Gas turbine component and process for producing gas turbine component

• US 9,719,420 B2
• Filed: 06/02/2014
• Issued: 08/01/2017
• Est. Priority Date: 06/02/2014
• Status: Active Grant

• Current Assignee: GE Infrastructure Technology, LLC (GE Vernova, Inc.)
• Original Assignee: General Electric Company
• Inventors: Roberts, Jr., Frederic Woodrow, Parolini, Jason Robert, Kittleson, Jacob John, Taxacher, Glenn Curtis, DiMascio, Paul Stephen, Morgan, Victor John, Delvaux, John McConnell
• Primary Examiner(s): CIGNA, JACOB JAMES
• Application Number:
  US14/292,969
• Publication Number:
  US 20150345388A1
• Time in Patent Office: 1,156 Days
• CPC Class Codes: B23K 1/0018 Brazing of turbine parts
• CPC Class Codes: B23P 6/002 Repairing turbine components, e.g. moving or stationary blades, rotors, B23P6/045 takes precedence
• CPC Class Codes: B23P 6/007 using only additive methods, e.g. build-up welding
• CPC Class Codes: B24B 33/00 Honing machines or devices; Accessories therefor
• CPC Class Codes: C04B 35/00 Shaped ceramic products characterised by their composition porous ceramic products C04B38/00; ceramic articles characterised by particular shape, see the relevant classes, e.g. linings for casting ladles, tundishes, cups or the like B22D41/02; ceramic substrates for microelectronic semi-conductors H01L23/15; Ceramics compositions containing free metal bonded to carbides, diamond, oxides, borides, nitrides, silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides or sulfides other than as macroscopic reinforcing agents C22C; shaping of ceramics B28B; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products chemical preparation of powders of inorganic compounds C01; infiltration of sintered ceramic preforms with molten metal C04B41/51
• CPC Class Codes: C04B 35/80 Fibres, filaments, whiskers, platelets, or the like
• CPC Class Codes: C04B 41/0072 Heat treatment
• CPC Class Codes: C04B 41/009 characterised by the material treated
• CPC Class Codes: C04B 41/4529 applied from the gas phase
• CPC Class Codes: C04B 41/4531 by C.V.D.
• CPC Class Codes: C04B 41/4539 as a emulsion, dispersion or suspension
• CPC Class Codes: C04B 41/5025 with ceramic materials copper oxide or solid solutions thereof C04B41/5074
• CPC Class Codes: C04B 41/5096 Silicon C04B35/573 takes precedence
• CPC Class Codes: C04B 41/5133 with a composition mainly composed of one or more of the refractory metals
• CPC Class Codes: C04B 41/5144 with a composition mainly composed of one or more of the metals of the iron group
• CPC Class Codes: C04B 41/53 involving the removal of at least part of the materials of the treated article, e.g. etching, drying of hardened concrete C04B41/0036 - C04B41/0054 take precedence
• CPC Class Codes: C04B 41/85 with inorganic materials
• CPC Class Codes: C04B 41/87 Ceramics
• CPC Class Codes: C04B 41/88 Metals
• CPC Class Codes: C04B 41/91 involving the removal of part of the materials of the treated articles, e.g. etching
• CPC Class Codes: C23C 16/24 : Deposition of silicon only
• CPC Class Codes: F02C 7/00 : Features, components parts, details or accessories, not provided for in, or of interest apart form groups F02C1/00 - F02C6/00; Air intakes for jet-propulsion plants controlling F02C9/00
• CPC Class Codes: F05D 2230/30 : with deposition of material
• CPC Class Codes: F05D 2230/90 : Coating; Surface treatment
• CPC Class Codes: F05D 2300/6033 : Ceramic matrix composites [CMC]
• CPC Class Codes: Y10T 156/10 : Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 428/24355 : Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]

