• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    To deposit an environmental barrier, a bonding layer (120) is applied to the substrate (110) of a gas turbine component, and a first layer (140) is applied to the bonding layer (120) by thermal spraying. A second layer (150) is applied by slurry coating over the first layer (140).
    公开号:CH708651B1
    申请号:CH00129/15
    申请日:2013-07-25
    公开日:2018-09-14
    发明作者:Lee Margolies Joshua；Chidsey Roberts Herbert；Mark Lipkin Don；Harold Kirby Glen；Edward Antolino Nicholas
    申请人:Gen Electric；
    IPC主号:
    专利说明:

    description
    Technical Field The present disclosure relates to environmental barrier coatings, and more particularly to methods and systems for applying environmental barrier coatings to ceramic matrix composite gas turbine engine components.
    Background of the Invention Gas turbines are internal combustion engines that compress gases that push gases into a combustion chamber in which heat is added to increase the volume of the gases. The burned gases are then sent to a turbine to extract the energy generated by the expanding gases. Gas turbines have many practical applications, including the production of propulsion in jet engines and electricity generation in industrial power generation systems.
    The acceleration and conduction of gases within a gas turbine are often accomplished using rotating blades. The extraction of energy is typically accomplished by forcing expanded gases from the combustion chamber to gas turbine blades that are rotated by the force of the expanded gases exiting the gas turbine through the turbine blades. Due to the high temperatures of the exiting gases, the gas turbines must be designed to withstand extreme operating conditions. While gas turbine components are typically constructed of metal or metal alloys, more advanced materials such as intermetallics, ceramics, and ceramic matrix composites are being developed. By employing these and other advanced materials in the construction of gas turbine components which may be exposed to extreme environmental conditions, coatings may be applied to impart additional thermal and environmental protection to the gas turbine component to improve its durability.
    It is an object of the present invention to provide such a gas turbine component and such a method for the production thereof, that coatings with desired thickness and surface quality can be produced inexpensively.
    Brief Description of the Invention In the invention, a gas turbine engine component incorporating a substrate is disclosed. A bonding layer is applied to the substrate and a first layer is applied to the bonding layer by thermal spraying and comprises a sintering agent. A second layer is applied by slurry coating over the first layer.
    In the invention, a method of coating a gas turbine component is also disclosed. A tie layer is applied to a substrate of the gas turbine component. A first layer comprising a sintering agent is applied to the bonding layer by thermal spraying. A second layer is applied by slurry coating over the first layer.
    The foregoing summary, as well as the following detailed description, will be better understood when read in conjunction with the drawing. For the purpose of illustrating the claimed subject matter, examples illustrating various embodiments are shown in the drawings.
    Brief Description of the Drawing These and other features, aspects, and advantages of the present invention will become better understood upon reading the following detailed description with reference to the accompanying drawings, in which:
    Fig. 1 is a non-limiting example of coatings applied to an article.
    Fig. 2 is another non-limiting example of coatings applied to an article.
    Fig. 3 is another non-limiting example of coatings applied to an article.
    Figure 4 is another non-limiting example of coatings applied to an article.
    Fig. 5 is another non-limiting example of coatings applied to an article.
    Detailed Description of the Invention In one embodiment, an environmental barrier coating (EBC) is applied to an article, such as a gas turbine blade, which may be constructed of a ceramic matrix composite (CMC) material, such as an SiC-SiC composite material. The article is coated with a tie coat which acts as an oxidation barrier and can promote bonding to the EBC layers. An EBC may help protect the article from the effects of environmental threats, such as hot gas, water vapor, and oxygen, that may come into contact with the article while in use. For example, a gas turbine blade in use in a powered gas turbine may be exposed to such extreme environmental conditions. An EBC is applied as multiple layers of different materials and one or more of these layers may have a silicate base. Each EBC layer may serve at least one function, such as, but not limited to, providing a thermal barrier, providing a water vapor recession barrier, providing an interfacial reaction barrier, providing a water vapor barrier, and providing a corrosion barrier. According to embodiments of the present disclosure, the materials in each layer may be or include any material, including ceramic, silicon, and silicides.
