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WO2014137464A1 - Revêtement abradable en aluminium résistant à la fatigue thermomécanique - Google Patents

Revêtement abradable en aluminium résistant à la fatigue thermomécanique Download PDF

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Publication number
WO2014137464A1
WO2014137464A1 PCT/US2013/078183 US2013078183W WO2014137464A1 WO 2014137464 A1 WO2014137464 A1 WO 2014137464A1 US 2013078183 W US2013078183 W US 2013078183W WO 2014137464 A1 WO2014137464 A1 WO 2014137464A1
Authority
WO
WIPO (PCT)
Prior art keywords
particles
aluminum
powder
boride
coating
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.)
Ceased
Application number
PCT/US2013/078183
Other languages
English (en)
Inventor
Christopher W. Strock
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
Application filed by United Technologies Corp filed Critical United Technologies Corp
Priority to EP13877283.5A priority Critical patent/EP2964808B1/fr
Priority to US14/772,105 priority patent/US20160017474A1/en
Publication of WO2014137464A1 publication Critical patent/WO2014137464A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
    • B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/0408—Light metal alloys
    • C22C1/0416—Aluminium-based alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/10—Alloys containing non-metals
    • C22C1/1036—Alloys containing non-metals starting from a melt
    • C22C1/1042—Alloys containing non-metals starting from a melt by atomising
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
    • C22C32/0047—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
    • C22C32/0047—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents
    • C22C32/0073—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents only borides
    • 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
    • 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

