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Contents
Palladium Alloy Pinning Wires for Gas Turbine Blade Investment Casting 117
Abstracts 133
and J. P. Hartley
PLM Redfearn, Barnslep England
Refractory ceramics have long fonned a vital part of the glass making and
glassprocessing industries. Due to market pressures these industries are mov-
ing towards increasingly higher quulityproducts and progressively improved
plant efiiency. However, sipzjkant improvements to the refractory ceram-
ics are dzfiult because of the range of properties which they are required
to have. This second paper on A C T M(Advanced Coating Technology) using
platinum group metals, describes the latest developments and advantages
conferred by ACTMcoatings to the various ceramic forehearth components.
Fig. 1 Standard assembly design for an ACTT"coated tri-level thermocouple assembly; the
assembly length, coating length, coating thickness and coating material are selected according to
customer requkmentu
Indeed, for the highest quality glass products, only be justified for the highest added-value
such as optical and lens glasses, this is already products. A less costly method is to clad ceramic
done. However, capital cost is high because of or molybdenum substrates with sheets of plat-
the thickness of sheet that is needed, and may inum group metals. In this way the amount of
essential to ensure that the gob weight may be rhodium-platinum coating, and particularly the
maintained within the tight tolerance band portion that had been submerged in the molten
required, for example, in the production of glass glass, was found to be in excellent condition,
containers by the NNPB (narrow neck press see Figure 2(a). The traditional clad product
and blow) process. also appeared to be good, Figure 2@).However,
ACTTMcoated sheaths are already installed further examination of the clad thermocouple
worldwide in numerous plants in full scale pro- assembly revealed a significant amount of pore
duction. The success of the coating technology development within the structure of the
is demonstrated by the service lives, now in cladding, Figure 3. This degradation is seri-
excess of 2.5 years, shown in the Table. ous since it would be expected to promote con-
siderable mechanical weakening.
Comparison between ACTTM Coated and Alloy claddings are essentially separate struc-
Traditional Sheet-Clad Assemblies tures from the underlying ceramic sheathing
The second thermocouple assembly referred and are expected to have inherent mechanical
to in the Table entered service in May 1992 at strength. When the strength is compromised,
PLM Redfearn’s Barnsley plant. Approximately as happened here, the integrity of the whole
200 mm of its mullite sheath was coated with assembly must be at risk. A reduction in the
ACTTM10 per cent rhodium-platinum to a thick- mechanical strength of the component could
ness of about 200 pn, thickening to 250 pm at result in thimble failure and loss, with conse-
the glass line. The thermocouple ran continu- quential damage to the thermocouple element.
ously until its removal following mechanical In comparison, ACTTMcoated thermocou-
damage during forehearth repair work in ple sheaths are simple composite structures.
September 1994. It had been fractured during They do not lose integrity in the same way as
the repair work in the uncoated ceramic where clad products since the mechanical strength of
it had rested within the forehearth roof. the platinum group metal coating derives from
The thermocouple assembly was visually exam- &-intimate contact with the substrate sheath.
ined, evaluated, fully destructively analysed and The ACTTMcoating had fully protected the
compared to a traditional clad tri-level thermo- underlying ceramic sheath from glass corrosion,
couple sheath with a cemented ZGS 10 per cent even at the critical aidglass interface. It had per-
rhodium-platinum cladding that had been in ser- formed successfully for 27 months in a molten
vice for several years in a forehearth at the same glass environment, and could have continued
container manufacturer (10, 11). The cladding in service.
had an original thickness of at least 500 pm. The maximum service life of an ACTTMcoated
On visual examination the ACT^^ 10 per cent thermocouple assembly is therefore still
unknown, currently being 32 months operating Glass composition and chemical homogene-
in a forehearth in Scandinavia, as shown in the ity are largely determined by control at the melt-
Table. Ultimately service life will be dictated by ing stage and during conditioning of the glass.
specific operating and environmentalconditions. However, the feeder of the forehearth is crucial
for the effective manufacture of components
Development of ACTm Technology and dictates the shape, weight, thermal homo-
for Forehearth Consumables geneity and compositional homogeneity of the
The natural development of ACTTMcoating glass gob from which the products are made.
