CN116891967A

CN116891967A - High entropy alloy-based composition and bond coat formed therefrom

Info

Publication number: CN116891967A
Application number: CN202211544592.4A
Authority: CN
Inventors: 斯里尼瓦桑·斯维米纳坦; 沙里尼·西姆米奥达
Original assignee: General Electric Co
Current assignee: General Electric Co
Priority date: 2022-04-11
Filing date: 2022-12-02
Publication date: 2023-10-17

Abstract

A high entropy alloy-based composition is provided, the high entropy alloy-based composition having the formula: (M) ¹ _a M ² _b M ³ _c M ⁴ _d M ⁵ _e M ⁶ _f )CrAlY _1‑x‑ _z Zr _x Mo _z Wherein M is ¹ 、M ² 、M ³ 、M ⁴ 、M ⁵ And M ⁶ Each of which is selected from Ni, co, Fe. Different alloying elements in Si, mn and Cu such that M ¹ 、M ² 、M ³ 、M ⁴ 、M ⁵ And M ⁶ None of which are the same alloying elements; a is more than or equal to 0.05 and less than or equal to 0.35; b is more than or equal to 0.05 and less than or equal to 0.35; c is more than or equal to 0.05 and less than or equal to 0.35; d is more than or equal to 0.05 and less than or equal to 0.35; e is more than or equal to 0.05 and less than or equal to 0.35; f is more than or equal to 0 and less than or equal to 0.35; a+b+c+d+e+f=1; x is more than or equal to 0 and less than or equal to 1; z is more than or equal to 0 and less than or equal to 1; and 0.ltoreq.x+z.ltoreq.1.

Description

High entropy alloy-based composition and bond coat formed therefrom

PRIORITY INFORMATION

The present application claims priority from indian provisional patent application No. 202211021535 filed on day 2022, month 4 and day 11.

Technical Field

The present application relates generally to compositions suitable for use in coating systems on components exposed to high temperature environments (e.g., hot gas flow paths through gas turbine engines). More particularly, the present application relates to compositions for use in thermal barrier coating (thermal barrier coating) ("TBC") systems.

Background

Gas turbine engines typically include an inlet, a fan, one or more compressors, a combustor, and at least one turbine. The compressor compresses air that is channeled to the combustor where it is mixed with fuel. The mixture is then ignited for generating hot combustion gases. The combustion gases are directed to a turbine that extracts energy from the combustion gases for driving a compressor, and for producing useful work to propel an aircraft in flight or to drive a load (load) such as a generator.

TBCs are increasingly used on components of gas turbine engines such as combustors, high pressure turbine ("HPT") blades (blades), and vanes (vanes). Generally, the thermal insulation of TBCs enables such components to withstand higher operating temperatures, increases component durability, and improves engine reliability. In order for a TBC to remain effective throughout the planned life of the component it protects, a bond coat is typically present between the TBC and the substrate to help retain the TBC on the substrate during use.

Disclosure of Invention

The present application provides a high entropy alloy-based composition having the formula:

(M ¹ _a M ² _b M ³ _c M ⁴ _d M ⁵ _e M ⁶ _f )CrAlY _1-x-z Zr _x Mo _z ，

wherein,,

M ¹ 、M ² 、M ³ 、M ⁴ 、M ⁵ and M ⁶ Each of which is a different alloying element selected from Ni, co, fe, si, mn and Cu such that M ¹ 、M ² 、M ³ 、M ⁴ 、M ⁵ And M ⁶ None of which is a phaseAlloying elements; a is more than or equal to 0.05 and less than or equal to 0.35; b is more than or equal to 0.05 and less than or equal to 0.35; c is more than or equal to 0.05 and less than or equal to 0.35; d is more than or equal to 0.05 and less than or equal to 0.35; e is more than or equal to 0.05 and less than or equal to 0.35; f is more than or equal to 0 and less than or equal to 0.35; a+b+c+d+e+f=1; x is more than or equal to 0 and less than or equal to 1; z is more than or equal to 0 and less than or equal to 1; and 0.ltoreq.x+z.ltoreq.1.

Preferably, in the high-entropy alloy-based composition, a is more than or equal to 0.1 and less than or equal to 0.25; b is more than or equal to 0.1 and less than or equal to 0.25; c is more than or equal to 0.1 and less than or equal to 0.25; d is more than or equal to 0.1 and less than or equal to 0.25; and 0.1.ltoreq.e.ltoreq.0.25.

