GB2141359A - Improvements in or relating to the application of coatings to articles - Google Patents
Improvements in or relating to the application of coatings to articles Download PDFInfo
- Publication number
- GB2141359A GB2141359A GB08413508A GB8413508A GB2141359A GB 2141359 A GB2141359 A GB 2141359A GB 08413508 A GB08413508 A GB 08413508A GB 8413508 A GB8413508 A GB 8413508A GB 2141359 A GB2141359 A GB 2141359A
- Authority
- GB
- United Kingdom
- Prior art keywords
- coating
- applying
- carrier member
- article
- surface area
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 238000000576 coating method Methods 0.000 title claims abstract description 68
- 239000011248 coating agent Substances 0.000 claims abstract description 58
- 238000000034 method Methods 0.000 claims abstract description 32
- 239000000463 material Substances 0.000 claims abstract description 29
- 230000004888 barrier function Effects 0.000 claims abstract description 3
- 239000002131 composite material Substances 0.000 claims description 7
- 239000002245 particle Substances 0.000 claims description 6
- 239000012633 leachable Substances 0.000 claims description 5
- 238000003825 pressing Methods 0.000 claims description 5
- 238000002386 leaching Methods 0.000 claims 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 abstract description 2
- 238000005530 etching Methods 0.000 abstract description 2
- 238000003754 machining Methods 0.000 abstract description 2
- 239000010936 titanium Substances 0.000 abstract description 2
- 229910052719 titanium Inorganic materials 0.000 abstract description 2
- 230000003064 anti-oxidating effect Effects 0.000 abstract 1
- 238000001513 hot isostatic pressing Methods 0.000 description 7
- 238000000151 deposition Methods 0.000 description 5
- 230000008021 deposition Effects 0.000 description 5
- 239000007789 gas Substances 0.000 description 5
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 4
- 238000002485 combustion reaction Methods 0.000 description 4
- 238000001816 cooling Methods 0.000 description 4
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 2
- 238000004070 electrodeposition Methods 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 238000007750 plasma spraying Methods 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 238000005507 spraying Methods 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 238000005524 ceramic coating Methods 0.000 description 1
- 239000007795 chemical reaction product Substances 0.000 description 1
- 239000012809 cooling fluid Substances 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 238000010894 electron beam technology Methods 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 239000003779 heat-resistant material Substances 0.000 description 1
- 238000007654 immersion Methods 0.000 description 1
- 239000011261 inert gas Substances 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 238000007747 plating Methods 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 230000005068 transpiration Effects 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
- RUDFQVOCFDJEEF-UHFFFAOYSA-N yttrium(III) oxide Inorganic materials [O-2].[O-2].[O-2].[Y+3].[Y+3] RUDFQVOCFDJEEF-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/22—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Coating By Spraying Or Casting (AREA)
- Other Surface Treatments For Metallic Materials (AREA)
Abstract
It is known to apply coatings which have desired characteristics, e.g. wear resistance, thermal barrier capabilities anti-oxidation, to articles the material of which does not have the desired characteristic, wherein the coating is applied directly to the article. Some article materials, e.g. Titanium are highly reactive which immediately obviates several known methods of applying coatings. The invention uses a member (12) which would normally be preformed to mate with the article surface to be coated. The member (12) is manufactured from cheap, non reactive material, as a base to which the coating (14) is applied by the most suitable of any of the known means. The member (12) is then placed against the article with the coating (14) therebetween and the whole hot isostatically pressed. The member (12) is afterwards removed, e.g. by machining or etching. <IMAGE>
Description
SPECIFICATION
Improvements in or relating to the application of coatings to articles
This invention relates to a method of applying coatings to articles.
The invention has particular efficacy in the application of a coating to articles of non planarform, the coating of bore surfaces, and reactive materials.
Known methods of applying coatings, particularly metallic and ceramic coatings, includes spraying using various forms of energy, e.g. plasma and laser with which to melt the particles being sprayed on to the article, vapour deposition, pack processes and electro desposition.
Some of such methods are wasteful of material and none guarantee an homogenous end product.
Further, maintenance of coating thickness over a given surface area is all but impossible. Moreover, where the article is made from a reactive material such as titanium, some coating methods are excluded.
It is also known to apply a formed coating sheet to an article, and hot isostatically press it into place (see
GB-A-2063747) but in practice it is difficult to conform the sheet to the article unless the article is of a very simple shape. Other methods of directly applying a coating using hot isostatic pressing are shown in GB-A-2024256 and G B-A-20661 13.
