DE102011077620A1 - Component, useful in turbomachine and aircraft engine, comprises metallic coating provided on metallic base material, where metallic coating comprises adhesion zone connected with the metallic base material and structure zone - Google Patents

Abstract

The component comprises a metallic coating (1) applied on a metallic base material (11). The metallic coating comprises an adhesion zone (2) connected with the metallic base material, and a structure zone (3) placed over the adhesion zone with structural elements. The adhesion zone and the structure zone consist of the same material. The metallic coating is applied, by an electrical plating-, a spray- and/or a deposition method, on the base material. The structural elements of the structure zone are produced by a laser cladding process, and have an average height of 100-500 mu m. The component comprises a metallic coating (1) applied on a metallic base material (11). The metallic coating comprises an adhesion zone (2) connected with the metallic base material, and a structure zone (3) placed over the adhesion zone with structural elements. The adhesion zone and the structure zone consist of the same material. The metallic coating is applied, by an electrical plating-, a spray- and/or a deposition method, on the base material. The structural elements of the structure zone are produced by a laser cladding process, and have an average height of 100-500 mu m and an average distance of 0.5-2 mm. The structural elements comprise a round cross-section having a large diameter of 50-300 mu m, linear structures with an average width of 50-300 mu m, and an undercut in a transition region of the adhesion zone. A ceramic coating is partially provided on the metallic coating, where the structural elements are partially surrounded by a ceramic material. The component is arranged in a combustion chamber at a wall of a turbine and/or in an inlet area of a high pressure part of the turbine. An independent claim is included for a method for producing a component.

Description

The invention relates to a component with a metallic coating on a metallic base material for use in a turbomachine, an aircraft engine with this component, a method for producing a component and a component producible by a method.

In turbomachinery, such as Aircraft engines or stationary steam or gas turbines, very high operating temperatures are reached during operation. In modern aircraft engines, e.g. up to more than 2,000 K can be achieved. Thereby certain parts of the turbomachine, such as e.g. Combustion chambers or the input area of the turbine in an aircraft engine, subjected to very high thermal loads. Furthermore, these components must additionally withstand high mechanical loads, in particular when starting up a turbine, since the tips of the turbine blades come into contact with the turbine wall at least in the short term.

It is therefore known to coat certain parts of the turbomachine with a mechanically stable, heat-resistant, multilayer coating. From the EP 1 491 658 A1 Such a multi-layer coating is known. On a metallic substrate, a so-called metallic bond-coat layer is applied, on which in turn a ceramic layer is applied. Together, these two layers are also referred to as Thermal Barrier Coating (TBC).

However, the thermal expansion coefficients of the two layers are different, so that under thermal stress mechanical stresses between the metallic bond-coat layer and the ceramic layer can arise

From the US 6,652,227 B2 and the US 6,457,939 B2 Components are known in which the metallic base material is elaborately structured itself in a complex manner to better adhere to a ceramic layer arranged thereon.

Therefore, it makes sense to develop thermally and mechanically stable components that can be produced efficiently and flexibly.

A component according to claim 1 has a metallic coating with an adhesive zone for connection to the metallic base material. In an overlying structural zone structural elements are arranged, wherein the structural elements made of the same material as the metallic coating. The structural elements make it possible to securely connect further layers to the metallic coating. Due to the fact that the metallic coating with the structural elements consists of the same material, there are no additional mechanical stresses due to different thermal expansion coefficients.

Advantageously, an embodiment variant in which the metallic coating is applied to the base material by an electroplating, spraying and / or deposition process. This makes it possible to arrange metallic layers with precisely adjustable thickness even on more complex structures of a component.

An embodiment is particularly advantageous when the structural elements of the structural zone can be produced after application of the material in the adhesive zone by a structuring process, in particular a laser deposition welding process. Even very small structural elements can be produced efficiently and in large numbers by laser deposition welding. Advantageously, the structural elements, measured from the top of the adhesive zone to the tops of the structural elements, have an average height of between 50 and 500 μm.

