US20190218668A1 - NiCoCrAlY-ALLOY, POWDER AND LAYER SYSTEM - Google Patents

NiCoCrAlY-ALLOY, POWDER AND LAYER SYSTEM Download PDF

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Publication number
US20190218668A1
US20190218668A1 US16/328,907 US201716328907A US2019218668A1 US 20190218668 A1 US20190218668 A1 US 20190218668A1 US 201716328907 A US201716328907 A US 201716328907A US 2019218668 A1 US2019218668 A1 US 2019218668A1
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Prior art keywords
layer
alloy
bond coat
metallic
powder
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Abandoned
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US16/328,907
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Werner Stamm
Arturo Flores Renteria
Britta Stöhr
Winnie Tan
Apurv Jain
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Siemens AG
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Siemens AG
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Assigned to SIEMENS ENERGY, INC. reassignment SIEMENS ENERGY, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: TAN, WINNIE
Assigned to SIEMENS AKTIENGESELLSCHAFT reassignment SIEMENS AKTIENGESELLSCHAFT ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: Flores Renteria, Arturo, STÖHR, BRITTA, STAMM, WERNER, JAIN, Apurv
Assigned to SIEMENS AKTIENGESELLSCHAFT reassignment SIEMENS AKTIENGESELLSCHAFT ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SIEMENS ENERGY, INC.
Publication of US20190218668A1 publication Critical patent/US20190218668A1/en
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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
    • C23C28/32—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
    • 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%
    • 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
    • C22C19/058—Alloys based on nickel or cobalt based on nickel with chromium without Mo and W
    • 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

Definitions

  • the following relates to a NiCoCrAly-Alloy, a powder and a layer system using this alloy.
  • top layer is made of the usual metallic coating material while the bottom layer is made of a newly developed coating material which is richer in nickel (Ni) and has a reduced amount of cobalt (Co) as cobalt (Co) encourages the formation of spinels by destabilizing gamma prime state.
  • a new developed first layer NiCoCrAlY alloy coating comprises a gamma and gamma prime system whereas the gamma prime state has lower than 25 at % (Al, Ta) but a very high gamma/gamma prime transition temperature.
  • Titanium (Ti) will be caught because the free energy of formation of Ni 3 Ti is more negative than that of Ni 3 Al and it will be formed. Hence the titanium (Ti) cannot diffuse to the upper bond coat layer to form spinets.
  • composition of the alloy or the new first layer coating comprises or consists or consists essentially of (in wt %):
  • One inventive step is the addition of another metallic layer in the bond coat leading to a bi-layer bond coat system.
  • Embodiments of the invention are expected to result in increased efficiency of the turbine because the blades will be able to withstand higher temperatures with a lesser probability of coating failure by Titanium (Ti).
  • the FIGURE shows a layer system 1 .
  • the layer system 1 comprises at least a substrate 4 , at least one metallic bond coat 7 ′, 7 ′′ and an outer most ceramic layer 10 .
  • the metallic substrate 4 is a nickel or a cobalt based super alloy which is used for turbine components, especially turbine blades, very especially for gas turbines.
  • a metallic bond coat 7 ′ is present, which acts as an oxidation and corrosion resistance for the metallic substrate and the bond coat for the used outer most ceramic layer 10 .
  • This metallic bond coat 7 ′ is a NiCoCrAlY-alloy and could be also be a single layer made of the inventive alloy.
  • NiCoCrAlY layer 7 ′, 7 ′′ there is a two layered metallic NiCoCrAlY layer 7 ′, 7 ′′ with the underlying metallic layer 7 ′ according to the inventive alloy and on top a further but different NiCoCrAlY-alloy 7 ′′.
  • TGO thermal crown oxide layer
  • the ceramic layer 10 can be a zirconia-based layer as a single layer or as a double layer with an underlying partially stabilized zirconia and outer most fully stabilized zirconia layer or an outermost DVC layer or a two layered ceramic system with a pyrochlore layer as an outer most ceramic layer.

