Coatings for metallic substrates

Patent metadata

Field	Value
Publication number	US-9931815-B2
Application number	US-201414774998-A
Country	US
Kind code	B2
Filing date	Mar 12, 2014
Priority date	Mar 13, 2013
Publication date	Apr 3, 2018
Grant date	Apr 3, 2018

Abstract

Coatings for substrates, such as superalloy substrates, are provided. The coating can include: 15 wt % to 45 wt % cobalt; 20 wt % to 40 wt % chromium; 2 wt % to 15 wt % aluminum; 0.1 wt % to 1 wt % yttrium; and nickel. The coatings may include nickel, cobalt, chromium and aluminum, and other optional additives to improve oxidation and corrosion resistance of the substrate without significant debit to its mechanical properties.

First claim

What is claimed is:

1. A turbine component, comprising:
a superalloy substrate; and
a coating on the superalloy substrate, wherein the coating defines an external surface of the turbine component that is exposed to a hot gas flow path in a gas turbine, and wherein the coating comprises:
15 wt % to 45 wt % cobalt;
20 wt % to 40 wt % chromium;
2 wt % to 15 wt % aluminum;
0.1 wt % to 1 wt % yttrium; and
nickel;

wherein the coating comprises a distribution of pinning agents, the pinning agents are located at the interfaces between grains defined in the coating, and the average grain size of the coating is 0.1 microns to 5 microns.

2. The turbine component of claim 1 , wherein the coating comprises 30 wt % to 40 wt % cobalt, and wherein the coating comprises 55 wt % to 75 wt % of a combined amount of nickel and cobalt.

3. The turbine component of claim 1 , wherein the coating comprises 21 wt % to 30 wt % chromium.

4. The turbine component of claim 1 , wherein the coating comprises 5 wt % to 14 wt % aluminum.

5. The turbine component of claim 1 , wherein the coating has a thickness on the superalloy substrate that is 5 μm to 100 μm.

6. The turbine component of claim 1 , wherein the average grain size of the coating is 0.5 microns to 2.5 microns.

7. The turbine component of claim 1 , wherein the coating is deposited by chemical vapor deposition, atomic layer deposition, physical vapor deposition, plating, thermal spray, or diffusion coating processes, and wherein the superalloy substrate comprises a nickel-based superalloy, a cobalt-based superalloy, or an iron-based superalloy.

8. The turbine component of claim 1 , wherein the pinning agents comprise ceramic particles, and wherein the ceramic particles comprise oxides of aluminum, titanium, yttrium, hafnium, zirconium, lanthanum, or mixtures thereof; carbides of titanium, tantalum, niobium, zirconium, hafnium, or mixtures thereof; oxy-nitrides of titanium, tantalum, niobium, hafnium, zirconium, and yttrium or mixtures thereof; or a combination thereof.

9. The turbine component of claim 1 , wherein the coating further comprises at least one of lanthanum, cerium, zirconium, magnesium, a rare earth metal, or a combination thereof.

10. The turbine component of claim 1 , wherein the coating further comprises:
0 wt % to 10 wt % tungsten;
0 wt % to 10 wt % tantalum;
0 wt % to 0.5 wt % hafnium; and
0 wt % to 0.5 wt % silicon.

11. The turbine component of claim 1 , wherein the coating further comprises: tungsten, molybdenum, tantalum, rhenium, titanium, niobium, vanadium, a platinum group metal, or a combination thereof, wherein the total combined amount of these elements is 20 wt % or less.

12. The turbine component of claim 1 , wherein the coating consists essentially of:
30 wt % to 40 wt % cobalt;
22 wt % to 25 wt % chromium;
8 wt % to 12 wt % aluminum;
0.1 wt % to 1 wt % yttrium; and
nickel.

13. The turbine component of claim 1 , wherein the coating consists essentially of:
30 wt % to 40 wt % cobalt;
22 wt % to 25 wt % chromium;
8 wt % to 12 wt % aluminum;
0.1 wt % to 1 wt % yttrium;
nickel; and
the distribution of pinning agents.

14. A gas turbine comprising the turbine component of claim 1 , wherein the turbine component is positioned within a hot gas flow path of the gas turbine such that the coating exposed to the hot gas flow path protects the superalloy substrate within the gas turbine.

15. The turbine component of claim 1 , wherein the coating has a thickness on the superalloy substrate that is 10 μm to about 90 μm.

16. The turbine component of claim 1 , wherein the coating has a thickness on the superalloy substrate that is 12 μm to 75 μm.

Assignees

• Gen Electric

Inventors

• Mourer David Paul
• Ajdelsztajn Leonardo
• Bain Kenneth Rees
• Detor Andrew Joseph
• Emge Andrew William
• Ruud James Anthony
• Weimer Michael James

Classifications

• C23C4/18

  After-treatment · CPC title

• F05D2300/175

  Superalloys · CPC title

• C22C19/055

  with the maximum Cr content being at least 20% but less than 30% · CPC title

• B32B15/013 Primary

  one layer being formed of an iron alloy or steel, another layer being formed of a metal other than iron or aluminium · CPC title

• C23C10/28

  using solids, e.g. powders, pastes · CPC title