专利摘要:
An inlet seal (105), which has a metallic substrate (203) and a multilayer ceramic coating (201) on the metallic substrate (203). The multilayer ceramic coating contains a base layer (207) which is deposited on the metallic substrate (203), a running-in layer (209) which covers the first layer (207), and an abrasive layer (211) which covers the second layer (209 ) covered. The abrasive layer (211) is made from an abrasive material. A turbine system and a method for producing an inlet seal (105) are also disclosed.
公开号:CH710176B1
申请号:CH01323/15
申请日:2015-09-11
公开日:2020-06-30
发明作者:Singh Pabla Surinder;Stephane Leblanc Luc;Earl Floyd Donald
申请人:Gen Electric;
IPC主号:
专利说明:

FIELD OF THE INVENTION
The present invention relates to a method for producing inlet seals. More particularly, the present invention relates to a method of making an inlet seal that has abradable and abrasive properties.
BACKGROUND OF THE INVENTION
Many systems, for example in gas turbines, are exposed to thermal, mechanical and chemically aggressive environments. For example, in the compression section of a gas turbine, atmospheric air is compressed up to 10-25 times atmospheric pressure and adiabatically heated to about 426.67 ° C (800 ° F) to about 676.67 ° C (1250 ° F) in the process. This heated and compressed air is directed into a combustion chamber, where it is mixed with fuel. The fuel is ignited and the combustion process heats the gases to very high temperatures that exceed approximately 1648.89 ° C (3000 ° F). These hot gases flow through the turbine, where airfoils attached to rotating turbine disks draw energy to drive the turbine fan and compressor, and through the exhaust system, the gases providing sufficient energy to rotate a generator rotor to produce electricity to create. Tight seals and a precisely controlled flow of hot gases ensure efficiency during operation. Achieving such tight seals in the case of turbine seals and precisely directed flow may be problematic and costly to manufacture.
In operation, the turbine housing (shroud) remains stationary with respect to the rotating blades. The highest levels of efficiency can usually be achieved by maintaining a minimum threshold gap between the shroud and the blade tips in order to avoid an undesirable “leakage flow” of hot gas over the tip of the blades. Increased clearance gaps lead to leakage problems and bring about significant reductions in the overall efficiency of the gas turbine.
Attempts have been made to minimize the clearance gap to increase efficiency while avoiding excessive wear on the turbine blade tips. For example, some conventional turbine engines use thermal barrier coatings (TBCs) on the ring seal segments. Ceramic materials are usually used as TBC materials because of their high temperature resistance and their low thermal conductivity. Known run-in coating systems use thermal barrier coatings that are designed so that part of the coating is ground away when it comes into contact with a turbine blade, so that damage to the turbine blade is prevented. The thermal insulation layers also isolate the underlying turbine components from the hot gases present during operation, the temperature of which can exceed 1093.33 ° C (2000 degrees Fahrenheit). The thermal insulation layers keep the temperature of the underlying turbine component at a much lower temperature.
The need to maintain an adequate gap without a significant loss in efficiency is complicated by the fact that the gap between a rotor blade tip and the shroud may not be uniform over the entire circumference of the shroud. Non-uniformity is due to a number of factors, including machining tolerances, stacking tolerances, and uneven expansion due to changes in thermal mass and thermal response. Such non-uniformity leads to a deviation in the length of the turbine blade and its impact on the inlet coating, so that there is an uneven abrasion of the inlet coating. Known systems minimize the gap and construction in view of blade tip non-uniformity while avoiding turbine blade tip damage.
Another known problem with run-in coatings is that the coatings wear through sintering after being exposed to turbine engine operating temperatures for an extended period of time. The ability of the run-in coating to shear when it comes into contact with turbine blade tips is significantly reduced by sintering the run-in coating. In the case of high temperature operation, zirconia (YSZ) stabilized with yttrium oxide becomes unstable and the abrasion and shrinking properties of the coating are reduced.
