Advanced bond coat

Patent metadata

Field	Value
Publication number	US-2016010182-A1
Application number	US-201314106464-A
Country	US
Kind code	A1
Filing date	Dec 13, 2013
Priority date	Mar 15, 2013
Publication date	Jan 14, 2016
Grant date	—

Abstract

In some examples, an alloy may include less than 55 atomic percent aluminum; between about 10 and about 25 atomic percent of a platinum group metal; and a balance of nickel; at least one of chromium, silicon, tantalum, or cobalt; a reactive element; and diffusion impurities; where the alloy has a discrete gamma-prime Ni 3 Al region and a discrete beta NiAl region. In some examples, a coating system may include a substrate; a first layer including gamma-prime Ni 3 Al; and a second layer including beta NiAl, where the first region and the second region are discrete dual region.

First claim

What is claimed is:

1 . An alloy comprising:
less than about 55 atomic percent aluminum; between about 10 and about 25 atomic percent of a platinum group metal; and a balance nickel; at least one of chromium, silicon, tantalum, or cobalt, a reactive element; and diffusion impurities; wherein the alloy comprises a discrete gamma-prime Ni 3 Al region and a discrete beta NiAl region.

2 . The alloy of claim 1 , wherein the reactive element includes at least one of hafnium, yttrium, zirconium, lanthanum, or cerium.

3 . The alloy of claim 2 , wherein the alloy comprises an average reactive element content of less than about 2 atomic percent.

4 . The alloy of claim 2 , wherein the alloy comprises an average reactive element content of less than about 0.5 atomic percent.

5 . The alloy of claim 1 , wherein the alloy comprises an average content of the at least one of chromium, silicon, tantalum, or cobalt of less than about 35 atomic percent.

6 . The alloy of claim 1 , wherein the alloy comprises an average content of the at least one of chromium, silicon, tantalum, or cobalt of between about 5 and about 20 atomic percent.

7 . The alloy of claim 1 , wherein the discrete gamma-prime Ni 3 Al region and the discrete beta NiAl region of the alloy include a coating system on a substrate.

8 . The alloy of claim 7 , wherein the coating system further includes a transition zone between the substrate and the discrete gamma-prime Ni 3 Al region, and wherein the transition zone includes a gamma-Ni phase and a gamma-prime Ni 3 Al phase.

9 . The alloy of claim 7 , wherein an average of the atomic percent of aluminum is non-homogenous through the coating system.

10 . A coating system comprising:
a substrate; a first layer including a gamma-prime Ni 3 Al composition; and a second layer including a beta NiAl composition, wherein the first layer and the second layer are discrete dual layers.

11 . The coating system of claim 10 , wherein the gamma-prime Ni 3 Al composition includes:
less than about 25 atomic percent aluminum; between about 10 and about 25 atomic percent of a platinum group metal; and a balance of nickel; at least one of chromium, silicon, tantalum, of cobalt; a reactive element; and diffusion impurities.

12 . The coating system of claim 10 , wherein the beta NiAl composition includes:
between about 25 and about 55 atomic percent aluminum; between about 10 and about 25 atomic percent of a platinum group metal; and a balance of nickel; at least one of chromium, silicon, tantalum, or cobalt; a reactive element; and diffusion impurities.

13 . The coating system of claim 10 , wherein the first layer includes a platinum group metal modified gamma-prime Ni 3 Al alloy and the second layer includes a platinum group metal modified beta NiAl alloy.

14 . The coating system of claim 10 , wherein the first layer includes a reactive element modified gamma-prime Ni 3 Al alloy and the second layer includes a reactive element modified beta NiAl alloy.

15 . The coating system of 10 , further including a transition zone between the substrate and the first layer, wherein the transition zone includes a gamma-Ni phase and a gamma-prime Ni 3 Al phase.

16 . A method comprising:
positioning a substrate and a precursor in a sealed vessel, wherein the precursor comprises at least one of a solid halide or a combination of a halide activator and a donor; vacuum purging and backfilling the sealed vessel; heating the substrate and the precursor in the sealed vessel to generate a coating gas from the precursor; and reacting the coating gas with the substrate to form a discrete dual region coating including a first region of gamma-prime Ni 3 Al and a second region of beta NiAl.

17 . The method of claim 16 , wherein the first region of gamma-prime Ni 3 Al includes:
less than about 25 atomic percent aluminum; between about 10 and about 25 atomic percent of a platinum group metal; and a balance of nickel; at least one of chromium, silicon, tantalum, or cobalt; a reactive element; and diffusion impurities.

18 . The method of claim 16 , wherein the second layer of beta NiAl includes:
between about 25 and about 55 atomic percent aluminum; between about 10 and about 25 atomic percent of a platinum group metal; and a balance of nickel; at least one of chromium, silicon, tantalum, or cobalt; a reactive element; and diffusion impurities.

19 . The method of claim 16 , further comprising electroplating a platinum group metal on the substrate, and wherein forming the discrete dual region coating comprises forming a platinum group metal modified gamma-prime Ni 3 Al and beta NiAl discrete dual region coating system.

20 . The method of claim 16 , further comprising depositing one or more elements of the discrete dual region coating in an order selected from a group consisting of simultaneous, co-deposited, sequential and combinations thereof.

Assignees

• Rolls Royce Corp

Inventors

• Lee Kang N

Classifications

• C23C16/06

  characterised by the deposition of metallic material · CPC title

• C23C28/021

  including at least one metal alloy layer · CPC title

• C22C19/057

  with the maximum Cr content being less 10% · CPC title

• C22C19/056 Primary

  with the maximum Cr content being at least 10% but less than 20% · CPC title

• B32B15/01

  all layers being exclusively metallic {(making layered metal workpieces by pressure cladding B23K20/22; making coatings with a metallic material characterised by its composition C23C30/00)} · CPC title