U.S. patent application number 11/637457 was filed with the patent office on 2007-12-20 for layer system.
This patent application is currently assigned to SIEMENS AKTIENGESELLSCHAFT. Invention is credited to Georg Bostanjoglo, Nigel-Philip Cox, Rolf Wilkenhoner.
Application Number | 20070292275 11/637457 |
Document ID | / |
Family ID | 34926898 |
Filed Date | 2007-12-20 |
United States Patent
Application |
20070292275 |
Kind Code |
A1 |
Bostanjoglo; Georg ; et
al. |
December 20, 2007 |
Layer system
Abstract
On account of their type of coating, layer systems of the prior
art often exhibit poor adhesion to the substrate. If the components
are subject to high mechanical stresses, the layer can then become
detached. The layer system according to the invention has
separately produced anchoring means which allow stronger attachment
to the substrate than the attachment of the outer layer to the
substrate.
Inventors: |
Bostanjoglo; Georg; (Berlin,
DE) ; Cox; Nigel-Philip; (Mulheim an der Ruhr,
DE) ; Wilkenhoner; Rolf; (Kleinmachnow, DE) |
Correspondence
Address: |
SIEMENS CORPORATION;INTELLECTUAL PROPERTY DEPARTMENT
170 WOOD AVENUE SOUTH
ISELIN
NJ
08830
US
|
Assignee: |
SIEMENS AKTIENGESELLSCHAFT
|
Family ID: |
34926898 |
Appl. No.: |
11/637457 |
Filed: |
December 12, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11240580 |
Sep 30, 2005 |
7182581 |
|
|
11637457 |
Dec 12, 2006 |
|
|
|
Current U.S.
Class: |
416/241B |
Current CPC
Class: |
C23C 28/345 20130101;
H01L 2924/0002 20130101; C23C 28/3215 20130101; C23C 28/3455
20130101; Y02T 50/60 20130101; H01L 2924/0002 20130101; H01L
2924/00 20130101 |
Class at
Publication: |
416/241.00B |
International
Class: |
F03B 3/12 20060101
F03B003/12 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 7, 2004 |
EP |
04023974.1 |
Claims
1-29. (canceled)
30. A layer system, comprising: a substrate having a substrate
surface; an outer layer arranged on the substrate and having an
outer surface spaced apart from the substrate surface of the
substrate; a continuous anchoring device arranged in the outer
layer that does not extend in the outer layer beyond the outer
surface and a cross-sectional area of the continuous anchoring
device is larger at the outer surface than at the substrate
surface; and an inner anchoring device arranged in the outer layer
that extends within at least 10% of the thickness of the outer
layer.
31. The layer system as claimed in claim 30, wherein the continuous
anchoring device or the inner anchoring device are joined to the
substrate by melt metallurgy.
32. The layer system as claimed in claim 30, wherein the material
of the continuous anchoring device or the inner anchoring device in
the outer layer corresponds to the material of the outer layer
33. The layer system as claimed in claim 30, wherein the material
of the continuous anchoring device or the inner anchoring device is
different than the material of the outer layer.
34. The layer system as claimed in claim 30, wherein the continuous
anchoring device or the inner anchoring device are present only
locally on the substrate.
35. The layer system as claimed in claim 30, wherein the continuous
anchoring device or the inner anchoring device are columnar in
form.
36. The layer system as claimed in claim 30, further comprising an
interlayer arranged between the substrate surface and the outer
layer, having an inner surface opposite the substrate surface.
37. The layer system as claimed in claim 36, wherein the continuous
anchoring device or the inner anchoring device are present in the
outer layer or the interlayer.
38. The layer system as claimed in claim 36, wherein the continuous
anchoring device or the inner anchoring device have a different
form of attachment to the substrate or to the interlayer than the
outer layer to the interlayer or the interlayer to the
substrate.
39. The layer system as claimed in claim 36, wherein the continuous
anchoring device extend as far as the inner surface of the
interlayer or as far as the outer surface of the outer layer.
40. The layer system as claimed in claim 36, wherein the continuous
anchoring device does not extend beyond the inner surface of the
interlayer, or The outer surface of the outer layer.
41. The layer system as claimed in claim 36, wherein the interlayer
is an MCrAlX layer.
42. The layer system as claimed in claim 30, wherein the layer
system is a new or refurbished turbine component.
43. A layer system, comprising: a substrate having a substrate
surface; an outer layer arranged on the substrate and having an
outer surface spaced apart from the substrate surface of the
substrate; and a continuous anchoring device in the outer layer,
wherein the continuous anchoring device extends in the outer layer
as far as the outer surface and cross-sectional area of the
continuous anchoring device is larger at the outer surface than at
the substrate surface.
