Manufacturing method for turbine blade-shaped component and turbine blade-shaped component using the same
Patent Information
- Application Number
- JP2022165027
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2022-10-13
- Publication Date
- 2025-08-04
- Estimated Expiration
- 2042-10-13
AI Technical Summary
Existing methods struggle to provide a stable and cost-effective oxidation-resistant coating on the cooling passages of turbine airfoil components, as high-temperature casting causes the coating to diffuse into the casting, and applying coatings to complex shapes like cooling passages is challenging.
A method using lost wax precision casting combined with a composite coating layer of oxidation-resistant metal and ceramic material layers, applied through a core and shell assembly, prevents diffusion during casting by forming a diffusion barrier.
The method effectively forms a stable oxidation-resistant coating on the cooling passages, preventing damage and maintaining the coating's functionality, even at high temperatures, while being cost-effective and applicable to complex shapes.
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Abstract
Description
[Technical field]
[0001] The present invention relates to a manufacturing method for a turbine airfoil component suitable for use in oxidation-resistant coating of a heat-resistant superalloy used in a gas turbine, and a turbine airfoil component using the same, and in particular to a manufacturing method for a turbine airfoil component suitable for use in oxidation-resistant multilayer coating of a cast alloy by an insert casting method, and a turbine airfoil component using the same. [Background technology]
[0002] Turbine airfoil parts are used as turbine blades for jet engines, gas turbines, etc., and are made of, for example, Ni-based superalloys and Co-based superalloys. In recent years, there has been a demand to increase the turbine inlet temperature in order to improve the efficiency of turbine engines. Therefore, it is necessary to improve the high-temperature properties (creep properties, oxidation resistance, etc.) of Ni-based superalloys, and it has been proposed to form an oxidation-resistant and corrosion-resistant coating layer of Al, Cr, Ni-Al, Pt-Al, MCrAlY, etc. on the surface of the Ni-based superalloy, and to provide a diffusion barrier coating to prevent the oxidation-resistant and corrosion-resistant coating layer from diffusing into the Ni-based superalloy (see Patent Document 1). It has also been proposed to provide an oxidation-resistant bond coat layer, the composition of which is in thermodynamic equilibrium with the Ni-based superalloy, between the surface of the Ni-based superalloy and the ceramic stop coat on the outermost surface of the substrate (see Patent Document 2).
[0003] In addition, because high-temperature combustion gas close to the melting temperature of Ni-based superalloys acts on the turbine inlet of turbine airfoil parts, cooling passages are formed inside the turbine airfoil parts even if the material has a high heat resistance temperature such as Ni-based superalloys. In order to manufacture turbine airfoil parts with such complicated shapes, they are manufactured by the lost-wax precision casting method (investment casting method) through the steps of forming a mold, melting and casting, and solidification control (see Non-Patent Documents 1 and 2). The application of an oxidation- and corrosion-resistant coating layer is performed on the outer surface of the turbine airfoil component, and conventionally, an oxidation- and corrosion-resistant coating layer has not been provided on the cooling passages formed inside the turbine airfoil component.
[0004] On the other hand, the cast-in method, in which a different material or component is placed in a mold and molten metal is poured in to integrate it with the casting, is widely used for aluminum castings, etc. Furthermore, a method of forming an oxidation-resistant or abrasion-resistant coating of ceramics or high-melting-point metal on a heat-resistant alloy by using an insert casting method has also been disclosed (Patent Document 3). [Prior art documents] [Patent documents]
[0005] [Patent Document 1] US6830827B2 (Japanese Patent Publication No. 2001-323332) [Patent Document 2] WO2008 / 032806 [Patent Document 3] US6616410B2 [Non-patent literature]
[0006] [Non-Patent Document 1] Lost wax precision casting (edited by the Japan Foundry Association, published by Sangyo Tosho, 2015) Molding method (pages 9-78), Melting and pouring (pages 78-82) and solidification control (pages 85-90) [Non-Patent Document 2] “The Superalloys Fundamentals and Applications” (Roger C. Reedcho, Cambridge University Press, 2006) “3.1 Processing of turbine blading by Solidification Processing” (pp. 122-147) Summary of the Invention [Problem to be solved by the invention]
[0007] However, with the recent rise in gas turbine temperatures, there have been reported cases in which cooling passages inside components such as gas turbine blades have been exposed to high temperatures and suffered oxidation damage. Therefore, if it were possible to provide an oxidation-resistant, corrosion-resistant coating layer inside the components, it would contribute to improving the reliability of gas turbine blades. On the other hand, even when a metal has a high melting point, in the case of casting a heat-resistant alloy whose casting temperature exceeds 1500°C, there is a problem that the metal applied to the mold diffuses into the casting during casting and does not remain on the casting surface. Also, in order to provide an oxidation-resistant and corrosion-resistant coating layer in a cavity such as the cooling passage of a turbine airfoil component, it is necessary to apply a corrosion-resistant coating layer to the cooling passage formed inside a gas turbine blade, which has a complex shape, and there has been a problem that it is very difficult to provide a corrosion-resistant coating layer of stable quality at a practical cost to the cooling passage of a turbine airfoil component.
[0008] The present invention has been made to solve such problems, and has an object to provide a method for manufacturing a turbine airfoil part, which utilizes an insert casting method when it is necessary to provide an oxidation-resistant coating layer in a cavity such as a cooling passage of the turbine airfoil part, and which can form the oxidation-resistant coating without diffusing a high-melting point metal or alloy used as the oxidation-resistant coating into the casting even at high casting temperatures. [Means for solving the problem]
[0009] [1] A method for producing a turbine airfoil part of the present invention is a method for casting a turbine airfoil part having a cavity for use in a gas turbine engine or a jet engine, as shown in, for example, FIG. 2 and FIG. 3, comprising the steps of: making or preparing a wax precursor 110 having a general outer shape of the turbine airfoil part (S300); wrapping the wax precursor 100 in a refractory layer coating material (ZrO2) to form a casting shell 120 (S305); and removing the wax precursor 110 from the casting shell 120 while leaving the refractory layer coating material (S310). A step (S320) of making or preparing a core having a general hollow shape of the turbine airfoil part, a step (S325) of coating an oxidation-resistant metal layer 102a on the surface of the core, and further coating the surface of the oxidation-resistant metal layer with a metal-containing ceramic material layer 102b to form a core 100 with a composite coating layer, a step (S330) of sintering an assembly of the casting shell 120 and the core 100 with the composite coating layer that has been subjected to the dewaxing step, and a step (S330) of completely dissolving or destroying the refractory layer coating material and the metal-containing ceramic material layer. The method includes a step (S340) of casting a heat-resistant superalloy into a mold formed by the composite coated core 100 and the casting shell 120 without any prior art work; a step (S350) of transferring a composite coating layer of an oxidation-resistant metal layer 102a and a metal-containing ceramic material layer 102b from the composite coated core 100 to the cast heat-resistant superalloy on the inner surface of the hollow shape of the turbine airfoil component; and a step (S360) of removing the mold to obtain the turbine airfoil component made of the cast heat-resistant superalloy and having the hollow shape.
