WO2006076130A2 - METHODS FOR MAKING HIGH-TEMPERATURE COATINGS HAVING PT METAL MODIFIED Ϝ-Ni + Ϝ’-Ni3 AL ALLOY COMPOSITIONS AND A REACTIVE ELEMENT - Google Patents
METHODS FOR MAKING HIGH-TEMPERATURE COATINGS HAVING PT METAL MODIFIED Ϝ-Ni + Ϝ’-Ni3 AL ALLOY COMPOSITIONS AND A REACTIVE ELEMENT Download PDFInfo
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- WO2006076130A2 WO2006076130A2 PCT/US2005/045927 US2005045927W WO2006076130A2 WO 2006076130 A2 WO2006076130 A2 WO 2006076130A2 US 2005045927 W US2005045927 W US 2005045927W WO 2006076130 A2 WO2006076130 A2 WO 2006076130A2
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- C23C10/34—Embedding in a powder mixture, i.e. pack cementation
- C23C10/58—Embedding in a powder mixture, i.e. pack cementation more than one element being diffused in more than one step
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- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
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- C23C28/028—Including graded layers in composition or in physical properties, e.g. density, porosity, grain size
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- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
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- C23C28/321—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer with at least one metal alloy layer
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
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- C23C28/322—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer only coatings of metal elements only
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
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- C23C28/32—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer
- C23C28/325—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer with layers graded in composition or in physical properties
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- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
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- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
- C23C28/34—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates
- C23C28/345—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer
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- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
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- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
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- C23C28/345—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer
- C23C28/3455—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer with a refractory ceramic layer, e.g. refractory metal oxide, ZrO2, rare earth oxides or a thermal barrier system comprising at least one refractory oxide layer
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
- Y10T428/125—Deflectable by temperature change [e.g., thermostat element]
- Y10T428/12507—More than two components
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
- Y10T428/12535—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.] with additional, spatially distinct nonmetal component
- Y10T428/12611—Oxide-containing component
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
- Y10T428/12771—Transition metal-base component
- Y10T428/12861—Group VIII or IB metal-base component
- Y10T428/12875—Platinum group metal-base component
Definitions
- This invention relates to methods for depositing alloy compositions for high-temperature, oxidation resistant coatings. Coatings based on these alloy compositions may be used alone or, for example, as part of a thermal barrier system for components in high-temperature systems.
- the components of high-temperature mechanical systems must operate in severe environments.
- the high-pressure turbine blades and vanes exposed to hot gases in commercial aeronautical engines typically experience metal surface temperatures of about 900-1000 0 C, with short-term peaks as high as 1150 0 C.
- a portion of a typical metallic article 10 used in a high-temperature mechanical system is shown in Fig. 1.
- the blade 10 includes a Ni or Co-based superalloy substrate 12 coated with a thermal barrier coating (TBC) 14.
- TBC thermal barrier coating
- the thermal barrier coating 14 includes a thermally insulative ceramic topcoat 20 and an underlying metallic bond coat 16.
- the topcoat 20 is currently most often a layer of yttria-stabilized zirconia (YSZ) with a thickness of about 300- 600 ⁇ m.
- YSZ yttria-stabilized zirconia
- the properties of YSZ include low thermal conductivity, high oxygen permeability, and a relatively high coefficient of thermal expansion (CTE).
- CTE coefficient of thermal expansion
- the YSZ topcoat 20 is also made "strain tolerant" by depositing a structure that contains numerous pores and/or pathways. The consequently high oxygen permeability of the YSZ topcoat 20 imposes the constraint that the metallic bond coat 16 must be resistant to oxidation attack.
- the bond coat 16 is therefore sufficiently rich in Al to form a layer 18 of a protective thermally grown oxide (TGO) scale OfAIaO 3 . in addition to imparting oxidation resistance, the TGO bonds the ceramic topcoat 20 to the substrate 12 and bond coat 16.
- TGO protective thermally grown oxide
- the adhesion and mechanical integrity of the TGO scale layer 18 is very dependent on the composition and structure of the bond coat 16. Ideally, when exposed to high temperatures, the bond coat 16 should oxidize to form a slow-growing, non-porous TGO scale that adheres well to the superalloy substrate 12.
