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WO2014126633A2 - Revêtement de barrière thermique résistant à l'éclatement - Google Patents

Revêtement de barrière thermique résistant à l'éclatement Download PDF

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Publication number
WO2014126633A2
WO2014126633A2 PCT/US2013/072558 US2013072558W WO2014126633A2 WO 2014126633 A2 WO2014126633 A2 WO 2014126633A2 US 2013072558 W US2013072558 W US 2013072558W WO 2014126633 A2 WO2014126633 A2 WO 2014126633A2
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WO
WIPO (PCT)
Prior art keywords
layer
substrate
along
airfoil
ceramic
Prior art date
Application number
PCT/US2013/072558
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English (en)
Other versions
WO2014126633A3 (fr
Inventor
Brian T. Hazel
David A. Litton
Original Assignee
United Technologies Corporation
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Publication date
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Publication of WO2014126633A2 publication Critical patent/WO2014126633A2/fr
Publication of WO2014126633A3 publication Critical patent/WO2014126633A3/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
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
    • C23C14/24—Vacuum evaporation
    • C23C14/28—Vacuum evaporation by wave energy or particle radiation
    • C23C14/30—Vacuum evaporation by wave energy or particle radiation by electron bombardment
    • 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
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
    • C23C14/08—Oxides
    • C23C14/083—Oxides of refractory metals or yttrium
    • 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
    • C23C28/04—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 only coatings of inorganic non-metallic material
    • C23C28/042—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 only coatings of inorganic non-metallic material including a refractory ceramic layer, e.g. refractory metal oxides, ZrO2, rare earth 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
    • 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
    • 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
    • C23C4/10—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
    • 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

