GAS TURBINE ENGINE COMPONENT WITH PROTECTIVE COATING

Abstract

A gas turbine engine component made of a nickel-based superalloy, the gas turbine engine component comprising a protective coating. The protective coating includes an inner diffusion barrier layer including any one or any combination of elements selected from the group consisting of platinum, palladium, tantalum, tungsten, hafnium and iridium, and an outer layer of hard material formed of hard particles embedded in a matrix.

Claims

1. A gas turbine engine component made of a nickel-based superalloy, the gas turbine engine component comprising a protective coating including: an inner diffusion barrier layer including any one or any combination of elements selected from the group consisting of platinum, palladium, tantalum, tungsten, hafnium and iridium, and an outer layer of hard material formed of hard particles embedded in a matrix.

2. A component according to claim 1, wherein the selected element(s) of the barrier layer form at least 80% by weight of the mass of the barrier layer

3. A component according to claim 1, wherein the hard particles are cubic boron nitride.

4. A component according to claim 1, wherein the matrix is Co—CrC, Ni or Ni alloy.

5. A component according to claim 1, wherein the outer layer is electroplated.

6. A component according to claim 1, wherein the protective coating further includes a separation layer of nickel between the diffusion barrier and the outer layer, the separation layer spacing the hard particles from the diffusion barrier layer.

7. A component according to claim 1, wherein the protective coating further includes an entrapment layer of nickel immediately beneath the outer layer, undersides of the hard particles of the outer layer being entrapped in the entrapment layer to hold the hard particles in position before encapsulation of the hard particles in the matrix of the outer layer.

8. A component according to claim 1, wherein the component has one or more seal fins having the protective coating.

9. A component according to claim 1, wherein the component is a rotor blade, a rotor disc or rotor drum.

10. A component according to claim 1, wherein the diffusion barrier layer does not comprise the element nickel.

11. A component according to claim 1, wherein the inner diffusion barrier layer consisting of any one or any combination of elements selected from the group consisting of platinum, palladium, tantalum, tungsten, hafnium and iridium.

12. A component according to claim 1, wherein the inner diffusion barrier layer comprises two or more layers.

13. A gas turbine engine having a component according to claim 1.

14. Use of the component according to claim 1 in a gas turbine engine at temperatures above 600° C.

15. A gas turbine engine component made of a nickel-based superalloy, the gas turbine engine component comprising a protective coating including: an inner diffusion barrier layer excluding nickel, but including any one or any combination of elements selected from the group consisting of platinum, palladium, tantalum, tungsten, hafnium and iridium, and an outer layer of hard material formed of hard particles embedded in a matrix.

16. A gas turbine engine component made of a nickel-based superalloy, the gas turbine engine component comprising a protective coating including: an inner diffusion barrier layer consisting of any one or any combination of elements selected from the group consisting of platinum, palladium, tantalum, tungsten, hafnium and iridium, and an outer layer of hard material formed of hard particles embedded in a matrix.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Embodiments of the invention will now be described by way of example with reference to the accompanying drawings in which:

[0037] FIG. 1 shows schematically an abrasive coating on a cross-section through a tip of a seal fin;

[0038] FIG. 2 shows a longitudinal cross-section through a ducted fan gas turbine engine; and

[0039] FIG. 3 shows schematically a protective coating on a cross-section through a tip of a seal fin according to the present invention.

DETAILED DESCRIPTION AND FURTHER OPTIONAL FEATURES

[0040] With reference to FIG. 2, a ducted fan gas turbine engine incorporating the invention is generally indicated at 10 and has a principal and rotational axis X-X. The engine comprises, in axial flow series, an air intake 11, a propulsive fan 12, an intermediate pressure compressor 13, a high-pressure compressor 14, combustion equipment 15, a high-pressure turbine 16, an intermediate pressure turbine 17, a low-pressure turbine 18 and a core engine exhaust nozzle 19. A nacelle 21 generally surrounds the engine 10 and defines the intake 11, a bypass duct 22 and a bypass exhaust nozzle 23.

[0041] During operation, air entering the intake 11 is accelerated by the fan 12 to produce two air flows: a first air flow A into the intermediate-pressure compressor 13 and a second air flow B which passes through the bypass duct 22 to provide propulsive thrust. The intermediate-pressure compressor 13 compresses the air flow A directed into it before delivering that air to the high-pressure compressor 14 where further compression takes place.

[0042] The compressed air exhausted from the high-pressure compressor 14 is directed into the combustion equipment 15 where it is mixed with fuel and the mixture combusted. The resultant hot combustion products then expand through, and thereby drive the high, intermediate and low-pressure turbines 16, 17, 18 before being exhausted through the nozzle 19 to provide additional propulsive thrust. The high, intermediate and low-pressure turbines respectively drive the high and intermediate-pressure compressors 14, 13 and the fan 12 by suitable interconnecting shafts.

[0043] The engine 10 has labyrinth seals radially inwards of the working gas annulus to control leakage of hot working gas from the annulus to disc cavities in the engine. These seals typically comprise a series of seal fins.

[0044] FIG. 3 shows schematically a cross-section through a tip of a seal fin according to the present invention. The component which provides the seal fin is made of a nickel-based superalloy such as IN718, U720, 720Li or RR1000 and is installed in a gas turbine engine such that the seal fin is in contact with a runner surface of an adjacent facing component.

