US20060057418A1 - Alluminide coatings containing silicon and yttrium for superalloys and method of forming such coatings - Google Patents
Alluminide coatings containing silicon and yttrium for superalloys and method of forming such coatings Download PDFInfo
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- US20060057418A1 US20060057418A1 US10/943,116 US94311604A US2006057418A1 US 20060057418 A1 US20060057418 A1 US 20060057418A1 US 94311604 A US94311604 A US 94311604A US 2006057418 A1 US2006057418 A1 US 2006057418A1
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C6/00—Coating by casting molten material on the substrate
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C10/00—Solid state diffusion of only metal elements or silicon into metallic material surfaces
- C23C10/02—Pretreatment of the material to be coated
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- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
- C23C18/02—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition
- C23C18/06—Coating on selected surface areas, e.g. using masks
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- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
- C23C18/02—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition
- C23C18/12—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition characterised by the deposition of inorganic material other than metallic material
- C23C18/1204—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition characterised by the deposition of inorganic material other than metallic material inorganic material, e.g. non-oxide and non-metallic such as sulfides, nitrides based compounds
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
- C23C18/02—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition
- C23C18/12—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition characterised by the deposition of inorganic material other than metallic material
- C23C18/1204—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition characterised by the deposition of inorganic material other than metallic material inorganic material, e.g. non-oxide and non-metallic such as sulfides, nitrides based compounds
- C23C18/1208—Oxides, e.g. ceramics
- C23C18/1216—Metal oxides
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- 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
- C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
- C23C18/02—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition
- C23C18/12—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition characterised by the deposition of inorganic material other than metallic material
- C23C18/1225—Deposition of multilayers of inorganic material
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- C—CHEMISTRY; METALLURGY
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- 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
- C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
- C23C18/02—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition
- C23C18/12—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition characterised by the deposition of inorganic material other than metallic material
- C23C18/125—Process of deposition of the inorganic material
- C23C18/1279—Process of deposition of the inorganic material performed under reactive atmosphere, e.g. oxidising or reducing atmospheres
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
- C23C18/02—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition
- C23C18/12—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition characterised by the deposition of inorganic material other than metallic material
- C23C18/125—Process of deposition of the inorganic material
- C23C18/1295—Process of deposition of the inorganic material with after-treatment of the deposited inorganic material
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- 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
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
- C23C28/32—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer
- C23C28/325—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer with layers graded in composition or in physical properties
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
- C23C28/34—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates
- C23C28/345—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer
- C23C28/3455—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer with a refractory ceramic layer, e.g. refractory metal oxide, ZrO2, rare earth oxides or a thermal barrier system comprising at least one refractory oxide layer
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- 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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T50/00—Aeronautics or air transport
- Y02T50/60—Efficient propulsion technologies, e.g. for aircraft
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- 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.]
- Y10T428/12535—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.] with additional, spatially distinct nonmetal component
- Y10T428/12542—More than one such component
- Y10T428/12549—Adjacent to each other
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- 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.]
- Y10T428/12535—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.] with additional, spatially distinct nonmetal component
- Y10T428/12583—Component contains compound of adjacent metal
- Y10T428/1259—Oxide
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- 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.]
- Y10T428/12535—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.] with additional, spatially distinct nonmetal component
- Y10T428/12611—Oxide-containing component
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- 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
Definitions
- the present invention relates to formation of an intermetallic layer on a metal component and, more particularly, to formation of an intermetallic layer on an airflow surface of a jet engine metal component.
- Intermetallic layers are often applied to a surface of a metal component for protecting the underlying metal substrate of the component and thereby extending its useful life during operation.
- a metal component for protecting the underlying metal substrate of the component and thereby extending its useful life during operation.
- the aerospace industry coats many components having airflow surfaces in a jet engine, like turbine blades, vanes, and nozzle guides, with an aluminide layer to protect the underlying base metal from high temperature oxidation and corrosion.
- a ceramic thermal barrier coating may be applied over the aluminide layer to insulate the jet engine component from combustion and exhaust gases, permitting the combustion and exhaust gases from the engine to be hotter than would otherwise be possible with an aluminide layer alone. Increasing the temperature of the combustion and exhaust gases improves the efficiency of operation of the jet engine.