Definitions

  • the disclosure relates gas turbine engines. More particularly, the disclosure relates to thermal barrier coatings for gas turbine engines.
  • Exemplary thermal barrier coating systems include two-layer thermal barrier coating systems.
  • An exemplary system includes NiCoCrAlY bond coat (e.g., low pressure plasma sprayed (LPPS) ) and an yttria-stabilized zirconia (YSZ) thermal barrier coat (TBC) (e.g., air plasma sprayed (APS) or electron beam physical vapor deposited (EBPVD) ) .
  • LPPS low pressure plasma sprayed
  • YSZ yttria-stabilized zirconia
  • TBC thermal barrier coat
  • APS air plasma sprayed
  • EBPVD electron beam physical vapor deposited
  • TGO thermally grown oxide
  • An exemplary YSZ is 7 weight percent yttria-stabilized zirconia (7YSZ) .
  • US2003/0152814 discloses a thermal barrier coating wherein a strain-tolerant columnar grain ceramic (e.g., 7YSZ) is applied by EB-PVD followed by air plasma spray or low pressure plasma spray of an insulative layer (e.g.,
  • US7306859 discloses EB-PVD of YSZ to form a columnar layer followed by plasma spray to form a non-columnar layer that is relatively thick along the platform surface of a blade .
  • Exemplary TBCs are applied to thicknesses of 1-40 mils ( 0.025-1. Omm) and can contribute to a temperature reduction of up to 300°F (167°C) at the base metal. This temperature reduction translates into improved part durability, higher turbine operating temperatures, and improved turbine
  • One aspect of the disclosure involves a method for coating a substrate.
  • a ceramic first layer is applied by electron beam physical vapor deposition (EB-PVD) .
  • a ceramic second layer is applied by suspension plasma spray.
  • EB-PVD electron beam physical vapor deposition
  • an environmental pressure remains at least 95kPa.
  • a metallic bondcoat is applied prior to the electron beam physical vapor deposition of the first layer .
  • the second layer is applied directly atop the first layer.
  • the substrate is a substrate of a turbine element having an airfoil and a gaspath surface transverse thereto; a characteristic thickness of the first layer is greater along the airfoil than along the gaspath surface; and a characteristic thickness of the second layer is greater along the gaspath surface than along the airfoil.
  • the characteristic thickness of the first layer along the gaspath surface is less than 65% of the characteristic thickness of the first layer along the airfoil; and the characteristic thickness of the second layer along the airfoil is less than 50% of the characteristic thickness of the second layer along the gaspath surface.
  • the first layer has a thickness of 0.013-0.076mm; and the second layer has a thickness of
  • the electron beam physical vapor deposition of the ceramic first layer is to a first layer depth of at least 0.013mm; and the suspension plasma spraying of the ceramic second layer is to a second layer depth of at least 0.025mm.
  • the second layer comprises
  • the substrate comprises a nickel-based superalloy .
  • a coated article may comprise: a substrate; an EB-PVD ceramic first layer; and a suspension plasma sprayed ceramic second layer above the first layer.
  • the first layer comprises material selected from the group consisting of yttria-stabilized zirconia or gadolinium-stabilized zirconia or combinations thereof; and the second layer comprises yttria-stabilized zirconia or gadolinium-stabilized zirconia.
  • the substrate comprises a
  • a bondcoat is between the first layer and the substrate.
  • the article consists essentially of the substrate, the bondcoat, the first layer, and the second layer .
  • FIG. 1 is a partially schematic sectional view of substrate having a thermal barrier coating (TBC) .
  • TBC thermal barrier coating
  • FIG. 2 is a partially schematic view of a vane bearing the TBC.
  • FIG. 3 is a partially schematic view of a blade bearing the TBC.
  • FIG. 4 is a flowchart of a process for coating the substrate of FIG. 1.
  • FIG. 1 shows a thermal barrier coating system 20 atop a metallic substrate 22.
  • the thermal barrier coating system 20 atop a metallic substrate 22.
  • substrate is a nickel-based superalloy or a cobalt-based superalloy such as a cast component (e.g., a single crystal casting) of a gas turbine engine.
  • exemplary components are hot section components such as combustor panels, turbine blades, turbine vanes, and airseals.
  • One particular alloy is PWA 1484.
  • the coating system 20 may include a bondcoat 30 atop a surface 26 of the substrate 22 and a thermal barrier coating (TBC) system 28 atop the bondcoat.
  • TBC thermal barrier coating
  • a thermally grown oxide (TGO) layer 24 may form at the interface of the bondcoat to the TBC.
  • the TBC is a multi-layer TBC with at least two layers.
  • a first layer 40 is a lower layer.
  • a second layer 42 is over the first layer.
  • the TBC consists of or consists essentially of the first and second layers (e.g., subject to relatively small gradation/transition with each other and with the bondcoat (if any) as noted above) .
  • FIG. 2 shows a vane 50 comprising the cast metallic substrate 22.
  • the vane includes an airfoil 52 having a surface comprising a leading edge 54, a trailing edge 56, a pressure side 58, and a suction side 60.
  • the airfoil extends from an inboard end at a platform or band segment 62 to an outboard end and an outboard shroud or band segment 64.
  • the segments 62 and 64 have respective gaspath surfaces 66 and 68. These are essentially normal to the airfoil surfaces.
  • the TBC system extends at least along the surface of the airfoil and the surfaces 66 and 68.
  • the exemplary first layer 40 is applied in such a way as to be thicker along the airfoil surface than along the surfaces 66 and 68.
  • it may be applied via
  • EB-PVD electron beam physical vapor deposition
  • the airfoil may be rotated and tilted relative to the vapor source to provide full circumferential coverage of the airfoil surface.
  • the surfaces 66 and 68 are relatively parallel to the flow direction and receive only a fraction of the coating thickness achieved on the airfoil.
  • the thickness of the first layer along the surfaces 66 and 68 is substantially less than along the surface of the airfoil.
  • the EB-PVD process preferentially coats the airfoil surface relative to the surfaces 66 and 68.
  • Exemplary average EB-PVD thicknesses along the surfaces 66 and 68 are less than 75% of average EB-PVD thickness along the airfoil.
  • the second layer 42 may be applied via a process which preferentially coats the surfaces 66 and 68 relative to the airfoil surface.
  • a suspension plasma spray process may be used.