technology was into forehearth consumables The introduction of foreign material or defects
and these applications are achieving major suc- at this stage in the manufacture will almost cer-
cess, as the following case studies illustrate. tainly have a discernable and detrimental effect
Wor,king
end
Forehearth
~
Fig. 5 Schematic diagram of glass melting furnace forehearthshowing the position of the feeder
1
mechanism at the end of the forehearth
Diagram councsy of Zedrec Glass Condmonlng
Spout Bowls
The spout bowl is located at the end of the
forehearth, see Figures 4 to 6. The glass flow- Fi% 6-
0
diagramofsfoldledlfeeder
ing down the forehearth, which may be 1200 mechanism showing the forming end com-
mm wide and 150 mm deep, is funnelled ponents: spout bowl, plunger, tube and
orifice ring
through a hole in the spout bowl into the ori-
fice ring. Therefore the ceramic bowl, especially
the leading edges of the basal hole, is subjected
to extremely erosive and corrosive conditions with other downtimes, must be beneficial. The
due to the passage of high volumes of molten followingservice experience of P L M Redfearn,
glass. Barnsley, illustrates that a spout bowl ACTTM
If erosion takes place it has a detrimental effect coated with platinum can provide these
on the maintenance of gob weight control and benefits.
in some product types defects, such as cord and The alumino-silicate bowl, installed in May
stones, may be formed. Erosion can also make 1993, was in a forehearth used for green glass
it impossible to close off the glass flow to allow production. As can be seen in Figure 7, the bowl
the orifice ring to be changed, so the whole spout was partially coated only in the most critical
bowl has to be removed and replaced. region, that is, around the exit hole. No prob-
Changing the spout bowl is a major operation, lems were reported at any time throughout its
requiring the glass in the forehearthto be “ h z e n service, although by December 1993 there were
o f f while the old bowl is removed. Installing concerns about cracks which had developed
a new bowl takes the major part of a shift, and in the refractory substrate. While not causing
re-establishment of a flow of high quality glass leakage, under normal circumstancesthe cracks
may take several hours. would have been sdliciently serious to indicate
Thus, changing the spout bowl causes major that the bowl might not survive until the next
downtime and production loss, and while it may scheduled break for maintenance. In fact the
be possible to schedule changes to coincide with ACTm coating sustained the bowl for a fi.uther
other downtimes, the true cost can be very high. full year.
Clearly anything which can extend the intervals When the bowl was finally removed at a
between changes, or improve the coincidence planned shutdown it had been in service for
20 months. The area of the bowl carrying the of the original substrate surface, allowing the
ACTTMplatinum coating was separated from glass flow to be shut off.
the bulk of the ceramic and returned for exam- The ACT^^ platinum coating on the critical
ination. section of the spout bowl had performed effec-
The ACTTMcoating was found to be intact tively. A very significant extension to its life had
over the major portion of the original surface, been achieved, and downtime, from one or more
see Figure 8. The refractory substrate was in component changes, had been eliminated. The
two pieces, resulting from cracks in the ceramic weakness, if any, lay with the refractory ceramic.
which had developed after only a few months The cracking could have presented a problem
of service. The regions of the coating that were if the ACTTMcoating had not been so stable and
not associated with any ceramic substrate crack- effective. In non-ACTTMcoated ceramics,
ing appeared to have performed superbly. In the cracked areas usually erode more rapidly than
areas where the ceramic had cracked the plat- the surrounding ceramic, and this accelerated
inum coating had even maintained the profile erosion/corrosion would traditionally have
production scheduling, ACTTM platinum coat- cal strength and thermal shock resistance
ing technology can be used for orifice rings in becomes possible, and the compromises needed
forehearths where both different sized contain- to select a ceramic are reduced.
ers and continuous runs of the same sized con- In fact ceramic substrates can now be reassess-
tainer are produced. ed, perhaps enabling alternative ceramics which
Operational benefits include improved con- have some inherently valuable property, but
trol of the gob weight and a reduction in down- which have been unusable for reasons such as
times caused by the need to change the ceramic coloration, to be chosen. Optimised refractory
orifice ring. Being able to maintain the glass ceramic substrates, compatible with ACTTM
flow between different sized containers also coating technology will yield composites hav-
avoids the need to re-establish flow, which oth- ing far higher capabilities, such as longer ser-
erwise can often result in defects in the glass. vice lives, than currently used materials. Such
issues are now being studied.
Refractory Ceramics as Substrates The quality of the surface finish of the refrac-
While many refractory ceramics are available, tories used for ACTTMcoating is important. It
current usage tends to limit the range employed is not unusual to find pores and gas holes on
within each zone of the glass melting furnace. the surface of a ceramic. In order to develop a
At the forming end, for example, the choice is surface coating with high interfacial integrity, a
dominated by variants of alumino-silicate and pre-coating preparatory stage may be required
zircon-mullite. The one selected is generally a if the initial quality is poor. This pre-process-
compromise to provide the most appropriate ing is clearly undesirable and refractory ceramic
combination of strength, thermal shock prop- manufacturers must be encouraged to supply
erties and corrosion resistance. materials with the improved quality of surface
ACT^^ technology creates a special relation- finish that is now needed.
