EP1008672A1 - Platinum modified diffusion aluminide bond coat for a thermal barrier coating system - Google Patents
Platinum modified diffusion aluminide bond coat for a thermal barrier coating system Download PDFInfo
- Publication number
- EP1008672A1 EP1008672A1 EP98310176A EP98310176A EP1008672A1 EP 1008672 A1 EP1008672 A1 EP 1008672A1 EP 98310176 A EP98310176 A EP 98310176A EP 98310176 A EP98310176 A EP 98310176A EP 1008672 A1 EP1008672 A1 EP 1008672A1
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- European Patent Office
- Prior art keywords
- bond coat
- component
- coating system
- ceramic layer
- thermal barrier
- Prior art date
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- 229910000951 Aluminide Inorganic materials 0.000 title claims abstract description 41
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 title claims abstract description 30
- 239000012720 thermal barrier coating Substances 0.000 title claims abstract description 21
- 229910052697 platinum Inorganic materials 0.000 title claims abstract description 15
- 238000009792 diffusion process Methods 0.000 title abstract description 26
- 239000000919 ceramic Substances 0.000 claims abstract description 33
- 239000000654 additive Substances 0.000 claims abstract description 31
- 238000000576 coating method Methods 0.000 claims abstract description 31
- 230000000996 additive effect Effects 0.000 claims abstract description 28
- 239000011248 coating agent Substances 0.000 claims abstract description 26
- 229910052751 metal Inorganic materials 0.000 claims abstract description 26
- 239000002184 metal Substances 0.000 claims abstract description 26
- 238000000034 method Methods 0.000 claims abstract description 20
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims abstract description 12
- 229910052727 yttrium Inorganic materials 0.000 claims abstract description 12
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 claims abstract description 12
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 claims abstract description 8
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims abstract description 7
- 229910052804 chromium Inorganic materials 0.000 claims abstract description 7
- 239000011651 chromium Substances 0.000 claims abstract description 7
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 claims abstract description 6
- 229910052735 hafnium Inorganic materials 0.000 claims abstract description 6
- VBJZVLUMGGDVMO-UHFFFAOYSA-N hafnium atom Chemical compound [Hf] VBJZVLUMGGDVMO-UHFFFAOYSA-N 0.000 claims abstract description 6
- 229910052710 silicon Inorganic materials 0.000 claims abstract description 6
- 239000010703 silicon Substances 0.000 claims abstract description 6
- 229910052726 zirconium Inorganic materials 0.000 claims abstract description 6
- 229910052703 rhodium Inorganic materials 0.000 claims abstract description 5
- 239000010948 rhodium Substances 0.000 claims abstract description 5
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 claims abstract description 5
- 229910052763 palladium Inorganic materials 0.000 claims abstract description 4
- 238000005328 electron beam physical vapour deposition Methods 0.000 claims description 3
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 2
- 229910000601 superalloy Inorganic materials 0.000 abstract description 15
- 229910052782 aluminium Inorganic materials 0.000 abstract description 14
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 abstract description 14
- 238000007792 addition Methods 0.000 abstract description 11
- 238000000151 deposition Methods 0.000 abstract description 4
- 238000005269 aluminizing Methods 0.000 abstract description 2
- 239000010410 layer Substances 0.000 description 38
- 230000003647 oxidation Effects 0.000 description 17
- 238000007254 oxidation reaction Methods 0.000 description 17
- 239000000758 substrate Substances 0.000 description 17
- 239000007789 gas Substances 0.000 description 12
- 230000007613 environmental effect Effects 0.000 description 10
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 8
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 8
- 239000000470 constituent Substances 0.000 description 7
- 239000000463 material Substances 0.000 description 7
- 150000002739 metals Chemical class 0.000 description 7
- 239000003870 refractory metal Substances 0.000 description 7
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 6
- 230000008569 process Effects 0.000 description 6
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 5
- 230000008901 benefit Effects 0.000 description 5
- 239000000203 mixture Substances 0.000 description 5
- 229910052750 molybdenum Inorganic materials 0.000 description 5
- 239000011733 molybdenum Substances 0.000 description 5
- 229910052702 rhenium Inorganic materials 0.000 description 5
- WUAPFZMCVAUBPE-UHFFFAOYSA-N rhenium atom Chemical compound [Re] WUAPFZMCVAUBPE-UHFFFAOYSA-N 0.000 description 5
- 229910052715 tantalum Inorganic materials 0.000 description 5
- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum atom Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 description 5
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 5