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

Abstract

A metallic bond coat Ni16+/−1% Co15+/−1% Cr 8+/−0.5% Al2+/−0.2% Ta0.5+/−0.1% Y: Sicoat 2496 leads to a fusion barrier of titanium into the metallic bond coat so that a substrate is not depleted by titanium.

Description

    CROSS-REFERENCE TO RELATED APPLICATIONS
  • This application claims priority to PCT Application No. PCT/EP2017/070536, having a filing date of Aug. 14, 2017, which is based on Indian Application No. 201611031021, having a filing date of Sep. 12, 2016, the entire contents both of which are hereby incorporated by reference.
    • FIELD OF TECHNOLOGY
  • The following relates to a NiCoCrAly-Alloy, a powder and a layer system using this alloy.
    • BACKGROUND
  • Due to the high temperatures involved in the operation of modern gas turbines the titanium (Ti) from Ni— or Co-base material diffuses to a bond coat of NiCoCrAlY and forms spinels. These spinels subsequently lead to reduced creep resistance of the bond coat, thereby increasing the chances of failure.
  • In case of the older machines the operating temperatures were not so high and the problem of failure of the coating due to titanium spinels was not so prevalent. But with the relatively newer machines, in the pursuit of achieving higher efficiency the operating temperatures are increasing and this problem could become more prevalent.
    • SUMMARY
  • Instead of using a single bond coat layer, it is proposed to use a bi-layered bond coat system where the top layer is made of the usual metallic coating material while the bottom layer is made of a newly developed coating material which is richer in nickel (Ni) and has a reduced amount of cobalt (Co) as cobalt (Co) encourages the formation of spinels by destabilizing gamma prime state.
  • A new developed first layer NiCoCrAlY alloy coating comprises a gamma and gamma prime system whereas the gamma prime state has lower than 25 at % (Al, Ta) but a very high gamma/gamma prime transition temperature.
  • Titanium (Ti) will be caught because the free energy of formation of Ni3Ti is more negative than that of Ni3Al and it will be formed. Hence the titanium (Ti) cannot diffuse to the upper bond coat layer to form spinets.
  • The composition of the alloy or the new first layer coating comprises or consists or consists essentially of (in wt %):
    • 16.0%+/−10% Co 15.0%+/−10% Cr 8.0%+/−10% Al 2.0%+/−10% Ta 0.5%+/−10% Y
  • base Nickel (Ni).
    +/−10% has to be read as relative, e.g. 2%+/−10% means 1.8%-2.2%.
  • One inventive step is the addition of another metallic layer in the bond coat leading to a bi-layer bond coat system. Embodiments of the invention are expected to result in increased efficiency of the turbine because the blades will be able to withstand higher temperatures with a lesser probability of coating failure by Titanium (Ti).
    • BRIEF DESCRIPTION
  • The FIGURE shows a layer system 1.
    •  DETAILED DESCRIPTION
  • The layer system 1 comprises at least a substrate 4, at least one metallic bond coat 7′, 7″ and an outer most ceramic layer 10.
  • The metallic substrate 4 is a nickel or a cobalt based super alloy which is used for turbine components, especially turbine blades, very especially for gas turbines.
  • Direct on this metallic substrate 4 a metallic bond coat 7′ is present, which acts as an oxidation and corrosion resistance for the metallic substrate and the bond coat for the used outer most ceramic layer 10.
  • This metallic bond coat 7′ is a NiCoCrAlY-alloy and could be also be a single layer made of the inventive alloy.
  • In a further embodiment of the invention there is a two layered metallic NiCoCrAlY layer 7′, 7″ with the underlying metallic layer 7′ according to the inventive alloy and on top a further but different NiCoCrAlY-alloy 7″.
  • For the top layer 7″ other coatings like (in wt %):
    • Ni-(24-26)Co-(11-14)Cr-(10-12)Al-(0.1-0.5)Y, Ni-(24-26)Co-(23-25)Cr-(10-11)Al-(0.2-0.4)Y, Ni-(24-26)Co-(14-17)Cr-(10-11)Al-(0.2-0.4)Y, Ni-(24-26)Co-(14-17)Cr-(10-11)Al-(0.4-0.8)-(0.3-0.7)Ta, Ni-(24-26)Co-(16-18)Cr-(10-11)Al-(1.0-2.0)Re-(0.1-0.5)Y,
  • Co-(29-31)Ni-(27-29)Cr-(7-8)Al-(0.5-0.7)Y(0.3-0.7)Si, are used.
  • Not shown but during coating with a ceramic layer or at least during operation a thermal crown oxide layer (TGO) is grown on top of the outermost metallic bond coat 7′ or 7″, which is responsible for oxidation resistance.
  • The ceramic layer 10 can be a zirconia-based layer as a single layer or as a double layer with an underlying partially stabilized zirconia and outer most fully stabilized zirconia layer or an outermost DVC layer or a two layered ceramic system with a pyrochlore layer as an outer most ceramic layer.
  • Although the invention has been illustrated and described in greater detail with reference to the preferred exemplary embodiment, the invention is not limited to the examples disclosed, and further variations can be inferred by a person skilled in the art, without departing from the scope of protection of the invention.
  • For the sake of clarity, it is to be understood that the use of “a” or “an” throughout this application does not exclude a plurality, and “comprising” does not exclude other steps or elements.

