US3869779A - Duplex aluminized coatings - Google Patents
Duplex aluminized coatings Download PDFInfo
- Publication number
- US3869779A US3869779A US436315A US43631574A US3869779A US 3869779 A US3869779 A US 3869779A US 436315 A US436315 A US 436315A US 43631574 A US43631574 A US 43631574A US 3869779 A US3869779 A US 3869779A
- Authority
- US
- United States
- Prior art keywords
- manufacture
- article
- cladding
- alloy layer
- aluminum
- Prior art date
- Legal status (The legal status 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 status listed.)
- Expired - Lifetime
Links
- 238000000576 coating method Methods 0.000 title claims abstract description 35
- 230000003647 oxidation Effects 0.000 claims abstract description 29
- 238000007254 oxidation reaction Methods 0.000 claims abstract description 29
- 229910000951 Aluminide Inorganic materials 0.000 claims abstract description 24
- 239000011248 coating agent Substances 0.000 claims abstract description 21
- 229910001092 metal group alloy Inorganic materials 0.000 claims abstract description 16
- 238000005253 cladding Methods 0.000 claims description 43
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 34
- 229910045601 alloy Inorganic materials 0.000 claims description 26
- 239000000956 alloy Substances 0.000 claims description 26
- 229910000601 superalloy Inorganic materials 0.000 claims description 26
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 19
- 229910052782 aluminium Inorganic materials 0.000 claims description 19
- 238000004519 manufacturing process Methods 0.000 claims description 18
- 229910052759 nickel Inorganic materials 0.000 claims description 17
- 239000000758 substrate Substances 0.000 claims description 17
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 16
- 229910052804 chromium Inorganic materials 0.000 claims description 16
- 239000011651 chromium Substances 0.000 claims description 16
- 229910052710 silicon Inorganic materials 0.000 claims description 14
- 239000011888 foil Substances 0.000 claims description 13
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 12
- 229910052727 yttrium Inorganic materials 0.000 claims description 11
- 239000010703 silicon Substances 0.000 claims description 8
- 229910052742 iron Inorganic materials 0.000 claims description 6
- 229910052748 manganese Inorganic materials 0.000 claims description 6
- 239000002131 composite material Substances 0.000 claims description 5
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 claims description 5
- 230000005496 eutectics Effects 0.000 claims description 4
- 229910052715 tantalum Inorganic materials 0.000 claims description 4
- 229910052776 Thorium Inorganic materials 0.000 claims description 3
- 238000012360 testing method Methods 0.000 description 13
- 239000000203 mixture Substances 0.000 description 10
- 229910002543 FeCrAlY Inorganic materials 0.000 description 7
- 230000008859 change Effects 0.000 description 7
- 239000010941 cobalt Substances 0.000 description 7
- 229910017052 cobalt Inorganic materials 0.000 description 7
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 7
- 230000001681 protective effect Effects 0.000 description 6
- 230000007797 corrosion Effects 0.000 description 4
- 238000005260 corrosion Methods 0.000 description 4
- 239000007789 gas Substances 0.000 description 4
- 229910001120 nichrome Inorganic materials 0.000 description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 3
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 3
- 229910052799 carbon Inorganic materials 0.000 description 3
- 238000005336 cracking Methods 0.000 description 3
- 125000004122 cyclic group Chemical group 0.000 description 3
- 230000003628 erosive effect Effects 0.000 description 3
- 238000007733 ion plating Methods 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 229910052750 molybdenum Inorganic materials 0.000 description 3
- 239000011733 molybdenum Substances 0.000 description 3
- 238000004544 sputter deposition Methods 0.000 description 3
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 3
- 229910052721 tungsten Inorganic materials 0.000 description 3
- 239000010937 tungsten Substances 0.000 description 3
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 2
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 238000007739 conversion coating Methods 0.000 description 2
- 238000007598 dipping method Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000004070 electrodeposition Methods 0.000 description 2
- 238000001962 electrophoresis Methods 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 239000010955 niobium Substances 0.000 description 2
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 description 2
- 238000005240 physical vapour deposition Methods 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 239000002002 slurry Substances 0.000 description 2
- 238000004901 spalling Methods 0.000 description 2
- 238000005507 spraying Methods 0.000 description 2
- 230000008646 thermal stress Effects 0.000 description 2
- 239000010936 titanium Substances 0.000 description 2
- 229910052719 titanium Inorganic materials 0.000 description 2
- 229910052726 zirconium Inorganic materials 0.000 description 2
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- 235000008247 Echinochloa frumentacea Nutrition 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- 240000004072 Panicum sumatrense Species 0.000 description 1
- 208000021017 Weight Gain Diseases 0.000 description 1
- 238000005269 aluminizing Methods 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 230000002939 deleterious effect Effects 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 238000010894 electron beam technology Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 239000006023 eutectic alloy Substances 0.000 description 1
- 229910052735 hafnium Inorganic materials 0.000 description 1
- VBJZVLUMGGDVMO-UHFFFAOYSA-N hafnium atom Chemical compound [Hf] VBJZVLUMGGDVMO-UHFFFAOYSA-N 0.000 description 1
- 150000004820 halides Chemical class 0.000 description 1
- 239000001307 helium Substances 0.000 description 1
- 229910052734 helium Inorganic materials 0.000 description 1
- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium atom Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 238000007750 plasma spraying Methods 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000000197 pyrolysis Methods 0.000 description 1
- 238000010791 quenching Methods 0.000 description 1
- 230000000171 quenching effect Effects 0.000 description 1
- 229910052702 rhenium Inorganic materials 0.000 description 1
- WUAPFZMCVAUBPE-UHFFFAOYSA-N rhenium atom Chemical compound [Re] WUAPFZMCVAUBPE-UHFFFAOYSA-N 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 238000005728 strengthening Methods 0.000 description 1
- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum atom Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 description 1
- ZCUFMDLYAMJYST-UHFFFAOYSA-N thorium dioxide Chemical compound O=[Th]=O ZCUFMDLYAMJYST-UHFFFAOYSA-N 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
- 230000004584 weight gain Effects 0.000 description 1
- 235000019786 weight gain Nutrition 0.000 description 1
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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/22—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded
- B23K20/233—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded without ferrous layer
- B23K20/2333—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded without ferrous layer one layer being aluminium, magnesium or beryllium
-
- 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
- C23C10/00—Solid state diffusion of only metal elements or silicon into metallic material surfaces
- C23C10/02—Pretreatment of the material to be coated
-
- 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
- C23C28/02—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 only coatings only including layers of metallic material
- C23C28/023—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 only coatings only including layers of metallic material only coatings of metal elements only
-
- 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
- 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
-
- 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
- C23C28/341—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 carbide 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
- 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
-
- 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
-
- C—CHEMISTRY; METALLURGY
- C30—CRYSTAL GROWTH
- C30B—SINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
- C30B21/00—Unidirectional solidification of eutectic materials
- C30B21/02—Unidirectional solidification of eutectic materials by normal casting or gradient freezing
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S428/00—Stock material or miscellaneous articles
- Y10S428/922—Static electricity metal bleed-off metallic stock
- Y10S428/9335—Product by special process
- Y10S428/941—Solid state alloying, e.g. diffusion, to disappearance of an original layer
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12431—Foil or filament smaller than 6 mils
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
- Y10T428/12736—Al-base component
- Y10T428/1275—Next to Group VIII or IB metal-base component
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
- Y10T428/12771—Transition metal-base component
- Y10T428/12861—Group VIII or IB metal-base component
- Y10T428/12931—Co-, Fe-, or Ni-base components, alternative to each other
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
- Y10T428/12986—Adjacent functionally defined components
Definitions
- This invention is concerned with coating metallic base systems.