Thus, there is a need for a run-in coating that copes with the non-uniform rotor blade length, provides sufficient insulation for the underlying substrate, allows abrasion of the run-in coating under operating conditions, adheres to the substrate, and enables long-term reliability and improved efficiency. In the art, an inlet seal and a method of manufacturing an inlet seal would be desirable that do not have one or more of the disadvantages mentioned above.
SUMMARY OF THE INVENTION
The invention relates to an inlet seal which has a metallic substrate and a multilayer ceramic coating on the metallic substrate. The multi-layer ceramic coating includes a base layer that is deposited on the metallic substrate, a run-in layer that covers the first layer, and an abrasive layer that covers the second layer. The abrasive layer is made from an abrasive material.
In one embodiment of the inlet seal, it may be advantageous that the inlet seal between the substrate and the multilayer ceramic coating additionally has a bonding layer.
In one embodiment of the inlet seal, it may be advantageous for the binding layer to be an MCrAlX overlay coating.
In one embodiment of the inlet seal, it may be advantageous for the base layer to have a ceramic layer made of a material selected from the group consisting of zirconia, which is stabilized with cerium oxide, zirconia, which is stabilized with magnesia, zirconia which is stabilized with calcium oxide, zirconia which is stabilized with yttrium oxide and mixtures thereof.
In one embodiment of the inlet seal, it may be advantageous for the base layer to have zirconia (YSZ) stabilized with yttrium oxide and containing about 7 to about 8% by weight of yttrium oxide.
In one embodiment of the inlet seal, it can be advantageous for the base layer to have a microstructure with dense vertical microcracks.
In one embodiment of the inlet seal, it may be advantageous for the inlet layer to have zirconia (YSZ) stabilized with yttrium oxide with approximately 18 to approximately 20% by weight yttrium oxide.
In one embodiment of the inlet seal, it can be advantageous for the inlet layer to have a microstructure with dense vertical microcracks.
[0016] In one embodiment of the inlet seal, it can be advantageous for the inlet layer to have Yb4Zr3O12.
In one embodiment of the inlet seal, it can be advantageous for the inlet layer to be arranged in a geometric pattern.
In one embodiment of the inlet seal, it can be advantageous that the geometric pattern is a diamond pattern.
In one embodiment of the inlet seal, it may be advantageous that the geometric pattern is a toothed pattern.
In one embodiment of the inlet seal, it may be advantageous for the abrasive material to be yttria-stabilized zirconia (YSZ) containing about 7 to about 8 wt% yttria.
In one embodiment of the inlet seal, it can be advantageous that the base layer and the abrasive layer are formed from the same material.
[0022] The invention further relates to a turbine system which has a plurality of rotating components and an inlet seal. The inlet seal contains a metallic substrate and a multilayer ceramic coating on the metallic substrate. The multilayer ceramic coating includes a base layer deposited on the tie layer, a run-in layer covering the first layer, and an abrasive layer covering the second layer. The abrasive layer is made from an abrasive material. The rotating components and inlet seal are set up and arranged to bring the inlet seal into contact with the rotating component.
[0023] The invention further relates to a method for producing an inlet seal. The process includes the following steps: depositing a multilayer ceramic coating on the metallic substrate. The multilayer ceramic coating contains a base layer that is deposited on the bonding layer, a run-in layer that covers the first layer, and an abrasive layer that covers the second layer. The abrasive layer is made from an abrasive material.
In one embodiment of the method, it may be advantageous that the method additionally has the step of bringing the multilayer ceramic coating into contact with a rotating component.
In one embodiment of the method, it can be advantageous for the component to be a turbine blade.
In one embodiment of the method, it can be advantageous for the coating to include structuring in the run-in layer to form a geometric pattern.
Further features and advantages of the present invention will become apparent from the following more detailed description of the preferred embodiment in conjunction with the accompanying figures which illustrate the principles of the invention by way of examples.
BRIEF DESCRIPTION OF THE DRAWINGS
1 shows an exemplary turbine arrangement having an inlet seal, according to an embodiment of the disclosure.
