BACKGROUND OF THE INVENTION
[0001] The present invention relates to the technology of power plants. It refers to a power
plant component according to of claim 1.
PRIOR ART
[0002] Several power plant components such as compressor blade, steam turbine blade and
wind blade undergo water droplet erosion, corrosion and fouling. The best way of protection
against these damages is protecting blades (or other components) using multi-function
composite coatings.
[0003] The steel material that is used for compressor blades in gas turbines suffers from
water droplet erosion and corrosion pitting induced cracking as well as fouling.
[0004] On-line and off-line washings are performed in required intervals in order to improve
the performance of the turbine. By applying functional composite coatings on compressor
blades, the off-line washing intervals can be extended; less blade erosion occurs
during on-line washing and in high fogging systems compressor efficiency is increased.
[0005] In addition gas turbines are used in environments, which are highly corrosive for
instance in industrial areas or coastlines and therefore undergo a heavy pitting corrosion.
[0006] The presence of aerosols and soot in atmosphere causes fouling formation on the blades
that worsens the corrosion.
[0007] The existing solutions do not address the main three properties of erosion, corrosion
and fouling, especially fouling is not addressed or it is very vague. Or the coating
considered as anti-fouling is not erosion resistant and therefore anti-fouling property
will be lost during operation. Or coating application methods such as sputtering or
CVD and PVD are used which are not cost effective or difficult to apply.
[0008] Document
US 2010/0247321 A1 presents an article including a metallic substrate. The article further includes
a sacrificial layer disposed on a surface of the substrate and an anti-fouling layer
disposed on the sacrificial layer. The anti-fouling layer includes a metal-polymer
composite. An article including an anti-fouling layer having a nitride is also presented.
[0009] Document
US 2009/0176110 A1 discloses a coating system and process capable of providing erosion and corrosion-resistance
to a component, particularly a steel compressor blade of an industrial gas turbine.
The coating system includes a metallic sacrificial undercoat on a surface of the component
substrate, and a ceramic topcoat deposited by thermal spray on the undercoat. The
undercoat contains a metal or metal alloy that is more active in the galvanic series
than iron, and electrically contacts the surface of the substrate. The ceramic topcoat
consists essentially of a ceramic material chosen from the group consisting of mixtures
of alumina and titania, mixtures of chromia and silica, mixtures of chromia and titania,
mixtures of chromia, silica, and titania, and mixtures of zirconia, titania, and yttria.
[0010] EP 2 374 916 A1 describes a process for providing a protective coating to a metal surface which comprises
applying a nickel or tantalum plate layer to the surface and dispersing particles
of a hard material such as diamond, alumina, vanadium nitride, tantalum carbide and/or
tungsten carbide within the nickel or tantalum plate layer as the plating is occurring.
[0011] EP 2 060 328 A2 discloses a method of forming a composite powder coating which comprises depositing
multiple layers of a powder coating composition onto a substrate, wherein adjacent
layers are formed of a different powder coating composition; and curing the multiple
layers of the powder coating composition in a single thermal curing step. The layers
can be used to protect power generation equipment from aqueous corrosion, particle
erosion, slurry erosion, fretting, and fouling.
[0012] US 8,007,246 B2 provides a method of fabricating a component for a gas turbine engine is provided.
The method includes applying a bond coat to at least a portion of the component, applying
a dense vertically cracked (DVC) thermal barrier coating to at least a portion of
the bond coat using a spray mechanism positioned a first distance from the component,
and overlying at least a portion of the DVC thermal barrier coating with a soft coat
thermal barrier coating using a spray mechanism that is positioned a second distance
away from the component, wherein the second distance is greater than the first distance
to facilitate adherence of the soft coating thermal barrier coating to the DVC thermal
barrier coating.
SUMMARY OF THE INVENTION
[0013] It is an object of the present invention to provide a power plant component with
a functional surface with anti-erosion, anti-corrosion and anti-fouling properties.
[0014] It is another object of the invention to provide a power plant component with a composite
coating system for providing metal and ceramic surfaces with improved water droplet
erosion, enhanced corrosion resistance and enhanced anti-fouling properties.
[0015] These and other objects are obtained by a power plant component according to Claim
1.