44. The layer system as claimed in claim 43, further comprising an
interlayer arranged between the substrate surface and the outer
layer and having an inner surface opposite the substrate
surface.
45. The layer system as claimed in claim 44, wherein the interlayer
is an MCrAlX layer.
46. The layer system as claimed in claim 44, wherein an inner
anchoring device extends only within at least 10% of the thickness
of the interlayer or only within at least 10% of the thickness of
the outer layer.
47. The layer system as claimed in claim 46, wherein the continuous
anchoring device or the inner anchoring device are columnar in
form.
48. The layer system as claimed in claim 44, wherein the continuous
anchoring device does not extend beyond the inner surface of the
interlayer, or The outer surface of the outer layer.
49. The layer system as claimed in claim 43, wherein the layer
system is a new or refurbished turbine component.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority of the European application
No. 04023974.1 EP filed Oct. 7, 2004, which is incorporated by
reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The invention relates to a layer system.
BACKGROUND OF THE INVENTION
[0003] Nowadays, components which are intended for use at high
temperatures are generally provided with protective layers. These
may be metallic corrosion-resistant layers (MCrAlX layers) or
ceramic thermal barrier coatings, as well as layer systems
comprising both metallic corrosion-resistant layers and ceramic
thermal barrier coatings. Plasma-enhanced powder spraying processes
are used as the coating process for these coatings, on account of
their relatively favorable economics. Layers of this type are
attached to the substrate by mechanical interlock and subsequent
diffusion heat treatment. In operation, the layer may become
detached on occasion in highly stressed regions or at unfavorable
areas of the component, i.e. areas which are subject to
particularly high mechanical stresses. The layer flaking off in
operation leads to damage to the base material, with the result
that the component life is significantly reduced.
[0004] U.S. Pat. No. 5,869,798 discloses a process in which
elevations are produced on a surface by means of a welding process,
the elevation consisting of a different material than the
underlying substrate.
[0005] EP 1 275 748 A2 discloses anchoring means which are arranged
on a surface of a substrate or of an interlayer or project through
a plurality of layers.
[0006] DE 100 57 187 A1 discloses anchoring means which project
into a metallic substrate in order to improve the bonding of a
metallic material, such as ceramic, to the metallic substrate. The
anchoring means do not extend as far as an outer surface.
[0007] EP 0 713 957 A1 discloses a process in which a recess in a
layer is filled with material.
[0008] Further prior art is known from DE 30 38 416 A1 and from
Journal of Materials Science 24 (1989), pages 115-123, entitled
"Enhanced metal-ceramic adhesion by sequential sputter deposition
and pulsed laser melting of copper films on sapphire substrates" by
A. J. Pedraza, M. J. Godbole.
SUMMARY OF THE INVENTION
[0009] Therefore, it is an object of the invention to provide a
layer system which has improved attachment of a protective layer to
a substrate and/or of layers to one another.
[0010] The object is achieved by the layer system as claimed in the
claims.
[0011] The layer system according to the invention has separately
produced anchoring means, which have a very good attachment to the
substrate or to an interlayer arranged below on the substrate and
are attached to the substrate or to the other layer in a different
way than the layer.
[0012] The subclaims list further advantageous measures. The
measures listed in the subclaims can be advantageously combined
with one another in any desired way.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] In the drawings:
[0014] FIGS. 1, 2, 6, 7, 8 show layer systems,
[0015] FIG. 3 shows a perspective plan view of a layer system,
[0016] FIG. 4 shows process steps involved in the production of a
layer system,
[0017] FIG. 5 shows process steps involved in the production of a
layer system,
[0018] FIGS. 9, 20, 21, 22 show a layer system formed in accordance
with the invention,
[0019] FIGS. 10-12 show process steps involved in the production of
a layer system,
[0020] FIGS. 13, 14, 15 show process steps involved in the
production of a layer system,
[0021] FIGS. 16, 17 show process steps involved in the production
of a layer system,
[0022] FIG. 18 shows a gas turbine,
[0023] FIG. 19 shows a combustion chamber, and
[0024] FIG. 23 shows a turbine blade or vane.
DETAILED DESCRIPTION OF THE INVENTION
[0025] FIG. 1 shows a layer system 1' in accordance with the prior
art. The layer system 1' has a substrate 4. At least an outer layer
9 is present on the substrate surface 5 of the substrate 4. This
outer layer 9 may be a metallic and/or ceramic outer layer 9.
[0026] In accordance with the prior art, the outer layer 9 is
attached to the substrate 4 solely by mechanical interlock (surface
roughness) on the underlying surface and a subsequent diffusion
heat treatment.
