Coated articles and method for making

Patent metadata

Field	Value
Publication number	US-2018245194-A1
Application number	US-201815965839-A
Country	US
Kind code	A1
Filing date	Apr 27, 2018
Priority date	Dec 18, 2015
Publication date	Aug 30, 2018
Grant date	—

Abstract

An article includes a substrate comprising a precipitate-strengthened alloy and a coating disposed over the substrate. The alloy comprises a) a population of gamma-prime precipitates, the population having a multimodal size distribution with at least one mode corresponding to a size of less than about 100 nanometers; or b) a population of gamma-double-prime precipitates having a median size less than about 300 nanometers. The coating comprises at least two elements, and further comprises a plurality of prior particles. At least a portion of the coating is substantially free of rapid solidification artifacts. Methods for fabricating the article and for processing powder useful for fabricating the article are also provided.

First claim

1 - 18 . (canceled)

19 . A method comprising:
heat-treating a quantity of metallic powder, the powder having particulates comprising at least two elements and a plurality of rapid solidification artifacts present within the particulates, wherein the heat-treating is performed at a combination of time and temperature effective to remove substantially all of the rapid solidification artifacts from the powder, thereby forming a processed powder having a desired particle size distribution.

20 . The method of claim 19 , wherein heat-treating further includes agitating the powder during heat-treatment.

21 . The method of claim 19 , further comprising mechanically processing sintered material formed during the heat-treating.

22 . The method of claim 21 , wherein mechanically processing comprises milling the sintered material.

23 . The method of claim 19 , further comprising disposing a coating material on a substrate, wherein the processed powder is used as a feedstock for the coating material.

24 . The method of claim 23 , wherein the disposing step comprises spraying the feedstock using a technique that does not melt a substantial portion of the particulates in the feedstock.

25 . The method of claim 24 , wherein the technique includes cold-spraying, flame spraying, liquid injection flame spraying, air plasma spraying, liquid injection air plasma spraying, high-velocity oxyfuel spraying, liquid injection high velocity oxyfuel spraying, high-velocity air-fuel spraying, or liquid injection high-velocity air-fuel spraying.

26 . The method of claim 24 , wherein the technique includes liquid injection high velocity air-fuel spraying.

27 . The method of claim 23 , wherein the substrate comprises a nickel-based superalloy, a nickel-iron-based superalloy, or a cobalt-based superalloy.

28 . The method of claim 9 , wherein the particulates comprise a NiCrAlY composition.

29 . The method of claim 28 , wherein the composition comprises cobalt; from about 28 percent to about 35 percent nickel; from about 17 percent to about 25 percent chromium; from about 5 percent to about 15 percent aluminum; and from about 0.01 to about 1 percent yttrium.

30 . The method of claim 28 , wherein the coating comprises beta phase, at least about 25 percent gamma phase by volume, and less than about 1 percent sigma phase by volume.

31 . A method comprising:
heat-treating a quantity of powder having particulates comprising a MCrAlX composition at a temperature in a range from about 925 degrees Celsius to about 1200 degrees Celsius for at least about 5 minutes to form a processed powder; and disposing a coating material on a substrate using cold-spraying, flame spraying, air plasma spraying, high-velocity oxyfuel spraying, or high-velocity air-fuel spraying, wherein the processed powder is used as a feedstock for the coating material, and wherein the substrate comprises a nickel-based superalloy; wherein the disposing step comprises spraying the feedstock using a technique that does not melt a substantial portion of the particulates in the feedstock.

32 . A method comprising:
disposing a coating onto a substrate by spraying a feedstock, the feedstock comprising a plurality of particulates comprising at least two elements and having at least a portion of the plurality of particulates substantially free of rapid solidification artifacts; wherein spraying the feedstock comprises using a deposition technique that does not melt a substantial portion of the particulates in the feedstock; wherein the substrate comprises a precipitate-strengthened alloy, the alloy comprising a) a population of gamma-prime precipitates, the population having a multimodal size distribution with at least one mode corresponding to a size of less than about 100 nanometers; or b) a population of gamma-double-prime precipitates having a median size less than about 300 nanometers.

33 . The method of claim 32 , wherein the substrate comprises a nickel-based superalloy, a nickel-iron-based superalloy, or a cobalt-based superalloy.

34 . The method of claim 32 , wherein the feedstock comprises a MCrAlY composition.

35 . The method of claim of claim 34 , wherein the feedstock comprises cobalt; from about 28 percent to about 35 percent nickel; from about 17 percent to about 25 percent chromium; from about 5 percent to about 15 percent aluminum; and from about 0.01 to about 1 percent yttrium.

36 . The method of claim 34 , wherein the feedstock comprises a gamma phase and a beta phase.

37 . The method of claim 36 , wherein the feedstock includes less than about 1 percent sigma phase by volume.

38 . The method of claim 36 , wherein the coating is disposed in direct contact with the substrate at an interface, and wherein an interdiffusion zone extending from the interface into the substrate has a thickness of less than about 5 micrometers.

39 . A method comprising:
disposing a coating onto a substrate by spraying a feedstock, the feedstock comprising a plurality of particulates comprising a MCrAlX composition and having at least a portion of the plurality of particulates substantially free of rapid solidification artifacts; wherein spraying the feedstock comprises using a deposition technique that does not melt a substantial portion of the particulates in the feedstock; wherein the substrate comprises a nickel-based superalloy comprising a population of gamma-prime precipitates, the population having a multimodal size distribution with at least one mode corresponding to a size of less than about 100 nanometers.

Assignees

• Gen Electric

Inventors

• Detor Andrew Joseph
• Ajdelsztajn Leonardo
• Bigelow Thomas Michael
• Didomizio Richard
• Emge Andrew William
• Ruud James Anthony
• Weimer Michael James

Classifications

• B22F2301/45

  Rare earth metals, i.e. Sc, Y, Lanthanides (57-71) · CPC title

• B22F2301/15

  Nickel or cobalt · CPC title

• C23C4/073 Primary

  containing MCrAl or MCrAlY alloys, where M is nickel, cobalt or iron, with or without non-metal elements · CPC title

• B22F2301/052

  Aluminium · CPC title

• F05D2300/177

  Ni - Si alloys · CPC title