- the invention is particularly directed to oxidation resistant alloy overlay coatings and claddings for superalloys and dispersion-strengthened alloys.
- Aluminide conversion coatings are currently used to protect superalloy components in aircraft gas turbine engines from oxidation, hot corrosion, thermal fatique, and erosion.
- the majority of such coatings are applied by diffusion controlled aluminum enrichment of the superalloy surface.
- the substrate chemistry and the processing temperature exert a major influence on coating chemistry, thickness, and properties.
- aluminide conversion coatings alone offer less potential for providing long time oxidation and thermal fatique resistance.
- Nickel and cobalt base superalloys and dispersionstrengthened alloys are used as turbine vanes and blades in aircraft and land-based gas turbine engines. Oxidation, hot corrosion, and thermal fatigue cracking are major factors which limit the useful life of those superalloys by providing a more oxidation and hot corrosion resistant surface in which thermal fatigue cracking is reduced.
- the aluminide coatings are in themselves made of a hard, brittle outer-layer and a hard, brittle multiphase sub-layer that can crack under high thermal stresses. Once cracked, the oxidizing and/or hot corrosion environment has direct access to the underlying substrate, and deleterious attacks can occur. Also certain elements in the superalloy substrate enter into these coatings. This generally reduces the .environmental resistance of the coatings and makes them less ductile.
- the substrate is initially overlayed with a ductile, oxidation resistant metallic alloy layer.
- This overlay is achieved by foil cladding or other means, such as physical vapor desposition, ion plating, sputtering, plasma spraying, or slurry sintering.
- Foil cladding requires more preliminary effort and fixturing, but it supplies a well characterized homogeneous material directly on the superalloy. Thus it provides the protection potential and metallurgical interactions for weak, oxidation resistant alloy coatings on strong, less environmentally resistant superalloys and dispersion-strengthened alloys.
- the chemistry of the overlay coating is such that the oxidation resistance of the subsequently aluminized outermost layer is not seriously degraded.
- the aluminide outer layer can be developed by pack cementation, metallizing, dipping, spraying, physical vapor deposition, ion plating, sputtering, or electrophoresis. Thus, a failsafe system is provided.
- the aluminide outer layer has a tendency to be less embrittled by substrate elements. It has a lessened tendency to crack because it is supported by a ductile layer, not a brittle, multiphase layer that is conventionally the case. If a crack occurs in the aluminide outer-layer, the ductility of the underlayer restricts its propagation. Widespread oxidation of the underlayer does not occur because the metallic underlayer is oxidation resistant.
- Another object of the invention is to provide an aluminized coating having long time oxidation and thermal fatigue resistance for these materials.
- a further object of the invention is to provide an improved aluminized coating for nickel base and cobalt base superalloys, dispersion-strengthened alloys, composites, and directional eutectics.
- a ductile, oxidation resistant metallic alloy is initially applied to the superalloy.
- An aluminide coating is then applied to the metallic alloy.
- NiCrAlSi and FeCrAlY foil claddings were applied to typical nickel and cobalt base superalloys of the type used in gas turbine engines.
- the nominal composition of the first mentioned cladding was 15 to 25% chromium, 3 to 6% aluminum, 0.5 to 1.5% silicon, and the remainder nickel.
- the preferred composition was 18% chromium, 4% aluminum, 1% silicon, and the remainder nickel.
- the other cladding had a nominal composition of 15 to 2% chromium, 3 to 6% aluminum, 0.1 to 1% yttrium, and the remainder iron.
- the preferred composition was 25% chromium, 4% aluminum, 1% yttrium, and the remainder iron.
- claddings were applied to nickel base superalloys known as lN-l00 and Wl-52.
- the nominal composition of the lN-IOO alloy was 15% cobalt, 9.5% chromium, 5.3% aluminum, 4.3% titanium, 3.2% molybdenum and the remainder nickel.
- the nominal composition of the Wl-52 was 21% chromium, 11% tungsten, 2.2% iron, 1.9% columbium, 0.9% silicon and the remainder cobalt.
- the claddings were also applied to WAZ-20 and NX-188 advanced superalloys and to TD- NiCr dispersionstrengthened alloy.
- the nominal compositions were, for WAZ-20, 20% tungsten, 6.5% aluminum, 1.5% zirconium, 0.2% carbon and the remainder nickel; for NX-l88, 18% molybdenum, 8% aluminum, 0.04% carbon and the remainder nickel; and for TD-NiCr, 20% chromium, 2% thorium dioxide, and the remainder nickel. It is further contemplated that the substrate can be nickel and cobalt base composites and directional eutectic alloys.
- Claddings having a thickness of 0.127 millimeter of both materials were applied to the substrate specimens by hot isostatic gas pressure bonding at a helium pressure of 15,000 to 20,000 psi for two hours at 1090C.