- 229910052721 tungsten Inorganic materials 0.000 description 5
- 239000010937 tungsten Substances 0.000 description 5
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 4
- 229910052759 nickel Inorganic materials 0.000 description 4
- 229910000510 noble metal Inorganic materials 0.000 description 4
- 239000012071 phase Substances 0.000 description 4
- 238000004544 sputter deposition Methods 0.000 description 4
- 229910052719 titanium Inorganic materials 0.000 description 4
- 239000010936 titanium Substances 0.000 description 4
- RUDFQVOCFDJEEF-UHFFFAOYSA-N yttrium(III) oxide Inorganic materials [O-2].[O-2].[O-2].[Y+3].[Y+3] RUDFQVOCFDJEEF-UHFFFAOYSA-N 0.000 description 4
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 3
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 3
- 230000001464 adherent effect Effects 0.000 description 3
- 229910045601 alloy Inorganic materials 0.000 description 3
- 239000000956 alloy Substances 0.000 description 3
- CETPSERCERDGAM-UHFFFAOYSA-N ceric oxide Chemical compound O=[Ce]=O CETPSERCERDGAM-UHFFFAOYSA-N 0.000 description 3
- 229910000422 cerium(IV) oxide Inorganic materials 0.000 description 3
- 230000007797 corrosion Effects 0.000 description 3
- 238000005260 corrosion Methods 0.000 description 3
- 230000008021 deposition Effects 0.000 description 3
- 229910052742 iron Inorganic materials 0.000 description 3
- 230000001737 promoting effect Effects 0.000 description 3
- 239000007921 spray Substances 0.000 description 3
- 229910052717 sulfur Inorganic materials 0.000 description 3
- 239000011593 sulfur Substances 0.000 description 3
- NPXOKRUENSOPAO-UHFFFAOYSA-N Raney nickel Chemical compound [Al].[Ni] NPXOKRUENSOPAO-UHFFFAOYSA-N 0.000 description 2
- 241000968352 Scandia <hydrozoan> Species 0.000 description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 2
- 230000004888 barrier function Effects 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 229910010293 ceramic material Inorganic materials 0.000 description 2
- 238000005229 chemical vapour deposition Methods 0.000 description 2
- 229910017052 cobalt Chemical group 0.000 description 2
- 239000010941 cobalt Chemical group 0.000 description 2
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical group [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 2
- 230000002939 deleterious effect Effects 0.000 description 2
- 239000012535 impurity Substances 0.000 description 2
- HJGMWXTVGKLUAQ-UHFFFAOYSA-N oxygen(2-);scandium(3+) Chemical compound [O-2].[O-2].[O-2].[Sc+3].[Sc+3] HJGMWXTVGKLUAQ-UHFFFAOYSA-N 0.000 description 2
- 238000005240 physical vapour deposition Methods 0.000 description 2
- 230000002195 synergetic effect Effects 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 229910000967 As alloy Inorganic materials 0.000 description 1
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 238000005275 alloying Methods 0.000 description 1
- 238000010420 art technique Methods 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000010406 cathode material Substances 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000000567 combustion gas Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 230000001627 detrimental effect Effects 0.000 description 1
- 238000009713 electroplating Methods 0.000 description 1
- 230000003628 erosive effect Effects 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 238000005247 gettering Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 238000011835 investigation Methods 0.000 description 1
- 239000000395 magnesium oxide Substances 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 229910000907 nickel aluminide Inorganic materials 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- -1 platinum group metals Chemical class 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- HYXGAEYDKFCVMU-UHFFFAOYSA-N scandium(III) oxide Inorganic materials O=[Sc]O[Sc]=O HYXGAEYDKFCVMU-UHFFFAOYSA-N 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 238000004901 spalling Methods 0.000 description 1
- 230000035882 stress Effects 0.000 description 1
- 238000005382 thermal cycling Methods 0.000 description 1
- 230000008646 thermal stress Effects 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- 238000007740 vapor deposition Methods 0.000 description 1
- 230000008016 vaporization Effects 0.000 description 1
- 238000001947 vapour-phase growth Methods 0.000 description 1
Images
Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
- F01D5/288—Protective coatings for blades
-
- C—CHEMISTRY; METALLURGY
- C23—COATING 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
- C23C—COATING 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
- C23C28/00—Coating 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
Definitions
- This invention relates to thermal barrier coating systems for components exposed to high temperatures, such as the hostile thermal environment of a gas turbine engine. More particularly, this invention is directed to a thermal barrier coating system which employs a ceramic layer and a diffusion aluminide bond coat incorporating an additive metal and an active element, which together promote the spallation resistance of the ceramic layer.