[0010] [2] The method of manufacturing a turbine airfoil component of the present invention [1] preferably includes a step (S370) of applying a layer of metal-containing ceramic material (a diffusion barrier layer) to a surface of the as-cast outer shape of the turbine airfoil component, and further overcoating an oxidation-resistant metal layer (oxidation-resistant layer). [3] The method for producing a turbine airfoil part of the present invention is a method for casting a turbine airfoil part having a cavity for use in a gas turbine engine or a jet engine, as shown in, for example, FIG. 4 and FIG. 5, and includes the steps of: producing or preparing a wax precursor 110 having a general outer shape of the turbine airfoil part (S500); wrapping the wax precursor 110 in a refractory layer coating material (ZrO2), and coating an oxidation-resistant metal layer 112a on an inner surface corresponding to the outer shape of the turbine airfoil part, and further coating the surface of the oxidation-resistant metal layer 112a with a metal-containing ceramic material layer 112b to form a coated casting shell 120 (S505); and removing the wax precursor 110 from the coated casting shell 120 while leaving the refractory layer coating material (S510). A step of producing or preparing a core having a general hollow shape of the turbine airfoil component (S520); a step of coating an oxidation-resistant metal layer 102a on a surface of the core, and further coating the surface of the oxidation-resistant metal layer with a metal-containing ceramic material layer 102b to form a composite-coated core 100 (S525); A step (S530) of sintering an assembly of the casting shell 120 having undergone the dewaxing step and the core 100 having the composite coating layer; A step (S540) of casting by pouring a molten metal of a heat-resistant superalloy into a mold formed by the core with the composite coating layer and the casting shell 120 without completely dissolving or destroying the composite coating layer of the refractory layer coating material, the metal-containing ceramic material layer, and the oxidation-resistant metal layer; A composite coating layer of the oxidation-resistant metal layer 102a and the metal-containing ceramic material layer 102b is transferred from the composite coating layer-coated core 100 to the cast heat-resistant superalloy on the inner surface of the cavity shape of the turbine airfoil component (S550), and a composite coating layer of the oxidation-resistant metal layer 112a and the metal-containing ceramic material layer 112b is transferred from the casting shell 120 to the cast heat-resistant superalloy on the inner surface of the outer shape of the turbine airfoil component (S555); and removing (S560) the mold to obtain the turbine airfoil component made of the cast heat-resistant superalloy and having the cavity shape.
[0011] [4] In the methods [1] to [3] of manufacturing a turbine airfoil component of the present invention, preferably, when coating the metal-containing ceramic material layer (102b) on the surface of the core, at least one of the metal-containing ceramic material layer (Al2O3) or the oxidation-resistant metal layer is applied by paste coating. [5] In the methods [1] to [4] for manufacturing a turbine airfoil component of the present invention, preferably, the heat-resistant superalloy is a Ni-base or Co-base superalloy, the oxidation-resistant metal layer is a high-melting point metal layer mainly composed of Pt, or a high-melting point alloy layer selected from PtIr and NiAl, and the metal-containing ceramic material layer is a layer containing Al2O3 containing 0 to 50 wt.% of an oxidation-resistant alloy. [6] In the method [5] for producing a turbine airfoil component of the present invention, the oxidation-resistant alloy is preferably Pt, an alloy containing Pt as a main element, PtIr, or NiAl. [7] In the method for manufacturing a turbine airfoil component according to the present invention [5] or [6], preferably, the oxidation-resistant metal layer is an alloy mainly composed of Pt, and the metal-containing ceramic material layer is mainly composed of Al2O3. Here, the oxidation-resistant metal layer is an alloy mainly composed of Pt, which means that the oxidation-resistant metal layer contains 50% by mass or more of Pt, preferably 80% by mass or more, and more preferably 90% by mass or more of Pt. The metal-containing ceramic material layer is mainly composed of Al2O3, which means that the metal-containing ceramic material layer contains 50% by mass or more of Al2O3, preferably 70% by mass or more, and more preferably 90% by mass or more of Al2O3. [8] In the method of manufacturing a turbine airfoil component of the present invention [7], preferably the oxidation-resistant metal layer is Pt having a thickness of 20 μm or less, and the metal-containing ceramic material layer (diffusion barrier layer) is Al2O3 having a thickness of 20 μm or less.
[0012] [9] The present invention provides a turbine airfoil component having a cavity for use in a gas turbine engine or jet engine formed by casting, comprising: an oxidation-resistant film structure of a metal-containing ceramic material layer 102b and an oxidation-resistant metal layer 102a having a predetermined shape fixed and held on the hollow-shaped inner surface of the turbine airfoil component; a heat resistant superalloy adjacent to the metal-containing ceramic material layer 102b; a surface of the contour of the turbine airfoil component; During casting, as it cools from a molten state, it flows and solidifies in contact with metal-containing ceramic material layer 102b, and does not cause decomposition of metal-containing ceramic material layer 102b and oxidation-resistant metal layer 102a.
[10] The present invention provides a turbine airfoil component having a cavity for use in a gas turbine engine or jet engine formed by casting, comprising: a first composite coating layer structure of a first metal-containing ceramic material layer 102b and a first oxidation-resistant metal layer 102a having a predetermined shape fixed and held on the cavity-shaped inner surface of the turbine airfoil component; a second composite coating layer structure of a second metal-containing ceramic material layer 112b and a second oxidation-resistant metal layer 112a having a predetermined shape fixedly held on a surface of the outer shape of the turbine airfoil component; a heat resistant superalloy having a first surface adjacent a first metal-containing ceramic material layer (102b) of the first oxidation-resistant film structure and a second surface adjacent a second metal-containing ceramic material layer (112b) of the second oxidation-resistant film structure; During casting, as it cools from a molten state, it flows and solidifies in contact with the first and second metal-containing ceramic material layers (102b, 112b), without causing decomposition of the first and second metal-containing ceramic material layers (102b, 112b) and the first and second oxidation-resistant metal layers (102a, 112a). Effect of the Invention
[0013] According to the manufacturing method of the turbine airfoil component of the present invention, by combining the casting of the turbine airfoil component by the lost wax precision casting method with the coating of the inner surface of the hollow shape of the turbine airfoil component using a core by utilizing the advantages of the insert casting method, it is possible to form an oxidation-resistant composite coating layer on the cooling passage of the gas turbine blade and prevent oxidation damage in the cooling passage. Furthermore, if the insert casting method is applied as is, the oxidation-resistant coating layer will disappear due to diffusion into the casting during casting, but by providing a diffusion barrier layer, the oxidation-resistant coating layer remains on the surface, making it possible to transfer an oxidation-resistant multilayer coating for heat-resistant alloys that maintains its oxidation-resistant function to the casting surface.
