• 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:
    The invention relates to a method for the production of a coating (206). The method of making the coating (206) comprises providing an iron-based alloy substrate (202) and depositing a protective coating (206) on a surface of the iron-based substrate (202). The protective coating (206) comprises a cobalt-chromium-based coating material (212) having at least one anodic element (214) dispersed therein. The at least one anodic element (214) is anodic with respect to the iron-based alloy substrate (202). Such coated substrates can be used for example for hot gas path components of gas turbines and aircraft engines.
    公开号:CH710306A2
    申请号:CH01522/15
    申请日:2015-10-19
    公开日:2016-04-29
    发明作者:Calla Eklavya；Anand Krishnamurthy；Singh Pabla Surinder
    申请人:Gen Electric；
    IPC主号:
    专利说明:

    FIELD OF THE INVENTION
    The present invention is directed to a coated article and a process for the preparation of a coating. More specifically, the present invention is directed to an anodic-coated article and a method of making an anodic coating.
    STATE OF THE ART
    Hot gas path components of gas turbines and aircraft engines, in particular turbine blades, vanes, nozzles, seals and stationary shells, are at elevated temperatures, often of over 2,000 ° F, in operation. These components are typically formed from iron-based alloy compositions such as martensitic stainless steels.
    Frequently, the hot gas path components are provided with protective coatings to reduce wear, erosion, corrosion and / or degradation during operation. For example, to reduce or eliminate erosion and wear of gas and steam turbine components, particularly backside gas turbine compressor blades and blades, an erosion resistant or abrasion resistant coating may be deposited on the components. However, the erosion-resistant or abrasion-resistant coating may not provide protection against corrosion of the component.
    Even in the absence of an erosion-resistant or abrasion-resistant coating, the martensitic stainless steels may undergo corrosion due to material deposits formed on the surface of the component during operation (e.g., soiling). In addition, the martensitic stainless steels may be anodic with respect to many of the erosion resistant or abrasion resistant coatings. If it is present, the galvanic incompatibility of the component and the coating increases the corrosion rate of the component.
    Articles and methods having improvements in the process and / or properties of the components formed would be desirable in the art.
    BRIEF DESCRIPTION OF THE INVENTION
    [0006] In one embodiment, the method of making a coating comprises providing an iron-based alloy substrate and depositing a protective coating on a surface of the iron-based substrate, the protective coating comprising a cobalt-chromium-based coating material and at least one having anodic element distributed therein. The at least one anodic element is anodic with respect to the iron-based alloy substrate.
    [0007] In another embodiment, a method of making a coating comprises providing an iron-based alloy substrate, depositing a sub-layer on a surface of the iron-based alloy substrate, the sub-layer comprising at least one anodic element, and depositing a topcoat over the substrate Underlayer wherein the topcoat comprises a cobalt-chromium based coating material. The at least one anodic element is anodic with respect to the iron-based alloy substrate.
    [0008] In another embodiment, a coated article comprises an iron-based alloy substrate and a protective coating deposited on a surface of the iron-based alloy substrate, the protective coating comprising a cobalt-chromium-based coating material comprising at least one anodic element distributed therein. The at least one anodic element is anodic with respect to the iron-based alloy substrate and the protective coating comprising the at least one anodic element forms an anode with respect to the iron-based alloy substrate. The protective coating reduces the galvanic corrosion of the iron-based alloy substrate.
    Other features and advantages of the present invention will become apparent from the following more particular description when taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
    BRIEF DESCRIPTION OF THE DRAWINGS
    [0010]<Tb> FIG. 1 <SEP> is a perspective view of a coated article.<Tb> FIG. Figure 2 is a sectional view taken along lines 2-2 of Figure 1 of the coated article, according to one embodiment of the disclosure.<Tb> FIG. 3 <SEP> is an improved view of a coating deposited from the coated article of FIG. 2 according to an embodiment of the disclosure.<Tb> FIG. Figure 4 is a sectional view of a coated article including a backsheet and a topcoat of one embodiment of the disclosure.
    As far as possible, the same reference numbers are used throughout the drawings to represent the same parts.
    DETAILED DESCRIPTION OF THE INVENTION
    There is provided a coated article and a method of making a coated article. Embodiments of the present disclosure, as compared to methods and articles wherein one or more of the features disclosed herein are not used, reduce component corrosion, increase electrodepositability, maintain wear resistance of a coating, or substantially maintain efficiency , extend a period of time between inspection, increase the service life, reduce the maintenance costs, provide a one-step coating process for corrosion and erosion protection, permit wet compression in gas turbines, or a combination thereof.