[0016] The power plant component according to the invention comprises a substrate the surface
of which is coated with a functionally graded coating of a predetermined thickness,
with anti-erosion, anti-corrosion and anti-fouling properties.
[0017] It is characterized in that said functionally graded coating comprises a corrosion
resistant first means, and an erosion resistant and hydrophobic second means, and
that said functionally graded coating is a composite coating consisting of a single
layer, whereby the concentration of said corrosion resistant first means and the concentration
of said erosion resistant and hydrophobic second means vary gradually along the thickness
of said composite coating, whereby the concentration of said corrosion resistant first
means varies gradually from a high concentration at the inner side of said composite
coating to a low concentration at the outer side of said composite coating, and that
the concentration of said erosion resistant and hydrophobic second means varies gradually
from a low concentration at the inner side of said composite coating to a high concentration
at the outer side of said composite coating.
[0018] According to an embodiment of the invention said substrate is a metal or composite
polymer substrate.
[0019] According to the invention said corrosion resistant first means comprises a metal,
ceramic, cermet and/or polymer matrix, in which particles are embedded, whereby the
concentration of said particles varies gradually from a high concentration at the
inner side of said composite coating to a low concentration at the outer side of said
composite coating.
[0020] Said particles comprise micro or nano metal, ceramic and/or polymer materials, which
provide corrosion protection by electronegativity and/or self-healing reaction.
[0021] According to a further embodiment of the invention said corrosion resistant first
means comprise a Ni matrix with one of Al, Zn, Zr or Mg particles.
[0022] According to the invention said erosion resistant and hydrophobic second means comprises
a metal, ceramic, cermet and/or polymer matrix, in which hard ceramic, metallic and/or
polymer nano or micro materials are included, whereby the concentration of said materials
varies gradually from a low concentration at the inner side of said composite coating
to a high concentration at the outer side of said composite coating.
[0023] According to the invention said erosion resistant and hydrophobic second means comprises
ceramic, metallic or intermetallic particles coated with ceramic or polymer material,
whereby said ceramic, metallic or intermetallic particles are erosion resistant and
said ceramic or polymer coating material is anti-fouling.
[0024] Said ceramic, metallic and/or polymer nano or micro particles or fibers may comprise
one of SiC, Al
2O
3, SiO
2, WC, BN, MAX phases (e.g. Ti
3SiC
2, Ti
2AlC, Cr
2AlC), carbon nanotubes (CNTs), graphene oxide and hydrophobic particles, especially
of PTFE.
[0025] The method for manufacturing a power plant component according to the present disclosure
is characterized in that the surface of said substrate is activated and prepared with
a thin bonding layer and chemical or mechanical treatments.
[0026] According to an embodiment of the method said composite coating is applied by spraying
process, especially Atmospheric Plasma Spraying (APS), cold spray, High Voltage Oxide
Fuel (HVOF) process, or electro and electroless plating and electrophoretic process.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The present invention is now to be explained more closely by means of different embodiments
and with reference to the attached drawings.
- Fig. 1
- shows the surface structure with a graded composite coating of a component according
to an embodiment of the invention;
- Fig. 2
- shows a diagram of the thickness-dependant concentration of an erosion resistant material
within said graded composite coating of Fig. 1; and
- Fig. 3
- shows a diagram of the thickness-dependant concentration of a corrosion resistant
material within said graded composite coating of Fig. 1.
DETAILED DESCRIPTION OF DIFFERENT EMBODIMENTS OF THE INVENTION
[0028] The present invention is about producing engineered functional coatings and surfaces
for power plant components for example gas turbine compressor blades using new materials,
design and processing. New functional surfaces are provided with anti-erosion, anti-
corrosion and anti-fouling properties.
[0029] The present invention presents a composite coating system for providing metal and
ceramic surfaces with improved water droplet erosion, enhanced corrosion resistance
and enhanced anti-fouling properties.
[0030] The coating comprises only one functionally graded layer, where the required properties
of corrosion resistance and erosion resistance and hydrophobic properties are varied
gradually along the thickness of the layer.