2 shows an exemplary seal arrangement that has multiple layers disposed on a substrate, according to an embodiment of the disclosure.
3 illustrates grinding of the rotating member enabled by the inlet seal, according to an embodiment of the disclosure.
Figure 4 illustrates removal data showing comparable removal rates for different layers stabilized by YSZ.
Figure 5 illustrates removal data showing comparable removal rates for different layers stabilized by YSZ.
Wherever possible, the same reference numerals are used to designate corresponding parts throughout the drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0034] An inlet seal and a method for producing an inlet seal are provided, which have properties of abradability and abrasion. Compared to similar concepts that disadvantageously lack one or more of the features described herein, embodiments of the disclosure provide a tight seal in the context of turbine systems that include systems with non-uniform rotor blade length. In addition, the inlet seal, according to the disclosure, maintains insulating properties, allows the inlet coating to abrade, and adheres to the substrate under turbine system operating conditions, allowing longer term reliability and improved gas turbine efficiency.
FIG. 1 shows a schematic sectional view of a turbine section of a gas turbine system 100, viewed in the direction of a central axis of the axis of rotation. The gas turbine system 100 contains a stationary component 101, for example a cover band, which surrounds a rotor 103. The stationary component 101 is any suitable component that remains in a fixed position with respect to a rotating component.
An inlet seal 105 is arranged on the stationary component 101. Rotating components 107 are fastened to the rotor 103. The rotating components 107 are suitable turbine blades or turbine blades. The terms "blade" and "shovel" are used interchangeably here. During the rotation of the rotor 103, the rotating components 107 touch the inlet seal 105 or almost come into contact with it.
2 shows a sectional schematic view of an inlet seal 105 according to an embodiment. The inlet seal 105 is based on a multilayer ceramic coating 201 on a metallic substrate 203. In the sense used here, the term “metallic” is intended to include metals, alloys, composite metals, intermetallic materials, or any combination thereof. In one embodiment, substrate 203 contains or is stainless steel. In another embodiment, substrate 203 contains or consists of a nickel-based alloy. Other suitable alloys include, but are not limited to, cobalt-based alloys, chromium-based alloys, carbon steel, and combinations thereof. Suitable metals include, but are not limited to, titanium, aluminum, and combinations thereof. In one embodiment, the metallic substrate 203 is arranged on an inner surface of the stationary component 101, the inner surface being the surface which faces the rotor 103. However, the metallic substrate 203 is not so limited and includes other suitable surfaces. In the embodiment shown in FIG. 2, the inlet seal 105 contains a binding layer 205 between the multilayer ceramic coating 201 and the metallic substrate. The binding layer 205 contains, for example, MCrAlY, where M is nickel (Ni), cobalt (Co), iron (Fe) or some Combinations of these, or an intermetallic phase of beta NiAl. The binding layer 205 can be produced, for example, but without wishing to be restricted thereto, from materials such as powders, for example CoCrAlY, NiCrAlY, CoNiCrAlY and rhenium, which contains variants and other suitable materials.
The multilayer ceramic coating 201, which covers the binding layer 205, has a base layer 207. The base layer 207 contains a thermal barrier material. The thermal barrier coating material contains, for example, barium strontium aluminum silicate or zirconia, which is partially stabilized with yttrium oxide. In one embodiment, the base layer 207 contains less than about 10 wt% yttria, or about 6 wt% to about 8 wt% yttria, or about 7 wt% to about 8 wt% yttria. Likewise, while yttria is disclosed as a suitable stabilizer, other stabilizers can be used, e.g. Erbium oxide, gadolinium oxide, neodymium oxide, ytterbium (III) oxide, lanthanum oxide and / or dysprosium oxide. The partial stabilization of the YSZ with 6 to 8 wt .-% yttrium oxide (for example less than about 10 wt .-% YSZ) results in a layer that adheres better under conditions of high temperature cycling and is more resistant to splitting than a YSZ thermal insulation layer with higher proportions of yttrium oxide. In addition, the YSZ partially stabilized (e.g., with less than about 10 wt% YSZ) is more resistant to erosion than fully stabilized YSZ (e.g. with about 20 wt% YSZ). The base layer 207 provides an adhesive coating that is resistant to sintering and cleavage. In one embodiment, the base layer 207 has a microstructure, referred to here as dense vertical microcracks (DVC). Thermally sprayed DVC thermal barrier coatings are described, for example, in US Pat. Nos. 5,073,433; 5 520 516; 5,830,586; 5,897,921; 5,989,343 and 6,047,539, all of which are incorporated by reference in this patent application. Suitable thicknesses for the base layer include less than about 1.905mm (75 thousandths of an inch), from about 0.025mm (1 thousandths of an inch) to about 1.905mm (75 thousandths of an inch), or from about 0.127mm (5 thousandths of an inch) to about 1.27mm (50 thousandths of an inch) ).
