LOW FRICTION COBALT-BASED COATINGS FOR TITANIUM

Abstract: A cobalt-based coating is provided which is functional to reduce the coefficient of friction between two operatively, frictionally engaging titanium alloy surfaces.

Description: LOW FRICTION COBALT BASED COATINGS FOR TITANIUM FIELD OF THE INVENTION The present Invention relates to protective coatings adapted for titanium based alloy parts which come Into frlctlonal engagement with one another resulting In metal-to-metal wear. More specifically, the coatings find particular application In the protection from adhesive and fretting wear and galling and seizure of gas turbine and jet engine parts or the like made from titanium and titanium alloys. BACKGROUND OF THE INVENTION In certain applications, titanium based alloys are utilized under conditions wherein there Is frlctlonal metal-to-metal contact between two titanium alloy surfaces. An exemplary use would be that between the frlctlonal parts of the roots of the compressor blades against the discs of a jet engine. The blades are secured to their respective discs by means of a dovetail arrangement In which the dovetail base of a blade fits Into a groove formed on the periphery of a rotating turbine disc. During operation of the jet engine, centrifugal forces and vibration cause the blade to move in the groove. The fit of the dovetail base portion of the blade in the disc groove is designed to allow for this movement. Local aerodynamic effects, resulting from the vane or strut positions relative to the rotating components in the high pressure compressor, will produce high frequency, low amplitude vibrations. The combination of high contact stress due to the centrifugal forces and high frequency vibration cause extensive surface damage to unprotected surfaces. Stated otherwise, maintenance of direct metal to metal contact between two titanium alloy surfaces leads to a high coefficient of friction with serious damage to both surfaces due to adhesive wear of the metal alloy. Generally, it is the fan and the front stage compressor blades operating under relatively low 9 - 2 - temperatures and which are manufactured from light-weight titanium based alloys which are prone to adhesive wear, whereas the rear stage compressor components operating under relatively higher temperatures are formed from materials such as steel or nickel based alloys which are less prone to adhesive wear. The current commercial practice involves protecting the titanium alloy components of gas turbine and jet engines by the application of a thermal spray coating, preferably in conjunction with a solid film lubricant, to the dovetail base of the blade. The protective coating is composed of a soft copper-nickel alloy or a copper-nickel- indium alloy, which is applied by plasma spraying. Subsequently, the coating is dry film lubricated using molybdenum disulphlde in an organic resin binder. This solid film lubricant initially provides a low coefficient of friction in an attempt to prevent galling, and to delay the onset of adhesive wear originating from metal-to-metal contact. This Is described in ASM Handbook, Volume 18, October 1992, pp. 588-592 by Schell, J.D. et al. Once this solid lubricant has been eroded, the CuNiln coating on the dovetail base of the blade rubs against the titanium alloy disc groove surfaces damaging the disc by removal of the metal from the disc and by creating pits in the disc. The disc damage may lead to seizure of the blades within the disc grooves or, in extreme cases, to premature fatigue failure of the disc. Thus, these prior art coatings have not proved fully successful in the prevention of the adhesive wear of surfaces of titanium alloys In frlctlonal contact with one other. Disadvantageously, too, such copper-nickel-indium and copper-nickel alloy systems display a good oxidation resistance up to about 315°C. Usually, jet engines and the like are subjected to a broad temperature gradient in the fan/compressor which ranges from sub-zero (-60°C) SUBSTiTUTE SHEET up to approximately 650°C at .the rear compressor stage, substantially above the effective 315°C upper temperature limit of the copper-nickel and copper-nickel-indium alloys. It is well known In the art to utilize cobalt based alloys for overlay coatings on substrates to reduce oxidation and corrosion at elevated temperatures. In the United States Patent No. 4,034,142 issued July 5, 1977 to R. J. Hecht, there are disclosed overlay coatings for use exclusively in high temperature applications for the protection of substrates against oxidation and hot corrosion. The coatings contain aluminum, chromium, yttrium and silicon and a metal chosen from the group consisting of nickel, cobalt and iron or mixtures thereof. The coatings are