- FIG. 2 A Another approach to depositing a protective coating on a ⁇ -Ni + ⁇ '- Ni 3 Al-based metallic article 28, described in U.S. Patent Nos. 5,667,663 and 5,981,091 to Rickerby et al., is shown in Fig. 2 A.
- a superalloy substrate 30 is coated on an outer surface with a layer 32 of Pt and then heat-treated.
- Fig. 2B during this heat treatment, interdiffusion occurs, which includes the diffusion of Al from the superalloy substrate 30 into the Pt layer 32 to form an Al-enriched Pt-modif ⁇ ed outer surface region 34 on the superalloy substrate (Fig. 2B).
- An AI 2 O 3 TGO scale layer 38 may then form on the surface-modified region 34 and a ceramic layer topcoat 40 may also be deposited using conventional techniques.
- transition metals from the superalloy substrate 30 are also present in the surface modified region 34, it is difficult to precisely control the composition and phase constitution of the surface region 34 to provide optimum properties to improve adhesion of the TGO scale layer 38.
- Rickerby et al. further suggest that this platinizing and heat treatment process may include the incorporation up to 0.8 wt% of Hf or Y into the platinum-enriched surface layer, but no specific deposition methods or pack compositions were provided to achieve this surface layer composition.
- U.S. Publication No. 2004/0229075 Al describes alloy compositions suitable for bond coat applications.
- the alloys include a Pt- group metal, Ni and Al in relative concentration to provide a ⁇ + ⁇ ' phase constitution, with ⁇ referring to the solid-solution Ni phase and ⁇ ' referring to the solid-solution Ni 3 Al phase.
- a Pt-group metal, Ni and Al are present, and the concentration of Al is limited with respect to the concentrations of Ni and the Pt-group metal such that the alloy includes substantially no ⁇ -NiAl phase.
- the ternary Ni-Al-Pt alloy in the copending '649 application includes less than about 23 at% Al, about 10 at% to about 30 at% of a Pt-group metal, preferably Pt, and the remainder Ni.
- Additional reactive elements such as Hf, Y, La, Ce and Zr, or combinations thereof, may optionally be added to or present in the ternary Pt-group metal modified ⁇ -Ni + ⁇ '-Ni 3 Al alloy and/or improve its properties. The addition of such reactive elements tends to stabilize the ⁇ ' phase. Therefore, if sufficient reactive metal is added to the composition, the resulting phase constitution may be predominately ⁇ ' or solely ⁇ '.
- the Pt-group metal modified ⁇ -Ni + ⁇ ' -Ni 3 Al alloy exhibits excellent solubility for reactive elements compared to conventional ⁇ -NiAl-based alloys, and in the '075 publication the reactive elements may be added to the ⁇ + ⁇ ' alloy at a concentration of up to about 2 at% ( ⁇ 4 wt%).
- a preferred reactive element is Hf.
- other typical superalloy substrate constituents such as, for example, Cr, Co, Mo, Ta, and Re, and combinations thereof, may optionally be added to or present in the Pt-group metal modified ⁇ -Ni + ⁇ '- Ni 3 Al alloy in any concentration to the extent that a ⁇ + ⁇ ' phase constitution predominates.
- the Pt-group metal modified alloys have a ⁇ -Ni + ⁇ ' -Ni 3 Al phase constitution that is both chemically, physically and mechanically compatible with the ⁇ 4- ⁇ ' microstructure of a typical Ni-based superalloy substrate.
- Protective coatings formulated from these alloys will have coefficients of thermal expansion (CTE) that are more compatible with the CTEs of Ni-based superalloys than the CTEs of ⁇ -NiAl-based coatings.
- CTE coefficients of thermal expansion
- the Pt-group metal modified ⁇ -Ni + ⁇ '- Ni 3 Al alloy coatings grow an ⁇ - Al 2 O 3 scale layer at a rate comparable to or slower than the thermally grown scale layers produced by conventional ⁇ - NiAl-Pt bond coat systems, and this provides excellent oxidation resistance for ⁇ -Ni + Y -Ni 3 Al alloy compositions.
- the Pt-metal modified ⁇ + ⁇ ' alloys further modified with a reactive element such as, for example, Hf, and applied on a superalloy substrate as a coating, the growth of the TGO scale layer is even slower than comparable coating compositions without Hf addition. After prolonged thermal exposure, the TGO scale layer further appears more planar and has enhanced adhesion on the coating layer compared to scale layers formed from conventional ⁇ -NiAl-Pt coatings.
