U.S. patent application number 12/067274 was filed with the patent office on 2009-07-02 for method of producing a protective coating, protective coating, and component with a protective coating.
Invention is credited to Klaus Breitschwerdt, Christian Friedrich.
Application Number | 20090169372 12/067274 |
Document ID | / |
Family ID | 37450740 |
Filed Date | 2009-07-02 |
United States Patent
Application |
20090169372 |
Kind Code |
A1 |
Friedrich; Christian ; et
al. |
July 2, 2009 |
METHOD OF PRODUCING A PROTECTIVE COATING, PROTECTIVE COATING, AND
COMPONENT WITH A PROTECTIVE COATING
Abstract
A method for producing a wear-resistant, temperature-resistant,
and corrosion-resistant protective coating for a component, in
particular for components of a gas turbine, using thermal spraying,
wherein during the application onto the component of the protective
coating, which consists of a hard material-metal combination, in
order to produce an abrasive surface a structuring of that surface
of the protective coating that faces away from the component takes
place, the hard material or materials consisting of boron nitride
particles, titanium carbide particles, tungsten carbide particles,
chromium carbide particles, and zirconium oxide particles, or a
mixture thereof, and the hard materials having a particle size of
0.1 .mu.m-200 .mu.m, and the protective coating having a thickness
of 10 .mu.m-6.0 mm.
Inventors: |
Friedrich; Christian; (West
Hartford, CT) ; Breitschwerdt; Klaus; (Germering,
DE) |
Correspondence
Address: |
GREER, BURNS & CRAIN
300 S WACKER DR, 25TH FLOOR
CHICAGO
IL
60606
US
|
Family ID: |
37450740 |
Appl. No.: |
12/067274 |
Filed: |
September 16, 2006 |
PCT Filed: |
September 16, 2006 |
PCT NO: |
PCT/DE2006/001636 |
371 Date: |
November 26, 2008 |
Current U.S.
Class: |
415/200 ;
427/142; 427/450; 428/614 |
Current CPC
Class: |
Y10T 428/12486 20150115;
C23C 4/01 20160101; Y02T 50/60 20130101; C23C 4/00 20130101 |
Class at
Publication: |
415/200 ;
427/450; 428/614; 427/142 |
International
Class: |
F01D 25/00 20060101
F01D025/00; C23C 4/10 20060101 C23C004/10 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 21, 2005 |
DE |
10 2005 044 991.3 |
Claims
1-13. (canceled)
14. A method for producing a wear-resistant, temperature-resistant,
and corrosion-resistant protective coating for a component, in
particular for components of a gas turbine, using thermal spraying,
characterized in that during the application onto the component of
the protective coating, which consists of a hard material-metal
combination, in order to produce an abrasive surface a structuring
of that surface of the protective coating that faces away from the
component takes place, the hard material or materials consisting of
boron nitride particles, titanium carbide particles, tungsten
carbide particles, chromium carbide particles, and zirconium oxide
particles, or a mixture thereof, and the hard materials having a
particle size of 0.1 .mu.m-200 .mu.m, and the protective coating
having a thickness of 10 .mu.m-6.0 mm.
15. The method as recited in claim 14, wherein the structuring is
produced by a covering masking during the application of the
protective coating.
16. The method as recited in claim 14, wherein the structuring is
produced by a segmented application of the protective coating.
17. The method as recited in claim 14, wherein the structuring is
produced by applying the protective coating onto the component with
different thicknesses.
18. A protective coating, namely a wear-resistant,
temperature-resistant, and corrosion-resistant protective coating
for a component, in particular for components of a gas turbine,
having an abrasive surface, wherein the protective coating has a
one-layer construction and is produced using a method according to
claim 14, and that the protective coating is made of a hard
material-metal combination, and that the hard material or materials
consist of boron nitride particles, titanium carbide particles,
tungsten carbide particles, chromium carbide particles, and
zirconium oxide particles, or a mixture thereof, and that the hard
materials have a particle size of 0.1 .mu.m-200 .mu.m, and that the
protective coating has a thickness of 10 .mu.m-6.0 mm.
19. The protective coating as recited in claim 18, wherein the
protective coating has a thickness of 30 .mu.m-300 .mu.m, in
particular 30-150 .mu.m.
20. The protective coating as recited in claim 18, wherein the hard
materials are situated in a matrix made of metal or a metal
alloy.
21. The protective coating as recited in claim 14, wherein the
protective coating is fashioned as a continuous or segmented
layer.
22. The protective coating as recited in claim 14, wherein the
protective coating has different thicknesses.
