Article having variable composition coating

Patent metadata

Field	Value
Publication number	US-11834963-B2
Application number	US-202217672107-A
Country	US
Kind code	B2
Filing date	Feb 15, 2022
Priority date	Nov 19, 2013
Publication date	Dec 5, 2023
Grant date	Dec 5, 2023

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 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 an amount of at least one of Cr, Al, and Y by lateral location on the substrate and with respect to localized property requirements of the coated article, wherein the coating is functionally graded between locations that vary in composition.

2. The coated article as recited in claim 1 , wherein the localized property requirements are selected from the group consisting of corrosion resistance, erosion resistance, spallation resistance, fatigue resistance, oxidation resistance, creep resistance, impact resistance, and combinations thereof.

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

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

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

6. The coated article as recited in claim 1 , wherein the MCrAlY coating includes at least one alloying element of 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.

7. 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.

8. 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 to provide better erosion resistance at the leading edge relative to the other location on the airfoil.

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 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 on the substrate with respect to localized property requirements of the coated article, wherein the coating is functionally graded between locations that vary in composition.

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 localized property requirements are selected from the group consisting of corrosion resistance, erosion resistance, spallation resistance, fatigue resistance, oxidation resistance, creep resistance, impact resistance, and combinations thereof.

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

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

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

16. The gas turbine engine as recited in claim 10 , wherein the MCrAlY coating includes at least one alloying element of 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.

17. 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.

18. 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 to provide better erosion resistance at the leading edge relative to the other location on the airfoil.

Assignees

• Raytheon Tech Corp
• Rtx Corp

Inventors

• Ucasz Mark T

Classifications

• F01D5/288 Primary

  Protective coatings for blades · CPC title

• C23C28/028

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

• C23C28/048

  with layers graded in composition or physical properties · CPC title

• C23C28/3215

  at least one MCrAlX layer · CPC title

• C23C28/345

  with at least one oxide layer · CPC title