    When introducing elements of various embodiments of the present invention, the articles "a," "an," "the" and "said" mean that one or more of the elements are present. The terms "comprising," "including," and "having" are intended to be inclusive, meaning that additional elements other than the listed elements may be present.
    Referring to Fig. 1, a coated article 100 is shown. The coated article includes, but is not limited to, a turbine component, a hot gas path component, a rotating component, or a combination thereof. For example, in one embodiment, the coated article 100 includes a compactor cup 102. In another embodiment, the coated article 100 includes a backside or last-stage cup. Other coated articles 100 may include a compressor blade, a centrifugal pump impeller, a pipeline, or a combination thereof. The term "cup," as used herein, is intended to be synonymous with the term "shovel."
    Referring to FIGS. 2-4, in one embodiment, the coated article 100 includes a substrate 202 that defines a substrate surface 204 and a coating 206 on the substrate surface 204. The substrate 202 includes any substrate material having a mechanical strength suitable for the operating conditions of the coated article 100. Suitable substrate materials include, but are not limited to, nickel-based alloys, iron-base alloys, ferrous materials, superalloys, or a combination thereof. As used herein, a nickel-base alloy is an alloy having an amount of nickel higher than any other element, and an iron-based alloy is an alloy having an amount of iron higher than any other element. For example, in another embodiment, the substrate 202 is formed from a martensitic stainless steel having a nominal composition, by weight, of about 15.5% chromium, about 6.3% nickel, about 1.5% copper, about 0.4% niobium , about 0.05% carbon, the remainder consisting essentially of iron and incidental impurities. Other suitable compositions for forming the substrate 202 include, but are not limited to, percent by weight, from about 11.0% to about 12.5% chromium, from about 2.0% to about 3.0% nickel, about 1.5%. to about 2.0% molybdenum, about 0.5% to about 0.9% manganese, about 0.25% to about 0.40% vanadium, about 0.08% to about 0.15% carbon, about 0, From about 0% to about 0.05% nitrogen, up to about 0.35% silicon, with the balance consisting essentially of iron and incidental impurities; about 0.15% carbon, about 1.00% manganese, about 0.50% silicon, about 11.5% to about 13.0% chromium, about 0.04% phosphorus, about 0.03% sulfur, wherein the Remainder consisting essentially of iron and incidental impurities; or a combination of them.
    The coating 206 includes any protective coating, such as, but not limited to, an antisoiling coating, an erosion control coating, an anticorrosive coating, or a combination thereof. As used herein, the term "protective coating" refers to a layer of material positioned over an article, such as substrate 202, to reduce or eliminate erosion, wear and / or corrosion of the article. In an embodiment, the coating 206 comprises a coating material 212 and at least one anodic element 214. The coating material 212 comprises any material suitable for reducing or eliminating erosion and / or wear of the substrate 202.
    Suitable coating materials include wear resistant coating materials such as, but not limited to, cobalt-chromium (CoCr) based alloys, WC-CoCr based alloys, or a combination thereof. As used herein, a cobalt-chromium based alloy is an alloy that has a combined amount of cobalt and chromium that is higher than any other element. In addition, as used herein, an alloy based on tungsten carbide-cobalt-chromium is an alloy that has a combined amount of tungsten carbide, cobalt, and chromium that is higher than any other element. For example, an alloy based on tungsten-carbide-cobalt-chromium, by weight, comprises from about 80% to about 95% (eg, 83% or 92%) of tungsten carbide, with the balance consisting of either cobalt or cobalt-chromium, wherein the chromium is present in an amount of about 4%.