- Coating materials that have found wide use for this purpose include diffusion aluminide coatings, which are generally single-layer oxidation-resistant layers formed by diffusion processes, such as a pack cementation process. Diffusion processes generally entail reacting the surface of a component with an aluminum-containing gas composition to form two distinct zones, the outermost of which is an additive layer containing an environmentally-resistant intermetallic represented by MAl, where M is iron, nickel or cobalt, depending on the substrate material. Beneath the additive layer is a diffusion zone comprising various intermetallic and metastable phases that form during the coating reaction as a result of diffusional gradients and changes in elemental solubility in the local region of the substrate. During high temperature exposure in air, the MAl intermetallic forms a protective aluminum oxide (alumina) scale or layer that inhibits oxidation of the diffusion coating and the underlying substrate.
- alumina aluminum oxide
- thermal barrier coating systems For particularly high temperature applications, environmental coating systems often include a layer of thermal insulating ceramic over a diffusion coating, the latter of which is then termed a bond coat.
- the combination of the bond coat and ceramic layer is known in the art as a thermal barrier coating system.
- Various ceramic materials have been employed as the ceramic layer, particularly zirconia (ZrO 2 ) fully or partially stabilized by yttria (Y 2 O 3 ), magnesia (MgO), ceria (CeO 2 ), scandia (Sc 2 O 3 ), or another oxide. These particular materials are widely employed in the art because they exhibit desirable thermal cycle fatigue properties, and also because they can be readily deposited by plasma spray, flame spray and vapor deposition techniques.
- a bond coat is critical to the service life of the thermal barrier coating system in which it is employed, and is therefore also critical to the service life of the component protected by the coating system.
- the oxide scale formed by a diffusion aluminide bond coat is adherent and continuous, and therefore not only protects the bond coat and its underlying superalloy substrate by serving as an oxidation barrier, but also chemically bonds the ceramic layer. Nonetheless, aluminide bond coats inherently continue to oxidize over time at elevated temperatures, which gradually depletes aluminum from the bond coat and increases the thickness of the oxide scale until such time as the scale reaches a critical thickness that leads to spallation of the ceramic layer at the interface between the bond coat and the aluminum oxide scale. Once spallation has occurred, the component deteriorates rapidly, and must be refurbished or scrapped at considerable cost.
- the ability of the bond coat to form and maintain a suitable aluminum oxide scale can be hampered by the interdiffusion of aluminum in the bond coat with the superalloy substrate, and from the diffusion of elements from the superalloy into the bond coat, such as during formation of the aluminide bond coat or during high temperature exposure.
- the diffusion and subsequent oxidation of elements such as molybdenum, tungsten, rhenium, titanium and tantalum within the aluminide bond coat can become thermodynamically favored as the aluminum within the coating is depleted through oxidation and interdiffusion.