In addition, the multilayer ceramic coating 201, as shown in FIG. 2, has a run-in layer 209 which covers the base layer 207. The run-in layer 209 contains a ceramic thermal barrier coating material and has a hardness that is sufficiently low to allow abrasion and / or abrasion of the run-in layer 209 when it comes into contact with rotating components 107. Similar to the base layer 207, the thermal barrier material of the inlet layer 209 contains, for example, barium strontium aluminum silicate or zirconia, which is partially or completely stabilized with yttrium oxide, magnesia, calcium oxide or other stabilizers. In one embodiment, the run-in layer 209 uses yttria as a stabilizer and contains at least 15 wt% yttria and up to about 22 wt% yttria, or about 18% to about 20% yttria. In one embodiment, the run-in layer 209 contains Yb4Zr3O12. Likewise, other stabilizers can also be used, e.g. Erbium oxide, gadolinium oxide, neodymium oxide, ytterbium (III) oxide, lanthanum oxide and / or dysprosium oxide. In one embodiment, the run-in layer 209 has yttria-stabilized zirconia (YSZ) or Yb4Zr3O12 with dense vertical microcracks. Suitable thicknesses for abrasive layer 211 include ranges from about 0.635mm (25 mils) to about 1.905mm (75 mils), from about 1.016mm (40 mils) to about 1.524mm (60 mils) or about 1.270mm (50 mils) . In addition, the run-in layer 209 is temperature resistant and maintains the properties of grindability and thermal conductivity under the operating conditions of a gas turbine. The fully stabilized YSZ (e.g. zirconia, which contains about 20% by weight yttrium oxide) provides a material with low thermal conductivity, for example 20-30% or 25-30% or about 30% lower thermal conductivity compared to partially stabilized YSZ (eg YSZ with about 8% by weight of yttrium oxide) and greater grindability if it comes into contact with the rotating components 107. In one embodiment, the run-in layer 209 has a DVC microstructure. As used herein, "grindable" and "grindable" means that the material has the property of being grinded or abraded to form a friction path when it comes into contact with rotating components 107, the rotating components being damaged little or not at all become.
[0040] In one embodiment, the run-in layer 209 is deposited to a geometric pattern. The geometric pattern is designed to achieve sealing and abrasion properties. By “geometric pattern”, it is intended to express that the run-in layer 209 is deposited with raised or protruding sections from the underlying layer, a pattern being formed that is repeated and visible from above. The geometric pattern can include, but is not intended to be limited to, patterns such as, for example, a rhombus, web, hexagon, ellipse, circle, triangle, rectangle, or other suitable geometric pattern. In one embodiment, the raised or protruding portions of the geometric pattern above the underlying layer extend less than or equal to about 1,651mm (0.065 inches) or less than or equal to about 0.889mm (0.035 inches) or less than or equal to about 0.381mm ( 0.015 inches).
