U.S. patent application number 11/247874 was filed with the patent office on 2006-12-28 for titanium treatment to minimize fretting.
This patent application is currently assigned to GENERAL ELECTRIC COMPANY. Invention is credited to Robert William Bruce, Frank Ernst, Arthur H. Heuer, Gary Michal.
Application Number | 20060289088 11/247874 |
Document ID | / |
Family ID | 37075834 |
Filed Date | 2006-12-28 |
United States Patent
Application |
20060289088 |
Kind Code |
A1 |
Bruce; Robert William ; et
al. |
December 28, 2006 |
Titanium treatment to minimize fretting
Abstract
A method for surface treating a titanium gas turbine engine
component. The method includes providing a gas turbine engine
component having a titanium-containing surface. The component is
heated to a temperature sufficient to diffuse carbon into the
titanium and below 1,000.degree. F. The surface is contacted with a
carbon-containing gas to diffuse carbon into the surface to form
carbides. Thereafter, the carbide-containing surface is coated with
a lubricant comprising a binder and a friction modifier. The binder
preferably including titanium oxide and the friction modifier
preferably including tungsten disulfide. The coefficient of
friction between the surface and another titanium-containing
surface is less than about 0.6 in high altitude atmospheres.
Inventors: |
Bruce; Robert William;
(Loveland, OH) ; Heuer; Arthur H.; (Cleveland,
OH) ; Michal; Gary; (Brecksville, OH) ; Ernst;
Frank; (Cleveland, OH) |
Correspondence
Address: |
MCNEES WALLACE & NURICK LLC
100 PINE STREET
P.O. BOX 1166
HARRISBURG
PA
17108-1166
US
|
Assignee: |
GENERAL ELECTRIC COMPANY
Schenectady
NY
|
Family ID: |
37075834 |
Appl. No.: |
11/247874 |
Filed: |
October 11, 2005 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
60694759 |
Jun 28, 2005 |
|
|
|
Current U.S.
Class: |
148/237 |
Current CPC
Class: |
C23C 8/20 20130101 |
Class at
Publication: |
148/237 |
International
Class: |
C23C 8/20 20060101
C23C008/20 |
Claims
1. A method for surface treating a titanium-containing substrate
comprising: providing a substrate having a surface comprising
titanium; heating the substrate to a temperature sufficient to
diffuse carbon into the titanium and less than about 1,000.degree.
F.; and contacting the surface with a carbon-containing gas for a
period of time sufficient to diffuse carbon into the substrate to
form a surface layer comprising one or more of carbides and
interstitial carbon.
2. The method of claim 1, wherein the substrate is a
titanium-containing alloy selected from the group consisting of
Ti-6-4, Ti-17, Ti-4-4-2, Ti-6-2-4-2, Ti-8-1-1 and
titanium-containing superalloys.
3. The method of claim 1, further comprising cleaning the substrate
prior to contacting the substrate with the carbon-containing
gas.
4. The method of claim 1, wherein the carbon-containing gas
includes a gas selected from the group consisting of methane,
propane, ethylene gas, acetylene, carbon dioxide, carbon monoxide
and combinations thereof.
5. The method of claim 4, wherein the carbon-containing gas further
includes a non-reactive gas selected from the group consisting of
argon, helium, or hydrogen.
6. The method of claim 1, wherein the contacting step takes place
for up to about 1,500 hours.
7. The method of claim 6, wherein the contacting step takes place
for up to about 1,000 hours.
8. An article comprising: a first titanium-containing alloy having
a surface layer comprising one or more of carbides and interstitial
carbon formed at a temperature less than about 1,000.degree. F.,
the surface layer having a pre-selected thickness from the surface,
and wherein the surface layer of the substrate has a sufficient
amount of carbon and a sufficient thickness to resist fretting when
placed in frictional contact with a second metallic alloy.
9. The article of claim 8, wherein the first titanium-containing
alloy is selected from the group consisting of Ti-6-4, Ti-17,
Ti-4-4-2, Ti-6-2-4-2, Ti-8-1-1 and titanium-containing
superalloys.
10. The article of claim 8, wherein the pre-selected distance is up
to about 0.01 inches.
11. The article of claim 8, wherein the pre-selected distance is up
to about 0.001 inches.
12. The article of claim 8, wherein the surface of the first
titanium-containing alloy has a coefficient of friction of up to
about 0.6 when in contact with the second metallic alloy.
