Power plant component and method for manufacturing such component

Abstract

A power plant component is disclosed having a substrate, the surface of which is coated with a functionally graded coating of a predetermined thickness, with anti-erosion, anti-corrosion and anti-fouling properties. Improved operation properties are achieved by the functionally graded coating having a corrosion resistant portion, and an erosion resistant and hydrophobic portion, whereby the functionally graded coating is a composite coating consisting of a single layer.

1 . Power plant component, comprising:
 a substrate, the surface of which is coated with a functionally graded coating of a predetermined thickness, with anti-erosion, anti-corrosion and anti-fouling properties, wherein the functionally graded coating includes a corrosion resistant first means, and an erosion resistant and hydrophobic second means, said functionally graded coating being a composite coating consisting of a single layer, whereby the concentration of said corrosion resistant first means and the concentration of said erosion resistant and hydrophobic second means vary gradually along a thickness (x) of said composite coating, whereby the concentration of said corrosion resistant first means varies gradually from a high concentration (c 3 ) at the inner side (x 1 ) of said composite coating to a low concentration (c 4 ) at the outer side (x 2 ) of said composite coating, and that the concentration of said erosion resistant and hydrophobic second means varies gradually from a low concentration (c 1 ) at the inner side (x 1 ) of said composite coating to a high concentration (c 2 ) at the outer side (x 2 ) of said composite coating.   
     
     
         2 . Power plant component as claimed in  claim 1 , wherein said substrate is a metal or composite polymer substrate. 
     
     
         3 . Power plant component as claimed in  claim 1 , wherein said corrosion resistant first means comprises:
 a metal, ceramic, cermet and/or polymer matrix, in which particles are embedded, whereby the concentration of said particles varies gradually from a high concentration at the inner side of said composite coating to a low concentration at the outer side of said composite coating.   
     
     
         4 . Power plant component as claimed in  claim 3 , wherein said particles comprise:
 micro or nano metal, ceramic and/or polymer materials, which provide corrosion protection by electronegativity and/or self-healing reaction.   
     
     
         5 . Power plant component as claimed in  claim 1 , wherein said corrosion resistant first means comprise:
 a Ni matrix with one of Al, Zn, Zr or Mg particles.   
     
     
         6 . Power plant component as claimed in  claim 1 , wherein said erosion resistant and hydrophobic second means comprises:
 a metal, ceramic, cermet and/or polymer matrix, in which hard ceramic, metallic and/or polymer nano or micro materials are included, whereby a concentration of said materials varies gradually from a low concentration at the inner side of said composite coating to a high concentration at the outer side of said composite coating.   
     
     
         7 . Power plant component as claimed in  claim 1 , wherein said erosion resistant and hydrophobic second means comprises:
 ceramic, metallic or intermetallic particles coated with ceramic or polymer material, whereby said ceramic, metallic or intermetallic particles are erosion resistant and said ceramic or polymer coating material is anti-fouling.   
     
     
         8 . Power plant component as claimed in  claim 4 , wherein said ceramic, metallic and/or polymer nano or micro particles or fibers comprises:
 one of SiC, Al 2 O 3 , SiO 2 , WC, BN, MAX phases (e.g. Ti 3 SiC 2 , Ti 2 AlC, Cr 2 AlC), carbon nanotubes (CNTs), graphene oxide and hydrophobic particles, and PTFE.   
     
     
         9 . Method for manufacturing a power plant component according to  claim 1 , wherein the surface of said substrate is activated and prepared with a thin bonding layer and chemical or mechanical treatments. 
     
     
         10 . Method as claimed in  claim 9 , wherein said composite coating is applied by a spraying process, which spraying process can be one ore more of Atmospheric Plasma Spraying (APS), cold spray, High Voltage Oxide Fuel (HVOF) process, or electro and electroless plating and electrophoretic process.