Patent Application
20110076413
The present invention relates generally to protective coatings applied to metal substrates. More specifically, the invention is directed to a single layer bond coat having the benefits of conventional bi-layer bond coats, and to the related method for application of such single layer bond coats.
Higher operating temperatures for gas turbine engines are continuously sought in order to increase their efficiency. However, as operating temperatures increase, the temperature durability of the engine components must correspondingly increase. Significant advances in high temperature capabilities have been achieved through the formulation of nickel and cobalt-based superalloys, and through the development of oxidation-resistant overlay coatings deposited directly on the surface of the superalloy substrate to form a protective oxide scale during high temperature exposure. Nonetheless, superalloys protected by overlay coatings often do not retain adequate mechanical properties for components located in certain sections of a gas turbine engine, such as the combustor and augmentor. A common solution is to thermally insulate such components in order to minimize their service temperatures. For this purpose, thermal barrier coating (TBC) systems formed on the exposed surfaces of high temperature components have found wide use.
To be effective, TBC systems must have low thermal conductivity, strongly adhere to the article, and remain adherent throughout many heating and cooling cycles. The latter requirement is particularly demanding due to the different coefficients of thermal expansion between materials having low thermal conductivity and superalloy materials typically used to form turbine engine components. TBC systems capable of satisfying the above requirements generally require a metallic bond coat deposited on the component surface, followed by an adherent thermal barrier ceramic layer that serves to thermally insulate the component. Various ceramic materials have been employed as the thermal barrier layer, particularly zirconia (ZrO2) stabilized by yttria (Y2 O3), magnesia (MgO), ceria (CeO2), scandia (Sc2O3), or another oxide.
The bond coat is typically formed from an oxidation-resistant aluminum-containing alloy to promote adhesion of the ceramic layer to the component and inhibit oxidation of the underlying superalloy. Examples of prior art bond coats include overlay coatings such as MCrAlY (where M is iron, cobalt and/or nickel), and diffusion coatings such as diffusion aluminide or platinum aluminide, which are oxidation-resistant aluminum-base intermetallics. The bond coat is typically disposed on the substrate by a thermal spray processes, such as vacuum plasma spray (VPS) (also know as low pressure plasma spraying (LPPS)), air plasma spray (APS), and high velocity oxy-fuel (HVOF) spray processes.
Conventional bond coats are typically applied as a bi-layer construction wherein a fine powder is first deposited on the substrate to form a dense, low oxide layer. Commercially available HVOF systems are typically used to deposit this layer. It is generally recognized that conventional HVOF processes are sensitive to particle size distributions, generally requiring finer particles ranging from −45+10 μm. The fine particle layer serves to protect the substrate from oxidation and corrosion, but the low surface roughness of the layer results in inadequate adhesion of the ceramic material layer.
A coarse powder layer is then deposited over the fine powder layer to achieve a desired degree of surface roughness for adequate adhesion of the ceramic material. APS bond coating techniques are often favored for the coarse powder layer due to lower equipment cost and ease of application and masking. Adhesion of the ceramic material layer to an APS bond coat is promoted by forming the bond coat to have a surface roughness of about 200 microinches (about 5 μm) to about 500 microinches (about 13 μm) Ra (Arithmetic Average Roughness (Ra) as determined from ANSI/ASME Standard B461-1985).
Although APS-applied bond coats provide better TBC adhesion due to their roughness, the coarse powder layer is generally unsuitable as a protective coating system. The coarse powder layer is relatively porous and prone to oxidation damage.
Thus, conventional bond coats are applied as a bi-layer in separate processes with separate equipment configurations to achieve the desired characteristics of a dense, low-oxide protective layer, and the surface roughness of a coarse powder layer. This practice, however, requires maintaining both powders in inventory, as well as the different coating systems. The process is time consuming in that it involves set up for two different processes, and can result in rework of coated pieces due to equipment or powder mix-ups.
Accordingly, the art would benefit from an improved commercially viable process for applying a single layer bond coat from a single powder composition, with the bond coat having the desired properties of conventional bi-layer bond coats.
Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
The present invention provides a protective coating system for a metal substrate, and is particularly suited for metal components of a gas turbine engine. The system includes a superalloy metal substrate having a single layer bond coat applied to the substrate. The bond coat is applied in a thermal spray process, for example a high velocity oxy-fuel (HVOF) process, from a homogeneous powder composition that results in a bond coat having properties comparable to bi-layer bond coats. The powder composition has a particle size distribution wherein about 90% of the particles by volume are within a range of about 10 μm to about 100 μm. The particles are distributed relatively uniformly within the range in that the percentage of particles within any 10 μm band within the range does not exceed about 20% by volume, and the percentage of particles within any two adjacent 10 μm bands within the range does not deviate by more than about 8% by volume. The coating system may also encompass a ceramic thermal barrier layer applied to the single layer bond coat, or the bond coat may be the only layer of the protective coating system.