Preferably, in the high entropy alloy-based composition, the alloy has the formula:

(Cu _0.2 Mn _0.2 Fe _0.2 Co _0.2 Ni _0.2 )CrAlY _1-x-z Zr _x Mo _z ，

wherein x is more than or equal to 0 and less than or equal to 1; z is more than or equal to 0 and less than or equal to 1; and 0.ltoreq.x+z.ltoreq.1.

(Cu _0.2 Si _0.2 Fe _0.2 Co _0.2 Ni _0.2 )CrAlY _1-x-z Zr _x Mo _z ，

wherein x is more than or equal to 0 and less than or equal to 1; z is more than or equal to 0 and less than or equal to 1, and x+z is more than or equal to 0 and less than or equal to 1.

In another aspect, the application relates to a coated component comprising:

a substrate having a surface, wherein the substrate comprises a metal;

a bond coat on a surface of the substrate, wherein the bond coat comprises a layer comprising the high entropy alloy-based composition; and

a thermal barrier coating on the bond coat.

Alternatively, the application relates to a coated component comprising:

a substrate having a surface, wherein the substrate comprises a metal;

a bond coat on a surface of the substrate, wherein the bond coat comprises a plurality of layers; and

a thermal barrier coating on the bond coat layer,

wherein each of the plurality of layers of the bond coat layer comprises 80 wt% or more of a high entropy alloy-based composition having the formula:

wherein M is ¹ 、M ² 、M ³ 、M ⁴ 、M ⁵ And M ⁶ Each of which is a different alloying element selected from Ni, co, fe, si, mn and Cu such that M ¹ 、M ² 、M ³ 、M ⁴ 、M ⁵ And M ⁶ None of which are the same alloying elements; a is more than or equal to 0.05 and less than or equal to 0.35; b is more than or equal to 0.05 and less than or equal to 0.35; c is more than or equal to 0.05 and less than or equal to 0.35; d is more than or equal to 0.05 and less than or equal to 0.35; e is more than or equal to 0.05 and less than or equal to 0.35; f is more than or equal to 0 and less than or equal to 0.35; a+b+c+d+e+f=1; x is more than or equal to 0 and less than or equal to 1; z is more than or equal to 0 and less than or equal to 1; and 0.ltoreq.x+z.ltoreq.1.

Preferably, in the coated component, the bond coat comprises an innermost layer adjacent to the substrate surface and comprising a first high entropy alloy-based composition, and the bond coat comprises an outermost layer adjacent to the thermal barrier coating and comprising a second high entropy alloy-based composition, wherein the first high entropy alloy-based composition and the second high entropy alloy-based composition are at their respective M ¹ _a M ² _b M ³ _c M ⁴ _d M ⁵ _e M ⁶ _f Is compositionally different in at least one of (a).

Preferably, in the coated component, the bond coat has a composition gradient from an innermost layer adjacent to the substrate surface to an outermost layer adjacent to the thermal barrier coating.

Preferably M ¹ _a M ² _b M ³ _c M ⁴ _d M ⁵ _e M ⁶ _f Has the composition gradient in at least one of (a).

Preferably, in the coated member, the alloy is a single-phase alloy.

Preferably, in the coated member, the thickness of the bond coat layer is 10 μm to 100 μm.

The application also relates to an engine component having the coated component.

Preferably, the engine component includes at least one of an HP turbine stator vane, an HP turbine rotor blade, an LP turbine stator vane, an LP turbine rotor blade, or a combustion liner.

Drawings

A full and enabling disclosure of the present application, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:

FIG. 1 is a schematic illustration of an exemplary coated component;

FIG. 2 is a schematic illustration of an exemplary bond coat on a surface of a component; and

FIG. 3 is a schematic cross-sectional view of an exemplary gas turbine engine according to various embodiments of the present subject matter.

Detailed Description

Reference now will be made in detail to the present embodiments of the application, one or more examples of which are illustrated in the drawings. The detailed description uses numerical and letter designations to refer to features in the drawings. The same or similar reference numerals have been used in the drawings and the description to refer to the same or similar parts of the application.

As used herein, the term "exemplary" means "serving as an example, instance, or illustration. Any embodiment described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments. In addition, all embodiments described herein should be considered exemplary unless specifically indicated otherwise. Indeed, it will be apparent to those skilled in the art that various modifications and variations can be made to the present application without departing from the scope of the application. For example, features illustrated or described as part of one embodiment can be used with another embodiment to yield still a further embodiment. Accordingly, it is intended that the present application cover such modifications and variations as fall within the scope of the appended claims and their equivalents.

The singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

The term "at least one" in the context of, for example, "at least one of A, B and C" refers to any combination of a alone, B alone, C alone, or A, B and C.

The term "gas turbine engine" refers to an engine having a turbine as all or part of its power source. Exemplary gas turbine engines include turbofan engines, turboprop engines, turbojet engines, turboshaft engines, and the like, as well as hybrid-electric versions of one or more of these engines. The term "turbomachinery" or "turbomachinery" refers to a machine that includes one or more compressors, a heat-generating section (e.g., a combustion section), and one or more turbines that together produce a torque output.

In the present application, when a layer is described as being "on" or "over" another layer or substrate, it is to be understood that the layers can either be in direct contact with each other or have another layer or feature between the layers unless expressly stated to the contrary. Thus, these terms merely describe the relative position of the layers to one another and do not necessarily mean "on top of" since the relative position above or below depends on the orientation of the device with respect to the viewer.

In the present application, chemical elements are discussed using their common chemical abbreviations, such as those common on the periodic table of elements. For example, hydrogen is represented by its common chemical abbreviation H; helium is represented by its common chemical abbreviation He; etc.

As used herein, the term "high entropy alloy" ("HEA") refers to an alloy formed by mixing equal or relatively large proportions of 5 or more elements.

As used herein, "rare earth element" refers to a rare earth element of scandium (Sc), yttrium (Y), lanthanum (La), cerium (Ce), praseodymium (Pr), neodymium (Nd), promethium (Pm), samarium (Sm), europium (Eu), gadolinium (Gd), terbium (Tb), dysprosium (Dy), holmium (Ho), erbium (Er), thulium (Tm), ytterbium (Yb), lutetium (Lu), or a mixture thereof.

As used herein, the term "substantially free" is to be understood as either completely free of the recited ingredient or containing trace amounts of the same ingredient. "traces" are quantitative levels of chemical components that are barely detectable and provide no benefit to the functional or aesthetic properties of the subject composition (subject composition). The term "substantially free" also includes complete absence.

As used herein, the term "substantially equal" should be understood to include minor trace changes at quantitative levels that are barely detectable and provide no benefit to the functional or aesthetic properties of the subject composition. For example, "substantially" may refer to a range of 1% (i.e., including values within 1% of the specified value). The term "substantially equal" also includes perfect equality.

It is generally desirable to improve the performance of bond coats to extend the useful life of the TBC.

The present application relates generally to a composition comprising an alloy including a high-entropy alloy ("HEA") within an MCrAlY-based alloy to form a high-entropy alloy-based composition that is particularly useful for bond coats having excellent properties. For example, the alloy may have improved oxidation resistance to help slow the formation of thermally grown oxides ("TGO") thereon.

Typically, the high entropy alloy-based composition comprises at least 5 different alloying elements (replacing "M" in the MCrAlY-based alloy), wherein the at least 5 different alloying elements are selected from Ni, co, fe, si, mn and Cu. Without wishing to be bound by any particular theory, it is believed that selecting at least 5 different alloying elements such that each alloying element has an atomic radius within 15% of the atomic radius of nickel may allow for the formation of a desired crystal structure in the high entropy alloy-based composition. Furthermore, the use of HEA allows for control of the coefficient of thermal expansion ("CTE") of the material and inhibits TGO formation on the high entropy alloy-based composition.

In one embodiment, each of the at least 5 different alloying elements is present in an amount of 5 atomic% to 35 atomic%, wherein the sum of the atomic percentages of the at least 5 different alloying elements is equal to 1. For example, the high entropy alloy-based composition may have the formula shown in formula 1:

formula 1: (M) ¹ _a M ² _b M ³ _c M ⁴ _d M ⁵ _e M ⁶ _f )CrAlY _1-x-z Zr _x Mo _z ，

Wherein,,

M ¹ 、M ² 、M ³ 、M ⁴ 、M ⁵ and M ⁶ Each of which is a different alloying element selected from Ni, co, fe, si, mn and Cu such that M ¹ 、M ² 、M ³ 、M ⁴ 、M ⁵ And M ⁶ None of which are the same alloying elements;