Abstract

A process of producing a ceramic matrix composite gas turbine component and a ceramic matrix composite gas turbine component are provided. The process includes modifying a surface of the ceramic matrix composite gas turbine component to produce a modified surface with a surface roughness of less than 6 micrometers. The modifying is selected from the group of techniques consisting of applying unreinforced matrix plies to the surface, vapor depositing silicon on the surface, honing the surface, applying braze paste to the surface, and combinations thereof. The component includes a modified surface including a surface roughness of less than 6 micrometers. The modified surface being selected from the group consisting of unreinforced matrix plies applied to a surface of the ceramic matrix composite gas turbine component, silicon vapor deposited on the surface, a honed surface, a braze paste applied to the surface, and combinations thereof.

Claims

1. A process of producing a ceramic matrix composite gas turbine component, the process comprising:

modifying a surface of the ceramic matrix composite gas turbine component to produce a modified surface with a surface roughness of less than 6 micrometers;

wherein modifying the surface includes machining with a non-abrasive material, machining with the non-abrasive material applying a contact pressure on the surface and depositing at least a portion of the non-abrasive material into crevasses on the surface.

2. The process of claim 1, wherein the surface is selected from the group consisting of a damper cavity surface for a damper pin in the ceramic matrix composite gas turbine component, a dovetail attachment face of a ceramic matrix composite gas turbine rotating airfoil, and the dovetail attachment face of a ceramic matrix composite gas turbine non-rotating airfoil.

3. The process of claim 1, wherein modifying further comprises machining with an abrasive material, and then machining with the non-abrasive material.

4. The process of claim 1, wherein the crevasses are formed by plies selected from the group consisting of unreinforced matrix plies and fiber-reinforced plies.

5. The process of claim 1, wherein the depositing the non-abrasive material into the crevasses on the surface decreases a coefficient of friction of the surface.

6. The process of claim 1, wherein the surface roughness is less than 3 micrometers.

7. The process of claim 1, wherein the surface roughness is between 1 micrometer and 2 micrometers.

8. The process of claim 1, wherein the process is a manufacturing process.

9. The process of claim 1, wherein the process is a repair process.

10. The process of claim 1, wherein the modified surface is substantially devoid of fibers.

11. The process of claim 1, wherein the modified surface includes a deposited material having a composition, by weight, of about 0.015% boron, about 0.05% to about 0.15% carbon, about 20% to about 24% chromium, about 3% iron, about 0.02% to about 0.12% lanthanum, about 1.25% manganese, about 20% to about 24% nickel, about 0.2% to about 0.5% silicon, about 13% to about 15% tungsten, and balance cobalt.

12. The process of claim 1, wherein modifying further includes applying at least one unreinforced matrix ply, and then machining with the non-abrasive material.

13. The process of claim 1, wherein the surface is positioned in a seal slot along a hot gas path of the ceramic matrix composite gas turbine component.

14. The process of claim 13, wherein the modifying of the surface decreases leakage in the seal slot.

15. The process of claim 13, further comprising positioning a seal in the seal slot.

16. The process of claim 15, wherein the modified surface prohibits reactions between free silicon in matrix of the ceramic matrix composite gas turbine component and metal in the seal.

17. The process of claim 15, wherein the seal includes ceramic matrix composite material.

18. The process of claim 15, wherein the seal includes a nickel-based alloy.

19. The process of claim 18, wherein the nickel-based alloy has a composition, by weight, of about 0.015% boron, about 0.05% to about 0.15% carbon, about 20% to about 24% chromium, about 3% iron, about 0.02% to about 0.12% lanthanum, about 1.25% manganese, about 20% to about 24% nickel, about 0.2% to about 0.5% silicon, about 13% to about 15% tungsten, and balance cobalt.

20. The process of claim 18, wherein the nickel-based alloy has a composition, by weight, of between about 19% and about 21% chromium, about 15% tungsten, between about 9% and about 11% nickel, about 3% iron, between about 1% and about 2% manganese, about 0.40% silicon, about 0.030% sulfur, and balance cobalt.