Claims (8)

1. An alloy, at least comprising (in wt %):
Cobalt (Co) 16.0%+/−10%,
Chromium (Cr) 15.0%+/−10%,
Aluminum (Al) 8.0%+/−10%,
Tantalum (Ta) 2.0%+/−10%,
Yttrium (Y) 0.5%+/−10%; and
base nickel (Ni).
2. A powder comprising the alloy according to claim 1.
3. A layer system according to claim 2 comprising:
a metallic substrate, including a nickel- or a cobalt-based super alloy, at least one metallic layer made of the alloy or produced by using the powder and an outer most ceramic layer.
4. A ceramic layer system according to claim 3, wherein the ceramic layer is a two layered system, which comprises:
a partially stabilized zirconia layer and an outer most fully stabilized zirconia layer, or zirconia based ceramic layer with an outer most pyrochlore layer.
5. The layer system according to claim 3, wherein the metallic bond coat is a two layered metallic bond coat with an underlying metallic bond coat and an outer metallic bond coat, which especially selected from the compositions (in wt %):
Ni-(24-26)Co-(11-14)Cr-(10-12)Al-(0.1-0.5)Y,
Ni-(24-26)Co-(23-25)Cr-(10-11)Al-(0.2-0.4)Y,
Ni-(24-26)Co-(14-17)Cr-(10-11)Al-(0.2-0.4)Y,
Ni-(24-26)Co-(14-17)Cr-(10-11)Al-(0.4-0.8)-(0.3-0.7)Ta,
Ni-(24-26)Co-(16-18)Cr-(10-11)Al-(1.0-2.0)Re-(0.1-0.5), and
Co-(29-31)Ni-(27-29)Cr-(7-8)Al-(0.5-0.7)Y(0.3-0.7)Si.
6. The layer system according to claim 3, wherein only a single ceramic layer is present, said ceramic layer is made of zirconia.
7. An alloy, consisting of (in wt %):
Cobalt (Co) 16.0%+/−10%,
Chromium (Cr) 15.0%+/−10%,
Aluminum (Al) 8.0%+/−10%,
Tantalum (Ta) 2.0%+/−10%,
Yttrium (Y) 0.5%+/−10%, and
base nickel (Ni).
8. A powder consisting of the alloy according to claim 1.
US16/328,907 2016-09-12 2017-08-14 NiCoCrAlY-ALLOY, POWDER AND LAYER SYSTEM Abandoned US20190218668A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
IN201611031021 2016-09-12
IN201611031021 2016-09-12
PCT/EP2017/070536 WO2018046239A1 (en) 2016-09-12 2017-08-14 Nicocraly-alloy, powder and layer system

