WO2014133538A1 - High temperature bond coating with increased oxidation resistance - Google Patents

High temperature bond coating with increased oxidation resistance Download PDF

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Publication number
WO2014133538A1
WO2014133538A1 PCT/US2013/028559 US2013028559W WO2014133538A1 WO 2014133538 A1 WO2014133538 A1 WO 2014133538A1 US 2013028559 W US2013028559 W US 2013028559W WO 2014133538 A1 WO2014133538 A1 WO 2014133538A1
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WO
WIPO (PCT)
Prior art keywords
weight percent
bond coating
bond
coating
gamma
Prior art date
Application number
PCT/US2013/028559
Other languages
French (fr)
Inventor
Anand A. Kulkarni
Jonathan E. Shipper
Werner Stamm
Original Assignee
Siemens Aktiengesellschaft
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Siemens Aktiengesellschaft filed Critical Siemens Aktiengesellschaft
Priority to CN201380074167.6A priority Critical patent/CN105209662B/en
Priority to EP13762607.3A priority patent/EP2961860A1/en
Priority to PCT/US2013/028559 priority patent/WO2014133538A1/en
Publication of WO2014133538A1 publication Critical patent/WO2014133538A1/en

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Classifications

    • 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
    • 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
    • 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
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
    • C23C14/14—Metallic material, boron or silicon
    • C23C14/16—Metallic material, boron or silicon on metallic substrates or on substrates of boron or silicon
    • 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
    • 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
    • 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
    • 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

