Patent Application
20100104440
The present invention relates to a coating material, a method of manufacturing the coating material, a coating method, and a moving blade fitted with a shroud.
However, with APS, a problem arises in that the coating film exhibits poor adhesion with the base material at the contact surface 3 of the shroud 2, meaning the coating film tends to be probe to peeling. Accordingly, Patent Citation 1 discloses a coating method in which the Tribaloy coating film is formed on a shroud contact surface 3 of a turbine moving blade 1 by High Velocity Oxy-Fuel (HVOF) spraying, Low Pressure Plasma Spraying (LPPS) or atmospheric plasma spraying, and is then subjected to a diffusion heat treatment.
Patent Citation 1:
Japanese Unexamined Patent Application, Publication No. 2001-152803
However, although the T-800 coating film has excellent ductility and high abrasion resistance, in the high-temperature gas turbines of recent years, the metal temperature at the tips of the three-stage moving blades reaches 750° C. or higher, causing significant oxidative loss and a deterioration in the function of the abrasion-resistant coating film.
The present invention has been developed in light of the above circumstances, and has an object of providing a coating material, a method of manufacturing the coating material, and a coating method using the coating material that are capable of forming a coating film that retains high abrasion resistance while offering improved oxidation resistance at high temperatures, as well as providing a moving blade fitted with a shroud.
In order to achieve the above object, the present invention provides the following aspects.
In other words, the present invention provides a coating material, which comprises not less than 14% by mass and not more than 30% by mass of molybdenum (Mo), not less than 13% by mass and not more than 20% by mass of chromium (Cr), and not less than 0.5% by mass and not more than 4% by mass of silicon (Si), which may comprise not more than 1.5% by mass of nickel (Ni), not more than 1.5% by mass of iron (Fe), and not more than 0.08% by mass of carbon (C), and which comprises a balance of cobalt (Co) and unavoidable impurities, wherein the coating material further comprises at least one added component selected from the group consisting of not less than 0.01% by mass and not more than 3% by mass of yttrium (Y), not less than 0.01% by mass and not more than 10% by mass of aluminum (Al), and not less than 0.1% by mass and not more than 10% by mass of Fe.
The coating material of the present invention is used for depositing a coating film that achieves a combination of high abrasion resistance, and high oxidation resistance at high temperatures.
In the coating material of the present invention, the added component may be not less than 0.01% by mass and not more than 3% by mass of Y.
By adding Y, as described below, the oxidation resistance of the coating film can be improved.
In the coating material of the present invention, the added component may be not less than 0.01% by mass and not more than 10% by mass of Al.
By adding Al, as described below, the oxidation resistance of the coating film at high temperatures can be improved.
In the coating material of the present invention, the added component may be not less than 0.1% by mass and not more than 10% by mass of Fe.
By adding Fe, as described below, the oxidation resistance of the coating film at high temperatures can be improved.
In the coating material of the present invention, the added component may be not less than 0.01% by mass and not more than 10% by mass of Al, and not less than 0.1% by mass and not more than 10% by mass of Fe.
In this case, by adding predetermined quantities of both Al and Fe, the oxidation resistance of the coating film at high temperatures can be further improved.
In the coating material of the present invention, the added component may be not less than 0.01% by mass and not more than 10% by mass of Al, and not less than 0.01% by mass and not more than 3% by mass of Y.
In this case, by adding predetermined quantities of both Al and Y, the oxidation resistance of the coating film at high temperatures can be further improved.
In the coating material of the present invention, the added component may be not less than 0.01% by mass and not more than 10% by mass of Al, not less than 0.1% by mass and not more than 10% by mass of Fe, and not less than 0.01% by mass and not more than 3% by mass of Y.
In this case, by adding predetermined quantities of the three components Al, Fe, and Y, the oxidation resistance of the coating film at high temperatures can be improved even further.
In a coating method according to the present invention, a coating film is formed on a substrate surface by high-velocity flame spraying, using a spray powder composed of any of the coating materials described above.
The coating method of the present invention can be used to deposit a dense coating film that provides a combination of high abrasion resistance and high oxidation resistance at high temperatures.
Furthermore, in another coating method according to the present invention, a coating film is formed on a substrate surface by low pressure plasma spraying or atmospheric plasma spraying, using a spray powder composed of any of the coating materials described above.
This coating method can be used to deposit a dense coating film that provides a combination of high abrasion resistance and high oxidation resistance at high temperatures.