- Aluminide coatings were then applied to the claddings by pack cementation at 1900 to 2000F in argon using a powder mixture consisting of 1% sodium or amonium halide, 1% aluminum, and the remainder aluminum oxide. It is also contemplated that the aluminide coating can be applied by a sintered or fused slurry, electrodeposition, physical vapor deposition, ion plating, sputtering, hot dipping, or pyrolysis.
- the electrodeposition can be of the aqueous, fused salt, or electrophoresis type.
- the spraying can be either a flame or plasma type.
- the system performance was primarily evaluated on the basis of weight change, visual appearance, and metallographic change.
- Weight change results of furnace tests on NiCrAlSi clad 1N-10O and Wi-52 at 1090C for 20 hour exposure cycles were obtained. These tests showed that the clad-cladding alloy was oxidation resistant in that it gained weight in forming a protective oxide and then little further weight change occurred. While NiCrAlSi clad on lN-lOO showed a slight turnaround primarily due to spalling, it was more protective than on Wi-52. Both bare lN-lOO and bare Wi-52 lost weight rapidly. Exposure at 1040C resulted in more protective behavior for both cladding systems for times up to 400 hours.
- NiCrAlSi cladding on ln-lOO showed this system was relatively uneffected by 200 hour cyclic furnace oxidation at 1090C.
- NiCrAlSi clad Wi-52 showed considerable surface oxide penetration and internal oxidation in the cladding after only 120 hours of tests.
- the FeCrAlY cladding was evaluated in cyclic furnace oxidation on ln-lOO and Wi-52.
- the 1090C weight change behavior of the clad Wi-52 was almost identical to that of the cladding alloy itself.
- the clad In- 100 showed more rapid weight gains accompanied by significant spalling.
- a lower exposure temperature of 1040C resulted in less oxidation attack for the claddings on both substrates.
- the FeCrAlY cladding on Wl-52 was in much better condition than the completely degraded coating, but it was about twice as thick in the as-clad condition. This ease in controlling thickness is a beneficial technical effect of the overlay or cladding process.
- the most promising cladding systems based on furnace testing were the NiCrAlSi clad lN-l and the FeCrAlY clad Wl-52; FeCrAlY clad lN-l00 also appeared to have some potential. These systems were subjected to Mach 1 burner rig testing at both 1040 and 1090C using one hour exposure cycles followed by air blast quenching. Such testing imposed significantly greater thermal stress on the protection system and the surface oxide, especially at the leading edges of the burner rig specimens. The FeCrAlY cladding performed better on both lN-100 and WI-52 than did the NiCrAlSi cladding.
- NiCrAlSi clad lN-lOO burner specimens were aluminized to obtain the benefits of both protective systems.
- Soft ductile claddings had shown superior resistance to thermal fatigue cracking while harder and more brittle aluminide coatings resisted oxidation better.
- Aluminizing the NiCrAlSi claddings produced a markedly improved protection system for lN-lOO.
- the system withstood at least 800 hours of Mach 1 burner rig testing at lOC. Based on the time to show weight change turaround, the aluminized cladding was four to five times as protective as the commercial aluminide coating. Its thermal fatigue resistance was about three times better than the aluminide coating.
- the primary cause for improvement in thermal fatigue resistance is believed to be the existence of a rather ductile oxidation resistant layer of aluminum enriched cladding under the external aluminide coating.
- a hard, carbide rich zone is typically found here.
- Benefits may also be derived from the conversion of the relatively simple NiCrAlSi alloy to the aluminide. This aluminide would be expected to contain little of the strengthening elements found in the lN-lOO.
- Burner rig tests at 1090C and Mach-1 were conducted on aluminized, electron beam melted and physical vapor deposited NiCrAlSi coatings on lN-l00 and NASA-TRW Vl-A.
- the nominal composition on the coatings as-deposited is 15% chromium, 4% aluminum, 1% silicon, and the remainder nickel.
- the nominal composition of NASA-TRW Vl-A superalloy is 7.5% cobalt, 6.0% chromium, 5.8% tungsten, 5.4% aluminum, 9.0% tantalum, 2.0% molybdenum, 1.0% titanium, 9.5% columbium, 0.40% rhenium, 0.5% hafnium, 0.1% zirconium, 0.13% carbon, 0.015% boron, and the remainder nickel. After hours of testing in the very severe environment, the specimens showed no evidence of thermal fatigue crackling and the coating had completely protected the superalloy substrates from oxidation and erosion.
- claddings of NiCrAl containing one or more of Si, Y, Mn and Th can be used.
- claddings of FeCrAl containing one or more of Y, Si, Mn and Ta can be used.
- a coated article of manufacture comprising a superalloy substrate selected from the group consisting of nickel-base superalloys and cobalt-base superalloys, dispersion-strengthened alloys, com posites, and directional eutectics,
- foil cladding is a NiCrAl alloy containing one or more elements selected from the group consisting of Si, Y, Mn, and Th.
- foil cladding is an alloy consisting essentially of from to 25% chromium, 3 to 6% aluminum, 0.5 to 1.5% silicon, and the balance nickel.
- foil cladding is a FeCrAl alloy containing one or more elements selected from the group consisting of Y, Si, Mn, and Ta.
- foil cladding is an alloy consisting essentially of from 15 to 25% chromium, 3 to 6% aluminum, 0.1 to 1% yttrium, and the balance iron.
Abstract
The surface of a metallic base system is initially coated with a metallic alloy layer that is ductile and oxidation resistant. An aluminide coating is then applied to the metallic alloy layer. The chemistry of the metallic alloy layer is such that the oxidation resistance of the subsequently aluminized outermost layer is not seriously degraded.
Description
United States Patent 1191 Gedwill et al.
[4 1 Mar. 11, 1975 1 DUPLEX ALUMINIZED COATINGS [75] Inventors: Michael A. Gedwill, North Olmsted;
Salvatore J. Grisaffe, Rocky River, both of Ohio [73] Assignee: The United States of America as represented by the Administrator of the National Aeronautics and Space Administration, Washington, DC.
22 Filed: Jan. 24, 1974 21 Appl. No: 436,315
Related US. Application Data [62] Division of Ser. No. 298,156, Oct. 16, 1972.