23. The protective coating as recited in claim 14, wherein the
protective coating has a blade-like construction.
24. The protective coating as recited in claim 14, wherein the
protective coating has a multiplicity of projections on the surface
of the layer that faces away from the component.
25. A component, in particular a component of a gas turbine, having
a protective coating as recited in claim 18.
26. The use of a wear-resistant, temperature-resistant,
oxidation-resistant, and corrosion-resistant protective coating as
recited in claim 18, for the coating and/or repair of turbine parts
and engine parts, in particular of gas turbines in an aircraft
engine.
Description
[0001] The present invention relates to a method for producing a
wear-resistant, temperature-resistant, and corrosion-resistant
protective coating or layer for a component, in particular for
components of a gas turbine, using thermal spraying. In addition,
the present invention relates to a protective coating, namely a
wear-resistant, temperature-resistant, and corrosion-resistant
protective coating for a component, in particular for components of
a gas turbine, having an abrasive surface. In addition, the present
invention relates to a component, in particular a component of a
gas turbine, having a protective coating.
[0002] Such coatings for protecting against corrosion and against
oxidation are known, and are used in particular in parts of
turbines or aircraft engines, and also combustion chambers. What
are known as MCrAlY coatings are used as heat corrosion protective
coatings, as described for example in U.S. Pat. No. 4,080,486,
EP-B1-0486489, and U.S. Pat. No. 4,585,481. In addition, these
MCrAlY coatings may be used as bonding agents or as an adhesive
layer between the metallic substrate onto which the protective
coating is applied and a ceramic covering layer. The application of
the protective coating takes place in particular using thermal
spraying methods, such as e.g. flame spraying, high-speed flame
spraying, detonation spraying, plasma spraying, electric arc
spraying, laser spraying, or melt-bath spraying. From
DE-A1-10260462 and DE-A1-10351168, additional methods are known for
producing a wear-free layer using thermal spraying. U.S. Pat. No.
5,935,407 also describes the application of a MCrAlY base layer
onto a workpiece using a plasma spraying method.
[0003] A disadvantage of these known methods, and of the protective
coatings that result from them, is that in order to produce known
protective coatings having abrasive surfaces or properties, it is
always necessary to use a plurality of method steps to apply the
actual protective coating. In addition, the protective coatings
resulting therefrom always have a multilayer construction (see also
EP-A1-0443877). Because of the high time expense involved in a
corresponding coating of a workpiece and the material outlay
connected therewith, this results in relatively high manufacturing
costs. In addition, required repairs of damaged protective coatings
are also very time-intensive and expensive to perform.
[0004] Therefore, the object of the present invention is to provide
a method of the type named above that on the one hand can be
carried out economically and on the other hand permits a simple and
rapid coating of corresponding components.
[0005] In addition, the object of the present invention is to
provide a protective coating of the type named above that can be
manufactured simply and with a low material outlay and that has
abrasive properties.
[0006] The object of the present invention is also to provide a
component of the type named above that is at least partly coated
with a protective coating that is simple and that can be applied
economically.
[0007] These objects are achieved by a method, a protective
coating, and a component according to the features and method steps
described in independent Claims 1, 5, and 16.
[0008] Advantageous constructions are described in the
subclaims.
[0009] In a method according to the present invention, a
wear-resistant, temperature-resistant, and corrosion-resistant
protective coating is applied to a component, in particular a
component of a gas turbine, by thermal spraying, the protective
coating, which consists of ceramic and/or of a hard material-metal
combination, being applied onto the component in order to produce
an abrasive surface of a structuring of the surface of the
protective coating facing away from the component. In this way, it
is advantageously possible for the wear-resistant layer to be
applied in a single working step, i.e. in one layer, using thermal
spraying. The structuring of the surface of the protective coating
facing away from the component takes place simultaneously. Because
no additional work steps are required to produce the protective
coating, the method can be carried out economically, simply, and
rapidly.
[0010] In an advantageous construction of the method according to
the present invention, the structuring is produced by a covering
masking during the application of the protective coating. However,
it is also possible for the structuring to be produced by a
segmented application of the protective coating, or of individual
protective coating elements. In addition, is possible for the
structuring to be produced by an application of the protective
coating onto the component having different thicknesses.
Advantageously, the type of structuring can be predetermined and
adapted to the corresponding requirements of the component or of
the protective coating.