21. A process of producing a ceramic matrix composite gas turbine component, the process comprising:

modifying a surface positioned in a seal slot along a hot gas path of the ceramic matrix composite gas turbine component to produce a modified surface with a surface roughness of less than 3 micrometers; and

positioning a seal in the seal slot;

wherein the modified surface is substantially devoid of fibers; and

wherein modifying includes vapor depositing silicon, and then machining with a non-abrasive material, machining with the non-abrasive material applying a contact pressure on the surface and depositing at least a portion of the non-abrasive material into crevasses on the surface.

22. A process of machining a ceramic matrix composite surface of a gas turbine component, the process comprising:

providing a non-abrasive material;

positioning the non-abrasive material adjacent to the ceramic matrix composite surface of the gas turbine component; and

applying a contact pressure on the surface and depositing at least a portion of the non-abrasive material into crevasses on the ceramic matrix composite surface by conducting at least about 300 machining cycles;

wherein each of the machining cycles comprises moving at least one of the non-abrasive material or the ceramic matrix composite surface relative to the other.

23. The process of claim 22, further comprising conducting between about 500 and about 10,000 machining cycles.

24. The process of claim 22, wherein the depositing of the non-abrasive material decreases a coefficient of friction of the ceramic matrix composite surface.

25. The process of claim 22, wherein the depositing of the non-abrasive material decreases a roughness of the ceramic matrix composite surface.

26. The process of claim 22, wherein the depositing of the non-abrasive material increases a compliance of the ceramic matrix composite surface.

27. The process of claim 22, wherein each of the machining cycles includes a honing displacement of between about 0.0005 inches and 0.040 inches.

28. The process of claim 22, wherein the non-abrasive material comprises a nickel-based alloy.

29. The process of claim 22, further comprising providing a machining temperature of between about 450°

F. and 1200°

F.

30. The process of claim 29, wherein increasing the machining temperature decreases a coefficient of friction of the ceramic matrix composite surface with a decreased number of the machining cycles.

31. The process of claim 22, further comprising providing a machining contact pressure of between about 40,000 psi and about 80,000 psi.

32. The process of claim 31, wherein increasing the machining contact pressure decreases a coefficient of friction of the ceramic matrix composite surface with a decreased number of the machining cycles.

33. A process of producing a ceramic matrix composite gas turbine component, the process comprising:

modifying a surface of the ceramic matrix composite gas turbine component to produce a modified surface with a surface roughness of less than 6 micrometers, wherein the surface is selected from the group consisting of a damper cavity surface for a damper pin in the ceramic matrix composite gas turbine component, a dovetail attachment face of a ceramic matrix composite gas turbine rotating airfoil, and the dovetail attachment face of a ceramic matrix composite gas turbine non-rotating airfoil;

wherein modifying includes machining with a non-abrasive material, machining with the non-abrasive material applying a contact pressure on the surface and depositing at least a portion of the non-abrasive material into crevasses on the surface, the crevasses being formed by plies selected from the group consisting of the unreinforced matrix plies and fiber-reinforced plies.

34. The process of claim 33, wherein depositing the non-abrasive material into the crevasses on the surface decreases a coefficient of friction of the surface.

35. The process of claim 33, wherein the surface roughness is less than 3 micrometers.

36. The process of claim 33, wherein the surface roughness is between 1 micrometer and 2 micrometers.

37. The process of claim 33, wherein the process is a manufacturing process.

38. The process of claim 33, wherein the process is a repair process.

39. The process of claim 33, wherein the modified surface is substantially devoid of fibers.

40. The process of claim 33, wherein modifying further includes vapor depositing silicon, and then machining with the non-abrasive material.

41. The process of claim 33, wherein modifying further includes applying braze paste, and then machining with the non-abrasive material.

42. The process of claim 33, wherein modifying further includes applying at least one unreinforced matrix ply, and then machining with the non-abrasive material.