MCrAlY bond coat with enhanced yttrium

Patent metadata

Field	Value
Publication number	US-9428825-B1
Application number	US-201213363486-A
Country	US
Kind code	B1
Filing date	Feb 1, 2012
Priority date	Feb 1, 2012
Publication date	Aug 30, 2016
Grant date	Aug 30, 2016

Abstract

One or more embodiments relates to a method of producing an MCrAlY bond coat comprising an MCrAlY layer in contact with a Y—Al 2 O 3 layer. The MCrAlY layer is comprised of a γ-M solid solution, a β-MAl intermetallic phase, and Y-type intermetallics. The Y—Al 2 O 3 layer is comprised of Yttrium atoms coordinated with oxygen atoms comprising the Al 2 O 3 lattice. The method comprises depositing an MCrAlY material on a substrate, applying an Y 2 O 3 paste, and heating the substrate in a non-oxidizing atmosphere at a temperature between 400-1300° C. for a time sufficient to generate the Y—Al 2 O 3 layer. Both the MCrAlY layer and the Y—Al 2 O 3 layer have a substantial absence of Y 2 O 3 , YAG, and YAP phases.

First claim

What is claimed is:

1. A method of producing a bond coat comprising:
depositing an MCrAlY material to a substrate surface of a substrate, where the MCrAlY material is comprised of chromium, aluminum, yttrium, and a base metal M, where the base metal M is Ni, Co, Fe, or combinations thereof, thereby generating an MCrAlY material surface, where the MCrAlY material surface is a surface of the MCrAlY material separated from the substrate surface by some portion of the MCrAlY material;
applying a Y 2 O 3 paste to the MCrAlY material surface, where the Y 2 O 3 paste is comprised of Y 2 O 3 and a halide activator, balance inert filler and inert transport fluid, and where the Y 2 O 3 is at least 10 wt. % of the combined weight of the Y 2 O 3 , halide activator, and inert filler, and where the halide activator is at least about 0.1 wt. % of the combined weight of the Y 2 O 3 and the halide activator, thereby generating a Y 2 O 3 upper surface, where the Y 2 O 3 upper surface is a surface of the Y 2 O 3 paste separated from the MCrAlY material surface by some portion of the Y 2 O 3 paste, and thereby forming a paste covered article;
heating the paste covered article at a temperature of about 400° C. to about 1300° C. in a non-oxidizing atmosphere for a period of time, where the period of time is sufficient to generate an MCrAlY layer and a Y—Al 2 O 3 layer, where the MCrAlY layer is comprised of γ-M solid solution, β-MAl intermetallic, and Y-type intermetallics, and the Y—Al 2 O 3 layer is comprised of Yttrium atoms and Al 2 O 3 , where the Yttrium atoms are coordinated with oxygen atoms comprising the Al 2 O 3 , and where the Y—Al 2 O 3 layer is in contact with the MCrAlY layer, thereby generating a heat treated article; and
removing any remaining Y 2 O 3 paste from the heat treated article, thereby generating a bond coated article, where the bond coated article is comprised of the bond coat.

2. The method of claim 1 where the MCrAlY material is comprised of at least 7 wt. % aluminum, less than about 25 wt. % chromium, from about 0.05 to about 1.5 wt. % yttrium, and greater than about 50 wt. % of the base metal M.

3. The method of claim 2 where the paste covered article has a MCrAlY material thickness and a Y 2 O 3 paste thickness, where the MCrAlY material thickness is a first distance measured in a direction substantially normal to the substrate surface and between the substrate surface and the MCrAlY material surface, where the Y 2 O 3 paste thickness is a second distance measured in a direction substantially normal to the substrate surface and between the MCrAlY material surface and the Y 2 O 3 upper surface, and where the MCrAlY material thickness is less than about 20 microns thick and the Y 2 O 3 paste thickness is less than about 1 micron thick.

4. The method of claim 3 further comprised of applying a topcoat material to the Y 2 O 3 upper surface of the paste covered article.

5. The method of claim 4 where the topcoat material is comprised of yttria stabilized zirconia.

6. The method of claim 2 where the MCrAlY material is comprised of from about 15 to about 25 wt. % chromium and from about 10 to about 15 wt. % aluminum.

7. The method of claim 6 where the non-oxidizing atmosphere has a partial pressure of oxygen less than about 10 −3 mbar.

8. The method of claim 7 where the substrate is comprised of a nickel-base alloy, and where the base metal M is Ni, Co, or Ni and Co.

