Article having variable composition coating

Patent metadata

Field	Value
Publication number	US-11261742-B2
Application number	US-201415036938-A
Country	US
Kind code	B2
Filing date	Nov 17, 2014
Priority date	Nov 19, 2013
Publication date	Mar 1, 2022
Grant date	Mar 1, 2022

Abstract

A coated article includes a substrate and an MCrAlY coating supported on the substrate. The M includes at least one of nickel, cobalt, and iron, Cr is chromium, Al is aluminum, and Y is yttrium. The composition of the MCrAlY coating varies in an amount of at least one of Cr, Al, and Y by location on the substrate with respect to localized property requirements. In one example, the coated article is an article of a gas turbine engine.

First claim

What is claimed is:

1. A coated article comprising:
a substrate; and
an MCrAlY coating supported on a surface of substrate, where the M includes at least one of nickel, cobalt, and iron, Cr is chromium, Al is aluminum, and Y is yttrium, the composition of the MCrAlY coating varying in an amount of at least one of Cr, Al, and Y by lateral location along the substrate and with respect to localized property requirements of at least one of oxidation resistance, corrosion resistance, erosion resistance, spallation resistance, creep resistance, fatigue resistance, or impact resistance.

2. The coated article as recited in claim 1 , wherein the composition of the MCrAlY coating varies in the amount of Cr.

3. The coated article as recited in claim 1 , wherein the composition of the MCrAlY coating varies in the amount of Al.

4. The coated article as recited in claim 1 , wherein the composition of the MCrAlY coating varies in the amount of Y.

5. The coated article as recited in claim 1 , wherein the MCrAlY coating includes at least one alloying element of cobalt (Co), tantalum (Ta), tungsten (W), molybdenum (Mo), silicon (Si), hafnium (Hf), and zirconium (Zr), and the amount of the alloying element differs by location on the substrate and with respect to the localized property requirements.

6. The coated article as recited in claim 1 , wherein the MCrAlY coating includes at least one alloying element of tantalum (Ta), tungsten (W), molybdenum (Mo), and zirconium (Zr), and the amount of the alloying element differs by location on the substrate and with respect to the localized property requirements such that the MCrAlY includes at least one of Ta, W, Mo, and Zr at a first location on the substrate and the MCrAlY coating is free of any Ta, W, Mo, and Zr at a second location on the substrate.

7. The coated article as recited in claim 1 , wherein the substrate is an airfoil, and the composition of the MCrAlY coating varies between a leading edge of the airfoil and another location on the airfoil.

8. The coated article as recited in claim 1 , wherein the MCrAlY coating includes a compositional transition between a first location having a first composition and a second location having a second composition.

9. The coated article as recited in claim 1 , wherein the MCrAlY coating is a continuous coating.

10. A gas turbine engine comprising:
an article having a substrate and an MCrAlY coating supported on a surface of the substrate, where the M includes at least one of nickel, cobalt, and iron, Cr is chromium, Al is aluminum, and Y is yttrium, the composition of the MCrAlY coating varying in at least one of Cr, Al, and Y by lateral location along the substrate with respect to localized property requirements of at least one of oxidation resistance, corrosion resistance, erosion resistance, spallation resistance, creep resistance, fatigue resistance, or impact resistance.

11. The gas turbine engine as recited in claim 10 , including a compressor section, a combustor in fluid communication with the compressor section, and a turbine section in fluid communication with the combustor.

12. The gas turbine engine as recited in claim 10 , wherein the composition of the MCrAlY coating varies in the amount of Cr.

13. The gas turbine engine as recited in claim 10 , wherein the composition of the MCrAlY coating varies in the amount of Al.

14. The gas turbine engine as recited in claim 10 , wherein the composition of the MCrAlY coating varies in the amount of Y.

15. The gas turbine engine as recited in claim 10 , wherein the MCrAlY coating includes at least one alloying element of cobalt (Co), tantalum (Ta), tungsten (W), molybdenum (Mo), silicon (Si), hafnium (Hf), and zirconium (Zr), and the amount of the alloying element differs by location on the substrate and with respect to the localized property requirements.

16. The gas turbine engine as recited in claim 10 , wherein the MCrAlY coating includes at least one alloying element of tantalum (Ta), tungsten (W), molybdenum (Mo), and zirconium (Zr), and the amount of the alloying element differs by location on the substrate and with respect to the localized property requirements such that the MCrAlY includes at least one of Ta, W, Mo, and Zr at a first location on the substrate and the MCrAlY coating is free of any Ta, W, Mo, and Zr at a second location on the substrate.

17. The gas turbine engine as recited in claim 10 , wherein the substrate is an airfoil in a turbine section of the engine, and the composition of the MCrAlY coating varies between a leading edge of the airfoil and another location on the airfoil.

18. The gas turbine engine as recited in claim 10 , wherein the MCrAlY coating includes a compositional transition between a first location having a first composition and a second location having a second composition.

19. The coated article as recited in claim 1 , wherein the MCrAlY coating includes at least one alloying element of tantalum (Ta), tungsten (W), molybdenum (Mo), silicon (Si), hafnium (Hf), and zirconium (Zr), and the amount of the alloying element differs by location on the substrate and with respect to the localized property requirements.

20. The coated article as recited in claim 19 , wherein the substrate is an airfoil, and the amount of the at least one alloying element varies between a leading edge of the airfoil and another location on the airfoil.

21. The gas turbine engine as recited in claim 10 , wherein the MCrAlY coating includes at least one alloying element of tantalum (Ta), tungsten (W), molybdenum (Mo), silicon (Si), hafnium (Hf), and zirconium (Zr), and the amount of the alloying element differs by location on the substrate and with respect to the localized property requirements.

22. The gas turbine engine as recited in claim 21 , wherein the substrate is an airfoil, and the amount of the at least one alloying element varies between a leading edge of the airfoil and another location on the airfoil.

23. The coated article as recited in claim 1 , wherein the MCrAlY coating includes hafnium (Hf) and the amount of the hafnium differs by location on the substrate and with respect to the localized property requirements.

24. The coated article as recited in claim 23 , wherein the substrate is an airfoil, and the amount of the hafnium varies between a leading edge of the airfoil and another location on the airfoil.

Assignees

• United Technologies Corp
• Raytheon Tech Corp

Inventors

• Ucasz Mark T

Classifications

• F05D2230/90

  Coating; Surface treatment · CPC title

• C23C28/028

  Including graded layers in composition or in physical properties, e.g. density, porosity, grain size · CPC title

• F01D5/288 Primary

  Protective coatings for blades · CPC title

• F01D5/02

  Blade-carrying members, e.g. rotors (rotors of non-bladed type F01D1/34; stators F01D9/00 {; selecting particular materials F01D5/28}) · CPC title

• C23C28/048

  with layers graded in composition or physical properties · CPC title