[0014] According to the manufacturing method of the turbine airfoil component of the present invention [4], it is possible to apply a two-layer coating using a metal-containing ceramic material layer (Al2O3) and an oxidation-resistant metal layer simply and inexpensively by using paste coating.
[0015] The manufacturing method for turbine airfoil components of the present invention[5] can be applied to Ni-base or Co-base superalloys used in gas turbines to maximize the performance of oxidation-resistant multi-layer coatings for heat-resistant alloys that can withstand high casting temperatures. According to the manufacturing method for a turbine airfoil component of the present invention [5], a diffusion barrier layer of Al2O3-X wt%Pt (X=50~0) is provided under an oxidation-resistant coating layer having a high melting point and oxidation resistance, such as Pt or NiAl, to prevent diffusion of metallic elements into the casting during casting.
[0016] According to the manufacturing method for turbine airfoil parts of the present invention[7], the diffusion of Pt, which acts as an oxidation-resistant layer, into the casting can be effectively prevented by the Al2O3 barrier layer, making it possible to cast for a long time and at higher temperatures, such as by directional solidification. According to the manufacturing method for a turbine airfoil component of the present invention[8], the thickness of the Pt layer is 20 μm or less, and the thickness of the Al2O3 layer is 20 μm or less, which makes it possible to withstand thermal shock during heating and cooling, thereby improving the oxidation resistance in a gas turbine environment where heating and cooling are repeated. [Brief description of the drawings]
[0017] [Figure 1] FIG. 1 is an explanatory diagram of components used in the manufacturing method of a turbine airfoil part of the present invention, in which (A) is a ceramic core, (B) is an external view of a turbine blade, and (C) is a cutaway view showing a cooling passage formed inside the turbine blade. [Diagram 2] FIG. 2 is an explanatory diagram showing a first manufacturing method of the turbine airfoil part of the present invention, using a ceramic core and a casting shell of a turbine rotor blade body. [Diagram 3] 4 is a flow chart showing a first method for manufacturing a turbine airfoil component of the present invention. [Figure 4] FIG. 4 is an explanatory diagram of a second manufacturing method of the turbine airfoil part of the present invention, using a ceramic core and a casting shell of a turbine rotor blade body. [Diagram 5] 4 is a flow chart showing a second method of manufacturing the turbine airfoil component of the present invention. [Figure 6A]This figure shows the steps of manufacturing a single crystal test piece using the turbine blade body manufacturing method shown in Figure 4. (A) shows the creation of a mold, (B) shows the wax injection molding, (C) shows the extraction of the wax precursor, (D) shows the application and drying of the composite coating layer, (E) shows the creation of a mold, and (F) shows dewaxing. [Figure 6B] This figure shows the process of manufacturing a single crystal test piece using the manufacturing method of the turbine blade body shown in Figure 4, where (G) shows the binder removal treatment and sintering treatment of the mold, (H) shows casting, and (I) shows the removal of the single crystal test piece, which is a cast product. [Figure 7A] FIG. 2 is a diagram for explaining the details of a composite coating layer of an oxidation-resistant metal layer and a metal-containing ceramic material layer in a single crystal test piece, where (A) is an explanatory diagram of the production of a single crystal test piece by unidirectional solidification. [Figure 7B] FIG. 10 is a diagram explaining the details of a composite coating layer of an oxidation-resistant metal layer and a metal-containing ceramic material layer in a single crystal test piece; (B) is an optical photograph of the composite coating layer, and (C) shows the distribution of the composition ratios of the constituent elements in the thickness direction from the surface. [Figure 8] 8 is a SEM photograph of the single crystal test piece shown in FIG. 7 in the thickness direction from the surface. [Figure 9] FIG. 1 is a diagram showing a method for manufacturing a directionally solidified test piece using a core. [Figure 10A] This figure shows the structure after molten Ni-10 atomic % was poured into a two-layer coating applied to an Al2O3 tube, Pt layer / Pt-40 wt% Al2O3 layer (holding time 7 minutes). The top photo shows a cross-sectional structure photograph taken with an SEM, and the bottom photo shows the results of elemental analysis using EDS. [Figure 10B] This is a Pt-Ir layer / Pt-40 wt % Al2O3 layer (holding time 7 minutes), and the upper part shows a cross-sectional structure photograph taken with an SEM, and the lower part shows the results of elemental analysis using an EDS. [Figure 11A] This is a Pt layer / Pt-70 wt % Al2O3 layer (holding time 7 minutes), and the upper part shows a cross-sectional micrograph taken with an SEM, and the lower part shows the results of elemental analysis using an EDS. [Figure 11B]This is a Pt-Ir layer / Pt-70 wt % Al2O3 layer (holding time 13 minutes), and the upper part shows a cross-sectional micrograph taken with an SEM, and the lower part shows the results of elemental analysis using an EDS. [Figure 12A] This is a Pt layer / Al2O3 layer (holding time 7 minutes). The upper part shows a cross-sectional micrograph taken with an SEM, and the lower part shows the results of elemental analysis using EDS. [Figure 12B] This is a Pt-Ir layer / Al2O3 layer (holding time 26 minutes). The upper part shows a cross-sectional micrograph taken with an SEM, and the lower part shows the results of elemental analysis using EDS. [Figure 13A] This figure shows the structure of the two-layer coating transferred from the inner wall of the mold to a casting containing Ni atomic % Al. It is a Pt layer / Pt-70 wt%Al2O3 layer (holding time 5 minutes). The upper part shows a cross-sectional photograph of the structure taken with an SEM, and the lower part shows the results of elemental analysis using EDS. [Figure 13B] The structure is a Pt layer / Al2O3 layer / Al2O3 layer (holding time 5 min). The upper part shows a cross-sectional micrograph taken with an SEM, and the lower part shows the results of elemental analysis using an EDS. [Figure 14A] This figure shows a cross section of Ni-10 atomic % Al with a two-layer coating transferred onto the surface after a thermal cycle oxidation test. The alloy is Pt layer / Pt-70 wt % Al2O3 layer / Ni-10 atomic % Al. The top part shows a cross-sectional micrograph taken with an SEM, and the bottom part shows the results of elemental analysis using EDS. [Figure 14B] The structure is a Pt layer / Al2O3 layer / Ni-10 atomic % Al alloy. The upper part shows a cross-sectional micrograph taken with a SEM, and the lower part shows the results of elemental analysis using an EDS. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] The nickel-cobalt-based alloy and the turbine airfoil member made of the nickel-cobalt-based alloy will be described in more detail below with reference to examples, but the present invention is not limited to the following examples. FIG. 1 is an explanatory diagram of components used in the manufacturing method of a turbine airfoil part of the present invention, where (A) is a ceramic core, (B) is an external view of a turbine blade, and (C) is a cutaway view showing a cooling passage formed inside the turbine blade. The ceramic core has a negative mold shape of the cooling passage formed inside the turbine blade. The turbine blade has the outer shape of a single turbine blade of a gas turbine engine or a jet engine, as shown in Figure 1(B). The cooling passage formed inside the turbine blade has a positive mold shape of the cooling passage, as shown in Figure 1(C).
