Patent Grant
11059751
The present application is National Phase of International Application No. PCT/JP2016/053786 filed Feb. 9, 2016, and claims priority from Japanese Application No. 2015-023374, filed Feb. 9, 2015, the disclosure of which is hereby incorporated by reference herein in its entirety.
The present invention relates to a coated member, a method of manufacturing the same, and a coating material, and more particularly, to a member which is used in a high-temperature environment and on which a heat-shielding coating layer is formed.
Since an oxide-based ceramic fiber-reinforced oxide-based ceramic matrix composite (oxide CMC) such as an Al2O3 fiber-reinforced Al2O3 matrix composite, a SiC fiber-reinforced SiC matrix composite (CMC), or silicon-based ceramics such as SiC, Si3N4, and the like, is lightweight and has excellent mechanical properties at a high temperature, these materials are promising materials as high-temperature members of aircraft engine, industrial gas turbines, and the like. Particularly, since the Al2O3 fiber-reinforced Al2O3 matrix composite is cheaper than the SiC fiber-reinforced SiC matrix composite, the Al2O3 fiber-reinforced Al2O3 matrix composite is a promising material as a member for aircraft engines.
However, since the Al2O3 fiber-reinforced Al2O3 matrix composite has a heat resistant temperature of about 1000° C., in the case of applying the Al2O3 fiber-reinforced Al2O3 matrix composite to the aircraft engines, the industrial gas turbines, or the like, there is a need to form a heat-shielding coating layer on an outermost surface thereof.
In a general heat-shielding coating layer, yttria-stabilized zirconia (Y2O3—ZrO2) has been used. The yttria-stabilized zirconia has a low thermal conductivity of 1.5 W/mK. However, since phase stability of the yttria-stabilized zirconia is not sufficient at a high temperature, phase transformation accompanied with a volume change can occur after using the yttria-stabilized zirconia for a long period of time, such that the heat-shielding coating layer can be damaged.
Patent Document 1 suggests that a ytterbia-stabilized zirconia (Yb2O3—ZrO2) having excellent phase stability at a high temperature as compared to yttria-stabilized zirconia is used in a heat-shielding coating layer.
Patent Document 2 discloses formation of a heat-shielding coating layer in which ZrO2 particles are dispersed on a surface of Y2SiO5 corresponding to a matrix phase on a surface of an oxide CMC.
For example, since in a gas turbine combustion environment, a gas turbine is operated in a high-temperature and high-pressure steam oxidation environment, the silicon-based ceramic or the ceramic fiber-reinforced ceramic matrix composite becomes corroded and thinned due to steam while being oxidized, such that durability is remarkably deteriorated.
Therefore, environmental barrier coating is performed on a surface of the silicon-based ceramic or the ceramic fiber-reinforced ceramic matrix composite. Patent Document 3 discloses a coating made of yttrium silicate. Patent Document 4 discloses a coating made of Lu2Si2O7.
Patent Document 5 discloses a coating made of a monosilicate of a rare earth element such as Lu, Yb, or Y (that is, rare earth monosilicate), a disilicate of the rare earth element (that is, rare earth disilicate), or a combination thereof. In the technology in Patent Document 5, a coating film of a rare earth monosilicate is formed on a substrate and subjected to heat-treatment in an oxygen-containing environment, thereby partially converting the rare earth monosilicate to the rare earth disilicate.
Japanese Unexamined Patent Application, Publication No. 2003-160852
U.S. Pat. No. 7,348,287
The publication of Japanese Patent No. 3866002
The publication of Japanese Patent No. 4690709
Japanese Unexamined Patent Application, Publication No. 2006-28015
A thermal expansion coefficient of ytterbia-stabilized zirconia is 10.3×10−6/K (addition amount of Yb2O3: 16 wt %). Meanwhile, a thermal expansion coefficient of an Al2O3 fiber-reinforced Al2O3 matrix composite is 6×10−6/K to 8×10−6/K, and a thermal expansion coefficient of a SiC fiber-reinforced SiC matrix composite is 3.5×10−6/K to 4.5×10−6/K or so, such that the thermal expansion coefficients of these materials are significantly smaller than that of the ytterbia-stabilized zirconia. Therefore, in the case of using the Al2O3 fiber-reinforced Al2O3 matrix composite or the SiC fiber-reinforced SiC matrix composite as a substrate, and directly forming a heat-shielding coating layer made of ytterbia-stabilized zirconia on a surface of the substrate to manufacture a high-temperature member, there has been a problem in that the heat-shielding coating layer can be delaminated by repeatedly using the high-temperature member.
A thermal expansion coefficient of a rare earth disilicate is close to that of the substrate (for example, Y2Si2O7 has a thermal expansion coefficient of 3.7×10−6/K at 1000° C.). Therefore, in the case of laminating a layer of the rare earth disilicate on the substrate, it is possible to alleviate thermal stress during use at a high temperature to prevent a coating from being delaminated. However, since the rare earth disilicate has a high activity of SiO2, the rare earth disilicate can react with steam under a high-temperature and high-pressure steam oxidation environment, thereby being easily eroded.
Since Y2Si2O7 is a relatively cheap material among the rare earth disilicates, Y2Si2O7 is advantageous in view of cost for coating large-area substrates of aircraft engines, gas turbines, and the like. However, since phase transformation of Y2Si2O7 (γ→β) accompanied with a volume change can occur in the vicinity of 1300° C., coating can be damaged during use at the high temperature.
A rare earth monosilicate has excellent steam resistance as compared to the rare earth disilicate, but at the time of using the rare earth monosilicate at a high temperature for a long period of time, the rare earth monosilicate reacts with steam, such that it is impossible to ignore erosion of a coating caused by volatilization of SiO2. Since the rare earth monosilicate has a high thermal expansion coefficient, in the case of forming a layer of the rare earth monosilicate on the substrate, delamination due to thermal stress can occur.