- thermodynamic activity of Al in the Pt-group metal modified K-Ni + K' -Ni 3 Al alloys can, with sufficient Pt content, decrease to a level below that of the Al in Ni-based superalloy substrates.
- this variation in thermodynamic activity causes Al to diffuse up its concentration gradient from the superalloy substrate into the coating.
- Such "uphill diffusion” reduces and/or substantially eliminates Al depletion from the coating. This reduces spallation in the scale layer, increases the long-term stability of the coating and scale layers, and would greatly enhance the reliability and durability of a thermal barrier coating system.
- the Pt-group metal modified K-Ni + K' -Ni 3 Al alloy may be applied to a superalloy substrate using any known process, including for example, plasma spraying, chemical vapor deposition (CVD), physical vapor deposition (PVD) and sputtering to create a coating and form a temperature-resistant article. Typically this deposition step is performed under non- or minimal oxidizing conditions.
- CVD chemical vapor deposition
- PVD physical vapor deposition
- sputtering to create a coating and form a temperature-resistant article.
- this deposition step is performed under non- or minimal oxidizing conditions.
- the growth of the TGO scale layer is even slower than comparable coating compositions without Hf addition.
- the TGO scale layer further appears more planar and has enhanced adhesion on the coating layer compared to scale layers formed from conventional ⁇ -NiAl-Pt bond coat materials.
- inclusion of a reactive element in the Pt-metal modified ⁇ + ⁇ ' alloys described in the '075 publication is highly desirable.
- the invention is a method for making an oxidation resistant article, including (a) depositing a layer of a Pt group metal on a substrate to form a platinized substrate; and (b) depositing on the platinized substrate a reactive element selected from the group consisting of Hf, Y, La, Ce and Zr and combinations thereof to form a surface modified region thereon, wherein the surface-modified region comprises the Pt-group metal, Ni 5 Al and the reactive element in relative concentration to provide a ⁇ -M + ⁇ ' -Ni 3 Al phase constitution.
- the surface modified region comprises greater than 0.8 wt% and less than 5 wt% of the reactive element.
- a preferred reactive element is Hf.
- the invention is a method of making a temperature resistant article, including (a) depositing a layer of Pt on a superalloy substrate to form a platinized substrate; (b) heat treating the platinized substrate; and (c) depositing from a pack onto the platinized substrate to form a surface modified region thereon, wherein the pack comprises sufficient Hf such that the surface modified region includes Pt, Ni, Hf and Al in relative concentration to provide a ⁇ -Ni + 7'-Ni 3 Al phase constitution, and wherein the surface-modified region includes greater than 0.8 wt% and less than 5 wt% Hf.
- the invention is a heat resistant article including a superalloy with a surface region including a reactive element selected from the group consisting of Hf, Y, La, Ce and Zr and combinations thereof, wherein the surface region includes a Pt-group metal, Ni, Al and the reactive element in relative concentration to provide a K-Ni + K' -Ni 3 Al phase constitution.
- the Pt+reactive element-modified ⁇ -Ni + ⁇ ' -Ni 3 Al coatings described herein have a number advantages over conventional ⁇ -NiAl containing coatings, including: (1) compatibility with the Ni-based superalloy substrate in terms of phase constitution and thermal expansion behavior; (2) no performance limiting phase transformations in the coating layer (i.e., destabilization of ⁇ to martensite or ⁇ ') or in the coating/substrate interdiffusion zone (i.e., formation of brittle topologically close-packed (TCP) phases such as sigma); (3) the existence of a chemical driving force for the Al to diffuse up its concentration gradient from the substrate to the coating; (4) and exceptionally low TGO scale growth kinetics due, in part, to the presence of a preferred reactive element content of 0.8-5 wt%.
- TCP brittle topologically close-packed
- FIG. 1 is a cross-sectional diagram of a metallic article with a thermal barrier coating.
- FIG. 2A is a cross-sectional diagram of a metallic article coated with a Pt layer, prior to heat treatment.
- FIG. 2B is a cross-sectional diagram of the metallic article of FIG.
