POWER PLANT COMPONENT AND METHOD FOR MANUFACTURING SUCH COMPONENT

Abstract

A power plant component is disclosed having 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. Improved operation properties are achieved by the functionally graded coating having a corrosion resistant portion, and an erosion resistant and hydrophobic portion, whereby the functionally graded coating is a composite coating consisting of a single layer.

Claims

1. Power plant component, comprising: 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, wherein the functionally graded coating includes a corrosion resistant first means, and an erosion resistant and hydrophobic second means, said functionally graded coating being 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 a thickness (x) of said composite coating, 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 to a low concentration (c4) at the outer side (x2) of said composite coating, 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 to a high concentration (c2) at the outer side (x2) of said composite coating.

2. Power plant component as claimed in claim 1, wherein said substrate is a metal or composite polymer substrate.

3. Power plant component as claimed in claim 1, 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.

4. Power plant component as claimed in claim 3, wherein said particles comprise: micro or nano metal, ceramic and/or polymer materials, which provide corrosion protection by electronegativity and/or self-healing reaction.

5. Power plant component as claimed in claim 1, wherein said corrosion resistant first means comprise: a Ni matrix with one of Al, Zn, Zr or Mg particles.

6. Power plant component as claimed in claim 1, 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 a 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.

7. Power plant component as claimed in claim 1, wherein 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.

8. Power plant component as claimed in claim 4, wherein said ceramic, metallic and/or polymer nano or micro particles or fibers comprises: one of SiC, Al.sub.2O.sub.3, SiO.sub.2, WC, BN, MAX phases (e.g. Ti.sub.3SiC.sub.2, Ti.sub.2AlC, Cr.sub.2AlC), carbon nanotubes (CNTs), graphene oxide and hydrophobic particles, and PTFE.

9. Method for manufacturing a power plant component according to claim 1, wherein the surface of said substrate is activated and prepared with a thin bonding layer and chemical or mechanical treatments.

10. Method as claimed in claim 9, wherein said composite coating is applied by a spraying process, which spraying process can be one ore more of Atmospheric Plasma Spraying (APS), cold spray, High Voltage Oxide Fuel (HVOF) process, or electro and electroless plating and electrophoretic process.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The present invention is now to be explained more closely by means of different embodiments and with reference to the attached drawings.

[0030] FIG. 1 shows the surface structure with a graded composite coating of a component according to an embodiment of the invention;

[0031] FIG. 2 shows a diagram of the thickness-dependant concentration of an erosion resistant material within said graded composite coating of FIG. 1; and

[0032] 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

[0033] 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.

[0034] 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.

[0035] 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.

[0036] 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.

[0037] Said substrate 11 may be a metal or composite polymer substrate.

[0038] Said corrosion resistant first means may 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.

[0039] Especially, said particles/fibers may comprise micro or nano metal, ceramic and/or polymer materials, which provide corrosion protection by electronegativity and/or self-healing reaction.

[0040] Furthermore, said corrosion resistant first means may comprise a Ni matrix with one of Al, Zn, Zr or Mg particles.

[0041] Said erosion resistant and hydrophobic second means may 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).

[0042] On the other hand, 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.

[0043] Especially, said ceramic, metallic and/or polymer nano or micro particles or fibers may comprise one of SiC, Al.sub.2O.sub.3, SiO.sub.2, WC, BN, MAX phases (e.g. Ti.sub.3SiC.sub.2, Ti.sub.2AlC, Cr.sub.2AlC), carbon nanotubes (CNTs), graphene oxide and hydrophobic particles, especially of PTFE.

LIST OF REFERENCE NUMERALS

[0044] 10 power plant component [0045] 11 substrate [0046] 12 composite coating [0047] c,c1,c2,c3,c4 concentration [0048] x,x1,x2 coating thickness (coordinate)