Patent Grant
7264887
The present invention relates to a layered bond coating deposited on an article and to a method of depositing the bond coating.
Components designed for the use in the area of high temperature, e.g. blades or vanes of a gas turbine, are usually coated with environmentally resistant coatings. The coating protects the base material against corrosion and oxidation due to the thermal effect of the hot environment and consists of an alloy mostly using the elements Al and Cr. Most turbine components are coated for the protection from oxidation and/or corrosion with, for example, a MCrAlY coating (base coat) and some are also coated with a Thermal Barrier Coating (TBC) for thermal insulation. MCrAlY protective overlay coatings are widely known in the prior art. They are a family of high temperature coatings, wherein M is selected from one or a combination of iron, nickel and cobalt. As an example, U.S. Pat. No. 3,528,861 or U.S. Pat. No. 4,585,481 disclose such kind of oxidation resistant coatings. U.S. Pat. No. 4,152,223, as well discloses such method of coating and the coating itself. Besides the γ/β-MCrAlY-coating, there is another class of overlay MCrAlY coatings which are based on a γ/γ′-gamma/gamma prime-structure, such as is disclosed in U.S. Pat. No. 4,973,445. The advantages of γ/γ′-coatings is that they have a negligible thermal expansion mismatch with alloy of the underlying turbine article. For higher thermal fatigue resistance the γ/γ′-coating are more convenient compared to the γ/β-type of MCrAlY-coatings. A higher thermal fatigue resistance in coatings is most desirable since failure of the most turbine blades and vanes at elevated temperature is typically thermal fatigue driven.
Among γ/γ′-coatings and γ/β-coatings, the field of γ/β-coatings have been an active area of research and a series of patents has been issued. E.g. a NiCrAlY coating is described in U.S. Pat. No. 3,754,903 and a CoCrAlY coating in U.S. Pat. No. 3,676,058. U.S. Pat. No. 4,346,137 discloses an improved high temperature fatigue resistance NiCoCrAlY coating. U.S. Pat. No. 4,419,416, U.S. Pat. No. 4,585,481, U.S. Reissue Pat. No. RE-32,121 and U.S. Pat. No. 4,743,514 describe MCrAlY coatings containing Si and Hf. U.S. Pat. No. 4,313,760 discloses a superalloy coating composition with good oxidation, corrosion and fatigue resistance.
Furthermore, in the state of the art Thermal Barrier Coatings (TBC) are known from different patents. U.S. Pat. No. 4,055,705, U.S. Pat. No. 4,248,940, U.S. Pat. No. 4,321,311 or U.S. Pat. No. 4,676,994 disclose a TBC-coating for the use in the turbine blades and vanes. The ceramics used are yttria stabilized zirconia and applied by plasma spray (U.S. Pat. Nos. 4,055,705 and 4,248,940) or by electron beam process (U.S. Pat. Nos. 4,321,311 and 4,676,994) on top of the MCrAlY bond coat.
Attempts have made in the literature in improving the adhesion of TBC by surface modification of the underlying bond coats. Briefly, U.S. Pat. No. 5,894,053 formed a rough surface on bond coat by applying a particulate metallic powders prior to ceramic thermal barrier coatings. The essential content of the patent is a process of forming a roughened surface by applying particulate materials on the bond coat using binder, and soldering powder. The disadvantages of the process could be the microstructural incompatibilities of the soldering materials with the coatings and thereby weakening the TBC interface at the Thermal Grown Oxide (TGO). In U.S. Pat. No. 4,095,003 a rough bond coat surface is formed by spraying a second layer of the bond coat using coarser plasma spray powders. In details the goal of U.S. Pat. No. 4,095,003 was to first provide a sealing layer to protect the substrate by a bond coat and then form a rough surface upon the bond coat by plasma spraying with coarse particles. Not considered was the formation of higher amount of transient oxides on the rough surface of MCrAlY coatings. These oxides are NiO and Cr2O3 including mixed oxides or spinel are formed during early oxidation. This observation is relevant to the TGO formed on the bond coat. The transient oxides formed are in contact with the TBC thusly weakening the interface.
Similar concepts of surface roughening were also used by U.S. Pat. No. 5,403,669; U.S. Pat. No. 5,579,534. In U.S. Pat. No. 5,403,669 the substrate is coated with a bond coat, then a rough bond coat is formed by plasma spraying then over aluminising the bond coat which is followed by TBC deposition. In U.S. Pat. No. 5,866,271 formed the rough surface on the superalloy substrate itself by either grit blasting, water jet blasting, plasma etching or atmospheric plasma spraying followed by aluminising or Pt aluminising of the surface prior to TBC application. In U.S. Pat. No. 6,242,050 formed the rough surface on the bond coat by application of powder using aluminum-silicon slurry. In yet in another patent U.S. Pat. No. 6,264,766 produced the rough surface by interwoven wires followed by metallic slurry coatings on the interwoven wires.