The present invention also encompasses a method for forming a protective coating system on a metal substrate. The method includes applying a single layer bond coat to a superalloy metal substrate, such as a Ni or Co based superalloy, in a thermal spray process, for example an HVOF process, from a homogeneous powder composition having a particle size distribution such that the resulting bond coat has properties at least comparable to bi-layer bond coats. About 90% by volume of the particles are within a range of about 10 μm to about 100 μm. The percentage of particles within any 10 μm band within the range does not exceed about 20% by volume, and the percentage of particles within any two adjacent 10 μm bands within the range does not deviate by more than about 8% by volume. A single layer bond coat formed in accordance with the present method may have a surface roughness of at least about 300 μinch Ra, a density of at least about 90% of theoretical density; and a bond coat to substrate tensile strength of at least about 6.0 ksi. The bond coat powder composition may include MCrAlY alloy particles, where M is at least one of iron, cobalt, or nickel. In a further refinement of the method, a ceramic thermal barrier layer is applied over the single layer bond coat, with a thermal barrier layer to bond coat tensile strength that exceeds the cohesive strength of the ceramic layer, regardless of the morphology of the ceramic layer. This ceramic barrier layer may be formed from, for example, commercially available yttria stabilized ceramic coating particles.
These and other embodiments and features of the invention will be described in greater detail in the following description.
A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment, can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
As previously discussed, thermal barrier coating (TBC) systems are often used to improve the efficiency and performance of metal parts which are exposed to high temperatures, such as nozzles, buckets, shrouds, airfoils, and other gas turbine components. The combustion gas temperatures present in conventional gas turbines are maintained as high as possible for operating efficiency, and turbine combustion components and other elements of the engine are usually made of alloys which can resist the high temperature environment, e.g., superalloys, which have an operating temperature limit of about 1000-1150 degrees Celsius. The TBC systems effectively increase the operating temperature of the turbine by maintaining or reducing the surface temperature of the alloys used to form the various engine components.
The TBC systems are also critical for protecting the surfaces of various turbine components. Referring to
Referring to
Single layer bond coatings 54 in accordance with the invention may be applied to components of a gas turbine, as discussed above, or used in other environments, such as selected components of diesel or other types of internal combustion engines.
The SLBC 54 is applied to any manner of metal substrate 40 in a thermal spray process from a homogeneous powder composition having a particle size distribution that provides the SLBC 54 with comparable characteristics of a bi-layer bond coat. In particular, the SLBC 54 has the density and low oxide content of a fine powder layer comparable to layer 34 of
Referring to the particle size distribution graph of
The graph C in
Graph A in
Graph E in
The SLBC 54 formed from a powder composition as described above has a surface roughness of at least about 300 μinch Ra (Arithmetic Average Roughness (Ra) as determined from ANSI/ASME Standard B461-1985). In particular embodiments, the surface roughness will be at least about 400 μinch Ra. The rough surface serves to ensure good adhesion between the bond coat and a subsequently applied thermal barrier material. It should be appreciated that the surface roughness value of the SLBC is not an issue when the SLBC is used as the only layer in the protective coating system, i.e., a ceramic thermal barrier material layer is not applied over the SLBC.
Single layer bond coats 54 according to the present process may be formed having any suitable thickness. Typical bond coats in a bi-layer coating system are typically within a range of about 250 μm to about 500 μm. A SLBC 54 in accordance with the present invention may not need to be as thick as these conventional bond coats, and may have a thickness less than conventional bond coats, for example, of about 125 μm, or 200 μm. It is believed that a 200 μm SLBC will produce the equivalent life of a 350 μm bi-layer bond coat.
The SLBC 54 will also have a density of at least about 90% of theoretical density, and in particular embodiments, at least about 95% of theoretical density.
The SLBC 54 also has a bond coat to substrate tensile strength of at least about 6.0 ksi, and in particular embodiments, at least about 12.0 ksi.
The SLBC 54 is applied in a thermal spray process having a particle velocity of at least about 400 m/s. Various techniques are available for measuring particle velocity downstream from the plasma gun exit, using a variety of sensor systems. As a non-limiting example, measuring systems for determining particle velocity and particle velocity distribution are described in U.S. Pat. No. 6,862,536 (Rosin). One example of an on-line particle monitoring and measurement device which is commercially available is the DPV-2000 system, available from Tecnar Automation Ltd, Montreal, Canada (http://www.tecnar.com/).
