METHOD FOR COATING BY THERMAL SPRAYING WITH AN INCLINED PARTICLE JET
A substrate is coated by cold-gas spraying in which a particle jet is oriented at an inclination to the surface of a substrate thus forming a spraying angle. To increase the possible spraying angle compared to the known art, the surface is applied with a directional patterning, for example trenches and ridges. The orientation of this patterning has an angle of inclination in the direction of the spraying angle. As a result, the adhesion of striking particles is improved and it is possible to achieve larger spraying angles.
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This application is the U.S. national stage of International Application No. PCT/EP2013/069218, filed Sep. 17, 2013 and claims the benefit thereof. The International Application claims the benefit of German Application No. 102012217685.3 filed on Sep. 28, 2012, both applications are incorporated by reference herein in their entirety.
BACKGROUNDDescribed below is a method for coating by thermal spraying. Herein, a particle jet is directed onto a substrate to be coated and the particles of the particle jet are deposited onto the substrate. In that context, the axis of the particle jet is inclined to the surface normal of the untreated substrate forming a spray angle α.
EP 1 534 877 B1 discloses that the deposition of particles during thermal spraying can be improved by a laser being guided along therewith on the workpiece surface which is to be coated. This laser can warm the substrate at the point of incidence of the particle jet, whereby the incident particles adhere better to the substrate. However, this improvement in adhesion works only in the case of a particle jet which is oriented approximately perpendicular to the surface of the substrate to be coated. In the case of such a particle jet, the spray angle is approximately 0°. The spray angle is defined by a non-oriented angle between the axis of symmetry of the particle jet (in the following denoted simply as the jet axis) and the surface normal at the point of incidence of the particle jet. In the following, the spray angle will be denoted as α.
The particle jet is normally set with a spray angle α=0°. Any orientation of the jet axis which deviates therefrom results in a positive value of the spray angle α. Depending on the basic conditions such as processed particles, surface material and spray parameters, there is a permissible interval for the spray angle, below which the adhesion of the deposited particles reaches maximum values. The zero angle may or may not be included in this interval. The set of all permissible spray angles thus produces a space between two conical surfaces, whose tips meet at the point of incidence of the particle jet. If the zero angle is included in the interval, only one cone oriented in the described manner is required to describe the spray angle interval.
In particular in the case of cold gas spraying, optimum results can be obtained only in a comparatively small spray angle interval since, as the spray angle α increases, the component of the kinetic energy of the particles in the direction of the surface normal is ever-decreasing. It is thus possible, in the case of components having complex shapes, for certain regions of the component to not be coated by the thermal spraying, in particular cold gas spraying since, for geometric reasons, taking into account the spray angle interval, no particle jet can be oriented onto the surface.
Cold gas spraying is a method known per se, in which particles provided for the coating are accelerated by a convergent-divergent nozzle, e.g., to supersonic speeds, in order that these adhere to the surface to be coated by virtue of the kinetic energy imparted to them. In this process, the kinetic energy of the particles is used and leads to a plastic deformation of the latter, wherein upon impact the coating particles are melted only at their surface. For that reason, this method is termed cold gas spraying in comparison with other thermal spraying methods because it is carried out at comparatively low temperatures at which the coating particles remain largely solid. For cold gas spraying, which is also termed kinetic spraying, a cold gas spraying apparatus may be used which has a gas heating device for heating a gas. A stagnation chamber is connected to the gas heating device, wherein the outlet of this chamber is connected with the convergent-divergent nozzle, such as a de Laval nozzle. Convergent-divergent nozzles have a convergent part section and a divergent part section which are connected by a nozzle throat. The convergent-divergent nozzle generates, on the outlet side, a powder jet in the form of a gas stream with high-speed—e.g., supersonic—particles therein.
SUMMARYDescribed below is a method for coating by thermal spraying, in particular a method for cold gas spraying, by which it is possible to coat even hard-to-reach regions of a component, with a satisfactory coat result.
This is achieved with the method mentioned in the introduction in that, prior to the thermal spraying, the substrate undergoes pretreatment in which the surface is structured. In that context, structure elements of the structured surface are produced obliquely on the surface such that the structure elements are oriented towards the inclined axis of the particle jet, that is to say the jet axis. The structure elements are produced obliquely, in other words, so that the finished structure elements do not stand upright, but their principal geometric orientation deviates from the surface normal. If, for example, a structure element is any raised portion, the orientation of the latter would for example be determined taking into account the center line of the structure element. This line is then not oriented parallel to the surface normal but forms an angle of inclination β thereto, wherein the inclined orientation of the structure elements is such that these are oriented towards the inclined jet axis. In other words, the orientation of the named center line of a structure element will be at least similar to that of the jet axis.