Further, there is a problem in that erosion resistance of rare earth silicates at a high temperature is not sufficient.
An object of the present invention is to provide a coated member in which a heat-shielding coating layer capable of having a good heat-shielding property, suppressing a coating film from being damaged in a high-temperature environment, and having excellent steam resistance and erosion resistance is formed, and a method of manufacturing the same. Another object of the present invention is to provide a coating material capable of being used as a raw material of the heat-shielding coating layer.
According to a first aspect of the present invention, there is provided a coated member including: a heat-shielding coating layer on a substrate made of a silicon-based ceramic or a ceramic fiber-reinforced ceramic matrix composite, wherein the heat-shielding coating layer is a layer made of a zirconia-dispersed silicate in which ytterbia-stabilized zirconia is precipitated as a dispersed phase in a matrix phase which is any one of a rare earth disilicate, a rare earth monosilicate, and a mixed phase of the rare earth disilicate and the rare earth monosilicate, the rare earth disilicate being any one of a (Y1-a[Ln1]a)2Si2O7 solid solution (here, Ln1 is any one of Sc, Yb, and Lu, a is 0.05 or more and less than 1 when Ln1 is Sc, and a is 0.2 or more and less than 1 when Ln1 is Yb or Lu), Sc2Si2O7, Yb2Si2O7, and Lu2Si2O7,
the rare earth monosilicate being Y2SiO5, [Ln1′]2SiO5, or a (Y1-b[Ln1′]b)2SiO5 solid solution (here, Ln1′ is any one of Sc, Yb, and Lu, and 0<b≤0.5), and the ytterbia-stabilized zirconia containing ytterbia in a content of 8 wt % or more and 27 wt % or less.
According to a second aspect of the present invention, there is provided a coating material including a zirconia-dispersed silicate in which ytterbia-stabilized zirconia is precipitated as a dispersed phase in a matrix phase which is any one of a rare earth disilicate, a rare earth monosilicate, and a mixed phase of the rare earth disilicate and the rare earth monosilicate, wherein the rare earth disilicate is any one of a (Y1-a[Ln1]a)2Si2O7 solid solution (here, Ln1 is any one of Sc, Yb, and Lu, a is 0.05 or more and less than 1 when Ln1 is Sc, and a is 0.2 or more and less than 1 when Ln1 is Yb or Lu), Sc2Si2O7, Yb2Si2O7, and Lu2Si2O7, the rare earth monosilicate is Y2SiO5, [Ln1′]2SiO5, or a (Y1-b[Ln1′]b)2SiO5 solid solution (here, Ln1′ is any one of Sc, Yb, and Lu, and 0<b≤0.5), and the ytterbia-stabilized zirconia contains ytterbia in a content of 8 wt % or more and 27 wt % or less.
According to a third aspect of the present invention, there is provided a coated member including: a heat-shielding coating layer on a substrate made of a silicon-based ceramic or a ceramic fiber-reinforced ceramic matrix composite, wherein the heat-shielding coating layer is a layer made of a zirconia-dispersed silicate in which ytterbia-stabilized zirconia is precipitated as a dispersed phase in a matrix phase which is any one of a rare earth disilicate, a rare earth monosilicate, and a mixed phase of the rare earth disilicate and the rare earth monosilicate, the rare earth disilicate being any one of a (Y1-c[Ln2]c)2Si2O7 solid solution (here, Ln2 is any one of Nd, Sm, Eu, and Gd, c is 0.1 or more and less than 1 when Ln2 is Nd, Sm, or Eu, and c is 0.2 or more and less than 1 when Ln2 is Gd), Nd2Si2O7, Sm2Si2O7, Eu2Si2O7, and Gd2Si2O7, the rare earth monosilicate being Y2SiO5 or a (Y1-d[Ln2′]d)2SiO5 solid solution (here, Ln2′ is any one of Nd, Sm, Eu, and Gd, and 0<d≤0.5), and the ytterbia-stabilized zirconia containing ytterbia in a content of 8 wt % or more and 27 wt % or less.
According to a fourth aspect of the present invention, there is provided a coating material including a zirconia-dispersed silicate in which ytterbia-stabilized zirconia is precipitated as a dispersed phase in a matrix phase which is any one of a rare earth disilicate, a rare earth monosilicate, and a mixed phase of the rare earth disilicate and the rare earth monosilicate, wherein the rare earth disilicate is any one of a (Y1-c[Ln2]c)2Si2O7 solid solution (here, Ln2 is any one of Nd, Sm, Eu, and Gd, c is 0.1 or more and less than 1 when Ln2 is Nd, Sm, or Eu, and c is 0.2 or more and less than 1 when Ln2 is Gd), Nd2Si2O7, Sm2Si2O7, Eu2Si2O7, and Gd2Si2O7, the rare earth monosilicate is Y2SiO5, [Ln2′]2SiO5, or a (Y1-d[Ln2′]d)2SiO5 solid solution (here, Ln2′ is any one of Nd, Sm, Eu, and Gd, and 0<d≤0.5), and the ytterbia-stabilized zirconia contains ytterbia in a content of 8 wt % or more and 27 wt % or less.
In the first and third aspect, it is preferable that a difference in thermal expansion coefficient between the substrate and the heat-shielding coating layer is less than 3×10−6/K.
Thermal expansion coefficients of a rare earth disilicate and a rare earth monosilicate are smaller than that of ytterbia-stabilized zirconia. Therefore, a difference in thermal expansion coefficient between a substrate and a heat-shielding coating layer is decreased and thermal stress can be sufficiently alleviated by using a mixed phase of the rare earth silicates and ytterbia-stabilized zirconia in the heat-shielding coating layer, thereby making it possible to prevent the heat-shielding coating layer from being delaminated. Particularly, damage of the heat-shielding coating layer can be reliably prevented by changing a mixing ratio of respective components so that the difference in thermal expansion coefficient between the substrate and the heat-shielding coating layer is less than 3×10−6/K.