[0011] A protective coating according to the present invention,
namely a wear-resistant, temperature-resistant, corrosion-resistant
protective coating for a component, in particular for components of
a gas turbine, has an abrasive surface, the protective coating
having a one-layer construction and being applied onto the
corresponding component by thermal spraying, a structuring of the
surface of the protective coating facing away from the component
taking place during the application of the protective coating,
which is made of ceramic and/or a hard material-metal combination,
in order to produce the abrasive surface. Such a protective coating
can be produced simply and economically. In particular, repairs to
damaged protective coatings can be carried out very quickly.
[0012] In an advantageous embodiment of the protective coating
according to the present invention, this layer has a thickness of
10 .mu.m-6 mm, in particular 10 .mu.m-300 .mu.m. In addition, the
hard material or materials are made up of boron nitride particles,
titanium carbide particles, tungsten carbide particles, chromium
carbide particles, or zirconium oxide particles, or a mixture
thereof. The hard materials can have a particle size of 0.1
.mu.m-200 .mu.m.
[0013] In another advantageous embodiment of the present invention,
the hard materials are arranged in a matrix made of metal or a
metal alloy. Standardly, the metallic matrix is composed according
to the formula MCrAlXAE, where M=Fe, Co, Ni, NiCo or CoNi, X=Si,
Ta, V, Nb, Pt, Pd, and AE=Y, Ti, Hf, Zr, Yb.
[0014] In further advantageous constructions of the protective
coating according to the present invention this layer can be
fashioned as a continuous or as a segmented layer. In addition, it
is possible for the protective coating to have different
thicknesses, to be formed with a blade-like shape, or to have a
multiplicity of projections on the surface of the layer that faces
away from the component. These projections can be for example
tooth-like, blade-like, or pointed. The named structuring
possibilities of the protective coating according to the present
invention are used to form the named abrasive surface.
[0015] A component according to the present invention, in
particular a component of a gas turbine, in particular a blade, has
in at least one partial area, in particular the blade tip, a
protective coating having the features described above.
[0016] The wear-resistant, high-temperature-resistant,
oxidation-resistant, and corrosion-resistant protective coating
according to the present invention is used in particular for the
coating and/or repair of turbine parts and engine parts, in
particular of gas turbines in aircraft engines.
[0017] Further details, features, and advantages of the present
invention result from the exemplary embodiments and examples of use
shown in the Figures.
[0018] FIG. 1 shows a schematic representation of a first exemplary
embodiment of a component according to the present invention having
a protective coating according to the present invention;
[0019] FIG. 2 shows a schematic representation of a second
exemplary embodiment of a component according to the present
invention having a protective coating according to the present
invention; and
[0020] FIGS. 3a to 3c show schematically represented side views of
further exemplary embodiments of components according to the
present invention, each having a protective coating according to
the present invention.
[0021] FIG. 1 shows a schematic representation of a first exemplary
embodiment of a component 10 having a protective coating 12. The
depicted component 10 is a turbine blade 20 having a blade foot 22
and a blade tip 18 situated opposite blade foot 22. It can be seen
that protective coating 12 is fashioned on blade tip 18. Here,
protective coating 12 is intended to be wear-resistant,
temperature-resistant, and corrosion-resistant, and is standardly
called a blade tip armor. In order to produce an abrasive surface
or abrasive properties, protective coating 12 is fashioned so as to
be structured on the surface of the layer that faces away from
component 10. The structuring takes place during the application of
protective coating 12 onto component 10. In the depicted exemplary
embodiment, protective coating 12 has a multiplicity of projections
16 on surface 14 that faces away from component 10.
[0022] FIG. 2 shows a schematic representation of a second
exemplary embodiment of a component 10 having a protective coating
12. In this exemplary embodiment, component 10 is also a turbine
blade 20. It can be seen that in this exemplary embodiment,
protective coating 12 is fashioned as a continuous layer. Abrasive
properties of protective coating 12 are achieved in this exemplary
embodiment through different thicknesses of protective coating 12,
or also through a blade-like design of protective coating 12 (cf.
FIG. 3c).
[0023] FIGS. 3a to 3c show schematic side views of additional
exemplary embodiments of components 10, each having a protective
coating 12. These components 10 are, again, turbine blades 20. It
can be seen that each of the blade tips 18 is covered at least
partly with protective coating 12. Protective coating 12 shown in
FIG. 3a has a segmented construction (cf. also FIG. 1). The
protective coatings 12 shown in FIGS. 3b and 3c have cross-sections
that taper outwardly. This results in cutting edges 24 that create
the abrasive property of protective coating 12 on surface 14
situated opposite component 10.
* * * * *