Description
FIELD OF THE INVENTION
[0001] The present invention is directed to a method for surface
treating titanium and titanium alloys. In particular, the invention
is drawn to surface treating gas turbine engine components.
BACKGROUND OF THE INVENTION
[0002] A gas turbine engine generally operates by pressurizing air
in a compressor and mixing the air with fuel in a combustor. The
air/fuel mixture is ignited and hot combustion gasses result, which
flow downstream through a turbine section. The compressor typically
includes compressor disks having airfoils dovetailed into the
compressor disk. The compressor may include multiple disks, each
having a plurality of airfoils.
[0003] Each of the compressor disk and the airfoils typically
contain titanium, usually in the form of a titanium alloy. The
titanium-to-titanium surface contact is susceptible to fretting
wear and fretting fatigue. Fretting is the degradation of the
surface usually resulting from localized adhesion between the
contacting surfaces as the surfaces slide against each other. The
problem of fretting is magnified in systems having a
titanium-containing surface contacting another titanium-containing
surface. For example, in a titanium compressor disk and titanium
airfoil system, the fretting fatigue may result from movement of
the dovetail of the airfoil within the slot in the compressor disk.
As the disk rotates at a higher rotational speed, the centrifugal
force on the airfoil urges the blade to move outward and slip along
the surface of the dovetail. As the disk rotates at a lower
rotational speed, the centrifugal force on the airfoil is less and
the airfoil may slip inward toward the compressor disk. A second
source of movement resulting in fretting fatigue in the dovetail
system is the vibration from the airfoil. Aerodynamic forces may
result in oscillation of the airfoil within the dovetail slot. The
oscillation translates to high frequency vibration through the
airfoil to the dovetail portion of the airfoil. As the airfoil
vibrates, the surface of the dovetail section of the airfoil slides
against the surface of the slot of the compressor disk, resulting
in fretting fatigue.
[0004] In an attempt to solve the fretting wear and fatigue
problem, the titanium dovetail surface of the airfoil may be
shot-peened to create compressive stress in the airfoil surface.
The increased compressive stress on the surface results in
increased hardness, which reduces the adhesion between surfaces
thereby reducing the fretting fatigue and wear. However, the
shot-peening process requires expensive equipment, additional
processing steps and may result in surfaces having variability in
roughness and dimensional accuracy. In addition, the shot-peened
surface provides insufficient resistance to fretting fatigue and
wear.
[0005] In another attempt to solve the fretting wear and fatigue
problem, a coating of CuNiIn, aluminum bronze or a MoS.sub.2
lubricant may be coated onto the airfoil's dovetail surface to
provide a surface that experiences less adhesion between surfaces.
The application of lubricants such as MoS.sub.2 provides some
protection from localized adhesion, but the lubricants alone,
without additional coating layers, fail to provide sufficient
resistance to fretting fatigue and wear.
[0006] Carburizing is a method that has been used to increase
hardness of a surface. It is a well-known method for hardening
steel surface to improve wear properties. Known carburizing methods
take place at high temperatures, including temperatures of greater
than about 1,700.degree. F. (927.degree. C.). High temperature
carburization methods suffer from the drawback that the method
requires expensive, specialized equipment, capable of operating
under high temperatures. High-temperature thermal treatments of
blade dovetails and disks preclude use of conventional carburizing
practices.
[0007] What is needed is an inexpensive, low-temperature titanium
treatment that reduces fretting fatigue and wear that does not
suffer from the drawbacks of the prior art.
SUMMARY OF THE INVENTION
[0008] The present invention includes a method for surface treating
a gas turbine engine component comprising a titanium or titanium
alloy. The method includes providing a gas turbine engine component
having a titanium-containing surface. The component is heated to a
temperature sufficient to diffuse carbon into the titanium and
below 1,000.degree. F. The surface is contacted with a
carbon-containing gas to diffuse carbon into the surface to form
carbides and/or interstitial carbon. Thereafter, the
carbon-containing surface may be coated with a lubricant to further
reduce the coefficient of friction between surfaces. The
coefficient of friction between the surface and another
titanium-containing surface is preferably less than about 0.6.