- these elements tend to form voluminous, nonadherent scales that are deleterious to adhesion of the ceramic layer.
- the coating system includes a diffusion aluminide bond coat that is formed on the surface of the component.
- the coating system includes a thermal insulating ceramic layer that is anchored to the component with an aluminum oxide scale on the surface of the aluminide bond coat.
- the aluminide bond coat is modified to produce a relatively slow-growing oxide scale that is relatively free of impurities and resists cracking and spalling.
- the aluminide bond coat includes an additive metal and an active element, which together yield a bond coat characterized by increased resistance to oxidation as a result of the slower growth rate for the oxide scale, and further characterized by improved adhesion of the oxide scale to the bond coat, such that the spallation resistance of the ceramic layer is also promoted.
- the present invention generally provides a thermal barrier coating system and a method for forming the coating system on a component designed for use in a hostile thermal environment, such as superalloy turbine, combustor and augmentor components of a gas turbine engine.
- the method is particularly directed to a thermal barrier coating system that includes an oxidation-resistant diffusion aluminide bond coat on which an aluminum oxide scale is grown to protect the underlying surface of the component and adhere an overlying thermal-insulating ceramic layer.
- the aluminide bond coat to include one or more specific metal additives, namely the noble metals (platinum, palladium and rhodium), chromium and/or silicon, and limited additions of the active elements yttrium and/or zirconium.
- the additive metal and active element constituents of the bond coat may be deposited prior to the aluminide bond coat, such as by sputtering or through a cathodic arc process. Alternatively, the active element constituent may be simultaneously deposited with the aluminide bond coat using pack cementation or gas phase processing. Once formed, the modified aluminide bond coat undergoes oxidation to form an aluminum oxide scale that serves as an oxidation-resistant barrier layer and chemically bonds the thermal-insulating ceramic layer.
- appropriately alloying the aluminide bond coat to contain one or more of the above-noted additive metals and one or more of the above-noted active elements serves to significantly enhance the spallation resistance of the overlying ceramic layer by promoting the adherence of the aluminum oxide scale and slowing the growth of the oxide scale.
- the active elements improve oxide scale adhesion by altering the structure of the oxide, bond coat and oxide-bond coat interface and/or by tying up tramp elements such as sulfur.
- the additive metals generally promote the selective oxidation of aluminum at lower concentrations of aluminum in the bond coat.
- the noble metals impede the diffusion of refractory metals from the substrate so as to prevent their oxides from doping the oxide scale.
- Additive elements such as silicon and chromium react with refractory metals to form compounds that tie up the refractory metals, thereby preventing the formation of refractory metal oxides at the surface of the aluminide bond coat.
- the additive metals provide advantages that are particularly notable where the component is a superalloy containing one or more refractory metals, such as tantalum, tungsten, molybdenum, titanium and rhenium.
- a synergistic effect appears to result due to the presence of both the additive and active elements, yielding a significantly slower oxide growth rate. Because stresses rise and adhesion declines as oxide scale thickness increases, the ultimate result being spallation, the slowed oxide growth rate provided by this invention is able to significantly extend the life of a thermal barrier coating system.
- the present invention is generally applicable to components that operate within environments characterized by relatively high temperatures, and are therefore subjected to a hostile oxidizing environment and severe thermal stresses and thermal cycling.
- Notable examples of such components include the high and low pressure turbine nozzles and blades, shrouds, combustor liners and augmentor hardware of gas turbine engines.
- An example of a high pressure turbine blade 10 is shown in Figure 1.
- the blade 10 generally includes an airfoil 12 and platform 16 against which hot combustion gases are directed during operation of the gas turbine engine, and whose surfaces are therefore subjected to severe attack by oxidation, corrosion and erosion.
- the airfoil 12 and platform 16 are anchored to a turbine disk (not shown) with a dovetail 14 formed on a shank section of the blade 10.