[52] US. Cl 29/194, 29/196.2, 29/196.6, 29/197 [5 l] Int. Cl B32b 15/00 [58] Field of Search 29/194, 196.2, 197, 196.6
[56] References Cited UNITED STATES PATENTS 3,542,530 11/1970 Talboorn et a1 29/196.6 X
3,620,693 11/1971 Sama 29/197 X 3,649,225 3/1972 Simmons 29/194 3,676,085 7/1972 Evans et a1. 29/194 3,741,791 6/1973 Maxwell et a1. 29/194 X 3,754,903 8/1973 Goward et a1. 29/194 X Primary ExaminerL. Dewayne Rutledge Assistant Examiner-E. L. Weise Attorney, Agent, or Firm-N. T. Musial; G. E. Shook; .1. R. Manning 57 ABSTRACT 9 Claims, No Drawings DUPLEX ALUMINIZED COATINGS ORIGIN OF THE INVENTION The invention described herein was made by employees of the United States Government and may be manufactured and used by or for the Government for governmental purposes without the payment of any royalties thereon or therefor.
RELATED APPLICATION This application is a division of copending application, Ser. No. 298,156 which was filed Oct. 16, 1972.
BACKGROUND OF THE INVENTION This invention is concerned with coating metallic base systems. The invention is particularly directed to oxidation resistant alloy overlay coatings and claddings for superalloys and dispersion-strengthened alloys.
Aluminide conversion coatings are currently used to protect superalloy components in aircraft gas turbine engines from oxidation, hot corrosion, thermal fatique, and erosion. The majority of such coatings are applied by diffusion controlled aluminum enrichment of the superalloy surface. In such a process the substrate chemistry and the processing temperature exert a major influence on coating chemistry, thickness, and properties. Thus, it is difficult to tailor an aluminide coating to resist a particular engine environment. As engine temperatures increase to improve performance, aluminide conversion coatings alone offer less potential for providing long time oxidation and thermal fatique resistance.
Nickel and cobalt base superalloys and dispersionstrengthened alloys are used as turbine vanes and blades in aircraft and land-based gas turbine engines. Oxidation, hot corrosion, and thermal fatigue cracking are major factors which limit the useful life of those superalloys by providing a more oxidation and hot corrosion resistant surface in which thermal fatigue cracking is reduced.
The aluminide coatings are in themselves made of a hard, brittle outer-layer and a hard, brittle multiphase sub-layer that can crack under high thermal stresses. Once cracked, the oxidizing and/or hot corrosion environment has direct access to the underlying substrate, and deleterious attacks can occur. Also certain elements in the superalloy substrate enter into these coatings. This generally reduces the .environmental resistance of the coatings and makes them less ductile.
SUMMARY OF THE INVENTION According to the present invention the substrate is initially overlayed with a ductile, oxidation resistant metallic alloy layer. This overlay is achieved by foil cladding or other means, such as physical vapor desposition, ion plating, sputtering, plasma spraying, or slurry sintering. Foil cladding requires more preliminary effort and fixturing, but it supplies a well characterized homogeneous material directly on the superalloy. Thus it provides the protection potential and metallurgical interactions for weak, oxidation resistant alloy coatings on strong, less environmentally resistant superalloys and dispersion-strengthened alloys.
The chemistry of the overlay coating is such that the oxidation resistance of the subsequently aluminized outermost layer is not seriously degraded. The aluminide outer layer can be developed by pack cementation, metallizing, dipping, spraying, physical vapor deposition, ion plating, sputtering, or electrophoresis. Thus, a failsafe system is provided. The aluminide outer layer has a tendency to be less embrittled by substrate elements. It has a lessened tendency to crack because it is supported by a ductile layer, not a brittle, multiphase layer that is conventionally the case. If a crack occurs in the aluminide outer-layer, the ductility of the underlayer restricts its propagation. Widespread oxidation of the underlayer does not occur because the metallic underlayer is oxidation resistant.
OBJECTS OF THE INVENTION It is, therefore, an object of the present invention to provide an improved oxidation resitant coating for superalloys and dispersion-strengthened alloys.
Another object of the invention is to provide an aluminized coating having long time oxidation and thermal fatigue resistance for these materials.
A further object of the invention is to provide an improved aluminized coating for nickel base and cobalt base superalloys, dispersion-strengthened alloys, composites, and directional eutectics.
These and other objects of the invention will be apparent from the specification which follows.
PREFERRED EMBODIMENT OF THE INVENTION According to the present invention a ductile, oxidation resistant metallic alloy is initially applied to the superalloy. An aluminide coating is then applied to the metallic alloy.
In order to illustrate the beneficial technical effects of the invention NiCrAlSi and FeCrAlY foil claddings were applied to typical nickel and cobalt base superalloys of the type used in gas turbine engines. The nominal composition of the first mentioned cladding was 15 to 25% chromium, 3 to 6% aluminum, 0.5 to 1.5% silicon, and the remainder nickel. The preferred composition was 18% chromium, 4% aluminum, 1% silicon, and the remainder nickel.
The other cladding had a nominal composition of 15 to 2% chromium, 3 to 6% aluminum, 0.1 to 1% yttrium, and the remainder iron. The preferred composition was 25% chromium, 4% aluminum, 1% yttrium, and the remainder iron.
These claddings were applied to nickel base superalloys known as lN-l00 and Wl-52. The nominal composition of the lN-IOO alloy was 15% cobalt, 9.5% chromium, 5.3% aluminum, 4.3% titanium, 3.2% molybdenum and the remainder nickel. The nominal composition of the Wl-52 was 21% chromium, 11% tungsten, 2.2% iron, 1.9% columbium, 0.9% silicon and the remainder cobalt. The claddings were also applied to WAZ-20 and NX-188 advanced superalloys and to TD- NiCr dispersionstrengthened alloy. The nominal compositions were, for WAZ-20, 20% tungsten, 6.5% aluminum, 1.5% zirconium, 0.2% carbon and the remainder nickel; for NX-l88, 18% molybdenum, 8% aluminum, 0.04% carbon and the remainder nickel; and for TD-NiCr, 20% chromium, 2% thorium dioxide, and the remainder nickel. It is further contemplated that the substrate can be nickel and cobalt base composites and directional eutectic alloys.