Also, the spatial extent of the structure elements is smaller, at least in the plane of the spray angle α, than the average diameter of the particles. The plane of the spray angle α is to be defined as a plane containing both arms of the spray angle α. If one considers the spatial extent of the structure elements in this plane, the geometry of the structure elements—as seen in the section of this plane—should be smaller than the size of the particles. It has namely been found that particles which are incident on a surface structured in this manner can, in spite of a spray angle α, convert a larger proportion of their kinetic energy into deformation than particles which are incident on the unstructured, i.e. smooth, surface at the same spray angle α. In other words, on account of the geometry of the structure elements, the surface to be coated presents greater adhesion resistance to the incident particles, at least in the direction of the spray angle. This has the advantageous effect that the surface can still be reliably coated at higher spray angles, especially in the direction of the spray angle α. It is thus for example possible to coat components with undercuts by thermal spraying, because those regions of the component which are hard to reach on account of the undercuts are made accessible for the spray jet.
It is provided according to one advantageous embodiment that the angle of inclination β of the oblique orientation of the structure elements largely corresponds to the spray angle α. In other words, the angle of inclination of the oblique orientation of the structure elements is determined so as to achieve an optimal improvement of the spray angle α. From a manufacturing aspect, it is particularly advantageous in that context if the entire hard-to-reach region of the component is provided with structure elements which have at least largely the same orientation. For the purpose of coating this region, the particle jet is then also oriented such that when coating the region the jet is displaced at least essentially parallel. This can also be achieved if the jet-generating device (for example the spray nozzle of an apparatus for cold gas spraying) is at a large distance from the substrate with respect to the region to be coated and, for the purpose of coating this region, is pivoted by for example plus/minus 5°. The resulting angular offsets are then relatively small.
The structuring of the surface of the substrate to produce the structure elements, can also be termed a microscopic striation. The binding mechanism of the particles on the surface can also be described more simply in that, when the particles are incident on the “peaks” of the striation, the latter pierce the former and thus improve adhesion. This can be compared with the function of a metal file, which also has a striation. This striation usually has the effect that the file must be guided over the workpiece in a specific direction in order to guarantee optimal chip removal. This is only possible if the striation has an angle of inclination of the oblique orientation of the individual structure elements. This analogy clarifies the function of the microscopic striation. Microscopic hereinbelow means that the extent of the structure elements, as already explained, must be smaller than that of the particles so that the particles can act like the workpiece under the file, so to speak.
The surface normal of the substrate is defined by the surface of the untreated substrate. This means that, after treating the substrate by generating the structure elements, other local surface normals can result. However, of relevance are the surface normals which are to be determined on account of the superordinate structure of the substrate. The structuring, which is small in comparison, thus generates a surface which is much more finely structured, such that after structuring the substrate the surface normal could only be determined by averaging over multiple structure elements.
One further configuration provides that the plane of the spray angle α and the plane of the angle of inclination β of the oblique orientations of the structure elements are at an angle γ of at most 25° to one another. In this context, manufacturing considerations play a role. On one hand, there are production-induced tolerances when producing the structure elements. In addition, the geometry of the substrate to be coated can be designed such that an ideal orientation of the structure elements, i.e. an orientation with an angle γ of 0°, would lead to more complex production. In this case, it is possible to choose an orientation of the structure elements which, in parts of the hard-to-coat regions of the component, deviates to a greater or lesser extent—but never by more than 25°—from the ideal orientation. It is also possible to establish an upper limit of 15° or 10° for the angle γ. This is then advantageous if, on account of the processed particles, the chosen thermal coating method or the substrate material, a tighter tolerance for the angle γ is required in order to still achieve the required coating results.
It is of particular advantage if trenches are produced as structure element. Advantageously, these trenches are particularly easy to create in manufacturing terms. They may be created for example by a laser, by moving the latter over the surface of the workpiece. The trenches can then run parallel to one another in order to make best use of the available surface area of the substrate. Depending on the geometry of the substrate to be coated, the trenches can be either straight or curved. The latter is also important for optimizing the angle γ.
Particularly advantageously, the trenches have, at least locally, planes of symmetry which are oriented during production such that they are oriented towards the inclined axis of the particle jet during the thermal spraying. This produces, so to speak, the required orientation to the particle jet. It is to be noted in this context that not only the trenches but in particular the ridges remaining between the trenches are responsible for the resulting effect of an improvement in adhesion. The structuring of the surface is thus influenced not only by the trenches produced but also by the structure elements in the form of ridges therebetween.
