Aircraft engine part including a coating for protection against erosion, and a method of fabricating such a part

Abstract

An aircraft engine-part including at least a metal substrate and a protective coating for protection against erosion that is present on the substrate, the coating including at least one phase including at least chromium at an atom content greater than or equal to 45% and carbon at an atom content lying in the range 5% to 20%, the phase including Cr.sub.7C.sub.3 and Cr.sub.23C.sub.6 chromium carbides. A method of fabricating such a part in which electroplating is used to deposit a coating composition on the part and the part is subjected to heat treatment at a temperature lying in the range 250 C. to 70 C.

Claims

1. A method of fabricating an aircraft engine part comprising at least a metal substrate and a protective coating for protection against erosion that is present on the substrate, the coating comprising at least one phase comprising at least chromium at an atom content lying in the range of 45% to 58% and carbon at an atom content lying in the range of 5% to 20%, said phase comprising Cr.sub.7C.sub.3 and Cr.sub.23C.sub.6 chromium carbides, the method comprising at least the following steps: depositing on the substrate a coating composition comprising at least chromium at an atom content greater than or equal to 45% and carbon at an atom content lying in the range of 5% to 20%, the coating composition being deposited on the substrate by electroplating from an electrolyte bath comprising at least trivalent chromium and an organic compound; and subjecting the part coated with said composition to heat treatment at a temperature lying in the range of 250 C. to 700, in order to obtain the coating.

2. The method according to claim 1, wherein the heat treatment temperature lies in the range of 300 C. to 600 C.

3. The method according to claim 1, wherein the electrolyte bath further comprises metal particles and/or ceramic particles in suspension, the resulting coating further including metal particles and/or ceramic particles.

4. The method according to claim 1, wherein a thickness of the coating lies in the range of 5 m to 100 m.

5. The method according claim 1, wherein the substrate is made of steel, of aluminum-based alloy, of titanium-based alloy, or of nickel-based alloy.

6. The method according to claim 1, wherein the part constitutes an aircraft engine part selected from the following: at least a portion of a diffuser; at least a portion of an axial or centrifugal compressor; at least a portion of a nozzle.

7. The method according to claim 1, wherein the duration of the heat treatment lies in the range of 15 min to 280 min.

8. The method according to claim 1, wherein the at least one phase comprises carbon at an atom content lying in the range of 12% to 18%.

9. The method according to claim 1, wherein the at least one phase comprises chromium at an atom content lying in the range of 45% to 55%.

10. A method of fabricating an aircraft engine part comprising at least a metal substrate and a protective coating for protection against erosion that is present on the substrate, the coating comprising at least one phase comprising at least chromium at an atom content greater than or equal to 45% and carbon at an atom content lying in the range of 5% to 20%, said phase comprising Cr.sub.7C.sub.3, and Cr.sub.23C.sub.6 chromium carbides, the method comprising at least the following steps: depositing on the substrate a coating composition comprising at least chromium at an atom content greater than or equal to 45% and carbon at an atom content lying in the range of 5% to 20%, the coating composition being deposited on the substrate by electroplating from an electrolyte bath comprising at least trivalent chromium and an organic compound; and subjecting the part coated with said composition to heat treatment at a temperature lying in the range of 250 C. to 700, in order to obtain the coating, wherein the electrolyte bath further comprises metal particles and/or ceramic particles in suspension, the resulting coating further including metal particles and/or ceramic particles.

11. The method according to claim 10, wherein the heat treatment temperature lies in the range of 300 C. to 600 C.

12. The method according to claim 10, wherein a thickness of the coating lies in the range of 5 m to 100 m.

13. The method according claim 10, wherein the substrate is made of steel, of aluminum-based alloy, of titanium-based alloy, or of nickel-based alloy.

14. The method according to claim 10, wherein the part constitutes an aircraft engine part selected from the following: at least a portion of a diffuser; at least a portion of an axial or centrifugal compressor; at least a portion of a nozzle.

15. The method according to claim 10, wherein the duration of the heat treatment lies in the range of 15 minutes to 280 minutes.

16. A method of fabricating an aircraft engine part comprising at least a metal substrate and a protective coating for protection against erosion that is present on the substrate, the coating comprising at least one phase comprising at least chromium at an atom content greater than or equal to 45% and carbon at an atom content lying in the range of 5% to 20%, said phase comprising Cr.sub.7C.sub.3 and Cr.sub.23C.sub.6 chromium carbides, the method comprising at least the following steps: depositing on the substrate a coating composition comprising at least chromium at an atom content greater than or equal to 45% and carbon at an atom content lying in the range of 5% to 20%, the coating composition being deposited on the substrate by electroplating from an electrolyte bath comprising at least trivalent chromium and an organic compound; and subjecting the part coated with said composition to heat treatment at a temperature lying in the range of 250 C. to 700, in order to obtain the coating, wherein the part constitutes an aircraft engine part selected from the following: at least a portion of a diffuser; at least a portion of an axial or centrifugal compressor; at least a portion of a nozzle.