The multilayer ceramic coating contains an abrasive layer 211, which covers the running-in layer 209. The abrasive layer 211 contains a thermal barrier material. In one embodiment, abrasive layer 211 is of sufficient hardness to abrade the rotating components that come in contact with abrasive layer 211. In the sense used here, “abrasive” is to be used to express that the material has the property of eroding or removing rotating components 107 when it comes into contact with the rotating components 107. Similar to the base layer 207, the thermal barrier material of the abrasive layer 211 contains, for example, barium strontium aluminum silicate or zirconia, which is partially stabilized with yttrium oxide. In one embodiment, abrasive layer 211 contains less than about 10 wt% yttria, or about 7 wt% to about 8 wt% yttria. Likewise, while yttria is disclosed as a suitable stabilizer, other stabilizers can be used, e.g. Erbium oxide, gadolinium oxide, neodymium oxide, ytterbium (III) oxide, lanthanum oxide and / or dysprosium oxide. The abrasive layer 211 is configured to minimize the gap between the rotating components 107 and the stationary component 101, optionally grinding the rotating components that strike the layer due to non-uniform length, particularly while the turbine components, e.g. during a warm restart, in different expansion states. The amount and rate of ablation will depend on the degree of non-uniformity of the rotating components 107. The thickness of the abrasive coating is sufficient to provide abrasive properties and allow ablation to expose the run-in layer 209. Suitable thicknesses for abrasive layer 211 include less than 0.254mm (10 mils), from about 0.0254mm (1 mils) to about 0.254mm (10 mils), or from about 0.0254mm (1 mils) to about 0.127mm (5 In one embodiment, the abrasive layer 211 has a DVC microstructure, in one embodiment the abrasive layer 211 has a porous structure, in one embodiment the abrasive layer 211 contains the same material as the base layer 207. In another embodiment, it contains abrasive layer 211 is a material that differs from base layer 207.
Fig. 3 shows a method of using the inlet seal 105, for example when starting up the gas turbine. As shown in FIG. 3, the rotating component 107 has a tip region 301, which comes into contact with the inlet seal 105 on the abrasive layer 211. While the rotating component 107 comes into contact with the abrasive layer 211, the tip region 301 of the rotating component 107 is ground off. In addition, the abrasive layer 211 is removed from the inlet seal 105. With further rotation, the rotating components 107 continue to touch the inlet layer 209 and grind a sealing path in the inlet layer 209. The grinding of the tip region 301 changes the length of the rotor blade, so that the rotor blade length becomes more uniform. The greater uniformity of the rotor blade length results in a small or no gap between the rotating component 107 and the inlet seal 105.
The application of the base layer 207, the running-in layer 209 and the abrasive layer 211 can be achieved by any suitable coating method which is known for the application of TBC materials. Suitable methods include hot spray application (e.g. air plasma spraying (APS) and high speed oxygen flame (HVOF) spraying) and physical vapor deposition (PVD) techniques such as electron beam PVD coating (EBPVD). A particularly suitable method for applying the base layer 207, the run-in layer 209 and the abrasive layer 211 is disclosed in US Pat. No. 5,073,433. As a result of this process, the base layer 207, the run-in layer 209 and the abrasive layer 211 each have vertical microcracks, preferably at least twenty five cracks per linear 25.4mm (inch) of the surface, with at least some of the microcracks completely extending through the outer layer extend their interface with the underlying layer.
Figures 4 and 5 illustrate ablation data showing comparative ablation rates for different YSZ stabilized layers. As shown in FIG. 4, the removal of the 8% by weight YSZ (8YSZ), which has dense vertical microcracks (DVC), is significantly less than the zirconia stabilized with 20% by weight yttrium oxide and than the Yb4Zr3O12 (YbZirc) . Figure 5 shows that the removal rates at equivalent temperatures at which the 8YSZ begins to erode substantially when compared to the 20YSZ and the Yb4Zr3O12 when exposed to higher temperatures. As shown, the combination of the 8YSZ and 20YSZ (or Yb4Zr3O12) in the arrangement as described provides the grindability (i.e., ablation) in the run-in layer 209 as well as the desired abrasive properties of the high temperature strength abrasive layer 211.