Claddings having a thickness of 0.127 millimeter of both materials were applied to the substrate specimens by hot isostatic gas pressure bonding at a helium pressure of 15,000 to 20,000 psi for two hours at 1090C.
Aluminide coatings were then applied to the claddings by pack cementation at 1900 to 2000F in argon using a powder mixture consisting of 1% sodium or amonium halide, 1% aluminum, and the remainder aluminum oxide. It is also contemplated that the aluminide coating can be applied by a sintered or fused slurry, electrodeposition, physical vapor deposition, ion plating, sputtering, hot dipping, or pyrolysis. The electrodeposition can be of the aqueous, fused salt, or electrophoresis type. The spraying can be either a flame or plasma type.
The system performance was primarily evaluated on the basis of weight change, visual appearance, and metallographic change. Weight change results of furnace tests on NiCrAlSi clad 1N-10O and Wi-52 at 1090C for 20 hour exposure cycles were obtained. These tests showed that the clad-cladding alloy was oxidation resistant in that it gained weight in forming a protective oxide and then little further weight change occurred. While NiCrAlSi clad on lN-lOO showed a slight turnaround primarily due to spalling, it was more protective than on Wi-52. Both bare lN-lOO and bare Wi-52 lost weight rapidly. Exposure at 1040C resulted in more protective behavior for both cladding systems for times up to 400 hours.
Metallographic cross sections of the NiCrAlSi cladding on ln-lOO showed this system was relatively uneffected by 200 hour cyclic furnace oxidation at 1090C. NiCrAlSi clad Wi-52 showed considerable surface oxide penetration and internal oxidation in the cladding after only 120 hours of tests.
The FeCrAlY cladding was evaluated in cyclic furnace oxidation on ln-lOO and Wi-52. The 1090C weight change behavior of the clad Wi-52 was almost identical to that of the cladding alloy itself. The clad In- 100, however, showed more rapid weight gains accompanied by significant spalling. A lower exposure temperature of 1040C resulted in less oxidation attack for the claddings on both substrates.
Metallographic and weight change data obtained after 1090C furnace tests on the commercial aluminide coatings were compared with similar data with the most protective claddings on each substrate. These comparisons indicated that both the attack on the microstructure and weight changes of the coating and Ni- CrAlSi cladding on lN-lOO were very similar after 200 hours (20 hour cycles) at lO90C. Here, both protection systems were approximately the same thickness.
The FeCrAlY cladding on Wl-52 was in much better condition than the completely degraded coating, but it was about twice as thick in the as-clad condition. This ease in controlling thickness is a beneficial technical effect of the overlay or cladding process.
The most promising cladding systems based on furnace testing were the NiCrAlSi clad lN-l and the FeCrAlY clad Wl-52; FeCrAlY clad lN-l00 also appeared to have some potential. These systems were subjected to Mach 1 burner rig testing at both 1040 and 1090C using one hour exposure cycles followed by air blast quenching. Such testing imposed significantly greater thermal stress on the protection system and the surface oxide, especially at the leading edges of the burner rig specimens. The FeCrAlY cladding performed better on both lN-100 and WI-52 than did the NiCrAlSi cladding. The thermal fatigue resistance of these clad systems was markedly superior to that of the aluminide coated systems. In all tests, no cracks were observed in the claddings within the test times. Only the FeCrAlY clad WI-52 performed better in oxidation erosion than the aluminide coating.
Some NiCrAlSi clad lN-lOO burner specimens were aluminized to obtain the benefits of both protective systems. Soft ductile claddings had shown superior resistance to thermal fatigue cracking while harder and more brittle aluminide coatings resisted oxidation better. Aluminizing the NiCrAlSi claddings produced a markedly improved protection system for lN-lOO. The system withstood at least 800 hours of Mach 1 burner rig testing at lOC. Based on the time to show weight change turaround, the aluminized cladding was four to five times as protective as the commercial aluminide coating. Its thermal fatigue resistance was about three times better than the aluminide coating.
The primary cause for improvement in thermal fatigue resistance is believed to be the existence of a rather ductile oxidation resistant layer of aluminum enriched cladding under the external aluminide coating. In conventional aluminide coatings on superalloys, a hard, carbide rich zone is typically found here. Benefits may also be derived from the conversion of the relatively simple NiCrAlSi alloy to the aluminide. This aluminide would be expected to contain little of the strengthening elements found in the lN-lOO.
Several aluminized NiCrAlSi clad WAZ-20, NX-188, and TD-NiCr specimens were tested in cyclic furnace oxidation at 1150C to see how effective the coating would be for higher temperature applications. The oxidation life of the clad was well in excess of 500 and 300 hours, respectively, on WAZ-20 and NX-188, and slightly more than 600 hours on TC-NiCr. This is a substantial improvement over aluminide coatings alone on these substrates which generally failed well within hours in the same tests.
Burner rig tests at 1090C and Mach-1 were conducted on aluminized, electron beam melted and physical vapor deposited NiCrAlSi coatings on lN-l00 and NASA-TRW Vl-A. The nominal composition on the coatings as-deposited is 15% chromium, 4% aluminum, 1% silicon, and the remainder nickel. The nominal composition of NASA-TRW Vl-A superalloy is 7.5% cobalt, 6.0% chromium, 5.8% tungsten, 5.4% aluminum, 9.0% tantalum, 2.0% molybdenum, 1.0% titanium, 9.5% columbium, 0.40% rhenium, 0.5% hafnium, 0.1% zirconium, 0.13% carbon, 0.015% boron, and the remainder nickel. After hours of testing in the very severe environment, the specimens showed no evidence of thermal fatigue crackling and the coating had completely protected the superalloy substrates from oxidation and erosion.
While several preferred embodiments of the invention have been described it is contemplated that various modifications may be made without departing from the spirit of the invention or the scope of the subjoined claims. By way of example, claddings of NiCrAl containing one or more of Si, Y, Mn and Th can be used. Also claddings of FeCrAl containing one or more of Y, Si, Mn and Ta can be used.
What is claimed is:
1. A coated article of manufacture comprising a superalloy substrate selected from the group consisting of nickel-base superalloys and cobalt-base superalloys, dispersion-strengthened alloys, com posites, and directional eutectics,
a ductile, oxidation resistant metallic alloy layer covering said substrate, and
an aluminide coating covering said metallic alloy layer.
