Hot gas path component with a layer arrangement and method for producing such a hot gas path component

Abstract

Hot gas path component (101) of a turbine, wherein the hot gas path component (101) has a layer arrangement (100), wherein the layer arrangement (100) has: a substrate layer (102) made of a material including a nickel-based alloy or superalloy, a chromium-based alloy or superalloy, a cobalt-based alloy or superalloy, an iron-based alloy or superalloy, or a combination thereof; a ceramic matrix composite layer (104); and a non-metallic spacer (106) between the substrate layer (102) and the ceramic matrix composite layer (104) configured to define a plurality of pockets (806); wherein the plurality of pockets (806) contain a substance having better thermal insulation properties than the substrate layer (102), wherein the substrate layer (102), the ceramic matrix composite layer (104) and the non-metallic spacer (106) form a plurality of fully enclosed pockets (806) such that flow into the plurality of fully enclosed pockets (806) is prevented, and wherein the hot gas path component (101) is a component along a hot gas path (109) of the turbine.

Description

FIELD OF THE INVENTIONThe present invention is directed to manufacturing components and methods for manufacturing manufacturing manufacturing components. More particularly, the present invention is directed to hot path components of turbines having a ceramic matrix composite layer in layered arrangements and a method of making such hot path components.BACKGROUND OF THE INVENTIONCeramic matrix composites are known to have high temperature resistance. However, components using such ceramic matrix composites may have an undesirably low load capacity. In contrast, metal components may have high load capacity. However, for metal components exposed to high temperatures, such as along a hot gas path of a turbine, such a load capacity decreases when exposed to such high temperatures.Layered components with different materials are known to present challenges. Such challenges are greater for direct contact materials having different properties. For example, the difference in thermal expansion coefficients, thermal conductivity, and other properties may cause the joint to separate between these layers and / or form undesirable features, thereby limiting the applications of such layered components.US 2009 / 0 260 364 A1 discloses a hot gas path component in the form of a transition piece along a hot gas path of a turbine having a layer arrangement composed of a metallic substrate layer, a ceramic matrix composite layer and a resilient porous, optionally ceramic element which is arranged as a spacer between the two layers and is mechanically fastened, for example, by means of screws to at least one of these. The porous element is capable of flowing a flow of cooling air through itself.U.S. Pat. No. 6,769,866 B1 discloses a turbine vane having an outer wall made of a carbon composite material as substrate layer, an inner wall which can likewise be formed from the carbon composite material as composite layer and spacers arranged therebetween in the form of ribs which form a grid and define a multiplicity of pockets or cavities between one another. The inner wall and the outer wall contain inlets and outlets for conducting a protective gas through the cavities.U.S. Pat. No. 6,767,659 B1 discloses a combustor liner for a gas turbine made of a ceramic matrix composite material (CMC) having a substrate layer which may be formed from a nickel superalloy, a CMC layer and an air gap which is arranged in the space between the substrate layer and the CMC layer.US 7 500 828 B2 discloses a gas turbine blade comprising an airfoil wall, a plurality of rib-like spacers integrally formed with the airfoil wall and defining therebetween pockets or cavities filled with a porous metal, and a thermal barrier layer applied over the porous metal. A plurality of cooling holes pass through the airfoil wall to flow cooling air from a central channel within the gas turbine blade into the porous metal-filled cavities.US 2010 / 0 166 565 A1 discloses a turbine vane having an outer blade airfoil structure made of a ceramic matrix composite material, a substrate body in the interior of the outer blade airfoil structure and a gap therebetween, in which a metallic mesh is arranged as a spacer. The net defines a plurality of pockets fluidly connected to each other. Cooling air supply holes provide fluid flow communication between an inner cooling air supply passage of the turbine vane and the gap having the mesh disposed therein.It is an object of the invention to provide a hot gas path component of a turbine having a stack and a method of making a hot gas path component of a turbine having a stack that are not subject to one or more of the foregoing disadvantages.BRIEF DESCRIPTION OF THE INVENTIONIn a first aspect of the invention, a hot gas path component of a turbine includes a stack including a substrate layer of a material including a nickel-based alloy or superalloy, a chromium-based alloy or superalloy, a cobalt-based alloy or superalloy, an iron-based alloy or