Great research starts with great data.

Learn More
More >
Patent Analysis of

Barrier layer for a turbocharger

Updated Time 12 June 2019

Patent Registration Data

Publication Number

US10001021

Application Number

US14/893478

Application Date

22 May 2014

Publication Date

19 June 2018

Current Assignee

OERLIKON SURFACE SOLUTIONS AG, PFAFFIKON

Original Assignee (Applicant)

OERLIKON TRADING AG, TRUBBACH

International Classification

B32B9/00,C23C14/32,F01D5/28,C23C14/08,F02B33/02

Cooperative Classification

F01D5/288,C23C14/08,C23C14/325,F02B33/02,F05D2220/40

Inventor

RAMM, JUERGEN

Patent Images

This patent contains figures and images illustrating the invention and its embodiment.

US10001021 Barrier layer turbocharger 1 US10001021 Barrier layer turbocharger 2 US10001021 Barrier layer turbocharger 3
See all images <>

Abstract

A system, in particular a turbocharger with a barrier layer for protecting against high temperature corrosion of parts and/or components of the system or turbocharger that are subjected to high temperatures, where the barrier layer includes at least one Cr—Al—O layer.

Read more

Claims

1. A PVD-coated part or a PVD-coated component of a turbocharger, comprising: a PVD-coated substrate having an oxidation- and chemical barrier layer that includes at least one Al—Cr—O layer, which at least partially has a corundum structure and shows at least reflections of a crystal structure of an AlCr intermetallic phase in an X-ray diffraction diagram, and wherein the substrate is a part or component of a turbocharger that is subjected to temperatures greater than 400° C., but not greater than 800° C., during operation of the turbocharger, and wherein a crystallite size of an oxide in the Al—Cr—O layer is so small that oxide crystallites can no longer be detected with XRD and as a result, no oxide phase can be detected in the X-ray diffraction diagram.

2. The PVD-coated part or the PVD-coated component of a turbocharger according to claim 1, wherein the barrier layer includes a chromium nitride layer, which is situated between the substrate and the Al—Cr—O layer.

3. The PVD-coated part or the PVD-coated component of a turbocharger according to claim 1, wherein the chemical composition of the Al—Cr—O layer produces a composition of (Al,Cr)2O3-y where y≤0.3.

4. The PVD-coated part or the PVD-coated component of a turbocharger according to claim 1, wherein the X-ray diffraction diagram shows the reflections of an (Al,Cr)2O3 layer in a corundum structure.

5. The PVD-coated part or the PVD-coated component of a turbocharger according to claim 1, wherein the X-ray diffraction diagram shows the reflections of a crystal structure of an AlCr intermetallic phase.

Read more

Claim Tree

  • 1
    1. A PVD-coated part or a PVD-coated component of a turbocharger, comprising:
    • a PVD-coated substrate having an oxidation- and chemical barrier layer that includes at least one Al—Cr—O layer, which at least partially has a corundum structure and shows at least reflections of a crystal structure of an AlCr intermetallic phase in an X-ray diffraction diagram, and wherein the substrate is a part or component of a turbocharger that is subjected to temperatures greater than 400° C., but not greater than 800° C., during operation of the turbocharger, and wherein a crystallite size of an oxide in the Al—Cr—O layer is so small that oxide crystallites can no longer be detected with XRD and as a result, no oxide phase can be detected in the X-ray diffraction diagram.
    • 2. The PVD-coated part or the PVD-coated component of a turbocharger according to claim 1, wherein
      • the barrier layer includes a chromium nitride layer, which is situated between the substrate and the Al—Cr—O layer.
    • 3. The PVD-coated part or the PVD-coated component of a turbocharger according to claim 1, wherein
      • the chemical composition of the Al—Cr—O layer produces a composition of (Al,Cr)2O3-y where y≤0.3.
    • 4. The PVD-coated part or the PVD-coated component of a turbocharger according to claim 1, wherein
      • the X-ray diffraction diagram shows the reflections of an (Al,Cr)2O3 layer in a corundum structure.
    • 5. The PVD-coated part or the PVD-coated component of a turbocharger according to claim 1, wherein
      • the X-ray diffraction diagram shows the reflections of a crystal structure of an AlCr intermetallic phase.
See all independent claims <>

Description

FIELD OF THE INVENTION

The present invention relates to a system, in particular a turbocharger with a barrier layer for protecting against high temperature corrosion of parts and/or components of the system or turbocharger, which are subjected to high temperatures.

BACKGROUND OF THE INVENTION

EP2112252 has disclosed the use of a barrier layer made of titanium dioxide or a mixture of titanium dioxide with at least one other ceramic material as a thermal insulation layer for reducing the dissipation of heat from parts such as those of turbochargers. This barrier layer is preferably deposited by means of thermal spraying.

