Method for protection against corrosion

Patent metadata

Field	Value
Publication number	US-2022251713-A1
Application number	US-202017614145-A
Country	US
Kind code	A1
Filing date	May 26, 2020
Priority date	May 27, 2019
Publication date	Aug 11, 2022
Grant date	—

Abstract

The present invention relates to a method for the protection of a hafnium-free, nickel-based monocrystalline superalloy part against corrosion and oxidation. The method comprises at least the following steps of: manufacturing a hafnium-free, nickel-based monocrystalline superalloy part ( 1 ), depositing on the part a first hafnium-free sublayer ( 2 ), depositing, on the first sublayer ( 2 ), a second hafnium-doped sublayer ( 3 ), depositing, on the second sublayer ( 3 ), a third hafnium-free sublayer ( 4 ), sandblasting the third sublayer ( 4 ) to at least partially separate the third sublayer ( 4 ) and increase the surface roughness of an upper sub-layer formed by the second sublayer ( 3 ) and at least partially by the third sublayer ( 4 ), performing oxidation treatment so as to obtain at the surface a layer of hafnium-doped oxidised material ( 5 ), depositing a thermal barrier layer ( 6 ) on the layer of oxidised material ( 5 ).

First claim

1 . A process for protecting a hafnium-free nickel-based single-crystal superalloy component against corrosion and oxidation, wherein the process comprises:
manufacturing a hafnium-free nickel-based single-crystal superalloy component, depositing a first hafnium-free bond coat on the component, depositing a second hafnium-doped bond coat on the first bond coat, depositing a third hafnium-free bond coat on the second bond coat, stripping the third bond coat by sandblasting to at least partially remove the third bond coat and increase the surface roughness of an upper bond coat formed by the second bond coat and at least partially by the third bond coat, carrying out an oxidation treatment so as to obtain a layer of hafnium-doped oxidized material on the surface, depositing a thermal barrier layer on the layer of hafnium-doped oxidized material.

2 . The process as claimed in claim 1 , wherein the thermal barrier layer is deposited by thermal spraying according to a suspension plasma spraying method.

3 . The process as claimed in claim 1 , wherein the thermal barrier layer is deposited according to a physical vapor deposition PVD method.

4 . The process as claimed in claim 1 , wherein the third bond coat is completely stripped off during stripping by sandblasting.

5 . The process as claimed in claim 1 , wherein the mass percentage of hafnium C3 in the second bond coat corresponds to a predetermined value as a function of a mean mass percentage of hafnium in the component expected.

6 . The process as claimed in claim 5 , wherein the mass percentage C3 of hafnium in the second bond coat 3 is determined as follows:

C
⁢
3

=

Cmean
⁢

V
⁢
2

+

V
⁢
3

+

V
⁢
4

V
⁢
3

with V2 the volume of the first bond coat, V3 the volume of the second bond coat and V4 the volume of the third bond coat, and Cmean the mean mass percentage of hafnium in the component.

7 . The process as claimed in claim 1 , wherein the oxidation treatment of the second bond coat is carried out by a heat treatment under partial pressure of oxygen or argon, the heat treatment comprising a phase of increasing the temperature until a temperature comprised between 900° C. and 1200° C. is reached, a phase of holding this temperature for less than one hour and a phase of cooling until room temperature is reached.

8 . The process as claimed in claim 1 , wherein the first bond coat and/or the third bond coat consists of an alloy selected from NiPtAl or MCrAlX, with M equal to cobalt, nickel, or cobalt-nickel, and with X equal to yttrium or silicon.

9 . The process as claimed in claim 1 , wherein the second bond coat consists of an alloy selected from AlHf or MCrAlYHf, with M equal to cobalt, nickel, or cobalt-nickel.

10 . The process as claimed in claim 1 , wherein the third bond coat consists of an alloy selected from NiPtAl or MCrAlX, with M equal to cobalt, nickel, or cobalt-nickel, and with X equal to yttrium or silicon.

11 . The process as claimed in claim 1 , wherein all the deposition steps are performed by the same deposition device.

12 . A hafnium-free nickel-based single-crystal superalloy component, protected against corrosion by a process as claimed in claim 1 .

13 . The process as claimed in claim 1 , wherein the thermal barrier layer is deposited by sputtering.

Assignees

• Safran

Inventors

• Saboundji Amar
• Bianchi Luc Patrice

Classifications

• C23C4/11

  Oxides · CPC title

• C23C8/02 Primary

  Pretreatment of the material to be coated (C23C8/04 takes precedence) · CPC title

• C23C4/02

  Pretreatment of the material to be coated, e.g. for coating on selected surface areas · CPC title

• C23C4/134

  Plasma spraying · CPC title

• C23C28/3455 Primary

  with a refractory ceramic layer, e.g. refractory metal oxide, ZrO2, rare earth oxides or a thermal barrier system comprising at least one refractory oxide layer · CPC title