superalloy, or a combination thereof, a ceramic matrix composite layer, and a non-metallic spacer between the substrate layer and the ceramic matrix composite layer configured to define a plurality of pockets. The plurality of pockets contain a substance having better thermal insulation properties than the substrate layer. The substrate layer, the ceramic matrix composite layer, and the non-metallic spacer form a plurality of fully enclosed pockets such that flow into the plurality of fully enclosed pockets is prevented. The hot gas path component is a component along a hot gas path of the turbine.The substrate layer may be a nickel-based superalloy.The non-metallic spacer of the hot gas path component may be made of ceramic.The non-metallic spacer may include a thermal barrier coating.The non-metallic spacer may contain yttria-stabilized zirconia.The non-metallic spacer may at least partially enclose air in the stack.The stack of hot gas path components may be used for a sidewall of a turbine vane.The stack of hot gas path components may be used for an airfoil surface.The stack of hot gas path components may be used for a turbine shroud.The non-metallic spacer of the hot gas path component may include a fin extending along the stack.The non-metallic spacer may include intersecting ribs.The non-metallic spacer defines the plurality of pockets, wherein the plurality of pockets may be configured to contain air.The plurality of pockets may be filled with a thermally insulating substance comprising fibers, fuel, cooling fluid, liquid, gel, vapor, or combinations thereof.The non-metallic spacer may be mechanically attached to either the substrate layer or the ceramic matrix composite layer, or both.The non-metallic spacer may be bonded to the substrate layer or the ceramic matrix composite layer.The non-metallic spacer may have a thermal conductivity less than half the thermal conductivity of the substrate layer.The substrate layer of the hot gas path component stack may be at least 254 μm (10 mils) thick, wherein the ceramic matrix composite layer may be at least 508 μm (20 mils) thick, and the non-metallic spacer may have a maximum thickness dimension of at least 762 μm (30 mils).In an embodiment of the hot gas path component according to the invention, the substrate layer may be a nickel-based superalloy layer and the non-metallic spacer may be a ceramic spacer between the nickel-based superalloy layer and the ceramic matrix composite layer. The ceramic spacer may be mechanically attached to either the nickel-based superalloy layer or the ceramic matrix composite layer, or both, and the ceramic spacer may be bonded to the nickel-based superalloy layer or the ceramic matrix composite layer.In another aspect of the invention, a method of making a hot gas path component of a turbine having a stack includes providing a substrate layer of a material including a nickel-based alloy or superalloy, a chromium-based alloy or superalloy, a cobalt-based alloy or superalloy, an iron-based alloy or superalloy, or a combination thereof, securing a non-metallic spacer between the substrate layer and a ceramic matrix composite layer of the stack, and receiving the stack in the hot gas path component which is a component along a hot gas path of the turbine. The non-metallic spacer is configured to define a plurality of pockets, wherein the plurality of pockets are filled with a substance having better thermal insulation properties than the substrate layer, and wherein the substrate layer, the ceramic matrix composite layer, and the non-metallic spacer form a plurality of fully enclosed pockets such that flow into the plurality of fully enclosed pockets is prevented.Other features and advantages of the present invention will become apparent from the following more detailed description of the preferred embodiment taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.BRIEF DESCRIPTION OF THE DRAWINGSFIG. 1 illustrates a side view of an example stack according to an embodiment of the disclosure. FIG. 2 illustrates a perspective view of an example stack according to the embodiment of FIG. 1. FIG. 3 illustrates a perspective view of an example turbine vane with layered sidewalls according to an embodiment of the disclosure. FIG. 4 illustrates a cross-sectional view of an example airfoil with a layered arrangement, according to an embodiment of the disclosure. FIG. 5 illustrates a side view of an example turbine shroud with a layered arrangement according to an embodiment of the disclosure. FIG. 6 illustrates a cross-sectional view taken along line 6- 6 of the example turbine shroud illustrated in FIG. 5. FIG. 7 illustrates a perspective sectional view of an example turbine shroud with a layered assembly according to an embodiment of the disclosure. FIG. 8 illustrates a perspective view of an example non-metallic multi-rib spacer according to the disclosure. FIG. 9 illustrates a perspective view of an example non-metallic multi-rib spacer according to the disclosure. FIG. 10 illustrates a perspective view of an example non-metallic spacer having multiple intersecting ribs, in accordance with the disclosure.As far as