Consequently, some parts of a turbocharger according to the prior art are inevitably subjected to high temperatures. Such parts are therefore as a rule composed of very temperature-stable materials such as Ni- and/or Ti alloys, which are very expensive and difficult to produce.

There are also known coatings of parts of turbochargers for other purposes. For example, EP2406476 and EP2041400 disclose catalytic coatings that can be deposited onto surfaces of turbocharger components. According to EP2041400, such a catalytic coating can be used as a means for reducing dirt deposits on a flow-guiding part of a compressor of a turbocharger.

The object of the present invention is to offer a solution for extending the service life of turbocharger components that are subjected to high temperatures.

SUMMARY OF THE INVENTION

This object is attained according to the invention in that turbocharger components that are subjected to high temperatures are coated with an oxidation- and chemical barrier layer, said barrier layer including at least one aluminum chromic oxide layer (Al—Cr—O).

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a calotte-grinding measurement for evaluating the layer thickness of the layer 1 resulting from exemplary embodiment 1.

FIG. 2 shows a calotte-grinding measurement for evaluating the layer thickness of the layer 2 resulting from exemplary embodiment 1.

FIG. 3 is an x-ray diffraction diagram of an (Al,Cr)2O3 layer, which was produced by an Al0.7Cr0.3 target and clearly shows the reflections for an (Al,Cr)2O3 layer in a corundum structure.

FIG. 4 is an x-ray diffraction diagram of an (Al,Cr)2O3 layer, which was produced by an Al0.7Cr0.3 target and clearly shows the reflections of the crystal structure of the intermetallic phase Al8Cr5.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In the context of the present invention, the expression “high temperatures” is understood to mean temperatures greater than 400° C., in particular greater than 500° C.

Barrier layers according to the present invention have turned out to be outstanding barriers against oxidation and chemical attacks, in particular for components in turbochargers that are subjected to temperatures of up to 600° C. and even up to 800° C. and more.

Preferably, the layer is deposited according to the invention by means of a PVD process, preferably by means of reactive arc vaporization without a droplet filter.

Preferably, the layer contains an interface layer of CrN and a functional layer of Al—Cr—O.

Other details of the invention will be described in conjunction with exemplary embodiments:

In order to produce the layers according to two exemplary embodiments I and 2, the following process parameters were used (see Tables 1 and 2):


TABLE 1
Process parameters in the deposition of the interface
Discharge
Pretreatment
Interface
current ×
Substrate
(etching
(deposition
Example
Targets
target
temperature
process)
process)
1
2 × Cr
Cr: 140 A
450° C.
Cr-metal ion
CrN (at 3 Pa N2
etching (18 min)
for 13 min)
2
2 × Cr
Cr: 140 A
450° C.
Cr-metal ion
CrN (at 3 Pa N2
etching (18 min)
for 7 min)


TABLE 2
Process parameters in the deposition of the functional layer
Discharge
current ×
Substrate
Example
Targets
target
temperature
Gas flow
Functional layer
1
2 × AlCr
AlCr: 200 A
450° C.
400 sccm O2
Al—Cr—O (for 60 min
2
2 × AlCr
AlCr: 200 A
450° C.
400 sccm O2
Al—Cr—O (for 30 min)

The layer thicknesses of the layers produced according to the invention according to exemplary embodiments 1 and 2 were measured with the aid of a layer thickness testing device using the calotte grinding process (see Table 3 and FIGS. 1 and 2):


TABLE 3
Layer thickness of the layers 1 and 2 resulting from
exemplary embodiments 1 and 2
Example
Interface thickness
Functional layer
1
0.5 μm
4.0 μm
2
0.3 μm
1.9 μm

In order to produce Al—Cr—O layers according to the present invention, preferably targets with an Al1-xCrx composition where 0.2≤x≤0.9 in atomic concentration are used. In general, these targets are produced by means of powder metallurgy so that any chemical compositions can be used in the indicated region.

Preferably, the targets are vaporized in an oxygen atmosphere, as has already been indicated in the above-described exemplary embodiments I and 2. According to the invention, the targets can be operated with different discharge currents in order to control the vaporization rate.

According to the invention, the chemical composition of the layers is preferably controlled so that the analysis of a layer produced in this way yields a composition of (Al,Cr)2O3-y, where y≤0.3.

Depending on the case, the coating temperature can be adapted to the substrate material that is to be coated and to the subsequent use. Typically, the coating temperatures are between 100° C. and 600° C.

Since the substrates to be coated can have different shapes and sizes, the embodiment of the substrate holder with which they are secured during the coating in the system is adapted to the shape of the substrate.

All of this results in the fact that in all cases, the above-described chemical composition is in fact retained, but other phase compositions of the oxide layer are produced for the different process parameters.

