The present invention relates generally to turbine disks for gas turbine engines, and more particularly to turbine disks having an oxidation barrier coating.
Gas turbine engines having hotter exhaust gases and which operate at higher temperatures are more efficient. To maximize the efficiency of gas turbine engines, attempts have been made to form gas turbine engine components, such as turbine disks, having higher operating temperature capabilities (e.g., above about 1300° F.). In particular, there is considerable commercial interest in superalloy components for turbine disk applications which exhibit dwell fatigue and creep resistance at relatively high temperatures (e.g., exceeding about 1300° F.).
Conventional alloy turbine disks are limited to an operating temperature of <1300° F. (typically about 1100° F.). Such disks are typically made by inert gas atomization of the alloys into powder form. The powder may be subsequently screened to an appropriate size range and consolidated by hot compaction or by hot isostatic pressing (HIP). The consolidated powder may be then extruded into a form suitable for isothermal forging into a shape that can be machined into a turbine disk or other engine component. Components may also be formed by hot isostatic pressing (HIP) without the extrusion and isothermal forging steps, and subsequently machined to final shape. These methods of manufacture are common throughout the industry and well known in the art. However, providing a conventional turbine disk for sustained elevated temperature service is problematic because resistance to dwell fatigue and corrosion resistance properties for conventional alloy turbine disks tend to be poor at temperatures greater than about 1300° F.
As can be seen, there is a need for apparatus, compositions, and methods for providing components for gas turbine engines, such as turbine disks, capable of sustained operation at turbine disk rim temperatures in excess of 1300° F.
In one aspect of the present invention, a coated component comprises a turbine disk, and an oxidation barrier coating disposed on at least an outer portion of the turbine disk; wherein the turbine disk comprises a superalloy, and the oxidation barrier coating comprises a ductile metal.
In a further aspect of the present invention, there is provided a coated component comprising a turbine disk and a platinum coating disposed on an outer portion of the turbine disk; wherein the turbine disk comprises a nickel-based superalloy or a cobalt-based superalloy, and the platinum coating consists essentially of platinum.
In another aspect of the present invention, a coated component comprises a turbine disk, and an oxidation barrier coating disposed on at least an outer portion of the turbine disk, wherein the turbine disk comprises a superalloy, and the oxidation barrier coating comprises palladium, platinum, nickel, or a platinum alloy.
In yet a further aspect of the present invention, a coated component comprises a turbine disk, and an oxidation barrier coating disposed on at least an outer portion of the turbine disk, wherein the turbine disk comprises a superalloy, and the oxidation barrier coating comprises a binary platinum alloy comprising Al, Cr, Ni, Pd, Ti, or Zr.
In yet another aspect of the present invention, a method for preparing a coated component comprises providing a turbine disk, and applying an oxidation barrier coating to at least an outer portion of the turbine disk, wherein the turbine disk comprises a superalloy, and the oxidation barrier coating comprises platinum, palladium, nickel, or a platinum alloy.
These and other features, aspects, and advantages of the present invention will become better understood with reference to the following drawings, description, and claims.
The following detailed description is of the best currently contemplated modes of carrying out the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.
Broadly, the present invention provides apparatus, compositions, and methods for providing coated components for gas turbine engine operation at sustained high temperatures (e.g., >1300° F.). In one embodiment, the present invention provides an alloy turbine disk or rotor having a ductile oxidation barrier coating (OBC) disposed on at least an outer portion thereof. The present invention may find applications in turbomachinery, including turbo fan, turbo shaft, and turbo prop engines. The present invention may be used for gas turbine engine of aircraft, as well as for industrial turbomachinery for power generation, and the like.
Alloy turbine disks of the present invention may include an oxidation barrier coating disposed on at least an outer portion of the turbine disk, wherein the oxidation barrier coating may comprise a layer of ductile metal, e.g., comprising platinum (Pt), palladium (Pd), or a Pt alloy. The ductile oxidation barrier coating on the outer portion or rim of the turbine disk of the present invention may prevent surface oxide formation and intergranular attack, thereby delaying the onset of surface initiated low cycle fatigue (LCF) cracking, hence, the component life of the coated turbine disks of the present invention may be dramatically extended. In contrast to the present invention, turbine disks of the prior art lack a ductile oxidation barrier coating on the outer rim of the disk. Consequently, turbine disks of the prior art are readily susceptible to oxidation and corrosion, resulting in greatly decreased life of conventional components.
Oxidation barrier coating 14 may be a ductile coating. Oxidation barrier coating 14 may be resistant to prolonged exposure to temperature cycling at temperatures up to >1300° F. without cracking or spalling. Oxidation barrier coating 14 may comprise a ductile metal such as, but not limited to, platinum (Pt). In exemplary embodiments of the present invention, oxidation barrier coating 14 may comprise typically at least about 97 wt. % platinum, usually at least about 99 wt. % platinum, and often at least about 99.9 wt. % platinum. In some exemplary embodiments of the present invention, oxidation barrier coating 14 applied to disk outer portion 12 may consist essentially of platinum.