Definitions

  • thermo- mechanical fatigue (TMF) resistant aluminum abradable coating which has particular utility as an outer air seal .
  • Compressor efficiency is related to blade tip clearance and outer air seal roughness. Coatings for the fan and the low pressure compressor are typically applied on titanium or iron based parts. The coefficient of thermal expansion (CTE) mismatch between the aluminum coating and the base metal (the titanium or iron) is almost a factor of two. This may lead to high
  • thermo- mechanical fatigue cracking and coating spallation With many thermal cycles from room temperature and back, the result is thermo- mechanical fatigue cracking and coating spallation.
  • Blades that mate with an aluminum seal may be titanium- or iron-based. During rub interaction, under certain conditions, metal is transferred to the blade tips. This may cause localized wear of the seal in what is known as record groove patterns. The result is increased average tip clearance and increased roughness in the air flow direction.
  • an aluminum coating having a
  • an aluminum coating to be deposited on a substrate having a first coefficient of thermal expansion which aluminum coating broadly comprises an aluminum matrix, particles of a material having a low thermal expansion coefficient incorporated into the matrix; and the particles bonding sufficiently we 11 to the aluminum matrix to carry a portion of the mechanical load .
  • the particles are selected from the group consisting of carbides, borides, oxides , and combinations thereof .
  • the particles are aluminum boride particles .
  • the particles are titanium boride particles .
  • the titanium boride particles have a ratio of titanium to boron in the range of 1:1 to 1:4.
  • the particles are present in an amount from 1.0 to 33 vol% .
  • the particles are present in an amount of from 10 to 25 vol%
  • the particles are present in an amount of 15 to 20 vo 1% .
  • the aluminum coating further comprises a pore making
  • the pore making material is selected from the group consisting of hexagonal boron nitride, polyester and Lucite .
  • the part providing step comprises providing a part formed from a titanium based alloy or an iron based alloy.
  • the powder forming step comprises forming a powder containing particles selected from the group consisting of oxide material, a carbide, a boride, and combinations thereof.
  • the powder forming step comprises forming the powder to have from 1.0 to 33 vol% of the particles.
  • the powder forming step comprises forming the powder to have from 10 to 25 vol% of the particles.
  • the powder forming step comprises forming the powder to have from 15 to 20 vol% of the particles.
  • the powder forming step comprises using titanium boride particles .
  • the powder forming step comprises using aluminum boride particles .
  • the process further comprises adding a pore making material to the powder .
  • the process further comprises melt atomization of a boride containing aluminum alloy and quenching the boride containing aluminum alloy during atomization to form particles of a metastable solid solution.
  • the process further comprises subjecting the aluminum coating to a heat treatment in the range of from 1100 to 1200 degrees Centigrade for 2.0 hours.
  • a process for forming an aluminum alloy matrix containing fine particles which broadly comprises the steps of: melt atomizing a boride containing aluminum alloy; and quenching the boride containing aluminum alloy during atomization to form particles of a metastable solid solution.
  • thermo-mechanical fatigue resistant aluminum abradable coating are set forth in the following detailed description.
  • the substrate to which the aluminum coating described herein may be applied may be formed from a titanium alloy or from an iron based alloy.
  • the substrate may be a fan casing or a casing for a compressor section of gas turbine engine.
  • the aluminum coating has an aluminum matrix formed from an aluminum alloy such as an aluminum-silicon alloy.
  • the aluminum coating further includes fine particles in the range of 20 nm to 5 microns mean particle diameter of a low coefficient of thermal expansion (cte) material, which is defined as having a cte that is lower than that of the aluminum matrix, which are incorporated into the aluminum matrix.
  • the fine particles may be in the range of from 20 nm to 2 microns in mean particle size.
  • the inclusion of the fine particles of a low coefficient of thermal expansion material results in hardening, strengthening and coefficient of thermal expansion reduction.
  • the fine particles to be incorporated into the aluminum coating may be fine particles selected from the group consisting of an oxide material, a boride, a carbide, and combinations thereof. Only those particles which bond sufficiently well to the aluminum matrix material and are capable of carrying a portion of the mechanical load and which act as a composite material are used in the aluminum coating described herein.
  • the fine particles may be boride particles, such as aluminum boride particles and titanium boride
  • Aluminum boride particles form high aspect ratio platelets when precipitated at a temperature of below about 650 degrees Centigrade. When aluminum boride particles are used, the technique used to manufacture the aluminum coatings must contain sufficient heating of the alloy constituents to fully dissolve any A1B12 which tends to form at temperatures between 650 degrees
  • A1B12 Centigrade and 1550 degrees Centigrade depending on boron concentration.
  • the formation of A1B12 during cooling may be suppressed by quenching to below 650 degrees
  • Centigrade This can bed one by rapid cooling of the melt or passively as one of the characteristics of thermal spray coating in which molten particles are quench cooled upon impact with a surface. If desired, the thermal spray coating may be subsequently heat treated to a temperature of up to 650 degrees Centigrade.
  • Aluminum boride is a desirable candidate due to its low cost, high thermal conductivity, low coefficient of thermal expansion, and good adhesion to the matrix.
  • Aluminum boride at 20 vol% has been shown to increase the strength of aluminum by 80%.
  • Titanium boride is also a desirable candidate for the aluminum coating.
  • the titanium boride particles may be incorporated into the aluminum matrix by precipitation from a quenched metastable solid solution.
  • the titanium boride may have a ratio of titanium to boron which ranges from 1:1 to 1:4. It is also possible to include the titanium boride particles by mechanical alloying, agglomeration with the matrix alloy in a thermal spray feed stock powder, pressed and sintered.
  • borides such as titanium boride or aluminum boride
  • they may be present in a range of from 1.0 vol% to 33 vol%, balance aluminum matrix.
  • the boride particles may be present in an amount from 10 to 25 vol% .
  • the boride particles may be present in an amount from 15 to 20 vol% .
  • the borides may be dissolved in melt
  • melt atomization of a boride containing aluminum alloy that quenches during
  • precipitation of undesirable phases may be suppressed as a result of rapid cooling rates.
  • other powder manufacturing routes that result in powder with undesirable phases may be melted and solutionized during the spray coating operation. Either way, molten or softened particles may then be quench cooled during deposition.
  • titanium boride precipitates from a metastable quenched structure to form precipitates in the 20nm to 2.0 micron size range, depending on subsequent heat treat temperature. The heat treatment could be heating the aluminum coating at 625 to 650 degrees Centigrade for 2.0 hours .
  • Carbides which may be used include those in the covalent and interstitial carbide groups with prime candidates being silicon carbide and titanium carbide.
  • the aluminum matrix with fine particles is formed into a powder with the fine particles is formed into a powder so that it can be applied on the substrate by a spray process such as thermal spraying.
  • the fine particles may be included in the particles forming the aluminum matrix material by agglomeration, alloying and precipitation, or ball milling and cold working.
  • the amount of fine particles is a function of the desired coefficient of thermal expansion for the aluminum coating. Also, considerations of through thickness thermal gradient may be taken into account.
  • the aluminum coating may be applied to the substrate by thermally spraying the matrix material with the incorporated fine particles. If desired, a pore making fugitive or soft filler material may also be added to the matrix material while it is being sprayed.
  • the fugitive or soft filler material do not affect the coefficient of thermal expansion of the aluminum coating. To affect the coefficient of thermal expansion, the filler material would have to both bond with the aluminum matrix and have sufficient elastic modulus to at least partially elastically constrain the aluminum matrix.
  • the elastic modulus of the filler material may be higher than that of aluminum.
  • Fugitives and fillers like hexagonal boron nitride, polyester, and Lucite are candidates for affecting the abradability of the aluminum coating and may be used to offset the strengthening of the matrix material by the fine particles.
  • Fugitives and soft fillers may be used at up to about 70 volume percent of the coating.
  • the fugitives and soft fillers may be present in an amount from 40 to 65 volume percent.
  • the coating may be made from an aluminum alloy containing 70.4 wt% aluminum, 13.8 wt% titanium, 9.6 wt% silicon, and 6.2 wt% boron and hexagon boron nitride to produce a coating of 40 volume % metal alloy, 50 volume % hBN and 10% porosity.
  • the titanium boride particles may be precipitated from a quenched metal alloy with heat treatment at 625 to 650 degrees Centigrade for 2.0 hours. [ 0041 ] While the aluminum coating particles are sprayed onto the substrate, the sprayed particles may be quenced by conduction of heat to the coating and
  • the substrate with the sprayed particles may be subjected to a heat treatment in the range of from 625 to 650 degrees Centigrade for 2.0 hours.
  • the benefits of the abradable coating described herein include reduced coefficient of thermal expansion and thermo-mechanical fatigue. This results in a more stable part shape with temperature change and improved coating durability.
  • the filler material also helps to reduce metal transfer to blades during low interaction rate sliding contact wear and result in tighter tip clearance and a smoother coating. As compared to choosing a conventional alloy that has a lower
  • the technique described herein does not increase the incipient melting point of the coating.
  • this is because the titanium and boride constituents fully precipitate as a high melting point phase.
  • the blade tip temperature, particularly of a titanium blade tip, during rub is still limited to the melting point of aluminum. This helps reduce the risk of a titanium fire .
  • thermo- mechanical fatigue resistant aluminum abradable coating There has been described herein a thermo- mechanical fatigue resistant aluminum abradable coating. While the coating has been described in the context of specific embodiments thereof, other unforeseeable alternatives, modifications, and variations may become apparent to those skilled in the art having read the foregoing description. Accordingly, it is intended to embrace those alternatives, modifications, and variations as fall within the broad scope of the appended claims.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)