According to the present invention there is provided a method of applying a coating to a surface area of a substantially rigid component, to form a composite article having a pre-determined shape, comprising the steps of:
(a) forming a carrier member a part of which has a surface area shaped in a pre-determined configuration,
(b) applying a coating on said surface area of the carrier member, the combination of the carrier member and coating being substantially rigid and the coating having a surface area on the opposite side thereof from the carrier member which is shaped in reverse conformity to said surface area of the rigid component,
(c) assembling together the component and the carrier member, with the conforming surfaces of the component and the coating adjacent each other, and
(d) hot isostatically pressing the assembled component and member with sufficient heat and pressure to bond together the adjacent conforming surfaces of the component and the coating to form a composite article.
At least two coatings may be applied to the carrier member in reverse order relative to their desired order on the article.
The method may include applying the coating to the carrier member in the form of spaced portions and hot isostatically pressing the member into the spaces, onto the article and thereafter removing those portions of the member covering the coating.
A stop off material may be applied between the member and the coating.
The invention will now be described, by way of example and with reference to the accompanying drawings in which:
Figures 1 to 1c depict steps in one embodiment of the invention.
Figures 2to 2c depict a second embodiment of the invention.
Figure 3 depicts a still further embodiment, Figures 4 to 46 depict steps in afurtherembodi- ment of the invention,
Figures 5 and 6 shows steps in a further method for forming an article with cooling channels, and
Figure 7 shows a turbine blade with such cooling channels.
Referring to Figures 1 to ic. An article 10 which, merely by way of example, may be a turbine blade, is to have a coating applied thereto. The coating would normally be metallic and for example could comprise any of the following:- Hard surfacing alloys, thermal barrier materials, materials having desired electrical characteristics, and materials having resistance to chemical environments.
A carrier member 12 which can be made in steel iron or other cheap material, is formed so that it includes a shape 13 which corresponds with the shape of that surface of article 10 which is to be coated.
Referring now to Figure lathe desired coating 14 is applied to the shaped surface 13 of member 12.
Application can be achieved by any suitable known means, such as plasma spraying, pack deposition, electro deposition or by first applying a tacky adhesive to the surface 13 and then springling the coating in a dry powder form onto the tacky surface.
This latter method is fully described and claimed in
British Patent specification 1,334,683.
Member 12 is placed against article 10 with the coating 14 therebetween, as shown in Figure 16. The assembly is placed in a metal bag (not shown) which is then evacuated and as a result, collapses onto the assembly and clamps it together. The bag (not shown) is placed in a furnace (not shown) which is then pressurized and heated so as to achieve hot isostatic pressing of the assembly into an homogenous structure.
On completion of the process, the bag is removed from around the assembly, along with the member 12, by any suitable means, thus leaving article 10 with a homogenous coating 14 as depicted in Figure 1c.
Should it be required that article 10 be completely coated, two members 12 are formed, a coating applied to each and then members 12 are placed against respective sides of article 10 and welded around their edges so that they form the bag. A small aperture is left to enable evacuation of the interior of the container and thereafter, the hot isostatic pressing process is carried out as described hereinbefore.
Alternatively the welding process can be carried out in vacuum, for example using an electron beam process, thus obviating the need for a separate evacuation procedure.
in Figure 2 an article 16 has a bore 18, on the surface 20 of which, it is desired to apply a coating. A carrier mandrel 22 (Figure 2a) of appropriate diameter is provided and the desired coating 24 applied thereto by any suitable method. The thickness of coating 24 is such as to achieve a push fit between the coated mandrel 22 and bore 18 (Figure 2b). The assembly is then placed in a metallic bag (not shown) which is then evacuated, placed in a furnace and the whole assembly is hot isostatically pressed.
Afterwards, the bag (not shown) is removed by machining or other suitable means, as is the mandrel 22 leaving article 16 with its bore surface 20 coated (Figure 2b).
Referring now to Figure 3. Where the member 28 is a single sheet, its removal after hot isostatic pressing may be facilitated by the insertion of a stop off material 26, e.g. Yttria in powder form, between the member 28 and the coating 30. As is known, the stop off material 26 will prevent diffusion bonding occurring between the member 28 and coating 30, which will result in a relatively weak key between them.
Referring now to Figure 4. A coating is required to be applied to an article 40 in the form of alternate strips 36 and 38 of different materials.
This is achieved by making a carrier member from one of the desired materials, say material 36, the member being in sheet form as illustrated in Figure 4a. Strips of the alternating material 38 are laid on member 36 and the sub assembly then placed against the article 40 with the strips 38 therebetween. All the steps to achieve hot isostatic pressing are carried out as described hereinbefore and afterwards, those portions of member 36 which stand proud of strips 38 as seen in Figure 4b, are machined off, to leave the smooth surface 42 depicted in Figure 4.