  • Suspension plasma spray similar to other thermal spray processes, uses high velocity plumes focused by the nozzle of the plasma spray gun, which enables coating of targeted surfaces. In this case, the platform surfaces would be targeted and the airfoil surfaces would be avoided. If it is critical to ensure no coating of certain surfaces, masks can be affixed onto those surfaces during suspension plasma spraying. The result is that SPS may produce greater thickness along the platform than along the airfoil.
  • a relative thickness is such that an average SPS thickness (if any) along the airfoil is less than 75% of an average SPS thickness along the surfaces 66 and 68.
  • pseudo-columnar strain tolerant microstructure depending upon the demands of the component to be coated.
  • Exemplary materials for the layers 40 and 42 may be of similar nominal composition (e.g., 7YSZ) or may be of
  • the exemplary bondcoat 30 is a metallic bondcoat such as an overlay bondcoat or a diffusion aluminide.
  • An exemplary MCrAlY overlay bondcoat is PWA 1386 NiCoCrAlYHfSi . This may be applied by low-pressure plasma spray (LPPS) among several possibilities.
  • Alternative bondcoats are gamma/gamma prime and NiAlCrX bondcoats and may be applied via processes further including cathodic arc and ion plasma.
  • Exemplary bondcoat thicknesses are 2-500 micrometers, more narrowly, 12-250 micrometers or 25-150 micrometers on average.
  • An exemplary first layer 40 thickness along the airfoil is 0.010 inch (0.25mm) with an exemplary range of 0.002-0.016 inch (0.05-0.41mm) , more narrowly, 0.003-0.012 inch
  • Such exemplary layer thickness may be a local thickness or an average thickness (e.g., mean, median, or modal as may be thicknesses of the second layer discussed below) .
  • a similarly-measured first layer thickness along the surfaces 66 and 68 may be substantially lower on average
  • An exemplary thickness of the second layer 42 along the surfaces 66 and 68 is at least 0.001 inch (0.025mm) (more particularly, 0.001-0.019 inch (0.025-0.48mm) or 0.004-0.015 inch ( 0.1-0.038mm) .
  • An exemplary total thickness of both ceramic layers is from 0.002-0.020 inch (0.05-0.5mm) (more particularly, 0.005-0.016 inch (0.13-0.41mm) ) .
  • similarly-measured second layer thickness along the airfoil surface may be substantially lower on average (e.g., less than 75% or less than 50% or less than 40%, more particularly, 0-30% or 1-10% or 0-10%) .
  • An exemplary first layer composition is a YSZ or a gadolinia-stabilized zirconia (GSZ) or a mixture thereof .
  • An exemplary second layer may also be in such families.
  • a more specific first layer material would be YSZ or a YSZ/GSZ combination.
  • a more particular second layer material would be YSZ.
  • Another situation would be the first layer as the
  • FIG. 3 shows a blade 100 having an airfoil 102
  • the blade includes an attachment root 106 inboard of the platform.
  • the platform 104 has an outboard gaspath surface 108 which may be subject to similar coating considerations relative to the airfoil 102 as the surfaces 66 and 68 are relative to the airfoil 52.
  • FIG. 4 shows an exemplary process 200 for coating the substrate.
  • initial substrate manufacture e.g., casting, finish machining, cleaning, and the like
  • the bondcoat is applied 202. This may be done by LPPS (e.g., as described above) . This may be performed in a first chamber (not shown) whereafter the substrate (s) are transferred 204 to a second chamber.
  • a surface preparation 206 may comprise further cleaning and/or grit blasting (e.g., in yet other chambers) .
  • the first layer 40 may be applied 210 via EB-PVD in the second chamber.
  • a further surface preparation (not shown) may follow.
  • the substrate is transferred 218 to a third location (e.g., a plasma spray booth) where the second layer 42 is then applied 220 by SPS.
  • a third location e.g., a plasma spray booth
  • Exemplary SPS deposition and apparatus are disclosed in US Ser. No. 13/408,460 entitled “Spallation-Resistant Thermal Barrier Coating” and filed February 29, 2012, the disclosure of which is incorporated by reference in its entirety herein as if set forth at length.
  • the traversal of the spray may be controlled (e.g., manually or automated) to target surface areas transverse to the airfoil.
  • Additional layers may be deposited (whether in the aforementioned chambers or otherwise) .
  • the SPS columnar microstructure may have different column structure/microstructure.
  • the SPS coating will be polycrystalline, typically free of distinct lamellar features common in historic plasma spray coatings.
  • the SPS coating is characterized by columns separated by vertical cracks or defined gaps (e.g., the column diameter is such that the coating is characterized by greater than 100 gaps per inch (40 gaps/cm), more narrowly >80 gaps/cm or 80- 160 gaps/cm (characteristic "diameters" being the inverse thereof) ) .
  • a typical EB-PVD coating has
  • the SPS coating typically contains porosity ranging from 10 to 40% by volume, more particularly 15% to 25% by volume.
  • the SPS coating typically has a thermal conductivity ranging from 0.7 to 2.5 W/mK, more particularly, 0.8 to 2 W/mK.
  • particles as raw material e.g., ⁇ 10ym, more particularly, 20nm-2ym or 200nm-lym average particle size
  • the interface between the SPS layer 42 and the EB-PVD layer 40 may be superior to prior art bi-layers in TBC
  • SPS ceramic coatings have columnar morphology, they are more strain tolerant. Thus, the strain energy release rate on propagating a crack at the interface, which is the driving force for spallation, is lower. The strain energy release rate during interface crack propagation arises due to the
  • CTE coefficient of thermal expansion
  • the lower strain tolerance of the ceramic coating causes strain energy release rates that are sufficient to drive spallation of ceramic coatings that have smooth interfaces with the metallic substrate.
  • the interface is made rough, mechanical interlocking forces increase the resistance of the interface to strain energy release during crack propagation, so cracks don not propagate and spallation does not occur.
  • the SPS process may make columnar type structures similar to those of EB-PVD in addition to providing superior interface that will retain the strain tolerance desired.
  • the result is a low in-place stress during thermal cycling that produces low strain energy at the interface and therefore high resistance to spallation.
  • parenthetical ' s units are a conversion and should not imply a degree of precision not found in the English units.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Plasma & Fusion (AREA)
  • Physics & Mathematics (AREA)
  • Ceramic Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)

