Thermal barrier-coated Ni alloy component and manufacturing method thereof

Patent metadata

Field	Value
Publication number	US-10358700-B2
Application number	US-201615052243-A
Country	US
Kind code	B2
Filing date	Feb 24, 2016
Priority date	Sep 18, 2013
Publication date	Jul 23, 2019
Grant date	Jul 23, 2019

Abstract

A thermal barrier-coated Ni alloy component includes: a substrate made of a Ni alloy containing Al; an intermediate layer formed on a surface of the substrate; and a thermal barrier layer made of a ceramic and formed on a surface of the intermediate layer. The intermediate layer includes a γ′ layer, which is formed from a γ′-Ni3Al phase on the surface on the thermal barrier layer side, and contains Pt.

First claim

What is claimed is:

1. A method of manufacturing a thermal barrier-coated Ni alloy component comprising:
a substrate forming step of forming a substrate from a Ni alloy containing Al;
an intermediate layer forming step of forming an intermediate layer by depositing a Pt—Ir alloy film on a surface of the substrate, followed by a thermal treatment, the intermediate layer including
a γ′ layer which is provided on a surface side of the intermediate layer, is formed from a γ′-Ni 3 Al phase and contains Pt and Ir, and
a γ containing layer located on the substrate side of the γ′ layer, the γ containing layer being made of any one of
a γ+γ′ layer, which is formed from a γ-Ni solid solution phase and the γ′-Ni 3 Al phase and contains Pt and Ir, and
a γ layer, which is formed from the γ-Ni solid solution phase and contains Pt and Ir,

the γ′ layer having a higher concentration of Pt than the γ containing layer has, and
the γ containing layer having a higher concentration of Ir than the γ′ layer has; and

a thermal barrier layer forming step of forming a thermal barrier layer on the surface of the intermediate layer by using a ceramic.

2. The method of manufacturing a thermal barrier-coated Ni alloy component according to claim 1 , wherein
a surface on the thermal barrier layer side of the γ′ layer is formed into an indented shape at a pitch greater than 0 μm and equal to or below 5 μm.

3. The method of manufacturing a thermal barrier-coated Ni alloy component according to claim 1 , wherein the γ′ layer is formed from a single phase of the γ′-Ni 3 Al phase without containing any γ-Ni solid solution phase.

4. The method of manufacturing a thermal barrier-coated Ni alloy component according to claim 1 , wherein, in the intermediate layer forming step, a ratio of Ir in the Pt—Ir alloy film is greater than 0 at % and equal to or below 30 at %.

5. The method of manufacturing a thermal barrier-coated Ni alloy component according to claim 4 , wherein the ratio of Ir in the Pt—Ir alloy film is in a range from 10 at % to 30 at % inclusive.

6. The method of manufacturing a thermal barrier-coated Ni alloy component according to claim 5 , wherein, the ratio of Ir in the Pt—Ir alloy film is in a range from 10 at % to 20 at % inclusive.

7. The method of manufacturing a thermal barrier-coated Ni alloy component according to claim 1 , wherein, in the intermediate layer forming step, the Pt—Ir alloy film is deposited by electroplating.

8. The method of manufacturing a thermal barrier-coated Ni alloy component according to claim 7 , wherein, in the electroplating of the Pt—Ir alloy film in the intermediate layer forming step,
a liquid mixture prepared by mixing Na 3 IrBr 6 , K 2 PtCl 4 , NaBr, NaCl, C 18 H 14 N 2 Na 2 O 6 .2H 2 O, and C 6 H 6 O 7 is used for a plating bath,
platinum titanium electrodes are used for electrodes, and
an alloy composition of the Pt—Ir alloy film is controlled by changing ratios of Na 3 IrBr 6 and K 2 PtCl 4 .

9. The method of manufacturing a thermal barrier-coated Ni alloy component according to claim 1 , wherein, in the intermediate layer forming step,
a thermal treatment temperature is in a range from 900° C. to 1200° C., and
a thermal treatment time period is in a range from 1 hour to 100 hours.

10. The method of manufacturing a thermal barrier-coated Ni alloy component according to claim 9 , wherein, in the intermediate layer forming step,
the thermal treatment temperature is in a range from 1000° C. to 1100° C., and
the thermal treatment time period is in a range from 1 hour to 10 hours.

11. The method of manufacturing a thermal barrier-coated Ni alloy component according to claim 1 , wherein, in the substrate forming step, the Ni alloy contains Re and Ru.

12. The method of manufacturing a thermal barrier-coated Ni alloy component according to claim 11 , wherein
the Ni alloy is a Ni-based single crystal superalloy which has the following composition in terms of mass ratio,
Co: equal to or below 15.0% by mass,
Cr: from 4.1% by mass to 8.0% by mass inclusive,
Mo: from 2.1% by mass to 6.5% by mass inclusive,
W: equal to or below 3.9% by mass,
Ta: from 4.0% by mass to 10.0% by mass inclusive,
Al: from 4.5% by mass to 6.5% by mass inclusive,
Ti: equal to or below 1.0% by mass,
Hf: equal to or below 0.5% by mass,
Nb: equal to or below 3.0% by mass,
Re: from 3.0% by mass to 8.0% by mass inclusive,
Ru: from 0.5% by mass to 6.5% by mass inclusive, and
with the balance including Ni and unavoidable impurities, and

P1 (parameter 1)≤700 is satisfied when P1=137×[W (% by mass)]+24×[Cr (% by mass)]+46×[Mo (% by mass)]−18×[Re (% by mass)].

Assignees

• Ihi Corp
• Nat Inst Materials Science

Inventors

• Yoshizawa Hiroki
• Tateno Akira
• Sato Akihiro
• Sasaki Kota
• Ishida Masato
• Yasui Yoshito
• Murakami Hideyuki
• Murakami Hiromichi

Classifications

• F05D2300/175

  Superalloys · CPC title

• C23C28/3455

  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 · CPC title

• F05D2230/90

  Coating; Surface treatment · CPC title

• C22C5/04

  Alloys based on a platinum group metal · CPC title

• B22D21/005

  with high melting point, e.g. Be 1280 degrees C, Ti 1725 degrees C · CPC title