    FIG. 1 illustrates an exemplary coating applied to a gas turbine engine component constructed from a CMC. Substrate 110 of the CMC article is coated with a bonding layer 120, which serves as a primary oxidation barrier and can assist in bonding the other EBC layers to the substrate 110. In one embodiment, tie layer 120 may be a silicon-based tie layer or a silicide-based tie layer. The EBC layer 140 is applied to the bonding layer 120. Additional EBC layers 150, 160, and 170 may be further deposited over EBC layer 140. These layers may serve at least one function, such as, but not limited to, providing a thermal barrier, providing a water vapor recession barrier, providing an interlayer reaction barrier, providing a water vapor barrier, and providing a corrosion barrier. Any number of EBC layers may be applied to substrate 110 and any other article or surface disclosed herein, any material for any article, bonding layer, and EBC layer disclosed herein including, without limitation Bonding layer 120, EBC layers 140, 150, 160 and 170 and substrate 110. All such embodiments are considered to fall within the scope of the present disclosure.
    In one embodiment, a thermal spraying method, such as air plasma spraying, is used to apply one or more of the layers. Thermal spray processes are particularly effective in applying a silicon based tie coat, such as layer 120, and thick deposits of any of the overlying EBC layers. However, the application of thick films from an EBC using a plasma spray process can result in coatings that have undesirably high roughness for turbine application. Further, plasma spraying can produce EBC coating defects which can result in a lack of EBC hermeticity and / or reduced adhesion after heat treatment. Such errors may arise due to stresses arising in the plasma sprayed coatings after crystallization and, in some cases, additional solid state transformations.
    While a silicon-based bond coat, such as layer 120, may be applied using other means, such as a slurry coating process, slurry coating may be less suitable for applying the bond coat, due to the need for at least one high Temperature executed, non-oxidizing sintering cycle after deposition. In addition to higher manufacturing costs, the high temperature sintering cycle for slurry applied binder coatings may stress the mechanical properties of the substrate material. By using slurry coating for each layer, several immersion, drying and sintering heat treatment cycles may be needed to achieve the desired layer thickness. However, slurry coatings can produce smooth coatings that do not require subsequent surface finishing, thereby avoiding the risk of removing too much material from the surface.
    In one embodiment, slurry coatings are applied to thermally sprayed coatings to take advantage of the unique benefits of each coating application process. As used herein, slurry coating includes any slurry coating agent and method including, but not limited to, slurry dip coating, slurry spray coating, and slurry based electrophoretic deposition.
    Depositing a slurry on thermally sprayed layers may produce slurry layers that do not fully densify due to loss of a portion of the sintering aid by transport into the thermally sprayed layers. In another embodiment, therefore, sintering aids may be included below the slurry layer to help achieve the desired density in the slurry EBC layers. The sintering aids may be added as an additive to the thermal spray powder, such as by using pre-alloyed powders or physical mixtures containing sintering aid components. Alternatively or additionally, sintering aids can be applied as a post-spatter deposit, such as by solution deposition, to create a reservoir of sintering agent in the sprayed coating.
    As used herein, "sintering aids" and "sintering agents" may include any sintering aid, including, but not limited to, carbonyl iron, Fe 2 O 3, and Al 2 O 3. Sintering aids and sintering agents as described herein may also include elemental iron, aluminum, boron, nickel, cobalt, manganese, tin, copper, gallium, titanium, magnesium, calcium, strontium, barium, lithium, sodium, potassium, rubidium, cesium , any compound containing these elements and including any mixture of these elements or compounds. Sintering aids and sintering agents as described herein may also include compounds including oxides such as gallium oxide, nickel oxide, cobalt oxide, manganese oxide, tin oxide, copper oxide, titanium oxide, boron oxide, magnesium oxide, calcium oxide, strontium oxide, barium oxide, lithium oxide, sodium oxide, potassium oxide, Rubidium oxide and cesium oxide. Sintering aids and semiconductors as described herein may also include hydroxides, carbonates, oxalates, acetates, acetylacetates, ethoxides, propoxides, chlorides, sulphates, carbides, nitrides as well as silicides of iron, aluminum, boron, nickel, cobalt, manganese, Tin, copper, gallium, titanium, magnesium, calcium, strontium, barium, lithium, sodium, potassium, rubidium and cesium. Sintering aids and sintering agents as described herein may include any compound containing at least one of iron, aluminum, boron, nickel, cobalt, manganese, tin, copper, gallium, titanium, magnesium, calcium, strontium, barium, lithium, potassium , Rubidium and cesium together with at least one of yttrium, scandium, lanthanum, cerium, praseodymium, neodymium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, lutetium and at least one of oxygen, silicon, chlorine, Contains carbon and nitrogen. Sintering aids and sintering agents as described herein may also include phosphorus and any phosphorus-containing compound. All such embodiments are considered to fall within the scope of the present invention.