- Cooling passages 18 are present through the airfoil 12 through which bleed air is forced to transfer heat from the blade 10. While the advantages of this invention will be described with reference to the high pressure turbine blade 10 shown in Figure 1, the teachings of this invention are generally applicable to any component on which a thermal barrier coating system may be used to protect the component from its environment.
- the coating system 20 includes a ceramic layer 26 and a diffusion aluminide bond coat 24 overlying a substrate 22, which is typically the base material of the blade 10.
- Suitable materials for the substrate 22 (and therefore the blade 10) include nickel, iron and cobalt-base superalloys, with the invention being particularly advantageous with nickel-base superalloys that contain one or more refractory metals, such as molybdenum, tungsten, rhenium, titanium and tantalum.
- the aluminide bond coat 24 is generally characterized by an additive layer 24a that overlies a diffusion zone 24b, the former of which is usually a monoaluminide layer of an oxidation-resistant MAl intermetallic phase, such as the nickel-aluminide beta phase (NiAl). Coatings of this type form an aluminum oxide scale (not shown) on the surface of the additive layer during exposure to engine environments. The oxide scale inhibits oxidation of the bond coat 24 and substrate 22, and chemically bonds the ceramic layer 26 to the bond coat 24.
- a suitable thickness for the bond coat 24 is about 25 to about 150 micrometers.
- the ceramic layer 26 overlying the aluminide bond coat 24 is required for high temperature components (such as the blade 10) of gas turbine engines. As noted above, the ceramic layer 26 is chemically bonded to the oxide scale on the surface of the aluminide bond coat 24.
- a preferred ceramic layer 26 has a strain-tolerant columnar grain structure achieved by physical vapor deposition (PVD) techniques known in the art, e.g., electron beam physical vapor deposition (EBPVD), though ceramic layers are also formed by air plasma spray (APS) techniques.
- PVD physical vapor deposition
- EBPVD electron beam physical vapor deposition
- APS air plasma spray
- a suitable material for the ceramic layer 26 is zirconia that is partially or fully stabilized with yttria (YSZ), though other ceramic materials could be used, including yttria or zirconia stabilized by magnesia, ceria, scandia or another oxide.
- the ceramic layer 26 is deposited to a thickness that is sufficient to provide the required thermal protection for the underlying substrate 22 and blade 10, generally on the order of about 75 to about 300 micrometers.
- the bond coat 24 includes additions of certain metals and active elements to promote the spallation resistance of the ceramic layer 26.
- Metal additives employed by this invention are chromium, silicon and/or a noble metal such as platinum, rhodium and palladium, which help selectively oxidize aluminum at lower concentrations.
- the active elements are yttrium and zirconium, with possible additions of hafnium.
- the bond coat 24 can be codeposited with the active element constituent, or diffused into a predeposited layer of the metal additive and active element.
- the addition of these constituents to a diffusion aluminide bond coat has been found to slow the oxide scale growth rate, in addition to forming stable oxides, trapping or tying up deleterious tramp elements such as sulfur, and promoting adhesion of the oxide scale on the bond coat 24, all of which promotes the spallation resistance of the ceramic layer 26.
- the preferred additive metals are selected on the basis of their ability to enhance the environmental resistance (i.e., oxidation and hot corrosion resistance) of the bond coat 24 and promote the selective oxidation of aluminum, while the active elements improve oxide scale adhesion by mechanisms such as oxide pegging and/or gettering of tramp elements such as sulfur. These additions may also impede the diffusion of elements from the substrate 22, and therefore render the bond coat 24 less susceptible to interactions and interdiffusion of elements observed between prior art bond coats and their superalloy substrates.
- Thermal barrier coating systems according to this invention have exhibited thermal cycle resistance of about 2.5 times better than prior art coating systems with platinum aluminide bond coats, and about six times better than prior art coating systems with aluminide bond coats.
- the additive metals are present in amounts of about 5 to about 50 weight percent, while the active elements are preferably present in amounts of about 10 parts per million (ppm) to about 1.0 weight percent yttrium and/or about 0.01 to about 5.0 weight percent zirconium, with possible additions of about 0.01 to about 5.0 weigh percent hafnium.
