Patent Application
20180371932
The present disclosure relates to a method of fabricating an abradable coating of varying density, and also to such an abradable coating of varying density.
Such an abradable coating may be used in particular for fitting to a ring of a rotary machine so as to provide the machine with sealing at the tips of rotating blades, for example. Such an abradable coating is particularly adapted for fitting to turbine rings in the field of aviation, and most particularly in airplane turbojets.
In numerous rotary machines, it is now the practice to provide the stator ring with abradable tracks facing the tips of blades of the rotor. Such tracks are made using so-called “abradable” materials that, on coming into contact with the rotating blades, wear more easily than the blades. This ensures minimal clearance between the rotor and the stator, thereby improving the performance of the rotary machine, without running the risk of damaging the blades in the event of them rubbing against the stator. On the contrary, such rubbing abrades the abradable tracks, thereby automatically matching the diameter of the stator ring very closely to the rotor. Such abradable tracks are thus often put into place in the compressors of turbine engines.
In contrast, they are used much more rarely in the turbines of such machines, particularly in high pressure turbines, where physico-chemical conditions are extreme.
Specifically, the burnt gas from the combustion chamber penetrates into the high pressure turbine at temperature and pressure levels that are very high, thereby leading to premature erosion of conventional abradable tracks.
Under such circumstances, in order to protect the turbine ring, it is often preferred to provide it with a thermal barrier type coating of materials that serve to protect the ring against erosion and corrosion while presenting density that is too great for the coating to be effectively abradable.
Nevertheless, it can naturally be understood that under such circumstances, the integrity of the blades is no longer ensured in the event of contact with the stator, which means that it is necessary to provide greater clearance between the rotor and the stator, thereby increasing the rate of leakage past the tips of the blades and thus reducing the performance of the turbine.
There therefore exists a real need for a method of fabricating an abradable coating and for such an abradable coating that avoid the drawbacks inherent to the above-mentioned known configurations, at least in part.
The present disclosure provides a fabrication method for fabricating an abradable coating of varying density, the method comprising the following steps: providing a substrate having a first portion and a second portion; depositing a first precursor material on the first portion of the substrate; compressing the first precursor material between the substrate and a first bearing surface; sintering the first precursor material as compressed in this way in order to obtain a first abradable coating portion on the first portion of the substrate, and possessing a first density; depositing a second precursor material on the second portion of the substrate; compressing the second precursor material between the substrate and a second bearing surface; and sintering the second precursor material as compressed in this way in order to obtain a second abradable coating portion on the second portion of the substrate, and possessing a second density distinct from the first.
This method makes it possible to obtain a coating of varying density. Specifically, various parameters can be adjusted differently for each portion of the substrate so as to obtain abradable coating portions that present different properties. Firstly, it is possible to select different precursor materials. In particular, the size of the particles making up the precursor material or the initial porosity of the precursor material serve to influence the final porosity of the abradable coating, and thus its density.
It is also possible to deposit a greater or smaller quantity of precursor material prior to the compression step, i.e. to deposit a layer of precursor material of greater or lesser thickness. This quantity of material thus has an influence on the final density of the abradable coating.
It is also possible to compress the precursor materials more or less strongly during the compression step so as to compact these materials to a greater or lesser extent prior to sintering: this reduces their porosity to a greater or lesser extent, thereby influencing the final porosity and thus the final density of each portion of the abradable coating.
It is also possible to act on the temperatures and/or the durations of the sintering steps in order to have an influence on the microstructure of the abradable coating, and in particular on its final porosity and on its density.
In the present disclosure, the term “porosity” is used to designate the ratio of the volume of interstitial spaces between the grains of the material in question divided by the overall volume of said material. In addition, in the present disclosure, it should be understood that the first and second portions of the substrate, like the first and second portions of the abradable coating, are of significant size in order to be able to perform the functions for which they are intended. Thus, as can be seen in the figures, each portion of the substrate, and thus each portion of the abradable coating possesses a width that is greater than 2 millimeters (mm), preferably greater than 5 mm, and thus a length that is greater still.
Under such circumstances, by means of this method, it is possible to adjust locally the porosity, and thus the density, of the coating in order to satisfy requirements or constraints that differ locally. For example, it is possible to provide those zones of the coating that are sensitive to erosion with density that is high, and to provide those zones of the coating that are to come into contact with a moving body with density that is lower, thereby reinforcing the easily abradable nature of such zones. In addition, it is possible to arrange the first coating portion, i.e. the portion of greater density, in such a manner as to mask and thus protect the second coating portion, which is of density that is lower.