Advantageously, the structural elements have an average spacing of 0.5 to 2 mm between them.

In advantageous embodiments, the structural elements essentially have a round cross-section, the largest diameter being on average between 50 and 300 μm. Another advantageous embodiment has structural elements with linear structures with a mean width of 50 to 300 .mu.m.

In advantageous embodiments, the metallic coating and the structural elements have a share
M CrAlY with M = Fe, Ni, and / or Co,
M CrAl with M = Fe, Ni, and / or Co,
NiAl, or NiAlPt
on or consist entirely of the materials. These materials are temperature stable and easy to process.

To further increase the temperature stability, at least partially a ceramic coating is arranged in advantageous embodiments on the metallic coating, wherein structural elements are at least partially surrounded by the ceramic material, in particular a ceramic material containing yittrium, zirconium, zirconium oxide, magnesium spinel and / or alumina.

In this case, an advantageous embodiment is provided when the structural elements have an undercut in the transition region to the adhesive zone, which contributes to improving the adhesion with the layers lying above the structural elements.

The object is also achieved by an aircraft engine having the features of claim 9, in which at least one of the described components is used. In particular, the components are arranged in a combustion chamber, on a wall of the turbine and / or in the inlet region of the high-pressure part of the turbine.

Furthermore, the object is achieved by a method for producing a component, wherein a metallic coating is applied to a metallic base material, and then at least partially structural elements made of the same material as the metallic coating are applied to the metallic coating by a patterning process, in particular a laser process ,

In advantageous embodiments, the metallic coating is applied to the metallic base material with an electroplating, plasma spray and / or a deposition process. As materials for the coating and the structural elements in the embodiments advantageously a powder containing a proportion of
M CrAlY with M = Fe, Ni, and / or Co,
M CrAl with M = Fe, Ni, and / or Co,
NiAl, or NiAlPt
used.

The temperature resistance of the components can be increased in particular if, after the structuring of the metallic coating, a ceramic coating is applied, in particular with a ceramic material containing yttrium, zirconium, zirconium oxide, magnesium spinel and / or aluminum oxide. In this case, advantageous embodiments are present when the surface of the metallic coating and the structural elements is roughened before the application of the ceramic layer.

Particularly advantageous embodiments are those in which the structural elements are applied by a laser deposition welding process.

The object is also achieved by a component produced according to at least one of the methods according to claims 10 to 15.

In the following figures, various embodiments are described by way of example, in which shows

1 : a schematic representation of the initial situation for the production of a component;

2 a schematic representation of a first manufacturing step of a component;

3 a schematic representation of a second manufacturing step of a component;

3A a schematic representation of a component after the second manufacturing step;

4A FIG. 2: shows a schematic plan view of a first embodiment of a component with essentially one-dimensional structural elements; FIG.

4B FIG. 2: shows a schematic plan view of a second embodiment of a component with essentially one-dimensional structural elements; FIG.

4C FIG. 2: shows a schematic plan view of a first embodiment of a component with essentially two-dimensional structural elements; FIG.

4D FIG. 2 is a schematic plan view of a second embodiment of a component with essentially two-dimensional structural elements; FIG.

5 a schematic representation of a third manufacturing step of a component;

6 : a diagrammatic representation of a microscopic sectional view of a component;

7 : a diagrammatic representation of a microscopic sectional view of a structural element;

8th : A representation of a part of an aircraft engine with a component according to 3 ,

In 1 is shown in a sectional view of a metallic layer, the starting point for the construction of a device 10 which is particularly thermally and mechanically stable. The metallic base material 11 (For example, a nickel-based superalloy) may have the shape of a plate, which is used for example in the lining of a combustion chamber, the lining of the wall (so-called liner) in the region of a turbine or the inlet region of the high pressure part of a turbine. Such plates have for example a length of about 10 cm, a width of about 2 cm and a thickness of about 4 mm. The Plate does not necessarily have cuboidal dimensions. The plate may also have a curvature and / or a more complex outer contour. The component can also be part of an aircraft engine (see 8th ).