[0019] FIG. 2 is an explanatory diagram showing a first manufacturing method for a turbine airfoil part of the present invention, using a ceramic core and a casting shell of a turbine blade body, in which (A) shows the ceramic core, (B) shows the casting shell and ceramic core assembled together, (C) shows the state in which the coating layer of the oxidation-resistant metal layer and the metal-containing ceramic material layer of the ceramic core are transferred to the cast heat-resistant superalloy as the molten metal solidifies, and (D) shows the coating state of the oxidation-resistant metal layer and the metal-containing ceramic material layer of the cast turbine airfoil part. It should be noted that FIG. 2 is for explaining the technical concept of the present invention, and the dimensions of the drawing do not exactly match those of the turbine airfoil member that is actually manufactured. Also, in order to explain the coating layer of the oxidation-resistant metal layer and the metal-containing ceramic material layer of the ceramic core, the casting shell, the turbine airfoil part, and the ceramic core are shown partially cut away.
[0020] The ceramic core 100 has roughly the negative shape of a cooling passage formed inside a turbine blade, and is coated with a composite coating layer of an oxidation-resistant metal layer 102a and a metal-containing ceramic material layer 102b. The casting shell 120 has roughly the negative shape of a turbine airfoil part, and is produced in the usual manner of lost-wax precision casting by forming a wax precursor (wax pattern) from a metal mold, sprinkling sand called stucco around the wax precursor, drying, and repeatedly immersing in a slurry, and then firing after a dewaxing process.
[0021] The assembled state of the casting shell 120 and ceramic core 100 shown in FIG. 2(B) is also called a casting mold. When molten metal is poured into the casting mold, the composite coating layer of the oxidation-resistant metal layer 102a and the metal-containing ceramic material layer 102b is transferred from the ceramic core 100 to the solidified cast heat-resistant superalloy 140 as shown in FIG. 2(C).
[0022] As shown in Fig. 2(D), the composite coating layer of the oxidation-resistant metal layer 102a and the metal-containing ceramic material layer 102b is transferred to the cast turbine airfoil component 140 in any of the processes of directional solidification casting, single crystal casting, and conventional casting. The conditions of the casting process are determined so that the composite coating layer of the oxidation-resistant metal layer 102a and the metal-containing ceramic material layer 102b is not diffused into the cast heat-resistant superalloy substrate and disappears during the process of directional solidification or single crystal casting.
[0023] 3 is a flow chart showing a first method for manufacturing a turbine airfoil part of the present invention, which is a method for casting a turbine airfoil part having a cavity for use in a gas turbine engine or a jet engine, and includes forming a diffusion barrier layer and an oxidation resistant layer on a core, followed by forming a diffusion barrier layer and an oxidation resistant layer on a cast body.
[0024] First, in preparation for casting the main body of the turbine airfoil component, a wax precursor 110 having a rough outer shape of the turbine airfoil component is produced (S300). In lost wax precision casting, in order to obtain the shape of the turbine airfoil component after casting, it is necessary to determine the shape of the wax precursor 110 taking into consideration thermal contraction due to the temperature difference between room temperature and the molten metal. The purpose of the term "wax precursor 110 having a rough outer shape of the turbine airfoil component" is that the shape of the wax precursor 110 is determined with the goal of obtaining the outer shape of the turbine airfoil component after casting.
[0025] The wax precursor 100 is then encased in a refractory layer coating material to form a casting shell 120 (S305), and the wax precursor 110 is removed from the casting shell 120 in a dewaxing process (S310), leaving behind the refractory layer coating material. The refractory layer coating material is, for example, ZrO2, but can also be other molding materials used for stucco in lost wax precision casting. Next, in preparation for casting the core, a core roughly having a hollow shape of the turbine airfoil part is produced or prepared (S320). In lost-wax precision casting, in order to obtain the shape of the turbine airfoil part after casting, it is necessary to determine the shape of the core taking into consideration thermal contraction that occurs due to the temperature difference between room temperature and the molten metal. The reason for the phrase "core roughly having a hollow shape of the turbine airfoil part" is that the shape of the core is determined with the goal of obtaining the outer shape of the turbine airfoil part after casting.
[0026] Next, the oxidation-resistant metal layer 102a is coated on the surface of the core, and the surface of the oxidation-resistant metal layer is further coated with a metal-containing ceramic material layer 102b to form a core 100 with a composite coating layer (S325). The material used for the oxidation-resistant metal layer 102a is typically a platinum-based metal element such as Pt-Ir (iridium), but is not limited thereto and may be other oxidation-resistant alloys (Pt, NiAl, etc.). The material used for the metal-containing ceramic material layer 102b is typically (Al2O3-(Pt,Ir)), but may be any material that forms a barrier layer that can prevent the oxidation-resistant metal layer 102a from diffusing into the cast turbine airfoil component 140 and disappearing during the casting process in any of the processes of unidirectional solidification casting, single crystal casting, and normal casting. The material used for the metal-containing ceramic material layer 102b may be a layer containing 0 to 50 weight % of an oxidation-resistant alloy (Pt, PtIr, NiAl, etc.) in Al2O3.
[0027] Next, the assembly of the casting shell 120 and the composite-coated core 100 that has been subjected to the dewaxing step is sintered to prepare a mold (S330). A heat-resistant superalloy is cast using the mold formed by the composite-coated core 100 and the casting shell 120 without completely dissolving or destroying the refractory layer coating material and the metal-containing ceramic material layer (S340). Then, the oxidation-resistant metal layer 102a and the metal-containing ceramic material layer 102b are transferred from the composite-coated core 100 to the cast heat-resistant superalloy on the inner surface of the hollow shape of the turbine airfoil component (S350). Finally, the mold is removed to obtain a turbine airfoil component made of the cast heat-resistant superalloy and having a hollow shape (S360).
[0028] Next, a metal-containing ceramic material layer (diffusion barrier layer) may be applied to the surface of the cast outer shape of the turbine airfoil component, and then an oxidation-resistant metal layer (oxidation-resistant layer) may be overcoated (S370). After this, the cast single crystal test piece of the turbine airfoil component is subjected to an appropriate heat treatment, such as a solution treatment or aging treatment, in accordance with the manufacturing standards for turbine blades.