2. An article of manufacture is claimed in claim 1 wherein the metallic alloy layer comprises a cladding.
3. An article of manufacture as claimed in claim 2 wherein the metallic alloy layer comprises a foil cladding.
4. An article of manufacture as claimed in claim 3 wherein the foil cladding is a NiCrAl alloy containing one or more elements selected from the group consisting of Si, Y, Mn, and Th.
5. An article of manufacture as claimed in claim 4 wherein the foil cladding is an alloy consisting essentially of from to 25% chromium, 3 to 6% aluminum, 0.5 to 1.5% silicon, and the balance nickel.
6. An article of manufacture as claimed in claim 5 wherein the alloy consists essentially of about 18% chromium, about 4% aluminum, about 1% silicon, and the balance nickel.
7. An article of manufacture as claimed in claim 3 wherein the foil cladding is a FeCrAl alloy containing one or more elements selected from the group consisting of Y, Si, Mn, and Ta.
8. An article of manufacture as claimed in claim 7 wherein the foil cladding is an alloy consisting essentially of from 15 to 25% chromium, 3 to 6% aluminum, 0.1 to 1% yttrium, and the balance iron.
9. An article of manufacture as claimed in claim 8 wherein the alloy consists essentially of about 25% chromium, about 4% aluminum, 1% yttrium, and the balance iron.
Claims (9)
1. A COATED ARTICLE OF MANUFACTURE COMPRISING A SUPERALLOY SUBSTRATE SELECTED FROM THE GROUP CONSISTING OF NICKEL-BASE SUPERALLOYS AND COBALT-BASE SUPERALLOYS, DISPERSION-STRENGTHENED ALLOYS, COMPOSITES, AND DIRECTIONAL EUTECTICS, A DUCTILE, OXIDATION RESISTANT METALLIC ALLOY LAYER COVERING SAID SUBSTRATE, AND AN ALUMIDE COATING COVERING SAID METALLIC ALLOY LAYER.
1. A coated article of manufacture comprising a superalloy substrate selected from the group consisting of nickel-base superalloys and coablt-base superalloys, dispersion-strengthened alloys, composites, and directional eutectics, a ductile, oxidation resistant metallic alloy layer covering said substrate, and an aluminide coating covering said metallic alloy layer.
2. An article of manufacture is claimed in claim 1 wherein the metallic alloy layer comprises a cladding.
3. An article of manufacture as claimed in claim 2 wherein the metallic alloy layer comprises a foil cladding.
4. An article of manufacture as claimed in claim 3 wherein the foil cladding is a NiCrAl alloy containing one or more elements selected from the group consisting of Si, Y, Mn, and Th.
5. An article of manufacture as claimed in claim 4 whereIn the foil cladding is an alloy consisting essentially of from 15 to 25% chromium, 3 to 6% aluminum, 0.5 to 1.5% silicon, and the balance nickel.
6. An article of manufacture as claimed in claim 5 wherein the alloy consists essentially of about 18% chromium, about 4% aluminum, about 1% silicon, and the balance nickel.
7. An article of manufacture as claimed in claim 3 wherein the foil cladding is a FeCrAl alloy containing one or more elements selected from the group consisting of Y, Si, Mn, and Ta.
8. An article of manufacture as claimed in claim 7 wherein the foil cladding is an alloy consisting essentially of from 15 to 25% chromium, 3 to 6% aluminum, 0.1 to 1% yttrium, and the balance iron.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US436315A US3869779A (en) | 1972-10-16 | 1974-01-24 | Duplex aluminized coatings |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US00298156A US3849865A (en) | 1972-10-16 | 1972-10-16 | Method of protecting the surface of a substrate |
US436315A US3869779A (en) | 1972-10-16 | 1974-01-24 | Duplex aluminized coatings |
Publications (1)
Publication Number | Publication Date |
---|---|
US3869779A true US3869779A (en) | 1975-03-11 |
Family
ID=26970509
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US436315A Expired - Lifetime US3869779A (en) | 1972-10-16 | 1974-01-24 | Duplex aluminized coatings |
Country Status (1)
Country | Link |
---|---|
US (1) | US3869779A (en) |
Cited By (29)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3955935A (en) * | 1974-11-27 | 1976-05-11 | General Motors Corporation | Ductile corrosion resistant chromium-aluminum coating on superalloy substrate and method of forming |
US4005989A (en) * | 1976-01-13 | 1977-02-01 | United Technologies Corporation | Coated superalloy article |
US4029477A (en) * | 1975-10-29 | 1977-06-14 | General Electric Company | Coated Ni-Cr base dispersion-modified alloy article |
US4034142A (en) * | 1975-12-31 | 1977-07-05 | United Technologies Corporation | Superalloy base having a coating containing silicon for corrosion/oxidation protection |
US4080486A (en) * | 1973-04-02 | 1978-03-21 | General Electric Company | Coating system for superalloys |
US4087589A (en) * | 1975-10-14 | 1978-05-02 | General Electric Company | Coated article |
US4109061A (en) * | 1977-12-08 | 1978-08-22 | United Technologies Corporation | Method for altering the composition and structure of aluminum bearing overlay alloy coatings during deposition from metallic vapor |
US4123594A (en) * | 1977-09-22 | 1978-10-31 | General Electric Company | Metallic coated article of improved environmental resistance |
US4123595A (en) * | 1977-09-22 | 1978-10-31 | General Electric Company | Metallic coated article |
US4145481A (en) * | 1977-08-03 | 1979-03-20 | Howmet Turbine Components Corporation | Process for producing elevated temperature corrosion resistant metal articles |
DE3010608A1 (en) * | 1979-05-29 | 1980-12-11 | Howmet Turbine Components | COATING COMPOSITION FOR NICKEL, COBALT AND IRON CONTAINING SUPER ALLOY AND SUPER ALLOY COMPONENT |
US4339509A (en) * | 1979-05-29 | 1982-07-13 | Howmet Turbine Components Corporation | Superalloy coating composition with oxidation and/or sulfidation resistance |