[0031] According to Fig. 1-3 the power plant component 10, e.g. a turbine blade, comprises
a substrate 11 made of a metal or a composite polymer the surface of which is covered
with composite coating 12. Thickness x of the coating begins at coordinate x1 (inner
side) and ends at coordinate x2 (outer side). Composite coating 12 contains corrosion
resistant first particles (corrosion resistant first means; small circles in Fig.
1) and erosion resistant and hydrophobic second particles/fibers (erosion resistant
and hydrophobic second means; larger circles and tildes in Fig. 1) with different
profiles of their concentration c. As shown in Fig. 2 the concentration c of the erosion
resistant and hydrophobic particles increases from a low concentration c1 at x1 (inner
side) to a high concentration c2 at x2 (outer side). On the other hand (see Fig. 3),
the concentration c of the corrosion resistant particles decreases from a high concentration
c3 at x1 to a low concentration c4 at x2.
[0032] Said substrate 11 may be a metal or composite polymer substrate.
[0033] Said corrosion resistant first means comprise a metal, ceramic, cermet and/or polymer
matrix, in which particles/fibers are embedded, whereby the concentration of said
particles varies gradually from a high concentration at the inner side of said composite
coating to a low concentration at the outer side of said composite coating.
[0034] Said particles/fibers comprise micro or nano metal, ceramic and/or polymer materials,
which provide corrosion protection by electronegativity and/or self-healing reaction.
[0035] Furthermore, said corrosion resistant first means may comprise a Ni matrix with one
of Al, Zn, Zr or Mg particles.
[0036] Said erosion resistant and hydrophobic second means comprise a metal, ceramic, cermet
and/or polymer matrix, in which hard ceramic, metallic and/or polymer nano or micro
materials are included, whereby the concentration of said materials varies gradually
from a low concentration at the inner side of said composite coating to a high concentration
at the outer side of said composite coating (see Fig. 2), or said erosion resistant
and hydrophobic second means may comprise ceramic, metallic or intermetallic particles
coated with ceramic or polymer material, whereby said ceramic, metallic or intermetallic
particles are erosion resistant and said ceramic or polymer coating material is anti-fouling.
Especially, said ceramic, metallic and/or polymer nano or micro particles or fibers
may comprise one of SiC, Al
2O
3, SiO
2, WC, BN, MAX phases (e.g. Ti
3SiC
2, Ti
2AlC, Cr
2AlC), carbon nanotubes (CNTs), graphene oxide and hydrophobic particles, especially
of PTFE.
LIST OF REFERENCE NUMERALS
[0037]
- 10
- power plant component
- 11
- substrate
- 12
- composite coating
- c,c1,c2,c3,c4
- concentration
- x,x1,x2
- coating thickness (coordinate)
1. Power plant component (10), comprising a substrate (11) the surface of which is coated
with a functionally graded coating (12) of a predetermined thickness, with anti-erosion,
anti-corrosion and anti-fouling properties, wherein said functionally graded coating
(12) comprises a corrosion resistant first means, and an erosion resistant and hydrophobic
second means, and that said functionally graded coating is a composite coating (12)
consisting of a single layer, whereby the concentration of said corrosion resistant
first means and the concentration of said erosion resistant and hydrophobic second
means vary gradually along the thickness (x) of said composite coating (12), whereby
the concentration of said corrosion resistant first means varies gradually from a
high concentration (c3) at the inner side (x1) of said composite coating (12) to a
low concentration (c4) at the outer side (x2) of said composite coating (12), and
that the concentration of said erosion resistant and hydrophobic second means varies
gradually from a low concentration (c1) at the inner side (x1) of said composite coating
(12) to a high concentration (c2) at the outer side (x2) of said composite coating
(12),
wherein said corrosion resistant first means comprises a metal, ceramic, cermet and/or
polymer matrix, in which particles are embedded, whereby the concentration of said
particles varies gradually from a high concentration at the inner side of said composite
coating to a low concentration at the outer side of said composite coating, and said
particles comprise micro or nano metal, ceramic and/or polymer materials, which provide
corrosion protection by electronegativity and/or self-healing reaction, and
wherein said erosion resistant and hydrophobic second means comprises:
- a metal, ceramic, cermet and/or polymer matrix, in which hard ceramic, metallic
and/or polymer nano or micro materials are included, whereby the concentration of
said materials varies gradually from a low concentration at the inner side of said
composite coating to a high concentration at the outer side of said composite coating,
or
- ceramic, metallic or intermetallic particles coated with ceramic or polymer material,
whereby said ceramic, metallic or intermetallic particles are erosion resistant and
said ceramic or polymer coating material is anti-fouling.
