(19)

TEPZZ7Z58B_T
(11)

EP 2 270 258 B1

EUROPEAN PATENT SPECIFICATION

(12)

(45) Date of publication and mention

(51) Int Cl.:

C23C 28/02 (2006.01)

F01D 5/28 (2006.01)

of the grant of the patent:

16.05.2012 Bulletin 2012/20

C22C 19/00 (2006.01)

(21) Application number: 10006717.2

(22) Date of filing: 29.06.2010
(54) High reliability turbine metal sealing material
Metallischer Dichtungswerksotff fr Turbinen
Materiau dtanchit mtallique pour turbines
(84) Designated Contracting States:
AL AT BE BG CH CY CZ DE DK EE ES FI FR GB
GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO
PL PT RO SE SI SK SM TR

(30) Priority: 29.06.2009 JP 2009154205

(43) Date of publication of application:
05.01.2011 Bulletin 2011/01

(60) Divisional application:

12158240.7

(73) Proprietor: Hitachi, Ltd.

Chiyoda-ku
Tokyo 100-8280 (JP)

Mebata, Akira
Chiyoda-ku
Tokyo 100-8220 (JP)
Doi, Hiroyuki
Chiyoda-ku
Tokyo 100-8220 (JP)
Toriya, Hajime
Chiyoda-ku
Tokyo 100-8220 (JP)
Narita, Kenjiro
Chiyoda-ku
Tokyo 100-8220 (JP)

(74) Representative: Beetz & Partner

Patentanwlte
Steinsdorfstrasse 10
80538 Mnchen (DE)

(72) Inventors:

EP 2 270 258 B1

Kojima, Yoshitaka
Chiyoda-ku
Tokyo 100-8220 (JP)
Arikawa, Hideyuki
Chiyoda-ku
Tokyo 100-8220 (JP)

(56) References cited:

EP-A1- 1 734 145
US-A- 3 825 364

WO-A1-2005/014979
US-A- 5 780 116

Note: Within nine months of the publication of the mention of the grant of the European patent in the European Patent
Bulletin, any person may give notice to the European Patent Ofce of opposition to that patent, in accordance with the
Implementing Regulations. Notice of opposition shall not be deemed to have been led until the opposition fee has been
paid. (Art. 99(1) European Patent Convention).
Printed by Jouve, 75001 PARIS (FR)

EP 2 270 258 B1
Description
BACKGROUND OF THE INVENTION
5

Field of the Invention

10

[0001] The present invention relates to high-reliability metal sealing materials used in sealing devices of turbines, in
particular, steam turbines of combined cycle power plants, conventional thermal power plants, atomic power plants and
the like. A turbine metal sealing material as described in the preamble portion of patent claim 1 is known, e.g., from WO
2005/014979 A1.
Background Art

