Oxidation-resistant coated superalloy

Patent metadata

Field	Value
Publication number	US-11518143-B2
Application number	US-202017029572-A
Country	US
Kind code	B2
Filing date	Sep 23, 2020
Priority date	Aug 20, 2012
Publication date	Dec 6, 2022
Grant date	Dec 6, 2022

Abstract

A coating-substrate combination includes: a Ni-based superalloy substrate comprising, by weight percent: 2.0-5.1 Cr; 0.9-3.3 Mo; 3.9-9.8 W; 2.2-6.8 Ta; 5.4-6.5 Al; 1.8-12.8 Co; 2.8-5.8 Re; 2.8-7.2 Ru; and a coating comprising, exclusive of Pt group elements, by weight percent: Ni as a largest content; 5.8-9.3 Al; 4.4-25 Cr; 3.0-13.5 Co; up to 6.0 Ta, if any; up to 6.2 W, if any; up to 2.4 Mo, if any; 0.3-0.6 Hf; 0.1-0.4 Si; up to 0.6 Y, if any; up to 0.4 Zr, if any; up to 1.0 Re, if any.

First claim

What is claimed is:

1. An article comprising:
a Ni-based superalloy substrate comprising, by weight percent: 2.0-5.1 Cr; 0.9-3.3 Mo; 3.9-9.8 W; 2.2-6.8 Ta; 5.4-6.5 Al; 1.8-12.8 Co; 2.8-5.8 Re; 2.8-7.2 Ru; and
a coating comprising, exclusive of Pt group elements, by weight percent: Ni as a largest content; 7.4-9.0 Al; 9.3-11.9 Cr; 7.4-9.0 Co; 0.0 Ta; 0.0 W; 0.0 Mo; 0.1-0.5 Hf; 0.1-0.3 Si; 0.3-0.6 Y; 0.1-0.5 Zr; and 0.0 Re,

wherein:
the coating has less than 0.50 weight percent Ru, if any; and
in weight percent exclusive of Pt group elements, the coating has less than 1.0 weight percent individually elements other than said Ni, Al, Cr, Co, Ta, W, Mo, Hf, Si, Y, Zr, Re, Ru, and Pt group elements, if any.

2. The article of claim 1 wherein:
the substrate comprises 0.05-0.7 weight percent Hf.

3. The article of claim 1 wherein:
the substrate has a 1800° F. & 45 ksi (982° C. & 310 MPa) rupture life of at least 120 hours.

4. The article of claim 1 wherein:
the substrate is a single crystal alloy.

5. The article of claim 1 wherein:
the coating has less than 1.0 weight percent overall said Pt group elements combined.

6. The article of claim 1 wherein:
in weight percent the coating has 55.0≤Ni+Cr≤67.0 and Ni≥52.

7. The article of claim 1 wherein:
the coating has said weight percent combined of said Y, Hf, Zr, and Si of up to 1.5 weight percent.

8. The article of claim 1 wherein:
a SRZ, if any, is less than 0.001 inch (0.025 mm) thick.

9. The article of claim 1 being a turbine blade.

10. The article of claim 1 wherein at least one of:
the substrate is a single crystal alloy;
the substrate has a density of 0.315-0.327 pounds per cubic inch (8.72-9.05 g/cm 3 ); and
the substrate has a creep resistance of at least 50° F. (28° C.) greater than that of PWA1484.

11. An article comprising:
a Ni-based superalloy substrate comprising, by weight percent: 2.0-3.0 Cr; 2.0-3.0 Mo; 7.0-9.0 W; 2.0-4.0 Ta; 5.0-6.0 Al; 7.0-9.0 Co; 3.0-5.0 Re; 4.0-6.0 Ru; and
a coating comprising, exclusive of Pt group elements, by weight percent: Ni as a largest content; 6.3-7.7 Al; 4.1-5.3 Cr; 11.8-14.2 Co; 5.0-6.2 Ta; 4.3-5.3 W; 0.0 Mo; 0.1-0.5 Hf; 0.2-0.4 Si; 0.3-0.7 Y; 0.0 Zr; and 0.0 Re,

wherein:
in weight percent exclusive of Pt group elements, the coating has less than 1.0 weight percent individually elements other than said Ni, Al, Cr, Co, Ta, W, Hf, Si, Y, and Pt group elements, if any.

12. An article comprising:
a Ni-based superalloy substrate comprising, by weight percent: 2.0-5.1 Cr; 0.9-3.3 Mo; 3.9-9.8 W; 2.2-6.8 Ta; 5.4-6.5 Al; 1.8-12.8 Co; 2.8-5.8 Re; 2.8-7.2 Ru; and
a coating comprising, exclusive of Pt group elements, by weight percent: Ni as a largest content; 6.3-7.7 Al; 4.1-5.3 Cr; 11.8-14.2 Co; 5.0-6.2 Ta; 4.3-5.3 W; 0.0 Mo; 0.1-0.5 Hf; 0.2-0.4 Si; 0.3-0.7 Y; 0.0 Zr; and 0.0 Re,

wherein:
the coating has less than 0.50 weight percent Ru, if any; and
in weight percent exclusive of Pt group elements, the coating has less than 1.0 weight percent individually elements other than said Ni, Al, Cr, Co, Ta, W, Mo, Hf, Si, Y, Zr, Re, Ru, and Pt group elements, if any.

13. The article of claim 12 wherein:
the substrate comprises 0.05-0.7 weight percent Hf.

14. The article of claim 12 wherein:
the substrate has a 1800° F. & 45 ksi (982° C. & 310 MPa) rupture life of at least 120 hours.

15. The article of claim 12 wherein:
a SRZ, if any, is less than 0.001 inch (0.025 mm) thick.

16. The article of claim 12 being a turbine blade.

17. The article of claim 12 wherein at least one of:
the substrate is a single crystal alloy;
the substrate has a density of 0.315-0.327 pounds per cubic inch (8.72-9.05 g/cm 3 ); and
the substrate has a creep resistance of at least 50° F. (28° C.) greater than that of PWA1484.

18. The article of claim 12 wherein:
the coating has less than 1.0 weight percent overall said Pt group elements combined.

19. The article of claim 12 wherein:
the substrate is a single crystal alloy.

Assignees

• Pratt & Whitney Canada

Inventors

• Larose Joel
• Cetel Alan D
• Litton David A
• Tryon Brian S

Classifications

• 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

• B32B15/04

  comprising metal as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a bituminous or tarry layer B32B11/08; next to a water-setting substance layer B32B13/06; next to a glass layer B32B17/061; next to a cellulosic plastic layer B32B23/042)} · CPC title

• C23C28/3215

  at least one MCrAlX layer · CPC title

• C23C30/005

  on hard metal substrates · CPC title

• C23C28/022

  with at least one MCrAlX layer · CPC title