In certain implementations, the steps of depositing, compressing, and sintering the second precursor material take place after the steps of depositing, compressing, and sintering the first precursor material. By separating these steps in this way, it is possible to individualize the deposition, compression, and sintering parameters for each substrate portion, thus making it easy to obtain different properties for each portion of the abradable coating.
In certain implementations, the steps of compressing and sintering the first precursor material are performed within a first mold; the steps of compressing and sintering the second precursor material are performed within a second mold; and the second mold is distinct from the first mold.
In certain implementations, the first and second molds are a single mold.
In certain implementations, the first mold includes the first bearing surface together with at least one protection wall provided so as to lie beside the first precursor material at the interface between the first and second portions of the substrate during the steps of compressing and sintering the first precursor material. This protection wall serves to prevent pieces of the first precursor material from moving and becoming attached on the second portion of the substrate.
In certain implementations, the second mold includes a movable portion extending facing the second portion of the substrate and including the second bearing surface, and a stationary portion extending facing, preferably against, the first portion of the substrate. This stationary portion serves to protect the already-finished first abradable coating portion. Thus, and preferably, only the mold portion that faces the second portion of the substrate is movable.
In certain implementations, the steps of depositing the first and second precursor materials take place simultaneously or in succession, the steps of compressing the first and second precursor materials take place simultaneously, and the step of sintering the first and second precursor materials take place simultaneously. This serves to reduce the total time required for performing the method. It is also possible to use only one mold. Under such circumstances and by way of example, the difference in final density can be obtained by using precursor materials that are different, thicknesses of precursor material layers that are different, or indeed different amounts of compression. By way of example, such differing compression may be obtained using a mold possessing bearing surfaces lying at different levels, or using a mold that possesses a plurality of movable portions that are independent.
In certain implementations, the first portion of the substrate is situated at a first level, and the second portion of the substrate is situated at a second level different from the first level. By means of this level difference between the first and second portions of the substrate, the reduction in volume that is available during the compression step is greater when the substrate is close to the bearing surface in the initial state: for example, assuming that the second level is deeper than the first level, the portion of the precursor material situated over the first portion of the substrate is thus compressed to a greater extent than the portion of the precursor material situated over the second portion of the substrate. Higher pressure thus exists in this portion of the precursor material, thereby leading to greater density for the material after sintering. Conversely, in the second portion of the precursor material, since the compression is smaller, the reduction in the porosity of the material and thus its densification are smaller.
In certain implementations, the second portion of the substrate is obtained by machining at least one groove in a blank for the substrate. Such a two-level substrate is thus easy to fabricate since it suffices to fabricate a blank that is regular and then machine a groove in the blank solely at the desired locations.
In certain implementations, the first portion of the substrate is obtained by adding at least one low wall on a blank for the substrate. This method is particularly suitable for repairing an existing part of thickness that is not sufficient for machining a groove.
In certain implementations, the low wall is fabricated directly on the blank for the substrate by sintering, in particular by a sintering method of the spark plasma sintering (SPS) type.
In certain implementations, the low wall is fabricated independently and is fitted on by welding or brazing. In particular, it may be fitted on by a tungsten inert gas (TIG) type welding method.
In certain implementations, the first and second bearing surfaces are continuous, one extending the other. It should be understood that the bearing surfaces do not have any discontinuity such as a step or any other sudden change of level within them or at their interface.
In certain implementations, the bearing surfaces are rectilinear, at least in a direction extending transversely to the first and second portions of the substrate. There thus exists a section plane passing both through the first portion and the second portion of the substrate and in which the bearing surfaces are rectilinear.
In certain implementations, at least one bearing surface, and preferably each bearing surface, is in the form of a sector of a cylinder, preferably a sector of a circular cylinder.
In certain implementations, at least one bearing surface, and preferably each bearing surface, is a surface of a shaping mold.
In certain implementations, the first portion of the abradable coating possesses final porosity of less than 15%, preferably less than 5%. The first portion of the coating thus possesses porosity that is sufficiently low, and thus density that is sufficiently high, to withstand erosion.
In certain implementations, the second portion of the abradable coating possesses final porosity greater than 20%, preferably greater than 30%. The second portion of the coating thus possesses porosity that is sufficiently high, and thus density that is sufficiently low, to present easily-abradable behavior.
In certain implementations, the first portion of the abradable coating is subjected to densification by at least 80%, and preferably by least 100% during the compression and sintering steps. In the present disclosure, the term “densification” is used to mean the increase in the density of the material making up the abradable coating between its initial step when the precursor material is deposited and its final step obtained after the compression and sintering steps. In other words, it is the difference between the final density and the initial density divided by the initial density.
In certain implementations, the second portion of the abradable coating is subjected to densification of at most 70%, preferably at most 50%, and more preferably at most 10% during the compression and sintering step.
