Abrasive Coating and Manufacture and Use Methods

Patent metadata

Field	Value
Publication number	US-2016003065-A1
Application number	US-201514750415-A
Country	US
Kind code	A1
Filing date	Jun 25, 2015
Priority date	Jul 2, 2014
Publication date	Jan 7, 2016
Grant date	—

Abstract

A method for applying an abrasive comprises: applying, to a substrate, the integral combination of a self-braze material, an abrasive, a matrix in which the abrasive is at least partially embedded, and an intermediate layer between the self-braze material and the matrix; and heating to cause the self-braze material to braze to the substrate.

First claim

1 . A method for applying an abrasive, the method comprising:
applying, to a substrate, the integral combination of: a self-braze material; an abrasive; a matrix in which the abrasive is at least partially embedded; and an intermediate layer between the self-braze material and the matrix; and heating to cause the self-braze material to braze to the substrate.

2 . The method of claim 1 wherein the intermediate layer is a cast layer.

3 . The method of claim 1 wherein the heating leaves at least a portion of the self-braze material with a composition comprising, in weight percent:
cobalt 2.5-13.5;
chromium 12-27;
aluminum 5-7;
yttrium 0.0-1.0;
hafnium 0.0-1.0;
silicon 1.0-3.0;
tantalum 0.0-4.5;
tungsten 0.0-6.5;
rhenium 0.0-2.0;
molybdenum 0.1-1.0; and
the balance nickel.

4 . The method of claim 3 wherein:
said portion of the self-braze material has said composition comprising, in weight percent:
cobalt 2.5-13.5;
chromium 12-27;
aluminum 5-7;
yttrium 0.0-1.0;
hafnium 0.0-1.0;
silicon 1.0-3.0;
tantalum 2.0-4.5;
tungsten 2.0-6.5;
rhenium 0.0-2.0;
molybdenum 0.1-1.0; and
the balance nickel.

5 . The method of claim 3 wherein:
said composition has no more than 1.0 weight percent of any other individual element.

6 . The method of claim 3 wherein:
said composition has no more than 3.0 weight percent of all other individual elements combined.

7 . The method of claim 1 wherein:
the matrix comprises an MCrAlY; and
the abrasive comprises cubic boron nitride.

8 . The method of claim 3 wherein the self-braze material comprises a sintered sheet of:
at least one first alloy of low melting point relative to the substrate; and
at least one second alloy of high melting point relative to the first alloy.

9 . The method of claim 8 wherein:
the at least one first alloy comprises about 21.25-22.75 chromium, about 5.7-6.3 aluminum, about 11.5-12.5 cobalt, about 5.7-6.3 silicon, boron in an amount no greater than 1.0 weight percent, and a balance of nickel plus impurities if any; and
the at least one second alloy comprises about 4.75-10.5 chromium, about 5.5-6.7 aluminum, up to about 13 weight percent cobalt, about 3.75-9.0 tantalum, about 1.3-2.25 molybdenum, about 3.0-6.8 tungsten, about 2.6-3.25 rhenium, up to about 0.02 boron, about 0.05-2.0 hafnium, up to about 0.14 carbon, up to about 0.35 zirconium, and a balance of nickel plus impurities if any.

10 . The method of claim 9 wherein:
a boron content of the first alloy is at least 0.30 weight percent greater than a boron content, if any, of the second alloy.

11 . The method of claim 9 wherein:
the at least one first alloy comprises no more than 1.0 weight percent of any other individual element; and
the at least one second alloy comprises no more than 1.0 weight percent of any other individual element.

12 . The method of claim 1 wherein:
the matrix has a characteristic thickness T 2 of 0.10-0.50 millimeters;
the intermediate layer has a thickness of T 3 of 0.50-2.50 millimeters; and
the self-braze material has a characteristic thickness Ti of 0.20-2.5 millimeters.

13 . The method of claim 1 wherein:
the applied combination consists of the self-braze material, the intermediate layer, the abrasive, and the matrix.

14 . The method of claim 1 further comprising forming the combination by:
slurry plating the abrasive and one or more components of the matrix to a first face of a sheet of material of the intermediate layer; and
securing said sheet to a sheet of self braze-material; and
cutting the combination of the plated sheet of intermediate layer material and sheet of self-braze material.

15 . The method of claim 14 further comprising forming the sheet of self-braze material by:
mixing powders of at least two different alloys; and
sintering the mixture.

16 . The method of claim 14 wherein:
the slurry plating comprises nickel and/or cobalt entrapment plating of CrAlY particulate; and
nickel and/or cobalt entrapment plating of the abrasive.

17 .- 18 . (canceled)

19 . An article comprising:
a metallic substrate; a base layer bonded to the substrate; an intermediate layer bonded to the base layer; and a matrix bonded to the intermediate layer and at least partially embedding an abrasive.

20 . The article of claim 19 wherein:
at least a portion of the material has a composition comprising, in weight percent:
cobalt 2.5-13.5;
chromium 12-27;
aluminum 5-7;
yttrium 0.0-1.0;
hafnium 0.0-1.0;
silicon 1.0-3.0;
tantalum 0.0-4.5;
tungsten 0.0-6.5;
rhenium 0.0-2.0;
molybdenum 0.1-1.0; and
the balance nickel plus impurities, if any.

21 . The article of claim 19 being a turbine blade and wherein the base layer is along a tip surface of an airfoil of the blade.

22 . An abrasive braze preform comprising:
a self-braze layer; an intermediate layer secured to the self-braze layer; and a matrix bonded to the intermediate layer and at least partially embedding an abrasive.

23 . The preform of claim 22 wherein one or more of:
the self-braze layer comprises a sintered sheet of:
at least one first alloy of low melting point relative to the substrate; and
at least one second alloy of high melting point relative to the first alloy;
the matrix is an MCrAlY;
the intermediate layer is a pre-cast layer; and
the intermediate layer is diffusion brazed to the self-braze layer.

Assignees

• United Technologies Corp

Inventors

• Stratton Eric W
• Minor Michael J

Classifications

• F05D2220/32

  in gas turbines · CPC title

• C23C24/103

  Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides · CPC title

• F05D2300/132

  Chromium · CPC title

• C23C28/022

  with at least one MCrAlX layer · CPC title

• F05D2300/2282

  of boron · CPC title