Definitions

  • the invention relates to a bond coating and more particularly, to a bond coating configured to protect nickel-based or cobalt-based materials forming components suited for use in gas turbine engines.
  • components residing therein are typically formed from nickel-based or cobalt-based materials. These materials are optimized for strength and are typically not able to withstand oxidation and corrosion at higher temperatures. Thus, these materials must be protected from oxidation via coatings, which are typically formed from MCrAIY and other aluminum rich coatings. Such coatings can be used for oxidation and corrosion protection and as bond coatings for thermal barrier coating (TBC) systems as well.
  • TBC thermal barrier coating
  • the MCrAIY coating protects the underlying material from hot gas exposure and provides a mechanism for adherence of the TBC systems to the component.
  • Turbine engines that are often being operated at ever increasing internal hot gas path temperatures are exposed to a heightened propensity of failure of the coating which leads to spallation of the thermal barrier coating.
  • a need for improved coatings capable of withstanding a higher temperature environment with a lower propensity of bond coating degradation and provides for an enhanced resistance of the TBC to spallation.
  • the bond coating may be an optimized NiCrAIY material with additional materials that eliminate the presence of beta phase for oxidation by replacing the beta phase with a gamma/gamma prime system.
  • the bond coating may also decrease the presence of phases that are detrimental to the mechanical and oxidation properties of the system like the sigma and BCC chromium phases.
  • the bond coating may also have a gamma/gamma prime transition temperature that is about 400 degrees Celsius higher than conventional bond coatings, which enables local stresses to be reduced.
  • the bond coating for gas turbine engines may be formed from materials including, but not limited to aluminum, chromium, tantalum, iron, yttrium and neodymium.
  • the bond coating may be formed from 7.75 weight percent aluminum, 0 weight percent cobalt, 14.4 weight percent chromium, 6 weight percent tantalum, 2.7 weight percent iron, 0.3 weight percent yttrium, and 0.03 weight percent neodymium.
  • a method of protecting a gas turbine engine component from high temperatures present in a hot gas path of the gas turbine engine may include applying the bond coating to a component.
  • the bond coating may be positioned between the component and one or more thermal barrier coating (TBC) layers.
  • TBC thermal barrier coating
  • the method may include presenting a bond coating material formed from materials including, but not limited to aluminum, chromium, tantalum, iron, yttrium and neodymium.
  • the bond coating may be formed from 7.75 weight percent aluminum, 0 weight percent cobalt, 14.4 weight percent chromium, 6 weight percent tantalum, 2.7 weight percent iron, 0.3 weight percent yttrium, and 0.03 weight percent neodymium.
  • the method may also include applying the bond coating to the gas turbine component.
  • Application of the bond coating may be via a high velocity oxy-fuel process, via an air plasma spraying process, via a low pressure plasma spray process, via an electron beam vapor deposition process, via a cold spray process or
  • An advantage of the bond coating is that the bond coating has improved adhesion of the thermally grown oxide layer and has enhanced TBC spallation resistance. Another advantage of the bond coating is that the elimination of the presence of the deleterious sigma phase results in improved mechanical properties over conventional high aluminum coatings.
  • Figure 1 is a phase diagram of a prior art high oxidation resistance bond coating.
  • Figure 2 is a phase diagram of a bond coating of this invention.
  • Figure 3 is a partial cross-sectional view of a turbine component with the bond coating and a thermal barrier coating.
  • this invention is directed to a bond coating 10 having high corrosion and oxidation resistance and good compatibility with a thermal barrier coating 12.
  • the bond coating 10 may be an optimized NiCrAIY material with additional materials that eliminates the presence of beta phase for oxidation by replacing the beta phase with a gamma/gamma prime system.
  • the bond coating 10 may also decrease the presence of phases that are detrimental to the mechanical and oxidation properties of the system, such as the sigma and BCC chromium phases. These phases are topographically close-packed (TCP) structures that reduce a system's ductility and thermo-mechanical performance.
  • TCP topographically close-packed
  • the bond coating 10 has a gamma/gamma prime transition temperature that is about 400 degrees Celsius higher than conventional bond coatings, which enables local stresses to be reduced.
  • the bond coating 10 may have a good, long life, with acceptable mechanical properties and an improved oxidation resistance.
  • the bond coating 10 for gas turbine engines may be formed from materials including, but not limited to aluminum, chromium, tantalum, iron, yttrium and neodymium.
  • the bond coating 10 may be formed from at least one weight percent aluminum, 0 weight percent cobalt, at least one weight percent chromium, between four and eight weight percent tantalum, between 0.5 and five weight percent iron, between 0.1 and 0.7 weight percent yttrium, and between 0 and 1.5 weight percent neodymium.
  • the bond coating 10 may be formed from at least one weight percent aluminum, 0 weight percent cobalt, at least one weight percent chromium, between five and seven weight percent tantalum, between one and four weight percent iron, between 0.1 and 0.7 weight percent yttrium, and between 0 and 1.5 weight percent neodymium. In yet another embodiment, the bond coating 10 may be formed from 7.75 weight percent aluminum, 0 weight percent cobalt, 14.4 weight percent chromium, 6 weight percent tantalum, 2.7 weight percent iron, 0.3 weight percent yttrium, and 0.03 weight percent neodymium. The bond coating 10 has been optimized such that the sigma and BCC chromium phases that decrease thermo-mechanical properties have been reduced to accommodate aluminum.
  • Neodymium has been included in an amount that improves the adhesion of the thermally grown oxide layer and promotes enhanced TBC spallation resistance. In addition, neodymium has been added in an amount that provides these benefits without detrimentally affecting the mechanical properties of the bond coating 10.
  • the bond coating 10 may include tantalum and iron which results in a coating with a high gamma to gamma prime transition temperature that replaces the beta phase resulting in a greater oxidation resistance at higher temperature than conventional coatings.
  • the elimination of the beta phase if accomplished in conjunction with complete elimination of the presence of the deleterious sigma phase, results in improved mechanical properties over conventional high aluminum coatings.
  • the bond coating 10 may have an improved gamma/gamma prime transition temperature that is about 400 degrees Celsius higher than conventional coatings, as depicted in Figure 1. As such, local stresses in the service temperature area are reduced.
  • the bond coating 10 may have similar Al-rich beta content that along with the high gamma prime and low gamma concentrations contribute to excellent oxidation resistance.
  • the bond coating 10 may also have a lower concentration of detrimental sigma and BCC phases 12, which show the superior thermo-mechanical properties of the bond coating 10 at low temperature.
  • a method of protecting a gas turbine engine component from high temperatures present in a hot gas path of the gas turbine engine may include applying the bond coating 10 to a component 14, as shown in Figure 3.
  • the bond coating 10 may be positioned between the component and one or more thermal barrier coating (TBC) layers 12.
  • TBC thermal barrier coating
  • the method may include presenting a bond coating material formed from materials including, but not limited to aluminum, chromium, tantalum, iron, yttrium and neodymium.
  • the bond coating 10 may be formed from 7.75 weight percent aluminum, 0 weight percent cobalt, 14.4 weight percent chromium, 6 weight percent tantalum, 2.7 weight percent iron, 0.3 weight percent yttrium, and 0.03 weight percent neodymium.
  • the method may also include applying the bond coating 10 to the gas turbine component.
  • Application of the bond coating 10 may be via a high velocity oxy-fuel process, via an air plasma spraying process, via a low pressure plasma spray process, via an electron beam vapor deposition process, via a cold spray process or other appropriate method.

