Chromium Multilayer Coating for Gas Turbine Erosion Resistance
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Solution Overview
Problem
Gas turbine components face wear due to oxidation, corrosion, and erosion, and existing anti-wear coatings do not provide sufficient long-term protection against these stresses, especially at high temperatures and with minimal impact on vibration resistance.
Innovation Solution
A novel anti-wear coating with multilayer systems based on chromium, incorporating a mono-nanostructured diffusion barrier layer of CrN between the component surface and the multilayer system, which includes layers of metallic, metal alloy, graded metal-ceramic, and ceramic materials, ensuring high erosion and oxidation resistance with minimal vibration impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing anti-wear coatings are applied to gas turbine components, then erosion and corrosion protection is provided, but the coatings have insufficient long-term protection especially at high temperatures and adversely affect vibration resistance
Solution Approach 1:
The coating is divided into multiple thin layers (5-50 nanometers each) with alternating metallic and ceramic materials, creating a segmented multilayer structure that provides both protection and maintains vibration characteristics through distributed mass distribution
Solution Approach 2:
The patent uses composite materials combining metallic layers (such as Cr, CrAl, CrNi) and ceramic layers (such as CrN, CrAlN, TiN, TiAlN) in a multilayer system, where each material contributes specific properties: metals provide ductility and adhesion, while ceramics provide hardness and erosion resistance, achieving both protection and vibration compatibility
2Reliability
If multilayer coatings are applied to provide erosion and corrosion resistance, then protection is improved, but the coating complexity and number of layers increase
Solution Approach 1:
The coating system is segmented into repeating multilayer units, each consisting of a metallic layer followed by a ceramic layer. This modular segmentation allows systematic protection while maintaining manageable complexity through repetition of standardized layer sequences
Solution Approach 2:
The patent optimizes layer thickness parameters (5-50 nanometers per layer) and material composition parameters to achieve the desired balance between protection performance and structural simplicity, using parameter optimization to reduce the number of distinct layer types needed
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The chromium-based anti-wear coating provides excellent erosion and oxidation resistance, maintains high thermodynamic stability, and can operate effectively at very high temperatures with minimal influence on vibration resistance, extending the component's lifespan.
Implementation Method 1
a diffusion barrier layer being applied between the surface to be protected and the multilayer system(s)
Implementation Method 2
Components such as gas turbine components which are exposed to stresses in flow technology are subject to wear due to oxidation, corrosion and erosion. Erosion is a wear process induced by solid particles entrained in the gas flow.
Implementation Method 3
The inventive anti-wear coating ensures a very good erosion resistance and oxidation resistance. The inventive anti-wear coating may be used over a longer period of time at very high temperatures.
Data Source
AI summary
An anti-wear coating, in particular an anti-erosion coating, which is applied to a surface of a component that is stressed under fluid technology and is to be protected, in particular a gas turbine part, is disclosed. The anti-wear coating includes one or more multilayer systems applied in a repeating order to the surface to be coated, and the/each multilayer system includes at least one relatively soft metallic layer and at least one relatively hard ceramic layer. All the layers of the/each multilayer system are based on chromium, and a diffusion barrier layer is applied between the surface to be protected and the multilayer system(s).