- FIG. 3 is a portion of a 1100 0 C Ni-Al-Pt phase diagram showing an embodiment of the Pt metal modified K-Ni + IC-Ni 3 Al alloy compositions of the invention.
- FIG. 4 is a cross-sectional diagram of a metallic article including a
- FIG. 5 is a cross-sectional diagram of a metallic article including a
- Pt-group metal layer having a surface modified region enriched with a reactive metal.
- FIG. 6 is a cross-sectional diagram of a metallic article of Fig. 5 with a thermal barrier coating.
- FIGS. 7A and 7B are cross-sectional images of Pt-modified K-Ni +
- K' -Ni 3 Al coatings obtained by heat treating a CMSX-4 superalloy substrate having Pt-layers of differing thicknesses.
- FIGS. 8A, 8B and 8C are cross-sectional images of Pt-modified K-
- FIGS. 9 A and 9B are cross-sectional images showing the effect of heat treatment temperature on Pt-modified K-Ni + K' -Ni 3 Al coatings.
- FIG. 10 is a plot showing the oxidation behavior of a Ni22A130Pt alloy coating on aCMSX-4 superalloy substrate.
- FIG. 11 is a cross-sectional image of a reactive metal modified K-Ni
- FIG. 12 is a cross-sectional image of a reactive metal modified K-Ni
- FIG. 13 is a plat showing the oxidation spallation of reactive metal modified K-Ni + K' -Ni 3 Al coatings at 115O 0 C.
- FIG. 14 is a cross-sectional image of a reactive metal modified K-Ni
- FIG. 15 is a plot of an EPMA analysis of the coating of FIG. 14.
- the invention is a method for making an oxidation resistant article that includes an oxidation resistant region on a substrate, typically a superalloy substrate.
- the oxidation resistant alloy layer includes a modified K-Ni + K' -Ni 3 Al alloy containing a Pt-group metal, Ni, Al and a reactive element in relative concentration such that a K-Ni + K' -Ni 3 Al phase constitution results; although, stabilization effects by certain elements may cause Y -Ni 3 Al to be the sole phase.
- the concentration of Al is limited with respect to the concentration of Ni, the Pt-group metal and the reactive element such that substantially no ⁇ -NiAl phase, preferably no ⁇ -NiAl phase, is present in the alloy, and the K-Ni + K' -Ni 3 Al phase structure predominates.
- a typical high temperature article 100 includes a Ni or Co-based superalloy substrate 102.
- the initial step of the method includes depositing a layer of a Pt-group metal 104 on the substrate to form a platinized substrate 103.
- the Pt-group metal may be selected from, for example, Pt, Pd, Ir, Rh and Ru, or combinations thereof. Pt-group metals including Pt are preferred, and Pt is particularly preferred.
- the Pt-group metal may be deposited by any conventional technique, such as, for example, electrodeposition.
- the thickness of the layer 104 of Pt-group metal may vary widely depending on the intended application for the temperature resistant article 100, but typically will be about 3Tm to about 12Tm, ⁇ lTm, and preferably about 6Tm. It is preferred that the Pt layer be planar and compact; however, some roughness and porosity can be tolerated. [0041] As the layer of Pt-group metal 104 on the superalloy substrate 102 is heated, elements diffuse from the substrate 102 into the Pt-group metal region 104.
- a diffusion heat- treatment preferably follows deposition of the Pt layer.
- the heat treatment may be for 1-3 hours at 1000-1200 0 C.
- further diffusion occurs from the superalloy substrate 102 into the layer of Pt-group metal 104 to form a Pt-modified surface region in which ⁇ ' is the principal phase, most preferably the sole phase.
- ⁇ ' is the principal phase, most preferably the sole phase.
- Current experimental data indicates that reactive elements such as Hf, Zr and the like partition almost solely to the ⁇ ' phase.
- a reactive metal is deposited on the surface region 104 to form a surface modified region 106 thereon that is enriched in the reactive metal.
- Suitable reactive metals include Hf, Y, La, Ce and Zr, or combinations thereof, and Hf is preferred.
- the reactive metal may be deposited by any conventional process, including physical vapor deposition (PVD) processes such as sputtering and electron beam direct vapor deposition (EBDVD), as well as chemical vapor deposition (CVD) processes such as those in which the reactive metal is deposited using a pack process or in a chamber containing a gas including the reactive metal.