0.05.ltoreq.a.ltoreq.0.35 (e.g., 0.1.ltoreq.a.ltoreq.0.25);

b is 0.05.ltoreq.b.ltoreq.0.35 (e.g., 0.1.ltoreq.b.ltoreq.0.25);

c is 0.05.ltoreq.c.ltoreq.0.35 (e.g., 0.1.ltoreq.c.ltoreq.0.25);

d is 0.05.ltoreq.d.ltoreq.0.35 (e.g., 0.1.ltoreq.d.ltoreq.0.25);

e is 0.05.ltoreq.e.ltoreq.0.35 (e.g., 0.1.ltoreq.e.ltoreq.0.25);

0≤f≤0.35；

a+b+c+d+e+f＝1；

0.ltoreq.x.ltoreq.1 (e.g., 0.ltoreq.x.ltoreq.0.5, such as 0.ltoreq.x.ltoreq.0.25);

0.ltoreq.z.ltoreq.1 (e.g., 0.ltoreq.z.ltoreq.0.5, such as 0.ltoreq.z.ltoreq.0.25); and

0.ltoreq.x+z.ltoreq.1 (e.g., 0.ltoreq.x+z < 1).

In one embodiment, f is not more than a negligible trace amount (e.g., f is 0), such that only 5 alloying elements are present in the high entropy alloy-based composition. In one embodiment, the 5 alloying elements are present in different atomic weights from each other. In an alternative embodiment, the 5 alloying elements are present in substantially equal atomic weights to each other. For example, in this embodiment, when there are 5 alloying elements, a is substantially equal to b; b is substantially equal to c; c is substantially equal to d; d is substantially equal to e; f is not more than a negligible trace (e.g., f is 0).

In one particular embodiment, the high entropy alloy-based composition may have the formula shown in formula 2:

formula 2: (Cu) _0.2 Mn _0.2 Fe _0.2 Co _0.2 Ni _0.2 )CrAlY _1-x-z Zr _x Mo _z ，

Wherein,,

0≤x≤1；

z is more than or equal to 0 and less than or equal to 1; and

0≤x+z≤1。

in another particular embodiment, the high entropy alloy-based composition may have the formula shown in formula 3:

formula 3: (Cu) _0.2 Si _0.2 Fe _0.2 Co _0.2 Ni _0.2 )CrAlY _1-x-z Zr _x Mo _z ，

Wherein,,

0≤x≤1；

z is more than or equal to 0 and less than or equal to 1; and

0≤x+z≤1。

in an alternative embodiment, f is greater than 0 and less than or equal to 0.35 (i.e., 0<f +.0.35), such that each of Ni, co, fe, si, mn and Cu is present in the high entropy alloy based composition. In one embodiment, the 6 alloying elements are present at different atomic weights from each other. In an alternative embodiment, the 6 alloying elements are present in substantially equal atomic weights to each other. For example, in this embodiment, when there are 6 alloying elements, a is substantially equal to b; b is substantially equal to c; c is substantially equal to d; d is substantially equal to e; and e is substantially equal to f.

In one particular embodiment, the high entropy alloy-based composition may have the formula shown in formula 4:

formula 4: (Cu) _0.167 Si _0.167 Mn _0.167 Fe _0.167 Co _0.167 Ni _0.167 )CrAlY _1-x-z Zr _x Mo _z ，

Wherein,,

0≤x≤1；

z is more than or equal to 0 and less than or equal to 1; and

0≤x+z≤1。

it should be noted that equation 4 rounds one sixth (i.e., 1/6) to 0.167, while also recognizing that the sum of these six atomic percentages is substantially equal to 1.

Referring to each of formulas 1-4, Y may be replaced or combined with other elements having similar atomic radii (e.g., zr and/or Mo). In one embodiment, the high entropy alloy-based composition may include Zr such that x is greater than 0 and less than or equal to (e.g., 0< x+.1), such as 0< x+.0.25. In one embodiment, the high entropy alloy-based composition may include Mo such that z is greater than 0 and less than or equal to 1 (e.g., 0<z.ltoreq.1), e.g., 0<z.ltoreq.0.25. In a particular embodiment, Y has an atomic concentration greater than the sum of the atomic concentrations of Zr and Mo, for example when 0.ltoreq.x+z < 0.5.

In alternative embodiments, x does not exceed a negligible trace amount, such that the high entropy alloy-based composition is substantially free of Zr (e.g., x is 0). Similarly, in certain embodiments, z does not exceed a negligible trace amount, such that the high entropy alloy-based composition is substantially free of Mo (e.g., z is 0). In a particular embodiment, both x and z do not exceed insignificant traces such that Y is substantially free of any substitution (e.g., x+z is 0).

As noted above, the high entropy alloy-based composition is particularly useful in bond coats between the surface of a component and a thermal barrier coating thereon.