On the metallic base material 11 becomes in a first step a metallic coating 1 made of a heat-resistant material ( 2 ). The thickness of the coating can be between 50 and 500 μm, depending on the application. This coating 1 can eg a share of
M CrAlY with M = Fe, Ni, and / or Co,
M CrAl with M = Fe, Ni, and / or Co,
NiAl, or NiAlPt
or consist entirely of these materials. These materials are also used in known bond coat layers. These materials are thermally stable up to 1,400 K.

This coating 1 can eg with an electroplating, plasma spray and / or a deposition on the metallic base material 11 be applied. One possible method of deposition is the PVD (Physical Vapor Deposition) process, which ensures reliable bonding of the coating 1 to the metallic base material 11 is possible. The starting material (eg in the form of powder) is evaporated (eg in an electron beam) and on the metallic base material 11 deposited. To improve the deposition, for example, an ionization of the vapor or the application of a voltage can be used.

So that a ceramic layer 5 (please refer 5 ) sure on the coating 1 can hold, are in a second step with a structuring process, in particular a laser process, at least partially structural elements 4 on the already existing metallic coating 1 applied ( 3 ). An advantageous laser process is laser deposition welding, in which the metallic coating 1 is locally melted and at the same time the material for the structural elements 4 is applied. The application of the material for the structural elements 4 can be done in powder form or by means of a wire.

It is important that the structural elements 4 have the same material as the metallic coating 1 , So can the coating 1 and the structural elements 4 be prepared from the same metallic powder. This has structural elements 4 and the metallic coating 1 an identical thermal expansion coefficient, so that the additional thermal loads are kept small. This also creates an additional phase interface between the metallic coating 1 and the structural element 4 avoided, so that mechanical stresses are reduced.

The thus created metallic coating 1 has a high resistance to oxidation and corrosion in general, wherein the metallic base material 11 not changed. Furthermore, this metallic coating allows 1 a simple processing in later steps, if eg a repair is to be made.

After the second step, there is a component ( 3 . 3A ), where the coating 1 a detention zone 2 for connection to the metallic base material 11 and one above the detention zone 2 lying structural zone 3 with structural elements 4 having. Both zones 2 . 3 are in one piece from the same material of the metallic coating 1 educated. A separate adhesion-promoting layer, for example with particles, or a structuring of the metallic base layer 11 not necessary.

The shape and arrangement of the structural elements 4 in the metallic coating 1 can be varied within wide limits by controlling the structuring process. Particularly advantageous is the above-described laser deposition welding (laser cladding process).

In the 4A . 4B are essentially rod-shaped structural elements 4 shown in a plan view. The structural elements 4 in 4A have a circular cross section, the structural elements 4 in 4B have a rectangular cross section. In principle, prismatic or pyramidal structural elements are also 4 possible. In 4C . 4D , are the structural elements 4 designed as linear structures. In the embodiment according to 4C the structural elements are formed as parallel walls. In the embodiment according to 4D the structural elements are designed as crossing walls. It is also possible that combinations of different structural elements 4 be used. It should be noted that the presentation of the 3 . 3A and 4A . 4B . 4C . 4D , in particular with regard to the shape of the structural elements 4 , is only schematic.

The extension parallel to the metallic base material, eg the diameter of a structural element 4 according to 4A or the thickness of a linear structure according to 4C is between 50 and 300 microns.

Also, it is not mandatory that the structural elements 4 in a uniform arrangement, as in 4 dargstellt about the device 10 are distributed. It may be useful due to the load in the turbomachine that the structural elements 4 have a higher density in some areas than in others. Also need the structural elements 4 not always the same shape with each other. Rather, it is possible that the shape of the structural elements 4 adapted to the load. In particular, by the use of a laser process can thereby the arrangement and the shape of the structural elements 4 be selected variable and targeted.