[0027] Working on the basis of FIG. 1, FIG. 2 shows a layer system
1 with continuous anchoring means 10 or inner anchoring means
13.
[0028] The substrate 4 may be metallic or ceramic and in the case
of gas turbine components is produced in particular from an
iron-base, nickel-base or cobalt-based superalloy.
[0029] For turbine blades or vanes 120, 130 (FIG. 18), for example,
a metallic corrosion-resistant layer 9 (FIGS. 4, 5) of the MCrAlX
type is applied to the substrate 4, and then, for example, an outer
layer, for example a ceramic thermal barrier coating 9 (FIGS. 6, 7,
8), is additionally applied to the corrosion-resistant layer 9, so
that the corrosion-resistant layer then becomes an interlayer
7.
[0030] In the outer layer 9, there is at least one continuous
anchoring means 10 and/or at least one inner anchoring means 13, a
certain part 14 of which, for example, extends into the substrate
4.
[0031] The part 14, i.e. the extent of the continuous anchoring
means 10 or of the inner anchoring means 13 into the substrate 4,
constitutes the smaller part, based on the length or volume of the
continuous anchoring means 10 or of the inner anchoring means 13,
so that the majority of the length or volume of the continuous
anchoring means 10 or of the inner anchoring means 13 is located in
the outer layer 9.
[0032] The material of the continuous anchoring means 10 or of the
inner anchoring means 13 corresponds, for example, to the material
of the outer layer 9 in which it is mostly arranged. If the
continuous anchoring means 10 or the inner anchoring means 13 is
arranged mostly in the outer layer 9, the material of the
continuous anchoring means 10 or of the inner anchoring means 13
corresponds, for example, to the material of the outer layer 9.
Therefore, if most of the continuous anchoring means 10 or of the
inner anchoring means 13 is located in the interlayer 7 (FIGS. 6,
7, 8), the material of the continuous anchoring means 10 or of the
inner anchoring means 13 corresponds, for example, to the material
of the interlayer 7. The continuous anchoring means 10 or the inner
anchoring means 13 in particular have a different type of
attachment, in particular with an increased attachment force (more
specifically: force per unit contact area) to the substrate 4 or to
the interlayer 7 than the type of attachment of the interlayer 7 to
the substrate 4 or of the outer layer 9 to the interlayer 7.
[0033] The continuous anchoring means 10 or the inner anchoring
means 13, by way of example, are attached to the substrate 4 by
melt metallurgy using a suitably managed laser welding process. It
is also conceivable for the outer layer 9 to be applied to defined
locations by laser cladding (laser powder coating) and in this way
to form continuous anchoring means 10 or inner anchoring means 13.
The continuous anchoring means 10 or inner anchoring means 13 can
also be cast on or produced integrally during casting of the
substrate 4.
[0034] The continuous anchoring means 10 or inner anchoring means
13 constitute bonding bridges for the outer layer 9 surrounding the
continuous anchoring means 10 or inner anchoring means 13. The
continuous anchoring means 10 start from the substrate surface 5 of
the substrate 4 and extend only as far as the outer surface 16 of
the outer layer 9 (or if appropriate out of the substrate 4 if a
part 14 is present).
[0035] The inner anchoring means 13 are covered by the outer layer
9, and consequently the inner anchoring means 13 do not extend as
far as the outer surface 16 of the outer layer 9, i.e. are arranged
so as to end within the outer layer 9. In this case, they 13 extend
into the outer layer 9 over at least 10%, 20%, 30%, 40% or more of
the thickness of the outer layer 9.
[0036] A corresponding statement also applies to the continuous
anchoring means 10 or inner anchoring means 13 in the interlayer
7.
[0037] It is also possible for only continuous anchoring means 10
or only inner anchoring means 13 to be present in the outer layers
9.
[0038] The continuous anchoring means 10 or the inner anchoring
means 13 are, for example, only present in locally limited form
(FIG. 3) on the substrate 4 or the interlayer 7, namely where the
mechanical stresses are highest. This is, for example, the region
of the leading edge 409 (FIG. 24) of a turbine blade or vane 120,
130. The remaining blade or vane part 406 (FIG. 24) would not then
have any continuous anchoring means 10 or inner anchoring means
13.
[0039] FIG. 3 shows a plan view of an inner surface 8 of the
interlayer 7 or of an outer surface 16 of the outer layer 9. The
inner anchoring means 13, which do not extend as far as the inner
surface 8 (FIG. 6) of the interlayer 7, are indicated by dashed
lines.