US4374183A (en) * | 1980-06-20 | 1983-02-15 | The United States Of America As Represented By The Administrator, National Aeronautics And Space Administration | Silicon-slurry/aluminide coating |
USRE31339E (en) * | 1977-08-03 | 1983-08-09 | Howmet Turbine Components Corporation | Process for producing elevated temperature corrosion resistant metal articles |
US4485151A (en) * | 1982-05-06 | 1984-11-27 | The United States Of America As Represented By The Administrator Of The National Aeronautics And Space Administration | Thermal barrier coating system |
US4535033A (en) * | 1983-08-16 | 1985-08-13 | The United States Of America As Represented By The Administrator Of The National Aeronautics And Space Administration | Thermal barrier coating system |
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 |
US4897315A (en) * | 1985-10-15 | 1990-01-30 | United Technologies Corporation | Yttrium enriched aluminide coating for superalloys |
US4910092A (en) * | 1986-09-03 | 1990-03-20 | United Technologies Corporation | Yttrium enriched aluminide coating for superalloys |
US4933239A (en) * | 1989-03-06 | 1990-06-12 | United Technologies Corporation | Aluminide coating for superalloys |
US5512382A (en) * | 1995-05-08 | 1996-04-30 | Alliedsignal Inc. | Porous thermal barrier coating |
US5562998A (en) * | 1994-11-18 | 1996-10-08 | Alliedsignal Inc. | Durable thermal barrier coating |
WO1996034130A1 (en) * | 1995-04-27 | 1996-10-31 | Siemens Aktiengesellschaft | Metal component with a high-temperature protection coating system and a method of coating the component |
US6103386A (en) * | 1994-11-18 | 2000-08-15 | Allied Signal Inc | Thermal barrier coating with alumina bond inhibitor |
US6224963B1 (en) | 1997-05-14 | 2001-05-01 | Alliedsignal Inc. | Laser segmented thick thermal barrier coatings for turbine shrouds |
US6482537B1 (en) | 2000-03-24 | 2002-11-19 | Honeywell International, Inc. | Lower conductivity barrier coating |
US6673467B2 (en) | 2001-10-01 | 2004-01-06 | Alstom (Switzerland) Ltd | Metallic component with protective coating |
US20080261069A1 (en) * | 2007-04-18 | 2008-10-23 | Hitachi Ltd. | High temperature component with thermal barrier coating |
US20140041910A1 (en) * | 2011-03-31 | 2014-02-13 | Jx Nippon Mining & Metals Corporation | Metal Foil Provided with Electrically Resistive Layer, and Board for Printed Circuit Using Said Metal Foil |
Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3542530A (en) * | 1968-05-23 | 1970-11-24 | United Aircraft Corp | Nickel or cobalt base with a coating containing iron chromium and aluminum |
US3620693A (en) * | 1969-04-22 | 1971-11-16 | Gte Electric Inc | Ductile, high-temperature oxidation-resistant composites and processes for producing same |
US3649225A (en) * | 1969-11-17 | 1972-03-14 | United Aircraft Corp | Composite coating for the superalloys |
US3676085A (en) * | 1971-02-18 | 1972-07-11 | United Aircraft Corp | Cobalt base coating for the superalloys |
US3741791A (en) * | 1971-08-05 | 1973-06-26 | United Aircraft Corp | Slurry coating superalloys with fecraiy coatings |
US3754903A (en) * | 1970-09-15 | 1973-08-28 | United Aircraft Corp | High temperature oxidation resistant coating alloy |
-
1974
- 1974-01-24 US US436315A patent/US3869779A/en not_active Expired - Lifetime
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3542530A (en) * | 1968-05-23 | 1970-11-24 | United Aircraft Corp | Nickel or cobalt base with a coating containing iron chromium and aluminum |
US3620693A (en) * | 1969-04-22 | 1971-11-16 | Gte Electric Inc | Ductile, high-temperature oxidation-resistant composites and processes for producing same |
US3649225A (en) * | 1969-11-17 | 1972-03-14 | United Aircraft Corp | Composite coating for the superalloys |
US3754903A (en) * | 1970-09-15 | 1973-08-28 | United Aircraft Corp | High temperature oxidation resistant coating alloy |
US3676085A (en) * | 1971-02-18 | 1972-07-11 | United Aircraft Corp | Cobalt base coating for the superalloys |
US3741791A (en) * | 1971-08-05 | 1973-06-26 | United Aircraft Corp | Slurry coating superalloys with fecraiy coatings |
Cited By (38)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4080486A (en) * | 1973-04-02 | 1978-03-21 | General Electric Company | Coating system for superalloys |
US3955935A (en) * | 1974-11-27 | 1976-05-11 | General Motors Corporation | Ductile corrosion resistant chromium-aluminum coating on superalloy substrate and method of forming |
US4087589A (en) * | 1975-10-14 | 1978-05-02 | General Electric Company | Coated article |
US4029477A (en) * | 1975-10-29 | 1977-06-14 | General Electric Company | Coated Ni-Cr base dispersion-modified alloy article |
US4034142A (en) * | 1975-12-31 | 1977-07-05 | United Technologies Corporation | Superalloy base having a coating containing silicon for corrosion/oxidation protection |
US4005989A (en) * | 1976-01-13 | 1977-02-01 | United Technologies Corporation | Coated superalloy article |
FR2338386A1 (en) * | 1976-01-13 | 1977-08-12 | United Technologies Corp | SUPERALLY ARTICLE COVERED WITH AN INTERMEDIATE ALUMINUM COATING AND AN EXTERNAL COATING OF THE MCRALY TYPE |
USRE31339E (en) * | 1977-08-03 | 1983-08-09 | Howmet Turbine Components Corporation | Process for producing elevated temperature corrosion resistant metal articles |
US4145481A (en) * | 1977-08-03 | 1979-03-20 | Howmet Turbine Components Corporation | Process for producing elevated temperature corrosion resistant metal articles |
US4123595A (en) * | 1977-09-22 | 1978-10-31 | General Electric Company | Metallic coated article |
US4123594A (en) * | 1977-09-22 | 1978-10-31 | General Electric Company | Metallic coated article of improved environmental resistance |
FR2404055A1 (en) * | 1977-09-22 | 1979-04-20 | Gen Electric | METAL PART WITH AN IMPROVED COATING AGAINST CORROSION AND HOT OXIDATION |
