Three phase bond coat coating system for superalloys

Patent metadata

Field	Value
Publication number	US-2017306451-A1
Application number	US-201615138286-A
Country	US
Kind code	A1
Filing date	Apr 26, 2016
Priority date	Apr 26, 2016
Publication date	Oct 26, 2017
Grant date	—

Abstract

Provided is a nickel-based coating composition containing cobalt, chromium, aluminum, tantalum, and nickel. The coating composition has a three phase γ, γ′, β microstructure wherein at least 5 volume % of the coating composition is present in the β phase. Also provided are coating systems containing the coating composition, articles having the coating composition or coating system, and methods for protecting nickel-based superalloy substrates using the coating composition or coating system.

First claim

1 . A coating system on a substrate comprising:
a nickel-based superalloy substrate; and a nickel-based coating composition disposed on the substrate, the coating composition comprising:
2-12 wt % cobalt;
4-8 wt % chromium;
8-25 wt % aluminum;
5-10 wt % tantalum; and
35-81 wt % nickel,

said coating composition comprising a three phase γ, γ′, β microstructure wherein at least 5 volume % of the coating composition is present in the β phase and a remainder is present in the γ and γ′ phases.

2 . The coating system on a substrate according to claim 1 , wherein the coating composition does not comprise a platinum group metal.

3 . The coating system on a substrate according to claim 1 , wherein the coating composition does not comprise platinum.

4 . The coating system on a substrate according to claim 1 , wherein the nickel-based superalloy substrate comprises:
3-20 wt % cobalt; 2-22 wt % chromium; 0-4 wt % molybdenum; 0-10 wt % tungsten; 0-6 wt % rhenium; 2-8 wt % aluminum; 0-10 wt % tantalum; 0-2 wt % hafnium; 0-5 wt % niobium; 0-4 wt % titanium; 0-5 wt % ruthenium; and a remainder of nickel.

5 . The coating system on a substrate according to claim 4 , wherein the nickel-based superalloy substrate comprises:
3-17 wt % cobalt; 2-14 wt % chromium; 0-3 wt % molybdenum; 3-10 wt % tungsten; 0-6 wt % rhenium; 4-8 wt % aluminum; 3-10 wt % tantalum; 0-2 wt % hafnium; 0-1 wt % niobium; 0-4 wt % titanium; 0-5 wt % ruthenium; and a remainder of nickel.

6 . The coating system on a substrate according to claim 1 , wherein the nickel-based superalloy substrate comprises:
7-8 wt % cobalt; 6. 5-7.5 wt % chromium; 1-2 wt % molybdenum; 4.5-5.5 wt % tungsten; 2.5-3.5 wt % rhenium; 6-7 wt % aluminum; 6-7 wt % tantalum; 0.1-0.6 wt % hafnium; and a remainder of nickel.

7 . The coating system on a substrate according to claim 1 , wherein:
5-35 volume % of the coating composition is present in the 65 phase; 25-70 volume % of the coating composition is present in the γ′ phase; and 5-60 volume % of the coating composition is present in the β phase.

8 . The coating system on a substrate according to claim 7 , wherein:
5-30 volume % of the coating composition is present in the y phase; 30-50 volume % of the coating composition is present in the γ′ phase; and 20-45 volume % of the coating composition is present in the β phase.

9 . The coating system on a substrate according to claim 1 , wherein the coating composition comprises 0.01 to 2 wt % of hafnium, silicon, zirconium, yttrium, or a combination thereof.

10 . The coating system on a substrate according to claim 1 , wherein the coating composition comprises 0.1 to 15 wt % platinum.

11 . The coating system on a substrate according to claim 1 , wherein the coating composition comprises:
9-11 wt % cobalt; 5-7 wt % chromium; 9-16 wt % aluminum; 5-8 wt % tantalum; and 54-72 wt % nickel.

12 . The coating system on a substrate according to claim 11 , wherein:
5-35 volume % of the coating composition is present in the γ phase; 25-70 volume % of the coating composition is present in the γ′ phase; and 5-60 volume % of the coating composition is present in the β phase.

13 . The coating system on a substrate according to claim 11 , wherein the coating composition does not comprise platinum.

14 . An article comprising the coating system on a substrate according to claim 1 .

15 . The article according to claim 14 , wherein said article is a gas turbine engine component.

16 . A nickel-based coating composition comprising:
2-12 wt % cobalt; 4-8 wt % chromium; 8-25 wt % aluminum; 5-10 wt % tantalum; and 35-81 wt % nickel,
said coating composition comprising a three phase γ, γ′, β microstructure wherein at least 5 volume % of the coating composition is present in the β phase, and a remainder is present in the γ and γ′ phases.

17 . The nickel-based coating composition according to claim 16 , wherein the coating composition comprises:
9-11 wt % cobalt; 5-7 wt % chromium; 9-13 wt % aluminum; 5.5-8 wt % tantalum; and 54-72 wt % nickel,
and wherein:
5-35 volume % of the coating composition is present in the γ phase;
25-70 volume % of the coating composition is present in the γ′ phase; and
5-60 volume % of the coating composition is present in the β phase.

18 . The nickel-based coating composition according to claim 17 , wherein the coating composition does not comprise a platinum group metal.

19 . An article comprising the nickel-based coating composition according to claim 18 .

20 . A method for improving the cyclic oxidation life or TBC spallation performance of an article comprising a nickel-based superalloy substrate, the method comprising coating at least a portion of the substrate with a nickel-based coating composition comprising:
2-12 wt % cobalt; 4-8 wt % chromium; 8-25 wt % aluminum; 5-10 wt % tantalum; and 35-81 wt % nickel,
said coating composition comprising a three phase γ, γ′, β microstructure wherein at least 5 volume % of the coating composition is present in the β phase and a remainder is present in the γ and γ′ phases.

Assignees

• Gen Electric

Inventors

• Dheeradhada Voramon Supatarawanich
• Lipkin Don Mark
• Suzuki Akane

Classifications

• 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

• B32B2603/00

  Vanes, blades, propellers, rotors with blades · CPC title

• B32B15/043

  of metal (B32B15/01 takes precedence) · CPC title

• C22C19/058 Primary

  without Mo and W · CPC title

• C22C19/007

  with a light metal (alkali metal Li, Na, K, Rb, Cs; earth alkali metal Be, Mg, Ca, Sr, Ba, Al Ga, Ge, Ti) or B, Si, Zr, Hf, Sc, Y, lanthanides, actinides, as the next major constituent · CPC title