In general, a thermal expansion coefficient of the rare earth disilicate is smaller than those of the ytterbia-stabilized zirconia and the rare earth monosilicate, and is close to that of a silicon-based ceramic or a ceramic fiber-reinforced ceramic matrix composite used in the substrate. Therefore, in the case of applying the rare earth disilicate alone, or a mixed phase of the rare earth disilicate and the rare earth monosilicate to a matrix phase, an effect of alleviating thermal stress to prevent delamination damage can be improved.
Since a stable region of a β phase is expanded by partially substituting Y in Y2Si2O7 with Sc, Yb, or Lu at the ratio, phase transformation does not occur even at a high temperature of about 1300° C. to 1400° C. Phase stability in a high-temperature use environment can be secured by using a rare earth disilicate, which is any one of a (Y1-a[Ln1]a)2Si2O7 solid solution (here, Ln1 is any one of Sc, Yb, and Lu, a is 0.05 or more and less than 1 when Ln1 is Sc, and a is 0.2 or more and less than 1 when Ln1 is Yb or Lu), Sc2Si2O7, Yb2Si2O7, and Lu2Si2O7, in the matrix phase.
Since a stable region of an α phase is expanded by partially substituting Y in Y2Si2O7 with Nd, Sm, Eu, or Gd at the ratio, phase transformation does not occur at a high temperature. Phase stability in a high-temperature use environment can be secured by using a rare earth disilicate, which is any one of a (Y1-c[Ln2]c)2Si2O7 solid solution (here, Ln2 is any one of Nd, Sm, Eu, and Gd, c is 0.1 or more and less than 1 when Ln2 is Nd, Sm, or Eu, and c is 0.2 or more and less than 1 when Ln2 is Gd), Nd2Si2O7, Sm2Si2O7, Eu2Si2O7, and Gd2Si2O7, in the matrix phase.
Since the rare earth monosilicate has good steam resistance, steam resistance of the heat-shielding coating layer can be improved by applying the rare earth monosilicate alone or a mixed phase of the rare earth disilicate and the rare earth monosilicate to a matrix phase.
In the present invention, since ytterbia-stabilized zirconia is used as a dispersed phase, even in the case of using the coated member at a high temperature of about 1300° C. to 1400° C. for a long period of time, phase transformation does not occur, and it is possible to prevent the heat-shielding coating layer from being damaged. The heat-shielding coating layer includes the ytterbia-stabilized zirconia, erosion resistance of the heat-shielding coating layer can be improved.
According to a fifth aspect of the present invention, there is provided a method of manufacturing a coated member, the method including: forming a heat-shielding coating layer on a substrate by spraying particles onto a substrate made of a silicon-based ceramic or a ceramic fiber-reinforced ceramic matrix composite, the particles being obtained by mixing any one of rare earth disilicate powder, rare earth monosilicate powder and mixed powder of the rare earth disilicate powder and the rare earth monosilicate powder with ytterbia-stabilized zirconia powder containing ytterbia in a content of 8 wt % or more and 27 wt % or less and heat-treating the obtained mixed powder at a temperature of 1300° C. or more and 1700° C. or less, wherein the rare earth disilicate powder is made of any one of a (Y1-a[Ln1]a)2Si2O7 solid solution (here, Ln1 is any one of Sc, Yb, and Lu, a is 0.05 or more and less than 1 when Ln1 is Sc, and a is 0.2 or more and less than 1 when Ln1 is Yb or Lu), Sc2Si2O7, Yb2Si2O7, and Lu2Si2O7, and the rare earth monosilicate powder is made of any one of Y2SiO5,[Ln1′]2SiO5, and a (Y1-b[Ln1′]b)2SiO5 solid solution (here, Ln1′ is any one of Sc, Yb, and Lu, and 0<b≤0.5).
According to a sixth aspect of the present invention, there is provided a method of manufacturing a coated member, the method including: forming a heat-shielding coating layer on a substrate by spraying particles onto a substrate made of a silicon-based ceramic or a ceramic fiber-reinforced ceramic matrix composite, the particles being obtained by mixing any one of rare earth disilicate powder, rare earth monosilicate powder and mixed powder of the rare earth disilicate powder and the rare earth monosilicate powder with ytterbia-stabilized zirconia powder containing ytterbia in a content of 8 wt % or more and 27 wt % or less and heat-treating the obtained mixed powder at a temperature of 1300° C. or more and 1700° C. or less, wherein the rare earth disilicate powder is made of any one of a (Y1-c[Ln2]c)2Si2O7 solid solution (here, Ln2 is any one of Nd, Sm, Eu, and Gd, c is 0.1 or more and less than 1 when Ln2 is Nd, Sm, or Eu, and c is 0.2 or more and less than 1 when Ln2 is Gd), Nd2Si2O7, Sm2Si2O7, Eu2Si2O7, and Gd2Si2O7, and the rare earth monosilicate powder is made of any one of Y2SiO5 and a (Y1-d[Ln2′]d)2SiO5 solid solution (here, Ln2′ is any one of Nd, Sm, Eu, and Gd, and 0<d≤0.5).
In the present aspect, since zirconia-dispersed silicate particles having the above-mentioned composition are prepared in advance, and these particles are used as spray particles, a heat-shielding coating layer having a uniform composition can be formed.
In fifth and sixth aspects, it is preferable that rare earth disilicate powder, rare earth monosilicate powder, or mixed powder thereof is mixed with ytterbia-stabilized zirconia powder at a ratio at which the difference in thermal expansion coefficient between the substrate and the heat-shielding coating layer is less than 3×10−6/K.
In this way, damage of the formed heat-shielding coating layer can be reliably prevented.
