of, or arrangements for continuous combustion chambers; Combustion processes therefor
    • F23R2900/03041—Effusion cooled combustion chamber walls or domes

Definitions

  • the invention relates to a method for coating a substrate with a cavity structure having the features of claim 1.
  • components are subjected to high temperatures. In most cases, these components are exposed to hot gases, such as combustion gases in furnace furnaces or in the combustion chambers of aircraft engines. Therefore, the thermal resistance of such components is important.
  • Metallic substrates from which such components are constructed may have cavity structures, such as cooling channels, with the internal cavity structures opening into openings on the surface of the substrates.
  • the cavity structures can be built up in the substrate during the manufacturing process (e.g. by an additive layer application method; ALM (Additive Layer Manufacturing)) or the cavity structures are introduced into a cast substrate after the production of the substrate, e.g. by laser drilling.
  • ALM additive Layer Manufacturing
  • the object is to create efficient methods for coating substrates with an already existing internal cavity structure of the type described.
  • a substrate is coated with an internal cavity structure, in particular a cooling structure.
  • the cavity structure has openings in the surface of the substrate.
  • At least one adhesion-promoting layer is applied to the substrate.
  • a diffusion layer i.e. introduced by a diffusion process
  • the diffusion layer serves, among other things, to promote adhesion for the at least one thermal protective layer that is subsequently applied.
  • the at least one thermal protection layer is applied to the at least one diffusion layer using a suspension plasma spray (SPS) method.
  • SPS suspension plasma spray
  • This method is well suited to not or only slightly blocking the openings of the already existing internal cavity structure during the coating.
  • One of the reasons for this is that the fine particles in the gas streams present in the processes are so small that they are carried along by the gas stream. Keeping the openings free saves time-consuming rework, such as subsequent drilling with a laser drilling process.
  • the SPS process has a gas flow with a flow component parallel to the surface of the substrate, i.e. the main direction of flow of the gas flow is not perpendicular to the substrate.
  • the main flow direction of the gas flow has an angle ⁇ to the surface of the substrate which is less than 30°, in particular less than 15°.
  • the main flow direction of the gas flow is parallel to the surface of the substrate. A possible blockage of the openings of the cavity structures is minimized in the case of a flat angle of incidence or even a main flow direction parallel to the substrate.
  • the gas flow is a process gas flow and/or carrier gas flow of the SPS method. This is an interaction between the gas stream and the substrate by direct deposition from the Gas flow takes place on the surface of the substrate. This reduces deposition in pits in the surface.
  • the gas stream loaded with parts is characterized by a Stokes number St ⁇ 1, in particular St ⁇ 0.1, in particular St ⁇ 0.01, in particular St ⁇ 0.001.
  • the dimensionless Stokes number St is a measure of the mass inertia of a particle for its movement in a moving fluid, here a gas. It is the ratio of the characteristic time t T , with which the speed of the particle adapts to the speed of the surrounding gas due to friction, to the characteristic time t P , in which the gas itself changes its speed due to external influences.
  • the at least one diffusion layer is applied by pack aluminizing, a PVD method or an additive layer method. All of these methods allow the thin diffusion layer to be applied efficiently.
  • the at least one diffusion layer may contain a proportion of an X aluminide X selected from chromium, platinum and/or nickel or aluminum and chromium, platinum and/or nickel, or consists of these substances.
  • the at least one thermal protective layer has a proportion of yttrium (eg in the form of Y 2 O 3 ) and/or stabilized zirconium oxide (ZrO 2 ) or consists of this substance.
  • the substrate is metallic and is at least partially produced by an additive layer deposition process (ALM) or by a casting process.
  • ALM additive layer deposition process
  • casting process allow the production of components with complex shapes, such as turbine blades.
  • the substrate has a proportion of a high-temperature nickel alloy, in particular CMSX4, CMSX3, C 263, Mar M 002 and/or C 1023, or consists of such a material.