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EP (1) EP3485053A1 (en)
KR (1) KR20190052053A (en)
CN (1) CN109844149A (en)
WO (1) WO2018046239A1 (en)

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Publication number Priority date Publication date Assignee Title
CN111893363B (en) * 2020-07-31 2021-11-19 西安交通大学 NiCoCr-based medium-entropy alloy with excellent strength and plasticity matching and preparation method thereof

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20090011260A1 (en) * 2005-11-08 2009-01-08 Man Turbo Ag Heat-Insulating Protective Layer for a Component Located Within the Hot Gas Zone of a Gas Turbine
US20100297409A1 (en) * 2007-05-07 2010-11-25 Siemens Aktiengesellschaft Ceramic powder, ceramic layer and layer system with pyrochlore phase and oxides
US20130136648A1 (en) * 2010-03-23 2013-05-30 Anand A. Kulkarni Metallic bondcoat or alloy with a high gamma/gamma' transition temperature and a component
US20140342186A1 (en) * 2011-09-12 2014-11-20 Siemens Aktiengesellschaft Layer system with double mcralx metallic layer
EP2845924A1 (en) * 2013-09-10 2015-03-11 Siemens Aktiengesellschaft Porous ceramic coating system

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CA950710A (en) * 1971-05-17 1974-07-09 International Nickel Company Of Canada Dispersion-strengthened superalloys
US5171380A (en) * 1987-07-31 1992-12-15 General Electric Company Method of forming fatigue crack resistant Rene' 95 type nickel base superalloys and product formed
EP1380672A1 (en) * 2002-07-09 2004-01-14 Siemens Aktiengesellschaft Highly oxidation resistant component
US20090162692A1 (en) * 2007-12-24 2009-06-25 Bangalore Aswatha Nagaraj Coated Superalloy Articles
JP2009242836A (en) * 2008-03-28 2009-10-22 Mitsubishi Heavy Ind Ltd Alloy material having high temperature corrosion-resistance, heat-shielding coating material, turbine member and gas turbine
EP2392684A1 (en) * 2010-06-02 2011-12-07 Siemens Aktiengesellschaft Alloy, protective layer and component
US20120128525A1 (en) * 2010-11-24 2012-05-24 Kulkarni Anand A Metallic Bondcoat or Alloy with a High y/y' Transition Temperature and a Component
EP2584068A1 (en) * 2011-10-20 2013-04-24 Siemens Aktiengesellschaft Coating, coating layer system, coated superalloy component
CN105951030B (en) * 2016-04-28 2018-12-21 中国农业机械化科学研究院 Single crystal alloy surface double-layer structure adhesive layer and preparation method thereof

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20090011260A1 (en) * 2005-11-08 2009-01-08 Man Turbo Ag Heat-Insulating Protective Layer for a Component Located Within the Hot Gas Zone of a Gas Turbine
US20100297409A1 (en) * 2007-05-07 2010-11-25 Siemens Aktiengesellschaft Ceramic powder, ceramic layer and layer system with pyrochlore phase and oxides
US20130136648A1 (en) * 2010-03-23 2013-05-30 Anand A. Kulkarni Metallic bondcoat or alloy with a high gamma/gamma' transition temperature and a component
US20140342186A1 (en) * 2011-09-12 2014-11-20 Siemens Aktiengesellschaft Layer system with double mcralx metallic layer
EP2845924A1 (en) * 2013-09-10 2015-03-11 Siemens Aktiengesellschaft Porous ceramic coating system

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EP3485053A1 (en) 2019-05-22
WO2018046239A1 (en) 2018-03-15
KR20190052053A (en) 2019-05-15
CN109844149A (en) 2019-06-04

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