In the first, third, fifth, and sixth aspect, it is preferable that the substrate is made of an oxide-based ceramic fiber-reinforced oxide-based ceramic matrix composite or a SiC fiber-reinforced SiC matrix composite. In this case, it is preferable that the oxide-based ceramic fiber-reinforced oxide-based ceramic matrix composite is an Al2O3 fiber-reinforced Al2O3 matrix composite.
These ceramic fiber-reinforced ceramic matrix composites are lightweight and have excellent mechanical stability at a high temperature. Particularly, since an Al2O3 fiber-reinforced Al2O3 matrix composite is cheaper than a SiC fiber-reinforced SiC matrix composite, the Al2O3 fiber-reinforced Al2O3 matrix composite is advantageous in that manufacturing cost can be decreased.
In the first to sixth aspects it is preferable that an addition amount of the ytterbia-stabilized zirconia in the zirconia-dispersed silicate particles is 50 vol % or more and 90 vol % or less.
In order to secure a heat-shielding property, it is preferable that an addition amount of the ytterbia-stabilized zirconia is large. Meanwhile, as described above, since the ytterbia-stabilized zirconia has a high thermal expansion coefficient, a thermal expansion coefficient of zirconia-dispersed silicate is increased when the addition amount thereof is large.
Since a difference in thermal expansion coefficient between a heat-shielding coating layer made of the zirconia-dispersed silicate in the above-mentioned addition amount range and a substrate made of the silicon-based ceramic or ceramic fiber-reinforced ceramic matrix composite is small, it is possible to suppress the heat-shielding coating layer from being damaged.
According to the present invention, a heat-shielding coating layer, in which heat-shielding properties and erosion resistance are excellent and thermal stress is suppressed, can be obtained. In the case in which a matrix phase of zirconia-dispersed silicate includes a rare earth monosilicate, steam resistance of the heat-shielding coating layer can be further improved.
The substrate 101 is a turbine member of an aircraft engine or a gas turbine member for powder generation such as a shroud, a combustion liner, or the like. In detail, the substrate 101 is made of a silicon (Si)-based ceramic or a ceramic fiber-reinforced ceramic matrix composite. The silicon-based ceramic means a ceramic containing silicon such as SiC, Si3N4, or the like. The ceramic fiber-reinforced ceramic matrix composite is an oxide-based ceramic fiber-reinforced oxide-based ceramic matrix composite exemplified by a SiC fiber-reinforced SiC matrix composite or an Al2O3 fiber-reinforced Al2O3 matrix composite.
In the present embodiment, the heat-shielding coating layer 102 is a layer made of a zirconia-dispersed silicate in which ytterbia-stabilized zirconia (YbSZ) is precipitated as a dispersed phase in a matrix phase which is any one of a rare earth disilicate, a rare earth monosilicate, and a mixed phase of the rare earth disilicate and the rare earth monosilicate. A thickness of the heat-shielding coating layer 102 is 50 μm or more and 500 μm or less.
In the present embodiment, YbSZ is zirconia (ZrO2) to which ytterbia (Yb2O3) is added as a stabilizer in a content of 8 wt % or more and 27 wt % or less. YbSZ has excellent high-temperature stability at a high temperature (for example, about 1300° C. to 1400° C.) and imparts erosion resistance to the heat-shielding coating layer 102. When an addition amount of ytterbia is less than 8 wt %, phase stability is deteriorated. When the addition amount of ytterbia is more than 27 wt %, mechanical properties are deteriorated.
The rare earth disilicate is any one of a (Y1-a[Ln1]a)2Si2O7 solid solution (here, Ln1 is at least one of Sc, Yb, and Lu, a is 0.05 or more and less than 1 when Ln1 is Sc, and a is 0.2 or more and less than 1 when Ln1 is Yb or Lu), Sc2Si2O7, Yb2Si2O7, and Lu2Si2O7.
Alternatively, the rare earth disilicate is any one of a (Y1-c[Ln2]c)2Si2O7 solid solution (here, Ln2 is at least one of Nd, Sm, Eu, and Gd, c is 0.1 or more and less than 1 when Ln2 is Nd, Sm, or Eu, and c is 0.2 or more and less than 1 when Ln2 is Gd), Nd2Si2O7, Sm2Si2O7, Eu2Si2O7, and Gd2Si2O7.
An ionic radius of Y3+ is 0.90 Å, and referring to
Referring to
In the (Y1-a[Ln1]a)2Si2O7 solid solution in which Y is substituted with a separate rare earth element, an average ionic radius of rare earth elements (Y and Ln1) is changed depending on a substitution amount. In order to allow the average ionic radius to be smaller than that of Y, Y is substituted with a rare earth element having an ionic radius smaller than that of Y. Referring to
Table 1 illustrates a substitution amount of a substitution element (Sc, Yb, or Lu) in the (Y1-a[Ln1]a)2Si2O7 solid solution and an average ionic radius of the rare earth elements.
Referring to Table 1, the average ionic radius is to be 0.897 Å or less if a is 0.05 or more for Sc, and 0.1 or more for Yb or Lu. That is, when a is equal to or higher than the above-mentioned range, the coated member can withstand an operation temperature of 1300° C.
Further, referring to Table 1, the average ionic radius is to be 0.885 Å or less if a is 0.1 or more for Sc, and 0.5 or more for Yb or Lu. That is, when a is equal to or higher than the above-mentioned range, the coated member can withstand an operation temperature of 1400° C. or more.
In the case in which a rare earth element has a larger ionic radius as that of Y, there is a boundary between an α phase and a γ phase as illustrated in
In order to allow the average ionic radius to be larger than that of Y, Y is substituted with a rare earth element having an ionic radius larger than that of Y. As a difference in ionic radius between a rare earth element and Y is increased, an effect of changing an average ionic radius of the rare earth elements is increased. Therefore, it is advantageous to select an element having an ionic radius larger than that of Gd in
Table 2 illustrates a substitution amount of a substitution element (Gd, Eu, Sm, or Nd) in (Y1-c[Ln2]c)2Si2O7 and an average ionic radius of the rare earth elements.