Abstract

A bond coating having high corrosion and oxidation resistance and good compatibility with a thermal barrier coating is disclosed. The bond coating may be an optimized NiCrAlY material with additional materials that eliminates the presence of beta phase for oxidation by replacing the beta phase with a gamma/gamma prime system. The bond coating may also decrease the presence of phases that are detrimental to the mechanical and oxidation properties of the system, such as the sigma and BCC chromium phases. The bond coating may also have a gamma/gamma prime transition temperature that is about 400 degrees Celsius higher than conventional bond coatings, which enables local stresses to be reduced.

Description

HIGH TEMPERATURE BOND COATING WITH
INCREASED OXIDATION RESISTANCE
FIELD OF THE INVENTION
The invention relates to a bond coating and more particularly, to a bond coating configured to protect nickel-based or cobalt-based materials forming components suited for use in gas turbine engines.
BACKGROUND OF THE INVENTION
Because of the high temperature environment found within the hot gas path of gas turbine engines, components residing therein are typically formed from nickel-based or cobalt-based materials. These materials are optimized for strength and are typically not able to withstand oxidation and corrosion at higher temperatures. Thus, these materials must be protected from oxidation via coatings, which are typically formed from MCrAIY and other aluminum rich coatings. Such coatings can be used for oxidation and corrosion protection and as bond coatings for thermal barrier coating (TBC) systems as well. In TBC systems, the MCrAIY coating protects the underlying material from hot gas exposure and provides a mechanism for adherence of the TBC systems to the component. Turbine engines that are often being operated at ever increasing internal hot gas path temperatures are exposed to a heightened propensity of failure of the coating which leads to spallation of the thermal barrier coating. Thus, there exists a need for improved coatings capable of withstanding a higher temperature environment with a lower propensity of bond coating degradation and provides for an enhanced resistance of the TBC to spallation.
SUMMARY OF THE INVENTION
This application is directed to a bond coating having high corrosion and oxidation resistance and good compatibility with a thermal barrier coating. The bond coating may be an optimized NiCrAIY material with additional materials that eliminate the presence of beta phase for oxidation by replacing the beta phase with a gamma/gamma prime system. The bond coating may also decrease the presence of phases that are detrimental to the mechanical and oxidation properties of the system like the sigma and BCC chromium phases. The bond coating may also have a gamma/gamma prime transition temperature that is about 400 degrees Celsius higher than conventional bond coatings, which enables local stresses to be reduced.
The bond coating for gas turbine engines may be formed from materials including, but not limited to aluminum, chromium, tantalum, iron, yttrium and neodymium. In at least one embodiment, the bond coating may be formed from 7.75 weight percent aluminum, 0 weight percent cobalt, 14.4 weight percent chromium, 6 weight percent tantalum, 2.7 weight percent iron, 0.3 weight percent yttrium, and 0.03 weight percent neodymium.
A method of protecting a gas turbine engine component from high temperatures present in a hot gas path of the gas turbine engine may include applying the bond coating to a component. The bond coating may be positioned between the component and one or more thermal barrier coating (TBC) layers. The method may include presenting a bond coating material formed from materials including, but not limited to aluminum, chromium, tantalum, iron, yttrium and neodymium. In at least one embodiment, the bond coating may be formed from 7.75 weight percent aluminum, 0 weight percent cobalt, 14.4 weight percent chromium, 6 weight percent tantalum, 2.7 weight percent iron, 0.3 weight percent yttrium, and 0.03 weight percent neodymium. The method may also include applying the bond coating to the gas turbine component. Application of the bond coating may be via a high velocity oxy-fuel process, via an air plasma spraying process, via a low pressure plasma spray process, via an electron beam vapor deposition process, via a cold spray process or other appropriate method.
An advantage of the bond coating is that the bond coating has improved adhesion of the thermally grown oxide layer and has enhanced TBC spallation resistance. Another advantage of the bond coating is that the elimination of the presence of the deleterious sigma phase results in improved mechanical properties over conventional high aluminum coatings.
These and other embodiments are described in more detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and form a part of the specification, illustrate embodiments of the presently disclosed invention and, together with the description, disclose the principles of the invention.
Figure 1 is a phase diagram of a prior art high oxidation resistance bond coating.
Figure 2 is a phase diagram of a bond coating of this invention.