[0009] In accordance with the present invention, a metallic surface
comprising titanium is carburized, under controlled conditions,
using carbon-containing gases, such as methane, propane, ethylene
or acetylene gas or combinations thereof as the carburizing agent
in order to form stable carbides and/or interstitial carbon at a
controlled, preselected distance below the surface and/or diffuse
the carbon interstitially in the titanium matrix. The carbides
formed in the surface harden the surface, providing a reduced
coefficient of friction, and reducing fretting.
[0010] Another embodiment of the present invention includes a gas
turbine engine component having a titanium-containing compressor
disk. The compressor disk including a surface containing carbides
and/or interstitial carbon and a lubricant coating thereon having a
binder and a friction modifier. The binder preferably including
titanium oxide and the friction modifier preferably including
tungsten disulfide.
[0011] Another embodiment of the present invention includes a gas
turbine engine component having a titanium-containing airfoil. The
airfoil including one or more surfaces that contain carbides and/or
interstitial carbon and a lubricant coating thereon.
[0012] While the present invention contemplate the formation of
titanium carbide, titanium alloys may include other carbide forming
elements, such as, for example, vanadium. For example, alloys
containing vanadium treated according to the present invention may
include vanadium carbides, in addition to titanium carbides.
[0013] One advantage of an embodiment according to the present
invention is that the method according to the present invention
decreases the susceptibility of the surface to fretting.
[0014] Another advantage of an embodiment of the present invention
is that the method provides a hardened surface having carbides
and/or interstitial carbon, which resist corrosion.
[0015] Another advantage of an embodiment of the present invention
that the method according to the present invention provides a
hardened surface that is resistant to erosion.
[0016] Another advantage of an embodiment of the present invention
is that the carburization takes place at a low temperature, below
1,000.degree. F. , which reduces the cost of equipment required to
produce the carburized zone.
[0017] Another advantage of an embodiment of the present invention
is that the surfaces subjected to fretting wear and fatigue may be
replaced less often, decreasing servicing cost and reliability.
[0018] Other features and advantages of the present invention will
be apparent from the following more detailed description of the
preferred embodiment, taken in conjunction with the accompanying
drawings which illustrate, by way of example, the principles of the
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a cutaway view of a section of a known
high-pressure compressor for a turbine engine according to the
present invention
[0020] FIG. 2 shows a perspective view of a compressor disk
according to an embodiment of the present invention.
[0021] FIG. 3 shows a cutaway view of an airfoil dovetail
positioned in a slot of a compressor disk according to the present
invention.
[0022] FIG. 4 shows an enlarged cross-sections taken from FIG. 3
showing an embodiment of the present invention.
[0023] FIG. 5 shows an enlarged cross-sections taken from FIG. 3
showing an alternate embodiment of the present invention.
[0024] FIG. 6 shows an enlarged cross-sections taken from FIG. 3
showing an alternate embodiment of the present invention.
[0025] FIG. 7 shows an enlarged cross-sections taken from FIG. 3
showing an alternate embodiment of the present invention.
[0026] FIG. 8 shows an enlarged cross-section taken from FIG. 3
showing an alternate embodiment of the present invention.
[0027] FIG. 9 shows an enlarged cross-section taken from FIG. 3
showing an alternate embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0028] FIG. 1 is a cutaway view of a section of a high-pressure
compressor for a turbine engine according to the present invention.
The compressor includes a plurality of blades 100. The blades 100
include an airfoil 101 and a dovetail 103, which is positioned
within dovetail slots 105 in a compressor disk 107. The dovetail
103 of the blade 100 retains the blade 100 during operation of the
gas turbine engine. The blade 100 and the compressor disk 107
according to the invention include titanium and have one or more
surfaces that are in frictional contact that are carburized to
produce a surface having a carburized zone 401 (see FIGS. 4-9). In
addition, one or more of the surfaces of the dovetail 103 and
dovetails slots 105 of the compressor disk 107 may be coated with a
lubricant coating 601 (see FIGS. 6-9). Although FIG. 1 illustrates
a compressor disk 107 and blade 100, any titanium or titanium alloy
surface may be treated according to an embodiment of the
invention
[0029] FIG. 2 shows a perspective view of a compressor disk 107
according to an embodiment of the present invention, wherein FIG. 2
shows dovetail slots 105 into which the dovetail 103 section of
blades 100 are positioned. The surfaces of dovetail slots 105 are
subjected to sliding friction with dovetail 103 of blades 100 and
are susceptible to fretting. The surface of compressor disk 107
includes a carburized zone 401 and, optionally, a lubricant coating
601 (see FIGS. 4-9).