[0029] FIG. 4 is an explanatory diagram of a second manufacturing method for a turbine airfoil component of the present invention, using a ceramic core and a casting shell of a turbine blade body, in which (A) is a wax precursor (wax pattern), (B) is a ceramic core, (C) is the casting shell and ceramic core assembled together, (D) is the state in which the coating layer of the oxidation-resistant metal layer and metal-containing ceramic material layer of the ceramic core is transferred to the cast heat-resistant superalloy as the molten metal solidifies, and (E) shows the coating state of the oxidation-resistant metal layer and metal-containing ceramic material layer of the cast turbine airfoil component. It should be noted that FIG. 4 is for explaining the technical concept of the present invention, and the dimensions of the drawing do not exactly match those of the turbine airfoil member that is actually manufactured. Also, in order to explain the ceramic core, the wax precursor, the casting shell, the turbine airfoil part, and the coating layer of the oxidation-resistant metal layer and the metal-containing ceramic material layer of the casting shell, the wax precursor, the casting shell, and the ceramic core are partially cut away for explanation.
[0030] The ceramic core 100 generally has a negative shape of the cooling passage formed within a turbine blade and is coated with a composite coating of an oxidation-resistant metal layer 102a and a metal-containing ceramic material layer 102b. The wax precursor (wax mold) 110 is molded from a mold in accordance with the usual lost-wax precision casting method. The wax precursor 110 is coated with a composite coating layer of an oxidation-resistant metal layer 112a and a metal-containing ceramic material layer 112b. The casting shell 120 has a negative shape of a turbine airfoil part, and is manufactured by repeatedly sprinkling sand called stucco around the wax precursor 110, drying, and immersing in a slurry, and is fired after a dewaxing process. The composite coating layer of the oxidation-resistant metal layer 112a and the metal-containing ceramic material layer 112b that was on the wax precursor 110 has been transferred to the casting shell 120.
[0031] The composite coating layer of the oxidation-resistant metal layer 102a, 112a and the metal-containing ceramic material layer 102b, 112b is transferred to the cast turbine airfoil component 140 through any of the directional solidification, single crystal casting, and polycrystalline casting processes. The conditions of the casting process are determined so that the composite coating layer of the oxidation-resistant metal layer 102a, 112a and the metal-containing ceramic material layer 102b, 112b is not diffused into the cast heat-resistant superalloy substrate and disappears during the directional solidification and single crystal casting processes.
[0032] The assembled state of the casting shell 120 and the ceramic core 100 shown in Fig. 4(C) is also called a casting mold, and as shown in Fig. 4(D), when molten metal is poured into the casting mold, the composite coating layer of the oxidation-resistant metal layer 102a and the metal-containing ceramic material layer 102b is transferred from the ceramic core 100 to the solidified cast heat-resistant superalloy 140. When molten metal is poured into the casting mold, the composite coating layer of the oxidation-resistant metal layer 112a and the metal-containing ceramic material layer 112b is transferred from the casting shell 120 to the solidified cast heat-resistant superalloy 140. As shown in Fig. 4(E), the cast turbine airfoil component 140 has the composite coating layer of the oxidation-resistant metal layers 102a, 112a and the metal-containing ceramic material layers 102b, 112b transferred from the composite-coated core 100 and the coated casting shell 120 in any of the processes of directional solidification, single crystal casting, and polycrystal casting.
[0033] 5 is a flow chart showing a second method for producing a turbine airfoil part of the present invention, which is a method for casting a turbine airfoil part having a cavity for use in a gas turbine engine or a jet engine, and which performs simultaneous formation of a diffusion barrier layer and an oxidation resistant layer on a core and a casting body. First, in preparation for casting the main body of the turbine airfoil component, a wax precursor 110 having a rough outer shape of the turbine airfoil component is prepared (S500), the wax precursor 110 is wrapped in a refractory layer coating material (ZrO2), and an oxidation-resistant metal layer 112a is coated on the inner surface corresponding to the outer shape of the turbine airfoil component, and the surface of the oxidation-resistant metal layer 112a is further coated with a metal-containing ceramic material layer 112b to form a coated casting shell 120 (S505). Then, in a dewaxing step, the wax precursor 110 is removed from the coated casting shell 120, leaving the refractory layer coating material (S510). Next, in preparation for casting the core, a core having roughly the hollow shape of the turbine airfoil part is produced or prepared (S520), an oxidation-resistant metal layer 102a is coated onto the surface of the core 100, and the surface of the oxidation-resistant metal layer is further coated with a metal-containing ceramic material layer 102b to form core 100 with a composite coating layer (S525).
[0034] Next, in preparation for the mold, the assembly of the casting shell 120 that has been subjected to the dewaxing step and the core with the composite coating layer is sintered (S530). Next, a molten heat-resistant superalloy is poured into a mold formed by the core with the composite coating layer and the casting shell 120, without completely dissolving or destroying the refractory layer coating material and the composite coating layer of the metal-containing ceramic material layer and the oxidation-resistant metal layer (S540). Then, the composite coating layer of the oxidation-resistant metal layer 102a and the metal-containing ceramic material layer 102b is transferred from the core with the composite coating layer 100 to the cast heat-resistant superalloy on the inner surface of the hollow shape of the turbine airfoil component (S550), and the composite coating layer of the oxidation-resistant metal layer 112a and the metal-containing ceramic material layer 112b is transferred from the casting shell 120 to the cast heat-resistant superalloy on the inner surface of the outer shape of the turbine airfoil component (S555). Finally, the mold is removed to obtain a turbine airfoil component made of the cast heat-resistant superalloy and having a hollow shape (S560). Thereafter, the cast single crystal specimen is subjected to appropriate heat treatment, such as solution treatment and aging treatment, in accordance with the turbine blade manufacturing standards for the turbine airfoil component.
[0035] Figures 6A and 6B are diagrams showing the steps of manufacturing a single crystal test piece using the turbine blade body manufacturing method shown in Figure 4. In Figure 6A, (A) shows the creation of a mold, (B) shows the wax injection molding, (C) shows the removal of the wax precursor, (D) shows the application and drying of a composite coating layer, (E) shows the creation of a mold, and (F) shows dewaxing. In Figure 6B, (G) shows the debinding and firing treatment of the mold, (H) shows casting, and (I) shows the removal of a single crystal test piece, which is a casting.
[0036] FIG. 6(A) shows the creation of a mold 10 for a single crystal test piece. The mold 10 is composed of an upper mold 12 and a lower mold 14, and a molding space 16 located between the upper mold 12 and the lower mold 14 is a female mold for the single crystal test piece to be cast. The molding space 16 is provided with a lower gripping portion 22, an upper gripping portion 24, a tensile test target portion 26, and a selector portion 28 corresponding to the shape of the single crystal test piece to be cast. The tensile test target portion 26 is a round bar portion located between the lower gripping portion 22 and the upper gripping portion 24, and has a linear length and an inner diameter according to the tensile test standard. The selector portion 28 is used for single crystal casting of nickel-based superalloys, solidification control such as unidirectional solidification, etc.