particularly suited for the protection of nickel and cobalt superalloys at elevated temperatures, i.e. of the order of 1000°C, by the formation of a stable oxide surface layer of alumina on the coatings which acts as a diffusion barrier to minimize further reactions. A. R. Nicoll, in United States Patent No. 4,503,122 issued March 5, 1985, provides a high temperature protection layer for temperatures above 600°C, usually substantially above 900°C, for high temperature gas turbine parts manufactured from an austenitic material such as a nickel superalloy. The layer is composed of a base of chromium, aluminum and cobalt with silicon and yttrium. Again, the protective nature of the coatings rely on the formation of a continuous cover of an alumina skin resistant to high temperature corrosion at above 900°C. W. J. Brindley et al, United States Patent No. 5,116,690 issued May 26, 1992 discloses overlay coatings of MCrAlX in which M may be nickel, cobalt or iron and X may be yttrium, Yb, Zr, or Hf on Ti3Al+Nb titanium alloys in an oxidizing environment. The overlay coatings disclosed in the Hecht, Nicoll and Brindley et al patents are used at temperatures in SU&S i i i ϋ i ε ^rscc l excess of 900°C, well above the temperatures at which titanium alloys are used. The overlay coating protect the airfoil of a blade against destructive influence of hot gas atmospheres. No protection for wear due to rubbing of an overlay coating against another solid surface is contemplated. United States Patent No. 4,789,441 issued December 6, 1988 to J. Foster et al and United States Patent No. 4,810,334 issued March 7, 1989 to F. J. Honey et al disclose protection layers on turbine blades comprised of particles of chromium, aluminum, yttrium and silicon in a matrix of cobalt applied by composite electrolytic deposition. The protective layers and anchoring coats of a larger particle size are applied by electrolytic deposition and then spray coated with a thermal barrier of a refractory material by plasma deposition. These patents thus relate to the use of a cobalt alloy to anchor a ceramic coating to a substrate. Cobalt alloy coatings useful as wear-resistant materials are exemplified in such products as "Stellite"* and "Tribaloy"*. The Stellite type coatings are typically composed of a chromium, tungsten strengthened cobalt matrix containing a high percentage of very hard carbides, predominantly chromium carbides. The Tribaloy type coatings are either cobalt or nickel based with molybdenum, silicon and chromium as the major alloying elements. The Tribaloy compositions are so balanced that the bulk of the structure is in hard, brittle, laves phases having a Rockwell Hardness (HRC) in the 50 to 60 range. Both Stellite and Tribaloy alloys are so hard as to prove unmachinable, and it is this hardness which is responsible for the wear resistant properties of coated articles. Unfortunately, should a softer part, such as one formed from titanium based alloy, be abraded by the coating- hardened surface, the latter will cause the softer part to wear excessively. ♦ Trademarks S UBSTiTUTE SHEET Cobalt based superalloys have been developed for their high temperature mechanical properties and oxidation resistance. They are typically used as wrought or cast solid parts, not as a coating. Although such alloys will not damage other superalloy surfaces when in contact with them, they cannot be used with titanium alloys without deleterious effects thereto. SUMMARY OF THE INVENTION In accordance with the present invention, there are provided protective coatings particularly useful to reduce the coefficient of friction and enhance wear-resistance of titanium based alloys. In its simplest aspect, the coating comprises substantially pure cobalt which may be applied by thermal spraying onto one of the friction engaging metal-to-metal surfaces. In a second broad aspect, the invention provides a coating for titanium based alloy components which is functional to reduce the coefficient of friction and to increase wear resistance which coating comprises cobalt together with one or more of chromium, aluminum, silicon, yttrium, boron nitride or selective mixtures thereof. More particularly, the present invention comprises, a mechanical component of titanium or titanium alloy having a contacting surface for use in an apparatus having an opposed, contacting surface of titanium or titanium alloy, which in operation subjects the surface of said mechanical component to fretting adhesive wear, comprising the said surface of said mechanical component having an adherent, protective, lubricious coating comprising cobalt or cobalt and at least one alloying element selected from the group consisting of chromium, aluminum, silicon and yttrium in an amount