17. The method according to claim 16, wherein the heat treatment temperature lies in the range of 300 C. to 600 C.

18. The method according to claim 16, wherein a thickness of the coating lies in the range of 5 m to 100 m.

19. The method according claim 16, Wherein the substrate is made of steel, of aluminum-based alloy, of titanium-based alloy, or of nickel-based alloy.

20. The method according to claim 16, wherein the at least one phase comprises carbon at an atom content lying in the range of 12% to 18%.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Other characteristics and advantages of the present invention appear from the following description made with reference to the accompanying drawings. In the figures:

(2) FIG. 1 is a diagrammatic section view of an aircraft engine part coated in an erosion protection coating;

(3) FIG. 2 is a flow chart showing the main steps of a method of fabricating a coated part of the invention;

(4) FIG. 3 is a diagrammatic section view of a device used for electroplating a coating composition of the invention;

(5) FIG. 4A shows the influence of the temperature of the heat treatment on the hardness of the coating of a part of the invention; and

(6) FIG. 4B shows the influence of the temperature of heat treatment after depositing a chromium-based coating in the prior art.

DETAILED DESCRIPTION OF THE INVENTION

(7) Throughout the disclosure, the term lying in the range . . . to . . . should be understood as including the bounds.

(8) FIG. 1 is a diagrammatic section view showing the surface of a part 1 of an aircraft engine of the invention, e.g. constituted by a turboshaft engine diffuser.

(9) Such a part 1 comprises a metal substrate 2, e.g. made of steel, aluminum, titanium, an aluminum-based alloy, a titanium-based alloy, or a nickel-based alloy. The substrate 2 is coated by a protective coating 3 for protection against erosion. The erosion protective coating 3 in this example is in direct contact with the substrate 2 and covers it. The coating 3 preferably presents thickness e lying in the range 5 m to 100 m.

(10) In accordance with the invention, the coating 3 comprises a phase 4 constituting the majority by weight in the coating that is based on chromium and carbon. More precisely, the phase 4 comprises chromium at an atom content greater than or equal to 45%, and carbon at an atom content lying in the range 5% to 20%. The chromium and the carbon within the phase 4 of the coating 3 are present in particular in the form of chromium carbides of the Cr.sub.7C.sub.3 and Cr.sub.23C.sub.6 type.

(11) The coating 3 may also include a disperse phase 5 that is dispersed within the chromium and carbon phase 4 and that comprises metal and/or ceramic particles. By way of example, such metal particles may be particles of tungsten or of nickel. By way of example, such ceramic particles may be particles of alumina or of zirconia. The volume content in the coating of metal particles and/or of ceramic particles is preferably less than 20%, or more preferably lies in the range 5% to 15%. The metal particles and/or ceramic particles may have a size lying in the range 1 m to 30 m.

(12) Thus, the coating may be made up of a phase 4 comprising chromium and carbon that has metal particles and/or ceramic particles 5 dispersed therein. In a variant that is not shown, the coating 3 may be formed solely by the phase 4 comprising chromium and carbon.

(13) A method of fabricating an aircraft engine part 1 of the invention is described below with reference to the flow chart of FIG. 2 and to the diagram of FIG. 3 showing an electroplating device 6. The method described below includes a step of electroplating a coating composition 3. Naturally, the invention is not limited to depositing the coating composition by electroplating, and other techniques sire available for obtaining the coated part of the invention. By way of example, mention may be made of the techniques of physical vapor deposition, chemical vapor deposition, or indeed cementation.

(14) A first step of the method (step E1) may consist in decreasing the surface of the substrate on which a coating composition is to be deposited, e.g. by using an aqueous degreasing solution. Thereafter, the surface of the substrate may be prepared (step E2) in order to ensure that the electroplating is uniform over the substrate 2 and in order to increase its effectiveness. In order to prepare the surface, it is possible in known manner to subject it to sandblasting, chemical etching (e.g. with an acid solution), etc.

(15) Thereafter, it is possible to prepare an electrolyte bath 7 that contains at least ions of chromium (III) (trivalent chromium), and an organic complexing compound for chromium ions. By way of example, recourse may be had to known aqueous solutions comprising chromium (III) chloride and a carboxylic acid as a complexing agent. The electrolyte bath 7 may optionally be heated during the electroplating step. In addition, the electrolyte bath may include metal and/or ceramic particles in suspension, of the type mentioned above, so that they become integrated in the coating composition during electroplating.

(16) The part 1 with its prepared surface can then be connected to the negative terminal (acting as a cathode) of an electricity generator 8 and can be immersed in the electrolyte bath 7 as prepared beforehand. In the FIG. 3 device, two electrodes 9 acting as anodes are connected to the positive terminal of the generator 8 and immersed in the bath 7 so that the part 1 lies between the two electrodes 9 in the bath. The ratio of the area of the anode (corresponding to the working area of the two electrodes 9) divided by the area of the cathode (corresponding to the area of the substrate 2 of the part that is to be coated) is preferably about 4. The electrodes 9 forming the anodes are preferably spaced apart from the surface of the part, by a distance d lying in the range 1 centimeter (cm) to 20 cm.