15

20

25

30

35

40

45

50

[0002] The work efficiency of a steam turbine used in a power generation plant is affected by an amount of a fluid that
rotates a turbine blade to generate a motive force (rotating torque); accordingly, performance of a sealing technology
that reduces an amount of a fluid leaking from a gap between a stator and a rotor of a turbine determines performance
of the turbine. The sealing technology is expected to have a function (abradability) by which even in the worst case
where the stator and the rotor come into contact, without damaging both the stator and rotor, only a sealing material is
scrubbed and reduced in thickness. Owing to the abradability of the sealing material disposed between the stator and
rotor, a gap between the stator and rotor can be reduced to zero without limit, and thereby an amount of a fluid leaking
from the gap can be neared zero; accordingly, the work efficiency of the turbine can be largely improved.
[0003] As to the sealing technology, in particular, a porous coating layer, for example, JP. 61-171969A discloses a
sealing layer made of porous metal (density ratio: 26 to 40%, 60 to 74% in terms of porosity), and, further, discloses to
dispose, on the outermost surface portion thereof, a surface layer containing ceramic microparticles to impart corrosion
resistance to a working fluid. An object thereof is to prevent "self-erosion" of a sealing material owing to particle detachment
from a porous metal sealing material and it is disclosed that the outermost layer containing ceramic microparticles formed
on a surface layer exerts its effect of preventing particles from detaching. A target is a turbomachine, but there is no
description meaning a steam turbine environment.
[0004] In JP 2005-330586A, a metal bond layer of thermal barrier coating (TBC) for gas turbines is formed into a two
layer structure having a lower layer and an upper layer, and the upper layer is formed porous (porosity: 3 to 4%) and
integrated with a ceramic top layer to improve the heat endurance of the TBC. In this example, in order to alleviate
thermal stress, the porosities are gradually varied through the lower layer and upper layer of the metal bond layer and
more up to the ceramic top layer. However, there is such a large difference as about 1: 10 between thermal expansion
coefficients of the ceramic layer and the metal bond layer; accordingly, the thermal stress tends to be increased. JP
2005-330586A intends to relax thermal stress of a metal bond layer of a thermal barrier coating (TBC) for gas turbines,
but not of a metal sealing material of the present invention.
[0005] JP 2007-327139A discloses, as to a ceramic seal, a high temperature sealing material where a dysprosia
(Dy2O3)-stabilized zirconia (ZrO2) material (DySZ) that is a top ceramic layer is made porous so as to have the porosity
of 15 to 45% and integrated with a dense undercoat metal layer to form a two layer structure and that can be used up
to 1200C. JP 2007-327139A intends to provide a ceramic sealing material made of a ceramic up to 1200C, but not of
a metal sealing material of the present invention.
[0006] JP 09-67662A discloses, as to a ceramic coating member, a two-layer structure where a top ceramic layer is
densified so that the porosity may be 0 to 5% and an underlayer ceramic layer is made porous so as to have the porosity
of 20 to 30% to alleviate thermal stress. Similarly to JP 2005-330586 A, there is a large difference of about 1:10 between
thermal expansion coefficients of the ceramic layer and the metal bond layer; accordingly, a ceramic layer is formed
into two layers to alleviate thermal stress. JP 09-67662A discloses ceramic layers different in porosity to relax thermal
stress of a ceramic coating member, but not of a metal sealing material of the present invention.
[0007] WO 2005/014979 A1 as well as US 3 825 364 A each disclose a turbine metal sealing material used in a
sealing device for reducing a fluid leaking from a gap between a stator and a rotor of a turbine, wherein the metal sealing
material comprises a porous metal layer and the porous metal layer comprises a surface layer directly coming into
contact with a working fluid and a lower layer lying thereunder, wherein the porosity of the surface layer is smaller than
the porosity of the lower layer.
SUMMARY OF THE INVENTION

55

[0008] An object of the present invention is to provide a sealing material for a sealing device excellent in abradability,
steam resistance (for example, steam resistance heat cycle property assuming stop and start) and long-term durability
under a steam temperature, which are an original object of a metal sealing material.

EP 2 270 258 B1

[0009] A turbine metal sealing material of the present invention is a metal sealing material used in a sealing device
that reduces a fluid leaking from a gap between a stator and a rotor of a turbine, wherein the metal sealing material has
a porous metal layer, the porous metal layer includes a surface layer directly coming into contact with a working fluid
and a lower layer thereunder, and the porosity of the surface layer is lower than the porosity of the lower layer.
[0010] According to the present invention, a sealing material for a sealing device excellent in abradability, steam
resistance (for example, steam resistance heat cycle property assuming stop and start) and long-term durability under
a steam temperature, which are an original object of a metal sealing material, can be provided.
BRIEF DESCRIPTION OF THE DRAWINGS

10

[0011]

15

20

25

FIG. 1 and 2 show embodiments of the present invention, wherein Fig. 1A shows an example where a sealing
material of the present invention is disposed on a rotor side (a rotor side), and Fig. 1B shows an example where
the sealing material is disposed on a stator side (a casing side).
FIG. 2 shows an outline drawing of a high-temperature wear test that is used to evaluate the abradability at temperatures up to a steam temperature of a steam turbine.
FIG. 3 shows a plate thickness (d) of a ring material 7 and a groove width (D) of a groove formed in a porous metal layer.
FIG. 4 shows results of tests conducted by further expanding a range of the porosity of the porous metal layer at a
temperature of 600C.
FIG. 5 together shows results of tests evaluating characteristics.
FIG. 6A, 6B, 6C and 6D show schematic sectional views of a sealing material of the present invention.
FIG. 7 shows relationship between porosities and hardness of prepared coating films.
FIG. 8 shows an appearance of a seal portion of a simulated rotor to which a sealing material of No. 3 (Example 3)
in Table 3 is disposed.
FIG. 9 illustrates a steam turbine rotor provided with a sealing material of No. 3 (Example 3) in Table 3 and a labyrinth
sealing device.
FIG. 10 shows a sectional view of an actual machine of an 800 MW class high to medium pressure rotor steam
turbine to which a sealing material of No. 3 (Example 3) in Table 3 is disposed.