An important advantage which is derived from the application of a coating to a member prior to transferring it to an article, it that the member can be manufactured from virtually any cheap, relatively non reactive metal. It follows that any method of applying the coating to the member may be employed, including those methods which the material of the article to which the coating will be transferred may find hostile, e.g. immersion in chemical plating solutions.
A further advantage which accrues is that straight bores at least, no longer need spraying, which operation has always been difficult, particularly with respect to achievement of an even thickness by virtue of the enclosed nature of the surface to be coated.
A multiplicity of coatings may be applied to a single article by the method of the invention either via a corresponding number of carrier members, or by being laminated in the appropriate reverse order on a single carrier member.
Referring to Figure 5, the wall 110 of a combustion chamber for a gas turbine engine (not shown) is to be externally clad with a skin in the form of a sheet member 112. Wall 110 is shown in flat form, i.e. prior to bending into a barrel-like shape.
In the present example sheet member 112 hs been formed on a backing sheet 114 by the deposition thereon of particles of a heat resistant material to form a composite. The deposition of the particles is achieved by plasma spraying the particles on to the backing sheet 114. Provided, however, that the characteristics of the materials of the sheet 112 and
backing sheet 114 are suitable, the deposition of one into the other may be achieved by, e.g. electro chemical deposition, rolling or by any other known method.
After application of the sheet 112 to the backing sheet 114, grooves 116 are formed in the exposed face of the sheet 112 by conventional cutting or chemi-etching. Grooves 116 are then filled with a leachable material 118 which, e.g. may be a ceramic, steel or iron.
The composite of sheet 112 and backing sheet 114 is placed against combustion chamber wall 110 with the exposed surface of sheet 112 abutting a surface ofthe combustion chamber waIl 110, and the whole assembly is enveloped in a metallic bag (not shown) which is then evacuated and in turn placed in a furnace (not shown). The furnace is purged, filled with an inert gas and heated, the temperature and pressure attained being sufficient to bring about hot isostatic pressing and thus joining of the wall 110 and sheet 112 into a homogenous article.
Referring now to Figure 6. On cooling of the article, backing member 114 is removed by any suitable means, e.g. if a stop off material is sandwiched between the backing member 114 and sheet 112 prior to the hot isostatic pressing operation, a homogenous bond between them will be prevented.
Holes 120 may be drilled in the joint line and gas delivery tubes 122 inserted.
A gas such as Argon is then pumped through the tubes and penetrates the joint line, so urging sheet 122 a nd backing member 114 apart.
The filler 118 is then leached out and the wall 110 rolled and butt welded to form a cylinder which includes clear passageways. Radial holes 124 may be drilled into the passages to enable transpiration cooling to be achieved during operation of the combustion chamber in a gas turbine engine (not shown).
Referring now to Figure 7. Aturbine blade 126 has an aerofoil portion 128 clad in a skin 130, which has been applied to the aerofoil 128 in the manner described hereinbefore with reference to Figures 5 and 6.
Prior to its application to the aerofoil 128, skin 130 had grooves 132 formed and filled with a leachable material (not shown) as described hereinbefore and after the application of skin 130, the leachable material was leached out leaving an aerofoil 128 with no discontinuities in its surface, covered by a skin 130 which, with the aerofoil 128 forms clear passageways for the transport of cooling fluid during operation of turbine blade 126 in a gas turbine engine (not shown).
In either of the two examples just described the skin may be formed from a sheet of material having the same composition as the material of the core, or alternatively the skin may be made from a material having different composition to that of the core to provide, for example, greater oxidation or corrosion resistance at the outer surface of the finished article.
Claims (12)
1. A method of applying a coating to a surface area of a substantially rigid component, to form a composite article having a pre-determined shape, comprising the steps of:
(a) forming a carrier member a part of which has a surface area shaped in a pre-determined configuration,
(b) applying a coating on said surface area of the carrier member, the combination of the carrier member and coating being substantially rigid and the coating having a surface area on the opposite side thereof from the carrier member which is shaped in reverse conformity to said surface area of the rigid component.
(c) assembling together the component and the carrier member, with the conforming surfaces of the component and the coating adjacent each other, and
(d) hot isostatically pressing the assembled component and member with sufficient heat and pressure to bond together the adjacent conforming surfaces of the component and the coating to form a composite article.
2. A method of applying a coating as claimed in
Claim 1, including the further step of at least partly removing the carrier member from the composite article thus formed.