ship with the ceramic substrate; the coatings are
enhanced by high quality refractory substrates, Conclusions
but can be diminished by poor substrates. At Current trends require glass manufacturers to
the forming end, the ACTTM coating beneficially produce better quality products, and are forc-
modifies the corrosion resistance of the com- ing them to improve efficiency. With brittleness,
posite structure. Thus, the choice of refrac- poor thermal shock resistance, high porosity
tory substrate becomes easier, particularly when and poor corrosion/erosion resistance inher-
fully coated, and selection based on mechani- ent in primary refractory ceramic containment
References
1 D. R. Coupland, Platinum Metals Rev., 1993,37, 6 G. L. Selman, J. G. Day and A. A. Bourne,
(213 62 Platinurn Metals Rev., 1974, 18, (2), 46; G. L.
2 D. R. Coupland and H. E. Hunt, Proc. Selman and A. A. Bourne, Platinum Met& Rev.,
Scandinavian Glass SOC.,Autumn 1993, Viixjo, 1976,20, (3), 86
Sweden 7 J. Stokes, Platinum Metals Rev., 1987, 31, (2),
3 Canadian Ceramic Society, 92nd Annual Meeting 54
and Convention, Montreal, Canada, 20th to 22nd 8 D. Ott and Ch. J. Raub, Platinum Metals Rev.,
February 1994 1986, 30, (3), 132; 1987, 31, (2), 64
4 Johnson Matthey PLC, European Patent
9 D. A. Toenshoff, Glass, 1992,69, (l), 21
911307,268B
5 Johnson Matthey PLC, European Patent 10 Internal Johnson Matthey Report, Nov. 1994
931300,823B 1 1 Internal Johnson Matthey Report, Dec. 1994
Although most catalytic chemical produc- either ruthenium or rhodium with a complex
tion processes use heterogeneous gas or liquid collection of additives in a mixed solvent system.
phase systems, there are a significant number Many of these processes involve platinum
of industrial processes which depend upon the group metal catalysts, and their success, at least
use of soluble platinum group metal catalysts. in part, is due to their efficient use of the cata-
Separation of catalysts from the products has lyst, single catalyst charges having long lifetimes.
been a principal hindrance to more widespread If it were easier to separate catalysts from sub-
use of these systems. strates, many more applications might be pos-
However, recently developed approaches to sible for homogeneous systems. Attempts to
the use of soluble platinum group metal cata- anchor complexes onto polymeric supports,
lysts are helping to overcome this problem and such as polystyrene and silica are reported to
to provide useful new routes to organic prod- have been only partially successful (24). Some
ucts with significant market potential, particu- new approaches which may lead to significant
larly for pharmaceuticals. On the other hand, industrial developments are considered below.
modification of heterogeneous catalysts via
adsorption of certain organic species onto their Ligand-Enhanced Biphasic
surfaces is making them more selective, and is Rhodium Catalyst System
promoting investigation of their use into areas, Catalysis at the interface between phases in a
such as stereospecific organic synthesis, which biphasic aqueouslorganic system can be
to date have been predominantly the province enhanced using a ‘promoter ligand’. This lig-
of homogeneous catalysis. and is soluble in the organic phase but insolu-
The principal commercial uses of homoge- ble in the aqueous phase, and will bind to the
neous catalysts have been recently reviewed (1). water-soluble organometallic catalyst, thereby
These include the carbonylation of methanol increasingthe catalyst concentration at the inter-
(the Monsanto acetic acid process), hydro- face between the phases.
formylation for n-butyraldehyde and 2-ethyl- In a recent example, the hydroformylation of
hexanol production (the Johnson MattheyAJnion 1-octene was studied using a water soluble cat-
Carbide/Davy McKee process), the Wacker alyst system, m(COD)Cl],/tppts (where COD
process for the oxidation of alkenes, the Dupont is cycloocta-l,5-diene and tppts is triphenyl-
process for the hydrocyanation of butadiene, phosphine trisulphonate) in a biphasic system:
the oxidation of saturated hydrocarbons and
C6HI,CH=CH2-+ C6HI,CH2CH,CH0
alkylbenzenes, for example, cyclohexane to
1-octene n-nonaldehyde
cyclohexanoneand cyclohexanol, and lastly, the
+ C6H,,CH(CHO)CH3
Shell Higher Olefins Process (SHOP) which
iso-nonaldehyde
involves catalytic oligomerisation of ethene, fol-
lowed by isomerisation and alkene metathesis. When a ‘promoter ligand’, triphenylphosphine,
A process for the production of ethylene gly- is added to this system, it binds to the water-
col from synthesis gas has been developed by soluble organometallic catalyst, thus function-
a consortium of four Japanese companies, and ing as an enabling agent. Using this technique,
the catalyst system that is used is based on the catalyst concentration is increased at the
kIOW
Q-Q-Q
Scheme I
interface between the two phases and as a result Work on polymer-supported catalyst systems
promotes an enhancement in the reaction rate is continuing and there are recent reports of
of between 10 and 50 times (5, 6). interesting selectivities. One such report
describes the remarkable synergistic effect of
Polymer-Supported Catalyst polymer-anchored bimetallic palladium-ruthe-
Systems nium catalysts in the selective hydrogenation of
Ever since the 1970s polymer-supported metal pchloronitrobenzene, see Scheme I (7).