30

DESCRIPTION OF SYMBOLS

35

[0012] 1 ... Rotor, 2 ... Casing, 3 ... Fin, 4 ... Stator blade, 5 ... Sealing material, 6 ... Bar material (Fixing piece), 7 ...
Ring material (Movable piece), 8 ... Heater, 11 ... Base material, 12 ... Underlayer, 16 ... High pressure rotor blade, 17 ...
Medium pressure rotor blade, 18 ... High pressure inner wheel chamber, 19 ... High pressure outer wheel chamber,
20 ... Medium pressure inner wheel chamber, 21 ... Medium pressure inner wheel chamber, 22 ... Medium pressure
outer wheel chamber, 25 ... Flange, Elbow, 28 ... Main steam inlet, 33 ... High to medium pressure rotor shaft, 38 ...
Nozzle box, 43 ... Bearing, 51 ... Top layer portion of a sealing material of the present invention, 52 ... Lower layer of a
sealing material of the present invention, 61 ... Labyrinth sealing device.

40

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

45

50

55

[0013] An example of an embodiment of the present invention is shown in FIG. 1. In FIG. 1A, an example where a
sealing material 5 involving the present invention is disposed to a rotor 1 that is a rotating portion coping with fins 3
disposed to a casing 2 is shown. In FIG. 1B, an example where a sealing material 5 involving the present invention is
disposed to a casing 2 coping with fins disposed to a tip end of a rotor blade 4 is shown.
[0014] The sealing material is a porous metal layer and the porosity thereof is a material parameter. In a porous metal
layer, an MCrA1Y alloy as a main component and hexagonal boron nitride (h-BN) can be used. The MCrA1Y alloy
contains 15 to 30% of Cr, 6 to 15% of A1, and 0.3 to 1.0% of Y, the balance being composed of either one of Ni and Co
or both thereof. The thermal expansion coefficient of a porous metal layer is 13 3 10-6 and is not much different from
the thermal expansion coefficient (13 to 15 3 10-6) of ferrite steel constituting steam turbine rotors, blades and casings;
accordingly, there is no need to consider relaxation of thermal stress. Furthermore, in a steam turbine that is a target of
the present invention, the maximum temperature is 700C; accordingly, no ceramic material is required, and the metal
sealing material can secure sufficient heat resistance.
[0015] In the present invention, requirements necessary as a sealing material for steam turbines, that is, (1) abradability
in the temperature range up to a steam temperature of a steam turbine, (2) steam resistance heat cycle of start and
stop (after moisture impregnation at the time of stop, repetition of heating to a steam temperature and cooling therefrom),
and (3) endurance to a long term exposure at a steam temperature were investigated, and porous metal layers satisfying

EP 2 270 258 B1

10

15

all of the requirements were found.

[0016] FIG. 2 shows an outline drawing of a high-temperature wear test used to evaluate abradability at temperatures
up to a steam temperature of a steam turbine. A porous metal layer was disposed on a surface of a bar material 6 coping
with a ring material 7 on a rotation side and heated to a predetermined temperature by a heater 8, and a test was started.
The number of rotation of the ring material 7 (outer diameter : 25 mm) was set at 6000 rpm and, with an indentation
weight of the bar material 6 (103 10340 mm) gradually increasing, the bar material 6 was indented up to 80% of a
thickness of the porous metal layer. As the results of the tests, in the case where the abradability is deficient, the ring
material and the porous metal layer caused sticking, and in the case where the abradability is excellent, the sticking of
the ring material and the porous metal layer was not at all found and the porous metal layer was ground by the ring material.
[0017] FIG. 3 shows a plate thickness (d) of the ring material 7 and a groove width (D) of a groove formed by indenting
the ring material 7 in the porous metal layer disposed on a surface of the bar material 6. As an abradable property
showing a degree of the abradability, a ratio (d/D) of a plate thickness (d) of the ring to a groove width (D) formed on
the porous metal layer was used.
[0018] When the abradability is excellent, the abradable property (d/D) shows a value close to 1.0. The tests were
conducted at the respective temperatures of room temperature (RT), 400, 500, 600 and 700C
[Table 1]
Table 1 Abradable Property