[0040] The continuous anchoring means 10 or the inner anchoring
means 13 may have different geometries, such as circles,
quilted-seam profiles (i.e. they are elongate and cross one
another), wave shapes, parallel tracks and combinations thereof on
the substrate surface 5.
[0041] FIG. 6 shows a further layer system 1. The layer system 1
comprises a substrate 4, an interlayer 7 and an outer layer 9. The
interlayer 7 is, for example, a metallic MCrAlX layer, and the
outer layer 9 is, for example, a ceramic thermal barrier coating 9
on the interlayer 7.
[0042] Continuous anchoring means 10 or inner anchoring means 13
are present both in the interlayer 7 and in the outer layer 9.
[0043] The interlayer 7, however, does not have to have continuous
anchoring means 10 or inner anchoring means 13 (FIG. 8). It is
likewise possible for the anchoring means to be present only in the
interlayer 7 (FIG. 7).
[0044] In this case, some or even all of the continuous anchoring
means 10 or inner anchoring means 13 in the interlayer 7 and/or the
outer layer 9 may have a part 14 which extends into the substrate 4
or the interlayer 7.
[0045] The continuous anchoring means 10 in the interlayer 7 or in
the outer layer 9, starting from the substrate surface 5 of the
substrate 4 or from the inner surface 8 of the interlayer 7, extend
as far as the inner surface 8 of the interlayers 7 or as far as the
outer surface 16 of the outer layer 9, but not beyond, or they 13
are covered by the interlayer 7 or the outer layer 9, so that the
inner anchoring means 13 do not extend as far as the inner surface
8 of the interlayer 7 or the outer surface 16 of the outer layer
9.
[0046] The continuous anchoring means 10 or inner anchoring means
13 in the interlayer 7 improve the attachment of the interlayer 7
to the substrate 4. The material of the continuous anchoring means
10 of the interlayer 7 may, for example, also be selected in such a
way as to produce improved bonding of the outer layer 9 to the
anchoring means 10 (FIG. 7).
[0047] The material composition of the continuous anchoring means
10 or inner anchoring means 13 in the interlayer 7 or the outer
layer 9 is selected appropriately according to the particular
demands.
[0048] The material of the continuous anchoring means 10 or inner
anchoring means 13, for example, corresponds to the material of the
interlayer 7 or of the outer layer 9 in which it is mostly
arranged.
[0049] Therefore, if the continuous anchoring means 10 or inner
anchoring means 13 is located largely in the interlayer 7, the
material of the continuous anchoring means 10 or of the inner
anchoring means 13 corresponds, for example, to the material of the
interlayer 7. If the continuous anchoring means 10 or the inner
anchoring means 13 is arranged largely in the outer layer 9, the
material of the continuous anchoring means 10 or of the inner
anchoring means 13 corresponds, for example, to the material of the
outer layer 9.
[0050] The continuous anchoring means 10 or inner anchoring means
13 are present in particular in regions which are subject to high
thermal and/or mechanical stresses.
[0051] In the case of turbine blades or vanes, this means the
leading edge 409, the trailing edge 412 (FIG. 24) or the transition
between the main blade or vane part 406 and the platform 403 (FIG.
24).
[0052] The layer system 1 is, for example, a component of a gas
turbine 100 (FIG. 18) (or aircraft turbine) or of a steam turbine.
Components of the turbines which are subject to high thermal
stresses have a layer system of this type, for example turbine
blades or vanes 120, 130, heat shield elements 155 of a combustion
chamber 110 and further casing parts which are located along the
flow path of a hot steam or hot gas.
[0053] The layer system 1 can be applied to a newly produced
component and to components which are refurbished after use. In the
latter case, the components first of all have degraded layers
removed from them, any cracks repaired, and then the substrate 4 is
recoated.
[0054] FIG. 7 shows a further exemplary embodiment of a layer
system 1. In this layer system 1, the continuous anchoring means 10
or inner anchoring means 13 are present only in the interlayer 7.
The outer layer 9 is present on the interlayer 7. A contact surface
of the continuous anchoring means 10 against the inner surface 8
improves the bonding of the outer layer 9 compared to a comparable
contact surface with the interlayer 7. This is achieved, for
example, by virtue of the fact that the contact surfaces of the
continuous anchoring means 10 form nuclei, for example of aluminum
oxide, at the inner surface 8 for epitaxial growth, for example, of
an outer layer 9 on the interlayer 7. Even without interlayer 7
(FIGS. 4, 5, right-hand side), an improved layer system 1 is
achieved by virtue of the fact that the continuous anchoring means
10 or the inner anchoring means 13 lead to improved attachment of
the outer layer 9 to the substrate 4.