In either of the above coating methods, a diffusion heat treatment is preferably performed after the coating film is formed.
In this case, the film quality of the coating film is enhanced, and the adhesion between the coating film and the base material is further improved.
In a moving blade fitted with a shroud according to the present invention, a shroud is provided at the tip of a moving blade of a turbine, wherein the shroud comprises a contact surface that contacts another shroud provided at a tip of an adjacently positioned moving blade when the moving blade is in use, and this contact surface comprises a coating film formed by any of the coating methods described above.
Because the moving blade fitted with a shroud of the present invention has a dense coating film at the contact surface that provides a combination of high abrasion resistance and high oxidation resistance at high temperatures, the contact surface of the shroud suffers little oxidative loss, and has a long lifespan.
A description of the reasoning for restricting the quantity of each added component in the composition of the coating material according to the present invention is presented below. In the following description, unless otherwise specified, the quantity of each component is expressed as a percentage by mass in which the total mass of all the components is deemed to be 100.
In a coating film formed using the coating material of the present invention, Y has a so-called pegging effect that prevents generated oxide scales from flaking off, and therefore improves the oxidation resistance of the coating film. This effect is not realized if the added quantity of Y is less than 0.01% by mass, whereas if the quantity exceeds 3%, then significant segregation occurs within the coating film, adversely affecting the mechanical characteristics of the coating film such as the ductility. The added quantity of Y is preferably not less than 0.1% and not more than 2%, and is most preferably not less than 0.3% and not more than 1.0%.
In a coating film formed using the coating material of the present invention, Al contributes to improved stability of the Cr2O3 that acts as the protective oxide film, thereby improving the oxidation resistance of the coating film. This effect of enhancing the oxidation resistance of the coating film is not realized if the added quantity of aluminum is less than 0.01%, whereas if the quantity exceeds 10%, then although the oxidation resistance and abrasion resistance of the coating film improve, the resulting coating film is extremely hard and tends to crack more easily. The added quantity of Al is preferably not less than 1% and not more than 7%, and is most preferably not less than 3% and not more than 5%.
Experiments show that Fe improves the oxidation resistance of a coating film formed using the coating material of the present invention. The improved oxidation resistance of the coating film is thought to be due to Co and Fe forming a solid solution, thereby reducing the proportion of Mo, which has poor oxidation resistance. This effect of enhancing the oxidation resistance of the coating film is not realized when the added quantity of Fe is less than 0.01%, whereas if the quantity exceeds 10%, then although the oxidation resistance of the coating film improves, the abrasion resistance of the coating film tends to decrease. The added quantity of Fe is preferably not less than 1% and not more than 7%, and is most preferably not less than 3% and not more than 5%.
The present invention is able to provide a coating material, a method of manufacturing the coating material and a coating method using the coating material that are capable of forming a coating film that retains high abrasion resistance while offering improved oxidation resistance at high temperatures, as well as a moving blade fitted with a shroud.
Because the coating film obtained using the present invention can, for example, withstand continuous use at 850° C., the life of the contact surface, which is approximately 2 years when the coating surface is formed by depositing T-800, can be extended significantly to three years or longer, particularly in those cases where the coating film is used on the contact surfaces of the shroud of a three-stage moving blade in a high-temperature gas turbine.
Embodiments of the present invention are described below with reference to the drawings.
A coating material, a method of manufacturing the coating material, a coating method, and a moving blade fitted with a shroud according to a first embodiment of the present invention are described below in detail by way of examples with reference to the drawings. However, the present invention is in no way limited by the examples presented below.
Spray powders with the compositions of examples 1 to 7 shown in Table 1 were prepared by a gas atomization method using the device shown in
A predetermined alloy component was superheated and melted inside a levitation furnace 12, and the molten matter was then drained through a nozzle hole of a spray nozzle 14 provided at the base of the tundish to create a thin flow of molten matter. An inert jet fluid (typically helium gas or the like) was blown onto the flow of molten matter from a position around the periphery of the flow, and the energy of this jet fluid caused the molten matter to flow downward into a spray chamber 16. The downward flow of molten matter was broken up into liquid droplets, which were solidified as they fell to produce an alloy powder. The alloy powder was separated from the exhaust gas by a cyclone 18 provided on the downstream side of the device, and was then collected in a powder collection vessel 20 provided beneath the cyclone.