Referring to Table 2, the average ionic radius is to be 0.905 Å or more if c is 0.1 or more for Nd, Sm, or Eu, and 0.2 or more for Cd. That is, when c is equal to or higher than the above-mentioned range, the coated member can withstand an operation temperature up to 1300° C.
Further, referring to Table 2, the average ionic radius is to be 0.91 Å or more if c is 0.2 or more for Nd or Sm, and 0.3 or more for Eu or Gd. That is, when c is equal to or higher than the above-mentioned range, the coated member can withstand an operation temperature up to 1400° C.
In the case in which the rare earth disilicate is (Y1-a[Ln1]a)2Si2O7 (here, Ln1 is at least one of Sc, Yb, and Lu), the rare earth monosilicate is Y2SiO5, [Ln1′]2SiO5, or a (Y1-b[Ln1′]b)2SiO5 solid solution (here, Ln1′ is any one of Sc, Yb, and Lu, and 0<b≤0.5).
In the case in which the rare earth disilicate is (Y1-c[Ln2]c)2Si2O7 (here, Ln2 is at least one of Nd, Sm, Eu, and Gd), the rare earth monosilicate is Y2SiO5 or a (Y1-d[Ln2′]d)2SiO5 solid solution (here, Ln2′ is any one of Nd, Sm, Eu, and Gd, and 0<d≤0.5).
Since the rare earth monosilicate has a low activity of SiO2 as compared to the rare earth disilicate, the rare earth monosilicate has high steam resistance. Among the rare earth monosilicates, Y2SiO5 is cheap. Sc2SiO5, Yb2SiO5, Lu2SiO5, Nd2SiO5, Sm2SiO5, Eu2SiO5, and Gd2SiO5 have almost similar properties to those of Y2SiO5. Therefore, as the rare earth monosilicate, one of these compounds may be used alone or Y in Y2SiO5 can be substituted with at least one of Sc, Yb, and Lu, or at least one of Nd, Sm, Eu, and Gd.
As the rare earth monosilicate, Y2SiO5 (substitution amounts b=0, and d=0) can be used, but in order to prevent concentrations of the rare earth elements from being changed by interdiffusion with the rare earth disilicate, (Y1-aLn1a)2Si2O7 and (Y1-c[Ln2]c)2Si2O7, coexisting in the mixed phase, it is preferable that the substitution amounts b and d are the same as the substitution amounts a and c of the rare earth disilicate. When the substitution amounts b and d are large, cost is increased, such that upper limits of b and d are 0.5.
In a coated member 100 corresponding to a laminate, when a difference in thermal expansion coefficient between the substrate 101 and the heat-shielding coating layer 102 is large, thermal stress is generated in the heat-shielding coating layer 102. Cracks, or the like, occur in the heat-shielding coating layer 102 due to thermal stress generated in the heat-shielding coating layer 102 by repeating operation and stop of equipment (aircraft engine or gas turbine). In order to alleviate thermal stress generated in the heat-shielding coating layer 102, a difference between the thermal expansion coefficient of the heat-shielding coating layer 102 and the thermal expansion coefficient of the substrate 101 needs to be less than 3×10−6/K, and preferably, less than 2×10−6/K (at room temperature to 1200° C.)
A thermal expansion coefficient of a mixture is changed depending on a mixing ratio of each component. In order to allow the difference in thermal expansion coefficient to be above-mentioned range, a mixing ratio between the rare earth silicates and YbSZ, the kinds of rare earth disilicate and rare earth monosilicate, a substitution amount of the rare earth element, and a mixing ratio between the rare earth monosilicate and the rare earth disilicate in the case in which the mixed phase of the rare earth monosilicate and the rare earth disilicate is used as the matrix phase are determined depending on the kind of substrate 101.
For example, the thermal expansion coefficient of the substrate 101 is 6×10−6/K to 8×10−6/K (at room temperature to 1200° C.) if the substrate 101 is made of the Al2O3 fiber-reinforced Al2O3 matrix composite, the thermal expansion coefficient of the substrate 101 is 3.5×10−6/K to 4.5×10−6/K if the substrate 101 is made of the SiC fiber-reinforced SiC matrix composite, the thermal expansion coefficient of the substrate 101 is 4.5×10−6/K if the substrate is made of SiC, and the thermal expansion coefficient of the substrate 101 is 3.3×10−6/K if the substrate is made of Si3N4.
A thermal expansion coefficient of YbSZ (8 to 27 wt % Yb2O3—ZrO2) is 10.3×10−6/K (at room temperature to 1200° C.). The thermal expansion coefficient of the rare earth monosilicate is 7.1×10−6/K to 10.1×10−6/K (for example, a thermal expansion coefficient of Y2SiO5 is 7.4×10−6/K) (at room temperature to 1200° C.), and the thermal expansion coefficient of the rare earth disilicate is 3.7×10−6/K to 4.2×10−6/K (for example, a thermal expansion coefficient of Y2Si2O7 is 3.7×10−6/K) (at room temperature to 1200° C.)
YbSZ has a large thermal expansion coefficient as compared to the substrate. In the case in which an addition amount of YbSZ is large, thermal stress is generated in the heat-shielding coating layer 102. Meanwhile, in the case in which the addition amount of YbSZ is small, sufficient erosion resistance cannot be obtained. Therefore, it is preferable that the addition amount of YbSZ is 50 vol % or more and 90 vol % or less.
In the case in which the substrate 101 is made of the Al2O3 fiber-reinforced Al2O3 matrix composite, even though the matrix phase is made of the rare earth monosilicate, a difference in thermal expansion coefficient between the substrate 101 and the heat-shielding coating layer 102 is small, thereby suppressing thermal stress in the heat-shielding coating layer 102. This combination is advantageous in that a heat-shielding coating layer 102 having excellent steam resistance can be obtained.