possible, the same reference numerals are used throughout the drawings to represent the same parts.DETAILED DESCRIPTION OF THE INVENTIONAn example hot gas path component and method of making a hot gas path component with a stack according to the disclosure are provided. Embodiments of the present disclosure enable use of components at higher temperatures and / or for longer periods of time, enable use of positive properties of ceramic matrix composite and metal or metallic substrates in a layered component, enable higher turbine efficiency, enable prolonged use / durability of turbine components (hot gas path components), enable higher turbine quality, enable higher firing temperatures in turbines, enable a higher temperature gradient between layers of a component, or combinations thereof, for example, as compared to using layered components with a matrix ceramic composite and metal layers in direct contact.FIGS. 1 and 2 illustrate a laminate assembly 100 having a substrate layer 102, a ceramic matrix composite layer 104, and one or more non-metallic spacers 106 between the substrate layer 102 and the ceramic matrix composite layer 104. In one embodiment, a portion of a turbine component 101 includes the stack 100 and defines a surface 111 of the turbine component 101, such as a hot gas path 109 (see FIG. 1 ), a sidewall 302 of a turbine vane 300 (see FIG. 3 ), an airfoil surface 402 of an airfoil 400 (see FIG. 4 ), a turbine shroud 500 (see FIG. 5 ), or a combination thereof. Additionally or alternatively, the stack 100 may be used with components subjected to a load, such as a turbine housing.Referring to FIGS. 1 and 2, the substrate layer 102, the ceramic matrix composite layer 104, and the non-metallic spacer / spacers 106 may have any suitable dimensions based on the desired properties. For example, a suitable substrate thickness 103 for the substrate layer 102 is at least about 254 μm (10 mils), at least about 381 μm (15 mils), at least about 508 μm (20 mils), between about 254 (10 mils) and about 762 μm (30 mils), between about 1381 μm (15 mils) and about 635 μm (25 mils), between about 254 μm (10 mils) and about 508 μm (20 mils), between about 508 μm (20 mils) and about 762 μm (30 mils), about 508 μm (20 mils), or any suitable combination, sub-combination, range, or sub-range therein. A suitable ceramic matrix composite thickness 105 for the ceramic matrix composite layer 104 is at least about 508 μm (20 mils), at least about 762 μm (30 mils), at least about 1016 μm (40 mils), between about 762 μm (30 mils) and about 1270 μm (50 mils), between about 740 μm (30 mils) and about 1016 μm (40 mils), between about 1016 μm (40 mils) and about 1270 μm (50 mils), between about 889 μm (35 mils) and about 1143 μm (45 mils), about 1016 μm (40 mils), or any suitable combination, sub-combination, range, or sub-range therein. As will be described in more detail below, the dimensions of the non-metallic spacer / s 106 depend on the geometry of the non-metallic spacer / s 106.The substrate layer 102 is made of a suitable material. Suitable materials include nickel-based alloys and superalloys, chromium-based alloys and superalloys, cobalt-based alloys and superalloys, iron-based alloys and superalloys, or combinations thereof. In one embodiment, the substrate layer 102 has stress resistant properties that exceed those of the ceramic matrix composite layer 104.The ceramic matrix composite layer 104 is any suitable material that provides properties for the desired application, such as temperature resistance at the hot gas path 109 where the temperatures of the turbine components exceed about 1000° C. Suitable materials for the ceramic matrix composite layer 104 include, but are not limited to, carbon, silicon carbide (SiC), silicon nitride (Si 3 N 4), alumina (Al,O 3), mullite (Al 2 O 3- SiO 4) or a combination thereof. Fibrous reinforcement of the ceramic matrix composite layer 104 is performed with carbon, silicon carbide (SiC), silicon nitride (Si 3 N 4), aluminum oxide (Al 2 O 3), mullite (Al 2 O 3- SiO 4) or a combination thereof.The non-metallic spacer 106 separates any suitable portion or all of the ceramic matrix composite layer 104 from the substrate layer 102. In one embodiment, the non-metallic spacer 106 is mechanically attached to either or both of the substrate layer 102 and the ceramic matrix composite layer 104, for example as shown in FIG. 6, by interlocking between a protrusion 602 (on the ceramic matrix composite layer 104 and / or the substrate layer 102) and a groove 604 (on the ceramic matrix composite layer 104 and / or the substrate layer 102). Additionally or alternatively, the non-metallic spacer 106 is bonded to the substrate layer 102 or the ceramic matrix composite layer 104.The dimensions and geometry of the non-metallic spacer 106 depend on the configuration of the substrate layer 102 and the ceramic matrix composite layer 104. As shown in FIG. 5, in one embodiment, multiple of the non-metallic spacers 106 have non-uniform dimensions based on positioning. In other embodiments, as shown in FIG. 3, the non-metallic spacers 106 have substantially uniform dimensions. Additionally