3. A method of applying a coating as claimed in
Claim 1 or Claim 2, wherein said surface area of the rigid component and said conforming surface area of the coating are non-planar.
4. A method of applying a coating as claimed in
Claim 1 or 2 or 3 including the steps of applying two or more coatings to the carrier member in reverse order relative to their desired order on the article.
5. A method of applying a coating as claimed in
Claim 1 or 2 or 3 including the step of applying the coating to the carrier member in the form of spaced portions and hot isostatically pressing the member into said spaces, onto the article and thereafter removing those portions of the carrier member covering the coating.
6. A method of applying a coating as claimed in any previous claim including the step of applying a stop off material between the carrier member and the coating.
7. A method of applying a coating as claimed in
Claim 1 or 2 or 3, including the steps of forming grooves in said surface area of the coating and filling the grooves with a leachable material, prior to assembling together the component and the carrier member; and the step of leaching out the leachable material after hot isostatically pressing the component and member together, to leave passages in the article.
8. A method of applying a coating as claimed in
Claim 7, wherein the coating comprises a conglomerate of particles.
9. A method of applying a coating as claimed in
Claim 8 wherein the particles are metallic.
10. A method of applying a coating as claimed in any preceding claim wherein the coating comprises a thermal barrier.
11. A method of applying a coating as claimed in any preceding claim wherein the coating comprises an anti-wear skin.
12. A method of applying a coating, substantially as any described herein with reference to the accompanying drawings.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB08413508A GB2141359B (en) | 1983-05-26 | 1984-05-25 | Improvements in or relating to the application of coatings to articles |
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB8314669 | 1983-05-26 | ||
| GB8319182 | 1983-07-15 | ||
| GB08413508A GB2141359B (en) | 1983-05-26 | 1984-05-25 | Improvements in or relating to the application of coatings to articles |
Publications (3)
| Publication Number | Publication Date |
|---|---|
| GB8413508D0 GB8413508D0 (en) | 1984-07-04 |
| GB2141359A true GB2141359A (en) | 1984-12-19 |
| GB2141359B GB2141359B (en) | 1986-10-15 |
Family
ID=27262116
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB08413508A Expired GB2141359B (en) | 1983-05-26 | 1984-05-25 | Improvements in or relating to the application of coatings to articles |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2141359B (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0358829A1 (en) * | 1988-09-13 | 1990-03-21 | Triad Investors Corporation | Process for modifying the surface of metal or metal alloy substrates and surface modified products produced thereby |
| US11686208B2 (en) | 2020-02-06 | 2023-06-27 | Rolls-Royce Corporation | Abrasive coating for high-temperature mechanical systems |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB739565A (en) * | 1953-07-03 | 1955-11-02 | Libbey Owens Ford Glass Co | Electrically conducting films on bent glass |
| GB1339652A (en) * | 1970-10-20 | 1973-12-05 | United Aircraft Corp | Method for fabricating corrosion resistand composites |
| US3884771A (en) * | 1972-06-29 | 1975-05-20 | Fujitsu Ltd | Process of producing resinous board having a rough surface usable for firmly supporting thereon a printed circuit |
| GB2098240A (en) * | 1981-05-08 | 1982-11-17 | British Aerospace | Forming articles by plating |
-
1984
- 1984-05-25 GB GB08413508A patent/GB2141359B/en not_active Expired
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB739565A (en) * | 1953-07-03 | 1955-11-02 | Libbey Owens Ford Glass Co | Electrically conducting films on bent glass |
| GB1339652A (en) * | 1970-10-20 | 1973-12-05 | United Aircraft Corp | Method for fabricating corrosion resistand composites |
| US3884771A (en) * | 1972-06-29 | 1975-05-20 | Fujitsu Ltd | Process of producing resinous board having a rough surface usable for firmly supporting thereon a printed circuit |
| GB2098240A (en) * | 1981-05-08 | 1982-11-17 | British Aerospace | Forming articles by plating |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0358829A1 (en) * | 1988-09-13 | 1990-03-21 | Triad Investors Corporation | Process for modifying the surface of metal or metal alloy substrates and surface modified products produced thereby |
| US11686208B2 (en) | 2020-02-06 | 2023-06-27 | Rolls-Royce Corporation | Abrasive coating for high-temperature mechanical systems |
Also Published As
| Publication number | Publication date |
|---|---|
| GB8413508D0 (en) | 1984-07-04 |
| GB2141359B (en) | 1986-10-15 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PCNP | Patent ceased through non-payment of renewal fee |
Effective date: 19920525 |