20

25

30

35

40

45

50

55

Temperature (C)
Porosity (%)

RT

400

500

600

700

60

0.51)

0.51)

0.51)

0.51)

0.51)

65

0.61)

0.61)

0.61)

0.61)

0.61)

67

0.8

0.8

0.8

0.8

0.8

70

0.9

0.9

0.9

0.9

0.9

75

0.9

0.9

0.9

0.9

0.9

1): partial sticking

[0019] In Table 1, data of the test results are shown. In porous metal layers having a porosity of 60 or 65%, at all
temperatures, partial sticking was found between a ring material and the porous metal layer, and d/D was 0.5 and 0.6.
On the other hand, in porous metal layers having a porosity of 67, 70 or 75%, at all temperatures, partial sticking was
not found between a ring material and the porous metal layer, and d/D was 0.8 or more and the abradability was good.
[0020] FIG. 4 shows results when tests were conducted by further expanding a range of the porosity of the porous
metal layers at a temperature of 600C. At the porosity of 55%, remarkable sticking of the porous metal layer to the ring
material is caused and the porous metal layer is not at all ground. At the porosity of 77%, a groove wall of the porous
metal layer ground by the ring material falls and thereby the groove is collapsed. Results like this showing similar tendency
were obtained also in tests at other temperatures.
[0021] As the results of the above-mentioned tests, it was found that in a range from room temperature to 700C,
which is assumed to be a use condition of a stem turbine, a range where the porosity of the porous metal layer is 60 to
75% is excellent. It was found that in the range, the abradability (d/D) is 0.8 to 0.9 close to 1, that is, is very good.
[0022] In the next place, an evaluation of (2) the steam resistance heat cycle of the start and stop (repetition of heating
up to a steam temperature and cooling therefrom after moisture impregnation at the time of stop) was conducted. The
heat cycle where a porous metal layer is heated up to 700C from a state immersed in water, held there for about 10
min, and put again in water was conducted. The number of repetition was 500 times. As the result thereof, in the case
where the porosities of the porous metal layers are 55, 60 and 65%, no abnormality was found of the porous metal
layers. However, in the case where the porosities are 70 and 75%, after repetition of 100 times, a surface portion was
locally peeled (pitching damage), and as the number of repetitions increases, the number of occurrences and damage
depth increased. In the case of 77%, the degree of damage further worsened and a part of the porous metal layers was
completely peeled.
[0023] In an actual turbine, while, when a steam turbine comes to stop, a dew temperature of steam goes down to
generate moisture and a sealing portion is partially immersed in water, when the steam turbine is started, a temperature
goes up with the moisture contained in the sealing portion, and, in the porous metal layer high in porosity, since a bonding
force between individual particles is small, damaging and peeling proceed locally from a surface portion. In the actual
turbine, a steam flow rate is considered to synergetically work so that local peeling (pitching damage) of a surface portion
may be a starting point of the peeling; accordingly, the porosity is desirable to be inhibited from becoming too high.