or alternatively, in some embodiments, the non-metallic spacers 106 are arranged as individual spacer bodies 108 that extend from a spacer coating 110, as shown in FIG. 2, extend from the substrate layer 102, as shown in FIG. 7, and / or extend from the ceramic matrix composite layer 104.As shown in FIGS. 8-10, in some embodiments, the non-metallic spacers 106 are configured as one or more ribs or ledges 108 that extend along the assembly 100 (see FIG. 1 ). The ribs 802 include a plateau 804 (see FIG. 8 ), a tip 902 (see FIG. 9 ), intersecting ribs 1002 (see FIG. 10 ), or a combination thereof. As shown in FIG. 1, in one embodiment, a spacer thickness 107 (a thickness of the spacer bodies 108 and the spacer coating 110, if present) is at least about 35 mils, at least about 40 mils, at least about 45 mils, between about 35 mils and about 55 mils, between about 35 mils and about 45 mils, between about 45 mils and about 55 mils, between about 40 mils and about 50 mils, about 45 mils, or any suitable combination, sub-combination, region, or sub-region therein.Referring again to FIGS. 8-10, non-metallic spacer 106 defines pockets 806. The pockets 806 may contain a substance 112 (see FIG. 1 ), such as air, and / or any other suitable substance capable of better thermal insulation than the substrate layer 102, and optionally the ceramic matrix composite layer 104. Suitable substances include, but are not limited to, static air, fibers, fuel, static cooling fluid, liquid, gel, vapor, or combinations thereof. The non-metallic spacers 106 and the pockets 806 are fully enclosed by the substrate layer 102 and the ceramic matrix composite layer 104, thereby preventing flow into the pockets 806.The non-metallic spacer 106 is made of any suitable material or materials capable of reducing heat transfer between the ceramic matrix composite layer 104 and the substrate layer 102, and having a length to reduce the influence of the stress from the substrate layer 102 on the ceramic matrix composite layer 104. Suitable materials for the non-metallic spacer 106 include, but are not limited to, ceramics, yttrium stabilized zirconia, gadolinium zirconate, rare earth zirconates, thermal barrier coatings, or combinations thereof. For example, suitable materials have a thermal conductivity that is at least a predetermined amount less than that of the substrate layer 102, such as between about one tenth and about one third of the thermal conductivity of the substrate layer 102, between about one third and about one half of the thermal conductivity of the substrate layer 102, between about one quarter and about one half of the thermal conductivity of the substrate layer 102, between about one quarter and about one third of the thermal conductivity of the substrate layer 102, between about one tenth and about one third of the thermal conductivity of the substrate layer 102, about one half, about one quarter, about one third, about one tenth, or any suitable combination, sub-combination, range, or sub-range thereof.The non-metallic spacer 106, the individual spacer bodies 108, the spacer coating 110, or a combination thereof, are grown and / or are deposited on the substrate layer 102 and / or the ceramic matrix composite layer 104. In one embodiment, such deposition is by electron beam physical vapor deposition (EBPVD), air plasma spraying (APS), high speed flame spraying (HVOF), electrostatic spray assisted vapor deposition (ESAVD), direct vapor deposition, other suitable spraying techniques, or a combination thereof. In another embodiment, the non-metallic spacer 106 is positioned after processing the substrate layer 102 and / or after creating / stiffening the ceramic matrix composite layer 104, thereby completing geometric features of the substrate layer 102 and / or the ceramic matrix composite layer 104. For example, in these embodiments, the pockets 806 in the non-metallic spacers 106 are formed at least in part by non-planar features of the substrate layer 102 and / or the ceramic matrix composite layer 104. In another embodiment, the non-metallic spacer 106 is deposited after stripping an existing layer, such as the post-extended use non-metallic spacer 106, the substrate layer 102, the ceramic matrix composite layer 104, or a combination thereof.A hot gas path component and method for making a hot gas path component with a stack are disclosed. The laminate assembly includes a substrate layer, a ceramic matrix composite layer, and a non-metallic spacer between the substrate layer and the ceramic matrix composite layer configured to form a plurality of pockets. The hot gas path component includes a nickel-based superalloy layer, a ceramic matrix composite layer, and a ceramic spacer between the nickel-based superalloy layer and the ceramic matrix composite layer. The ceramic spacer is mechanically attached to either or both of the substrate layer and the ceramic matrix composite layer, and the ceramic spacer is bonded to the substrate layer or the ceramic matrix composite layer. The method includes securing a non-metallic spacer between a substrate layer and a ceramic matrix composite layer of the laminate.