    Compositions of the CoCr-based coatings include, for example, in weight percent, from about 27% to about 32% chromium, from about 4% to about 6% tungsten, from about 0.9% to about 1.4% carbon, up to about 3% nickel, up to about 3% iron, up to about 3% silicon, up to about 2% manganese, up to about 1.5% molybdenum, the balance consisting essentially of cobalt and incidental impurities; about 29.8% to about 30.2% chromium, about 5.9% to about 6.1% tungsten, about 1.05% to about 1.15% silicon, about 1.4% to about 1.5% Carbon, from about 0.5% to about 1.3% nickel, up to about 0.1% iron, up to about 0.1% manganese, from about 0.4% to about 0.6% molybdenum, with the balance being in the Consists essentially of cobalt and incidental impurities; from about 28% to about 31% chromium, from about 8% to about 9% tungsten, from about 1.4% to about 1.85% carbon, from about 1% to about 2% silicon, from about 0.5% to about 1.5 % Manganese, up to about 3% nickel, up to about 2.5% iron, the remainder being cobalt and incidental impurities; about 29.5% chromium, about 8.5% tungsten, about 1.4% to about 1.85% carbon, about 1.5% silicon, about 1% manganese, about 3% nickel, up to about 2.5 % Iron, the balance consisting essentially of cobalt and incidental impurities; about 31% to about 35% chromium, about 16% to about 19% tungsten, about 2.3% to about 2.6% carbon, about 0.5% to about 1.5% silicon, about 0.5% to about about 1.5% manganese, up to about 2.5% nickel, up to about 2.5% iron, the balance consisting essentially of cobalt and incidental impurities; about 33% chromium, about 17.5% tungsten, about 2.45% carbon, about 1% silicon, about 1% manganese, up to about 2.5% iron, up to about 2.5% nickel, with the balance consisting essentially of cobalt and incidental impurities; about 29.8% to about 30.2% chromium, about 6.9% to about 7.1% tungsten, about 0.95% to about 1.05% silicon, about 1.45% to about 1.55% Carbon, from about 4.1% to about 4.9% nickel, up to about 0.1% iron, up to about 0.5% manganese, from about 1.9% to about 2.1% molybdenum, with the balance being in the Consists essentially of cobalt and incidental impurities, or a combination thereof. The at least one anodic element 214 includes any element that is anodic with respect to the substrate 202. For example, elements that are anodic with respect to iron-based alloys include, but are not limited to, aluminum (Al), zinc (Zn), lithium (Li), or a combination thereof.
    Referring to FIGS. 2-3, in one embodiment, the coating 206 includes the at least one anodic element 214 distributed throughout the coating material 212. In another embodiment, the at least one anodic element 214 is distributed by the coating material 212 in elemental form as opposed to, for example, in oxide form. As illustrated in FIG. 3, in another embodiment, the at least one anodic element 214 in elemental form comprises particles that have a polygonal, flattened, and / or spherical geometry while the coating material 212 comprises spherical particles. When the coating 206 is cold sprayed and / or thermally sprayed and the at least one anodic element 214 is distributed in elemental form by the coating material 212, the sprayed coating formed therefrom is free or substantially free of precipitates such that tungsten (W) and or tungsten carbide (WC), but not limited to being precipitated. Subsequent heat treatment of the coating 206 forms the precipitates which provide protection against erosion and / or erosion. In one embodiment, the heat treatment comprises a multi-step heat treatment, including heating the coated article 100 to about 1100 ° C and holding the coated article 100 at about 1100 ° C for about 4 hours; cooling the coated article 100 to about 800 ° C and holding the coated article 100 at about 800 ° C for about 8 hours; then cooling the coated article 100 to room temperature. Other heat treatments include, but are not limited to, one-step heat treatment cycles including temperatures of, for example, about 450 ° C, about 800 ° C, and / or about 1100 ° C.
    Forming the coating 206, including the at least one anodic element 214 dispersed throughout the coating material 212, includes mixing / mixing the at least one anodic element 214 with the coating material 212 prior to depositing the coating 206 and / or simultaneously depositing the at least one anodic element 214 and the coating material 212. For example, in one embodiment forming the coating 206 comprises mixing the at least one anodic element 214 with the coating material 212 to form a coating mixture, then depositing the coating mixture to at least a portion of the substrate surface 204. Settling the coating composition includes, but is not limited to, cold spraying, thermal spraying, or a combination thereof. In another embodiment, forming the coating 206 includes providing separate sources of the at least one anodic element 214 and the coating material 212, then simultaneously depositing the at least one anodic element 214 and the coating material 212 over at least a portion of the substrate surface 204. Simultaneous settling For example, vapor deposition includes, but is not limited to, chemical vapor deposition, electron beam vapor deposition, physical vapor deposition, or a combination thereof. During simultaneous settling, the at least one anodic element 214 and the coating material 212 are mixed to form the coating 206 comprising the at least one anodic element 214 dispersed throughout the coating material 212.