In 5 is the component 10 presented after a third step. In this case, for example, was to increase the temperature resistance ceramic material 5 in the structural zone 4 the metallic coating 1 brought in. The structural elements 4 grip directly into the ceramic coating material 5 and ensure a close connection between the two layers. The structural elements 4 can before coating with the ceramic material 5 roughened to improve adhesion. Due to the shape of the structural elements 4 becomes a shading effect upon application of the ceramic layer 5 largely avoided.

It is advantageous if the ceramic material 5 especially yittrium and / or zirconium. Additionally or alternatively, the ceramic material 5 also magnesium spinel and / or alumina.

In 6 is a microscopic sectional view of a component 10 shown. The four structural elements shown 4 are laterally spaced from each other about 300 microns. The height of the structural elements 4 is about 200 microns.

From this real sectional view it becomes clear that the structural elements 4 form a well-defined surface, which can be the basis for further coatings.

In 7 is a single view of a structural element 4 shown in cross section. It can be seen that at the foot of the structural element 4 in the transition area between the detention zone 2 and structural zone 3 no inhomogeneities are recognizable. The metallic structure is uniform, giving a one-piece metallic coating 1 is present. Due to the manufacturing process lies in the foot region of the structural element 1 an undercut, ie the structural element 4 has a larger diameter in the upper part than in the area of the foot point. The ceramic material used in the device 10 about the structural elements 4 extends (see 5 ) thus also enters the region of the undercut, so that a special anchoring of the ceramic layer 5 on the device 10 is produced. The formation of the top of the structural element 4 enables targeted segmentation of the ceramic coating 5 that go beyond the structural elements 4 is applied.

In 8th is fragmentary an aircraft engine 20 shown in the components 10 of the type described above are used. The individual uses can be used individually or in combination.

Particularly high thermal loads are in the combustion chamber 21 in front. For this reason, plate-shaped components 10 with the described coating inside the combustion chamber 21 arranged.

The highest temperature is at the exit of the gases from the combustion chamber 21 and when entering the high pressure stage 22 the turbine in front. Therefore, it is advantageous if additionally or alternatively components 10 in the high pressure stage 22 are arranged. These are these components 10 advantageously not formed as plates, but the coating 1 is for example located directly on in the area of the stator of the turbine. Thus, the area of the stator per se becomes the coated device 10 , In principle, it is also possible that the coated components 10 still have channels or openings for cooling media.

Furthermore, it is also possible to provide blades of rotors and / or stators with the coating, that these become components 10 in the sense of the present description.

Another possibility is the component 10 as a coating, ie as a so-called liner 23 to use in the wall of the turbine wall, ie in particular the areas which are opposite to the blades of the rotors. liner 23 can be used in areas where rotor blades, for example of the turbine, at least temporarily have mechanical contact with the wall of the housing. This is at least quite desirable for minimizing the gap between the wall and the turbine blade. The components 10 with a metallic coating 1 with one-piece structural elements 4 and a ceramic coating 5 not only have a high thermal capacity, but are also mechanically designed to act as a liner 23 are usable.

Also in combustion chambers can be liners 23 can be used, or the coating can be directly part of the combustion chamber wall.

Basically, the device 10 be used in the places where thicker ceramic layers are usually arranged.

With the embodiments described here, it is possible to apply a fine structuring directly on a bond coat material, the height remains below 500 microns, the metallic base material 11 will not be affected. During operation, only small thermal gradients occur within the structural elements 4 on. Also, the adhesion of the layer to the base material is very good. These embodiments also have high resistance to oxidation.

Furthermore, it is possible to have a component 10 to repair and / or revise by known chemical and / or mechanical methods.