Claims

A hot gas path component (101) of a turbine, the hot gas path component (101) comprising a stack (100), the stack (100) comprising: a substrate layer (102) of a material including a nickel-based alloy or superalloy, a chromium-based alloy or superalloy, a cobalt-based alloy or superalloy, an iron-based alloy or superalloy, or a combination thereof; a ceramic matrix composite layer (104); and a non-metallic spacer (106) between the substrate layer (102) and the ceramic matrix composite layer (104) configured to define a plurality of pockets (806); wherein the plurality of pockets (806) contain a substance having better thermal insulation properties than the substrate layer (102), wherein the substrate layer (102), the ceramic matrix composite layer (104), and the non-metallic spacer (106) form a plurality of fully enclosed pockets (806) such that flow into the plurality of fully enclosed pockets (806) is prevented, and wherein the hot gas path component (101) is a component along a hot gas path (109) of the turbine.The hot gas path component (101) of claim 1, wherein the substrate layer (102) comprises a nickel-based superalloy.The hot gas path component (101) of claim 1 or 2, wherein the non-metallic spacer (106) includes a thermal barrier coating.The hot gas path component (101) of any preceding claim, wherein the non-metallic spacer (106) includes a fin (108, 802) extending along the stack (100) or intersecting fins (1002).The hot gas path component (101) of any preceding claim, wherein the plurality of pockets (806) enclose air in the stack (100).The hot gas path component (101) of any preceding claim, wherein the plurality of pockets (806) are filled with a thermally insulating substance comprising fibers, fuel, cooling fluid, liquid, gel, vapor, or combinations thereof.The hot gas path component (101) of any preceding claim, wherein the non-metallic spacer (106) has a thermal conductivity less than half the thermal conductivity of the substrate layer (102).The hot gas path component (101) of any preceding claim, wherein: the substrate layer (102) is a nickel-based superalloy layer (102); the non-metallic spacer (106) is a ceramic spacer (106) between the nickel-based superalloy layer (102) and the ceramic matrix composite layer (104); the ceramic spacer (106) is mechanically attached to either or both of the nickel-based superalloy layer (102) and the ceramic matrix composite layer (104); and the ceramic spacer (106) is bonded to the nickel-based superalloy layer (102) or the ceramic matrix composite layer (104).Use of the stack (100) of the hot gas path component (101) of any preceding claim for a sidewall (302) of a turbine vane (300), an airfoil surface (402), or a turbine shroud (500).A method of making a hot gas path component (101) of a turbine having a stack (100), the method comprising providing a substrate layer (102) of a material comprising a nickel-based alloy or superalloy, a chromium-based alloy or superalloy, a cobalt-based alloy or superalloy, an iron-based alloy or superalloy, or a combination thereof, securing a non-metallic spacer (106) between the substrate layer (102) and a ceramic matrix composite layer (104) to form the stack (100), and receiving the stack (100) into the hot gas path component (101), wherein: the non-metallic spacer (106) is configured to define a plurality of pockets (806); the plurality of pockets (806) are filled with a substance having better thermal insulation properties than the substrate layer (102), the substrate layer (102), the ceramic matrix composite layer (104), and the non-metallic spacer (106) form a plurality of fully enclosed pockets (806) such that flow into the plurality of fully enclosed pockets (806) is prevented, and wherein the hot gas path component (101) is a component along a hot gas path (109) of the turbine.

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