- metal additives, active elements and aluminum can be codeposited and diffused into the substrate 22 using suitable techniques.
- aluminum and the active element can be codeposited and simultaneously diffused into the substrate 22 using a suitable aluminizing technique, such as pack cementation and out-of-pack (gas or vapor phase deposition) processes.
- a suitable aluminizing technique such as pack cementation and out-of-pack (gas or vapor phase deposition) processes.
- one or more noble metals and the active elements can be applied simultaneously by sputtering or cathodic arc processes, each of which involves vaporizing and then condensing the desired elements on the substrate 22.
- aluminum and the active elements can be simultaneously applied by chemical vapor deposition (CVD) techniques, and aluminum and chromium can be codeposited by pack cementation and out-of-pack processes.
- CVD chemical vapor deposition
- Additive metals such as platinum and rhodium can be individually deposited by electroplating. Examples of the above would be to sputter or plate platinum, and then aluminiding with yttrium or sputtering yttrium followed by aluminiding. In the latter example, yttrium could be sputtered prior to deposition of platinum. It is also within the scope of this invention that the active element constituent of the bond coat 24 can be provided by the underlying superalloy 22, whose composition would be modified to achieve the desired active element content for the bond coat 24.
- Sputtering and cathodic arc coating techniques have the advantage over prior art techniques of being able to repeatably deposit specific alloy combinations.
- Deposition by either method can be carried out using a pre-alloyed target cathode material, such as alloy sheet, powder, etc., whose composition conforms to the desired combination of metal additive and active element.
- a pre-alloyed target cathode material such as alloy sheet, powder, etc.
- multiple targets of substantially pure constituents for the additive metal and active element could be formed, which are then simultaneously vaporized and deposited to form a homogeneous coating, or sequentially vaporized and deposited to form a multilayered coating.
- subsequent heat treatment or exposure to high service temperatures serves to interdiffuse the materials to form the modified composition for the bond coat 24.
- the surface of the component is then aluminized by any suitable method to form the aluminide bond coat 24.
- the selective additions of the additive metal in combination with the active elements are able to significantly enhance the spallation resistance of the ceramic layer 26, and therefore the service life of the component protected by the thermal barrier coating system 20.
- These selective additions promote the environmental resistance of the bond coat 24 while also slowing the growth of the oxide scale on the bond coat 24 and promoting a more adherent and stable oxide scale, such that the ceramic layer 26 is more adherent to the bond coat 24.
- the bond coat 24 may also be rendered more resistant to the diffusion of substrate constituents into the bond coat 24.
- the refractory metals tantalum, tungsten, molybdenum, titanium and rhenium which form less desirable oxides that can detrimentally affect the desired aluminum oxide scale on the bond coat 24.
- nickel-base superalloy specimens were coated with thermal barrier coating systems whose bond coats were either prior art diffusion aluminides or formed in accordance with this invention. Specifically, specimens were formed of the nickel-base superalloy René N5.
- This superalloy nominally contains, in weight percent, about 7.5% cobalt, about 7% chromium, about 1.5% molybdenum, about 5% tungsten, about 3% rhenium, about 6.5% tantalum, about 6.2% aluminum, about 0.15% hafnium, about 0.05% carbon, about 0.01% yttrium, and about 0.004% boron, with the balance nickel and incidental impurities.
- Bond coats formed in accordance with this invention were diffusion aluminides containing additions of about 20 to 40 weight percent platinum and about 0.01 to 0.1 weight percent yttrium.
- prior art bond coats evaluated were diffusion aluminides formed by pack cementation, gas or vapor, and tape diffusion processes.
- One group of prior art bond coats further included platinum to yield platinum-modified aluminide coatings.