FR2404054A1 (en) * | 1977-09-22 | 1979-04-20 | Gen Electric | METAL PART WITH A PROTECTIVE COATING AGAINST CORROSION AND HOT OXIDATION |
US4109061A (en) * | 1977-12-08 | 1978-08-22 | United Technologies Corporation | Method for altering the composition and structure of aluminum bearing overlay alloy coatings during deposition from metallic vapor |
US4339509A (en) * | 1979-05-29 | 1982-07-13 | Howmet Turbine Components Corporation | Superalloy coating composition with oxidation and/or sulfidation resistance |
US4313760A (en) * | 1979-05-29 | 1982-02-02 | Howmet Turbine Components Corporation | Superalloy coating composition |
FR2457907A1 (en) * | 1979-05-29 | 1980-12-26 | Howmet Turbine Components | COATING COMPOSITION FOR PROTECTION AGAINST HIGH TEMPERATURE OXIDATION OF SUPER-ALLOYS AND COMPONENTS OF SUPER-ALLOYS THUS COATED |
DE3010608A1 (en) * | 1979-05-29 | 1980-12-11 | Howmet Turbine Components | COATING COMPOSITION FOR NICKEL, COBALT AND IRON CONTAINING SUPER ALLOY AND SUPER ALLOY COMPONENT |
US4374183A (en) * | 1980-06-20 | 1983-02-15 | The United States Of America As Represented By The Administrator, National Aeronautics And Space Administration | Silicon-slurry/aluminide coating |
US4485151A (en) * | 1982-05-06 | 1984-11-27 | The United States Of America As Represented By The Administrator Of The National Aeronautics And Space Administration | Thermal barrier coating system |
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 |
US4535033A (en) * | 1983-08-16 | 1985-08-13 | The United States Of America As Represented By The Administrator Of The National Aeronautics And Space Administration | Thermal barrier coating system |
US4897315A (en) * | 1985-10-15 | 1990-01-30 | United Technologies Corporation | Yttrium enriched aluminide coating for superalloys |
US4910092A (en) * | 1986-09-03 | 1990-03-20 | United Technologies Corporation | Yttrium enriched aluminide coating for superalloys |
US4933239A (en) * | 1989-03-06 | 1990-06-12 | United Technologies Corporation | Aluminide coating for superalloys |
US6103386A (en) * | 1994-11-18 | 2000-08-15 | Allied Signal Inc | Thermal barrier coating with alumina bond inhibitor |
US5562998A (en) * | 1994-11-18 | 1996-10-08 | Alliedsignal Inc. | Durable thermal barrier coating |
US6395343B1 (en) | 1994-11-18 | 2002-05-28 | Alliedsignal | Durable thermal barrier coating |
WO1996034130A1 (en) * | 1995-04-27 | 1996-10-31 | Siemens Aktiengesellschaft | Metal component with a high-temperature protection coating system and a method of coating the component |
US5624721A (en) * | 1995-05-08 | 1997-04-29 | Alliedsignal Inc. | Method of producing a superalloy article |
US5512382A (en) * | 1995-05-08 | 1996-04-30 | Alliedsignal Inc. | Porous thermal barrier coating |
US6224963B1 (en) | 1997-05-14 | 2001-05-01 | Alliedsignal Inc. | Laser segmented thick thermal barrier coatings for turbine shrouds |
US6482537B1 (en) | 2000-03-24 | 2002-11-19 | Honeywell International, Inc. | Lower conductivity barrier coating |
US6673467B2 (en) | 2001-10-01 | 2004-01-06 | Alstom (Switzerland) Ltd | Metallic component with protective coating |
US20080261069A1 (en) * | 2007-04-18 | 2008-10-23 | Hitachi Ltd. | High temperature component with thermal barrier coating |
EP1995350A1 (en) | 2007-04-18 | 2008-11-26 | Hitachi, Ltd. | High temperature component with thermal barrier coating |
US20140041910A1 (en) * | 2011-03-31 | 2014-02-13 | Jx Nippon Mining & Metals Corporation | Metal Foil Provided with Electrically Resistive Layer, and Board for Printed Circuit Using Said Metal Foil |
US9578739B2 (en) * | 2011-03-31 | 2017-02-21 | Jx Nippon Mining & Metals Corporation | Metal foil provided with electrically resistive layer, and board for printed circuit using said metal foil |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US3869779A (en) | Duplex aluminized coatings | |
US3849865A (en) | Method of protecting the surface of a substrate | |
US4145481A (en) | Process for producing elevated temperature corrosion resistant metal articles | |
USRE31339E (en) | Process for producing elevated temperature corrosion resistant metal articles | |
US4339509A (en) | Superalloy coating composition with oxidation and/or sulfidation resistance | |
US4198442A (en) | Method for producing elevated temperature corrosion resistant articles | |
US4313760A (en) | Superalloy coating composition | |
US5035958A (en) | Nickel-base superalloys especially useful as compatible protective environmental coatings for advanced superaloys | |
US3928026A (en) | High temperature nicocraly coatings | |
US4447503A (en) | Superalloy coating composition with high temperature oxidation resistance | |
US4897315A (en) | Yttrium enriched aluminide coating for superalloys | |
US5238752A (en) | Thermal barrier coating system with intermetallic overlay bond coat | |
US5498484A (en) | Thermal barrier coating system with hardenable bond coat | |
US3649225A (en) | Composite coating for the superalloys | |
US4585481A (en) | Overlays coating for superalloys | |
US4005989A (en) | Coated superalloy article | |
US3754903A (en) | High temperature oxidation resistant coating alloy | |
US4419416A (en) | Overlay coatings for superalloys | |
US4615864A (en) | Superalloy coating composition with oxidation and/or sulfidation resistance | |
US5043138A (en) | Yttrium and yttrium-silicon bearing nickel-base superalloys especially useful as compatible coatings for advanced superalloys | |
US4326011A (en) | Hot corrosion resistant coatings | |
US3846159A (en) | Eutectic alloy coating | |
EP0194391B1 (en) | Yttrium and yttrium-silicon bearing nickel-base superalloys especially useful as compatible coatings for advanced superalloys | |
US4446199A (en) | Overlay metallic-cermet alloy coating systems | |
US4371570A (en) | Hot corrosion resistant coatings |