- PVD physical vapor deposition
- EBDVD electron beam direct vapor deposition
- CVD chemical vapor deposition
- the preferred deposition process to form the surface- modified region 106 is a pack or out- of-pack process in which the substrate 102 with the Pt-group metal layer 104 is either embedded in or above a pack including the reactive metal.
- the substrate 102 including the Pt-group metal layer 104, are embedded in a powder mixture containing either a pure or alloyed coating-source material called the master alloy, a halide salt that acts as an activator, and a filler material.
- the powders in the pack are heated to an elevated deposition temperature, which produces a halide gas containing the reactive metal.
- the gas reacts with the layer 104, and the reactive metal deposits on the layer 104 to form a diffusion coating referred to herein as the surface modified region 106.
- the composition of the surface modified region 106 is directly dependent on the composition of the powders in the pack.
- the pack powder composition preferably includes a filler, an activator and a master alloy source, and many compositions are possible. However, the pack powder composition should contain a sufficient amount of the master alloy source such that the reactive metal deposits on the Pt-group metal layer 104 and forms a surface- modified region 106 having the desired concentration of reactive metal.
- the surface modified region 106 includes an average of up to about 5 wt% reactive metal, preferably about 0.8 wt% to about 5 wt%, and most preferably about 0.8% to about 3 wt%.
- the master alloy source includes at least about 1 wt% of a reactive metal, preferably Hf, and is present in the pack at a content of about 1 wt% to about 5 wt% Hf, but most preferably about 3 wt% Hf.
- a salt containing one or more of reactive-elements may be an alternative source, such as, for example, hafnium chloride.
- the master alloy source may optionally include about 0.5wt% to about lwt% Al to provide surface enrichment of the Pt-metal layer 104.
- the pack powder composition also includes about 0.5 wt% to about 4wt%, preferably about lwt%, of a halide salt activator.
- the halide salt may vary widely, but ammonium halides such as ammonium chloride and ammonium fluoride are preferred.
- the balance of the pack powder composition is a filler that prevents the pack from sintering and to suspend the substrate during the deposition procedure.
- the filler typically is a minimally reactive oxide powder.
- the oxide powder may vary widely, but compounds such as aluminum oxide, silicon oxide, yttrium oxide and zirconium oxide are preferred, and aluminum oxide (Al 2 O 3 ) is particularly preferred to provide additional Al surface enrichment to Pt-metal layer 104.
- the pack powder composition is heated to a temperature of about 65O 0 C to about HOO 0 C, preferably less than about 800 0 C, and most preferably about 75O 0 C, for a time sufficient to produce a surface-modified region 106 with the desired thickness and reactive metal concentration gradient.
- the deposition time typically is about 0.5 hours to about 5 hours, preferably about 1 hour.
- the reactive metal and any other metals in the pack composition are deposited on the Pt-metal layer 104, diffusive mixing occurs at the surface of the layer 104 to form the surface modified region 106.
- the reactive metal preferably Hf, as well as any other metals in the pack, such as Al, diffuse into and mix to form an Al-enriched Pt ⁇ +- reactive-metal modified K-Ni + K'-NisAl surface region 106.
- This surface-modified region 106 is therefore enriched in the metals from the pack.
- the concentration of reactive metal is greatest at the surface 107, and gradually decreases over the thickness of the layer 106, thus forming a reactive metal concentration gradient across the thickness of the layer 106.
- the surface-modified region 106 typically has a thickness of about 5 Tm to about 50 Tm, preferably about 20 Tm. Over the first 20 Tm, the surface-modified region 106 has a composition including at least about lwt% of the reactive metal, preferably Hf, typically about lwt% Hf to about 3wt% Hf.
- metals also diffuse outward from the superalloy substrate 102 into the Pt- group metal layer 104 and further into the surface modified region 106.
- a superalloy substrate 102 such as CMSX-4 nominally contains at least about 12at% Al.
- the Al in the substrate diffuses into the Pt-group metal layer 104 and into the surface modified region 106.
- other elements from the superalloy substrate such as, for example, Cr, Co, Mn, Ta, and Re may diffuse outward from the superalloy substrate 102 into the Pt-group metal layer 104 and then into the surface modified region 106.
- Al deposited along with the reactive metal layer may diffuse inward into the surface modified region 106 and into the Pt-group metal layer 104.