[0030] FIG. 3 shows a cutaway view of a blade 100 positioned in
dovetail slots 105 of compressor disk 107 according to an
embodiment of the present invention. At least a portion of the
surface of slot 105 is in frictional contact with at least a
portion of the surface of dovetail 103. As the gas turbine engine
operates, the centrifugal forces provided by the variation of the
rotational speed of the compressor disk 107 results in rubbing
between the surface of the dovetail 103 and the surface of the
dovetail slot 105 in the compressor disk 107. The coefficient of
friction between the surfaces of the dovetail 103 and the surface
of the slot 105 are preferably maintained below 0.6. Preferably,
the coefficient of friction is below 0.4. More preferably, the
coefficient of friction is below 0.2. The lowering of the
coefficient of friction is a result of the hardened surface
resulting from the carburization. The carburized zone 401 (see
FIGS. 4-9) has a greater hardness than an untreated
titanium-containing surface. In addition, the application of a
lubricant coating 601 (see FIGS. 6-9) further decreases the
coefficient of friction. The additional lowering of the coefficient
of friction is a result of the tribological properties of
components of the lubricant coating 601.
[0031] FIGS. 4-9 shows enlarged cross-sections taken from region
301 from FIG. 3 illustrating alternate coating arrangements
according to the present invention. The cross sections in FIGS. 4-9
each include a dovetail slot 105 of compressor disk 107 and
dovetail 103 in frictional contact. The surface of the dovetail
slot 105 of compressor disk 107 and the surface of the dovetail 103
form opposed surfaces onto which a carburized zone 401 and
lubricant coating 601 may be applied. FIGS. 4-9 illustrate
alternate locations for placement of the carburized zone 401 and
lubricant coating 601. Lubricant coating 601 may be disposed on the
dovetail 103, the dovetail slot 105 of the compressor disk 107, a
carburized dovetail 103 or a carburized dovetail slot 105 of the
compressor disk 107 or on a combination thereof. The optional
coating 601 may include, but is not limited to, graphite, CuNiIn,
aluminum bronze or MoS.sub.2. Although a space has been shown
between the coatings on the compressor disk 107 and the dovetail
103 in FIGS. 4-9, the space is merely illustrative of the placement
of the coatings. The coating systems on each of the surface of the
dovetail slot 105 and the dovetail 103 are in frictional contact,
wherein the surfaces are adjacent and experience sliding or
rubbing. Also, FIGS. 4-9 are shown having thicknesses of the
carburized zone 401 and lubricant coating 601 that is merely
illustrative and does not indicate the relative thickness of the
carburization zone 401 or the lubricant coating 601.
[0032] FIG. 4 shows an enlarged cross-section taken from region 301
from FIG. 3 showing an embodiment of the present invention. FIG. 4
includes dovetail 103 interfacing with the dovetail slot 105 of
compressor disk 107. Surface 403 of the dovetail slot 105 of
compressor disk 107 and surface 409 of dovetail 103 have each been
carburized and include carburized zone 401. Surface 405 includes
the surface of the carburization coating 401 on the compressor disk
and is in frictional contact with surface 407. Surface 407 is the
surface of the carburized zone 401 on surface 409 of dovetail 103.
The embodiment shown in FIG. 4 has the benefit that carburized zone
401 is provided on both the dovetail and compressor disk 107
providing hardened sliding surfaces that slide against each other
providing desirable tribological properties. In particular, the
combination of the hard, wear resistant carburized zone 401 sliding
against each other provide a low coefficient of friction and
increased fretting resistance.
[0033] FIG. 5 shows an enlarged cross-section taken from region 301
from FIG. 3 showing an alternate embodiment of the present
invention. FIG. 5 includes dovetail 103, dovetail slot 105 of
compressor disk 107, as shown in FIG. 4. Surface 403 of the
dovetail slot 105 of compressor disk 107 has been carburized and
includes carburized zone 401. Surface 405 includes the surface of
the carburized zone 401 on the dovetail slot 105 on compressor disk
107 and is in frictional contact with surface 409 of dovetail 103.
The embodiment shown in FIG. 5 has the benefit that the carburized
zone 401 is coated only on the compressor disk 107. Therefore, the
application of carburized zone 401 requires less equipment and
labor that applying carburized zone 401 to both the compressor disk
107 and the blade 100.