(17) The generator 8 is then switched on in order to start electroplating the coating composition 3 on the part (step E3). During this step, the chromium (III) is reduced on the substrate 2 of the part 1 so as to form the coating composition 3 comprising chromium, carbon (coming from the organic compound present in the bath) and metal and/or ceramic particles that were in suspension in the bath. Parameters such as current density, bath temperature, and the duration of electroplating may be adapted, in particular as a function of the thickness of the coating that it is desired to obtain. In addition, it is possible to perform electroplating while using direct current (DC) either continuously or in the form of pulses.

(18) Once the part has been coated with the coating composition 3, it is rinsed and dried, and then placed in an oven. The part 1 with the coating composition 3 is then subjected to heat treatment (step E4) at a temperature that preferably lies in the range 250 C. to 700 C., or more preferably lies in the range 300 C. to 600 C., or even more preferably that lies in the range 400 C. to 500 C. The heat treatment may be performed under an inert atmosphere. The duration of the heat treatment may be longer than 10 min, e.g. longer than 15 min or even longer than 30 min. The duration of the heat treatment may for example lie in the range 15 min to 280 min. The duration of the heat treatment may be adapted as a function of the selected temperature and of the hardness desired for the coating.

(19) The coating 3 of the part 1 of the invention that is obtained at the end of the heat treatment step may present hardness greater than 1500 HV and it may present sufficient resistance to erosion for an application in an aircraft engine.

(20) By way of example, the part 1 may constitute at least a portion of a turboprop diffuser, at least a portion of an axial or centrifugal compressor, e.g. a centrifugal impeller, at least a portion of a nozzle, or any other part of a turbine engine that is to be subjected to a stream of air.

EXAMPLE 1

(21) In the example below, a steel turboprop diffuser part was coated in a coating by a method of the invention. The surfaces for coating were previously degreased and prepared.

(22) The coating composition was deposited by electroplating in an electrolyte bath. The electrolyte bath used was an aqueous solution comprising:

(23) 0.39 moles per liter (mol/L) of chromium (III) chloride hexahydrate (CrCl.sub.3; 6H.sub.2O);

(24) 3.72 mol/L of ammonium formiate (NH.sub.4COOH); and

(25) 0.81 mol/L of potassium chloride (KCl).

(26) The bath was heated to about 35 C. in order to perform electroplating. The part was immersed in the bath and connected to the negative terminal of the electricity generator. The anode-forming electrodes were immersed in the bath and connected to the generator, as described above. The ratio of anode area divided by cathode area was equal to 4.

(27) A continuous current density of 40 amps per square decimeter (A/dm.sup.2) was applied for 180 min so as to form the coating composition on the substrate. Once electroplating had been performed, the part was rinsed and dried.

(28) Finally, the part coated in the coating composition was placed in an oven, and subjected to heat treatment at 500 C. for 1 hour (h).

(29) The coating presented a thickness of about 35 m.

(30) The hardness of the coating formed in that way was about 2050 HV.

(31) The chemical composition of the coating as formed in that way (atom contents) as evaluated by X-ray photoelectron spectrometry (XPS) is given in Table 1 below.

(32) TABLE-US-00001 TABLE 1 Atom contents of elements in the coating Element C Cr N O at % 15.4 52.6 1.4 30.6

(33) Analysis of the coating by XRD also showed the presence of chromium carbides of the Cr.sub.7C.sub.3 and Cr.sub.23C.sub.6 type.

EXAMPLE 2

(34) Eleven steel substrates were coated under the same conditions as in Example 1, while varying the parameters of the heat treatment, (temperature and duration). The results are shown in the graph of FIG. 4A.

(35) FIG. 4B reproduces a graph showing the variation in the hardness of a chromium-based coating deposited by electroplating using a solution of chromium (VI) on a substrate as a function of the temperature of the heat treatment performed after deposition. The electrolyte bath used was a standard solution based on chromic acid having a composition of about 250 grams per liter (g/L) of CrO.sub.3, the solution also comprising 2.5 g/L of sulfuric acid H.sub.2SO.sub.4. In order to perform deposition, a current density of 40 A/dm.sup.2 was used. This data is taken from the work by F. Durut: Recherche des mcanismes microstructuraux qui rgissent les propritis macroscopiques de depts de chrome: influence des paramtres d'elaboration [Research into microstructural mechanisms that govern the macroscopic properties of chromium deposits: influence of preparation parameters], Engineering Sciences (physics, Ecole Rationale Superieure des Mines de Saint-Etienne, 1999.

(36) For the prior art chromium-based coating (FIG. 4B), it can be seen that heat treatment performed after deposition does not increase the hardness of the coating. More precisely, it can be seen that the hardness varies little or not at ail for heat treatment temperatures up to 400 C., after which it decreases.

(37) Conversely, for the coating of a part of the invention comprising chromium and carbon (FIG. 4A), it can be seen that the hardness of the coating increases with the temperature of the heat treatment performed after deposition. This figure also shows that the duration of the heat treatment has little incidence on the hardness of the coating for heat treatment durations longer than 10 h.