  • channels of the cavity structure and/or the openings of the cavity structure can have an average diameter of between 0.5 and 1.5 mm, in particular 1 mm. These dimensions allow efficient use of the cavity structure for cooling purposes.
  • a substrate with a cavity structure in the interior of the substrate can be produced with at least one of the embodiments for a method for coating, the cavity structure having openings in the surface of the substrate.
  • a substrate produced in this way can be used, for example, in a combustor shingle of an aircraft engine combustor, in a turbine blade of an aircraft engine or in a liner of a turbine in an aircraft engine.
  • the aircraft engine 10 according to FIG 1 shows a fundamentally known example of a turbomachine.
  • This is just an example of a device in which substrates 40 are provided with an internal cavity structure 41 (see 2 ) can be used for thermally stressed components.
  • substrates 40 in other devices, such as furnaces, for example.
  • the aircraft engine 10 is usually designed as a multi-shaft engine in a manner known per se and comprises, in the direction of flow, one behind the other an air inlet 11, a fan 12 rotating in a fan housing 24 (corresponding to a low-pressure compressor), a medium-pressure compressor 13, a high-pressure compressor 14, and a combustion chamber 15, a high-pressure turbine 16, an intermediate-pressure turbine 17 and a low-pressure turbine 18, and an exhaust nozzle 19, all of which are arranged around a central axis 1 of the engine.
  • the high-pressure turbine 16 is designed to drive the high-pressure compressor 14 via a high-pressure shaft 20 .
  • the medium-pressure turbine 17 is designed to drive the medium-pressure compressor 13 via a medium-pressure shaft 21 .
  • the low-pressure turbine 18 is designed to drive the fan 12 via a low-pressure shaft 22 .
  • Alternative embodiments of an aircraft engine 10 can also have two shafts instead of three shafts.
  • the drive shaft of the fan 12 is coupled to a reduction gear so that the fan 12 can be operated at a lower speed than the driving turbine.
  • Thermally stressed components with substrates 40 with internal cavity structures 41 are also used in such geared fan engines.
  • a first portion of the airflow passing through the aircraft engine 10 flows through the intermediate pressure compressor 13 and the high pressure compressor 14, increasing the pressure of the airflow.
  • This air flow is then fed to the combustion chamber 15 and burned with injected fuel.
  • the hot gases produced during combustion flow through the high-pressure turbine 16, the intermediate-pressure turbine 17 and the low-pressure turbine 18 and thereby drive them. Finally, the hot gases flow out of the exhaust nozzle 19 and thus generate part of the thrust of the aircraft engine 10.
  • a second portion of the airflow is directed around the main portion of the aircraft engine and flows through a bypass duct 23 defined by a fan casing 24 .
  • This second part of the air leaves the aircraft engine 10 through a fan nozzle 25 and thereby generates a larger part of the thrust of the aircraft engine 10 - compared to the exiting gas from the exhaust nozzle 19.
  • FIG. 2A to 2C An embodiment of a method for coating a substrate 40 with an internal cavity structure 41 is shown schematically.
  • FIG. 2A a starting situation, ie a substrate 40 having an internal cavity structure 41 .
  • the representation according to Figure 2A is simplified for the sake of simplicity in several respects.
  • the substrate 40 is shown as a cube for the sake of simplicity, although in principle other substrate shapes, in particular complex shapes, which are adapted to the structural conditions in the aircraft engine 10, for example, can also be used.
  • the illustrated substrate 40 according to FIG Figure 2A can also be understood as a section from a larger part.
  • the cavity structure 41 inside the substrate 40 is in the embodiment according to FIG Figure 2A by three tubular cavities (e.g. as bores inclined to the surface O at an angle ⁇ , see Figure 2B ) with openings 42 in two surfaces O of the substrate 40 symbolized.
  • the cavity structure 41 it is also possible for a large number of bores to be used as the cavity structure 41 .
  • the holes do not all have to run in one direction.
  • a complex, amorphous or honeycomb structure inside the substrate 40 is used as the cavity structure 41 .
  • the mean diameters of the voids (in 1 of the tubular cavities) in the range of 0.5 to 1.5 mm.
  • the cavity structure 41 can, for example, be part of a cooling system through which a coolant can flow.
  • turbine blades can be equipped with an internal cooling system.