[0037] 6(B) shows wax injection molding. Wax 29 is injected into the molding space 16 of the mold 10. 6(C) shows the removal of the wax precursor. When the wax 29 has solidified, the mold 10 is removed and the wax precursor 30 of the single crystal test piece is removed. The wax precursor 30 is provided with a lower gripping portion 32, an upper gripping portion 34, a tensile test target portion 36, and a selector portion 38 corresponding to the molding space 16.
[0038] 6(D) shows the application and drying of the composite coating layer to the wax precursor 30. The tensile test target portion 36 of the wax precursor 30 is coated with a metal-containing ceramic material layer 37b, and the surface of the metal-containing ceramic material layer 37b is further coated with an oxidation-resistant metal layer 37a to form a coated wax precursor 30.
[0039] 6(E) shows the creation of a casting mold. In the creation of the casting mold, a casting shell 40 is produced by repeatedly sprinkling sand, called stucco, on the coated wax precursor 30, drying, and dipping into a slurry in the lost wax precision casting method. 6(F) shows the dewaxing treatment of the casting shell 40. By the dewaxing treatment, the wax precursor 30 is removed from the casting shell 40. At this time, a composite coating layer of the metal-containing ceramic material layer 47b and the oxidation-resistant metal layer 47a is transferred to the inner surface of the casting shell 40 corresponding to the portion 36 to be tensile tested.
[0040] 6(G) shows the binder removal and firing treatments of the mold. A casting shell 40 serving as the mold is provided with a molding space 41 having a female shape of a single crystal test piece to be cast. Figure 6(H) shows the casting process. For nickel-based superalloys, a vacuum high-frequency induction melting furnace is used for solidification control of single crystal casting, unidirectional solidification, conventional casting, etc. Zirconia or alumina is used for the lining of the vacuum high-frequency induction melting furnace. The casting temperature is +90 to 170°C above the solidification start temperature of the casting alloy, and the preheating temperature of the mold is 1000 to 1100°C for conventional casting, and 1400 to 1550°C for single crystal casting and unidirectional solidification. FIG. 6(I) shows the removal of a single crystal test piece, which is a casting. Single crystal test piece 50 is provided with lower gripping portion 52, upper gripping portion 54, and tensile test target portion 56. Tensile test target portion 56 is provided with a composite coating layer of oxidation-resistant metal layer 57a and metal-containing ceramic material layer 57b. The portion corresponding to the selector portion is a portion necessary for single crystal casting, but is not necessary for the single crystal test piece, and is therefore removed. In accordance with the manufacturing standards for turbine blades, the cast single crystal test piece is subjected to an appropriate heat treatment, such as solution treatment or aging treatment. EXAMPLES
[0041] As shown in Fig. 7, a preliminary experiment was carried out in Example 1 using a manufacturing process in which Pt, a material with excellent oxidation resistance, was applied by a paste method or the like to the surface of a mold using a nickel-based superalloy, type name TMS138, and the applied layer was transferred to the cast material during casting, imparting oxidation resistance in the as-cast state. As a result, it was confirmed by the preliminary experiment that a concentrated layer of elements with excellent oxidation resistance was obtained on the surface of the cast material by paste coating transfer. Here, the nominal composition of TMS138, in mass%, is 5.8% Co (cobalt), 3.2% Cr (chromium), 2.8% Mo (molybdenum), 5.9% W (tungsten), 5.9% Al (aluminum), 0.0% Ti (titanium), 5.6% Ta (tantalum), 0.1% Hf (hafnium), 5.0% Re (rhenium), 2.0% Ru (ruthenium), with the balance being Ni (nickel) and unavoidable impurities.
[0042] FIG. 7 is a diagram explaining the details of the composite coating layer of an oxidation-resistant metal layer and a metal-containing ceramic material layer in a single crystal test piece, where (A) is an explanatory diagram of the production of a single crystal test piece by unidirectional solidification, (B) is an optical photograph of the composite coating layer, and (C) shows the distribution of the composition ratios of the composition elements in the thickness direction from the surface. A vacuum high-frequency induction melting furnace (not shown) is used to manufacture single crystal test pieces from nickel-based superalloys. The molten nickel-based superalloy is, for example, at 1560 to 1640°C and is poured into a ceramic mold installed in the vacuum high-frequency induction melting furnace to manufacture single crystal test pieces. A composite coating layer of an oxidation-resistant metal layer and a metal-containing ceramic material layer is applied to the inner peripheral surface of the ceramic mold.
[0043] The cross-sectional photograph of the structure in Figure 7(B) was taken with an optical microscope. The surface modified layer in the figure corresponds to a composite coating layer of an oxidation-resistant metal layer and a metal-containing ceramic material layer, and the molten metal solidification part is a region formed by solidification of the molten nickel-based superalloy. The film thickness of the surface modified layer is about 20 μm, and the region where the surface modified layer and the molten metal solidification part have mutually diffused is located in a region 20 to 30 μm from the surface. The main body of the molten metal solidification part is located in a region more than 30 μm deep from the surface.
[0044] The composition ratio distribution diagram of the composition elements in FIG. 7(C) was measured using an elemental analyzer using the EDS (Energy Dispersive X-ray spectroscopy) method. In the region from the surface to a depth of 20 μm, Pt is contained at 30-40 at%, Ni at 30-50 at%, Al at 6-20 at%, Co at 2-6 at%, and Cr at 2-4 at%. In the region from the surface to a depth of 20-30 μm, Pt decreases from 40 at% to 4 at% depending on the depth, whereas Ni increases from 40 at% to 75 at% depending on the depth. In the region from the surface to a depth of more than 30 μm, Ni is contained at 75 at%, Al at 6-10 at%, Co at 8 at%, and Cr at 4 at%, but Pt is only 0-1 at%. Figure 8 is an SEM photograph of the single crystal test piece shown in Figure 7 in the thickness direction from the surface. The cross-sectional photograph of the structure in Figure 8 was taken with a scanning electron microscope. EXAMPLES
[0045] Pt paste or Pt-20 wt% Ir paste was applied to the surface of an Al2O3 ceramic tube simulating a core and dried, and then a powder paste of either Al2O3, Pt-70 wt% Al2O3, or Pt-40 wt% was applied over the Pt paste surface and dried. The applied powder paste was then subjected to a debindering process at a medium temperature range and then sintered at a high temperature to form a two-layer coating. This coated Al2O3 tube was placed inside a mold and unidirectionally solidified.