[0055] In this context, it is not necessary for some or not
imperative for all of the continuous anchoring means 10 or inner
anchoring means 13 to have a part 14 extending into the substrate
4.
[0056] FIG. 8 shows a further exemplary embodiment of a layer
system 1. The continuous anchoring means 10 or inner anchoring
means 13 are only present in the outer layer 9 in this exemplary
embodiment.
[0057] In this case, some but not necessarily all of the continuous
anchoring means 10 or inner anchoring means 13 extend into the
substrate 4 or into the interlayer 7.
[0058] By way of example, FIG. 4 shows process steps involved in a
process for producing a layer system 1. In a first step, the at
least one outer layer 9 is applied to the substrate 4 in a known
way.
[0059] The outer layer 9 is treated, for example, with a laser 17
or an electron beam gun 17, which emits a corresponding laser or
electron beam 19. As a result of this type of treatment, the
material of the outer layer 9 is locally converted, for example
partially melted, down to the substrate surface 5 of the substrate
4 or even beyond it by way of a part 14 into the substrate 4, so as
to produce melt-metallurgical attachment of material from the outer
layer 9 into the substrate 4. This process produces continuous
anchoring means 10 which extend from the substrate surface 5 to the
outer surface 16 of the outer layer 9.
[0060] The statements which have been made in connection with the
outer layer 9 (without interlayer 7) apply similarly to an
interlayer 7 to which an outer layer 9 is also applied.
[0061] FIG. 5 shows a further production process. In a first step,
first of all the continuous anchoring means 10 or inner anchoring
means 13 are applied to the substrate 4, i.e. produced separately.
This can be done in various ways, such as for example by means of a
suitably guided laser welding process or laser cladding. The
continuous anchoring means 10 or inner anchoring means 13 in
particular have a very strong attachment, in particular by melt
metallurgy, to the substrate 4.
[0062] However, the continuous anchoring means 10 or inner
anchoring means 13 may also already have been produced during
production of the substrate 4, for example by a casting
process.
[0063] In a subsequent process, the outer layer 9 is applied, with
the continuous anchoring means 10 or inner anchoring means 13 being
surrounded by the material of the outer layer 9 and forming bonding
bridges for the layer 9.
[0064] The material of the continuous anchoring means 10 or inner
anchoring means 13 may be the same as the material of the outer
layer 9 or the same as the material of the substrate 4 or may
alternatively also have a different material composition.
[0065] The statements which have been made in connection with the
outer layer 9 (without interlayer 7) apply in a similar way to an
interlayer 7 to which an outer layer 9 is also applied.
[0066] FIG. 9a shows a component 1 according to the invention
(cross section through a continuous anchoring means 10). The
continuous anchoring means 10 has a larger cross-sectional area 11
at the outer surface 16 than at the substrate surface 5 below (FIG.
9b, plan view of FIG. 9a).
[0067] The shape of the continuous anchoring means 10 in cross
section is in this case, for example, in the form of a bell. The
cross-sectional contour may also take other shapes, such as for
example a parabolic profile, in which case the parabola is open at
the top 16 (FIG. 9b).
[0068] The cross section of the continuous anchoring means 10 is in
this case, by way of example, round in form (FIG. 9b). Other cross
sections are possible (oval). The cross-sectional area of the
continuous anchoring means 10 at the substrate surface 5 is
indicated by dashed lines.
[0069] In this case, the continuous anchoring means 10 may likewise
extend into the substrate 4 (not shown).
[0070] The material of the continuous anchoring means 10 may, in
the outer layer 9, for example, correspond to the material of the
substrate 4 (metallic) or may be ceramic.
[0071] In particular, the material of the outer layer 9 consists of
an alloy of the MCrAlX type, in which case the anchoring means 10
include a material of an alloy of the MCrAlX type, which
corresponds to that of the outer layer 9 or has been modified.
[0072] FIG. 20 shows a further exemplary embodiment of a component
1 according to the invention. The layer system 1 comprises a
substrate 4, an interlayer 7 and an outer layer 9. The substrate 4
is, for example, a superalloy, and the interlayer 7 consists of an
alloy of the MCrAlX type, to which an outer ceramic thermal barrier
coating 9 has then been applied. Likewise, as illustrated in FIG.
9a, in this case the continuous anchoring means 10 are formed only
in the interlayer 7.
[0073] In FIG. 21, the continuous anchoring means 10 is arranged
only in the outer layer 9. In FIG. 22, the continuous anchoring
means 10 are arranged both in the interlayer 7 and in the outer
layer 9.
[0074] Furthermore, inner anchoring means 13 may also be present in
the exemplary embodiments shown in FIGS. 9, 20 to 22.