Another advantageous possibility provides that the structure elements are produced as holes. Advantageously, holes can also be produced simply. These can for example be produced by punctiform laser shots to the surface of the substrate to be coated. Advantageously, these holes have axes of symmetry which are oriented obliquely during production such that they are oriented towards the inclined axes of the particle jet during the thermal spraying. The axes of symmetry of the holes thus simultaneously represent the center lines of the holes, wherein, when using a laser, these can in particular be directly influenced by the orientation of the latter. Moreover, this also holds for the production of trenches by the laser. In the case of producing holes, it is also worth mentioning that the uprights remaining between the holes also constitute oriented structures which, as structure elements, participate in the improvement of adhesion of the surface.
It is particularly advantageous if cold gas spraying is used as thermal spraying. This is advantageously well-suited to the relatively cost-effective production of relatively thick coats. Particularly if the coat is produced in multilayer fashion, i.e. coating by alternating multiple times between production of structure elements and production of layers of the desired coating, it is possible to produce relatively thick coats. In each case, the deposited layers in turn serve for the production of the next layer, wherein in the case of hard-to-reach regions of the substrate, of course, the layer must always once again be structured as a surface to be coated. Otherwise, subsequent layers would not adhere to the preceding layers.
In order to be able to coat workpieces with hard-to-reach regions, it is advantageous if the substrate is produced in the regions which are inaccessible to the particle jet while observing the maximum permissible spray angle in the case of the untreated substrate, such that an increase, connected thereto, of the permissible spray angle α results in the region being able to be coated with the thermal spraying method. This is the case if the maximum permissible spray angle α increases specifically in that direction whence the particle jet is incident on account of the geometric specifications of the substrate to be coated.
The structure elements may advantageously be generated with a laser beam, by an erosion method, by chip removal, by a shaping method or chemically, depending on which method is best suited to the relevant substrate.
If, for example, the surface structuring is carried out by an erosion process, the structure is copied by an erosion electrode onto the surface to be coated. To that end, it is necessary to provide the electrode with the desired structure prior to copying. The surface to be coated of the substrate can then be structured using one or more electrodes. If multiple electrodes are used, these can have different configurations in order to be able to treat different regions of the surface of the substrate at an optimum distance.
A particularly versatile erosion electrode is for example in the form of an elongate ellipsoid of revolution (similar to a cigar or a cylinder) whose surface is knurled circumferentially along the longitudinal extent of the electrode. These striation grooves can then be formed by bringing the workpiece surface close to the erosion tool, wherein the longitudinal axis of the erosion tool is oriented parallel to the direction of the smallest curvature of the workpiece surface at the point of contact with the erosion tool. The erosion tool can then be guided over the surface of the substrate, perpendicular to the longitudinal axis. A relatively effective structuring of the surface is thus possible.
If a laser machining process is chosen for structuring, the laser can be guided taking into account the accessibility of the workpiece and its geometric configuration. This is in particular possible using CAD data of the substrate. Using a laser has the advantage that it has an axis, similar to the particle jet, such that it can be guided in the same manner as the particle jet will be subsequently. That is to say that, if both the jet-generating device (for example a cold gas spray nozzle) and the laser are moved according to the same movement pattern, then the spray angle α always largely matches the angle of inclination β of the oblique orientation of the structure elements, making it possible to achieve an optimum coating result.
Accordingly, the coating apparatus and the device for generating the structure elements can be used in alternation or simultaneously. Simultaneous use advantageously shortens production times but is possible only if the region of the substrate is sufficiently accessible. Alternating use results in longer production times but harder-to-reach regions of the substrate can be optimally provided with a coating. In order to optimize the production method for a certain component, both simultaneous and alternating production of the structure elements and of the coating can be chosen, such that the production times for each substrate can be optimized.
One example for which the method according to the invention can be used is coating what are termed blade drillings for gas turbines. These have three blades which are produced together. This results in hard-to-reach regions between the blades, which can advantageously be coated with the method according to the invention.
These and other aspects and advantages will become more apparent and more readily appreciated from the following description of the exemplary embodiments, taken in conjunction with the accompanying drawings of which:
Reference will now be made in detail to the preferred embodiments, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout.
In addition, to improve an adhesion of the incident particles 12, the surface 14 is subjected to a structuring process using a laser beam 16. This involves generating trenches 17 by laser ablation, wherein the laser beam 16 is incident on the surface 14 of the substrate 11 at an angle of inclination β. This means that the trenches 17 and the resulting ridges 18 between the trenches are oriented obliquely. That is to say that they do not project vertically upwards in line with the surface normal 15 but the trenches have a plane of symmetry 19 which is inclined by the angle of inclination β, in line with the orientation of the laser beam 16. In
The difference which appears in the case of the cold spraying method according to
The background for a deviation γ between the planes 20, 21 being permitted is that real components have a more complex geometry than the substrates shown in
Moreover, a method of erosion is indicated on one of the blades, which method could serve to produce the surface structuring on the blades. In this case it is a roller which in
- I The substrate 11 is made available.