The rough surface tends to form transient oxides easily during early oxidation. The transient oxides are NiO and Cr2O3 and mixed oxides, i.e., spinel. Similarly, the rough surface formed by plasma spraying with coarse particles tends to form transient oxides during early oxidation. These transient oxides constituting the upper surface of the TGO is a weak point in the adhesion of TBC at the interface. The preferred oxide in the TGO is the alumina. A rough surface that does not form transient oxides or removal of transient oxides prior to TBC deposition will be a benefit in TBC adhesion. But, the rough surface formed by spraying of coarse particles tends to nucleate a higher amount of transient NiO and Cr2O3 in the scale.
Formation of alumina scale on the bond coat by pre-oxidation is known in the literature. In U.S. Pat. No. 6,123,997 preoxidized bond coats under defined temperatures and oxygen partial pressures to form alumina wherein the bond coat may also contain doped Pt or other noble metals. In yet another patent, U.S. Pat. No. 6,066,405, bond coats are used having an integrated bond coat with aluminum from 18 to 24 percent and integrated platinum content from 18 to 45 percent. U.S. Pat. No. 3,918,139 discloses a MCrAlY coating which comprises 3 to 12% of a noble metal selected from the group consisting of platinum or rhodium. The presence of platinum or rhodium greatly improves sulfidation resistance, and known to provide benefits to oxide adherence as well as reduce the propensity of forming transient oxides.
Furthermore, German Patent Document DE-A1-19842417 discloses a MCrAlY coating onto which a layer of pure platinum of 1 to 20 micrometer is deposited before it is coated with a ceramic coating. The platinum is applied for reasons of increased adherence of the Thermal Barrier Coating and the formation of a thin layer of aluminum oxide.
In addition, U.S. Pat. No. 5,942,337 discloses a multi-layered Thermal Barrier Coating for a superalloy article comprises a platinum enriched superalloy, a MCrAlY bond coating on the platinum enriched superalloy layer, a platinum enriched MCrAlY layer on the MCrAlY bond coating, a platinum aluminide coating on the platinum enriched MCrAlY layer, an oxide layer on the platinum aluminide coating and a ceramic Thermal Barrier Coating on the oxide layer.
An object of the present invention is to provide a method of depositing a thinner MCrAlY bond coating uniformly over the surface of the blades and vanes. The bond coat should be ductile. A further or alternate object of the present invention is to provide a bond coating with an enhanced surface roughness for an increased TBC adhesion. The roughened layer deposited for TBC adhesion should form continuous alumina scale devoid of any NiO or Cr2O3 i.e. mixed oxides. Yet a further or alternate object of the present invention is to provide a layer on top of the coating which forms an alumina TGO readily in the engine or by prior heat treatment. In addition, a coating process should be used that allows deposition of thin coatings. The attempt here is to reduce the effects of the coefficient thermal expansion (CTE) mismatch and bond coat properties effects i.e. modulas etc. on adhesion.
The present invention provides an article (1) coated on the surface with an inner layer (2) of a high temperature metallic coating consisting of β-NiAl comprising one or a combination of Fe, Ga, Mo, B, Hf or Zr or γ/β-MCrAlY comprising one or a combination of Fe, Ga, Mo, B, Hf or Zr or γ/γ′- or γ-MCrAlY, and the coating comprising a platinum type metal, the platinum type metal material selected from the group consisting of platinum (Pt), palladium (Pd) and rhodium (Rh) and coated with an outer layer (3) of a high temperature metallic coating consisting of β-NiAl comprising one or a combination of Fe, Ga, Mo, B, Hf or Zr or γ/β-MCrAlY comprising one or a combination of Fe, Ga, Mo, B, Hf or Zr or γ/γ′- or γ-MCrAlY, and a platinum type metal, the platinum type metal material selected from the group consisting of platinum (Pt), palladium (Pd) and rhodium (Rh), the outer layer (3) being deposited on top of the inner layer (2) and being more coarse than the inner layer (2) and coated with a Thermal Barrier Coating (4).