[0046] Figure 9 shows a method for manufacturing a directionally solidified test piece using a core. Ni-10 atomic % Al was used as a model alloy for a superalloy, and the molten metal was cast into a mold held at 1500°C at a temperature of 1500°C, after which the mold was pulled downward at a constant speed to allow unidirectional solidification. The time from melting to solidification differed because the specimens were cut at different positions to prepare specimens for cross-sectional observation, and the time until solidification was taken as the time the coating was in contact with the melt (holding time).
[0047] 10A, 10B, 11A, 11B, 12A, and 12B are diagrams showing the structure and composition analysis results of each coating layer after solidification. Figures 10A, 10B, 11A, 11B, 12A, and 12B are diagrams showing the structure after molten Ni-10 atomic % is poured into a two-layer coating applied to an Al2O3 tube. Figure 10A shows a Pt layer / Pt-40 wt% Al2O3 layer (holding time 7 minutes), the upper part shows a cross-sectional photograph of the structure taken with an SEM, and the lower part shows the results of elemental analysis using the EDS method. In Figures 10A, 11A, and 12A, the four elements targeted for elemental analysis are Pt, Ni, Al, and O.
[0048] Figure 10B shows a Pt-Ir layer / Pt-40 wt%Al2O3 layer (holding time 7 minutes), with the upper part showing a cross-sectional structure photograph taken with an SEM and the lower part showing the results of elemental analysis using EDS. In Figures 10B, 11B, and 12B, the five elements targeted for elemental analysis were Pt, Ir, Ni, Al, and O. Figure 11A shows a Pt layer / Pt-70 wt%Al2O3 layer (holding time 7 minutes), the top is a cross-sectional micrograph taken with an SEM, and the bottom is the result of elemental analysis using EDS. Figure 11B shows a Pt-Ir layer / Pt-70 wt%Al2O3 layer (holding time 13 minutes), the top is a cross-sectional micrograph taken with an SEM, and the bottom is the result of elemental analysis using EDS. Figure 12A shows a Pt layer / Al2O3 layer (holding time 7 minutes), the top is a cross-sectional micrograph taken with an SEM, and the bottom is the result of elemental analysis using EDS. Figure 12B shows a Pt-Ir layer / Al2O3 layer (holding time 26 minutes), the top is a cross-sectional micrograph taken with an SEM, and the bottom is the result of elemental analysis using EDS.
[0049] When Pt-40 wt% Al was used as the diffusion barrier layer (Figs. 10A and 10B), outward diffusion of Ni from the cast alloy to the outer layer and inward diffusion of Pt from the Pt or Pt-Ir outer layer into the alloy occurred, and no Pt remained in the outer layer. In the Pt-70 wt%Al2O3 layer (Fig. 11A and Fig. 11B), Ni was seen to penetrate into the barrier layer after 7 minutes of exposure, but not into the outer Pt layer, and the Pt coating, which is an oxidation-resistant layer, remained on the surface in a healthy state. However, after 13 minutes, Ni had diffused through the barrier layer and reached the outer Pt-Ir layer, and the outer layer was replaced by Ni, with almost no Pt remaining.
[0050] On the other hand, when Al2O3 is used as the barrier layer (Fig. 12A and Fig. 12B), no diffusion of Ni or Pt into the barrier layer is observed even in the sample after 26 minutes, which is the highest cut position, and a two-layer coating layer consisting of an oxidation-resistant layer of Pt or Pt-Ir alloy and a diffusion barrier layer of Al2O3 is formed on the surface of the Ni-10Al cast alloy.When there is no diffusion barrier layer and high-melting-point metals such as Pt or Ir come into direct contact with molten Ni-10 atomic % Al, they rapidly dissolve and diffuse into Ni-10 atomic % Al, and no surface concentrated layer of these elements is observed. EXAMPLES
[0051] To prepare the oxidation test specimens, Pt paste was applied to the inner wall of the mold in the unidirectional solidification furnace, dried, and then Pt-70 wt%Al2O3 paste or Al2O3 paste was applied, followed by debinding and sintering to form a two-layer coating. The oxidation specimens were prepared by casting Ni-10 atomic%Al alloy as a model alloy into the mold with these two-layer coatings at 1500℃.
[0052] Figures 13A and 13B show the structure of the two-layer coating transferred from the mold inner wall to the Ni atomic % Al casting. Figure 13A shows a Pt layer / Pt-70 wt% Al2O3 layer (holding time 5 minutes), the top shows a cross-sectional micrograph taken with an SEM, and the bottom shows the results of elemental analysis using EDS. Figure 13B shows a Pt layer / Al2O3 layer / Al2O3 layer (holding time 5 minutes), the top shows a cross-sectional micrograph taken with an SEM, and the bottom shows the results of elemental analysis using EDS. All coatings were transferred from the mold to the casting by casting in a sound form. The oxidation resistance of the coatings was evaluated by subjecting them to a thermal cycle oxidation test in which the coatings were heated from room temperature to 1,150°C in air, oxidized for 1 hour, and then cooled to room temperature 100 times.