Although it is generally held that conventional high velocity oxy-fuel (HVOF) thermal spray systems are sensitive to particle size distributions (generally requiring finer particles ranging from −45+10 μm), the present inventors have found that such HVOF systems may be used for the protective coating system and methodology of the present invention. By carefully monitoring and adjusting the HVOF thermal spray parameters, a single layer bond coat is achievable from a powder composition as described herein that is dense and relatively oxide-free, yet has the surface roughness and porosity required for good adhesion of a ceramic material layer. For example, the combustion ratio in a HVOF process for purposes of the present invention should be less than about 0.29, and desirably within a range of about 0.27 to about 0.29. This combustion ratio with the powder composition discussed above yields satisfactory deposition rates.
With respect to deposition rates, the relationship of pounds of powder per mil of coating per square unit of area coated is an objective standard. A deposit efficiency is desirable that produces a satisfactory coating without excess wastage of powder. A baseline parameter may first be established, for example 0.13 lbs. per mil of coating per square foot of surface coating. The combustion ratio may then be adjusted from a low baseline value of, for example, 0.235, until the plume temperature reaches a limit indicative of excessive oxide in past experience with similar powder chemistries. With the increased combustion ratio, an increased deposit rate efficiency results of about 0.08 lbs. of powder per square foot of area coated to a thickness of about 1 mil. A further increase of the combustion ratio so that even less powder is required may lead to unacceptable levels of oxide in the coating. A deposition rate range of about 0.15 to about 0.08 lbs/mil/ft2 at a combustion ratio that does not produce unacceptable oxides in the coating may be desired for purposes of the SLBC 54.
Examples of the other steps and process parameters that may be adjusted to achieve a SLBC 54 in accordance with the present invention include: cleaning of the surface prior to deposition; grit blasting to remove oxides; substrate temperature; other plasma spray parameters such as spray distance (gun-to-substrate); selection of the number of spray-passes, powder feed rate, torch power, plasma gas selection; angle-of-deposition, post-treatment of the applied coating; and the like.
Another suitable thermal spray process is a high velocity air plasma spray (HV-APS) process wherein particle velocity is maintained in the range of about 300 m/s to about 700 m/s. In some specific embodiments, the velocity is at least about 450 m/s, and may be about 600 m/s. These particle velocities are substantially greater than the typical velocities used in conventional APS systems (in the range of about 150-250 m/s). For a HV-APS system, a conventional APS system can be modified to effectively increase the plasma velocity and hence, the particle velocity. In general, modification of the APS system in this instance involves the selection of different configurations of anode nozzles which fit into the plasma spray guns, and commercial APS guns equipped with high-velocity anode nozzles can be employed to carry out the high velocity air plasma spray (HV-APS) process. Non-limiting examples include the 7 MB (or 9 MB, or 3 MB) plasma spray gun equipped with the 704 high velocity nozzle, available from Sulzer Metco, Inc. Another example is the SG100 plasma spray gun, operated in the “Mach 2” mode, available from Praxair Surface Technologies, Inc. These conventional APS gun systems may be operated in a power range of, for example, 30-50 KW.
The powder composition for the SLBC 54 may comprise MCrAlY alloy particles, where M is at least one of iron, cobalt, or nickel.
The resulting SLBC 54 has a density of at least 90% of theoretical density, and more particularly about 95% density. These densities reflect a decreased oxide content in the bond coating that greatly increases the effective TBC life and the substrate life against oxidation. Decreased oxide content in the bond coat (as reflected by an increased density) inhibits detrimental growth of thermally grown oxide (TGO) at the interface of the bond coat and ceramic coat during service of the component. It is generally accepted that TGO accelerates TBC failures, such as cracking, delamination, and spalling.
Referring to
Gas turbine component parts are exemplified as the “metal substrate” in this patent specification. It should be appreciated, however, that other types of components could serve as metal substrates for bond coats in accordance with the invention. As one example, the substrate may be the piston head of a diesel engine, or other automotive parts. It should be readily appreciated that the invention is not limited to any particular type of metal substrate or component.
The following examples are merely illustrative, and should not be construed to be any sort of limitation on the scope of the claimed invention.
A first (Sample A) bi-modal MCrAlY powder composition having a particle size distribution generally in accordance with Graph D of
A second (Sample B) bi-modal powder composition having a particle size distribution generally in accordance with Graph D of
The below table (Table 1) summarizes the results discussed above for the Sample A and Sample B SLBC systems as compared to a conventional bi-layer bond coat:
The samples of
While the present subject matter has been described in detail with respect to specific exemplary embodiments and methods thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing may readily produce alterations to, variations of, and equivalents to such embodiments. Accordingly, the scope of the present disclosure is by way of example rather than by way of limitation, and the subject disclosure does not preclude inclusion of such modifications, variations and/or additions to the present subject matter as would be readily apparent to one of ordinary skill in the art.