2. Power plant component as claimed in Claim 1, characterized in that said substrate (11) is a metal or composite polymer substrate.
3. Power plant component as claimed in Claim 1, characterized in that said corrosion resistant first means comprise a Ni matrix with one of Al, Zn, Zr
or Mg particles.
4. Power plant component as claimed in Claim 1, characterized in that said ceramic, metallic and/or polymer nano or micro particles or fibers comprises
one of SiC, Al2O3, SiO2, WC, BN, MAX phases (e.g. Ti3SiC2, Ti2AlC, Cr2AlC), carbon nanotubes (CNTs), graphene oxide and hydrophobic particles, especially
of PTFE.
1. Kraftwerkkomponente (10), umfassend ein Substrat (11) dessen Oberfläche mit einer
funktionellen abgestuften Beschichtung (12) einer vorbestimmten Dicke mit Erosionsschutz-,
Korrosionsschutz- und Bewuchsschutzeigenschaften beschichtet ist, wobei die funktionelle
abgestufte Beschichtung (12) ein korrosionsbeständiges erstes Mittel und ein erosionsbeständiges
und hydrophobes zweites Mittel umfasst, und dass die funktionelle abgestufte Beschichtung
eine Verbundbeschichtung (12) ist, die aus einer einzelnen Schicht besteht, wobei
die Konzentration des korrosionsbeständigen ersten Mittels und die Konzentration des
erosionsbeständigen und hydrophoben zweiten Mittels graduell entlang der Dicke (x)
der Verbundbeschichtung (12) variieren, wobei die Konzentration des korrosionsbeständigen
ersten Mittels graduell von einer hohen Konzentration (c3) an der inneren Seite (x1)
der Verbundbeschichtung (12) zu einer geringen Konzentration (c4) an der äußeren Seite
(x2) der Verbundbeschichtung (12) variiert, und dass die Konzentration des erosionsbeständigen
und hydrophoben zweiten Mittels graduell von einer geringen Konzentration (c1) an
der inneren Seite (x1) der Verbundbeschichtung (12) zu einer hohen Konzentration (c2)
an der äußeren Seite (x2) der Verbundbeschichtung (12) variiert,
wobei das korrosionsbeständige erste Mittel ein Metall, Keramik, Cermet und/oder eine
Polymermatrix umfasst, in der Partikel eingebettet sind, wobei die Konzentration der
Partikel graduell von einer hohen Konzentration an der inneren Seite der Verbundbeschichtung
zu einer geringen Konzentration an der äußeren Seite der Verbundbeschichtung variiert,
und die Partikel Mikro- oder Nanometall, Keramik und/oder Polymermaterialien umfassen,
die einen Korrosionsschutz durch Elektronegativität und/oder selbstheilende Reaktion
bereitstellen, und
wobei das erosionsbeständige und hydrophobe zweite Mittel umfasst:
- ein Metall, Keramik, Cermet und/oder eine Polymermatrix in der harte keramische,
metallische und/oder polymerische Nano- oder Mikromaterialien enthalten sind, wobei
die Konzentration der Materialien graduell von einer geringen Konzentration an der
inneren Seite der Verbundbeschichtung zu einer hohen Konzentration an der äußeren
Seite der Verbundbeschichtung variiert, oder
- keramische, metallische oder intermetallische Partikel, die mit Keramik- oder Polymermaterial
beschichtet sind, wobei die keramischen, metallischen oder intermetallischen Partikel
erosionsbeständig sind und das Keramik- oder Polymerbeschichtungmaterial bewuchsschützend
ist.
2. Kraftwerkkomponente nach Anspruch 1, dadurch gekennzeichnet, dass das Substrat (11) ein Metall- oder Verbundpolymersubstrat ist.