- II The surface 14 of the substrate 11 is structured. Trenches 17 and ridges 18 as shown in
FIG. 1 are produced. This is also the case for the following structuring in IV and VI. - III The first layer 31a is produced and makes the surface 14a available for the subsequent coating. It can also be seen that, in this context, the structuring of the surface 14 changes, wherein in this context an interlocking of the sprayed particles (no longer visible in
FIG. 5 ) with the surface 14 takes place simultaneously. This is also the case for V and VII. - IV The surface 14a again undergoes surface structuring (in the same manner as in II).
- V The next layer 31b is applied. This can be the same coat material as applied in III or a multilayer coat is produced in which another coat material is applied.
- VI The surface 14b resulting from V again undergoes surface structuring.
- VII The last layer 31c of the coat 30 is applied and forms the final surface 14c of the coated component.
A description has been provided with particular reference to preferred embodiments thereof and examples, but it will be understood that variations and modifications can be effected within the spirit and scope of the claims which may include the phrase “at least one of A, B and C” as an alternative expression that means one or more of A, B and C may be used, contrary to the holding in Superguide v. DIRECTV, 358 F3d 870, 69 USPQ2d 1865 (Fed. Cir. 2004).
Claims
1-12. (canceled)
13. A method for coating a substrate by thermal spraying, comprising:
- producing a structured surface of the substrate by pretreating the substrate, the structured surface having structure elements that are obliquely produced; and
- depositing particles of a particle jet onto the substrate by directing the particle jet onto the structured surface of the substrate at a spray angle between an axis of the particle jet and a surface normal of the substrate when the substrate is untreated, the structure elements being oriented towards the axis of the particle jet during the thermal spraying and having a spatial extent that is smaller, at least in a spray angle plane in which the spray angle lies, than an average diameter of the particles.
14. The method as claimed in claim 13, wherein the structure elements have an inclination angle substantially corresponding to the spray angle.
15. The method as claimed in claim 14, wherein the spray angle plane and an inclination plane in which the inclination angle of the structure elements form an angle of at most 25°.
16. The method as claimed in claim 16, wherein the structure elements include trenches with symmetry planes oriented obliquely during production such that the symmetry planes are oriented towards the axis of the particle jet during the thermal spraying.
17. The method as claimed in claim 15, wherein the structure elements are holes with symmetry axes oriented towards the axis of the particle jet during the thermal spraying.
18. The method as claimed in claim 15, wherein the thermal spraying is cold gas spraying.
19. The method as claimed in claim 18, wherein the substrate, prior to said pretreating, has a region inaccessible to the particle jet while observing a maximum permissible spray angle, and
- wherein said pretreating produces the structure elements in the region that enable the particle jet at the maximum permissible spray angle to coat the region with the particles.
20. The method as claimed in claim 19, wherein said pretreating produces the structure elements using at least one of a laser beam, an erosion method, chip removal, a shaping method, and application of a chemical.
21. The method as claimed in claim 20, further comprising repeating said pretreating and said depositing, thereby producing layers of the particles until a desired coating is produced.
22. The method as claimed in claim 21, wherein the substrate with the desired coating is a blade drilling of a gas turbine.
23. The method as claimed in claim 13, wherein the spray angle plane and an inclination plane in which the inclination angle of the structure elements form an angle of at most 25°.
24. The method as claimed in claim 13, wherein the structure elements include trenches.
25. The method as claimed in claim 24, wherein the trenches have symmetry planes oriented obliquely during production such that the symmetry planes are oriented towards the axis of the particle jet during the thermal spraying.
26. The method as claimed in claim 13, wherein the structure elements are holes.
27. The method as claimed in claim 26, wherein the holes have symmetry axes oriented towards the axis of the particle jet during the thermal spraying.
28. The method as claimed in claim 13, wherein the thermal spraying is cold gas spraying.
29. The method as claimed in claim 13, wherein the substrate, prior to said pretreating, has a region inaccessible to the particle jet while observing a maximum permissible spray angle, and
- wherein said pretreating produces the structure elements in the region that enable the particle jet at the maximum permissible spray angle to coat the region with the particles.
30. The method as claimed in claim 13, wherein said pretreating produces the structure elements using at least one of a laser beam, an erosion method, chip removal, a shaping method, and application of a chemical.
31. The method as claimed in claim 13, further comprising repeating said pretreating and said depositing, thereby producing layers of the particles until a desired coating is produced.
32. The method as claimed in claim 13, wherein the substrate after the coating is a blade drilling of a gas turbine.
Type: Application
Filed: Sep 17, 2013
Publication Date: Aug 27, 2015
Applicant: SIEMENS AKTIENGESELLSCHAFT (München)
Inventors: Ralph Reiche (Berlin), Oliver Stier (Berlin)
Application Number: 14/432,102