In certain implementations, prior to the step of depositing the precursor material on one of the portions of the substrate, preferably on the second portion of the substrate, the method further comprises a step of forming a backing layer by sintering on the portion under consideration of the substrate, the backing layer having porosity of less than 15%, and preferably less than 5%. This backing layer serves to conserve a highly densified layer under the second portion of the abradable coating, which second portion is densified little. Thus, the substrate remains protected in the event of the body traveling past the coating being subjected to a radial offset that is greater than the maximum expected offset. This serves in particular to protect the substrate in the event of a large unbalance in the moving body, for example.
In certain implementations, this step of forming a backing layer by sintering is performed in the second mold or in a mold that is identical to the second mold.
In certain implementations, after the step of sintering one of the precursor materials, the method further comprises a step of forming a surface layer by sintering on at least one of the portions of the abradable coating, preferably on its second portion, the surface layer having final porosity of less than 15%, and preferably less than 5%. This layer makes it possible to ensure that the coating has little surface roughness. It may also be formed on the entire surface of the abradable coating.
In certain implementations, the step of forming a surface layer by sintering is performed in the second mold or in a mold identical to the second mold.
In certain implementations, the thickness of the surface layer lies in the range 0.05 mm to 0.10 mm.
In certain implementations, at least one precursor material, preferably each precursor material, is a powder of metal or of ceramic.
In certain implementations, the first and second precursor materials are different. In other implementations, they are identical.
In certain implementations, the first precursor material is a powder of grain size less than 20 micrometers (μm).
In certain implementations, the second precursor material is a powder of grain size greater than 45 μm.
In certain implementations, the second precursor material is a powder of grain size less than 100 μm.
In certain implementations, the substrate is a ring sector. In particular, it may be a turbine ring sector for mounting on the stator of the turbine.
In certain implementations, the first portion of the substrate extends along the second portion of the substrate.
In certain implementations, the substrate possesses a longitudinal channel extending between two longitudinal shoulders, the shoulders forming part of the first portion of the substrate and the bottom of the channel forming part of the second portion of the substrate. At the end of the method, this leads to a strip of low density, i.e. that is easily abradable, in the zone that is likely to make contact, e.g. with the blades of a rotor, and two strips of coating that are of greater density on either side of the abradable strip, serving to protect the abradable strip from erosion, e.g. as caused by the axial flow of a stream of air.
The present disclosure also provides an abradable track of varying density, comprising a first portion including sintered material possessing a first density, and a second portion, contiguous with the first portion, including a sintered material possessing a second density distinct from the first density. As explained above, this makes it possible to protect the zones that are more sensitive to erosion, while providing a layer that is easily abradable in the zones that are to come into contact with the moving body.
In certain embodiments, the thickness of the first portion of the abradable track is less than the thickness of the second portion.
In certain embodiments, the materials of the first and second portions of the abradable track are different. In other embodiments, they are identical.
In certain embodiments, the abradable track is obtained using a fabrication method according to any one of the above implementations.
The present disclosure also provides a turbine or compressor ring including an abradable track according to any one of the above embodiments.
The present disclosure also provides a turbine engine including an abradable track or a turbine or compressor ring according to any of the above embodiments.
The above characteristics and advantages, and others, appear on reading the following detailed description of examples of the proposed device and method. The detailed description refers to the accompanying drawings.
The accompanying drawings are diagrammatic and seek above all to illustrate the principles of the invention.
In the drawings, from one figure to another, elements (or portions of an element) that are identical are identified by the same reference signs. In addition, elements (or portions of an element) belonging to different examples but having functions that are analogous are identified in the figures by numerical references incremented by 100, 200, etc.
In order to make the invention more concrete, examples of methods and abradable tracks are described below in detail with reference to the accompanying drawings. It should be recalled that the invention is not limited to these examples.
The high pressure turbine 6 has a plurality of blades 6a rotating with the rotor and a plurality of guide vanes 6b mounted on the stator. The stator of the turbine 6 comprises a plurality of stator rings 10 arranged facing the movable blades 6a of the turbine 6. As can be seen in
An example of such an abradable track 20 is described with reference to
As shown in
Together the two shoulders form a first substrate portion 33; the portion of the substrate 32 that is situated at the bottom of the groove 31 forms a second substrate portion 34.
As shown in
A first precursor material 35a, specifically a metal powder, is then placed on the shoulders 33, i.e. on the first portion of the substrate 32, while leaving the groove 31 and thus the second portion 34 of the substrate free from powder. On this occasion, a removable masking block may be arranged in the groove 31 in order to prevent the powder of the first precursor material 35a from becoming deposited on the second portion 34.