    The coating 206 comprises any suitable amount of the at least one anodic element 214 distributed throughout the coating material 212 to shift a total potential of the coating 206 from the cathodic to the anodic with respect to the substrate 202. Suitable amounts of the at least one anodic element 214 comprise, by volume, from about 1.5% to about 30%, from about 3% to about 30%, from about 5% to about 30%, from about 8% to about 30%, from about 3% to about 25%, about 1.5% to about 15%, about 1.5% to about 14%, about 3% to about 14%, about 10% to about 20%, about 5% to about 14%, about 1, 5% to about 10%, about 3% to about 10%, about 8% to about 15%, about 8% to about 14%, about 10% to about 15%, about 5% to about 10%, about 10% to about 14%, about 8% to about 12%, or any combination, subcombination, any range, or subset thereof. For example, in one embodiment, the coating material 212 comprises, by weight, from about 0.1% to about 30% Al, from about 0.5% to about 30%, from about 1% to about 30% Al, from about 2% to about 30 % Al or any combination, sub-combination, any area or sub-area thereof. By shifting the total potential of the coating 206, the at least one anodic element 214 increases the galvanic compatibility of the coating 206 such that the coating 206 is sacrificed at the expense of the substrate 202. Thus, the increased galvanic compatibility reduces or eliminates the corrosion (e.g., cracking, pitting) of the substrate 202, which increases the life and / or reliability of the coated article 100.
    In addition, the at least one anodic element 214 increases the galvanic compatibility between the coating 206 and the substrate 202 without reducing or significantly reducing the wear resistance of the coating material 212. As used herein, "without reducing or substantially reducing the abrasion resistance of the coating material," the addition of the at least one anodic element 214 means the hardness value of the coating composition 212 by less than about 15%, less than about 12%, less than about 10 %, less than about 5%, about 4%, to about 11% or a combination, subcombination, area or subregion thereof reduced. For example, by mixing about 12% by volume of aluminum with the CoCr-based coating material, the coating 206 comprising about 2.5% by weight of aluminum and the hardness value of the coating 206 of a Vickers hardness HV0.3 of about 914 are formed reduces HVO, 3 of about 871 (ie, less than about 5%). In another example, by mixing about 21% by volume of aluminum with the CoCr-based coating material, the coating 206 comprising about 5% by weight of aluminum and the hardness value of the coating 206 of HV0.3 from about 914 to HV0 are formed 3 reduced from about 821 (ie less than about 10%).
    Referring to FIG. 4, in one embodiment, the coating 206 includes the at least one anodic element 214 deposited between the substrate surface 204 and the coating material 212. In another embodiment, forming the coating 206 includes depositing the at least one anodic element 214 on the substrate surface 204 to form a sub-layer, then depositing the coating material 212 on the sub-layer to form a topcoat. In a further embodiment, the underlayer comprises the at least one anodic element 214 which is deposited in elemental form. The at least one anodic element 214 includes any element that is anodic with respect to the substrate 202, such as, but not limited to, Al, Zn, Ni-Al, or a combination thereof. The at least one anodic element 214 and the coating material 212 may be deposited by any of the settling methods disclosed herein. For example, settling of the at least one anodic element 214 may include cold spraying or thermal spraying, while settling of the coating material 212 may include cold spraying or high velocity flame spraying (HVOF). The at least one anodic element 214 is deposited to an appropriate thickness to increase the galvanic compatibility between the coating 206 and the substrate 202. Suitable underlayer thicknesses include, but are not limited to, about 1 to about 4 mils, about 1.5 to about 3.5 mils, about 2 to about 3 mils, or any combination, subcombination, range, or subregion thereof. The overall thicknesses of the coating 206 (ie, the backsheet and topcoat) include, but are not limited to, about 2 to about 5 mils, about 2.5 to about 4.5 mils, about 3 to about 4 mils, or any combination, subcombination , any area or subarea thereof.
    In one embodiment, the coating 206 is deposited over a leading edge of the compactor cup 102 to form the coated article 100. In another embodiment, the coated article 100 is positioned within a low pressure and / or final stage section of a steam turbine. In another embodiment, the output of the gas turbine is increased by wet compaction, which includes injecting water into the compressor section of the gas turbine. During operation and / or wet compaction, the coating 206 deposited over the leading edge of the compactor cup 102 reduces or eliminates corrosion and / or water droplet erosion of the substrate 202.
    While the invention has been described with reference to one or more embodiments, those skilled in the art will understand that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a specific situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the specific embodiment disclosed herein as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
    权利要求:
    Claims (15)
    [1]
    A method of making a coating 206 comprising:providing an iron-based alloy substrate 202; anddepositing a protective coating 206 on a surface of the iron-based alloy substrate 202, the protective coating 206 comprising a cobalt-chromium-based coating material 206 having at least one anodic element 214 dispersed therein;wherein the at least one anodic element 214 is anodic with respect to the iron-based alloy substrate 202.