[0034] FIG. 6 shows an enlarged cross-section taken from region 301
from FIG. 3 showing an alternate embodiment of the present
invention. FIG. 6 includes dovetail 103, dovetail slot 105 of
compressor disk 107, as shown in FIG. 4. Surface 403 of the
dovetail slot 105 of compressor disk 107 has been carburized and
includes carburized zone 401. Lubricant coating 601 is disposed on
surface 405 of the carburized zone 401. Surface 603 of lubricant
coating 601 is in frictional contact with surface 409 of dovetail
103. The embodiment shown in FIG. 6 has the benefit that the
carburized zone 401 and lubricant coating 601 are coated only on
the compressor disk 107. Therefore, the production of carburized
zone 401 requires less equipment and labor than producing
carburized zone 401 to both the dovetail slot of compressor disk
107 and the airfoil. In addition, the compressor disk 107 is
protected from fretting damage, whereas the less expensive, easier
to replace blade 100 has not been specially treated. The carburized
zone 401 and lubricant coating 601 provide protection of the
compressor disk 107 and blade 100 system, while not adding expense
to the blades 100.
[0035] FIG. 7 shows an enlarged cross-section taken from region 301
from FIG. 3 showing an alternate embodiment of the present
invention. FIG. 7 includes dovetail 103, dovetail slot 105 of
compressor disk 107, as shown in FIG. 4. Surface 409 of dovetail
103 of blade 100 has been carburized and includes carburized zone
401. Lubricant coating 601 is disposed on surface 407 of the
carburized zone 401. Surface 603 of lubricant coating 601 is in
frictional contact with surface 403 of the dovetail slot 105 of
compressor disk 107. The embodiment shown in FIG. 7 has the benefit
that the carburized zone 401 and lubricant coating 601 are coated
only on dovetail 103 of blade 100. Coating only the dovetail 103
has the advantage that the blades 100 may easily be removed from
the compressor disk 107 in order to be coated according to the
present invention. The compressor disk 107 and blade 100 system of
the present invention may be retrofitted into existing gas turbine
engines by removing the blades 100 from the compressor disks 107,
wherein the removal of the compressor disk 107 from the engine is
not necessary. In this embodiment, the dovetail 103 may provide the
resistance to fretting without requiring the removal or replacement
of the compressor disks 107 from the engine.
[0036] FIG. 8 shows an enlarged cross-section taken from region 301
from FIG. 3 showing an alternate embodiment of the present
invention. FIG. 8 includes dovetail 103, dovetail slot 105 of
compressor disk 107, as shown in FIG. 4. Surface 403 of the
dovetail slot 105 of compressor disk 107 has been carburized and
includes carburized zone 401. Lubricant coating 601 is disposed on
surface 409 of the dovetail 103. Surface 603 of lubricant coating
601 is in frictional contact with surface 405 of carburized zone
401 on the dovetail slot 105 of compressor disk 107. The embodiment
shown in FIG. 8 has the benefit that the carburized zone 401 is
present on the dovetail slot 105 of compressor disk 107 protecting
the surface from fretting. In addition, the dovetail 103 of blade
100 is coated with lubricant coating 601. The lubricant coating 601
may be easily replaced by removing the blade 100 from compressor
disk 107 and coating the lubricant coating 601 onto dovetail 103 of
blade 100. The lubricant coating 601 in this embodiment permits the
easy replacement of the lubricant coating 601 in the event that the
lubricant coating 601 wears thin or wears completely off.
[0037] FIG. 9 shows an enlarged cross-section taken from region 301
from FIG. 3 showing an alternate embodiment of the present
invention. FIG. 9 includes dovetail 103, dovetail slot 105 of
compressor disk 107, as shown in FIG. 4. Surface 403 of dovetail
slot 105 of compressor disk 107 has been carburized and includes
carburized zone 401. Surface 409 of dovetail 103 of blade 100 has
also been carburized and includes carburized zone 401. Lubricant
coating 601 is disposed on surface 407 of the carburized coatings
401, both on the dovetail 103 of blade 100 and on the dovetail slot
105 of compressor disk 107. Surface 603 of lubricant coating 601 on
the carburized zone 401 on the dovetail slot 105 of compressor disk
107 is in frictional contact with surface 603 of lubricant coating
601 on the carburized zone 401 on the dovetail 103 of blade 100.
