CA2612881A1 - Coating system for high temperature stainless steel - Google Patents

Coating system for high temperature stainless steel Download PDF

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Publication number
CA2612881A1
CA2612881A1 CA002612881A CA2612881A CA2612881A1 CA 2612881 A1 CA2612881 A1 CA 2612881A1 CA 002612881 A CA002612881 A CA 002612881A CA 2612881 A CA2612881 A CA 2612881A CA 2612881 A1 CA2612881 A1 CA 2612881A1
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CA
Canada
Prior art keywords
coating
aluminum
chromium
substrate
silicon
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA002612881A
Other languages
French (fr)
Other versions
CA2612881C (en
Inventor
Konstantin K. Tzatzov
Gary Anthony Fisher
Robert Prescott
Yan Chen
Hang Zheng
Chinnia Gounder Subramanian
Andrew George Wysiekierski
Juan Manuel Mendez Acevedo
Alexander S. Gorodetsky
Edward John Redmond
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Manoir Industries SAS
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Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US09/589,196 external-priority patent/US6585864B1/en
Priority claimed from US09/690,447 external-priority patent/US6475647B1/en
Priority claimed from CA002348145A external-priority patent/CA2348145C/en
Application filed by Individual filed Critical Individual
Priority to CA2612881A priority Critical patent/CA2612881C/en
Publication of CA2612881A1 publication Critical patent/CA2612881A1/en
Application granted granted Critical
Publication of CA2612881C publication Critical patent/CA2612881C/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C28/00Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/30Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/32Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer
    • C23C28/321Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer with at least one metal alloy layer
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C28/00Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/30Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/32Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer
    • C23C28/321Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer with at least one metal alloy layer
    • C23C28/3215Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer with at least one metal alloy layer at least one MCrAlX layer
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C28/00Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/30Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/34Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates
    • C23C28/345Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer

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  • Chemical & Material Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)

Abstract

A method for protecting carbon steel and stainless steel, and particularly high temperature stainless steel, from coking and corrosion at elevated temperatures in corrosive environments, such as during ethylene production by pyrolysis of hydrocarbons or the reduction of oxide ores, by coating the steel with a coating of MCrAlX or MCrAlXT in which M is nickel, cobalt, iron or a mixture thereof, X
is yttrium, hafnium, zirconium, lanthanum, scandium or combination thereof, and T
is silicon, tantalum, titanium, platinum, palladium, rhenium, molybdenum, tungsten, niobium, or combination thereof. The coating and substrate preferably are heat-treated at about 1000 to 1200°C for at least about 10 minutes, preferably about 20 minutes to 24 hours, effective to metallurgically bond the overlay coating to the substrate and to form a multiphased microstructure. The coating preferably is aluminized by depositing a layer of aluminum thereon and subjecting the resulting coating to oxidation at a temperature above about 1000°C for a time effective to form an alumina surface layer. An intermediary aluminum-containing interlayer may be deposited directly onto the substrate prior to deposition of the overlay coating and is heat-treated with the coating to form a protective interlayer between the stainless steel substrate and coating to disperse nitride formation at the substrate/coating interface. Also, the coating may be deposited onto and metallurgically bonded to the substrate by plasma transferred arc deposition of atomized powder of MCrAlXT, obviating the need for a separate heat treatment.
Alternatively, a blended powder composition to produce a desired MCrAlXT alloy may be applied to the substrate.

Claims (28)