    [2]
    2. The method of claim 1, wherein the at least one anodic element 214 is selected from the group consisting of elemental aluminum, elemental zinc, and combinations thereof.
    [3]
    3. The method of claim 1, further comprising combining the cobalt-chromium-based coating material 212 and the at least one anodic element 214 prior to depositing the protective coating 206.
    [4]
    4. The method of claim 3, wherein the settling of the protective coating 206 is selected from the group consisting of cold spraying, thermal spraying, and combinations thereof.
    [5]
    5. The method of claim 1, wherein the at least one anodic element 214 is deposited separately from the cobalt chromium based coating material 212.
    [6]
    6. The method of claim 5, wherein the at least one anodic element 214 is deposited by deposition from the gas phase.
    [7]
    The method of claim 6, wherein the vapor phase deposition is selected from the group consisting of chemical vapor deposition, electron beam vapor deposition, physical vapor deposition, or a combination thereof.
    [8]
    8. The method of claim 1, further comprising depositing the protective coating 206 to a thickness of between 3 and 4 mils.
    [9]
    9. The method of claim 1, wherein the at least one anodic element 214 comprises particles having a polygonal, flattened and / or spherical geometry.
    [10]
    10. The method of claim 1, wherein a composition of the cobalt chromium based coating material 212 comprises, in weight percent:from about 27% to about 32% chromium;from about 4% to about 6% tungsten;about 0.9% to about 1.4% carbon;up to about 3% nickel;up to about 3% iron;up to about 3% silicon;up to about 2% manganese;up to about 1.5% molybdenum; andthe remainder consisting essentially of cobalt and incidental impurities.
    [11]
    The method of claim 1, wherein the composition of the cobalt chromium-based coating material 212 comprises, in weight percent:from about 29.8% to about 30.2% chromium;about 5.9% to about 6.1% tungsten;approximately. 1.05% to about 1.15% silicon;from about 1.4% to about 1.5% carbon;about 0.5% to about 1.3% nickel;up to about 0.1% iron;up to about 0.1% manganese;from about 0.4% to about 0.6% molybdenum; andthe remainder consisting essentially of cobalt and incidental impurities.
    [12]
    The method of claim 1, wherein composition of the cobalt chromium-based coating material 212 comprises, in weight percent:from about 29.8% to about 30.2% chromium;about 6.9% to about 7.1% tungsten;about 0.95% to about 1.05% silicon;from about 1.45% to about 1.55% carbon;from about 4.1% to about 4.9% nickel;up to about 0.1% iron;up to about 0.5% manganese;from about 1.9% to about 2.1% molybdenum; andthe remainder consisting essentially of cobalt and incidental impurities.
    [13]
    13. The method of claim 1, wherein a volume fraction of the at least one anodic element 214 comprises about 10% to about 30%.
    [14]
    14. The method of claim 1, wherein a volume fraction of the at least one anodic element 214 comprises about 1.5% to about 14%.
    [15]
    15. The method of claim 1, wherein the protective coating 206 is substantially free of precipitates.
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    同族专利:
    公开号 | 公开日
    CH710306B1|2020-01-15|
    US20160115797A1|2016-04-28|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    ITMI20022056A1|2002-09-27|2004-03-28|Nuovo Pignone Spa|COBALT BASED ALLOY FOR THE COATING OF BODIES SUBJECT TO LIQUID EROSION.|
    US20050220995A1|2004-04-06|2005-10-06|Yiping Hu|Cold gas-dynamic spraying of wear resistant alloys on turbine blades|
    EP1645538A1|2004-10-05|2006-04-12|Siemens Aktiengesellschaft|Material composition for the production of a coating of a metallic component and coated metallic component|
    US20110041515A1|2007-10-18|2011-02-24|Michael Lee Fraim|High Efficiency, Corrosion Resistant Heat Exchanger and Method of Use Thereof|
    US9365932B2|2012-06-20|2016-06-14|General Electric Company|Erosion and corrosion resistant coatings for exhaust gas recirculation based gas turbines|US10513929B2|2017-08-31|2019-12-24|Pratt & Whitney Canada Corp.|Compressor turbine blade airfoil profile|
    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 |
    2021-05-31| PL| Patent ceased|
    优先权:
    申请号 | 申请日 | 专利标题
    US14/524,381|US20160115797A1|2014-10-27|2014-10-27|Coated article and method for producing coating|
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