effective for contact transfer of a portion of the adherent, lubricious, protective coating from the surface of the mechanical component to the opposed, contacting surface of the apparatus whereby the surfaces are l ISTITUTE SHEET O 95/2 - 6 - protected from fretting wear. Typically, the mechanical component is a jet engine component of titanium alloy, which in operation has a surface that is subjected to adhesive wear in a temperature range of -60°C to 650°C, said surface having a said protective, adherent, lubricious coating formed thereon such as by thermal spraying. The protective adherent, lubricious coating may comprise one or more of cobalt, cobalt and about 0.1 to about 35% by weight chromium, cobalt and about 0.1 to about 25% by weight aluminum, cobalt and about 0.1 to about 7% by weight silicon, cobalt and about 0.1 to about 2% by weight yttrium, and additionally hexagonal boron nitride in the range of about 0.1 to about 30% by volume. A preferred cobalt alloy composition range comprises, by weight, 17-35% chromium, 3-12.5% aluminum, 0.5-7% silicon, 0.3-2% yttrium, the balance cobalt. A preferred cobalt alloy composition comprises, by weight, 29.2% chromium, 6.1% aluminum, 2% silicon, 0.35% yttrium, the balance cobalt. Another preferred aspect of the invention contemplates the addition of hexagonal boron nitride to each specific coating formulation. It is postulated that there is uniform distribution of the boron nitride throughout the coating which results in improved lubrication. Advantageously, the coatings disclosed herein prevent destructive frlctlonal contact between the surfaces of titanium alloy components. It Is to be emphasized that the coatings are specific to titanium alloys. Furthermore, because of the low coefficient of friction in comparison to that of the uncoated titanium alloys, minimal disturbance of the titanium alloy surfaces occurs. Thus, the resultant diminution in scratching and pitting of the titanium alloy surface normally due to adhesive wear results in reduced risk of fatigue cracking. Additionally, SUBSTiTUTE SHEET the inclusion of the alloying elements In certain coatings provides high temperature capability. A marked advantage of the coatings disclosed herein lies in the fact that their protective properties are inherent at ambient temperatures, unlike the prior art overlay coatings which require the application of heat before becoming functional. It is to be noted also that the coatings exhibit predictable and stable long term wear and frlctlonal behaviour. Also, the coatings are longer lasting than those of the prior art and require less maintenance. Somewhat surprisingly, it has been observed that the coefficient of friction appears to decrease with time as opposed to the prior art coatings, which have an increasing coefficient of friction with time. In summary, therefore, the invention provides a novel coated mechanical component formed of titanium alloy substrate coated with a cobalt or cobalt alloy based coating which is capable of frictionally engaging a second component which is also. formed of titanium based alloy whereby the coefficient of friction therebetween is markedly reduced, with concomitant damage to both titanium alloy components being substantially eliminated. As will be evident to one skilled in the art, the present discovery provides a method of reducing damage to the surfaces of two frictionally engaging alloy surfaces, wherein the alloy is specifically titanium based. DESCRIPTION OF THE DRAWINGS Figure 1 is a cross-sectional view illustrating the applied coating as utilized in the context of a jet engine. Figure 2 is a plot showing the decrease of the coefficient of friction versus time for one coating formulation in comparison to that of a prior art coating. SUBSTJTUTE SHEET DESCRIPTION OF THE PREFERRED EMBODIMENT Having reference to the accompanying drawings wherein the application of the invention specifically to jet engines is demonstrated, there is shown in Figure 1 a single compressor blade 10. The compressor disc 12 has a groove 14 formed on the periphery thereof adapted to receive the root or base 16 of blade 10 in a dovetail engagement. The blade root 16 is thermally sprayed with coating 20, as illustrated. Whilst the invention is in part described with respect to a jet engine, it is to be understood that the invention is not to be limited to this application, but can be applied whenever two titanium or titanium alloy components come into frlctlonal engagement with one another. Other techniques such as physical vapor deposition, chemical vapor deposition and the like can be used to deposit the coating. The experimental data generated and given herebelow were obtained by applying the coating using standard high velocity