EP 2 270 258 B1

10

15

20

25

30

35

40

45

50

55

Accordingly, on a surface portion that comes into contact with steam, it is desirable to dispose a porous metal layer
having the porosity of 60 to 65%.
[0024] Then, (3) the endurance against a long term exposure at a steam temperature was evaluated by conducting
a long term exposure test under conditions of normal pressure and 700C by assuming a steam temperature (700C)
of a steam turbine. Each of porous metal layers having the porosities of 55, 60, 65, 67, 70, 75 and 77% was subjected
to a test for 1000 hr. As the results thereof, all porous metal layers were free from damages such as peeling and healthy.
[0025] In FIG. 5, experimental results of the (1) to (3) are shown all together. In FIG. 5, the porous metal layers having
the porosities of 60 to 65% show characteristics where the abradable property of (1) is about 0.6. However, in a single
layer structure of the porous metal layer in the range (a range indicated by a mark I), when a rotor and a stator come
into contact, sticking is caused and thereby sufficient sealing characteristics cannot be obtained. Furthermore, the porous
metal layers having the porosities of 67 to 75% exhibit characteristics where the abradable property of (1) is 0.8 to 0.9.
However, in a single layer structure of the porous metal layers in the range (a range indicated by a mark II), the steam
resistance heat cycle characteristics of (2) are poor; accordingly, the local peeling (pitching damage) is caused on a
surface portion during use, the surface irregularity becomes larger to result in lowering the sealing characteristics.
[0026] In this connection, a high endurance sealing material involving the present invention is formed into a two layer
structure made of a coating layer and a lower layer, wherein the coating layer uses a porous metal layer (in the range
shown by a mark I) excellent in the (2) steam resistance heat cycle characteristics, and the lower layer that is disposed
thereunder and not exposed directly to steam uses a porous metal layer (in the range shown by a mark II) that is poor
in the (2) steam resistance heat cycle characteristics but has excellent characteristics of 0.8 to 0.9 of abradable property.
Both of the coating layer and lower layer have sufficient characteristics of (3) the endurance against long term exposure
at a steam temperature.
[0027] In the high endurance sealing material of the present invention, a surface layer portion effectively works to (2)
the steam resistance heat cycle characteristics, and, in the case where the rotor and stator come into contact, although
an initial contact occurs on a surface layer portion, when the contact portion in due time reaches a lower layer, the
abradable property shows excellent characteristics of 0.8 to 0.9; accordingly, both of a portion that comes into contact
and a portion that does not come into contact show excellent sealing characteristics as a sealing material over a long term.
[0028] FIGS. 6A to 6D show a schematic sectional view of a sealing material of the present invention. In a sealing
material 5 of the present invention, a porous metal layer has a two layer structure constituted of I of a surface layer
portion 51 and II of a lower layer 52, wherein the porosity of I of the surface layer portion 51 is 60 to 65%, the porosity
of II of the lower layer 52 is 67 to 75%. In FIG. 6A, the sealing material 5 is disposed on a base material 9 via an
underlayer 10. In FIG. 6B, there is no undercoat layer 10 and a porous metal layer constituted of I: a surface layer portion
51 and II: a lower layer 52 is directly disposed on a base material 9. In FIG. 6C, a plurality of porous metal layers
constituted of I: a surface layer portion 51 and II: a lower layer 52 is laminated and disposed on a base material 9 via
an undercoat layer 10. In FIG. 6D, in a configuration of FIG. 6C, without an undercoat layer, a porous metal layer obtained
by laminating a plurality of layers is directly disposed on a base material 9. In the sealing materials 5 of the present
invention, FIGS. 6B and 6D can be used in a portion of which the temperature is relatively low, and, in FIGS. 6C and
6D, when used in a portion readily generating moisture owing to a decrease in a dew point of steam when a steam
turbine stops, even when a porous metal layer (constituted of I of a surface layer portion 51 and II of a lower layer 52)
of a surface portion of the present invention is damaged, a porous metal layer (constituted of I of a surface layer portion
51 and II of a lower layer 52) therebelow appears and is able to exert an advantage of the present invention. The number
of repetition of lamination was taken as two for the description, but three or more can also provide the same advantage.
[0029] A porous metal layer I and a porous metal layer II are produced by a spray coating process, particularly
preferably, by a plasma spraying process. A spraying raw material is preferably a powder containing a CoNiCrA1Y alloy
as a main component, hexagonal boron nitride (h-BN) that is a high temperature solid lubricant, and polyester, wherein
it is preferable that h-BN is contained in the range of 3 to 7% by mass and the polyester is contained in the range of 15
to 25% by mass. In particular, relationship between an addition amount of the polyester that is a material for forming
pores and the porosity of a coated film is important. A sprayed film is constituted of a CoNiCrAIY alloy, h-BN, and
polyester. Among the components, the polyester sublimates and disappears when heated at 400 to 500C and thereby,
in a sprayed film, the polyester portion becomes a vacant portion. Accordingly, porous metal layers different in porosity
according to the present invention are produced by heating sprayed films different in polyester content with spraying
powders different in polyester content. As an example, with a 9MB gun (trade name, manufactured by Sulzer Metco
Ltd.) and under the conditions of Ar-H2 mixed gas, output power 40 kW and a spraying distance 125 mm, at 17% of
polyester content to spraying powder, a sprayed film having a porosity of 60% was obtained; at 19%, a sprayed film
having a porosity of 65%; and at 24%, a sprayed film having a porosity of 75% were also obtained.
[0030] Furthermore, as a means for forming films different in porosity in the present invention, there is also a method
of controlling spraying conditions. With a 9MB gun (trade name, manufactured by Sulzer Metco Ltd.) and under the
conditions of Ar-H2 mixed gas, output power: 45 kW and a spraying distance: 125 mm, at a polyester content of spraying
powder of 17%, a sprayed film having a porosity of 55% was obtained; at 19%, a porosity of 60%; and at 24%, a porosity