[0075] Should the outermost layer 9 flake off or have local damage
in the region of the continuous anchoring means 10, the continuous
anchoring means 10 ensures that the interlayer 7 remains on the
substrate 4 and the substrate 4 is still protected.
[0076] The material of the continuous anchoring means 10 may also
be selected in such a way that it serves as a growth nucleus, in
particular for epitaxial growth, when coating the interlayer 7 with
the material of the outer layer 9, for example a ceramic material.
In particular, the material of the interlayer 7 consists of an
alloy of the MCrAlX type, in which case the anchoring means 10
likewise consist of an alloy of the MCrAlX type, which may if
appropriate have been modified with respect to the composition of
the interlayer 7.
[0077] In particular, the material class of the continuous
anchoring means 10 or of the inner anchoring means 13 corresponds
to the material class of the interlayer 7 or of the outer layer 9
in which it is arranged: metal or ceramic.
[0078] FIGS. 10 to 12 show a process for producing the layer system
1.
[0079] The outer layer 9 and the continuous anchoring means 10 or
inner anchoring means 13 are produced, for example, in layers, i.e.
the outer layer 9 is produced, and thereafter or simultaneously the
continuous anchoring means 10 or the inner anchoring means 13 are
produced. On no account are the anchoring means at least mostly or
completely produced first of all (FIG. 5), followed by the layer,
or vice-versa (FIG. 4).
[0080] Therefore, starting from the substrate 4, which does not yet
have any outer layer 9, material for the outer layer 9 is applied
in layers, and the continuous anchoring means 10 or inner anchoring
means 13 are likewise produced in layers. Depending on whether
continuous anchoring means 10 or inner anchoring means 13 are
produced, laser heating, for example, is applied at the locations
where a continuous anchoring means 10 or inner anchoring means 13
is to be formed, melting the material, i.e. temporarily and locally
increasing the temperature.
[0081] If an inner anchoring means 13 is to be produced (FIG. 11),
which is not intended to extend as far as the outer surface 16 of
the layer 9, beyond a certain height the outer layer 9 is no longer
melted locally (FIG. 12).
[0082] The statements made in connection with the outer layer 9
(without interlayer 7) apply in a corresponding way for an
interlayer 7, to which an outer layer 9 is also applied.
[0083] FIGS. 13 to 15 show a further production process.
[0084] In this case, an outer layer 9 is already present on the
substrate 4. This is the case in particular if the component 1 is a
component which is to be repaired, i.e. has already been used and
in particular has local damage in the form of a recess 34.
[0085] This recess 34 has, for example, been weakened or was
exposed to high demands in use, and in a first step is treated for
example by means of a laser 17 (or electron beam gun) and its laser
beams 19 (FIG. 13), so that continuous anchoring means 10 or inner
anchoring means 13 are formed (FIG. 14).
[0086] In a further process step, the recess 34 is filled with
layer material 25 from a material feed 22 (for example powder
feed), for example by laser build-up welding, in which case either
only layer material 25 forms the filling, without the inner
anchoring means 13 shown in FIG. 14 being formed any further, so as
to produce an inner anchoring means 13 which does not extend as far
as the outer surface 16, or alternatively, for example, the laser
17 for the laser build-up welding is also used, for example, to
allow the continuous anchoring means 10 shown in FIG. 14 to grow as
far as the outer surface 16.
[0087] The continuous anchoring means 10 or inner anchoring means
13 may but does not have to have a part 14 (indicated by dashed
lines) extending into the substrate 4, or may be of the form shown
in FIG. 9.
[0088] The layer material 25 may be material of the outer layer 9
or of the substrate 4, but may also have a different composition.
Also, it is possible for an outer layer 9 to be locally absent in
the recess 34 and for material of, for example, the outer layer 9
to be applied, producing continuous anchoring means 10 or inner
anchoring means 13.
[0089] The statements made in connection with the outer layer 9
(without interlayer 7) apply in a corresponding way to an
interlayer 7 to which an outer layer 9 is also applied.
[0090] FIGS. 16, 17 show a further exemplary embodiment of a
process for producing a layer system 1.
[0091] By way of example, a plasma torch 31 (FIG. 16) is used to
produce the outer layer 9.
[0092] By means of a laser 17 and its laser beams 19, a continuous
anchoring means 10 or inner anchoring means 13 is produced, for
example simultaneously, for example by melting, as a result of the
material being treated by means of the laser 17, i.e. for example
partially melted, at least from time to time at the locations
intended for the continuous anchoring means 10 or inner anchoring
means 13.