Meanwhile, in the case in which the substrate 101 is made of a material of which a thermal expansion coefficient is significantly different from that of YbSZ, such as the SiC fiber-reinforced SiC matrix composite or the silicon-based ceramic, thermal stress in the heat-shielding coating layer 102 can be suppressed by selecting the rare earth disilicate, which is a material having a small thermal expansion coefficient, as a matrix phase. Further, in the case of using the mixed phase of the rare earth disilicate and the rare earth monosilicate as the matrix phase, it is possible to impart excellent steam resistance to the heat-shielding coating layer 102 while decreasing the thermal expansion coefficient of the heat-shielding coating layer 102.
The heat-shielding coating layer 102 according to the present embodiment is formed by a spray method. Spray particles are prepared by the method described below.
The rare earth disilicate and the rare earth monosilicate corresponding to the matrix phase are prepared by the method described below.
As raw material powder of the rare earth disilicate, SiO2 powder, Y2O3 powder, [Ln1]2O3 (here, Ln1 is any one of Sc, Yb, and Lu), and [Ln2]2O3 powder (here, Ln2 is any one of Nd, Sm, Eu, and Gd) are weighed and mixed with each other so as to have a predetermined composition.
As raw material powder of the rare earth monosilicate, SiO2 powder, Y2O3 powder, [Ln1′]2O3 (here, Ln1′ is any one of Sc, Yb, and Lu), and [Ln2′]2O3 powder (here, Ln2′ is any one of Nd, Sm, Eu, and Gd) are weighed and mixed with each other so as to have a predetermined composition.
The mixed powder is heat-treated, thereby obtaining rare earth disilicate powder and rare earth monosilicate powder. As a method of performing heat-treatment, there is a method of performing heat-treatment at 1300° C. or more using an electric furnace, a method of performing plasma heat-treatment, a method of melting the raw material powder and grinding the obtained melt, or the like.
Since a reaction by heat-treatment can be promoted by using fine powder having a particle size of 1 μm or less as the raw material powder, it is possible to decrease a heat-treatment time while removing un-reacted particles.
The powder after heat-treatment was pulverized and classified into 1 μm to 50 μm or so.
Alternatively, commercial Y2Si2O7 powder, [Ln1]2Si2O7 powder, [Ln2]2Si2O7 powder, [Ln1′]2SiO5 powder, and [Ln2′]2Si2O5 powder may be used as the raw material powder.
In the case in which the mixed powder of the rare earth disilicate powder and the rare earth monosilicate powder is used as the matrix phase, the rare earth disilicate powder and the rare earth monosilicate powder prepared as described above are weighed and mixed with each other to have a predetermined composition ratio.
In order to obtain YbSZ, ZrO2 powder and Yb2O3 powder in a predetermined ratio (8 wt % or more and 27 wt % or less) are mixed together with a suitable binder and a suitable dispersant in a ball mill, thereby preparing slurry. This slurry is granulated and dried by a spray drier, and subjected to diffusion heat-treatment at 1300° C. to 1700° C. so that Yb2O3 and ZrO2 are solid-solubilized, thereby obtaining YbSZ powder.
The YbSZ powder after heat-treatment was pulverized and classified into 1 μm to 50 μm or so.
The rare earth disilicate powder, the rare earth monosilicate powder, or a mixed powder of the rare earth disilicate powder and the rare earth monosilicate powder is mixed with the YbSZ powder at a predetermined ratio.
Zirconia-dispersed silicate powder is obtained by performing heat-treatment on the mixed powder. As a method of performing heat-treatment, there is a method of performing heat-treatment at 100° C. or more using an electric furnace, a method of performing plasma heat-treatment, a method of melting the raw material powder and grinding the obtained melt, or the like.
The mixed powder is prepared by using fine powder having a particle size of 1 μm or less, such that a reaction by heat-treatment can be promoted, and it is possible to decrease a heat-treatment time while removing un-reacted particles.
The particles after heat-treatment are pulverized and classified, and particles having a size of 10 μm to 200 μm are used for spraying as a coating material.
In order to verify phase stability of the rare earth disilicate, spray powder of Y2Si2O7, a (Y0.8Yb0.2)2Si2O7 solid solution, and a (Y0.8Gd0.2)2Si2O7 solid solution were prepared by the method as described above. Further, spray coating films were manufactured using these powder.
The manufactured spray coating film was heat-treated at 1300° C. for 100 hours and 1400° C. for 100 hours, and a change in crystal phase was determined by X-ray diffraction (XRD). As illustrated in
Meanwhile,
Meanwhile,
The substrate 201 is made of the same material as in the first embodiment.
The bond coat 202 is to secure good adhesion between the substrate 201 and the top coat 203. The bond coat 202 is made of Si, silicide such as MoSi2, LuSi, or the like, mullite (3Al2O3-2SiO2), barium strontium aluminosilicate (BSAS, (Ba1-xSrx)O—Al2O3—SiO2), or the like. The bond coat 202 may be made of one of the above-mentioned materials or formed by laminating a plurality of materials. The bond coat 202 has a thickness of 20 μm or more and 200 μm or less.
The bond coat 202 is formed by a spray method, a sintering method, or the like.
A first layer 204 of the top coat is composed of a mixed phase of a rare earth disilicate and a rare earth monosilicate. A thickness of the first layer 204 is 20 μm or more and 400 μm or less.
In detail, the first layer 204 is composed of a mixed phase of a rare earth disilicate represented by a (Y1-e[Ln3]e)2Si2O7 solid solution (here, Ln3 is any one of Sc, Yb, and Lu, e is 0.05 or more and 0.5 or less when Ln3 is Sc, and e is 0.2 or more and 0.5 or less when Ln3 is Yb or Lu), and a rare earth monosilicate represented by a Y2SiO5 or a (Y1-f[Ln3′]f)2SiO5 solid solution (here, Ln3′ is any one of Sc, Yb, and Lu, and f is more than 0 to 0.5 or less).