oxy-fuel spraying equipment. In the spraying process a powder of the alloy to be applied is introduced into a hot supersonic plume formed by burning a combustion gas, for example, propylene, mixed with oxygen. The powder particles are heated • and accelerated in the plume. A portion of the heated particles adheres to the titanium alloy to form the continuous protective coating 20. The coating thickness preferably is approximately 125 micrometres but is adjustable by controlling spray parameters, as is well known in the art. EXAMPLE 1 Cobalt powder having a particle size less than 45 micrometres and comprising essentially cobalt with 0.69% oxygen, was sprayed onto a T1-6A1-4V sample. The titanium alloy sample had been previously degreased and grit blasted SUBSTITUTE SHEET using 40 grit (450 micrometers) alumina at a pressure of 550 kPa using a suction type grit blaster. The spraying was effected using an air cooled high velocity oxy-fuel (HVOF) unit. The spray conditions were as follows: Oxygen flow 20,400 litres/hour Propylene flow 4,200 litres/hour Spray distance 20.3 cm Powder flow rate 16 g/min The coating was sprayed to a 127 x thickness which is typical of the actual application. The coatings had the following mechanical properties: the diamond pyramid hardness load 300g (DPH300) was 228 and the ultimate tensile strength (U.T.S.) was 63.4 MPa. The coating oxygen content was 2%. The testing of the coating was carried out at room temperature in a wear-friction rig simulating the conditions encountered in the frlctlonal contact between a dovetail blade attachment in a jet engine disc. The coating was rubbed against a T1-6A1-4V block with the following results: TABLE 1 Initial Coefficient of Friction 0.43 Final Coefficient of Friction 0.31 Stability of Coefficient of Friction slightly variable T1-6AL-4V block material pick-up lβ um Deepest T1-6A1-4V block pit 0 jam Coating Wear 89 um EXAMPLE 2 Cobalt alloy powder having a particle size less than 45 micrometres was used . The powder had the composition given below: SUBSTITUTE SHEET Element Weight% Cr 28.9 Al 5.8 Si 1.7 Y 0.35 Co Balance The titanium alloy substrate, its preparation, spray equipment and spray parameters were similar to those given in Example 1 to yield a coating of 127 jam thickness. The coating had the following mechanical properties: the DPH300 was 650 and the U.T.S. was 54.1 MPa. The test results are set out herebelow: TABLE II Initial Coefficient of Friction 0.59 Final Coefficient of Friction 0.36 Stability of Coefficient of Friction slightly variable T1-6A1-4V block material pickup 12jum Deepest T1-6A1-4V block pit 0 um Coating wear 58 um EXAMPLE 3 A mechanical mixture of the CoCrAlSiY alloy powder having the composition described in Example 2 had 30 weight % hexagonal boron nitride (BN) of approximately 100 micrometre average particle size added thereto. The titanium alloy preparation, spray equipment and spray parameters were similar to those given in Example 1 to yield a coating of 127 jum thickness. The coating was found to have a DPH3 Q 0 of 330 and a U.T.S.of 39 MPa. The test results are given below: TABLE 3 Initial Coefficient of Friction 0.49 Final Coefficient of Friction 0.36 Stability of Coefficient of Friction stable T1-6A1-4V block material pick-up 12jum T1-6A1-4V block deepest pit 0 jam Coating wear 79 um SUBSTITUTE S X-ray analysis indicated the presence of hexagonal BN in the coating. Metallographic examination showed a uniform distribution of BN throughout the thickness of the coating. Chemical analysis indicated about 17 volume % of hexagonal BN in the coating. It was determined that the addition of BN softened the coating compared to the coating without BN (Example 2). BN also caused the initial coefficient of friction to be lowered and in general the coefficient of friction was more stable during rubbing. EXAMPLE 4 A CuNiln coating having a comparable chemical composition to that commonly used in the prior art was applied to the same titanium alloy and subjected to identical tests as those conducted on the coatings described above. The chemical composition of the CuNiln coating was approximately: 58% Cu, 37% Ni, 5% In. The data for the CoCrAlSiY-BN coating are the same as for Example 3. TABLE 4 CoCrAlSiY-BN CuNiln Coating Coating As sprayed Initial Coefficient of Friction 0.49 0.3 Final Coefficient of Friction 0.36 0.58 Stability of Coefficient of Friction stable unstable, increases with time T1-6AL-4V block wear -up) 58 jum (wear) Coating deepest pit 9 jam The superior performance of the CoCrAlSiY-BN coating was demonstrated by: (1) the observation that the CoCrAlSiY-BN coating material transferred from the coated substrate to the titanium alloy block provided wear protection thereto. The SUBSTITUTE SHEET - 12 - CuNiln coated item damaged the titanium alloy block extensively by removing a deep layer and pitting of the block material. (11) a lower and stable coefficient of friction, as shown in Figure 2. (ill) very reproducible performances in the wear and friction rig as demonstrated with the CoCrAlSlY-BN coatings sprayed with different batches of CoCrAlSlY and BN powders, (iv) the coating wear depth .and the maximum pitting depth were 92% and 93% of the CuNiln coating, compared to 60% and 67% respectively of the depth of CoCrAlSlY without BN addition relative'to CuNiln. EXAMPLE 5 Comparative tests were conducted on the test coatings shown in Table 5 below according to the method described in Example 1 above at temperatures of 24°Cand 454°C. Test results are shown In Tables 5 and 6. SUBSTITUTE SHEET - 13 - TABLE 6 The 24°C Sliding Wear Test data obtained by rubbing a block of T1-6A1-4V having protective coatings of a thickness of about 127 micrometers thereon against an uncoated block of T1-6A1-4V show clearly that cobalt metal and cobalt alloys of the invention containing Cr, Al, SI and Y all function similarly in that coating material was transferred to the uncoated T1-6A1-4V block and pitting damage to the uncoated block was virtually eliminated under the test conditions. Protective coatings comprised of CoCrAIYSi/BN produced 10 micron and 8 micron transfers (pick-up) of the coating to the uncoated surface and yielded significant coefficient of friction reductions of 0.17 to 0.15, i.e. from 0.59 to 0.42 and from 0.50 to 0.35, at 454°C. SUBSTITUTE SHEET The three high temperature tests on non-cobalt alloys (nickel and titanium alloys) containing BN had essentially unchanged or increased coefficients of friction, and up to 195 micron losses of titanium alloy surface materials with up to 310 micron deep pits in the uncoated surfaces were observed. Protective coatings comprised of Co/CoO (2% by weight oxygen largely resulting from oxidation during the spray coating process), CoCrAlYSi, CoCrAIYSi/BN, CoAl and CoCr produced 5 micron to 18 micron transfers of the coatings to the uncoated surfaces and yielded low final coefficients of friction in the range of 0.27 to 0.36, at 24°C. The addition of Ni, W, Si, C, or Mo to the cobalt- chrome alloy base clearly had a deleterious, and in one case, disastrous effect on the behaviour of the coating. The effect of nickel itself as a substitute for Si was definitely negative (see the results for the CoCrAlNiY alloy). The negative results on TRIBALOY ^ m (CoCrMoSi) and STELLITE tm (CoCrNiWSiC) coatings are significant, particularly the severe wear of 218 micron loss of uncoated surface and 315 micron deep pitting of the uncoated surface by the TRIBALOY coating. These tests confirm the importance of selecting the right alloying elements to add to the Co base alloy. It will be understood that changes and modifications may be made in the embodiments of the invention without departing from the scope and purview of the appended claims. SUBSTITUTE SHEET

Claims: CLAIMS 1. A mechanical component of titanium or titanium alloy having a contacting surface for use in an apparatus, having an opposed, contacting surface of titanium or titanium alloy which in operation subjects the surface of said mechanical component and the opposed contacting surface of the apparatus to fretting adhesive wear comprising the surface of said mechanical component having an adherent, lubricious, protective coating consisting essentially of cobalt or cobalt and at least one alloying element selected from the group consisting of chromium, aluminum, silicon and yttrium in an amount effective for contact transfer of a portion of the adherent, lubricious, protective coating from the surface of the mechanical component to the opposed, contacting surface of the apparatus whereby the surfaces are protected from fretting wear. 2. A gas turbine component of titanium alloy, which in operation has a first surface which is subjected to fretting adhesive wear against an opposed second surface of titanium alloy, said first surface having an adherent, lubricious, protective coating consisting essentially of cobalt or cobalt and at least one alloying element selected from the group consisting of chromium, aluminum, silicon and yttrium in an amount effective for contact transfer of a portion of the adherent, lubricious, protective coating from the surface of the mechanical component to the opposed, contacting surface of the apparatus whereby the surfaces are protected from fretting wear. 3. A mechanical component as claimed in claim 1 in which said surface has an adherent, lubricious, protective coating consisting essentially of cobalt. 