complex catalysts have been investigated, as their When PVP-PdC1,-RuCl, (I) (PVP = poly(N-
use would facilitate the separation of catalysts vinyl-2-pyrrolidone)) is used as the catalyst for
from products at the end of the reaction. Such the hydrogenation ofpchloronitmbenzene in the
materials were hailed as a third generation of presence of 0.01 per cent of sodium acetate, and
catalysts (3), after heterogeneous and homoge- with a pal1adium:ruthenium ratio of 1:1 or 1:2,
neous systems. Polymer-supported metal com- selectivitiesof 94.1 and 94.9 ofpchloroaniline
plex catalyst systems combine reasonable activ- are obtained, respectively. When PVP-PdCl, (II)
ity with selectivity, specificity and the easy was used as the catalyst in the presence of sodium
separation of the catalyst. Although activities acetate, the normal dehydrohalogenation to ani-
are usually reduced compared with homoge- line took place, giving selectivities of up to 97.8
neous systems, every metal atom is used in the aniline. Although ruthenium species are not active
catalysis, and this gives a potential advantage both for the hydrodechlorination and the reduc-
over heterogeneous systems where only a small tion of the nitro group of the nitrochloroani-
percentage of the metal atoms (those at the sur- l i e , the ruthenium species that are formed in sim
face) are exposed to the reactants. This last fac- may inhibit the oxidative addition of the carbon-
tor can be significant when selecting the plat- chlorine bond to the active palladium centres.
inum metals catalyst systems. As the structures
of homogeneous and polymer-supported sys- Use of Glass Micro-Beads
tems are well defined, their activities can be with a Chiral Ruthenium Catalyst
modified systematically by changing the chern- Stimulated by the demands of the regulatory
ical environment of the active site much more agencies, there is an increasing market for enan-
easily than in heterogeneous systems. tiomerically pure pharmaceuticals and for
CH3-CO-CO-OCzHg
Ethyl pyruvate
- H
31
OH
CH~-C-CO-OC~HS
R(+)-ethyl lactate
Scheme 111
an overall kinetic model of this reaction is help-by labile ligands (13), see Scheme IV.
ing to contribute to a greater understanding of Treatment of a dichloromethane solution of
chiral heterogeneous catalysis. [Rh(PPh,),(nbd)] C10, (nbd = norbornadiene
= bicyclo[2,2,1] hepta-2,5-diene) containing an
Rhodium Catalysed Rearrangement equimolar amount of lY2-diphenylhydrazine
of 1,2-Diphenylhydr&e with hydrogen gas (with caution, bearing in
The complexation behaviour of lY2-diphenyl- mind the possible explosion hazard) gives a deep
hydrazine to metals has not been widely stud- red solution of [Rh(o-semidine)(PPh3),1C10,
ied, but its reactions with samarium and tung- which contains a bidentate ligand bonded to
sten complexes have resulted in either the rhodium.
formation of hydrazido complexes or cleavage It is proposed that the rearrangement involves
of the N-N bond; no rearrangement of the aro- the initial co-ordination of the 1,%-diphenyl-
matic hydrazine has been observed. It has been hydrazine as a bidentate ligand to rhodium(1).
reported recently that lY2-diphenylhydrazine Steric constraints then place the phenyl rings of
rearranges exclusively to o-semidine in the pres- the co-ordinated ligand in a perfect position
ence of square planar rhodium(1) complexes to allow the exclusive formation of o-semidine
and this reaction is catalytic when there are two via a similar mechanism to that which occurs in
cis-sites in the square plane which are occupied the acid-catalysed benzidine rearrangement.