[0093] It is also possible to use two lasers 17, 17' (FIG. 17), in
which case one laser 17' is used for the build-up process, for
example laser build-up welding with the aid of a material feed 22,
which delivers the layer material 25, and a laser 17 which, as in
FIG. 16, produces the continuous anchoring means 10 or inner
anchoring means 13.
[0094] The statements made in connection with the outer layer 9
(without interlayer 7) correspondingly also apply to an interlayer
7 to which an outer layer 9 is subsequently applied.
[0095] In FIGS. 13, 14, 15, 16 and 17, the interlayer 7 or the
outer layer 9 and the continuous anchoring means 10 or inner
anchoring means 13 can be produced in layers.
[0096] It is also possible for electron beam guns to be used
instead of the lasers 17, 17' or plasma torches 31. The use of
lasers, plasma torches is not restricted to the embodiments on
continuous anchoring means 10 or inner anchoring means 13 which
have a part 14 extending into the substrate 4 or into the
interlayer 7 or to a specific cross-sectional shape as shown in
FIG. 9.
[0097] FIG. 18 shows a gas turbine 100 in longitudinal part
section. In the interior, the gas turbine 100 has a rotor 103 which
is mounted so as to rotate about an axis of rotation 102 and is
also referred to as the turbine rotor. An intake casing 104, a
compressor 105, a, for example, torroidal combustion chamber 110,
in particular an annular combustion chamber 106, with a plurality
of coaxially arranged burners 107, a turbine 108 and the
exhaust-gas casing 109 follow one another along the rotor 103. The
annular combustion chamber 106 is in communication with a, for
example, annular hot-gas duct 111. There, by way of example, four
turbine stages 112 connected in series form the turbine 108. Each
turbine stage 112 is formed from two blade or vane rings. As seen
in the direction of flow of a working medium 113, a row 125 of
rotor blades 120 follows a row 115 of guide vanes in the hot-gas
duct 111.
[0098] The guide vanes 130 are in this case secured to the stator
143, whereas the rotor blades 120 of a row 125 are arranged on the
rotor 103 by means of a turbine disk 133. A generator (not shown)
is coupled to the rotor 103.
[0099] While the gas turbine 100 is operating, the compressor 105
sucks in air 135 through the intake casing 104 and compresses it.
The compressed air which is provided at the turbine-side end of the
compressor 105 is passed to the burners 107, where it is mixed with
a fuel. The mixture is then burnt, forming the working medium 113
in the combustion chamber 110. From there, the working medium 113
flows along the hot-gas duct 111 past the guide vanes 130 and the
rotor blades 120. The working medium 113 expands at the rotor
blades 120 in such a manner as to transfer its momentum, so that
the rotor blades 120 drive the rotor 103 and the latter drives the
generator coupled to it.
[0100] When the gas turbine 100 is operating, the components
exposed to the hot working medium 113 are subject to thermal
stresses. The guide vanes 130 and rotor blades 120 of the first
turbine stage 112, as seen in the direction of flow of the working
medium 113, together with the heat shield bricks which line the
annular combustion chamber 106, are subject to the highest thermal
stresses. To be able to withstand the temperatures prevailing
there, these components are cooled by means of a cooling medium. It
is likewise possible for the blades or vanes 120, 130 to have
coatings protecting against corrosion (MCrAlX; M=Fe, Co, Ni, X=Y,
rare earths) and heat (thermal barrier coating, for example
ZrO.sub.2, Y.sub.2O.sub.4--ZrO.sub.2).
[0101] The guide vane 130 has a guide vane root (not shown here)
facing the inner casing 138 of the turbine 108 and a guide vane
head at the opposite end from the guide vane root. The guide vane
head faces the rotor 103 and is fixed to a securing ring 140 of the
stator 143.
[0102] FIG. 19 shows a combustion chamber 110 of a gas turbine 100.
The combustion chamber 110 is configured, for example, as what is
known as an annular combustion chamber, in which a multiplicity of
burners 107, which are arranged around the turbine shaft 103 in the
circumferential direction, open out into a common combustion
chamber space. For this purpose, the combustion chamber 110 as a
whole is configured as an annular structure which is positioned
around the turbine shaft 103.
[0103] To achieve a relatively high efficiency, the combustion
chamber 110 is designed for a relatively high temperature of the
working medium M of approximately 1000.degree. C. to 1600.degree.
C. To allow a relatively long operating time even under these
operating parameters, which are unfavorable for the materials, the
combustion chamber wall 153 is provided, on its side which faces
the working medium M, with an inner lining formed from heat shield
elements 155. On the working medium size, each heat shield element
155 is equipped with a particularly heat-resistant protective layer
or is made from material that is able to withstand high
temperatures. Moreover, on account of the high temperatures in the
interior of the combustion chamber 110, a cooling system is
provided for the heat shield elements 155 and/or for their holding
elements.