- the composition of the pack is selected considering these outward and inward diffusive mixing behaviors, and it is important that while a variety of metals may be present in the surface modified region 106, the Al content of the region 106 is preferably controlled with respect to concentration of the Pt- group metal, Ni, and reactive element such that a K-Ni + K' -Ni 3 Al phase constitution results, with K' -Ni 3 Al being the principal or even sole phase.
- the concentration of Al is limited with respect to the concentration of Ni, the Pt-group metal and the reactive element such that substantially no ⁇ -NiAl phase structure, preferably no ⁇ -NiAl phase structure, is present in the region, and the K-Ni + K' -Ni 3 Al phase structure predominates.
- the amount of metallic Al as the master alloy source in the pack composition is preferably maintained at a very low level, less than about 1 wt%. Even master alloy sources including Owt% Al have been found to produce a K-Ni + K' -Ni 3 Al phase, particularly if the filler material includes at least some Al 2 O 3 powder.
- the main source for Al in the surface modified region 106 can be the superalloy substrate 102, not the pack.
- the chemical interaction between Al and Pt is such that a strong driving force exists for the Al to diffuse from the substrate 102 into Pt-group metal layer 104 and further into the surface modified region 106.
- Pack compositions with metallic Al concentrations of greater than about 1 wt% typically result in ⁇ -NiAl phase formation in the surface modified region 106, and often result in the formation of W-rich TCP precipitates therein.
- the thickness of the Pt-group metal layer 104 also has an impact on the diffusive mixing behavior in the article 100, as well as on the composition of the surface modified region 106. For example, if the Pt-group metal layer 104 has a thickness of about 2Tm, the surface modified layer 106 most likely will have a Pt-group metal modified K + K' coating with a primary K phase, while a Pt-group metal layer with a thickness greater than about 4 Tm, typically about 4 Tm to about 8 Tm, will most likely have a Pt-group metal modified K + K' coating with a primary K' phase.
- the temperature used in the pack cementation process also has an impact on the phase constitution of the surface modified layer 106.
- the amount of Al deposited along with the reactive metal becomes sufficiently high to produce unwanted ⁇ -NiAl phase structure in the surface modified region 106.
- a pack cementation temperature of about 900 0 C resulted in some ⁇ -NiAl phase formation. Therefore, to reduce formation of ⁇ -NiAl phase structure in the surface modified region 106, the pack cementation temperature should preferably be maintained at less than about 800°C, preferably about 75O 0 C.
- the article 100 is preferably cooled to room temperature, although this cooling step is not required.
- the deposition of the ceramic topcoat 204 conventionally takes place in an atmosphere including oxygen and inert gases such as argon.
- the presence of oxygen during the ceramic deposition process makes it inevitable that a thin oxide scale layer 206 is formed on the surface of the surface-modified region 106.
- the thermally grown oxide (TGO) layer 206 includes alumina and is typically an adherent layer OfI-Al 2 O 3 .
- the bond coat layer 106, the TGO layer 206 and the ceramic topcoat layer 204 form a thermal barrier coating 210 on the superalloy substrate 102.
- FIG. 7 shows the coatings obtained by heat-treating CMSX-4 samples having different electrodeposited Pt-layer thicknesses. Referring to Fig. 7A, it is seen that a thin Pt layer (about 2 ⁇ m) resulted in a Pt-modified K and K' coating with K being the primary phase. By contrast, as shown in Fig. 7B, a Pt modified K and K' coating in which K' is the primary phase formed from a thicker Pt layer (about 7 ⁇ m).
- the samples were first electrodeposited with a ⁇ 5 ⁇ m Pt layer, followed by pack aluminizing (3wt% Hf, 1 wt% Al, 1 wt% NH 4 Cl, and Al 2 O 3 -balance) and then a final heat-treatment. Further heat-treatment was found to result in a larger amount of W-rich precipitates in the interdiffusion zone. Moreover, ⁇ persisted with further heat treatment.
- the aluminizing or hafnizing temperatures should preferably be kept below about 800 0 C.
- a thin layer (about 60 microns) of a Ni-Al-Pt alloy is diffusion bonded to a CMSX-4 superalloy substrate.