    In some embodiments, chemical vapor deposition may be used to effectively apply a silicon-based bond coat. In other embodiments, a combination of a thermal spray process and a chemical vapor deposition process may be used to apply a silicon-based tie coat. In one embodiment, shown in FIG. 2, bonding layer 220 may be applied to substrate 210 using thermal spray, chemical vapor deposition, or a combination thereof. Tie layer 220 may be composed of silicon and / or silicide. Substrate 210 may be composed of silicon, SiC, Si 3 N 4, metal silicides (eg, Mo-Si, Nb-Si, W-Si) carbon, composites thereof (eg, SiC / SiC-CMC, C / C composite materials, MoSi 2 -based composite materials, and composite materials based on Nb5Si3) and any combination thereof.
    One or more layers may be applied over layer 220 to act as moisture barriers, thermal barriers, and / or vapor barriers. In one embodiment, the next layer, layer 230, may include a rare earth disilicate, such as, but not limited to, ytterbium disilicate and yttrium oxide ytterbium oxide di-silicate. In one embodiment, a particular or minimum thickness may be desired to achieve the desired durability and service interval for the article to which the layer may be applied. To achieve this thickness, layer 230 may be applied using multiple slurry coatings to build up the layer. In an alternative embodiment, a base deposit of a rare earth disilicate may be applied using plasma spraying as layer 230, and then a slurry coating may be further applied as layer 235 to fill any defects such as microcracks or small holes in the sprayed deposit, and so on Create hermeticity. In one embodiment, the slurry coating at layer 235 may be a low viscosity slurry coating.
    To aid in densifying the slurry applied layer 235, any portion of the layer 230 applied using thermal spraying may include a sintering agent. The sintering agent may help prevent layer 235 from losing sintering aid upon annealing by migration into the spray deposition. The sintering agent may be incorporated into the thermal spray powder used to apply the layer 230, using any method disclosed herein. In such an embodiment, the sintering agent can be pre-alloyed with the spray powder, while in another embodiment, the sintering agent can be mixed into the spray powder before the application of the coating. Alternatively, the sintering agent may be applied simultaneously with the spray powder but by a separate sprayer.
    In another embodiment, illustrated in FIG. 3, bonding layer 320 may be applied to substrate 310 using thermal spraying, chemical vapor deposition, or a combination thereof. Tie layer 320 may be composed of silicon and / or silicide. Substrate 310 may be silicon, Sic, Si 3 N 4, metal silicides (eg, Mo-Si, Nb-Si, W-Si) carbon, composites thereof (eg, SiC / SiC-CMC, C / C composites, MoSi 2 -based composites, and composite materials based on Nb5Si3) and any combination thereof.
    In this embodiment, layer 330 is applied over tie layer 320 to act as a moisture barrier and to prevent and mitigate evaporation. Instead of incorporating a sintering agent into a spray powder used to apply the thermally sprayed part 331 and / or the slurry applied part 333, sintering means 332 may be applied as a solution over the thermally sprayed part 331 of the layer 320 after being thermally sprayed sprayed portion 331 of layer 330 is applied over layer 320, but prior to the application of slurry applied portion 333 of layer 330.