  • the substrate 40 can be produced by an additive manufacturing method (ALM: Additive Layer Manufacturing) or by a casting method.
  • ALM additive Manufacturing
  • the cavity structure 41 can be constructed, for example, by laser drilling or with ALM.
  • the substrate 40 is built up layer by layer from a nickel alloy (examples are given below) by laser sintering or laser melting. Typical parameters are temperatures between 900 and 1000 °C, pressures between 100 and 110 MPa and times up to 2 hours. If deemed necessary, the substrate 40 may be polished or ground prior to coating.
  • the substrate 40 can also be produced by a blown powder ALM method or a cold spray method.
  • the substrate 40 already has an internal cavity structure 41 before the subsequent coatings.
  • the substrate 40 is metallic and is produced at least partially by a layer application method or by a casting method.
  • the substrate 40 can have a proportion of a high-temperature nickel alloy, in particular CMSX4, CMSX3, C 263, Mar M 002 or C 1023, or consist of such a material.
  • a diffusion layer 31 is applied to the substrate 40, which is shown in the sectional view of FIG Figure 2B is shown.
  • an aluminide layer is applied as a diffusion layer 31 by a pack aluminizing known per se, since this method is economically advantageous.
  • the substrate 41 is heated cyclically at temperatures between 800 and 1000° C. together with an aluminum-containing powder.
  • the pack aluminizing typically takes several hours, followed by a thermal post-treatment so that diffusion into the substrate 41 can take place.
  • a single diffusion layer 31 is applied, which in principle can also have a layer sequence.
  • a possible embodiment of the diffusion layer 31 can have a proportion of an X aluminide with X selected from aluminum, chromium, platinum and/or nickel, or consist of these substances.
  • X selected from aluminum, chromium, platinum and/or nickel, or consist of these substances.
  • a pure aluminide layer or a layer with two or more components can also be applied.
  • the at least one diffusion layer 31 can also have a proportion of MCrAlY with M selected from nickel, cobalt, iron and Y selected from yttrium, ytterbium, lanthanum or a rare earth, or consist of this substance.
  • Such a layer can be applied by means of an ALM method (blown powder) or a PVD method.
  • the diffusion layer 31 (e.g. with a thickness of 10 to 90 ⁇ m) allows sufficient adhesion promotion, offers protection against oxidation and provides sufficiently prepared surfaces for a subsequent coating with a thermal protective layer 32.
  • a thermal protective layer 32 is applied to the at least one diffusion layer 31 using a plasma spray PVD (PS-PVD) method or a suspension plasma spray (SPS) method (spray angle a). This is in Figure 2C shown.
  • PS-PVD plasma spray PVD
  • SPS suspension plasma spray
  • both methods do not clog the openings 42 of the cavity structure 41 or only do so to a small extent, so that, for example, after the coating, the openings 42 do not have to be reworked by means of laser drilling.
  • the coating is created from a gas flow (see 3 ) which may be inclined or parallel to the surface O of the substrate 40 (see FIG Figures 3A, 3B ). This can reduce or prevent the deposition of coating material in openings 42 .
  • a typical thermal protective layer 32 is composed of one to three individual layers approximately 0.1 mm to 0.3 mm thick.
  • the thermal protection layer 32 reflects incident hot gas radiation, forms a thermal insulation layer between the hot gas and the substrate 40 and forms a protective layer against hot gas corrosion (sulfidation).
  • the total thickness of the thermal protective layer 32 is 0.4 to 0.5 mm and means a temperature relief of between 40 and 70 K for the underlying metal of the substrate 40.
  • FIG. 3A a substrate 40 is shown onto which, as in connection with FIG Figure 2B described, a diffusion layer 31 was applied.
  • a gas flow G e.g. the carrier gas flow
  • the main flow direction H not perpendicular to the substrate surface O but at an angle
  • clogging of the openings 42 of the cavity structure 41 is minimized or prevented.
  • a maximum of 30% blockage of the openings 42 could be acceptable in one embodiment.
  • the gas stream G thus has a flow component X parallel to the surface O of the substrate 40 in any case. It is also possible to choose the angle ⁇ smaller than 30° or smaller than 15°.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Metallurgy (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Inorganic Chemistry (AREA)
  • General Engineering & Computer Science (AREA)
  • Combustion & Propulsion (AREA)
  • Ceramic Engineering (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)