[0053] Figures 14A and 14B show cross sections of Ni-10 atomic % Al with a two-layer coating transferred onto the surface after a thermal cycle oxidation test. Figure 14A shows a Pt layer / Pt-70 wt%Al2O3 layer / Ni-10 atomic % Al alloy, with the top row showing a microstructural cross-section photograph taken with an SEM and the bottom row showing the results of elemental analysis using an EDS. Figure 14B shows a Pt layer / Al2O3 layer / Al2O3 layer / Ni-10 atomic % Al alloy, with the top row showing a microstructural cross-section photograph taken with an SEM and the bottom row showing the results of elemental analysis using an EDS. Although cracks were observed in the Pt / Pt-70wt%Al2O3, no significant oxidation was observed in either the sample in Figure 14A or Figure 14B, and it was confirmed that they function as oxidation-resistant coatings. Note that these coatings are composed of two layers, an oxidation-resistant layer and a diffusion-resistant barrier layer, but if these two layers are present as a basic composition, a multi-layer coating of two or more layers can be formed by providing a graded composition layer to improve the adhesion between each layer. [Industrial Applicability]
[0054] According to the manufacturing method of the turbine airfoil component of the present invention, by combining the casting of the turbine airfoil component by the lost wax precision casting method with the coating of the inner surface of the hollow shape of the turbine airfoil component using a core by utilizing the advantages of the insert casting method, an oxidation-resistant composite coating layer can be formed on the cooling passage of the gas turbine rotor blade, and oxidation damage in the cooling passage can be prevented. This is suitable for use in the manufacture of turbine rotor blades for gas turbines and jet engines. [Explanation of symbols]
[0055] 10, 12, 14 Mold 16 Build space 20 Space for wax precursor (for casting single crystal specimens) 22, 32, 52 Lower grip of test piece 24, 34, 54 Upper grip of test piece 26, 36, 56 Elongation test section 28, 38 Selector section 29 Filling Wax 30 Wax precursor (for casting single crystal specimens) 37a, 47a, 57a Oxidation-resistant metal layer (Pt-Ir) 37b, 47b, 57b Metal-containing ceramic material layer (Al2O3-(Pt,Ir)) 40 Casting shell (for casting single crystal test pieces) 41 Space for pouring molten metal (for casting single crystal test pieces) 49 Molten Metal 50 Single crystal test piece (core) 100 core, core with composite coating layer 110 Wax Precursor 120 Casting Shell 140 Turbine airfoil parts 102a, 112a Oxidation-resistant metal layer (Pt-Ir) 102b, 112b Metal-containing ceramic material layer (Al2O3-(Pt,Ir))
Claims
1. A method for casting a turbine airfoil component having cavities used in a gas turbine engine or a jet engine, comprising: fabricating or providing a wax precursor having a general outer shape of the turbine airfoil component; wrapping the wax precursor with a refractory layer coating material to form a casting shell; a dewaxing step of removing the wax precursor leaving the refractory layer coating material from the casting shell; fabricating or providing a core having a general cavity shape of the turbine airfoil component; coating the surface of the core with an oxidation-resistant metal layer, and further coating the surface of the oxidation-resistant metal layer with a metal-containing ceramic material layer to form a core with a composite coating layer; a sintering step of sintering an assembly of the casting shell from which the dewaxing step has been performed and the core with the composite coating layer; injecting a molten heat-resistant superalloy into a mold formed by the core with the composite coating layer and the casting shell without completely melting or destroying the refractory layer coating material and the composite coating layer of the metal-containing ceramic material layer and the oxidation-resistant metal layer, and casting; on the inner surface of the cavity shape of the turbine airfoil component, a composite coating layer of the oxidation-resistant metal layer and the metal-containing ceramic material layer is transferred from the core with the composite coating layer to the cast heat-resistant superalloy; removing the mold to obtain the turbine airfoil component made of the cast heat-resistant superalloy and having the cavity shape. A method for manufacturing a turbine airfoil component.
2. including applying a metal-containing ceramic material layer to the surface of the outer shape of the turbine airfoil component after casting, and further overcoating with an oxidation-resistant metal layer. The method for manufacturing a turbine airfoil component according to Claim 1.
3. A method for casting a turbine airfoil component having cavities used in a gas turbine engine or a jet engine, comprising: fabricating or providing a wax precursor having a general outer shape of the turbine airfoil component; wrapping the wax precursor with a refractory layer coating material, and coating the inner surface corresponding to the outer shape of the turbine airfoil component with an oxidation-resistant metal layer, and further coating the surface of the oxidation-resistant metal layer with a metal-containing ceramic material layer to form a casting shell; a dewaxing step of removing the wax precursor leaving the refractory layer coating material from the casting shell; Producing or preparing a core having a substantially hollow shape of the turbine airfoil component; Coating the surface of the core with an oxidation-resistant metal layer, and further coating the surface of the oxidation-resistant metal layer with a metal-containing ceramic material layer to form a core with a composite coating layer; Sintering an assembly of the casting shell and the core with the composite coating layer, which is defective in the dewaxing step; Injecting and casting a molten heat-resistant superalloy into a mold formed by the core with the composite coating layer and the casting shell without completely melting or destroying the refractory layer coating material and the composite coating layer of the metal-containing ceramic material layer and the oxidation-resistant metal layer; On the inner surface of the hollow shape of the turbine airfoil component, the composite coating layer of the oxidation-resistant metal layer and the metal-containing ceramic material layer is transferred from the core with the composite coating layer to the cast heat-resistant superalloy, and on the inner surface of the outer shape of the turbine airfoil component, the composite coating layer of the oxidation-resistant metal layer and the metal-containing ceramic material layer is transferred from the casting shell to the cast heat-resistant superalloy; Removing the mold to obtain the turbine airfoil component made of the cast heat-resistant superalloy and having the hollow shape; A method for manufacturing a turbine airfoil component.
4. The method for manufacturing a turbine airfoil component according to any one of claims 1 to 3, wherein when coating the surface of the core with the metal-containing ceramic material layer, at least one of the metal-containing ceramic material layer or the oxidation-resistant metal layer is performed by paste coating.
5. The heat-resistant superalloy is a Ni-based or Co-based superalloy, The oxidation-resistant metal layer is a high-melting-point metal layer mainly composed of Pt, or a high-melting-point alloy layer selected from PtIr or NiAl; The metal-containing ceramic material layer contains 0 to 50% by weight of an oxidation-resistant alloy in Al ２ O ３ and is such that it contains 0 to 50% by weight of an oxidation-resistant alloy in Al The method for manufacturing a turbine airfoil component according to claim 1.
6. The method for manufacturing a turbine airfoil component according to claim 5, wherein the oxidation-resistant alloy is Pt, PtIr or NiAl.
7. The oxidation-resistant metal layer is an alloy mainly composed of Pt; The metal-containing ceramic material layer contains Al ２ O ３ as a main component The method for manufacturing a turbine airfoil component according to claim 5.
8. The thickness of Pt in the oxidation-resistant metal layer is 20 μm or less; The above-mentioned Al ２ O ３ layer shall have a thickness of 20 μm or less The method for manufacturing a turbine airfoil component according to claim 7.
9. A turbine airfoil component having a cavity, which is used in a gas turbine engine or a jet engine formed by casting. An oxidation-resistant film structure of a metal-containing ceramic material layer and an oxidation-resistant metal layer having a predetermined shape fixedly held on the inner surface of the cavity shape of the turbine airfoil component, A heat-resistant superalloy adjacent to the metal-containing ceramic material layer, And the surface of the outer shape of the turbine airfoil component, During casting, upon cooling from the molten state, it flows and solidifies in contact with the metal-containing ceramic material layer without causing decomposition of the metal-containing ceramic material layer and the oxidation-resistant metal layer, Turbine airfoil component.
10. A turbine airfoil component having a cavity, used in a gas turbine engine or a jet engine formed by casting, A first oxidation-resistant film structure of a first metal-containing ceramic material layer and a first oxidation-resistant metal layer fixedly held on the inner surface of the cavity shape of the turbine airfoil component, A second oxidation-resistant film structure of a second metal-containing ceramic material layer and a second oxidation-resistant metal layer fixedly held on the surface of the outer shape of the turbine airfoil component, A heat-resistant superalloy having a first surface adjacent to the first metal-containing ceramic material layer of the first oxidation-resistant film structure and a second surface adjacent to the second metal-containing ceramic material layer of the second oxidation-resistant film structure, Comprising, During casting, upon cooling from the molten state, it flows and solidifies in contact with the first and second metal-containing ceramic material layers without causing decomposition of the first and second metal-containing ceramic material layers and the first and second oxidation-resistant metal layers, Turbine airfoil component.