- the layer is seen to have excellent oxidation resistance, as well as excellent compatibility with the superalloy substrate.
- Figs. 11-12 show a reactive metal modified Ni-Al-Pt coating on two different superalloy substrates, CMSX-4 (Fig. 11) and CMSX-10 (Fig. 12). These coatings have minimal topologically close-packed (top) phase formation in the interdiffusion zone (i.e., the coating-to-base alloy transition zone).
- Fig. 13 shows the excellent oxidation resistance that can be gained by using a reactive metal modified Ni-Al-Pt coating with an enhanced concentration of reactive metal.
- the plot compares a ⁇ -NiAl coating, a reactive metal modified Ni-Al-Pt coating having 0.01 at% Hf (RR) and a coating with a reactive metal modified Ni-Al-Pt coating having 0.5 at% Hf (ISU).
- the coating ISU resisted spallation for over 1000 cycles, compared to about 50 cycles for the ⁇ -NiAl coating and 100 cycles for the RR coating.
- Fig. 14 shows a reactive metal modified Ni-Al-Pt coating according to an embodiment of the invention applied on a Ni-based Rene-N5 superalloy substrate.
- Fig. 15 shows the composition profile through the coating of Fig. 14 as measured using electron probe microanalysis (EPMA).
- EPMA electron probe microanalysis
Abstract
Description
Claims
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CA002597898A CA2597898A1 (en) | 2004-12-15 | 2005-12-15 | Methods for making high-temperature coatings having pt metal modified .gamma.ni+.gamma.'-ni3a1 alloy compositions and a reactive element |
EP05857130A EP1825025A2 (en) | 2004-12-15 | 2005-12-15 | METHODS FOR MAKING HIGH-TEMPERATURE COATINGS HAVING PT METAL MODIFIED GAMMA-Ni + GAMMA'-Ni3AL ALLOY COMPOSITIONS AND A REACTIVE ELEMENT |
MX2007007096A MX2007007096A (en) | 2004-12-15 | 2005-12-15 | METHODS FOR MAKING HIGH-TEMPERATURE COATINGS HAVING PT METAL MODIFIED ????-Ni + ????a????-Ni3 AL ALLOY COMPOSITIONS AND A REACTIVE ELEMENT. |
JP2007547002A JP4684298B2 (en) | 2004-12-15 | 2005-12-15 | Method of manufacturing high temperature resistant coating containing γ-Ni + γ'-Ni3Al alloy composition modified with platinum metal and reactive element |
BRPI0519084-3A BRPI0519084A2 (en) | 2004-12-15 | 2005-12-15 | METHODS FOR MANUFACTURING HIGH TEMPERATURE COATINGS HAVING METAL MODIFIED (gamma) -ni + (gamma) '- ni3a alloy compositions and a reactive element |
AU2005324336A AU2005324336B9 (en) | 2004-12-15 | 2005-12-15 | Methods for making high-temperature coatings having Pt metal modified gamma-Ni + gamma'-Ni3 Al alloy compositions and a reactive element |
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- 2005-12-15 BR BRPI0519084-3A patent/BRPI0519084A2/en not_active IP Right Cessation
- 2005-12-15 WO PCT/US2005/045927 patent/WO2006076130A2/en active Application Filing
- 2005-12-15 JP JP2007547002A patent/JP4684298B2/en not_active Expired - Fee Related
- 2005-12-15 EP EP05857130A patent/EP1825025A2/en not_active Withdrawn
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Also Published As
Publication number | Publication date |
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WO2006076130A3 (en) | 2006-10-26 |
JP2008524446A (en) | 2008-07-10 |
US20090226613A1 (en) | 2009-09-10 |
EP1825025A2 (en) | 2007-08-29 |
US20060127695A1 (en) | 2006-06-15 |
AU2005324336A1 (en) | 2006-07-20 |
CN101233262A (en) | 2008-07-30 |
JP4684298B2 (en) | 2011-05-18 |
BRPI0519084A2 (en) | 2008-12-23 |
CA2597898A1 (en) | 2006-07-20 |
AU2005324336B9 (en) | 2010-03-11 |
MX2007007096A (en) | 2008-01-11 |
US7531217B2 (en) | 2009-05-12 |
US20110197999A1 (en) | 2011-08-18 |
AU2005324336B2 (en) | 2010-02-11 |
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