EP3985137A1 - Nicocraly-alloy, a powder, a coating and a component - Google Patents
Nicocraly-alloy, a powder, a coating and a component Download PDFInfo
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- EP3985137A1 EP3985137A1 EP20201694.5A EP20201694A EP3985137A1 EP 3985137 A1 EP3985137 A1 EP 3985137A1 EP 20201694 A EP20201694 A EP 20201694A EP 3985137 A1 EP3985137 A1 EP 3985137A1
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- Prior art keywords
- coating
- alloy
- powder
- optionally
- coatings
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- 229910045601 alloy Inorganic materials 0.000 title claims abstract description 12
- 239000000956 alloy Substances 0.000 title claims abstract description 12
- 238000000576 coating method Methods 0.000 title claims description 30
- 239000011248 coating agent Substances 0.000 title claims description 18
- 239000000843 powder Substances 0.000 title claims description 6
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims abstract description 13
- 229910052727 yttrium Inorganic materials 0.000 claims abstract description 8
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 claims abstract description 7
- 239000011651 chromium Substances 0.000 claims abstract description 6
- 229910052759 nickel Inorganic materials 0.000 claims abstract description 6
- 229910017052 cobalt Inorganic materials 0.000 claims abstract description 5
- 239000010941 cobalt Substances 0.000 claims abstract description 5
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 claims abstract description 5
- 229910052707 ruthenium Inorganic materials 0.000 claims abstract description 5
- KJTLSVCANCCWHF-UHFFFAOYSA-N Ruthenium Chemical compound [Ru] KJTLSVCANCCWHF-UHFFFAOYSA-N 0.000 claims abstract description 4
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 4
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 4
- 229910052715 tantalum Inorganic materials 0.000 claims abstract description 4
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims abstract description 3
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 claims abstract description 3
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims abstract description 3
- 229910052804 chromium Inorganic materials 0.000 claims abstract description 3
- 229910052750 molybdenum Inorganic materials 0.000 claims abstract description 3
- 239000011733 molybdenum Substances 0.000 claims abstract description 3
- 229910052710 silicon Inorganic materials 0.000 claims abstract description 3
- 239000010703 silicon Substances 0.000 claims abstract description 3
- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum atom Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 claims abstract description 3
- 239000000203 mixture Substances 0.000 claims description 6
- 239000000758 substrate Substances 0.000 claims description 5
- 229910000601 superalloy Inorganic materials 0.000 claims description 4
- 239000000919 ceramic Substances 0.000 claims description 3
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 claims description 2
- 239000011230 binding agent Substances 0.000 claims description 2
- 229910052717 sulfur Inorganic materials 0.000 claims description 2
- 239000011593 sulfur Substances 0.000 claims description 2
- 238000005524 ceramic coating Methods 0.000 claims 1
- 239000002245 particle Substances 0.000 claims 1
- 230000003647 oxidation Effects 0.000 description 5
- 238000007254 oxidation reaction Methods 0.000 description 5
- 238000005260 corrosion Methods 0.000 description 3
- 230000007797 corrosion Effects 0.000 description 3
- 238000011161 development Methods 0.000 description 3
- 238000009792 diffusion process Methods 0.000 description 3
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 229910052741 iridium Inorganic materials 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 239000012720 thermal barrier coating Substances 0.000 description 2
- 238000013459 approach Methods 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000010894 electron beam technology Methods 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- GKOZUEZYRPOHIO-UHFFFAOYSA-N iridium atom Chemical compound [Ir] GKOZUEZYRPOHIO-UHFFFAOYSA-N 0.000 description 1
- 238000011068 loading method Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000005272 metallurgy Methods 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 238000005289 physical deposition Methods 0.000 description 1
- 238000007747 plating Methods 0.000 description 1
- 239000011253 protective coating Substances 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 239000011214 refractory ceramic Substances 0.000 description 1
- 239000003870 refractory metal Substances 0.000 description 1
- 230000008439 repair process Effects 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 238000007751 thermal spraying Methods 0.000 description 1
- 238000005019 vapor deposition process Methods 0.000 description 1
- RUDFQVOCFDJEEF-UHFFFAOYSA-N yttrium(III) oxide Inorganic materials [O-2].[O-2].[O-2].[Y+3].[Y+3] RUDFQVOCFDJEEF-UHFFFAOYSA-N 0.000 description 1
Classifications
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- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/12—Metallic powder containing non-metallic particles
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C19/00—Alloys based on nickel or cobalt
- C22C19/03—Alloys based on nickel or cobalt based on nickel
- C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
- C22C19/051—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W
- C22C19/056—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being at least 10% but less than 20%
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C30/00—Alloys containing less than 50% by weight of each constituent
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- 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
- C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
- C23C28/32—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer
- C23C28/321—Coatings 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
- C23C28/3215—Coatings 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
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- 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
- C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
- C23C28/34—Coatings 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
- C23C28/345—Coatings 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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- 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
- C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
- C23C28/34—Coatings 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
- C23C28/345—Coatings 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
- C23C28/3455—Coatings 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 with a refractory ceramic layer, e.g. refractory metal oxide, ZrO2, rare earth oxides or a thermal barrier system comprising at least one refractory oxide layer
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- 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
- C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
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- 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
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
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- 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
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
- C23C4/073—Metallic material containing MCrAl or MCrAlY alloys, where M is nickel, cobalt or iron, with or without non-metal elements
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- 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
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/18—After-treatment
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2301/00—Metallic composition of the powder or its coating
- B22F2301/15—Nickel or cobalt
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
Definitions
- the invention relates to a composition of a NiCoCrAlY based alloy especially used for gas turbines, a powder, a coating and a component.