References
1 A. W. Parkins in “Insights into Speciality Inorganic 7 Z. Yu, S. Liao, Y. Xu,B. Yang and D. Yu,J Chem.
Chemicals”, ed. D. T. Thompson, Royal Society SOC., Chem. Commun., 1995, 1155
of Chemistry, Cambridge, 1995, p. 105 8 J. M. Brown in “Insights into SpecialityInorganic
Chemicals”, ed. D. T Thompson, Royal Society
2 P. J. Davidson, R R Hignett and D. T. Thompson, of Chemistry, Cambridge, 1995, p. 123
in “Catalysis”, Spec. Per. Report, Royal Society G. C. Bond in “Insights into SpecialityInorganic
of Chemistry, London, 1977,1,369 Chemicals”, ed. D. T. Thompson, Royal Society
3 F. R. Hartley, “Supported Metal Catalysts”, of Chemistry, Cambridge, 1995, p. 63
Reidel, Dordrecht, Holland, 1985 10 K. T. Wan and M. E. Davis, Nature, 1994, 370,
4 Y. Iwasawa, “Tailored Metal Catalysts”, Reidel, (6489), 449
Dordrecht, Holland, 1986 11 J. M. Brown and S . G. Davies, Nature, 1994,370,
(6489), 418
5 D. T. Thompson, Platinum Metals Rev., 1995,39, 12 U. K. Singh, R. N. Landau, Y. Sun, C. LeBond,
(2), 62 D. G. Blackmond, S . K. Tanielyan and R. L.
6 R. V. Chaudhari, B. M. Bhanage, R. M. Augustine,.J Catal., 1995,154, 91
Deshpande and H. Delmas, Nature, 1995,373, 13 C. J. Davies, B. T. Heaton and C. Jacob, J. Chem.
(6514), 501 SOC.,Chem. Commun.,1995, 1177
Gas turbine engines find widespread use for and further increases in operating temperature,
aircraft and marine propulsion and for land- even if only marginal, can profoundly reduce
based power generation. The engines consist of the service life of these blades.
an inlet duct followed in sequence by a com- Over the years, designers have actually been
pressor section, combustion chambers, high and able to achieve higher operating temperatures
low pressure turbine sections and an exhaust at the same time as improving the service life of
duct. Gas turbine engines operate on the sim-
ple principle of converting heat energy into
mechanical work, by taking a large volume of
air, compressing it to high pressure, mixing the
compressed air with fuel and then igniting it.
Propulsion or power generation is obtained by
the very rapid expansion of this ignited fuel-
air mixture through the turbine blades.
Thermodynamic efficiency is an important
consideration in gas turbine engine design, most
particularly for those turbines destined for the
aerospace market where the power:weight ratio
and fuel efficiency are of major concern. A sig-
nificant parameter in the equations which
describe thermodynamic efficiency is the tem-
perature difference that can be achieved across
the engine. Designers of turbine engines try to
maximise the operating temperature of the tur-
bine section of the engine, or more specifically,
the high pressure turbine section. However, there
are limitations. A turbine is composed of hun-
dreds of turbine blades which rotate at very high
speed on a series of coaxial disks. Operating Fig. 1 A 2-inch long high-pressure turbine blade
suesses and temperatures are therefore very high showing some of the multiple air cooling channels
the turbine blades. This has been accomplished improve thermodynamic efficiency and, signif-
through improvements in the engineering design, icantly, reduce nitrous oxide emissions.
manufacturing techniques and by the use of The cooling channels are produced by plac-
‘superalloy’materials. A significant feature in ing ceramic cores within the mould cavity in
the engineering design has been the incorpora- which the turbine blade is cast. These ceramic
tion of special cooling systems into the high pres- cores are subsequently dissolved out of the cast
sure turbine blades, see Figures 1 and 2. These turbine blade, leaving behind the required net-
cooling systems consist of a network of chan- work of cooling channels. Precise positioning of
nels within each blade which allow relatively the ceramic cores within the mould cavity, and
cold air to be pumped at pressure through the maintenance of that position throughout an elab-
centre of the blades. The air then flows out of orate series of mould preparations, firing and
numerous small holes in the blade surfaces, blade-casting processes are vital for achieving
enveloping the turbine blade in a film of cooler blade dimensional stabilityholerances. However,
air. This causes a reduction in the operating the ceramic cores have a very high length to
temperature of the turbine blade, without there diameter ratio and are only poorly supported
being any significant reduction in the operating within the mould cavity. To overcome this dif-
temperature or efficiency of the turbine engine. ficulty pinning wires are anchored in the mould
The technology of incorporatingcooling chan- cavity wall and butt against the ceramic cores.
nels within turbine blades has traditionally been The pinning wires are used to maintain core
applied to aircraft propulsion plant. More position.