LIST OF REFERENCE NUMBERS

1

metallic coating

2

adhesion zone

3

structural zone

4

structural element

5

ceramic coating

10

module

11

metallic base material

20

Jet Engine

21

combustion chamber

22

High pressure stage of an aircraft engine

23

Liner on the wall of an aircraft engine

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• EP 1491658 A1 [0003]
• US 6652227 B2 [0005]
• US 6457939 B2 [0005]

Claims (19)

Component with a metallic coating on a metallic base material specially adapted and configured for use in a turbomachine, characterized in that the metallic coating ( 1 ) an adhesive zone ( 2 ) for connection to the metallic base material ( 11 ) and one above the detention zone ( 2 ) structural zone ( 3 ) with structural elements ( 4 ), wherein the adhesive zone ( 2 ) and the structural zone ( 3 ) consist of the same material. Component according to Claim 1, characterized in that the metallic coating ( 1 ) by electroplating, spraying and / or depositing on the base material ( 11 ) is applied. Component according to Claim 1 or 2, characterized in that structural elements ( 4 ) of the structural zone ( 3 ) after application of the material in the adhesive zone ( 2 ) are produced by a patterning process, in particular a laser deposition welding process. Component according to at least one of the preceding claims, characterized in that the structural elements ( 4 ) measured from the top of the adhesive zone ( 2 ) to the tops of the structural elements ( 4 ) have an average height of between 100 and 500 μm. Component according to at least one of the preceding claims, characterized in that the structural elements ( 4 ) have an average distance of 0.5 to 2 mm between them. Component according to at least one of the preceding claims, characterized in that the structural elements ( 4 ) are substantially round in cross-section, with the largest diameter averaging between 50 and 300 microns. Component according to at least one of the preceding claims, characterized in that the structural elements ( 4 ) have linear structures with a mean width of 50 to 300 microns. Component according to at least one of the preceding claims, characterized in that the metallic coating ( 1 ) and the structural elements ( 4 ) has a content of M CrAlY with M = Fe, Ni, and / or Co, M CrAl with M = Fe, Ni, and / or Co, NiAl, or NiAlPt or consists entirely of the materials. Component according to at least one of the preceding claims, characterized in that on the metallic coating ( 1 ) at least partially a ceramic coating ( 5 ), wherein structural elements ( 4 ) at least partially of the ceramic material, in particular a ceramic material containing yittrium, zirconium. Zirconium oxide, magnesium spinel and / or alumina, are surrounded. Component according to at least one of the preceding claims, characterized in that the structural elements ( 4 ) in the transition region to the detention zone ( 2 ) have an undercut. Aircraft engine, characterized by at least one component ( 10 ) according to at least one of the preceding claims, wherein the at least one component ( 10 ) especially in a combustion chamber ( 21 ), on the wall of the turbine and / or in the inlet region of the high-pressure part ( 22 ) a turbine ( 20 ) is arranged. Method for producing a component ( 10 ), wherein a) on a metallic base material ( 11 ) a metallic coating ( 1 ), wherein subsequently b) on the metallic coating ( 1 ) by a structuring process, in particular a laser process, at least partially structural elements ( 4 ) of the same material as the metallic coating ( 1 ) are applied. A method according to claim 12, characterized in that the structuring process is a laser drilling, a soldering process and / or an etching process, in particular an anisotropic etching process. A method according to claim 12 or 13, characterized in that the metallic coating ( 1 ) with an electroplating, plasma spray and / or a deposition process on the metallic base material ( 11 ) is applied. Method according to at least one of claims 12 to 14, characterized in that the metallic coating ( 1 ) and the application of the structural elements ( 4 ) with a powder containing a proportion of M CrAlY with M = Fe, Ni, and / or Co, M CrAl with M = Fe, Ni, and / or Co, NiAl, or NiAlPt. Method according to at least one of claims 12 to 15, characterized in that after the structuring of the metallic coating ( 1 ) a ceramic coating ( 5 ) is applied, in particular with a ceramic material containing yttrium, zirconium, zirconium oxide, magnesium spinel and / or alumina. Method according to at least one of claims 12 to 16, characterized in that after the structuring of the metallic coating ( 1 ) and before the application of the ceramic layer ( 5 ) the surface of the metallic coating ( 1 ) and the structural elements ( 4 ) is roughened. Method according to at least one of claims 12 to 17, characterized in that the structural elements ( 4 ) are applied by a laser deposition welding process. Component ( 10 ) can be produced according to at least one of the methods according to claims 10 to 15.

Images