EP 2 270 258 B1

10

15

20

25

of 67%. What is described here is an example of a production method of the present invention, as a spraying method,
either one of high velocity oxygen fuel (HVOF) spraying and air plasma spraying can be conducted, and the spraying
conditions are also an example.
[0031] The hardness of the coated film was measured by the use of a Superficial Tester under a weight of 15 kg. In
the hardness measurement, the hardness was measured at 7 points and an average value of 5 points excluding the
minimum and maximum values was adopted. The porosity was obtained by image analysis from observation results of
sectional structures of films with an optical microscope. In the image analysis, an area rate of a CoNiCrAlY alloy portion
that was seen white was measured and an area rate of the other portion obtained by calculation was taken as the
porosity. The porosity was measured after heat treatment in the range of 400 to 500C. By heat treatment, polyester
sublimates and disappears and forms voids in a film. Furthermore, h-BN in the film is not seen white with an optical
microscope and is difficult to differentiate from voids; accordingly, it is treated as voids. In the porosity measurement,
sectional structure observation was conducted at 3 points of the same test piece and an average value of measurements
at the 3 points was adopted.
[0032] FIG. 7 shows relationship between the porosities of the prepared coated films and hardness thereof. In the
present invention, the porous metal layer I is differentiated from the porous metal layer II based on the porosity. However,
as shown in FIG. 7, the porous metal layer I has the hardness of 77 to 74 and is differentiated from the porous metal
layer II that has the hardness of 74 to 65.
[0033] The underlayer shown in FIG. 6 is not particularly restricted. However, as a component thereof, a heat-resistant
metal such as an MCrAIY alloy, a Ni-A1 alloy or a Ni-Cr alloy is preferred and a relatively dense coated film having the
porosity of 5% or less is preferred. A base material is, for example, 12Cr steel used as a rotor material, airfoil material,
and CrMoV steel for a casing material.
[0034] Examples and comparative examples of the present invention will be detailed below.
[Table 2]
Table 2 Characteristics Comparison between the Present Inventions Examples and Comparative Examples (Surface
layer portion:0.3mm, Lower layer:1.7mm)
No

Surface layer
portion

Lower layer

Abradable
property

Steam
resistance

Porosity (%)

Porosity (%)

55

60

Comparative
examples

75

60

55

60

65

67

&

Present
invention

70

&

Present
invention

75

&

Present
invention

77

Comparative
examples

10

65

55

11

60

12

65

13

67

&

Present
invention

14

70

&

Present
invention

30

35

40

45

50

Total
evaluation

55

Remark

EP 2 270 258 B1
(continued)
No

Surface layer
portion

Lower layer

Abradable
property

Steam
resistance

Total
evaluation

Remark

Porosity (%)

Porosity (%)

15

75

&

Present
invention

16

77

Comparative
examples

17

67

55

18

60

19

65

20

67

21

70

22

75

23

77

10

15

20

s: Excellent s: Excellent
: Partial sticking 3 : Surface layer peeling
3 : Sticking
25

30

[0035] In Table 2, characteristics of sealing materials are shown by comparing Examples of the present invention and
Comparative Examples thereof. It was found that, while Nos. 6 to 8 and 13 to 15 in Table 2 respectively show the sealing
materials of Examples of the present invention and have excellent or almost excellent characteristics in both of the
abradable property and steam resistance, Nos. 1 to 5 and 9 to 12, which are Comparative Examples, are rejected in
either one of the abradable property or steam resistance, that is, do not reach characteristics adequate to use.
[Table 3]
Table 3 Characteristics of the Present Invention
No

35

40

45

Surface layer portion

Lower layer

Abradable
property

Steam resistance

Porosity (%)

Thickness (mm)

Porosity (%)

Thickness (mm)

60

0.3

67

1.7

60

70

60

0.3

75

1.7

60

0.6

75

2.4

60

0.1

75

0.2

65

0.3

67

1.7

65

0.3

70

1.7

65

0.3

75

1.7

65

0.1

75

0.2

50

55

[0036] Table 3 shows an example of Examples of the present invention. All Examples show good results of both
characteristics of abradability and steam resistance. When a thickness of an entire porous metal layer of the present
invention is 0.3 mm or less, the abradable property is not fully exerted, and, when the thickness is 3.0 mm or more, a
gap is too large. Accordingly, a thickness of the entire porous metal layer is preferable to be in the range of 0.3 to 3.0
mm. Furthermore, as to thicknesses of the porous metal layer I and the porous metal layer II, a ratio of the porous metal
layer I to the porous metal layer II (I/II) is preferably in the range of 0.1 to 1.0. This is because when the ratio is 0.1 or
less, the steam resistance owing to the porous metal layer I decreases, and, when the ratio is 1.0 or more, the abradable

EP 2 270 258 B1

10

15

20

property owing to the porous metal layer II is not sufficiently exerted.