The phases of the layer are usually measured using X-ray diffraction (XRD) methods. Consequently, the measured XRD spectrum in some cases can clearly show the reflections for an (Al,Cr)2O3 layer in a corundum structure, as shown for example in FIG. 3. In this case, FIG. 3 shows the X-ray diffraction diagram of an (Al,Cr)2O3 layer that was produced by an Al0.7Cr0.3 target.

In the figure, the XRD reflections of the positions of the tungsten carbide substrate (thick dashed line) and the positions for the diffraction reflections of Cr2O3 in an eskolaite structure (solid line) and Al2O3 in a corundum structure (dashed line) are plotted. Between these two lines is the respective measured diffraction reflection for the synthesized (Al,Cr)2O3 mixed crystal in a corundum structure, as is to be expected according to Vegard's law.

But if the process conditions are changed as described above, then the crystallite size of the oxide can be so small that the crystallites can no longer be detected with XRD or it is also possible that the change in the process conditions causes the structure of the resulting oxide to even become amorphous.

In such cases, the oxide can no longer be detected in the X-ray spectrum, but in almost every case, materially related compounds can be found, primarily intermetallic phases and metallic mixed crystals of the Al—Cr—O layer. One such materially related compound, for example, is the intermetallic phase Al5Cr5.

A corresponding X-ray diffraction diagram is shown in FIG. 4, which shows an X-ray spectrum measured in one layer, in which, although no oxide phase can be detected, the materially related intermetallic phase Al5Cr5 is clearly evident. This X-ray diffraction diagram once again illustrates the diffraction reflections for the tungsten carbide substrate (thick dashed line) and in addition, the diffraction reflections for the Al8Cr5 crystal structure (solid line), which clearly demonstrate the existence of this intermetallic compound in the oxide layer.

In an entirely analogous fashion, under certain process conditions, XRD can be used in the oxide layer, whose chemical composition has been described above, to also detect Al4Cr1 or Al9Cr4, for example, or other Al—Cr intermetallic compounds or mixed crystals, individually or together.

Read more
PatSnap Solutions

Great research starts with great data.

Use the most comprehensive innovation intelligence platform to maximise ROI on research.

Learn More

Patent Valuation

$

Reveal the value <>

24.8/100 Score

Market Attractiveness

It shows from an IP point of view how many competitors are active and innovations are made in the different technical fields of the company. On a company level, the market attractiveness is often also an indicator of how diversified a company is. Here we look into the commercial relevance of the market.

44.0/100 Score

Market Coverage

It shows the sizes of the market that is covered with the IP and in how many countries the IP guarantees protection. It reflects a market size that is potentially addressable with the invented technology/formulation with a legal protection which also includes a freedom to operate. Here we look into the size of the impacted market.

72.99/100 Score

Technology Quality

It shows the degree of innovation that can be derived from a company’s IP. Here we look into ease of detection, ability to design around and significance of the patented feature to the product/service.

48.0/100 Score

Assignee Score

It takes the R&D behavior of the company itself into account that results in IP. During the invention phase, larger companies are considered to assign a higher R&D budget on a certain technology field, these companies have a better influence on their market, on what is marketable and what might lead to a standard.

20.0/100 Score

Legal Score

It shows the legal strength of IP in terms of its degree of protecting effect. Here we look into claim scope, claim breadth, claim quality, stability and priority.

Citation

Patents Cited in This Cited by
Title Current Assignee Application Date Publication Date
Hard Material Layer OERLIKON TRADING AG, TRUEBBACH 19 January 2006 14 August 2008
A thermal barrier, an article with a thermal barrier, and a method of applying a thermal barrier to a surface ZIRCOTEC LIMITED 27 April 2009 28 October 2009
Permeation barrier layer OERLIKON TRADING AG, TRUEBBACH 23 January 2009 30 July 2009
Internal Combustion Engine Having A Combustion Chamber Surface Coating Or Surface Coating Which Is Close To The Combustion Chamber And Method For Producing The Coating EBERSPACHER EXHAUST TECHNOLOGY GMBH & CO. KG 03 March 2010 12 April 2012
High temperature alloy particularly suitable for a long-life turbocharger nozzle ring SCHALL GERALD 16 September 2002 13 January 2005
See full citation <>

More Patents & Intellectual Property

PatSnap Solutions

PatSnap solutions are used by R&D teams, legal and IP professionals, those in business intelligence and strategic planning roles and by research staff at academic institutions globally.

PatSnap Solutions
Search & Analyze
The widest range of IP search tools makes getting the right answers and asking the right questions easier than ever. One click analysis extracts meaningful information on competitors and technology trends from IP data.
Business Intelligence
Gain powerful insights into future technology changes, market shifts and competitor strategies.
Workflow
Manage IP-related processes across multiple teams and departments with integrated collaboration and workflow tools.
Contact Sales
Clsoe
US10001021 Barrier layer turbocharger 1 US10001021 Barrier layer turbocharger 2 US10001021 Barrier layer turbocharger 3