Alternatively, the first layer 204 is composed of a mixed phase of a rare earth disilicate represented by a (Y1-g[Ln4]g)2Si2O7 solid solution (here, Ln4 is any one of Nd, Sm, Eu, and Gd, g is 0.1 or more and 0.5 or less when Ln4 is Nd, Sm, or Eu, and g is 0.2 or more and 0.5 or less when Ln4 is Gd), and a rare earth monosilicate represented by a Y2SiO5 or a (Y1-h[Ln4′]h)2SiO5 solid solution (here, Ln4′ is any one of Nd, Sm, Eu, and Gd, and h is more than 0 to 0.5 or less).
When e and g of the rare earth disilicate in the first layer 204 are within the above-mentioned ranges, the coated member can withstand an operation temperature of 1400° C. or more. If e and g are large, an amount of the substitution element is increased. Therefore, in consideration of raw material cost, cost for substitution is increased by using Sc, Yb, and Lu, or Nd, Sm, Eu, and Gd, which are expensive elements. Therefore, there is an upper limit in the substitution amounts of Sc, Yb, and Lu, or Nd, Sm, Eu, and Gd. In detail, it is preferable that upper limits of e and g are 0.5.
As the rare earth monosilicate, Y2SiO5 (substitution amount f=0, and h=0) can be used. However, in order to prevent concentrations of rare earth elements from being changed by interdiffusion with the rare earth disilicate, coexisting in the mixed phase, it is preferable that the substitution amounts f and h are the same as substitution amounts e and g of the rare earth disilicate. Meanwhile, when the substitution amounts f and h exceed the above-mentioned ranges, raw material cost is increased, which is not preferable.
In order to alleviate thermal stress in the top coat 203, a difference in thermal expansion coefficient between the first layer 204 and a base (substrate 201 including the bond coat 202) is less than 3×10−6/K, and preferably, less than 2×10−6/K (at room temperature to 1200° C.). In order to allow the difference in thermal expansion coefficient to be in the above-mentioned range, a composition of the rare earth disilicate, a composition of the rare earth monosilicate, and a mixing ratio between the rare earth disilicate and the rare earth monosilicate are determined depending on the kinds of substrate 201 and bond coat 202.
The first layer 204 is formed by a spray method. Spray particles for forming the first layer 204 are prepared by the same process as that in the first embodiment described above. That is, rare earth disilicate powder and rare earth monosilicate powder having predetermined compositions are prepared in advance. The rare earth disilicate powder and the rare earth monosilicate powder are mixed with each other at a predetermined ratio and subjected to heat-treatment using the method described in the first embodiment. The powder after heat-treatment are pulverized and classified into 1 μm to 50 μm or so.
A second layer 205 of the top coat 203 is made of a rare earth monosilicate represented by Re2SiO5. Here, Re may be one of rare earth elements or a plurality of rare earth elements may be selected. In detail, the second layer 205 is made of Y2SiO5, Yb2SiO5, Lu2SiO5, (Y, Yb)2SiO5, (Y, Lu)2SiO5, or the like. Considering raw material cost, it is preferable that the second layer 205 is made of Y2SiO5 or a rare earth monosilicate, (Y, Re′)2SiO5 (here, Re′ is another rare earth element except for Y) in which Y is partially substituted with another rare earth element. Considering interdiffusion with the rare earth disilicate, it is preferable that a substitution element Re′ is Sc, Yb, Lu, Nd, Sm, Eu, or Gd. It is particularly preferable that the substitution element Re′ is the same material as the rare earth element contained in the first layer 204. Considering raw material cost, it is preferable that a substitution amount of Re′ is 0.5 or less.
The second layer 205 is formed by a spray method. A thickness of the second layer 205 is 50 μm or more and 300 μm or less.
In the case of applying the composite oxide containing a rare earth element selected from the plurality of rare earth elements to the second layer 205, particles solid-solubilized by heat-treatment after weighing and mixing raw material powder so as to have a predetermined substitution ratio can be used as the spray particles. In this way, uniformity of the composition in the second layer 205 is secured.
A difference in thermal expansion coefficient between the first layer 204 and the second layer 205 is less than 3×10−6/K, preferably, less than 2×10−6/K (at room temperature to 1200° C.). A material of the second layer 205 is selected so that the difference in thermal expansion coefficient described above is secured.
The third layer 206 of the top coat 203 is the heat-shielding coating layer, and the same material as that in the first embodiment is used therein. It is possible to prevent the substrate 201 from being eroded by steam in a high-temperature environment by forming the third layer 206 made of YbSZ and rare earth monosilicate which have excellent steam resistance.
Considering thermal stress of the top coat 203 under a use environment, a difference in thermal expansion coefficient between the second layer 205 and the third layer 206 is less than 3×10−6/K, preferably, less than 2×10−6/K (at room temperature to 1200° C.). A material of the third layer 206, that is, a composition of a matrix phase, and an addition amount of YbSZ are selected so that the difference in thermal expansion coefficient described above is secured.
Table 3 illustrates a difference in thermal expansion coefficient between a substrate and a heat-shielding coating layer (at room temperature to 1200° C.) in the case of forming a coated member having a configuration illustrated in
In Table 3, “YbSZ” is stabilized zirconia to which 16 wt % of Yb2O3 was added.
As illustrated in Table 3, since in Examples 1 to 5, the difference in thermal expansion coefficient between the heat-shielding coating layer and the substrate was 3×10−6/K or less, thermal stress in the top coat was alleviated. Particularly, in Examples 2 to 5, the difference in thermal expansion coefficient was less than 2×10−6/K, and heat cycle durability was improved as compared to Comparative Examples 1 and 2.