9. The method of claim 8 where the MCrAlY material is comprised of less than about 0.15 wt. % Yttrium.

10. The method of claim 7 where the temperature is about 900° C. to about 1300° C. and the period of time is greater than or equal to 2 hours.

11. The method of claim 7 where the MCrAlY layer and the Y—Al 2 O 3 layer have a substantial absence of Yttrium-Aluminum Garnet and Yttrium-Aluminum Perovskite.

12. A method of producing a bond coat comprising:
depositing an MCrAlY material to a substrate surface of a substrate, where the MCrAlY material is comprised of at least 7 wt. % aluminum, less than about 25 wt. % chromium, from about 0.05 to about 1.5 wt. % yttrium, and greater than about 50 wt. % of a base metal M, where the metal base M is Ni, Co, or Ni and Co, thereby generating an MCrAlY material surface, where the MCrAlY material surface is a surface of the MCrAlY material separated from the substrate surface by some portion of the MCrAlY material;
applying a Y 2 O 3 paste to the MCrAlY material surface, where the Y 2 O 3 paste is comprised of Y 2 O 3 and a halide activator, balance inert filler and inert transport fluid, and where the Y 2 O 3 is at least 10 wt. % of the combined weight of the Y 2 O 3 , halide activator, and inert filler, and where the halide activator is at least about 0.1 wt. % of the combined weight of the Y 2 O 3 and the halide activator, thereby generating a Y 2 O 3 upper surface, where the Y 2 O 3 upper surface is a surface of the Y 2 O 3 paste separated from the MCrAlY material surface by some portion of the Y 2 O 3 paste, and thereby forming a paste covered article;
heating the paste covered article at a temperature of about 400° C. to about 1300° C. in a non-oxidizing atmosphere for a period of time, where the period of time is sufficient to generate an MCrAlY layer and a Y—Al 2 O 3 layer, where the MCrAlY layer is comprised of γ-M solid solution, β-MAl intermetallic, and Y-type intermetallics, and the Y—Al 2 O 3 layer is comprised of Yttrium atoms and Al 2 O 3 , where the Yttrium atoms are coordinated with oxygen atoms comprising the Al 2 O 3 , and where the Y—Al 2 O 3 layer is in contact with the MCrAlY layer, thereby generating a heat treated article; and
removing any remaining Y 2 O 3 paste from the heat treated article, thereby generating a bond coated article, where the bond coated article is comprised of the bond coat.

13. The method of claim 12 where the MCrAlY material is comprised of from about 15 to about 25 wt. % chromium and from about 10 to about 15 wt. % aluminum.

14. The method of claim 13 where the substrate is comprised of a nickel-base alloy.

15. The method of claim 14 where the paste covered article has a MCrAlY material thickness and a Y 2 O 3 paste thickness, where the MCrAlY material thickness is a first distance measured in a direction substantially normal to the substrate surface and between the substrate surface and the MCrAlY material surface, where the Y 2 O 3 paste thickness is a second distance measured in a direction substantially normal to the substrate surface and between the MCrAlY material surface and the Y 2 O 3 upper surface, and where the MCrAlY material thickness is less than about 20 microns thick and the Y 2 O 3 paste thickness is less than about 1 micron thick.

16. The method of claim 15 where the non-oxidizing atmosphere has a partial pressure of oxygen less than about 10 −3 mbar.

17. The method of claim 16 where the period of time is greater than or equal to 2 hours.

18. The method of claim 17 further comprised of applying a topcoat material to the Y 2 O 3 upper surface of the paste covered article.

19. The method of claim 18 where the topcoat material is comprised of yttria stabilized zirconia.

20. The method of claim 17 where the temperature is about 900° C. to about 1300° C.

21. The method of claim 20 where the MCrAlY layer has a yttrium component, where the yttrium component is the weight percent of yttrium within the MCrAlY layer, and where the Y-type intermetallics comprise of at least 90 wt. % of the ytt

Assignees

• Jablonski Paul D
• Hawk Jeffrey A
• Us Dept Energy

Inventors

• Jablonski Paul D
• Hawk Jeffrey A

Classifications

• B32B15/20

  comprising aluminium or copper {(B32B15/016 and B32B15/017 take precedence)} · 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

• Y10T428/12611

  Oxide-containing component · CPC title

• C23C28/042

  including a refractory ceramic layer, e.g. refractory metal oxides, ZrO2, rare earth oxides · CPC title

• Y10T428/1266

  O, S, or organic compound in metal component · CPC title