For example, referring to FIG. 1, an exemplary coated component 100 is shown formed from a substrate 102 having a surface 103 and a coating system 106 on the surface. In general, coating system 106 includes bond coat layer 104 on surface 103 of substrate 102 and TBC 108 on outermost surface 107 of bond coat layer 104. In the embodiment shown, the bond coat 104 is directly on the surface 103 without any layer in between. The thickness of the bond coat 104 may be 10 μm to 100 μm on the surface 103 of the substrate 102.

In one embodiment, the bond coat 104 may include at least 80 wt% of a high entropy alloy-based composition (e.g., having a composition shown in any of formulas 1-4). The balance of bond coat 104 may be any material suitable for use in a bond coat or TBC, such as silicon, silicide, rare earth silicate, and the like. In one embodiment, the bond coat 104 may include 90 wt% to 100 wt% of the high entropy alloy-based composition (e.g., having a composition shown in any of formulas 1-4). In a particular embodiment, the bond coat 104 consists essentially of a high entropy alloy-based composition (e.g., having a composition shown in any of formulas 1-4).

In an exemplary embodiment, bond coat 104 is substantially a single phase alloy. That is, bond coat 104 is at least 80 volume percent (vol%) (e.g., 80vol% to 100 vol%) (e.g., 95vol% to 100 vol%)) of a single phase.

In certain embodiments, the bond coat 104 may have a composition gradient that varies along the thickness of the bond coat 104. For example, referring to fig. 2, an exemplary bond coat 104 is shown having a composition gradient with multiple layers 120 spanning its thickness from the surface 103 of the substrate 102 to the outermost surface 107 of the bond coat 104. Such a composition gradient may be formed within the bond coat 104 by applying separate layers 120 having different chemical compositions, and then curing/sintering the bond coat 104 together.

In a particular embodiment, the innermost layer 122 of the bond coat 104 adjacent the surface 103 of the substrate 102 may have a different composition than the outermost layer 124 defining the outermost surface 107 of the bond coat 104. For example, the innermost layer 122 may include a first high-entropy alloy-based composition and the outermost layer 124 may include a second high-entropy alloy-based composition, where the first high-entropy alloy-based composition and the second high-entropy alloy-based composition are at their respective M ¹ _a M ² _b M ³ _c M ⁴ _d M ⁵ _e M ⁶ _f (formulae 1-4) are different in composition. For example, the first high-entropy alloy-based composition may comprise a particular alloying element, while the second high-entropy alloy-based composition is substantially free of the particular alloying element. Conversely, the first high-entropy alloy-based composition may be substantially free of another particular alloying element, while the second high-entropy alloy-based composition comprises the other particular alloying element. Additionally or alternatively, at M ¹ _a M ² _b M ³ _c M ⁴ _d M ⁵ _e M ⁶ _f The concentration of the alloying element is different in the innermost layer 122 than in the outermost layer 124 (e.g., at least two of a, b, c, d, e and f are different in the innermost layer 122 than in the outermost layer 124).

The substrate 102 may be any suitable material, for example, a metal such as steel or a superalloy (e.g., a nickel-based superalloy, a cobalt-based superalloy, or an iron-based superalloy, such as Rene N5, N500, N4, N2, IN718, hastelloy X, or Haynes 188) or other suitable material for withstanding high temperatures. The coating system 106 may be disposed along one or more portions of the substrate 102 or substantially on the entire exterior of the substrate 102. In particular embodiments, the coating system 106 can have a total thickness of 50 μm (e.g., micrometers or μm) to 2500 μm (e.g., 100 μm to 700 μm).

TBC 108 may be formed from a plurality of individual layers 114. In particular embodiments, each of the layers 114 of the TBC 108 may have a layer thickness of 25 μm to 100 μm (e.g., 25 μm to 50 μm). One or more of the individual layers 114 may be formed of a stable ceramic capable of maintaining a fairly high temperature gradient so that the coated metal part may be operated at a gas temperature above the melting point of the metal. For example, the stabilized ceramic material may be Yttrium Stabilized Zirconia (YSZ) and other rare earth stabilized zirconia compositions, mullite (3 Al) ₂ O ₃ -2SiO ₂ ) Alumina, ceria (CeO) ₂ ) Lanthanum zirconate, rare earth oxide (e.g. La ₂ O ₃ 、Nb ₂ O ₅ 、Pr ₂ O ₃ 、CeO ₂ ) And one or more of metal-glass composites, and combinations thereof (e.g., alumina and YSZ, or ceria and YSZ). In addition to high temperature stability, YSZ is both highly ductile and chemically inert, and the coefficient of thermal expansion of YSZ is quite well matched to that of the coated metal part. In one embodiment, TBC 108 may include a YSZ (e.g., 8 YSZ) based layer closest to substrate 102 (such as directly on bond coat 104).