Abstract

La présente invention se rapporte à un revêtement en aluminium qui doit être déposé sur un substrat qui présente un premier coefficient de dilatation thermique, ledit revêtement en aluminium comprenant une matrice en aluminium et des particules d'un matériau qui présente un faible coefficient de dilatation thermique et qui sont incorporées dans la matrice. Les particules se lient de manière suffisante à la matrice en aluminium afin de supporter une partie de la charge mécanique.
PCT/US2013/078183 2013-03-06 2013-12-30 Revêtement abradable en aluminium résistant à la fatigue thermomécanique Ceased WO2014137464A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP13877283.5A EP2964808B1 (fr) 2013-03-06 2013-12-30 Revêtement abradable en aluminium résistant à la fatigue thermomécanique
US14/772,105 US20160017474A1 (en) 2013-03-06 2013-12-30 Thermo-Mechanical Fatigue Resistant Aluminum Abradable Coating

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201361773344P 2013-03-06 2013-03-06
US61/773,344 2013-03-06

Publications (1)

Publication Number Publication Date
WO2014137464A1 true WO2014137464A1 (fr) 2014-09-12

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PCT/US2013/078183 Ceased WO2014137464A1 (fr) 2013-03-06 2013-12-30 Revêtement abradable en aluminium résistant à la fatigue thermomécanique

Country Status (3)

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US (1) US20160017474A1 (fr)
EP (1) EP2964808B1 (fr)
WO (1) WO2014137464A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3276038A1 (fr) * 2016-07-29 2018-01-31 United Technologies Corporation Matériau abradable

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20190186281A1 (en) * 2017-12-20 2019-06-20 United Technologies Corporation Compressor abradable seal with improved solid lubricant retention
CN115852292A (zh) * 2022-11-08 2023-03-28 东莞城市学院 锅炉水冷壁电弧喷涂用铝基粉芯丝材的制备方法及应用

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4836982A (en) * 1984-10-19 1989-06-06 Martin Marietta Corporation Rapid solidification of metal-second phase composites
US5434210A (en) * 1990-11-19 1995-07-18 Sulzer Plasma Technik, Inc. Thermal spray powders for abradable coatings, abradable coatings containing solid lubricants and methods of fabricating abradable coatings
US20040057832A1 (en) * 2001-04-03 2004-03-25 Robert Fleck Gas turbine blade
US20070141369A1 (en) * 2005-12-19 2007-06-21 General Electric Company Strain tolerant corrosion protecting coating and spray method of application
US20090297720A1 (en) * 2008-05-29 2009-12-03 General Electric Company Erosion and corrosion resistant coatings, methods and articles

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8187720B2 (en) * 2005-11-14 2012-05-29 Lawrence Livermore National Security, Llc Corrosion resistant neutron absorbing coatings
US8034153B2 (en) * 2005-12-22 2011-10-11 Momentive Performances Materials, Inc. Wear resistant low friction coating composition, coated components, and method for coating thereof

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4836982A (en) * 1984-10-19 1989-06-06 Martin Marietta Corporation Rapid solidification of metal-second phase composites
US5434210A (en) * 1990-11-19 1995-07-18 Sulzer Plasma Technik, Inc. Thermal spray powders for abradable coatings, abradable coatings containing solid lubricants and methods of fabricating abradable coatings
US20040057832A1 (en) * 2001-04-03 2004-03-25 Robert Fleck Gas turbine blade
US20070141369A1 (en) * 2005-12-19 2007-06-21 General Electric Company Strain tolerant corrosion protecting coating and spray method of application
US20090297720A1 (en) * 2008-05-29 2009-12-03 General Electric Company Erosion and corrosion resistant coatings, methods and articles

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3276038A1 (fr) * 2016-07-29 2018-01-31 United Technologies Corporation Matériau abradable
US10697464B2 (en) 2016-07-29 2020-06-30 Raytheon Technologies Corporation Abradable material

Also Published As

Publication number Publication date
EP2964808A1 (fr) 2016-01-13
EP2964808B1 (fr) 2019-05-01
US20160017474A1 (en) 2016-01-21
EP2964808A4 (fr) 2016-10-26

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