The present invention also provides an article (1) coated on the surface with an inner layer (2) of a high temperature metallic coating consisting of β-NiAl comprising one or a combination of Fe, Ga, Mo, B, Hf or Zr or γ/γ-MCrAlY comprising one or a combination of Fe, Ga, Mo, B, Hf or Zr or γ/γ′- or γ-MCrAlY, and coated with an outer layer (3) of a high temperature metallic coating consisting of β-NiAl comprising one or a combination of Fe, Ga, Mo, B, Hf or Zr or γ/β-MCrAlY comprising one or a combination of Fe, Ga, Mo, B, Hf or Zr or γ/γ′- or γ-MCrAlY, the outer layer (3) being deposited on top of the inner layer (2) and being more coarse than the inner layer (2) and coated with at least a layer (5) of a platinum type metal, the platinum type metal material selected from the group consisting of platinum (Pt), palladium (Pd) and rhodium (Rh), the layer (5) of a platinum type metal is deposited on to the surface of the article (1), between the inner and the outer layer (2, 3) or on top of the outer layer (2), and coated with a Thermal Barrier Coating (4).
Furthermore, the present invention provides a method of depositing a bond coating to a surface of an article (1), wherein before a Thermal Barrier Coating (TBC) is applied, comprising the steps of:
In addition, the present invention provides a method of depositing a bond coating to a surface of an article (1), wherein before a Thermal Barrier Coating (TBC) is applied,
Present approaches to reduce or inhibit formation of transient scale on rough surface include:
In addition to above the other factors known beneficial to adhesion are a) minimize the Coefficient Thermal Expansion (CTE) mismatch and b) use a thinner and ductile bond coat. The addition of Fe in small quantity to β-NiAl or γ/β-MCrAlY has been found to enhance the coating ductility.
Recent development in coating manufacturing technologies have shown that the electroplated process, can deposit thin MCrAlY coating with the additional advantage that the process has no line of sight limitation and can coat large industrial gas turbine components without any difficulty.
Due to the fact that the outer bond coating layer is deposited using a powder which is more coarse then the underlying inner layer, the surface roughness and the TBC adherence is significantly increased. The coating will comprise one or a combination of Fe, Ga, Mo, B, Hf or Zr for the reason of increased ductility of the bond coating and improved fatigue resistance due to addition of individually or in combination (wt.-%) 0.01-8% Fe, 0.1-8% Ga, 0.1-8% Mo, 0.01-0.5% Zr, 0.05-1% B, preferably 0.01-4% Fe, 0-1% Ga, 0-2% Mo, 0.05-0.3% Zr, 0-0.1% B, 0.1-0.5% Hf or (wt.-%) below 4% Fe+Ga+Mo+B+Zr+Hf, whereby Zr is less than 0.3% and B is less than 0.01%. The platinum type metal in the range of (wt.-%) 0.1-20% Pt, Pd or Rh or the layer of pure platinum is added to promote formulation of pure Al2O3 with no transient oxides.
Pt can be blended with the dispersed β-NiAl or γ/β-MCrAlY particles, the β-NiAl or γ/β-MCrAlY particles comprising one or a combination of Fe, Ga, Mo, B, Hf or Zr in the structure. Where a γ/γ′- or γ-MCrAlY coating is applied it can be as well blended with dispersed α-NiAl or γ/β-MCrAlY particles, the β-NiAl or γ/β-MCrAlY particles comprising one or a combination of Fe, Ga, Mo, B, Hf or Zr in the structure can be over coated with Pt. The high aluminum β-NiAl or γ/β-MCrAlY particles are to replenish the aluminum lost by oxidation and depletion as a function of time and temperature. The γ/γ′- or γ-MCrAlY coating or the Pt type metal layer will comprise a volume fraction of 0.1-5% β-NiAl or γ/β-MCrAlY particles.
For the formation of Al2O3 prior to TBC-deposition the deposited bond coating can be heat-treated at temperatures up to 1150° C., which is possible in air, hydrogen, argon, vacuum or an environment conductive to form the alumina scale. Preferentially subsequent to heat-treatment the bond coating system can be thermally cycled to remove any transient that may have been formed during heat-treatment.
An inner layer of MCrAlY class of coatings can be conveniently deposited by electroplated process to provide a relatively thin and uniform coating, whereas when the inner layer is of β-NiAl it can be applied by CVD, gas phase, chemical vapor deposition or pack cementation process.
The outer and coarse layer of MCrAlY or β-NiAl comprising one or a combination of Fe, B, Ga, Mo, Hf or Zr may be deposited on the inner layer of the bond coat by plasma spray in air or vacuum or any other conventional methods used for deposition of overlay and bond coatings.
The layer of a pure platinum type metal can be deposited by plating or any other conventional process used for elemental deposition of platinum on metallic substrate such an electrolytic process.