1. A surface alloyed component comprising a high temperature stainless steel substrate tube and a coating of MCrAlXSiT alloy, where M = nickel, cobalt, iron or mixture thereof, X = yttrium, hafnium, zirconium, lanthanum, scandium, or mixture thereof, and T = tantalum, titanium, platinum, palladium, rhenium, molybdenum, tungsten, niobium or combination thereof, having about 10 to 40 wt% chromium, about 1 to 30 wt% aluminum, 0.1 to about 5 wt% X, 0 to about 40 wt% silicon, and 0.1 to about wt% T, the balance M metallurgically bonded to the stainless steel substrate tube.
2. A surface alloyed component claimed in claim 1, wherein a said MCrAlXSiT
alloy has about 10 to 25 wt% chromium, 5 to 20 wt% aluminum, 0.5 to 3 wt% X, 1 to 15 wt% silicon and 0.1 to 10 wt% T.
3. A surface alloyed component claimed in claim 2, in which X is present in the range of 0.25 to 1.5 wt%.
4. A surface alloyed component claimed in claim 2, in which silicon is present in the range of about 3 to 15 wt%.
5. A surface alloyed component claimed in claim 2, in which T is present in the range of 0.1 to 5.0 wt%.
6. A surface alloyed component claimed in claim 2, in which T is present in the range of 0.5 to 3.0 wt%.
7. A surface alloyed component claimed in claim 1, in which the thickness of the coating is from 20 µm to 6000 µm.
8. A surface alloyed component claimed in claim 1, in which the thickness of the coating is from 50 µm to 2000 µm.
9. A surface alloyed component claimed in claim 1, in which the thickness of the coating is from 80 µm to 500 µm.
10. A surface alloyed component claimed in claim 1, in which the MCrAlXSiT
alloy is NiCrAlXSi and has about 12 to 25 wt% chromium, about 4 to 15% aluminum, about 0.5 to 1.5 wt% X, 1 to about 15 wt% silicon and the balance nickel.
11. A surface alloyed component claimed in claim 2, in which the MCrAlXSiT is NiCrAlXTi and has about 12 to 25 wt% chromium, about 4 to 15% aluminum, about 0.5 to 1.5 wt% yttrium, 0.5 to about 5 wt% titanium and the balance nickel.
12. A surface alloyed component claimed in claim 2, in which the MCrAlXSiT is NiCrAlYTa and has about 12 to 25 wt% chromium, about 4 to 15 % aluminum, about 0.5 to 1.5 wt% yttrium, about 0.5 to 5 wt% tantalum and the balance nickel.
13. A surface alloyed component claimed in claim 2, in which the MCrAlXSiT is NiCrAlYPt and has about 12 to 25 wt% chromium, about 4 to 15% aluminum, about 0.5 to 1.5 wt% yttrium, about 0.5 to 5 wt% platinum and the balance nickel.
14. A surface alloyed component claimed in claim 2, in which the MCrAlXSiT is NiCrAlYPd and has about 12 to 25 w.t% chromium, about 4 to 15% aluminum, about 0.5 to 1.5 wt% yttrium, about 0.5 to 5 wt% palladium and the balance nickel.
15. A surface alloyed component claimed in claim 2, additionally comprising a surface layer of aluminum, aluminum alloy containing up to 50 wt% silicon, or aluminum alloy containing up to 60 wt% silicon, a total of up to 30 wt% of at least one of chromium and titanium, the balance being at least 20 wt% aluminum in a thickness up to about 50% of the thickness of MCrAlXSiT layer.
16. A surface alloyed component claimed in claim 13, additionally comprising a surface layer of aluminum or aluminum alloy, wherein the aluminum alloy contains 1 to about 15 wt% silicon and has a thickness of up to 20% of the MCrAlXSiT
coating.
17. A coking and corrosion resistant reactor tube for use in high temperature environments comprising an elongated tube of a high temperature stainless steel and a continuous coating metallurgically bonded on the inner surface of the elongated tube comprising a MCrAlXSiT coating wherein M is nickel, cobalt, iron or a mixture thereof, X is yttrium, hafnium, zirconium, lanthanum, scandium or combination thereof, and T is tantalum, titanium, platinum, palladium, rhenium, molybdenum, tungsten, niobium or combination thereof, and comprising, by weight, about 10 to 25% chromium, about 4 to 20% aluminum, 0.1 to about 3 wt% X, 1 to 15 wt% silicon and 0.1 to about 5 wt%
T, the balance M, deposited by physical vapor deposition, plasma thermal spray or plasma transferred arc surfacing, and wherein the MCrAlXSiT coating has a thickness of about 20 µm to 6000 µm.
18. A method for providing a protective and inert coating on carbon steel and stainless steel comprising depositing onto a steel substrate a continuous coating of a MCrAlXSi alloy, where M = nickel, cobalt or iron or mixture thereof and X =
yttrium, hafnium, zirconium, lanthanum, scandium or combination thereof, having about 10 to 40 wt% chromium, about 3 to 40 wt% aluminum, about 1 to 35 wt% silicon and 0.1 to about wt% X, the balance at least 40 wt% M by physical vapour deposition, thermal spray, plasma transferred arc, weld overlay, isostatic pressing and by slurry coating, and metallurgically bonding the coating thereto by heat treating the coating at a temperature up to 1200°C for at least 10 minutes.
19. A method as claimed in claim 18, in which the coating is comprised of at least two powders of the constituents of the MCrAlXSi partially prealloyed and blended together and deposited onto the substrate, and heated in a vacuum or an oxygen-free atmosphere to a temperature above 500 to about 1200°C for a time of at least 10 minutes effective to initiate reactive sintering and to metallurgically bond the coating as a continuous impermeable coating to the substrate.
20. A method as claimed in claim 19, in which the coating is deposited in a thickness of about 50 to 6000 µm and in which the MCrAlXSi coating comprises essentially about to 20 wt% chromium, about 4 to 20 wt% aluminum, about 5 to 20 wt% silicon, and about 0.25 to 1.5 wt% yttrium, the balance being a minimum 40 wt% nickel.
21. A method as claimed in claim 20, in which the substrate is a high chromium stainless steel having 18 to 38 wt% chromium, 18 to 48 wt% nickel, the balance iron and alloying additives and in which the coating is deposited in a thickness of about 120 to 500 µm.
22. A method as claimed in claim 21, in which the coating is deposited in a thickness of about 150 to 350 µm.
23. A method as claimed in claim 22, in which the coating is aluminized by depositing a layer of aluminum having a thickness up to about 50% of the MCrAlXSi coating onto said coating and heat-treating the aluminum layer at a soak temperature in the range of about 1000 to 1160°C for at least 10 minutes effective to establish a multiphased structure.
24. A method as claimed in claim 23, in which the layer of aluminum is deposited in a thickness of about 20% of the MCrAlXSi coating by magnetron sputtering physical vapour deposition at a temperature in the range of about 200 to 500°C.
25. A method as claimed in claim 20, in which the substrate, MCrAlYSi coating and aluminum layer are subsequently heated in an oxygen-containing atmosphere at a temperature in the range of 1000 to 1160°C for a time of at least 10 minutes effective to form a layer of %-alumina thereon.
26. A method as claimed in claim 20, in which chromium, aluminum and silicon are atomized to form a CrAlSi powder prior to blending with nickel, NiCr or NiAl powders, or combinations thereof.
27. A surface alloyed component produced by the method of claim 18.
28. A surface alloyed component produced by the method of claim 21.
CA2612881A 2000-06-08 2001-06-08 Coating system for high temperature stainless steel Expired - Lifetime CA2612881C (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA2612881A CA2612881C (en) 2000-06-08 2001-06-08 Coating system for high temperature stainless steel