Table 4 illustrates a difference in thermal expansion coefficient between a substrate and a heat-shielding coating layer (at room temperature to 1200° C.) in the case of forming a coated member having a configuration illustrated in
In Table 4, “YbSZ” is stabilized zirconia to which 16 wt % of Yb2O3 was added.
As illustrated in Table 4, since in Examples 6 to 9, the differences in thermal expansion coefficient between the first layer and the base, between the first and second layers, and between the second and third layers were 3×10−6/K or less, thermal stress in the top coat was alleviated. Particularly, in Examples 6 to 9, the difference in thermal expansion coefficient was less than 2×10−6/K, and heat cycle durability was improved as compared to Comparative Example 3.
| Number | Date | Country | Kind |
|---|---|---|---|
| JP2015-023374 | Feb 2015 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2016/053786 | 2/9/2016 | WO | 00 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2016/129588 | 8/18/2016 | WO | A |
| Number | Name | Date | Kind |
|---|---|---|---|
| 6296941 | Eaton, Jr. et al. | Oct 2001 | B1 |
| 6312763 | Eaton, Jr. et al. | Nov 2001 | B1 |
| 6733908 | Lee | May 2004 | B1 |
| 6759151 | Lee | Jul 2004 | B1 |
| 7348287 | Mechnich | Mar 2008 | B2 |
| 20030087120 | Torigoe | May 2003 | A1 |
| 20030138641 | Fukudome | Jul 2003 | A1 |
| 20040156724 | Torigoe | Aug 2004 | A1 |
| 20040175597 | Litton | Sep 2004 | A1 |
| 20060014029 | Saak | Jan 2006 | A1 |
| 20060073361 | Fukudome et al. | Apr 2006 | A1 |
| 20060100086 | Mechnich | May 2006 | A1 |
| 20060166015 | Spitsberg et al. | Jul 2006 | A1 |
| 20070151481 | Akiyama et al. | Jul 2007 | A1 |
| 20080160172 | Taylor et al. | Jul 2008 | A1 |
| 20080213617 | Taylor et al. | Sep 2008 | A1 |
| 20080220209 | Taylor et al. | Sep 2008 | A1 |
| 20090220776 | Meschter et al. | Sep 2009 | A1 |
| 20090250153 | Meschter et al. | Oct 2009 | A1 |
| 20100080984 | Lee | Apr 2010 | A1 |
| 20100159151 | Kirby et al. | Jun 2010 | A1 |
| 20110027557 | Kirby et al. | Feb 2011 | A1 |
| 20110256411 | Courcot et al. | Oct 2011 | A1 |
| 20120003102 | Taylor et al. | Jan 2012 | A1 |
| 20120122651 | Taylor et al. | May 2012 | A1 |
| 20120244383 | Meschter et al. | Sep 2012 | A1 |
| 20130228105 | Yamamura et al. | Sep 2013 | A1 |
| 20130316891 | Harada et al. | Nov 2013 | A1 |
| 20130330507 | Taylor et al. | Dec 2013 | A1 |
| 20140178632 | Taylor et al. | Jun 2014 | A1 |
| 20140334939 | Taylor et al. | Nov 2014 | A1 |
| 20160108510 | Kirby | Apr 2016 | A1 |
| Number | Date | Country |
|---|---|---|
| 2503027 | Sep 2012 | EP |
| H11-012050 | Jan 1999 | JP |
| 2003-160852 | Jun 2003 | JP |
| 2005-154885 | Jun 2005 | JP |
| 2006-028015 | Feb 2006 | JP |
| 2006-151720 | Jun 2006 | JP |
| 2006-200037 | Aug 2006 | JP |
| 3866002 | Jan 2007 | JP |
| 2007-091504 | Apr 2007 | JP |
| 2008-308374 | Dec 2008 | JP |
| 4453718 | Apr 2010 | JP |
| 2011-046598 | Mar 2011 | JP |
| 4690709 | Jun 2011 | JP |
| 2012-082994 | Apr 2012 | JP |
| 2012-513946 | Jun 2012 | JP |
| 5112681 | Jan 2013 | JP |
| 2015-172243 | Oct 2015 | JP |
| 2012077787 | Jun 2012 | WO |
| Entry |
|---|
| PCT/ISA/210, “International Search Report for International Application No. PCT/JP2016/053786,” dated Mar. 8, 2016. |
| PCT/ISA/237, “Written Opinion of the International Searching Authority for International Application No. PCT/JP2016/053786,” dated Mar. 8, 2016. |
| Europe Patent Office, “Search Report for European Patent Application No. 16749232.1,” dated Dec. 13, 2017. |
| Carrion, A. J. F. et al, “Structural and kinetic study of phase transitions in LaYSi2O7,” Journal of the European Ceramic Society, Aug. 2012, p. 2477-2486, vol. 32, Issue 10, Elsevier Ltd. |
| Monteverde, F. et al., “Structural data from X-ray powder diffraction for new high-temperature phases (Y1-xLnx) 2Si2O7 with Ln=Ce, Pr, Nd,” Journal of the European Ceramic Society, May 2002, p. 721-730, vol. 22, Issue 5, Elsevier Science Ltd. |
| Zhang, Q. Y. et al., “Effects of composition and structure on spectral properties of Eu3+-doped yttrium silicate transparent nanocrystalline films by metallorganic decomposition method,” Chemical Physics Letters, Apr. 2002, p. 161-167, vol. 356, Issues 1-2, Elsevier Science B.V. |
| Maier, N. et al, “Formation and stability of Gd, Y, Yb and Lu disilicates and their solid solutions,” Journal of Solid State Chemistry, Jun. 2006, p. 1630-1635,vol. 179, No. 6, Elsevier Inc. |
| U.S.P.T.O, “Office Action for U.S. Appl. No. 15/549,658,” dated Aug. 24, 2020. |
| Number | Date | Country | |
|---|---|---|---|
| 20180022649 A1 | Jan 2018 | US |