recently designers of land-based gas turbines Platinum-based materials have traditionally
are showing interest in applying this technology been used for ceramic core pinning. Seven to
to create cleaner, more efficient power gener- ten pins, each of 5 to 10 mm long are typically
ating plant. The higher operating temperatures required for a 2 inch high-pressure aero-engine
that are possible using cored turbine blades turbine blade. Platinum-based materials are
Fig. 3 Schematic of a crosgsectionthrough a prepared mould showing the pinned ceramic cores
within the wax preform and the ceramic shell mould
used because of their proven ability to maintain ufactured by the precision casting process of
ceramic core position and subsequentlydissolve investment casting, also known as the ‘lost wax
into the turbine blade without any deleterious process’. Ceramic cores for the cooling chan-
effects on the structure or properties of the blade nels are positioned within a master mould pat-
material. Oxide dispersion strengthened plat- tern. Wax is then injected into the mould cav-
inum and, more recently, pure platinum have ity to produce a preform of the turbine blade.
seen extensive application in this area. Pinning wires are then pressed through the wax
A drawback to the more widespread use of to butt against the ceramic cores within the pre-
platinum-based pinning wires is the cost of the form. Next, the preform is coated with multi-
raw material. Recognising this, Johnson Matthey ple layers of ceramic, ultimately forming a thick
Technology Centre embarked on a programme casing around the preform with the pinning
of work to develop novel pinning wire materi- wires embedded in it. The assembly is heated
als (1). This paper discusses some of the func- to melt out the wax and then tired to strengthen
tional requirements of pinning wires and shows the ceramic. The result is a ceramic shell mould
how these have been met by alloy design. So far, containing a complex ceramic core pattern which
this work has led to the development of a range is held in position by pinning wires anchored in
of commercial, novel pinning wire alloys based the ceramic shell, see Figure 3. Finally, the
on palladium and specific refractory metals (2) mould assembly is preheated prior to casting
and the acceptance of one alloy by Rolls-Royce the turbine blade.
plc. This alloy is cheaper than platinum and has Turbine blade manufacture crucially requires
been shown to give comparable performance. the nucleation and growth of precisely controlled
microstructures. The grain structure within the
Turbine Blade Manufacture turbine-blade superalloy material is frequently
Turbine blades have a complex geometry and described by terms such as ‘equi-axed’, ‘direc-
contain many areas of double curvature. tionally solidified’ and ‘single crystal’. These
Therefore the blades have to be precisely man- characterisethe grain boundary length and thus
lmmersm
level
' /' /
"/
R - 8Y.W
to survive within the molten superalloy during are more related to the melting temperature of
casting of directionally solidified aero-engine the alloying element, rather than to the melting
blades. In the first experiments the recession temperature of the alloy itself.
rates in molten superalloys of a number of dif- This initial work demonstrated that prospec-
ferent platinum and refractory metal wires, tive new pinning wire materials do not need to
including oxide dispersion strengthened plat- survive in the molten superalloy for very long
inum (the standard pinning wire material) were to be successful. In fact, it emphasised the impor-
compared. tance of rapid dissolution in order to ensure that
The experimentsrevealed that when oxide dis- no concentration of pinning wire material exists
persion strengthened platinum wire of diame- anywhere within the turbine blade.
ter 1.4 mm (more than four times the cross-sec- Following these melt exposure tests, the exper-
tional area of standard pinning wire) was dipped imental programme next examined the oxida-
into molten nickel-based superalloy to a depth tion properties of samples and evaluated their
of about 20 mm for three seconds, the wire com- high temperature stability under vacuum.