[0037] FIG. 8 shows an appearance of a seal portion of a simulated rotor to which a sealing material of No. 3 (Example
3) in Table 3 is disposed. FIG. 8 shows a constitution where a sealing material 5 of the present invention is disposed to
a portion corresponding to a rotor 1 of FIG. 1A. A method for producing a sealing material was conducted in such a
manner that a rotor was attached to a rotary jig and, with the rotor rotating at a predetermined rotation number, a spraying
process was applied. By the use of the simulated rotor, combinations shown in schematic diagrams of FIGS. 1A and
1B were subjected to room temperature rotation tests. The rotation number was set at 4000 rpm. By disposing a sealing
material, a gap can be made smaller (for example, from 0.8 mm to 0.26 mm). As the result thereof, a leakage amount
from the gap could be reduced by about 30%. Furthermore, even in a test where the gap was made further smaller, any
abnormality was not recognized during the test, also in the observation result after the test, a wear mark owing to fins
was recognized on the sealing material, that is, it was confirmed to have an excellent abradable property.
[0038] FIG. 9 illustrates appearances of a labyrinth sealing device 61 to which a sealing material 5 of No. 3 (Example
3) in Table 3 is provided and a rotor 1. In FIG. 9A, a sealing material 5 of the present invention was provided to the rotor
1, and, in FIG. 9B, a sealing material 5 of the present invention was provided to a seal stator 2. These sealing materials
5 of the present invention can reduce a gap in combination with an opposing fin 3 to the minimum of zero. When a
sealing material of the present invention is provided in a gap between a stator and a rotor of a steam turbine, the gap
can be made zero without limit over a long time, a fluid leaking from the gap can be made close to zero, which can
greatly contributes to efficiency improvement over a long term.
[0039] FIG. 10 shows an actual machine of an 800 MW high to medium pressure rotor steam turbine to which a sealing
material of No. 3 (Example 3) in Table 2 is disposed. A method for producing a sealing material was conducted in such
a manner that a rotor was attached to a rotary jig and with the rotor rotating at a predetermined rotation number a
spraying process was applied. Other plasma spraying conditions are the same as that mentioned above. According to
operation test results due to the actual machine, it was found that an improvement of about 1 % in working efficiency
of a steam turbine can be expected from the sealing material of the rotor.

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Claims
1.

A turbine metal sealing material used in a sealing device for reducing a fluid leaking from a gap between a stator
and a rotor of a turbine,
wherein the metal sealing material comprises a porous metal layer and
the porous metal layer comprises a surface layer directly coming into contact with a working fluid and a lower layer
lying thereunder, wherein
the porosity of the surface layer is smaller than the porosity of the lower layer, characterized in that the porosity
of the surface layer is 60 to 65% and the porosity of the lower layer is 67 to 75%.

2.

The turbine metal sealing material according to claim 1, wherein the porous metal layer comprises, as a main
component, an MCrAIY alloy where M is either one of Ni and Co or both thereof, and hexagonal boron nitride (h-BN).

3.

The turbine metal sealing material according to claim 2, wherein the MCrAIY alloy comprises 15 to 30% of Cr, 6 to
15% of Al and 0.3 to 1.0% of Y, the balance comprising either one of Ni and Co or both thereof.

4.

The turbine metal sealing material according to claim 1, wherein a thickness of the porous metal layer is in the range
of 0.3 to 3.0 mm, and a ratio of the surface layer to the lower layer is in the range of 0.1 to 1.0.

5.

The turbine metal sealing material according to claim 1, wherein the metal sealing material is used in a steam turbine.

6.

A steam turbine, comprising a metal sealing material according to claim 1.