The embodiment shown in FIG. 9 has the benefit that the carburized
coating 401 and lubricant coating 601 are present on both the
dovetail 103 of blade 100 and on the dovetail slot 105 on
compressor disk 107, providing additional protection against
fretting on both surfaces. In this embodiment, the coatings have
additional protection against the lubricant coating 601 wearing off
due to the two lubricant coatings 601. In addition, this embodiment
permits the opposed hard, wear resistant carburized zone 401
surfaces to slide against each other provide a low coefficient of
friction and increased fretting resistance with the addition
fretting resistance provided by the lubricant coatings 601 disposed
thereon.
[0038] The present invention also provides methods for carburizing
a metallic surface comprising titanium. In one embodiment,
titanium-containing blade 100 or compressor disk 107 for use in a
gas turbine engine is subjected to carburizing. The surface for
coating according to the present invention is preferably a titanium
alloy. In one embodiment of the invention, the titanium alloy is
Ti-6-4 titanium alloy having about 6 wt% aluminum, about 4 wt %
vanadium and balance essentially titanium. Other suitable alloys
for use in the blade 100 include, but are not limited to Ti-4-4-2
(about 4 wt % aluminum, about 4 wt % molybdenum, and about 2 wt %
tin), Ti-6-2-4-2 (about 6 wt % aluminum, about 2 wt % molybdenum,
about 4 wt % zirconium and about 2 wt % tin), Ti-8-1-1 (about 8 wt
% aluminum, about 1 wt % molybdenum, and about 1 wt % vanadium).
Other suitable alloys for use in the compressor disk 107 include,
but are not limited to Ti-17 (about 5 wt % aluminum, about 4 wt %
chromium, about 4 wt % molybdenum, about 2 wt % zirconium and about
2 wt % tin) and Ti-6-2-4-2 (about 6 wt % aluminum, about 2 wt %
molybdenum, about 4 wt % zirconium and about 2 wt % tin). Other
suitable alloys for fabrication of compressor disk 107 for use with
blades 100 having a carburized zone 401 include, but are not
limited to, nickel-based alloys, such as INCONEL.RTM. 718, R-95, or
R-88. INCONEL.RTM. is a federally registered trademark owned by
Huntington Alloys Corporation of Huntington, W. Va. The composition
of INCONEL.RTM. 718 is well-known in the art and is a designation
for a nickel-based superalloy comprising about 18 weight percent
chromium, about 19 weight percent iron, about 5 weight percent
niobium+tantalum, about 3 weight percent molybdenum, about 0.9
weight percent titanium, about 0.5 weight percent aluminum, about
0.05 weight percent carbon, about 0.009 weight percent boron, a
maximum of about 1 weight percent cobalt, a maximum of about 0.35
weight percent manganese, a maximum of about 0.35 weight percent
silicon, a maximum of about 0.1 weight percent copper, and the
balance nickel. R-95 includes a composition having about 8% cobalt,
about 13% chromium, about 3.5% molybdenum, about 3.5% tungsten,
about 3.5% aluminum, about 2.5% titanium, about 3.5% niobium, about
0.03% boron, about 0.03% carbon, about 0.03% zirconium, up to about
0.01% vanadium, up to about 0.3% hafnium, up to about 0.01% yttrium
and the balance essentially nickel. R-88 includes a composition
having about 13% cobalt, about 16% chromium, about 4% molybdenum,
about 4% tungsten, about 2% aluminum, about 3.7% titanium, about
0.75% niobium, about 0.4% zirconium, about 0.06% carbon, about
0.010% boron and the balance essentially nickel.
[0039] In accordance with the present invention, a metallic surface
comprising titanium is carburized, under controlled conditions,
using carbon-containing gases, such as methane, propane, ethylene
gas, acetylene, carbon dioxide, carbon monoxide or combinations
thereof as the carburizing agent in order to form stable carbides
at a controlled, preselected distance below the surface. The
carbides may include titanium carbides, vanadium carbides and
mixtures thereof, including titanium-vanadium carbide complexes.
These gases may be mixed in combination, or non-reactive gases such
as argon, helium, or hydrogen may be added in order to control the
reactivity of the carburizing gases. The titanium carbide formed in
the surface hardens the surface, providing a reduced coefficient of
friction, and reducing fretting. The concentration and/or presence
of interstitial carbon in the titanium matrix can also be a
controlling factor in the process.