Each individual layer 114 may be formed by any suitable process. For example, one or more of the individual layers 114 may be formed by air-plasma spraying (APS), suspension Plasma Spraying (SPS), solution Precursor Plasma Spraying (SPPS), electron Beam Physical Vapor Deposition (EBPVD), high Velocity Oxygen Fuel (HVOF), electrostatic Spray Assisted Vapor Deposition (ESAVD), and direct vapor deposition.

The coated component 100 is particularly useful as a component that exists in high temperature environments, such as components found in gas turbine engines, for example, combustor components, turbine blades, shrouds, nozzles, heat shields, and vanes. In particular, the coated component 100 may be a component that is positioned within a hot gas flow path of a gas turbine such that the coating system 106 forms a thermal barrier for the underlying substrate 102 to protect the component 100 within the gas turbine when exposed to the hot gas flow path.

FIG. 3 is a schematic cross-sectional view of a gas turbine engine according to an exemplary embodiment of the application. More specifically, for the embodiment of FIG. 3, the gas turbine engine is a high bypass turbofan engine 10, referred to herein as "turbofan engine 10". As shown in fig. 3, turbofan engine 10 defines an axial direction a (extending parallel to longitudinal axis 12 for reference) and a radial direction R. Generally, turbofan engine 10 includes a fan section 14 and a core turbine engine 16 disposed downstream of fan section 14. Although described below with reference to turbofan engine 10, the present application is generally applicable to turbomachinery, including turbojet engines, turboprop engines, and turboshaft gas turbine engines, including industrial and marine gas turbine engines and auxiliary power units. It may also be suitable for other high temperature applications containing water vapor in the gas phase, such as those resulting from the combustion of hydrocarbon fuels.

The exemplary core turbine engine 16 shown generally includes a generally tubular outer casing 18 defining an annular inlet 20. The housing 18 encloses, in serial flow relationship, a compressor section including a booster or Low Pressure (LP) compressor 22 and a High Pressure (HP) compressor 24; a combustion section 26; a turbine section including a High Pressure (HP) turbine 28 and a Low Pressure (LP) turbine 30; and an injection exhaust nozzle section 32. A High Pressure (HP) shaft or spool (spool) 34 drivingly connects HP turbine 28 to HP compressor 24. A Low Pressure (LP) shaft or spool 36 drivingly connects LP turbine 30 to LP compressor 22.

For the illustrated embodiment, the fan section 14 includes a variable pitch fan 38, the variable pitch fan 38 having a plurality of fan blades 40 connected to a disk 42 in a spaced apart manner. As shown, the fan blades 40 extend generally outwardly from the disk 42 in a radial direction R. Since the fan blades 40 are operatively connected to a suitable actuating member 44 (the actuating member 44 is configured to collectively and consistently vary the pitch of the fan blades 40), each fan blade 40 is rotatable relative to the disk 42 about a pitch axis P (a pitch axis). The fan blades 40, disk 42, and actuating member 44 are rotatable together about the longitudinal axis 12 by the LP spool 36 on an optional power gearbox 46. The power gearbox 46 includes a plurality of gears for reducing the rotational speed of the LP spool 36 to a more efficient rotational fan speed.

Still referring to the exemplary embodiment of FIG. 3, the disk 42 is covered by a rotatable forward nacelle 48, the forward nacelle 48 having an aerodynamic profile to facilitate airflow through the plurality of fan blades 40. Further, the exemplary fan section 14 includes an annular fan casing or nacelle 50 that circumferentially surrounds at least a portion of the fan 38 and/or the core turbine engine 16. It should be appreciated that the nacelle 50 may be configured to be supported relative to the core turbine engine 16 by a plurality of circumferentially spaced outlet guide vanes 52. Further, the downstream section 54 of the nacelle 50 may extend beyond the exterior of the core turbine engine 16 to define a bypass airflow passage 56 therebetween.