Claims (12)

  1. Procédé de revêtement d'un substrat (40) avec une structure alvéolaire (41), en particulier une structure de refroidissement, à l'intérieur du substrat (40), la structure alvéolaire (41) comportant des ouvertures (42) dans la surface (O) du substrat (40),
    a) au moins une couche favorisant l'adhérence, en particulier une couche de diffusion (31) ou au moins une autre couche métallique, étant appliquée sur le substrat (40), en particulier sur la surface (O) du substrat (40), puis
    b) au moins une couche de protection thermique (32) étant appliquée sur l'au moins une couche de diffusion (31) à l'aide d'un procédé de projection plasma en suspension (SPS),
    caractérisé en ce que
    la direction d'écoulement principale (H) du flux de gaz (G) est parallèle à la surface (O) du substrat (40) ou la direction d'écoulement principale (H) du flux de gaz (G) formant par rapport à la surface (O) du substrat (40) un angle α qui est inférieur à 30°.
  2. Procédé selon la revendication 1, caractérisé en ce que la direction d'écoulement principale (H) du flux de gaz (G) forme avec la surface (O) du substrat (40) un angle α inférieur à 15°.
  3. Procédé selon au moins l'une des revendications 1 ou 2, caractérisé en ce que le flux de gaz (G) est un flux de gaz de traitement et/ou un flux de gaz porteur.
  4. Procédé selon au moins l'une quelconque des revendications précédentes, caractérisé en ce que le flux de gaz chargé de particules (G) a un nombre de Stokes inférieur à 1, notamment inférieur à 0,1, tout particulièrement inférieur à 0,01, tout particulièrement inférieur à 0,001.
  5. Procédé selon au moins l'une quelconque des revendications précédentes, caractérisé en ce que l'au moins une couche de diffusion (31) est appliquée par une aluminisation en paquet, un procédé PVD ou un procédé de couches additives.
  6. Procédé selon au moins l'une quelconque des revendications précédentes, caractérisé en ce que l'au moins une couche de diffusion (31) comporte une proportion de MCrAlY, avec
    M choisi parmi le nickel, le cobalt, le fer et
    Y choisi parmi l'yttrium, l'ytterbium, le lanthane ou une terre rare
    ou est en cette substance.
  7. Procédé selon au moins l'une quelconque des revendications précédentes, caractérisé en ce que l'au moins une couche de diffusion (31) comporte une proportion d'un X-aluminure avec
    X choisi parmi le chrome, le platine et/ou le nickel ou l'aluminium et le chrome, le platine et/ou le nickel ou est en ces substances.
  8. Procédé selon au moins l'une quelconque des revendications précédentes, caractérisé en ce que l'au moins une couche métallique est appliquée sur l'au moins une couche de diffusion (31) à l'aide d'un procédé PVD par pulvérisation plasma (PS-PVD), un procédé de pulvérisation à cathode creuse ou un procédé de pulvérisation plasma en suspension (SPS).
  9. Procédé selon au moins l'une quelconque des revendications précédentes, caractérisé en ce que l'au moins une couche de protection thermique (32) comporte une proportion d'yttrium et/ou d'oxyde de zirconium stabilisé ou est en ladite substance.
  10. Procédé selon au moins l'une quelconque des revendications précédentes, caractérisé en ce que le substrat (40) est métallique et est réalisé au moins partiellement par un procédé d'application de couche ou par un procédé de coulée.
  11. Procédé selon au moins l'une quelconque des revendications précédentes, caractérisé en ce que le substrat (40) comporte une proportion d'un alliage de nickel à haute température, notamment CMSX4, CMSX3, C 263, Mar M 002 et/ou C 1023, ou est en un tel matériau.
  12. Procédé selon au moins l'une quelconque des revendications précédentes, caractérisé en ce que les canaux de la structure alvéolaire (41) et/ou les ouvertures (42) de la structure alvéolaire (41) ont un diamètre moyen compris entre 0,5 à 1,5 mm, en particulier 1 mm.
EP19174701.3A 2018-05-23 2019-05-15 Procédé de revêtement d'un substrat à l'aide d'une structure creuse Active EP3572551B1 (fr)

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DE102018112353.1A DE102018112353A1 (de) 2018-05-23 2018-05-23 Verfahren zur Beschichtung eines Substrates mit einer Hohlraumstruktur

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CN112853254B (zh) * 2020-12-31 2022-06-14 广东省科学院新材料研究所 一种非晶柱状结构涂层及其制备方法和应用
CN114015980B (zh) * 2022-01-10 2022-04-01 北京航空航天大学 发动机涡轮叶片表面制备热障涂层的方法

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DE102005060243A1 (de) * 2005-12-14 2007-06-21 Man Turbo Ag Verfahren zum Beschichten einer Schaufel und Schaufel einer Gasturbine
EP2354275A1 (fr) * 2009-12-29 2011-08-10 Siemens Aktiengesellschaft Système multicouche composé d'une couche métallique et d'une couche céramique
CN103189545A (zh) * 2010-11-02 2013-07-03 西门子公司 合金、保护层和构件
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