4. A mechanical component as claimed in claim 1 in which said surface has an adherent, lubricious, protective coating comprising cobalt and about 0.1 to about 35% by weight chromium. SUBSTITUTE SHEET 5. A mechanical component as claimed in claim 1 in which said surface has an adherent, lubricious, protective coating comprising cobalt and about 0.1 to about 25% by weight aluminum. 6. A mechanical component as claimed in claim 1 in which said surface has an adherent, lubricious, protective coating comprising cobalt and about 0.1 to about 7% by weight silicon. 7. A mechanical component as claimed in claim 1 in which said surface has an adherent, lubricious, protective coating comprising cobalt and about 0.1 to about 2% by weight yttrium. 8. A mechanical component as claimed in claim 1 in which said surface has an adherent, lubricious, protective coating additionally comprising an effective amount of hexagonal boron nitride in the range of about 0.1 to about 30% by volume. 9. A mechanical component as claimed in claim 4 in which said surface has an adherent, lubricious, protective coating additionally comprising about 0.1 to about 25% by weight aluminum. 10. A mechanical component as claimed in claim 9, in which said surface has an adherent, lubricious, protective coating additionally comprising about 0.1 to about 7% by weight silicon. 11. A mechanical component as claimed in claim 10, in which said surface has an adherent, lubricious, protective coating additionally comprising about 0.1 to about 2% by weight yttrium. 12. A mechanical component as claimed in claim 11 in which said surface has an adherent, lubricious, protective coating additionally comprising an effective amount of hexagonel boron nitride in the range of about 0.1 to about 30% by volume. 13. A mechanical component as claimed in claim 3 in which said surface has an adherent, lubricious, protective coating additionally comprising hexagonal boron nitride. SUBSTITUTE SHEET 14. A gas turbine engine component of titanium alloy, which in operation has a surface which is subjected to fretting adhesive wear in a temperature range of -60°C to 650°C, said surface having an adherent, lubricious, protective coating consisting essentially of by weight, 17- 35% chromium, 3-12.5% aluminum, 0.5-7% silicon and 0.3-2% yttrium, the balance cobalt. 15. A gas turbine engine component as claimed in claim 14 in which the coating comprises, by weight, 29.2% chromium, 6.1% aluminum, 2% silicon, and 0.35% yttrium, the balance cobalt, and additionally comprising, by volume, about 0.1 to about 30% boron nitride. 16. A method for protecting titanium and titanium alloy components of an apparatus having a pair of opposed, contacting surfaces which in operation are subjected to fretting adhesive wear at elevated temperatures comprising: spraying onto one only of said pair of opposed, contacting surfaces an adherent lubricious, protective coating consisting essentially of cobalt or cobalt and at least one alloying element selected from the group consisting of chromium, aluminum, silicon and yttrium in an amount effective for contact transfer of a portion of the adherent, lubricious, protecting coating from the coated surface to the opposed, uncoated, contacting surface whereby the surfaces are protected from fretting adhesive wear. 17. A method as claimed in claim 16 in which the adherent, lubricious, protective coating consists essentially of cobalt. 18. A method as claimed in claim 16 in which the adherent, lubricious protective coating consists essentially of cobalt and about 0.1 to about 35% by weight chromium. 19. A method as claimed in claim 16 in which the adherent, lubricious, protective coating consists essentially of cobalt and about 0.1 to about 25% by weight aluminum. SUBSTITUTE SHEET 20. A method as claimed in claim 16 in which the adherent , lubricious , protective coating consists essentially of cobalt and about 0.1 to about 7% by weight silicon. 21. A method as claimed in claim 16 in which the adherent , lubricious , protective coating consists essentially of cobalt and about 0.1 to about 2% by weight yttrium. 22. A method as claimed in claim 16 in which the adherent, lubricious, protective coating additionally comprises hexagonal boron nitride in an amount of about 0.1 to about 30% by volume. 23. A method as claimed in claim 16 in which the adherent , lubricious , protective coating consists essentially, by weight, of 17-35% chromium, 3-12.5% aluminum, 0.5-7% silicon and 0.3-2% yttrium, the balance cobalt . 24. A method as claimed in claim 23 which additionally comprises about 0.1 to about 30% by volume boron nitride. SUBSTITUTE SHEET

Inventors: CHILKOWICH ANTHONY P, HAJMRLE KAREL, CHILKOWICH, ANTHONY, P., HAJMRLE, KAREL
Applicants: SHERRITT INC
Application year: 1995
Main classification: C23C30
IPC codes: C23C4