Hot Gas Component Alloy Lining for Turbomachines
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Solution Overview
Problem
Hot-gas conducting components in flow machines face challenges with oxidation and corrosion under extreme thermal and mechanical loads, where existing nickel-base wrought alloys offer high heat resistance but moderate oxidizability, and ceramic coatings are costly to produce and apply.
Innovation Solution
A hot-gas conducting component using a solid-solution hardened nickel-base wrought alloy as structural material, combined with a hot gas-side lining made from iron-chromium-aluminum-yttrium (FeCrAlY) alloys, which provides enhanced oxidation resistance and stability, and optionally an ALUCHROM-yttrium-hafnium alloy for improved cyclic oxidation resistance, applied via high-temperature methods like soldering or cladding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If nickel-base wrought alloys are used as structural material, then heat resistance is improved, but oxidation resistance deteriorates
Solution Approach 1:
The patent applies composite materials by combining nickel-base wrought alloy (providing heat resistance) with FeCrAlY alloy lining (providing oxidation resistance). This composite structure allows the component to simultaneously achieve high temperature capability and oxidation protection, resolving the contradiction between heat resistance and oxidation resistance.
2Reliability
If ceramic-based coatings are applied to improve oxidation resistance, then oxidation resistance is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive ceramic-based coatings with a more cost-effective FeCrAlY alloy lining. This alternative material provides comparable oxidation resistance at lower manufacturing cost, aligning with the principle of substituting expensive materials with more economical alternatives that achieve the same functional requirement.
3Productivity
If operating temperature is increased to improve performance, then productivity is improved, but material degradation accelerates
Solution Approach 1:
The composite structure of nickel-base alloy substrate with FeCrAlY alloy lining enables the component to operate at higher temperatures without premature material degradation. The FeCrAlY lining protects the nickel-base alloy from oxidation at elevated temperatures, thus maintaining material stability while allowing increased operating temperature for improved productivity.
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 combination of nickel-base and FeCrAlY alloys increases operating temperature and stability of hot-gas conducting components, overcoming oxidation and heat resistance limitations, while reducing the risk of premature material degradation and costs associated with ceramic coatings.
Implementation Method 1
Iron-chromium-aluminum-yttrium alloys, abbreviated as FeCrAlY alloys, have a very good resistance to oxidation
Implementation Method 2
a solid-solution hardened nickel-base wrought alloy
Implementation Method 3
The FeCrAlY alloy preferably has iron as a base element and comprises 16% to 24% chromium, 3% to 9% aluminum, 0.02% to 0.2% yttrium, up to 0.1% hafnium, up to 0.1% zirconium, and up to 0.1% metals from the group of rare earths, particularly lanthanides. The hot gas-side lining can be applied by means of high-temperature soldering, welding, or cladding, particularly roll bonding cladding.
Implementation Method 4
The hot gas-side lining can be applied by means of high-temperature soldering, welding, or cladding, particularly roll bonding cladding.
Data Source
AI summary
A hot-gas conducting component for a flow machine has a nickel-base wrought alloy as structural material and a hot gas-side lining made from the group of iron-chromium-aluminum-yttrium alloys and a flow machine having a component of this type.