[0040] The present invention may include a step of cleaning the
article surface. Cleaning the article surface entails removing a
portion or substantially all oxides from the surface of the
substrate and preventing the reformation of oxides from the surface
that is to be carburized. The surface to be carburized is
preferably free of oxides. Removing oxides can be accomplished by
mechanical or chemical methods that do not damage or otherwise
adversely affect the substrate surface. The mechanical or chemical
oxide removal methods may be any oxide removal methods known in the
art, including but not limited to grit blasting or chemical
etching. After such cleaning, the surfaces may be cleaned with a
suitable solvent, while avoiding the formation of oxides. While
oxides are to be avoided, it may be desirable to mask portions of
the surface in order to prevent these portions from being
carburized. This may be desirable for any one of a number of
reasons, such as titanium containing surfaces that are not in
contact with other titanium containing surfaces and/or may not be
susceptible to fretting or wear. Therefore, when desirable, the
portion that does not require carburization may be masked.
[0041] Although masking may be provided to surface portions of the
compressor disk 107 and/or the blade 100, the carburizing of the
entire compressor disk 107 and/or blade 100 may provide the
compressor disk 107 and blade 100 with desirable surface
properties. For example, an airfoil 101 portion of a blade 100
having a carburized zone 401 may be resistant to corrosion due to
the presence of carbides and/or interstitial carbon at the surface.
The resistance to corrosion is desirable for airfoils 101 and
compressor disks 107 due to the fact that the airfoils 101 and
compressor disks may contact air that includes water and/or
corrosion accelerators, such as salt. In addition, the carburizing
of the entire compressor disk 107 and/or blade 100 may provide the
compressor disk 107 and blade 100 with protection against erosion
due to the hardened, wear-resistant carburized zone 401. The
resistance to erosion is desirable, for example, for airfoils 101
and compressor disks 107 due to contact with air that includes
abrasive material, such as sand or dirt. Therefore, the method of
the present invention may advantageously be utilized to coat the
entire compressor disk 107 and/or blade 100.
[0042] The cleaned article is then loaded into a furnace suitable
for performing the carburization process. Suitable furnaces include
vacuum furnaces or furnaces that can maintain a controlled
atmosphere. The furnace is heated to a temperature sufficient to
permit the diffusion of carbon into titanium, and less than about
1,000.degree. F. (538.degree. C.). Preferably, the furnace is
heated to about 750.degree. F. (400.degree. C.). After the
titanium-containing article has reached the carburization
temperature, the carburizing gases may be introduced into the
furnace by any method that prevents the introduction of oxygen. In
addition, introduction of the carburizing gases should be such that
the concentration of the carbon-containing gas may be varied. When
maintaining a controlled atmosphere, the atmosphere must be
non-oxidizing, as oxidation of the article surface and reaction of
the carburizing gas with oxygen must be prevented during heat-up to
the carburizing temperature and during carburizing. Once the
carburizing temperature is approached, the carburizing gas,
methane, propane, ethylene or acetylene, is introduced into the
furnace. These carburizing gases may be introduced below the
carburizing temperature with hydrogen or to gradually replace
hydrogen, but should not be added at a temperature or in a volume
that will result in excessive soot formation. The carburizing gas
is provided to ensure sufficient carbon is present at the article
surface for desired carburization so that carbon is diffused and is
formed in a layer having titanium carbide and/or carbon diffused
interstitially. The carbides and/or interstitial carbon increase
the hardness of the surface and reduce fretting. As the hardness of
the surface increases, the incident of localized adhesion between
titanium-containing surfaces is reduced. The reduction in localized
adhesion results in a greater resistance to fretting fatigue and
wear. The duration, temperature and concentration of carbon in the
carbon-containing gas of the carburization process may be
controlled to limit the depth of carbide layer formation. The
amount of carbon present in the layer is sufficient to provide the
titanium-containing surface with a reduced susceptibility to
fretting when in contact with other titanium-containing surfaces.
The amount of carbon present in the carburized zone 401 includes an
amount of carbon that is greater than the carbon present in a
conventional carburized surface that was carburized at high
temperatures, such as temperatures greater than about 1,000.degree.
F.
[0043] Carburization is continued until the desired carburization
depth is reached at which time the operation is stopped by
introducing an inert gas to the furnace. Carburization depth is
temperature, time and concentration dependent, wherein the
resultant depth may be governed by the laws of mass transfer and,
in particular, Fick's first and second law of diffusion.