Abstract

Dans un procédé de revêtement de substrat (22) selon l'invention, une première couche céramique (40) est appliquée par dépôt physique gazeux par faisceau d'électrons (210). Une seconde couche céramique (42) est pulvérisée par un procédé de plasma en suspension (220).
PCT/US2013/072558 2012-12-26 2013-12-02 Revêtement de barrière thermique résistant à l'éclatement WO2014126633A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201213726681A 2012-12-26 2012-12-26
US13/726,681 2012-12-26

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WO2014126633A2 true WO2014126633A2 (fr) 2014-08-21
WO2014126633A3 WO2014126633A3 (fr) 2014-11-13

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
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CN109877012A (zh) * 2019-02-09 2019-06-14 沈阳富创精密设备有限公司 一种制备高致密氧化钇涂层的方法
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CN106756811A (zh) * 2015-11-19 2017-05-31 中国航空工业集团公司北京航空制造工程研究所 一种高温合金涂层的制备方法
US20170152753A1 (en) * 2015-12-01 2017-06-01 United Technologies Corporation Thermal Barrier Coatings and Methods
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US10436042B2 (en) 2015-12-01 2019-10-08 United Technologies Corporation Thermal barrier coatings and methods
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US11673097B2 (en) 2019-05-09 2023-06-13 Valorbec, Societe En Commandite Filtration membrane and methods of use and manufacture thereof

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