[0104] FIG. 24 shows a perspective view of a rotor blade 120 or
guide vane 130 of a turbomachine, which extends along a
longitudinal axis 121.
[0105] The turbomachine may be a gas turbine of an aircraft or a
power plant for power generation, a steam turbine or a
compressor.
[0106] The blade or vane 120, 130 includes, in succession along the
longitudinal axis 121, a securing region 400, an adjoining blade or
vane platform 403 and a main blade or vane part 406. When used as
guide vane 130, the vane 130 may have a further platform at its
vane tip 415 (not shown).
[0107] A blade or vane root 183, which is used to secure the rotor
blades 120, 130 to a shaft or a disk (not shown), is formed in the
securing region 400. The blade or vane root 183 is configured, for
example, in hammerhead form. Other configurations, as a fir tree
root or dovetail root are possible. The blade or vane 120, 130 has
a leading edge 409 and a trailing edge 412 with a respect to a
medium which flows past the main blade or vane part 406.
[0108] In the case of conventional blades or vanes 120, 130, by way
of example solid metallic materials, in particular superalloys, are
used in all regions 400, 403, 406 of the blade or vane 120, 130.
Superalloys of this type are known, for example, from EP 1 204 776
B1, EP 1 306 454, EP 1 319 729 A1, WO 99/67435 or WO 00/44949;
these documents form part of the present disclosure with regard to
the chemical composition of the alloy. The blade or vane 120, 130
may in this case be produced by a casting process, also by means of
directional solidification, by a forging process, by a milling
process or by combinations thereof.
[0109] Workpieces with a single-crystal structure or structures are
used as components for machines which are exposed to high
mechanical, thermal and/or chemical stresses in operation.
Single-crystal workpieces of this type are produced, for example,
by directional solidification from the melt. This involves casting
processes in which the liquid metallic alloy solidifies to form the
single-crystal structure, i.e. the single-crystal workpiece, or
directionally. Dendritic crystals are formed along the direction of
heat flow and form either a columnar grain structure (i.e. grains
which run over the entire length of the workpiece and are referred
to here, in accordance with the usual terminology, as directionally
solidified) or a single-crystal structure, i.e. the entire
workpiece comprises a single crystal. In these processes,
transition to the globular (polycrystalline) solidification needs
to be avoided, since non-directional growth inevitably leads to the
formation of transverse and longitudinal grain boundaries which
negate the good properties of the directionally solidified or
single-crystal component. Wherever the text refers in general terms
to directionally solidified microstructures, this is also to be
understood as encompassing single crystals which do not have any
grain boundaries or at most have small-angle grain boundaries, as
well as columnar crystal structures, which do have grain boundaries
running in the longitudinal direction but do not have any
transverse grain boundaries. This second type of crystalline
structures is also referred to as directionally solidified
microstructures (directional solidified structures). Processes of
this type are known from U.S. Pat. No. 6,024,794 and EP 0 892 090
A1; these documents form part of the disclosure.
[0110] It is also possible for the blades or vanes 120, 130 to have
coatings protecting against corrosion or oxidation (MCrAlX; M is at
least one element selected from the group consisting of iron (Fe),
cobalt (Co), nickel (Ni), X is an active element and stands for
yttrium (Y) and/or silicon and/or at least one of the rare earth
elements, or hafnium (Hf)). Alloys of this type are known from
EP0486489 B1, EP0786017 B1, EP 0 412 397 B1 or EP 1 306 454 A1,
which are intended to form part of the present disclosure with
regard to the chemical composition of the alloy.
[0111] It is also possible for a thermal barrier coating
consisting, for example, of ZrO.sub.2,
Y.sub.2O.sub.4--ZrO.sub.2--i.e. this coating is not stabilized, is
partially stabilized or is completely stabilized by yttrium oxide
and/or calcium oxide and/or magnesium oxide--to be present on the
MCrAlX. Columnar grains are produced in the thermal barrier coating
by suitable coating processes, such as for example electron beam
physical vapor deposition (EB-PVD).
[0112] Refurbishment means that components 120, 130, after they
have been used, if appropriate have protective layers removed (e.g.
by sand blasting). Then, the corrosion and/or oxidation layers and
products are removed. Any cracks in the component 120, 130 are also
repaired. Then, the component 120, 130 is recoated and the
component 120, 130 is reused.
[0113] The blade or vane 120, 130 may be hollow or solid in form.
If the blade or vane 120, 130 is to be cooled, it is hollow and may
also have film cooling holes 418 (indicated by dashed lines).
* * * * *