The powder 35a then forms a continuous layer of constant thickness over the shoulders 33 of the substrate 32. In the present example, the powder is an alumina powder of grain size centered around 5 μm; this layer possesses a thickness of 10 mm and has initial porosity of about 30%.
As shown in
These bearing surfaces 45, which are rectilinear in the axial plane of
Stress is then exerted on the cover 43 of the mold 40 so as to bear against the layers of powder 35a and compress them between the substrate 32 and the bearing surfaces 45 of the cover 43 of the mold 40. The layer of powder 35a is thus compressed until its thickness is reduced to 2 mm. In this example, the front surface 44b of the protection block 44 of the cover 43 of the mold 40 then bears against the second portion 34 of the substrate.
During this compression step, the particles of powder of the first precursor material 35a are compacted against one another, thereby filling in some of the voids initially present between the particles, with the air that is expelled in this way being discharged from the mold 40. The porosity of the powder therefore decreases during this compression step, and the density of the powder increases.
Once such a compressed state has been obtained, the layer of powder 35a as compressed in this way is sintered using a conventional method so as to obtain a first portion 36a of coating 36 overlying the first portion 33 of the substrate 32 and possessing a thickness of 2 mm and porosity of 6%.
The substrate 32 is then transferred into a second shaping mold 50 having a main portion 51 with a cavity 52 of axial dimensions corresponding to the dimensions of the substrate 32, and a cover portion 53 (visible in
As shown in
The powder 35b then forms a continuous layer of constant thickness over the second portion 34 of the substrate 32. In the present example, the powder is an alumna powder having a grain size centered around 100 μm; this layer possesses a thickness of 12 mm and initial porosity of about 70%.
On this occasion, it should be observed that it is possible to obtain initial porosity that is greater by adding a pore-generating agent to the powder, which agent is eliminated subsequently while performing the method, e.g. during a step of pyrolysis.
As shown in
Stress is then exerted on the movable portion 55 of the cover 53 of the mold 50 in order to bear against the powder layer 35b and compress it between the substrate 32 and the bearing surface 55a of the cover 53 of the mold 50. The powder layer 35b is thus compressed in this way until its thickness is reduced to 7 mm. In this example, the level of the surface of the powder layer 35b is then flush with the level of the surface of the first coating portion 36a.
During this compression step, the powder particles of the second precursor material 35b are compacted against one another, thereby filling in certain voids initially present between the particles, with the air that is expelled in this way being discharged from the mold 50. The porosity of the powder thus decreases during this compression step, and the density of the powder increases, however not as much as for the first precursor material 35a.
Once such a compressed state has been obtained, the powder layer 35b as compressed in this way is sintered using a conventional method. At the end of this sintering step, the abradable track 20 of
Naturally, the depth of the groove 31 (which may potentially be zero), the materials 35a and 35b that are used, the initial thicknesses of the powder layers 35a and 35b, and the amplitudes of the compressions applied may be adjusted freely in order to achieve desired densities and thicknesses for the coating.
In a second example, shown in
The method begins in the same manner as in the above example with making a high density first coating portion 136a. These steps are therefore not described again.
After these steps, and as shown in
A third precursor material 135c is then deposited in the groove 131, i.e. on the second portion 34 of the substrate 32, so as to form a continuous layer of constant thickness over the second portion 34 of the substrate 32. In the present example, the third precursor material 135c is identical to the first precursor material used for making the first coating portion 136a; in addition, this layer possesses a thickness of 10 mm and initial porosity of about 30%.
As shown in
At the end of this sintering step, a backing layer 137 is then obtained covering the second portion 134 of the substrate 132, and possessing a thickness of 2 mm with porosity of 6%.
As shown in
At the end of the method, an abradable track 120 as shown in
In a third example, which is compatible with the first and second examples and is shown in
The method begins in the same manner as in the first example by making a high density first coating portion 236a and a low density second coating portion 236b. These steps are therefore not described again.
Nevertheless, it should be observed in
At the end of these steps, and as shown in
As shown in
At the end of the method, the abradable track 220 of
The examples described in the present disclosure are given by way of non-limiting illustration, and a person skilled in the art can easily, in the light of this disclosure, modify these examples or envisage others, while remaining within the scope of the invention.
Furthermore, the various characteristics of these embodiment or implementation examples may be used singly or combined with one another. When they are combined, the characteristics may be combined as described above or in other ways, the invention not being limited to the specific combinations described in the present disclosure. In particular, unless specified to the contrary, any characteristic described with reference to any one embodiment or implementation may be applied in analogous manner to any other embodiment or implementation.
| Number | Date | Country | Kind |
|---|---|---|---|
| 1562324 | Dec 2015 | FR | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/FR2016/053360 | 12/13/2016 | WO | 00 |