Carburization ceases when the surface temperature of the article is
less than the temperature at which carbon diffuses. The depth of
the carburization varies based upon a variety of factors including
the time the article is exposed to the carbon-containing gas, the
concentration of the carbon in the carbon-containing gas and the
temperature of the article. A preferable depth for the
carburization coating 401 is up to about 0.01 inches. More
preferably up to about 0.001 inches. The carburization process
according to the invention takes place for a time up to about 1,500
hours for the desired carburization coating 401 depth to be
achieved. Preferably, the carburization takes place for a time up
to about 1,000 hours.
[0044] The carburization process is completed by purging the
chamber of the carburizing gas. This can be accomplished by
stopping the flow of the carburizing gas and introducing an inert
gas, nitrogen or hydrogen into the chamber. This also serves to
cool the article. Any masking present on the surface may be
removed.
[0045] As will be recognized by those skilled in the art, several
operating parameters can be varied, therefore these parameters must
be controlled to control the desired carbide layer thickness. These
parameters include, but are not limited to gas flow rate, which
determines partial gas pressure, temperature, type of furnace,
working zone size, work load and time.
[0046] After processing and cooling, the work load, may comprise a
plurality of articles, can be removed from the work zone. Any
optional masking may be removed before or after the application of
the optional lubricant coating 601. Masking may be removed by any
suitable means that does not adversely affect the substrate
surface, such as chemical stripping, mechanical means such as
blasting, or other known methods consistent with the masking
material.
[0047] Compressor disks 107 and blades 100 that comprise titanium
are particularly suitable for use with the method of the present
invention. Carburized compressor disks 107 and/or dovetails 103
coated with a lubricant coating 601 provide desirable tribological
properties. The present invention utilizes the combination of the
relatively hard carburized zone 401 in combination with a
relatively soft, lubricious lubricant coating 601, which may be
placed on surfaces susceptible to wear. Suitable surfaces include
component surfaces within a compressor of a gas turbine engine. The
carburized zone 401 reduces the coefficient of friction between the
compressor disk 107 and blade 100. The lubricant coating 601
further reduces the coefficient of friction between the compressor
disk 107 and the blade 100, reducing localized adhesion between the
surfaces, thereby reducing fretting.
[0048] The coefficient of friction is preferably maintained in the
wear system of the dovetail slot 105 and dovetail 103 equal to or
less than 0.6 and preferably equal or less than 0.4. More
preferably, the coefficient of friction is maintained in the wear
system of the dovetail slot 105 and dovetail 103 equal to or less
than 0.2. The coefficient of friction is measured between the two
surfaces rubbing against each other. In the embodiments of the
present invention shown in FIGS. 4-9, the coefficient of friction
between the dovetail 103 of blade 100 and dovetail slot 105 of
compressor disk 107, is less than or equal to about 0.6. The
compressor disk 107 and blade 100 may be fabricated from any
suitable material, including but not limited to metals and metal
alloys. Preferred materials include titanium and its alloys. Other
suitable alloys include, but are not limited to, nickel-based
alloys, such as INCONEL.RTM. 718. In addition, compressor disks 107
may be fabricated from nickel-based alloys, such as R-95 and
R-88.
[0049] In another embodiment of the present invention, additives
may be included in the lubricant coating 601 to provide additional
desirable properties for the coating system. The additional
additive is an additive that provides desirable properties, such as
increased lubricity, increased adhesion of the lubricant coating
601 to the surface, or increased coating uniformity, to the
composition. Suitable additional additives include, but are not
limited to, polytetrafluoroethylene, adhesion promoters, dispersing
agents and combinations thereof. Examples of additional additives
include graphite, molybdenum sulfide, molybdenum diselenide and
copper.
[0050] Alternate systems that find use with the present invention
include titanium-containing components of the gas turbine engine,
including actuator mechanisms, dovetail surfaces elsewhere in the
engine and other surfaces where a low coefficient of friction is
required or desirable. In particular, the present invention finds
use in applications susceptible to fretting, including applications
where one titanium-containing surface slides against a second
titanium-containing surface. Treatment of one or both of the
surfaces in frictional contact reduces the coefficient of friction,
while also reducing fretting fatigue and wear.
[0051] While the invention has been described with reference to a
preferred embodiment, it will be understood by those skilled in the
art 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 particular 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
particular embodiment disclosed 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.
* * * * *