- This invention is to solve the problem by using recent research results and upgraded thermodynamic modelling to design an optimized and innovative NiCoCrAlX alloy coatings applied by means of thermal spraying in air, vacuum, or protected atmosphere, physical deposition, and plating on Ni or Co based superalloys.
- X is a combination of minor elements such as Y, Ru, Ir, Si, Hf, Ta and etc. instead of Yttrium (Y) in the current NiCoCrAlY coatings. It means that we will introduce other minor elements to replace part of Yttrium (Y) functions in order to keep Yttrium (Y) content low.
- NiCoCrAlX coatings are fabricated using Ruthenium (Ru) and Iridium (Ir) and reduces diffusion rate of Aluminum (Al) and forms diffusion barrier to minimize the interdiffusion between NiCoCrAlX coating and substrates. Ru addition increases mechanical durability of the coatings. Moreover, another approach in designing and manufacturing the innovative NiCoCrAlX coatings is reduce S content to ⁇ 10ppm to further increase coating lifetime.
- the coating thickness should be in the range of 30-800 ⁇ m depending on type of applications and application methods.
- the new NiCoCrAlX coating is Ni-based and possesses the preferred following composition (in wt%):
- a powder with this alloy composition can be mixed with a binder and/or refractory metals or ceramics if used as an abrasive coating.
- a metallic substrate like a nickel or cobalt based superalloy is used on which the inventive coating is applied on.
- the coating is applied especially by the thermal spray and electron beam vapor deposition processes.
- a layer system therefore at least comprises a metallic substrate, especially a Nickel based superalloy and at least a coating with the inventive alloy and optionally a ceramic layer on top the metallic bond and oxidation coating.
- the ceramic layer comprises preferably a Zirconia based composition, partly or fully stabilized.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Metallurgy (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Organic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Inorganic Chemistry (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Ceramic Engineering (AREA)
- Other Surface Treatments For Metallic Materials (AREA)
- Paints Or Removers (AREA)
Abstract
The invention comprisesa Nickel-based alloy,and least comprising (in wt%):25.7 % - 27.3% Cobalt (Co),15.0% - 16.0% Chromium (Cr),12.2% - 13.2% Aluminum (Al),0.3% - 0.5% Yttrium (Y),2.5% - 3.5% Ruthenium (Ru),0.4% - 0.8% Silicon (Si),0.4% - 0.6% Tantalum (Ta),0.4% - 0.6% Molybdenum (Mo).
Description
- The invention relates to a composition of a NiCoCrAlY based alloy especially used for gas turbines, a powder, a coating and a component.
- When further increasing engine efficiency, output power, availability, and reliability in the current gas turbine development, it is often limited by temperature capacity and lifetime of protective coatings for protection against hot corrosion and oxidation and bonding thermal barrier coating TBC on the hot turbine components. The used coatings were all developed more than 10 years ago and can not fulfil demands of further turbine development. In the MCrAlY coatings available today, one relies on Yttrium (Y) incorporation very much to have pegging and scavenge effects to increase oxidation and corrosion resistances of the coatings. However, it has recently been reported that Yttria inclusions in the protective aluminum oxide scale on top of MCrAlY provide fast oxygen diffusion routes, and therefore, accelerate oxidation of the coating (Nijdam TJ, Sloof WG. Acta Materialia 2007;55:5980).
High content of Sulfur > 10ppm existed in the current MCrAlY shortens coating lifetime (Smialek JL, Jayne DT, Schaeffer JC, Murphy WH. Thin Solid Films 1994;253:285; and Smialek JL. Metallurgical Transactions A, Physical Metallurgy and Materials Science 1991;22A:739). In addition, the increase in oxidation and corrosion lifetime of the MCrAlY coatings is often achieved in expense of their mechanical durability. The development of advanced turbines with flexible operations demands coatings withstanding operations with both higher temperature and longer time exposure and higher mechanical loadings. - This problem has not been solved yet.