In some embodiments of the present invention, oxidation barrier coating 14 may comprise a platinum alloy. Oxidation barrier coating 14 may comprise a binary platinum alloy. Oxidation barrier coating 14 may comprise Pt alloyed with aluminum (Al), chromium (Cr), titanium (Ti), nickel (Ni), palladium (Pd), or zirconium (Zr). In some embodiments of the present invention, oxidation barrier coating 14 may comprise nickel (Ni), palladium (Pd), or an alloy of Ni or Pd with Pt. In various embodiments of the present invention, oxidation barrier coating 14 may comprise: a Pt/Al alloy comprising about 3.75-23.1 wt. % Al, 76.9-96.25 wt. % Pt; a Pt/Cr alloy comprising about 0-60 wt. % Cr, 40-100 wt. % Pt; a Pt/Ni alloy comprising about 0-100 wt. % Ni, 0-100 wt. % Pt; a Pt/Pd alloy comprising about 0-100 wt. % Pd, 0-100 wt. % Pt; a Pt/Ti alloy comprising about 0-46 wt. % Ti, 54-100 wt. % Pt; or a Pt/Zr alloy comprising about 0-28 wt. % Zr, 72-100 wt. % Pt. Typically, the Pt/Ni alloy in the form of an intermetallic may comprise about 0-47 wt. % Ni, 53-100 wt. % Pt. Typically, the Pt/Ni alloy in the form of a solid solution may comprise about 1-50 wt. % Ni, 50-99 wt. % Pt, and usually about 5-50 wt. % Ni, 50-95 wt. % Pt. Typically, the Pt/Pd alloy in the form of a solid solution may comprise about 1-99 wt. % Pt, 1-99 wt. % Pd, and usually about 5-95 wt. % Pt, 5-95 wt. % Pd.
In some embodiments of the present invention, oxidation barrier coating 14 may comprise an intermetallic or a solid solution. As a non-limiting example, oxidation barrier coating 14 may comprise a solid solution of Ni/Pt or Pd/Pt; or oxidation barrier coating 14 may comprise an intermetallic phase such as Al2Pt, Al3Pt2, AlPt, AlPt3, Cr3Pt, CrPt, CrPt3, Ni3Pt, NiPt, Ti3Pt, Ti3Pt5, TiPt8, Pt3Zr, or Pt11Zr9. Oxidation barrier coating 14 may comprise more than one of these phases within a binary platinum alloy, e.g., oxidation barrier coating 14 may comprise CrPt in combination with CrPt3. Exemplary values for wt. % platinum of oxidation barrier coating 14 predominantly comprising each of the above phases are shown in Table 1. Each composition presented in Table 1 is a stable phase, as shown by published phase diagrams (see, e.g., Binary Alloy Phase Diagrams for Al (Al—Pt), Cr (Cr—Pt), Ni (Ni—Pt), Pd (Pd—Pt), and Pt (Pt—Ti and Pt—Zr), published by ASM International, 2002).
Oxidation barrier coating 14 may be applied to disk surface 10a using various deposition techniques well known in the art. As non-limiting examples, oxidation barrier coating 14 may be applied to disk surface 10a by physical vapor deposition (PVD), sputter coating, or electroplating.
Step 102 of method 100 may involve providing an alloy turbine disk. The turbine disk may be provided according to manufacturing techniques well known in the art, for example, powder metallurgy processes involving hot isostatic pressing (HIP), extrusion, and isothermal forging. Typically, turbine disk 10 may comprise a superalloy, such as a nickel-based superalloy or a cobalt-based superalloy. Such alloys are well known in the art.
Step 104 may involve preparing a surface of the turbine disk. The disk surface may be treated during step 104 such that all surface areas are water-break-free. Shop soils may be removed using a suitable aqueous degreaser or by vapor degreasing. In addition, surface oxides may be removed from the disk surface using a suitable acid etch. Such surface preparation techniques are well known in the art. Once the disk surface has been prepared, the turbine disk may be handled using lint-free cotton gloves.
Step 108 may involve applying the oxidation barrier coating to at least the outer portion of the turbine disk. During step 108, the entire outer portion of the turbine disk, including the blade attachment surface of each blade attachment slot, may be coated with the oxidation barrier coating. The oxidation barrier coating may be applied to the surface of the turbine disk using various deposition techniques, such as physical vapor deposition (PVD), sputter coating, or electroplating. Such deposition techniques are well known in the art. The oxidation barrier coating may be applied to the surface of the turbine disk as a single layer or as a plurality of layers.
As a result of masking the turbine disk in step 106 (infra), an inner portion of the turbine disk may remain uncoated after step 108 has been performed. That is to say, the oxidation barrier coating may be selectively applied to the outer portion of the turbine disk such that an inner portion of the turbine disk may lack the oxidation barrier coating.
The oxidation barrier coating applied in step 108 may have a thickness typically in the range of from about 800 nm to about 50 microns (0.002 inches), usually from about 800 nm to about 10 microns (μm), and often from about 1 micron to about 3 microns (μm). The oxidation barrier coating applied in step 108 may be a ductile coating which resists cracking and spalling following prolonged exposure to high temperatures (e.g., in excess of 1300° F.) and repeated temperature cycling.
In exemplary embodiments of the present invention, the oxidation barrier coating applied in step 108 may comprise platinum, typically comprising at least about 97 wt. % platinum, usually at least about 99 wt. % platinum, and often at least about 99.9 wt. % platinum. In some embodiments of the present invention, the oxidation barrier coating applied in step 108 may consist essentially of platinum. Optional, step 106 may involve masking the turbine disk such that only an outer portion of the disk is exposed during deposition of the oxidation barrier coating (see, e.g., step 108, infra). As a non-limiting example, the turbine disk may be masked using a pair of metal plates disposed over an inner portion of each side of the turbine disk (see, for example, FIGS. 3A-B). Following masking in step 106, the entire outer portion or outer rim of the turbine disk, including the blade attachment surface of each blade attachment slot (see,
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It is to be understood that the invention is not limited to coatings comprising platinum or platinum alloys, but rather other ductile oxidation barrier coatings which may effectively protect alloy turbine disks from corrosion and oxidation are also within the scope of the present invention.
Although the invention has been described primarily with respect to turbine disks, the present invention may also find applications for other components of gas turbine engines, and the like.
It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.