Because the gas-atomized alloy powder produced in this manner is obtained by instantaneously atomizing and cooling a liquid of a uniformly molten alloy, a uniform microstructure is obtained. Furthermore, because droplets are continuously produced from the same molten matter, there is very little difference in composition between particles, and this difference in composition is minimal for both large and small particles. The gas atomization method produces a spherical powder.
A sieve was used to obtain a particle size distribution of the spray powder of not more than 53 μm.
Next I a description of the coating method with reference to
The spray powder was supplied in a powdered state to a spray gun, melted by heating to a relatively low temperature (not higher than 1600° C.) by combusting oxygen and kerosene, and then sprayed at a high velocity (300 m/s or faster) onto the contact surface 3, thereby forming a coating film on the contact surface 3. The flame velocity of the HVOF process is within a range from 300 m/s to 500 m/s at its slowest, and by this enables a dense coating film to be deposited by the spray material striking the contact surface 3. The film thickness of the coating film was approximately 0.2 mm.
The specific HOVF spraying conditions (for a JP5000 system manufactured by Hobart Tafa Technologies) used in the present embodiment were as follows:
Firing pressure: 0.7 MPa
Kerosene flow rate: 20 L/h
Oxygen flow rate: 54 m3/h
Spray distance: 500 mm
Gun movement speed: 500 mm/sec.
Gun movement pitch: 6 mm
Spray device used: JP5000 manufactured by Praxair, Inc.
HVOF is conducted in the open atmosphere, and is therefore an advantageous deposition method due to factors such as its low cost and applicability to large components.
Because coating films formed by HVOF have few pores, and because little oxide formation occurs at the grain boundaries of the coating film due to oxidation being inhibited by the low spraying temperature, a diffusion heat treatment was performed in a vacuum furnace after film deposition in order to improve the film quality. This heat treatment may be performed, for example, by first performing solution heat treatment at 1121° C. for 2.5 hours, subsequently cooling the coating film in nitrogen, and then performing an aging heat treatment at 850° C. for 24 hours, followed by cooling in nitrogen. This heat treatment may be combined with a heat treatment of the base material.
This diffusion heat treatment can be performed as part of the heat treatment applied to the moving blade 1 itself. By conducting spraying using HVOF and then performing a diffusion heat treatment in the manner described above, the various structural moieties within the film derived from the base material, the coating film and the spray powder undergo diffusion and integration, enabling a coating film to be obtained that offers excellent adhesion to the base material of the contact surface 3 and does not peel easily.
From the results shown in
Using a spray powder (T-800) having the composition of comparative example 1 shown in Table 1, a coating film was deposited on the contact surface 3 of the shroud 2 using the same method as that described for example 1.
Deposition of the coating film may be performed using a HVAF (High Velocity Air Fuel) process instead of the HVOF process. In this case, a dense coating film with minimal oxides can be obtained. This improves the adhesion between the coating film on the contact surface 3 and the base material.
Deposition of the coating film may be performed by a low pressure plasma spraying (LPPS) process instead of the HVOF process. As the plasma working gas, argon or a mixed gas of argon and nitrogen or the like may be used.
Table 2 shows an example under LPPS spray conditions (using a low-pressure spraying system manufactured by Sulzer Metco Ltd.). The term “Clearing” in Table 2 refers to using a reversed polarity arc discharge to dislodge deposits from the surface of the target object.
Because no oxide formation occurs in a film sprayed under reduced pressure, the resulting film is dense and has excellent adhesion to the base material. In addition, by performing a diffusion heat treatment to enhance the film quality, adhesion is improved even further. As the LPPS spray powder, a powder with a particle size distribution of not less than 10 μm and not more than 44 μm can be used.
Atmospheric plasma spraying may be used instead of low pressure plasma spraying.
Deposition of the coating film may be performed using an atmospheric plasma spraying (APS) process instead of the HVOF process. As the APS spray powder, a powder with a particle size distribution of not more than 103 μm can be used.
Examples have been described above in which the coating material of the present invention is used to form a coating film on a contact surface of a shroud within a moving blade fitted with a shroud, but the present invention is not limited to such examples, and the coating film may also be applied to a turbine member having friction components that are exposed to high-temperature gases. The coating material of the present invention is also useful for forming a coating film on a seal pin or the like.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2007-088697 | Mar 2007 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2008/056097 | 3/28/2009 | WO | 00 | 9/22/2009 |