Figure 3 is a partial cross-sectional view of a turbine component with the bond coating and a thermal barrier coating. DETAILED DESCRIPTION OF THE INVENTION
As shown in Figures 2 and 3, this invention is directed to a bond coating 10 having high corrosion and oxidation resistance and good compatibility with a thermal barrier coating 12. The bond coating 10 may be an optimized NiCrAIY material with additional materials that eliminates the presence of beta phase for oxidation by replacing the beta phase with a gamma/gamma prime system. The bond coating 10 may also decrease the presence of phases that are detrimental to the mechanical and oxidation properties of the system, such as the sigma and BCC chromium phases. These phases are topographically close-packed (TCP) structures that reduce a system's ductility and thermo-mechanical performance. The bond coating 10 has a gamma/gamma prime transition temperature that is about 400 degrees Celsius higher than conventional bond coatings, which enables local stresses to be reduced.
The bond coating 10 may have a good, long life, with acceptable mechanical properties and an improved oxidation resistance. The bond coating 10 for gas turbine engines may be formed from materials including, but not limited to aluminum, chromium, tantalum, iron, yttrium and neodymium. In at least one embodiment, the bond coating 10 may be formed from at least one weight percent aluminum, 0 weight percent cobalt, at least one weight percent chromium, between four and eight weight percent tantalum, between 0.5 and five weight percent iron, between 0.1 and 0.7 weight percent yttrium, and between 0 and 1.5 weight percent neodymium. In at least one embodiment, the bond coating 10 may be formed from at least one weight percent aluminum, 0 weight percent cobalt, at least one weight percent chromium, between five and seven weight percent tantalum, between one and four weight percent iron, between 0.1 and 0.7 weight percent yttrium, and between 0 and 1.5 weight percent neodymium. In yet another embodiment, the bond coating 10 may be formed from 7.75 weight percent aluminum, 0 weight percent cobalt, 14.4 weight percent chromium, 6 weight percent tantalum, 2.7 weight percent iron, 0.3 weight percent yttrium, and 0.03 weight percent neodymium. The bond coating 10 has been optimized such that the sigma and BCC chromium phases that decrease thermo-mechanical properties have been reduced to accommodate aluminum. Neodymium has been included in an amount that improves the adhesion of the thermally grown oxide layer and promotes enhanced TBC spallation resistance. In addition, neodymium has been added in an amount that provides these benefits without detrimentally affecting the mechanical properties of the bond coating 10.
The bond coating 10 may include tantalum and iron which results in a coating with a high gamma to gamma prime transition temperature that replaces the beta phase resulting in a greater oxidation resistance at higher temperature than conventional coatings. The elimination of the beta phase, if accomplished in conjunction with complete elimination of the presence of the deleterious sigma phase, results in improved mechanical properties over conventional high aluminum coatings. As shown in Figure 2, the bond coating 10 may have an improved gamma/gamma prime transition temperature that is about 400 degrees Celsius higher than conventional coatings, as depicted in Figure 1. As such, local stresses in the service temperature area are reduced. As shown in Figure 2, the bond coating 10 may have similar Al-rich beta content that along with the high gamma prime and low gamma concentrations contribute to excellent oxidation resistance. The bond coating 10 may also have a lower concentration of detrimental sigma and BCC phases 12, which show the superior thermo-mechanical properties of the bond coating 10 at low temperature.
A method of protecting a gas turbine engine component from high temperatures present in a hot gas path of the gas turbine engine may include applying the bond coating 10 to a component 14, as shown in Figure 3. The bond coating 10 may be positioned between the component and one or more thermal barrier coating (TBC) layers 12. The method may include presenting a bond coating material formed from materials including, but not limited to aluminum, chromium, tantalum, iron, yttrium and neodymium. In at least one embodiment, the bond coating 10 may be formed from 7.75 weight percent aluminum, 0 weight percent cobalt, 14.4 weight percent chromium, 6 weight percent tantalum, 2.7 weight percent iron, 0.3 weight percent yttrium, and 0.03 weight percent neodymium. The method may also include applying the bond coating 10 to the gas turbine component. Application of the bond coating 10 may be via a high velocity oxy-fuel process, via an air plasma spraying process, via a low pressure plasma spray process, via an electron beam vapor deposition process, via a cold spray process or other appropriate method.
The foregoing is provided for purposes of illustrating, explaining, and describing embodiments of this invention. Modifications and adaptations to these embodiments will be apparent to those skilled in the art and may be made without departing from the scope or spirit of this invention.