During operation of turbofan engine 10, a volume of air 58 enters turbofan engine 10 through nacelle 50 and/or an associated inlet 60 of fan section 14. As a volume of air 58 passes over the fan blades 40, a first portion 62 of the air 58 is directed or channeled into the bypass airflow passage 56 as indicated by the arrows, and a second portion 64 of the air 58 is directed or channeled into the LP compressor 22 as indicated by the arrows. The ratio between the first portion of air 62 and the second portion of air 64 is commonly referred to as the bypass ratio. The pressure of the second portion of air 64 then increases as it is passed through the High Pressure (HP) compressor 24 and into the combustion section 26, where the second portion of air 64 mixes with fuel and combusts to provide combustion gases 66.

The combustion gases 66 are channeled through HP turbine 28 wherein heat energy and/or a portion of the kinetic energy from combustion gases 66 are extracted via stages of HP turbine stator vanes 68 (coupled to casing 18) and HP turbine rotor blades 70 (coupled to HP shaft or spool 34) in sequence, thereby causing HP shaft or spool 34 to rotate, thereby supporting operation of HP compressor 24. The combustion gases 66 are then channeled through LP turbine 30 wherein thermal energy and a second portion of the kinetic energy are extracted from combustion gases 66 via stages of LP turbine stator vanes 72 (coupled to casing 18) and LP turbine rotor blades 74 (coupled to LP shaft or spool 36) in sequence, thereby causing LP shaft or spool 36 to rotate, thereby supporting operation of LP compressor 22 and/or rotation of fan 38.

The combustion gases 66 are then channeled through injection exhaust nozzle section 32 of core turbine engine 16 to provide propulsion thrust. At the same time, as the first portion of air 62 is channeled through bypass airflow passage 56 (also providing propulsive thrust) before it is discharged from fan nozzle exhaust section 76 of turbofan engine 10, the pressure of first portion of air 62 increases substantially. The HP turbine 28, the LP turbine 30, and the injection exhaust nozzle section 32 at least partially define a hot gas path 78 for channeling the combustion gases 66 through the core turbine engine 16. For example, the coated component 100 (FIGS. 1 and 2) may be particularly suitable as a component in contact with the combustion gases 66, including, but not limited to, the HP turbine stator vanes 68, the HP turbine rotor blades 70, the LP turbine stator vanes 72, the LP turbine rotor blades 74, components within the combustion section 26 (e.g., combustion liners), and the like.

Other aspects of the application are provided by the subject matter of the following clauses:

1. a high entropy alloy-based composition having the formula:

wherein,,

M ¹ 、M ² 、M ³ 、M ⁴ 、M ⁵ and M ⁶ Each of which is a different alloying element selected from Ni, co, fe, si, mn and Cu such that M ¹ 、M ² 、M ³ 、M ⁴ 、M ⁵ And M ⁶ None of which are the same alloying elements; a is more than or equal to 0.05 and less than or equal to 0.35; b is more than or equal to 0.05 and less than or equal to 0.35; c is more than or equal to 0.05 and less than or equal to 0.35; d is more than or equal to 0.05 and less than or equal to 0.35; e is more than or equal to 0.05 and less than or equal to 0.35; f is more than or equal to 0 and less than or equal to 0.35; a+b+c+d+e+f=1; x is more than or equal to 0 and less than or equal to 1; z is more than or equal to 0 and less than or equal to 1; and 0.ltoreq.x+z.ltoreq.1.

2. The composition of any of the preceding clauses wherein 0.1.ltoreq.a.ltoreq.0.25; b is more than or equal to 0.1 and less than or equal to 0.25; c is more than or equal to 0.1 and less than or equal to 0.25; d is more than or equal to 0.1 and less than or equal to 0.25; and 0.1.ltoreq.e.ltoreq.0.25.

3. The composition of any of the preceding clauses wherein f is 0.

4. The composition of any of the preceding clauses wherein a is substantially equal to b; b is substantially equal to c; c is substantially equal to d; and d is substantially equal to e.

5. The composition of any of the preceding clauses wherein a is substantially equal to b; b is substantially equal to c; c is substantially equal to d; d is substantially equal to e; and e is substantially equal to f.

6. The composition of any of the preceding clauses wherein x is 0.

7. The composition of any of the preceding clauses wherein z is 0.

8. The composition of any of the preceding clauses wherein 0.ltoreq.x.ltoreq.0.5 and 0.ltoreq.z.ltoreq.0.5.

9. The composition of any of the preceding clauses wherein 0< x.ltoreq.0.25.

10. The composition of any of the preceding clauses wherein 0<z is less than or equal to 0.25.

11. The composition of any of the preceding clauses wherein 0.ltoreq.x+z <0.5, such that the atomic concentration of Y is greater than Zr and Mo.