    In another embodiment, illustrated in FIG. 4, tie layer 420 may be applied to substrate 410 using thermal spray, chemical vapor deposition, or a combination thereof. Tie layer 420 may be composed of silicon and / or silicide. Substrate 410 may be composed of silicon, SiC, Si 3 N 4, metal silicides (eg, Mo-Si, Nb-Si, W-Si) carbon, composites thereof (eg, SiC / SiC-CMC, C / C composites, MoSi 2 -based composites, and composite materials based on Nb5Si3) and any combination thereof. Layer 430 may be a rare earth disilicate layer, such as layer 230 of FIG. 2 or layer 330 of FIG. 3. Layer 420 is deposited in a manner other than a slurry deposition process. In this embodiment, layer 440 may include a rare earth monosilicate, such as, but not limited to, yttrium monosilicate. In one embodiment, layer 440 may be the outermost layer and, therefore, layer 440 may be applied using a slurry process to achieve a desired one
    权利要求:
    Claims (18)
    [1]
    To achieve density and a desired surface quality. As with all of the embodiments herein, the slurry coating process may also permit the deposition of a rare earth silicate without the melting that may take place where the coating is applied using thermal spraying. By avoiding the melting of the rare earth silicate, the rare earth silicate may not undergo defect-inducing volume changes which may be observed during heat treatment after coating, as may be the case in some Plas-maspritz applications. In another embodiment, illustrated in FIG. 5, tie layer 520 may be applied to substrate 510 using thermal spray, chemical vapor deposition, or a combination thereof. Tie layer 520 may be composed of silicon and / or silicide. Substrate 510 may be made of silicon, SiC, Si 3 N 4, metal silicides (eg, Mo-Si, Nb-Si, W-Si) carbon, composites thereof (eg, SiC / SiC-CMC, C / C composite materials, MoSi 2 -based composite materials and Nb5Si3-based composites) and any combination thereof. Layer 530 may be a rare earth disilicate layer, such as layer 230 of FIG. 2 or layer 330 of FIG. 3, but is applied completely using thermal spray techniques. Layer 540 may include barium strontium aluminosilicate (BSAS) to aid hermeticity and may be applied using thermal spray techniques. Layer 550 may be another rare earth disilicate layer, layer 230 of FIG. 2 or layer 330 of FIG. 3, and may be applied using thermal spraying, slurry methods, or a combination thereof, as referred to herein the same rare earth disilicate as layer 530, another rare earth disilicate, a mixture of BSAS and a rare earth disilicate, a mixture of BSAS and a rare earth monosilicate, or a combination thereof. Layer 550 may include a sintering agent that may be applied in any manner disclosed herein, including in a thermally sprayed portion of layer 550 and / or as a solution disposed between two sublayers of layer 550, as set forth above. Layer 560 may be the outermost layer and may be applied using slurry coating. Layer 560 may be essentially a rare earth monosilicate, such as a mixture of a rare earth monosilicate and a rare earth disilicate, or a mixture of a rare earth monosilicate and a rare earth oxide. It should be noted that for any embodiment disclosed herein, a sintering agent may be added below a slurry layer where the bottom layer may be applied using thermal spraying. The sintering agent may be applied using any method or means described herein, including by incorporating the sintering agent into the lower layer thermal spray powder or by applying the sintering agent as a solution over the thermal spray applied layer prior to applying the slurry layer , Those skilled in the art will recognize that the use of a combination of thermal spray applied layers and slurry applied layers provides many advantages to EBCs, including achieving a desired thickness cost-effectively by employing lower layer thermal spray processes and achieving a desired one Surface quality and density by applying slurry coating for the outermost layer or outer layers. With the present embodiments, there may be no need to subject the surface of a coated article to mechanical finishing, thereby avoiding operations that make the outer layer extremely thin in local areas or even remove it. This has the advantage of reducing process steps and maintaining the protective function of the coating. Slurry-deposited outer layers are not subject to crystallization or crystalline phase transformations during the heat treatment and therefore avoid the source of such defects in the underlying layers resulting from volume changes accompanying such conversions. The embodiments disclosed herein can extend the life of EBC layers and thereby extend devices and apparatus containing articles and components configured with such EBC layers, such as gas turbine blades, while being simple and cost effective to implement. claims
    A gas turbine component comprising: a substrate (110/210/310/410/510), a tie layer (120/220/320/420/520) applied to the substrate (110/210/310/410/510) a first layer (140/230/330/430/530) applied by thermal spraying over the tie layer (120/220/320/420/520) and a second layer (150/235/440/540) coated by slurry coating over the first layer (140/230/330/430/530), wherein the first layer (140/230/330/430/530) comprises a sintering agent.