While the invention has been described with reference to one or more embodiments, it will be apparent to those skilled in the art that various changes can be made and that elements thereof can be substituted by equivalent designs without affecting the scope of the invention. In addition, many modifications can be made to adapt a particular situation or material to the teachings of the invention without departing from the main subject of the invention. It is therefore not intended to limit the invention to the specific embodiment which is considered the most appropriate way of implementing the invention, rather the invention is intended to encompass all embodiments which fall within the scope of the appended claims. In addition, all numerical values used in the detailed description should be interpreted as if the exact and approximated values are both explicitly specified.
An inlet seal that has a metallic substrate and a multilayer ceramic coating on the metallic substrate. The multi-layer ceramic coating includes a base layer that is deposited on the metallic substrate, a run-in layer that covers the first layer, and an abrasive layer that covers the second layer. The abrasive layer is made from an abrasive material. A turbine system and method for making an inlet seal are also disclosed.
权利要求:
Claims (10)
[1]
1. Inlet seal, comprising:a metallic substrate; anda multilayer ceramic coating on the metallic substrate, the multilayer ceramic coating having:a base layer that is deposited on the metallic substrate,a run-in layer covering the first layer, andan abrasive layer covering the second layerwherein the abrasive layer is made of an abrasive material.
[2]
2. The inlet seal as claimed in claim 1, which also contains a bonding layer between the substrate and the multilayer ceramic coating.
[3]
3. Inlet seal according to claim 2, wherein the bonding layer is an MCrAlX overlay coating.
[4]
4. Inlet seal according to one of the preceding claims, wherein the base layer comprises a ceramic layer made of a material selected from the group consisting of zirconia, which is stabilized with cerium oxide, zirconia, which is stabilized with magnesia, zirconia, which is stabilized with calcium oxide is stabilized, zirconia, which is stabilized with yttrium oxide and mixtures thereof.
[5]
5. Inlet seal according to one of the preceding claims, wherein the base layer has yttrium oxide-stabilized zirconia (YSZ), which contains 7 to 8% by weight of yttrium oxide, and / or wherein the abrasive material is zirconia (YSZ) stabilized with yttrium oxide, the 7th contains up to 8 wt .-% yttrium oxide.
[6]
6. inlet seal according to one of the preceding claims, wherein the inlet layer with yttrium oxide stabilized zirconia (YSZ) with 18 to 20 wt .-% yttrium oxide.
[7]
7. The inlet seal according to any one of the preceding claims, wherein the inlet layer contains Yb4Zr3O12.
[8]
8. inlet seal according to one of the preceding claims, wherein the base layer and / or the inlet layer has a microstructure with vertical microcracks.
[9]
9. turbine system, comprising:several rotating components;an inlet seal, comprising:a metallic substrate; anda multilayer ceramic coating on the metallic substrate, a bonding layer between the substrate and the multilayer ceramic coating, the multilayer ceramic coating comprising:a base layer deposited on top of the tie layera run-in layer covering the first layer, andan abrasive layer covering the second layerwherein the abrasive layer is made of an abrasive material;wherein the rotating components and the inlet seal are set up and arranged to bring the inlet seal into contact with the rotating component.
[10]
10. Method of making an inlet seal, comprising the steps:Depositing a multilayer ceramic coating on a metallic substrate having a bonding layer, the multilayer ceramic coating having:a base layer deposited on top of the tie layera run-in layer covering the first layer, andan abrasive layer covering the second layerwherein the abrasive layer is made of an abrasive material.
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同族专利:
公开号 | 公开日
CH710176A2|2016-03-31|
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法律状态:
2017-03-15| NV| New agent|Representative=s name: GENERAL ELECTRIC TECHNOLOGY GMBH GLOBAL PATENT, CH |
2019-05-31| NV| New agent|Representative=s name: FREIGUTPARTNERS IP LAW FIRM DR. ROLF DITTMANN, CH |
优先权:
申请号 | 申请日 | 专利标题
US14/489,686|US20160084102A1|2014-09-18|2014-09-18|Abradable seal and method for forming an abradable seal|
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