The present invention is discussed in detail below with reference to the accompanying drawings, in which:
a-c show a second example for different layers of the bond coating according to the present invention; and
According to the invention the MCrAlY bond coating consists of two different layers 2, 3. An inner layer 2 on top of the surface of the article 1 consisting of MCrAlY with a structure of β-NiAl, γ/β-MCrAlY, γ/γ′- or γ-MCrAlY. The coating will comprise a platinum type metal, the platinum type metal material selected from the group consisting of platinum (Pt), palladium (Pd) and rhodium (Rh). The inner layer 2 is deposited with a powder in the size range from 3 to 65 μm i.e. 3 to 20 μm by electroplated process and 20 to 65 μm by plasma spraying. An outer layer 3 on top of the inner layer 2 consists again of β-NiAl, γ/β-MCrAlY or γ/γ′-MCrAlY or γ-MCrAlY comprising a platinum type metal, the platinum type metal material selected from the group consisting of platinum (Pt), palladium (Pd) and rhodium (Rh). But, in contradiction to the inner layer 2, the outer layer 3 is deposited with a powder, which is more coarse than the inner layer 2, in the size range from 30 to 150 μm. The composition and microstructure of the outer layer 3 can also be independently adjusted to allow formation of an alumina scale beneath the TBC.
A ceramic coating such as a Thermal Barrier Coating (TBC), which is zirconia stabilized by yttria, ceria, calcia, scandia or lanthania, is deposited on top of the outer bond coating layer 3. Due to the fact that the outer bond coating layer 3 is deposited using a powder which is coarser then the underlying inner layer, the surface roughness and the TBC adherence is significantly increased.
According to
As an example according to
If a β-NiAl or γ/1-MCrAlY is used as an inner or outer layer 2, 3 it will comprise alone or in combination Fe, Ga, Mo, B, Hf, or Zr for the reason of increased ductility of the bond coating and improved fatigue resistance without reducing the oxidation resistance. As an example the inner and/or the outer layer 2, 3 of β-NiAl or γ/β-MCrAlY coating comprise individually or in combination (wt.-%) 0.01-8% Fe, 0.1-8% Ga, 0.1-8% Mo, 0.01-0.5% Zr, 0.05-1% B, preferably 0.01-4% Fe, 0-1% Ga, 0-2% Mo, 0.05-0.3% Zr, 0-0.1% B, 0.1-0.5% Hf. As another example the β-NiAl or γ/β-MCrAlY coating will comprise (wt.-%) below 4% Fe+Ga+Mo+B+Zr+Hf, whereby Zr is less than 0.3% and B is less than 0.01%. These figures are as well valid for the above mentioned β-NiAl or γ/β′-MCrAlY particles within the layer 5 of platinum type metal or a γ/γ′- or γ-MCrAlY-coating.
If a γ/γ′- or γ-MCrAlY is used for the inner and/or outer layer 2, 3 it can be blended with disperses β-NiAl or γ/β-MCrAlY particles, the β-NiAl or γ/β-MCrAlY particles comprising one or a combination of Fe, Ga, Mo, B, Hf or Zr in the structure in the range as mentioned above. The high aluminum β-NiAl or γ/β-MCrAlY particles are to replenish the aluminum lost by oxidation and depletion as a function of time and temperature.
The oxidation resistance of the mentioned coating layer 2, 3 are improved by a small addition of Y, Hf, Si, Zr. These elements may added in the range of (wt. %) 0.001-0.5% Y, 0.1-4% Si, 0.01-0.2% Zr.
The overall bonding layer 2, 3 will have a thickness of 50 to 400 micrometers, a preferred range of 50 to 300 micrometers and a most preferred range of 50 to 125 micrometers. The fatigue resistance can be further increased by using thinner coatings. Thereby with the methods mentioned herein an inner layer 2 with a thickness in a range of 50 to 400 micrometers, an outer layer 3 a thickness in a range of 30-120 micrometers, a layer 5 of platinum type metal a thickness in a range of 10-30 micrometers and a layer 6 of aluminum oxide with a thickness in a range of 0.5 to 10 micrometers can be deposited or formed by preoxidation.
A β-NiAl coating may comprise (wt.-%) 20 to 25% Al, a γ/β-MCrAlY coating may comprise (wt.-%) 8 to 17% Al and a γ/γ′- or γ-MCrAlY coating may comprise (wt.-%) 3 to 6% Al.
Table 1 shows some example of contents of coatings (wt.-%)
Optionally, as seen in
The layer of a pure platinum type metal can be deposited by plating or any other conventional process for elemental deposition of platinum on metallic substrate.