    [2]
    2. A gas turbine component according to claim 1, wherein the sintering means (332) is applied to a first part (331) of the first layer (330) before a second part (333) of the first layer (330) is applied.
    [3]
    The gas turbine component of claim 1, further comprising a third layer (160/550) applied to the second layer (150/540) by slurry coating.
    [4]
    4. The gas turbine component of claim 1 further comprising a third layer (160/550) applied to the first layer (140/530) by thermal spraying, wherein the second layer (150/540) is slurry coated onto the third layer (160). 160/550) is applied.
    [5]
    The gas turbine component of claim 1, wherein the first layer (140/230/330/430/530) comprises a rare earth disilicate.
    [6]
    A gas turbine component according to claim 1, wherein the second layer (150/235/440/540) comprises a rare earth monosilicate.
    [7]
    The gas turbine component of claim 1, wherein: the first layer (140/530) comprises a rare earth disilicate applied over the bonding layer (120/520), wherein the first layer (140/530) comprises a sintering agent, and the second layer (150/235/440/540) comprises a rare earth monosilicate applied to the first layer (140/530) by slurry coating.
    [8]
    The gas turbine engine component of claim 7, further comprising: a barium-strontium aluminosilicate layer (540) applied to the first layer (140/530) by thermal spraying.
    [9]
    A gas turbine component according to claim 7, wherein the sintering agent is mixed in the first layer (140/530).
    [10]
    The gas turbine component of claim 7, wherein the first layer (140/530) comprises: a first portion of the first layer (140/530) applied by thermal spraying over the bonding layer (120/520) and a second portion of the first layer (140/530) first layer (140/530) applied by slurry coating to the first portion of the first layer (140/530).
    [11]
    A gas turbine component according to claim 10, wherein the first part comprises the sintering agent.
    [12]
    The gas turbine component of claim 10, wherein the sintering agent is applied to the first part of the first layer (140/530) before the second part of the first layer (140/530) is applied to the first part of the first layer (140/530) is.
    [13]
    13. A method of coating a gas turbine component, comprising: applying a bonding layer (120/220/320/420/520) to a substrate (110/210/310/410/510) of the gas turbine component, applying a first layer (140/230 / 330/430/530) by thermal spraying over the bonding layer (120/220/320/420/520), the first layer (140/230/330/430/530) comprising a sintering agent; and applying a second layer (150/235/440/540) by slurry coating over the first layer (140/230/330/430/530).
    [14]
    14. The method of claim 13, further comprising applying the sintering agent (332) as a solution to a first part (331) of the first layer (330) before applying a second part (333) of the first layer (330).
    [15]
    The method of claim 13, further comprising applying a third layer (160/550) by slurry coating onto the second layer (150/540).
    [16]
    16. The method of claim 13, further comprising applying a third layer (160/550) to the first layer (140/530) by thermal spraying, wherein the second layer (150/540) is slurry coated onto the third layer (160/530). 550) is applied.
    [17]
    The method of claim 13, wherein the first layer (140/230/330/430/530) comprises a rare earth disilicate.
    [18]
    The method of claim 13, wherein the second layer (150/235/440/540) comprises a rare earth monosilicate.
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    DE112013003838T5|2015-04-30|
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    法律状态:
    2017-03-15| NV| New agent|Representative=s name: GENERAL ELECTRIC TECHNOLOGY GMBH GLOBAL PATENT, CH |
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