pletely dissolved, see Figure 4. By comparison, Temperatures and times of exposure were
smaller diameter platinum-rhodium and plat- selected following consultation with major aero
inum-iridium wires suffered significant disso- engine manufacturers. Oxidation tests to sim-
lution and reduction in their length. While a ulate different ranges of mould firing conditions
platinum-8 per cent tungsten alloy also suffered were performed at 850°C for 18 hours and at
dissolution, t h i s was at a much slower rate than 1075°C for 8 hours. The same samples were
for the other alloys, and it still retained its orig- then placed under vacuum at 1475°C for up
inal length. Full results of these investigations to one hour. Tests were also conducted in air at
are shown in Table I. Clearly there is a rela- 950°C for 70 minutes followed by 30 minutes
tionship between the melting temperature and under vacuum at temperatures of 1500 to
the dissolution rate. It may also be suggested 1550°C. Results are shown in Tables I1,III and
that the dissolution rates of the platinum alloys IV.Samples were assessed by weight change,
Table IV
Assessment after 70 minutes at 950°C in Air (Stage 1)
and 30 minutes at 1500 to 1550°C under Vacuum (Stage 2)
Sample 0bservations
Pd-15YoMO Oxidation to 0.04 mrn depth after Stage 1; complete removal of oxide
layer by vaporisation after Stage 2, leaving behind a Pd-rich surface region
VI
TableVI
Table
Longitudinal Stress Rupture Properties
Nickel-based Pinning &mount of pinning Test Applied Sample Average
superalloy Nire used wire in superalloy. emperature. stress, size life,
wt. Yo OC MPa hours
AAisisaa proprietary
proprietary Ni-based
Ni-basedsuperalloy
superalloy used
usedfor
for directionally
directionallysolidified
solidifiedturbine
turbineblades
blades
Pd-l5%Mopinning
XX == Pd-15Y0Mo pinningwire
wire
YY = Pd-SO%Wpinning
= Pd-20Y0w pinning wire
wirewith
with 55ppm
m Pt
Ptcoating
coating
. Bibliography
E. Savitsky, V.Polyakova, N. Gorine and N. Roshan, P. G. Boswell and K. Majumdar, “New Palladium
“Physical Metallurgy of Platinurn Metals”, Pergamon Based Alloys”, Johnson Matthey Research Centre
Press Ltd., 1978 Final Report, Project 82J2/2, October 1981
Platinum 1995
DEMAND FOR PLATINUM A RECORD HIGH
Since 1985 Johnson Matthey has been the manufacture of autocatalysts, with the
publishing an annual survey of the com- U.S.A. consuming an increased 32 per cent
mercial aspects of the platinum group met- bringing the total for 1994 to 1.86 mil-
als, with particular emphasis on platinum. lion ounces. This was followed closely by
Following uadition, the launch of “Platinum the Japanese jewellery industry with its
1995” took place in London during eleventh consecutive year of growth. An
Platinum Week and was well received by the increase in the fabrication of Platinum 1000
analysts, financial journalists, mining engi- jewellery resulted in escalatingdemand with
neers and industrialists who attended. sales spirallingby 100,000 ounces to reach
Based, in essence, on information gathered 1.45 million ounces. Growing appreciation
from numerous sources worldwide and well of platinum jewellery in North America has
supported by statistical data, “Platinum encouraged established manufacturers to
1995”details the progress of the platinum step-up production and also new partici-
metals during 1994 and the events which pants to develop products.
afFected both supply and demand, with fore- In addition to dealing with industrial and
casts for the coming year. investment demand, “Platinum 1995”has
The price of platinum during the year devoted a chapter to mining and explo-
averaged $405.25per ounce, an eight per ration, principally in South Africa. It also
cent increase over 1993,peaking to $427.50 contains special features covering mining
in July. This was upheld by factors such the platinum group metals in Russia, world-
as economic recovery, speculation and spas- wide coverage of emissions legislation and
modic uncertainty over supply. However, the use of platinum in the car. On a lesser
prices began a further climb in late March scale, there are also surveys of the other
1995 and soared to reach a four year high platinum group metals markets, in partic-
of $459 per ounce on 4th April 1995,fol- ular palladium.
lowing the announcement of a new plat- This fifty-two page analysis of trends in
inum-based technology for the reduction the platinum group metals market world-
of ozone and carbon monoxide. wide is regarded as the authoritative source
Supplies of platinum during 1994 rose by of such information and is highly respected
three per cent to 4.53million ounces. A fall throughout the financial world. If you would
in output from South Africa was offset by like to receive your free copy of “Platinum
a significant increase in exports from Russia. 1995” or be added to its distribution list,
Supply and demand were closely matched. please contact Alison Cowley, Johnson
The motor industry again led the way in Matthey PLC, 78 Hatton Garden, London
the consumption of platinum, chiefly for EClN 8JP, England; F ~ :x0171-269-8389.
Platinum resistance thermometers have been inum target onto alumina substrates.The mean-
selected for use as the basic instrument to define der shape was then drawn by laser evaporation
and reproduce the International Temperature of the layer, using a pulsed Q-modulated
Scale (ITS-90) (1, 2). The upper limit of the Nd:YAG laser (h = 1.06 p)with pulse repe-
temperature region which they define has tition rate of 20 Hz and train energy (for 10
increased by some 300°C when compared to pulses in a train) of 50 to 60 mJ. This technique
the previous International Temperature Scale, is faster and more cost effective, and avoids
IPTS-68. On the ITS-90 scale the upper limit the mask writing and chemical treatment that
is defined by the freezing point of silver, are necessary for lithographic patterning.
961.78"C. Thin film platinum sensors have However, laser treatment of the layer para-
demonstrated that they are able to meet the meters is not controllable, and so the final char-
requirements of industrial operation, but ITS- acteristics of the layer cannot be predicted.
90 has underlined their shortcomings, and
improvements to production processes are TemperatureIResistance Values
required in order to enhance their performance, of the Layer
if ITS-90 is to be approached. An assessment of the purity of the platinum
target was made in accordance with ITS-90.