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- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
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Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP98310176A EP1008672A1 (en) | 1998-12-11 | 1998-12-11 | Platinum modified diffusion aluminide bond coat for a thermal barrier coating system |
JP10355568A JP3096026B2 (ja) | 1998-12-11 | 1998-12-15 | 断熱皮膜系のための改善された拡散アルミニウム化物ボンディングコートとその製法 |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP98310176A EP1008672A1 (en) | 1998-12-11 | 1998-12-11 | Platinum modified diffusion aluminide bond coat for a thermal barrier coating system |
JP10355568A JP3096026B2 (ja) | 1998-12-11 | 1998-12-15 | 断熱皮膜系のための改善された拡散アルミニウム化物ボンディングコートとその製法 |
Publications (1)
Publication Number | Publication Date |
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EP1008672A1 true EP1008672A1 (en) | 2000-06-14 |
Family
ID=26151526
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP98310176A Ceased EP1008672A1 (en) | 1998-12-11 | 1998-12-11 | Platinum modified diffusion aluminide bond coat for a thermal barrier coating system |
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EP (1) | EP1008672A1 (ja) |
JP (1) | JP3096026B2 (ja) |
Cited By (11)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2378452A (en) * | 2001-08-09 | 2003-02-12 | Rolls Royce Plc | A metallic article having a protective coating and a method therefor |
WO2006036171A1 (en) * | 2004-09-16 | 2006-04-06 | Aeromet Technologies, Inc. | Superalloy jet engine components with protective coatings and method of forming such protective coatings on superalloy jet engine components |
WO2006052277A3 (en) * | 2004-09-16 | 2007-02-15 | Aeromet Technologies Inc | Gas turbine engine components with aluminide coatings and method of forming such aluminide coatings on gas turbine engine components |
US7208230B2 (en) | 2003-08-29 | 2007-04-24 | General Electric Company | Optical reflector for reducing radiation heat transfer to hot engine parts |
US7306860B2 (en) | 2004-07-30 | 2007-12-11 | Honeywell International, Inc. | Protective coating for oxide ceramic based composites |
US7927714B2 (en) | 2008-08-20 | 2011-04-19 | The Trustees Of Princeton University | Barium-doped bond coat for thermal barrier coatings |
US8123967B2 (en) | 2005-08-01 | 2012-02-28 | Vapor Technologies Inc. | Method of producing an article having patterned decorative coating |
US9133718B2 (en) | 2004-12-13 | 2015-09-15 | Mt Coatings, Llc | Turbine engine components with non-aluminide silicon-containing and chromium-containing protective coatings and methods of forming such non-aluminide protective coatings |
CN108048776A (zh) * | 2017-11-28 | 2018-05-18 | 马鞍山蓝科再制造技术有限公司 | 一种热障涂层 |
CN115095588A (zh) * | 2022-06-28 | 2022-09-23 | 西安鑫垚陶瓷复合材料有限公司 | 陶瓷基复材与金属材料的粘接方法及控制胶层厚度的夹具 |
CN115198271A (zh) * | 2022-07-15 | 2022-10-18 | 广东省科学院新材料研究所 | 一种高热匹配性热障涂层及其制备方法与应用 |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
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FR2813318B1 (fr) * | 2000-08-28 | 2003-04-25 | Snecma Moteurs | Formation d'un revetement aluminiure incorporant un element reactif, sur un substrat metallique |
US20070231589A1 (en) * | 2006-04-04 | 2007-10-04 | United Technologies Corporation | Thermal barrier coatings and processes for applying same |
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US5514482A (en) * | 1984-04-25 | 1996-05-07 | Alliedsignal Inc. | Thermal barrier coating system for superalloy components |
EP0733723A1 (en) * | 1995-03-21 | 1996-09-25 | Howmet Corporation | Thermal barrier coating system |
EP0821078A1 (en) * | 1996-07-23 | 1998-01-28 | Howmet Research Corporation | Modified platinum aluminide diffusion coating and cvd coating method |