Applications Claiming Priority (8)

Application Number Priority Date Filing Date Title
US09/589,196 US6585864B1 (en) 2000-06-08 2000-06-08 Coating system for high temperature stainless steel
US09/589,196 2000-06-08
US09/690,447 2000-10-08
US09/690,447 US6475647B1 (en) 2000-10-18 2000-10-18 Protective coating system for high temperature stainless steel
CA2,348,145 2001-05-22
CA002348145A CA2348145C (en) 2001-05-22 2001-05-22 Protective system for high temperature metal alloys
CA002357407A CA2357407C (en) 2000-06-08 2001-06-08 Coating system for high temperature stainless steels
CA2612881A CA2612881C (en) 2000-06-08 2001-06-08 Coating system for high temperature stainless steel

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
CA002357407A Division CA2357407C (en) 2000-06-08 2001-06-08 Coating system for high temperature stainless steels

Publications (2)

Publication Number Publication Date
CA2612881A1 true CA2612881A1 (en) 2001-12-08
CA2612881C CA2612881C (en) 2012-09-18

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CA002357407A Expired - Lifetime CA2357407C (en) 2000-06-08 2001-06-08 Coating system for high temperature stainless steels
CA2612881A Expired - Lifetime CA2612881C (en) 2000-06-08 2001-06-08 Coating system for high temperature stainless steel
CA002614962A Abandoned CA2614962A1 (en) 2000-06-08 2001-06-08 Coating system for high temperature stainless steels

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CA002614962A Abandoned CA2614962A1 (en) 2000-06-08 2001-06-08 Coating system for high temperature stainless steels

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2013173916A1 (en) * 2012-05-25 2013-11-28 HYDRO-QUéBEC Alloys of the type fe3alta(ru) and use thereof as electrode material for the synthesis of sodium chlorate or as corrosion resistant coatings

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Publication number Priority date Publication date Assignee Title
US8637127B2 (en) 2005-06-27 2014-01-28 Kennametal Inc. Composite article with coolant channels and tool fabrication method
ATE512278T1 (en) 2006-04-27 2011-06-15 Tdy Ind Inc MODULAR EARTH DRILLING BIT WITH FIXED CUTTER AND MODULAR EARTH DRILLING BIT BODY WITH FIXED CUTTER
MX2009003114A (en) 2006-10-25 2009-06-08 Tdy Ind Inc Articles having improved resistance to thermal cracking.
US8790439B2 (en) 2008-06-02 2014-07-29 Kennametal Inc. Composite sintered powder metal articles
US8025112B2 (en) 2008-08-22 2011-09-27 Tdy Industries, Inc. Earth-boring bits and other parts including cemented carbide
US9050673B2 (en) 2009-06-19 2015-06-09 Extreme Surface Protection Ltd. Multilayer overlays and methods for applying multilayer overlays
US9643236B2 (en) 2009-11-11 2017-05-09 Landis Solutions Llc Thread rolling die and method of making same
US8800848B2 (en) 2011-08-31 2014-08-12 Kennametal Inc. Methods of forming wear resistant layers on metallic surfaces
US9016406B2 (en) 2011-09-22 2015-04-28 Kennametal Inc. Cutting inserts for earth-boring bits
MX2019001262A (en) 2016-07-29 2019-09-26 Basf Qtech Inc Catalytic coatings, methods of making and use thereof.
CN111960832B (en) * 2020-08-24 2022-10-11 青岛弘汉耐火材料有限公司 Bare body sintering coating for aluminum-carbon product and bare body sintering method

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2013173916A1 (en) * 2012-05-25 2013-11-28 HYDRO-QUéBEC Alloys of the type fe3alta(ru) and use thereof as electrode material for the synthesis of sodium chlorate or as corrosion resistant coatings

Also Published As

Publication number Publication date
CA2357407A1 (en) 2001-12-08
CA2612881C (en) 2012-09-18
CA2614962A1 (en) 2001-12-08
CA2357407C (en) 2008-01-08

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Effective date: 20210608