- It is therefore aim of the invention to overcome the problems mentioned above.
- The problem is solved by an alloy of claim 1, by a powder of claim 2, a coating by claim 3 and a layer system according to claim 4.
- Further advantages of the invention are listed in the dependent claims which can be combined arbitrarily with each other to yield further advantages.
- This invention is to solve the problem by using recent research results and upgraded thermodynamic modelling to design an optimized and innovative NiCoCrAlX alloy coatings applied by means of thermal spraying in air, vacuum, or protected atmosphere, physical deposition, and plating on Ni or Co based superalloys.
X is a combination of minor elements such as Y, Ru, Ir, Si, Hf, Ta and etc. instead of Yttrium (Y) in the current NiCoCrAlY coatings. It means that we will introduce other minor elements to replace part of Yttrium (Y) functions in order to keep Yttrium (Y) content low. Introduction of Ruthenium (Ru) and Iridium (Ir) reduces diffusion rate of Aluminum (Al) and forms diffusion barrier to minimize the interdiffusion between NiCoCrAlX coating and substrates. Ru addition increases mechanical durability of the coatings.
Moreover, another approach in designing and manufacturing the innovative NiCoCrAlX coatings is reduce S content to ≤10ppm to further increase coating lifetime. The coating thickness should be in the range of 30-800 µm depending on type of applications and application methods. - The new NiCoCrAlX coating is Ni-based and possesses the preferred following composition (in wt%):
- Ni balanced,
- 25.7 % - 27.3% Cobalt (Co),
- 15.0% - 16.0% Chromium (Cr),
- 12.2% - 13.2% Aluminum (Al),
- 0.3% - 0.5% Yttrium (Y),
- 2.5% - 3.5% Ruthenium (Ru),
- and
- optionally
- 0.4% - 0.8% Silicon (Si),
- 0.4% - 0.6% Tantalum (Ta),
- 0.4% - 0.6% Molybdenum (Mo).
- This invention results in NiCoCrAlYRu, NiCoCrAlYRuSi, NiCoCrAlYRuTa, NiCoCrAlYRuMo, NiCoCrAlYRuSiTa, NiCoCrAlYRuSiMo, NiCoCrAlYRuTaMo, NiCoCrAlRuMoSiTa coatings with a higher temperature capacity, longer life, and larger mechanical durability than the NiCoCrAlY coatings available today.
- A powder with this alloy composition can be mixed with a binder and/or refractory metals or ceramics if used as an abrasive coating.
- For turbine application especially a metallic substrate like a nickel or cobalt based superalloy is used on which the inventive coating is applied on.
- The coating is applied especially by the thermal spray and electron beam vapor deposition processes.
- Even SLM, SLS or any AM technique is possible to apply coatings or to produce components of this alloy or used as repair material.
- A layer system therefore at least comprises
a metallic substrate,
especially a Nickel based superalloy and
at least a coating with the inventive alloy and optionally a ceramic layer on top the metallic bond and oxidation coating. - The ceramic layer comprises preferably a Zirconia based composition, partly or fully stabilized.
Claims (5)
- Nickel-based alloy,
and least comprising (in wt%),
especially consisting of:Cobalt (Co) 25.7% - 27.3%especially 26.5%Chromium (Cr) 15.0% - 16.0%especially 15.5%Aluminum (Al) 12.2% - 13.2%especially 12.7%Yttrium (Y) 0.3% - 0.5%especially 0.4%Ruthenium (Ru) 2.5% - 3.5%especially 3.0%optionallyMolybdenum (Mo) 0.4% - 0.6%especially 0.5%Silicon (Si) 0.4% - 0.8%especially 0.6%Tantalum (Ta) 0.4% - 0.6%especially 0.5%,optionally Sulfur (S) ≤ 10ppm. - Alloy
comprising NiCoCrAlYRu, NiCoCrAlYRuSi, NiCoCrAlYRuMo, NiCoCrAlYRuTa, NiCoCrAlYRuSiTa, NiCoCrAlYRuSiMo, NiCoCrAlYRuTaMo or NiCoCrAlYRuSiTaMo. - Powder,
comprising,
especially consisting of,
an alloy according to claim 1 or 2,
optionally comprising a binder and/or ceramic particles. - Coating,
having a composition of an alloy according to claim 1, 2 or
produced with powder of claim 3,
especially having a thickness in the range of 30µm to 800µm. - Component,
comprising
a metallic substrate,
especially Nickel-based or Cobalt-based superalloy,
a metallic coating with a composition according to claim 1, 2
or
a coating according to claim 4,
and optionally
a ceramic coating above the substrate and the metallic coating.