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Patentansprche
1.
55

Metallischer Dichtungswerkstoff fr Turbinen, verwendet in einer Dichtungsvorrichtung zur Reduzierung eines Fluidaustritts aus einem Spalt zwischen einem Stator und einem Rotor einer Turbine,
wobei das metallische Dichtungsmaterial eine porse Metallschicht aufweist, und die porse Metallschicht eine
Oberflchenschicht, die direkt mit einem Arbeitsfluid in Kontakt kommt, und eine darunterliegende Schicht aufweist,
wobei die Porositt der Oberflchenschicht kleiner ist als die Porositt der unteren Schicht,
dadurch gekennzeichnet, dass die Porositt der Oberflchenschicht 60 bis 65% betrgt und die Porositt der

EP 2 270 258 B1
unteren Schicht zwischen 67 bis 75% betrgt.
2.

Metallischer Dichtungswerkstoff fr Turbinen nach Anspruch 1, wobei die porse Metallschicht als Hauptkomponente
eine MCrAlY-Legierung aufweist, wobei M entweder Nickel oder Kobalt ist oder beides, sowie hexagonales Bornitrid
(h-BN) aufweist.

3.

Metallischer Dichtungswerkstoff fr Turbinen nach Anspruch 2, wobei die MCrAlY-Legierung 15 bis 30% Chrom, 6
bis 15% Aluminium und 0,3 bis 1,0% Yttrium aufweist, und der Rest entweder Nickel oder Kobalt oder beide aufweist.

4.

Metallischer Dichtungswerkstoff fr Turbinen nach Anspruch 1, wobei die Dicke der porsen Metallschicht in dem
Bereich zwischen 0,3 und 3,0 mm liegt, und das Verhltnis der Dicke der Oberflchenschicht zu der Dicke der
unteren Schicht im Bereich zwischen 0,1 bis 1,0 liegt.

5.

Metallischer Dichtungswerkstoff fr Turbinen nach Anspruch 1, wobei das metallische Dichtungsmaterial in einer
Dampfturbine verwendet wird.

6.

Dampfturbine mit einem metallischen Dichtungsmaterial nach Anspruch 1.

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Revendications
1.

Matriau dtanchit mtallique pour turbine utilis dans un dispositif dtanchit pour rduire une fuite de fluide
provenant dun espace entre un stator et un rotor dune turbine,
le matriau dtanchit mtallique comprenant une couche mtallique poreuse et la couche mtallique poreuse
comprenant une couche de surface venant directement en contact avec un fluide de travail et une couche infrieure
situe en-dessous,
la porosit de la couche de surface tant infrieure la porosit de la couche infrieure, caractrise en ce que
la porosit de la couche de surface est comprise entre 60 % et 65 % et la porosit de la couche infrieure est
comprise entre 67 % et 75 %.

2.

Le matriau dtanchit mtallique pour turbine selon la revendication 1, dans lequel la couche mtallique poreuse
comprend, comme composant principal, un alliage de MCrAlY o M est soit du Ni ou du Co soit les deux, et du
nitrure de bore hexagonal (h-BN).

3.

Le matriau dtanchit mtallique pour turbine selon la revendication 2, dans lequel lalliage de MCrAlY comprend
entre 15 % et 30 % de Cr, entre 6 % et 15 % dAl et entre 0.3 % et 1.0 % de Y, le reste tant constitu soit de Ni
ou de Co soit des deux.

4.

Le matriau dtanchit mtallique pour turbine selon la revendication 1, dans lequel une paisseur de la couche
mtallique poreuse est comprise entre 0.3 et 3.0 mm et un rapport entre la couche de surface et la couche infrieure
est compris entre 0.1 et 1.0.

5.

Le matriau dtanchit mtallique pour turbine selon la revendication 1, dans lequel le matriau dtanchit
mtallique est utilis dans une turbine vapeur.

6.

Une turbine vapeur, comprenant un matriau dtanchit mtallique selon la revendication 1.

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REFERENCES CITED IN THE DESCRIPTION
This list of references cited by the applicant is for the readers convenience only. It does not form part of the European
patent document. Even though great care has been taken in compiling the references, errors or omissions cannot be
excluded and the EPO disclaims all liability in this regard.

Patent documents cited in the description

WO 2005014979 A1 [0001] [0007]

JP 61171969 A [0003]
JP 2005330586 A [0004] [0006]

17

JP 2007327139 A [0005]
JP 9067662 A [0006]
US 3825364 A [0007]