EP0987347A1 (en) * | 1997-01-16 | 2000-03-22 | General Electric Company | Thermal barrier coating system and method therefor |
EP0992612A2 (en) * | 1998-10-06 | 2000-04-12 | General Electric Company | Nickel aluminide coating systems |
EP0995817A1 (en) * | 1998-10-19 | 2000-04-26 | N.V. Interturbine | Thermal barrier coating system and methods |
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- 1998-12-11 EP EP98310176A patent/EP1008672A1/en not_active Ceased
- 1998-12-15 JP JP10355568A patent/JP3096026B2/ja not_active Expired - Fee Related
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US5514482A (en) * | 1984-04-25 | 1996-05-07 | Alliedsignal Inc. | Thermal barrier coating system for superalloy components |
EP0733723A1 (en) * | 1995-03-21 | 1996-09-25 | Howmet Corporation | Thermal barrier coating system |
EP0821078A1 (en) * | 1996-07-23 | 1998-01-28 | Howmet Research Corporation | Modified platinum aluminide diffusion coating and cvd coating method |
EP1191122B1 (en) * | 1996-07-23 | 2003-09-10 | Howmet Research Corporation (a Delaware Corporation) | Modified platinum aluminide diffusion coating and CVD coating method |
EP0987347A1 (en) * | 1997-01-16 | 2000-03-22 | General Electric Company | Thermal barrier coating system and method therefor |
EP0992612A2 (en) * | 1998-10-06 | 2000-04-12 | General Electric Company | Nickel aluminide coating systems |
EP0995817A1 (en) * | 1998-10-19 | 2000-04-26 | N.V. Interturbine | Thermal barrier coating system and methods |
Cited By (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2378452A (en) * | 2001-08-09 | 2003-02-12 | Rolls Royce Plc | A metallic article having a protective coating and a method therefor |
US7208230B2 (en) | 2003-08-29 | 2007-04-24 | General Electric Company | Optical reflector for reducing radiation heat transfer to hot engine parts |
US7306860B2 (en) | 2004-07-30 | 2007-12-11 | Honeywell International, Inc. | Protective coating for oxide ceramic based composites |
US8623461B2 (en) | 2004-09-16 | 2014-01-07 | Mt Coatings Llc | Metal components with silicon-containing protective coatings substantially free of chromium and methods of forming such protective coatings |
WO2006036171A1 (en) * | 2004-09-16 | 2006-04-06 | Aeromet Technologies, Inc. | Superalloy jet engine components with protective coatings and method of forming such protective coatings on superalloy jet engine components |
WO2006052277A3 (en) * | 2004-09-16 | 2007-02-15 | Aeromet Technologies Inc | Gas turbine engine components with aluminide coatings and method of forming such aluminide coatings on gas turbine engine components |
US7901739B2 (en) | 2004-09-16 | 2011-03-08 | Mt Coatings, Llc | Gas turbine engine components with aluminide coatings and method of forming such aluminide coatings on gas turbine engine components |
US9133718B2 (en) | 2004-12-13 | 2015-09-15 | Mt Coatings, Llc | Turbine engine components with non-aluminide silicon-containing and chromium-containing protective coatings and methods of forming such non-aluminide protective coatings |
US8123967B2 (en) | 2005-08-01 | 2012-02-28 | Vapor Technologies Inc. | Method of producing an article having patterned decorative coating |
US7927714B2 (en) | 2008-08-20 | 2011-04-19 | The Trustees Of Princeton University | Barium-doped bond coat for thermal barrier coatings |
CN108048776A (zh) * | 2017-11-28 | 2018-05-18 | 马鞍山蓝科再制造技术有限公司 | 一种热障涂层 |
CN115095588A (zh) * | 2022-06-28 | 2022-09-23 | 西安鑫垚陶瓷复合材料有限公司 | 陶瓷基复材与金属材料的粘接方法及控制胶层厚度的夹具 |
CN115198271A (zh) * | 2022-07-15 | 2022-10-18 | 广东省科学院新材料研究所 | 一种高热匹配性热障涂层及其制备方法与应用 |
Also Published As
Publication number | Publication date |
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JP3096026B2 (ja) | 2000-10-10 |
JP2000178764A (ja) | 2000-06-27 |
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