Thin Film Preparation It was found that the resistance ratio at the boil-
Thin f ilm sensors are usually produced by the ing point of water, W(H,O b.p.) > 1.3927 (W
deposition of platinum onto a suitable substrate. = Rlwoc/%oc, where R is the electrical resistance
In order to avoid any problems that might arise of the platinum layer). However, contrary to
at the interface between the platinum layer and this, the sensors that were produced had a resis-
the substrate, the following criteria have to be tance ratio W(H,O b.p.) = 1.385. In addition
taken into account (3): the resistance ratio at 4.2 K, W = &.2K/R,pc was
[a] Mismatch between the lattices must be less about lo-', which is two orders of magnitude
than k 0.2 per cent greater than that proposed by ITS-90 for the
[b] Differences in the coefficients of thermal most accurate thermometers.
expansion must be less than 20 per cent An earlier investigation with this type of sen-
[c] There must be stability at the chemical sor showed that they required individual cali-
interface. This means that the material which bration in order to achieve an accuracy of f 10
is selected for the substrate must not react chem- mK (6).The results for the percentage varia-
ically with the platinum layer. tion of the resistance with temperature for two
Since the coefficientsof thermal expansion of typical sputtered platindalumina sensors, pre-
platinum and polycrystalline alumina are almost pared by the same method, serial numbers 023
equal, being 7 X /K over the temperature and 028, are presented in the Table. Their
range 50 to 300 K (4), alumina was chosen as behaviour is characteristic of this type of
the substrate for these sensors. sensor.
The production technology has been described The sensors show significant differences in
elsewhere (5). Platinum layers were deposited, their values for resistance below 50 K. This can
at 580 K, by magnetron sputtering of a plat- be explained (via Matthiessen's rule) by any
residual relative resistance. However, there is platinum layer were spoilt. Therefore the cover
no reason to suppose that there are any impu- was removed, but small amounts of glass frit
rities present in the layer during the platinum which had been deposited in the laser-drawn
deposition process. lines still remained. For this reason, in Figures
Eleven sensors of the same type were repeat- 1(a) to (d), lighter (white) lines appear on part
edly subjected to thermal cycling between 60 of the sensor.
to 320 K, and measurements of resistance were Thus laser treatment of the sensors appears
taken at 48 temperature points during every to create some problems. First, the rough edges
cycle. A visible shift in the temperaturehesis- of the treated layer are clearly visible; these cause
tance, T(R),function was observed up to the a reduction in the cross-sectional area of the
sixteenth cycle and only after 20 cycles was sat- platinum film. In Figure 1(b), which has twice
uration achieved. These results may be due to the resolution of Figure 1(a), it can be seen that
both the laser processing of the layer during fab- in some places the dimensions of the vertical
rication of the meander shape andor to inter- cross section have become too small. Any
action between the layer and the substrate. The mechanical tensions which have arisen as a result
effects of the laser processing can be observed of the high temperature laser treatment w ill be
by scanning electron microscopy (SEM). increased in these cross-sectional areas and affect
the temperature/resistance ratio.
Effects of the Laser Treatment During laser patterning evaporated material
A SEM micrograph of a part of sensor 028 is is redeposited onto the nearby film,this is shown
shown in Figure 1(a). The sensor was covered by the spots in Figure 1(c) . Some of these drops
with a glass kit to isolate the layer electrically. have dimensions equal to the width of the mean-
However, where the glass frit acted as an elec- der line layer, see Figure 1(d). It is therefore
trical isolator the SEM micrographs of the important to know both the structure and the
Acknowledgements
This work was completed with the financial support
of the National Foundation for Science Investigations
under contract number TH-265.The author wishes
to thank Professor N. Kirov and Dr. E. Nazarova
for their valuable discussion during preparation of this
manuscript.
The sensors used in this investigation were
manufactured by Pribor Ltd, Bulgaria.
either Pt/p or Pt/uSY was studied during reforming WO,,E"O, and Pd/WO, grew into needle shapes
of n-hexane, methylcyclopentane, or methylcyclo- with a plate structure inside after sintering at 900"C,
hexane. The increase of the Pt loading increased the to form a network structure. However, the mean par-
aromatic selectivity for the hydrocarbons. Reactions ticle size of nanophase Pt and Pd increases only from
over the composites gave increased selectivities for < 10 nm to 30 nm and 50 nm, respectively.The results
C t 7 aromatics. This is attributed to the synergism of CO oxidation show that nanophase lWWOsxpow-
caused by the components of the composites in com- ders have better catalytic effects on converting CO to
bination with components of the feed mixture. CO, than nanophase WO,-, and Pd/WO,~,powders.