Claims

CLAIMS We claim:
1. A bond coating for gas turbine engine components, comprising:
at least one weight percent aluminum;
0 weight percent cobalt;
at least one weight percent chromium;
between four and eight weight percent tantalum;
between 0.5 and five weight percent iron;
between 0.1 and 0.7 weight percent yttrium; and
between 0 and 1.5 weight percent neodymium.
2. The bond coating of claim 1 , wherein the bond coating includes 7.75 weight percent aluminum.
3. The bond coating of claim 1 , wherein the bond coating includes 14.4 weight percent chromium.
4. The bond coating of claim 1 , wherein the bond coating includes between five and seven weight percent tantalum.
5. The bond coating of claim 4, wherein the bond coating includes 6 weight percent tantalum.
6. The bond coating of claim 1 , wherein the bond coating includes between one and four weight percent iron.
7. The bond coating of claim 6, wherein the bond coating includes 2.7 weight percent iron.
8. The bond coating of claim 1 , wherein the bond coating includes 0.3 weight percent yttrium.
9. The bond coating of claim 1 , wherein the bond coating includes 0.03 weight percent neodymium.
10. A bond coating for gas turbine engine components, comprising:
at least one weight percent aluminum;
0 weight percent cobalt;
at least one weight percent chromium;
between five and seven weight percent tantalum;
between one and four weight percent iron;
between 0.1 and 0.7 weight percent yttrium; and
between 0 and 1.5 weight percent neodymium.
1 1. The bond coating of claim 10, wherein the bond coating includes 7.75 weight percent aluminum.
12. The bond coating of claim 10, wherein the bond coating includes 14.4 weight percent chromium.
13. The bond coating of claim 10, wherein the bond coating includes 6 weight percent tantalum.
14. The bond coating of claim 10, wherein the bond coating includes 2.7 weight percent iron.
15. The bond coating of claim 10, wherein the bond coating includes 0.3 weight percent yttrium.
16. The bond coating of claim 10, wherein the bond coating includes 0.03 weight percent neodymium.
17. A bond coating for gas turbine engine components, comprising:
7.75 weight percent aluminum;
0 weight percent cobalt;
14.4 weight percent chromium;
6 weight percent tantalum;
2.7 weight percent iron;
0.3 weight percent yttrium; and
0.03 weight percent neodymium.
PCT/US2013/028559 2013-03-01 2013-03-01 High temperature bond coating with increased oxidation resistance WO2014133538A1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
CN201380074167.6A CN105209662B (en) 2013-03-01 2013-03-01 The high temperature bond coating that inoxidizability improves
EP13762607.3A EP2961860A1 (en) 2013-03-01 2013-03-01 High temperature bond coating with increased oxidation resistance
PCT/US2013/028559 WO2014133538A1 (en) 2013-03-01 2013-03-01 High temperature bond coating with increased oxidation resistance

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2013/028559 WO2014133538A1 (en) 2013-03-01 2013-03-01 High temperature bond coating with increased oxidation resistance

Publications (1)

Publication Number Publication Date
WO2014133538A1 true WO2014133538A1 (en) 2014-09-04

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Country Status (3)

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EP (1) EP2961860A1 (en)
CN (1) CN105209662B (en)
WO (1) WO2014133538A1 (en)

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4743514A (en) * 1983-06-29 1988-05-10 Allied-Signal Inc. Oxidation resistant protective coating system for gas turbine components, and process for preparation of coated components
EP0848077A1 (en) * 1996-12-12 1998-06-17 United Technologies Corporation Thermal barrier coating systems and materials
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