12. The composition of any of the preceding clauses wherein the alloy has the formula:

(Cu _0.2 Mn _0.2 Fe _0.2 Co _0.2 Ni _0.2 )CrAlY _1-x-z Zr _x Mo _z ，

13. The composition of any of the preceding clauses wherein the alloy has the formula:

(Cu _0.2 Si _0.2 Fe _0.2 Co _0.2 Ni _0.2 )CrAlY _1-x-z Zr _x Mo _z ，

14. A coated component comprising:

a substrate having a surface, wherein the substrate comprises a metal;

a bond coat on a surface of the substrate, wherein the bond coat comprises a layer comprising the composition of any of the preceding clauses; and

a thermal barrier coating on the bond coat.

15. A coated component comprising:

a substrate having a surface, wherein the substrate comprises a metal;

a thermal barrier coating on the bond coat layer,

16. The coated component of any of the preceding clauses, wherein the bond coat comprises an innermost layer adjacent to the surface of the substrate and comprising a first high-entropy alloy-based composition, and the bond coat comprises an outermost layer adjacent to the thermal barrier coating and comprising a second high-entropy alloy-based composition, wherein the first high-entropy alloy-based composition and the second high-entropy alloy-based composition are at their respective M ¹ _a M ² _b M ³ _c M ⁴ _d M ⁵ _e M ⁶ _f Is different in composition of at least one of (a).

17. The coated member according to any one of the preceding clauses wherein the bond coat layer has a composition gradient from an innermost layer adjacent to the surface of the substrate to an outermost layer adjacent to the thermal barrier coating.

18. The coated part of any preceding clause, wherein M ¹ _a M ² _b M ³ _c M ⁴ _d M ⁵ _e M ⁶ _f Has a composition gradient in at least one of (a).

19. The coated member according to any one of the preceding clauses wherein the alloy is a single phase alloy.

20. The coated part of any preceding clause, wherein the bond coat has a thickness of 10 μιη to 100 μιη.

21. An engine component comprising: the coated component of any one of the preceding clauses.

22. The engine component of any of the preceding clauses, wherein the engine component comprises at least one of an HP turbine stator vane, an HP turbine rotor blade, an LP turbine stator vane, an LP turbine rotor blade, or a combustion liner.

This written description uses examples to disclose the application, including the best mode, and also to enable any person skilled in the art to practice the application (including making and using any devices or systems and performing any incorporated methods). The patentable scope of the application is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

1. A high entropy alloy-based composition having the formula:

wherein,,

0.05≤a≤0.35；

0.05≤b≤0.35；

0.05≤c≤0.35；

0.05≤d≤0.35；

0.05≤e≤0.35；

0≤f≤0.35；

a+b+c+d+e+f＝1；

0≤x≤1；

z is more than or equal to 0 and less than or equal to 1; and

0≤x+z≤1。

2. the composition of claim 1, wherein,

0.1≤a≤0.25；

0.1≤b≤0.25；

0.1≤c≤0.25；

d is more than or equal to 0.1 and less than or equal to 0.25; and

0.1≤e≤0.25。

3. the composition of claim 1, wherein f is 0.

4. The composition of claim 1, wherein a is substantially equal to b; b is substantially equal to c; c is substantially equal to d; and d is substantially equal to e.

5. The composition of claim 1, wherein a is substantially equal to b; b is substantially equal to c; c is substantially equal to d; d is substantially equal to e; and e is substantially equal to f.

6. The composition of claim 1, wherein x is 0.

7. The composition of claim 1, wherein z is 0.

8. The composition of claim 1, wherein 0.ltoreq.x.ltoreq.0.5 and 0.ltoreq.z.ltoreq.0.5.

9. A coated component comprising:

a substrate having a surface, wherein the substrate comprises a metal;

a bond coat on a surface of a substrate, wherein the bond coat comprises a layer comprising the composition of claim 1; and

a thermal barrier coating on the bond coat.

10. A coated component comprising:

a substrate having a surface, wherein the substrate comprises a metal;

a thermal barrier coating on the bond coat layer,

wherein,,

0.05≤a≤0.35；

0.05≤b≤0.35；

0.05≤c≤0.35；

0.05≤d≤0.35；

0.05≤e≤0.35；

0≤f≤0.35；

a+b+c+d+e+f＝1；

0≤x≤1；

z is more than or equal to 0 and less than or equal to 1; and

0≤x+z≤1。