Priority Applications (5)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| EP20201694.5A EP3985137A1 (en) | 2020-10-14 | 2020-10-14 | Nicocraly-alloy, a powder, a coating and a component |
| EP21786784.5A EP4196620A1 (en) | 2020-10-14 | 2021-09-24 | Nicocraly-alloy, a powder, a coating and a component |
| PCT/EP2021/076386 WO2022078733A1 (en) | 2020-10-14 | 2021-09-24 | Nicocraly-alloy, a powder, a coating and a component |
| CN202180069346.5A CN116324035A (en) | 2020-10-14 | 2021-09-24 | NiCoCrAlY alloys, powders, coatings and components |
| US18/029,907 US20230366066A1 (en) | 2020-10-14 | 2021-09-24 | NiCoCrAlY- ALLOY, A POWDER, A COATING AND A COMPONENT |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| EP20201694.5A EP3985137A1 (en) | 2020-10-14 | 2020-10-14 | Nicocraly-alloy, a powder, a coating and a component |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| EP3985137A1 true EP3985137A1 (en) | 2022-04-20 |
Family
ID=72885364
Family Applications (2)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| EP20201694.5A Withdrawn EP3985137A1 (en) | 2020-10-14 | 2020-10-14 | Nicocraly-alloy, a powder, a coating and a component |
| EP21786784.5A Pending EP4196620A1 (en) | 2020-10-14 | 2021-09-24 | Nicocraly-alloy, a powder, a coating and a component |
Family Applications After (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| EP21786784.5A Pending EP4196620A1 (en) | 2020-10-14 | 2021-09-24 | Nicocraly-alloy, a powder, a coating and a component |
Country Status (4)
| Country | Link |
|---|---|
| US (1) | US20230366066A1 (en) |
| EP (2) | EP3985137A1 (en) |
| CN (1) | CN116324035A (en) |
| WO (1) | WO2022078733A1 (en) |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2000075398A1 (en) * | 1999-06-02 | 2000-12-14 | Abb Research Ltd. | Coating composition for high temperature protection |
| EP2256221A1 (en) * | 2008-03-28 | 2010-12-01 | Mitsubishi Heavy Industries, Ltd. | Alloy material having high-temperature corrosion resistance, heat-shielding coating material, turbine member, and gas turbine |
| EP2423439A2 (en) * | 2010-08-26 | 2012-02-29 | Honeywell International, Inc. | Methods for the formation of MCrA1Y coatings on gas turbine engine components |
| WO2013056935A1 (en) * | 2011-10-20 | 2013-04-25 | Siemens Aktiengesellschaft | Coating, coating layer system, coated superalloy component |
Family Cites Families (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US9138963B2 (en) * | 2009-12-14 | 2015-09-22 | United Technologies Corporation | Low sulfur nickel base substrate alloy and overlay coating system |
| CN104757863B (en) * | 2015-03-17 | 2016-08-17 | 浙江三禾厨具有限公司 | Plasma non-stick pan and manufacture method thereof |
-
2020
- 2020-10-14 EP EP20201694.5A patent/EP3985137A1/en not_active Withdrawn
-
2021
- 2021-09-24 CN CN202180069346.5A patent/CN116324035A/en active Pending
- 2021-09-24 US US18/029,907 patent/US20230366066A1/en not_active Abandoned
- 2021-09-24 WO PCT/EP2021/076386 patent/WO2022078733A1/en not_active Ceased
- 2021-09-24 EP EP21786784.5A patent/EP4196620A1/en active Pending
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2000075398A1 (en) * | 1999-06-02 | 2000-12-14 | Abb Research Ltd. | Coating composition for high temperature protection |
| EP2256221A1 (en) * | 2008-03-28 | 2010-12-01 | Mitsubishi Heavy Industries, Ltd. | Alloy material having high-temperature corrosion resistance, heat-shielding coating material, turbine member, and gas turbine |
| EP2423439A2 (en) * | 2010-08-26 | 2012-02-29 | Honeywell International, Inc. | Methods for the formation of MCrA1Y coatings on gas turbine engine components |
| WO2013056935A1 (en) * | 2011-10-20 | 2013-04-25 | Siemens Aktiengesellschaft | Coating, coating layer system, coated superalloy component |
Non-Patent Citations (3)
| Title |
|---|
| NIJDAM TJSLOOF WG., ACTA MATERIALIA, vol. 55, 2007, pages 5980 |
| SMIALEK JL.: "Metallurgical Transactions A", PHYSICAL METALLURGY AND MATERIALS SCIENCE, vol. 22A, 1991, pages 739 |
| SMIALEK JLJAYNE DTSCHAEFFER JCMURPHY WH., THIN SOLID FILMS, vol. 253, 1994, pages 285 |
Also Published As
| Publication number | Publication date |
|---|---|
| WO2022078733A1 (en) | 2022-04-21 |
| EP4196620A1 (en) | 2023-06-21 |
| CN116324035A (en) | 2023-06-23 |
| US20230366066A1 (en) | 2023-11-16 |
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