3. Kraftwerkkomponente nach Anspruch 1, dadurch gekennzeichnet, dass das korrosionsbeständige erste Mittel eine Ni-Matrix mit einem von Al-, Zn-, Zr-
oder Mg-Partikeln umfasst.
4. Kraftwerkkomponente nach Anspruch 1, dadurch gekennzeichnet, dass die keramischen, metallischen und/oder polymerischen Nano- oder Mikropartikel oder
- fasern eines von SiC, Al2O3, SiO2, WC, BN, MAX-Phasen (z.B. Ti3SiC2, Ti2AlC, Cr2AlC), Kohlenstoffnanoröhrchen (CNTs), Graphitoxid und hydrophoben Partikeln umfassen,
insbesondere aus PTFE.
1. Composant de centrale électrique (10), comprenant un substrat (11) dont la surface
est revêtue avec un revêtement à gradient de fonctionnalité (12) ayant une épaisseur
prédéterminée, présentant des propriétés anti-érosion, anticorrosion et anti-encrassement,
dans lequel ledit revêtement à gradient de fonctionnalité (12) comprend un premier
moyen résistant à la corrosion, et un second moyen hydrophobe et résistant à l'érosion,
et que ledit revêtement à gradient de fonctionnalité est un revêtement composite (12)
consistant en une monocouche, selon lequel la concentration dudit premier moyen résistant
à la corrosion et la concentration dudit second moyenne hydrophobe et résistant à
l'érosion varient graduellement le long de l'épaisseur (x) dudit revêtement composite
(12), selon lequel la concentration dudit premier moyen résistant à la corrosion varie
graduellement d'une concentration élevée (c3) au niveau du côté interne (x1) dudit
revêtement composite (12) à une concentration basse (c4) au niveau du côté externe
(x2) dudit revêtement composite (12), et que la concentration dudit second moyen hydrophobe
et résistant à l'érosion varie graduellement d'une concentration basse (c1) au niveau
du côté interne (x1) dudit revêtement composite (12) à une concentration élevée (c2)
au niveau du côté externe (x2) dudit revêtement composite (12),
dans lequel ledit premier moyen résistant à la corrosion comprend une matrice métallique,
céramique, en cermet et/ou polymère, dans laquelle des particules sont incrustées,
selon lequel la concentration desdites particules varie graduellement d'une concentration
élevée au niveau du côté interne dudit revêtement composite à une concentration basse
au niveau du côté externe dudit revêtement composite, et lesdites particules comprennent
des micro- ou nano-matériaux métalliques, céramiques et/ou polymères, qui fournissent
une protection contre la corrosion par électronégativité et/ou réaction d'auto-réparation,
et
dans lequel ledit second moyen hydrophobe et résistant à l'érosion comprend :
- une matrice métallique, céramique, en cermet et/ou polymère, dans laquelle des nano-
ou micro-matériaux céramiques, métalliques et/ou polymères durs sont inclus, selon
lequel la concentration desdits matériaux varie graduellement d'une concentration
basse au niveau du côté interne dudit revêtement composite à une concentration élevée
au niveau du côté externe dudit revêtement composite, ou
- des particules céramiques, métalliques ou intermétalliques revêtues avec un matériau
céramique ou polymère, selon lequel lesdites particules céramiques, métalliques ou
intermétalliques sont résistantes à l'érosion et ledit matériau de revêtement céramique
ou polymère est anti-encrassement.
2. Composant de centrale électrique selon la revendication 1, caractérisé en ce que ledit substrat (11) est un substrat métallique ou polymère composite.
3. Composant de centrale électrique selon la revendication 1, caractérisé en ce que ledit premier moyen résistant à la corrosion comprend une matrice de Ni avec l'une
de particules d'Al, Zn, Zr ou Mg.
4. Composant de centrale électrique selon la revendication 1, caractérisé en ce que lesdites nano- ou micro-particules ou fibres céramiques, métalliques et/ou polymères
comprennent l'un parmi SiC, Al2O3, SiO2, WC, BN, des phases MAX (par exemple Ti3SiC2, Ti2AlC, Cr2AlC), des nanotubes de carbone (CNT), un oxyde de graphène et des particules hydrophobes,
en particulier de PTFE.