[0045] The tip of the seal fin is provided with a protective coating 44 which includes an outer layer 48 made of a hard material with hard particles 50 embedded in a matrix 52. The hard particles may be cubic boron nitride particles and the matrix in which the particles are embedded may be Co—CrC, Ni or Ni alloy. When the component is installed in a gas turbine engine, the hard particles in the outer layer abrade the softer material of the runner surface to form a groove in the runner surface.

[0046] Below the outer layer 48, the protective coating 44 has a nickel entrapment layer 54 which entraps the undersides of the hard particles 50 to hold the particles in place before they are encapsulated in the matrix 52.

[0047] Below the entrapment layer 54, the protective coating 44 has a nickel separation layer 56 which spaces the particles 50 from the main body 42 of the seal fin.

[0048] In this way, the matrix 52 is shown to be a thickness which is less than the longest dimension of the hard particles 50 so that one or more of the hard particles 50 extend from the nickel entrapment layer 54 through the matrix 52 so as to protrude from the surface of the outer layer 48.

[0049] In some examples, one or more of the hard particles 50 extend from the nickel entrapment layer 54 through the matrix 52 without protruding from the surface of the outer layer 48. In further examples, one or more of the hard particles 50 are completely contained within the matrix 52 without protruding from the surface of the outer layer 48

[0050] In some examples, the matrix 52 is of a thickness which is less than the longest dimension of the hard particles 50 so that at least about 10% (by number) of the hard particles 50 extend from the nickel entrapment layer 54 through the matrix 52 so as to protrude from the surface of the outer layer 48. Alternatively, at least about 50% (by number) of the hard particles 50 extend from the nickel entrapment layer 54 through the matrix 52 so as to protrude from the surface of the outer layer 48. Alternatively, at least about 80% (by number) of the hard particles 50 extend from the nickel entrapment layer 54 through the matrix 52 so as to protrude from the surface of the outer layer 48. In final examples, at least about 90% (by number), or 95% (by number) of the hard particles 50 extend from the nickel entrapment layer 54 through the matrix 52 so as to protrude from the surface of the outer layer 48.

[0051] In some examples, the matrix 52 is of a thickness greater than the longest dimension of at least some of the hard particles 50 so that one or more of the hard particles 50 are completely contained within the matrix 52. Such hard particles 50 embedded within the matrix 52 provide added resistance to abrasion of the outer layer 48 by such abrasion revealing further hard particles 50. The revealing of further hard particles 50 provides added abrasive effect and prevents rapid wear of the outer layer 48 should hard particles 50 become worn or dislodged from the matrix 52. Where the matrix 52 is of a thickness equal to or greater than the longest dimension of the hard particles 50, it is required that one or more hard particles 50 protrude from the matrix 52 in order to provide an abrasive effect.

[0052] Where the matrix 52 is of a thickness which is less than, equal to, or greater than the longest dimension of at least some of the hard particles 50, the thickness of either or both of the matrix 52 and particle size distribution can vary so as to allow only a particular percentage (by number) of hard particles 50 to protrude from the matrix 52.

[0053] The protective coating 44 also has a diffusion barrier layer 46 located between the nickel-based main body 42 of the seal fin and the separation layer 56. The protective coating includes any one or any combination of platinum, palladium, tantalum, tungsten, hafnium and iridium, and it reduces or prevents the diffusion of either or both of nickel and other elements thereacross. Such diffusion can be particularly problematic at temperatures above 600° C. The diffusion barrier layer 46 thus reduces or prevents diffusion bonding of the protective coating 44 to the main body 42 of the seal fin. In this way, the propagation of cracks initiated at the hard particles 50 into the seal fin can be avoided. Thus, the likelihood of fatigue failure of the component occurring is reduced and the component's functional lifespan may be increased. In further examples, to reduce or prevent the diffusion of nickel between the nickel-based main body 42 of the seal fin and the separation layer 56, the diffusion barrier layer 46 excludes the element nickel. In yet further examples, to reduce or prevent the diffusion of nickel between the nickel-based main body 42 of the seal fin and the separation layer 56, the diffusion barrier layer 46 consists of (i.e. exclusively includes) any one or any combination of elements selected from the group consisting of platinum, palladium, tantalum, tungsten, hafnium and iridium.

[0054] For improved diffusion bonding protection, the selected element(s) of the barrier layer may form at least 80% (and preferably at least 90% or 95%) by weight of the mass of the barrier layer. Indeed, the barrier layer may consist substantially entirely of the selected element(s).

[0055] The diffusion barrier layer 46, separation layer 56, entrapment layer 54 and outer layer 48 may be applied by successive electroplating procedures. For example, Praxair Surface Technologies TBT406™ electroplating process or Abrasive Technologies ATA3C™ electroplating process may be used to form the separation, entrapment and outer layers. However, methods such as thermal spraying, plasma vapour deposition, chemical vapour deposition and sputtering may be used as appropriate to form any one or more of the layers.

[0056] While the invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. For example, the diffusion barrier layer can be applied to other coating systems where there is an outer layer of hard material formed of hard particles embedded in a matrix, and a risk of diffusion bonding of that layer to an underlying nickel-based superalloy substrate.

[0057] Moreover, the invention is not limited to seal fin applications. For example, in a gas turbine engine context, the protective coating can be usefully applied to the tips of rotor blades, thereby enhancing the ability of the blades to abrade surrounding casings. It can also be applied to rotor discs or rotor drums.

[0058] Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the spirit and scope of the invention.