An inner layer 2 of MCrAlY class of coatings can be conveniently deposited by electroplated process to provide a relatively thin and uniform coating. An inner layer 2 of β-NiAl coating can be applied by CVD, gas phase, chemical vapor deposition or pack cementation process.
The outer and coarse layer 3 of MCrAlY or P-NiAl comprising one or a combination of Fe, B, Ga, Mo, Hf or Zr may be deposited on the inner layer of the bond coat by plasma spray in air or vacuum or any other conventional methods used for deposition of overlay and bond coatings.
The layer of a pure platinum type metal can be deposited by plating or any other conventional process used for elemental deposition of platinum on metallic substrate such an electrolytic process.
| Number | Date | Country | Kind |
|---|---|---|---|
| 02000559 | Jan 2002 | EP | regional |
This application is a continuation of International Patent Application No. PCT/IB02/05488, having an international filing date of Dec. 18, 2002, which published as WO 03/057944, and which claims priority to European Patent Application No. EP 02000559.1, filed on Jan. 10, 2002. The entire disclosure of both applications is incorporated by reference herein.
| Number | Name | Date | Kind |
|---|---|---|---|
| 3528861 | Elam et al. | Sep 1970 | A |
| 3676085 | Evans et al. | Jul 1972 | A |
| 3754903 | Goward et al. | Aug 1973 | A |
| 3918139 | Felten | Nov 1975 | A |
| 4055705 | Stecura et al. | Oct 1977 | A |
| 4095003 | Weatherly et al. | Jun 1978 | A |
| 4152223 | Wallace et al. | May 1979 | A |
| 4248940 | Goward et al. | Feb 1981 | A |
| 4291448 | Cretella et al. | Sep 1981 | A |
| 4313760 | Dardi et al. | Feb 1982 | A |
| 4321311 | Strangman | Mar 1982 | A |
| 4346137 | Hecht | Aug 1982 | A |
| 4419416 | Gupta et al. | Dec 1983 | A |
| RE32121 | Gupta et al. | Apr 1986 | E |
| 4585481 | Gupta et al. | Apr 1986 | A |
| 4676994 | Demaray | Jun 1987 | A |
| 4714624 | Naik | Dec 1987 | A |
| 4743514 | Strangman et al. | May 1988 | A |
| 4880614 | Strangman et al. | Nov 1989 | A |
| 4973445 | Singheiser | Nov 1990 | A |
| 5403669 | Gupta et al. | Apr 1995 | A |
| 5511948 | Suzuki et al. | Apr 1996 | A |
| 5514482 | Strangman | May 1996 | A |
| 5579534 | Itoh et al. | Nov 1996 | A |
| 5645893 | Rickerby et al. | Jul 1997 | A |
| 5759301 | Konter et al. | Jun 1998 | A |
| 5817371 | Gupta et al. | Oct 1998 | A |
| 5843585 | Alperine et al. | Dec 1998 | A |
| 5866271 | Stueber et al. | Feb 1999 | A |
| 5894053 | Fried | Apr 1999 | A |
| 5900326 | Bornstein et al. | May 1999 | A |
| 5942337 | Rickerby et al. | Aug 1999 | A |
| 6020075 | Gupta et al. | Feb 2000 | A |
| 6066405 | Schaeffer | May 2000 | A |
| 6123997 | Schaeffer et al. | Sep 2000 | A |
| 6153313 | Rigney et al. | Nov 2000 | A |
| 6165628 | Borom et al. | Dec 2000 | A |
| 6242050 | Ritter et al. | Jun 2001 | B1 |
| 6264766 | Ritter et al. | Jul 2001 | B1 |
| 6306515 | Goedjen et al. | Oct 2001 | B1 |
| 6464128 | Messelling et al. | Oct 2002 | B1 |
| 6607789 | Rigney et al. | Aug 2003 | B1 |
| 6610419 | Stamm | Aug 2003 | B1 |
| 20030118863 | Darolia et al. | Jun 2003 | A1 |
| 20030157363 | Rigney et al. | Aug 2003 | A1 |
| Number | Date | Country |
|---|---|---|
| 19842417 | Mar 2000 | DE |
| 0366924 | May 1990 | EP |
| 0718419 | Jun 1996 | EP |
| 0792948 | Sep 1997 | EP |
| 0979881 | Feb 2000 | EP |
| 985745 | Mar 2000 | EP |
| 1111091 | Jun 2001 | EP |
| 1254967 | Nov 2002 | EP |
| 1260608 | Nov 2002 | EP |
| 9943861 | Sep 1999 | WO |
| 9955527 | Nov 1999 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 20050003227 A1 | Jan 2005 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/IB02/05488 | Dec 2002 | US |
| Child | 10887531 | US |