- a bond layer may be applied to the jet engine component before the ceramic thermal barrier coating is applied.
- Intermetallic aluminides like platinum aluminide, are common examples of such bond coatings that have been in use for many years.
- platinum aluminides are expensive to produce, which contributes to increasing the cost of jet engine components and the cost of refurbishing used jet engine components.
- a jet engine component consists essentially of a substrate of a nickel-based superalloy material and an aluminide layer including silicon and yttrium, in which the aluminide layer defines a working surface exposed to the environment when the jet engine component in service.
- a jet engine component comprises an aluminide layer including silicon and yttrium and disposed on the substrate of a nickel-based superalloy, and a zirconia layer disposed on the aluminide layer.
- the jet engine component may further include a ceramic thermal barrier layer disposed on the zirconia layer.
- a deposition process comprises applying a silicon-containing material to at least a portion of a surface of a jet engine component formed of a superalloy and exposing the jet engine component with the silicon-containing material to a donor material including a metal to begin forming an aluminide layer including metal from the donor material.
- the deposition process further includes exposing the thickening aluminide layer to a yttrium-containing material.
- an improved environmental coating, bond coat, and method of forming such coatings that include an aluminide layer containing minor concentrations of silicon and yttrium.
- the aluminide coating of the invention is competitive in performance with platinum aluminide and less expensive to produce than platinum aluminide.
- FIG. 1 is a diagrammatic cross-sectional view of a coated jet engine component of the invention
- FIG. 1A is a diagrammatic cross-sectional view of a coated jet engine component similar to FIG. 1 ;
- FIG. 2 is a diagrammatic view of the coated jet engine component of FIG. 1 coated with a ceramic thermal barrier coating
- FIG. 3 is a diagrammatic cross-sectional view of a coated jet engine component in accordance with another alternative embodiment of the invention.
- FIG. 3A is a diagrammatic cross-sectional view of a coated jet engine component in accordance with yet another alternative embodiment of the invention.
- FIG. 4 is a schematic view showing jet engine components, such as that from FIG. 1 or FIG. 1A , in a deposition environment of a simple CVD deposition system for purposes of explaining the principles of the present invention.
- FIG. 5 is a schematic view showing jet engine components, such as that from FIGS. 3 and 3 A, in a deposition environment of a simple CVD deposition system similar to FIG. 4 .
- the jet engine component 10 includes a metallic substrate 12 and an aluminide layer 14 coating an original surface 16 of the substrate 12 .
- the metallic substrate 12 is made of any nickel-, cobalt-, or iron-based high temperature superalloy from which such jet engine components 10 are commonly made.
- the substrate 12 may be the nickel-based superalloy Inconel 795 Mod5 A.
- the present invention is not intended to be limited to any particular jet engine component 10 , which may be a turbine blade, a vane, a nozzle guide, or any other part requiring protection from high temperature oxidation and corrosion while operating in a jet engine.
- the substrate 12 may be masked to define areas across which the aluminide layer 14 is absent.
- aluminide layer 14 operates as an environmental coating having a working surface 18 exposed to the atmosphere with the jet engine component 10 in service.
- the general composition of aluminide layer 14 is a chrome aluminide containing minor concentrations of silicon and a minor content of yttrium.
- the concentration of silicon in the aluminide layer 14 may be, for example, about 0.5 wt %.
- the concentration of yttrium in the aluminide layer 14 may be, for example, in a range of parts per million to less than about 0.5 wt %.
- Aluminide layer 14 may be formed by coating the substrate 12 with a layer of a silicon-containing material and placing it into a chemical vapor deposition environment suitable for forming an aluminide layer on jet engine component 10 .
- An exemplary procedure for coating jet engine components with a silicon-coating material prior to aluminiding is described in commonly-owned U.S. Pat. No. 6,605,161, issued on Aug. 12, 2003.
- the deposition environment is modified to include a vapor of a yttrium-containing material.
- An exemplary method for introducing additional elements from a separate receptacle to a main reaction chamber defining the bulk of the chemical vapor deposition environment is described in commonly-owned U.S. application Ser.
- No. 10/613,620 entitled “Simple Chemical Vapor Deposition System and Methods for Depositing Multiple-metal Aluminide Coatings.”
- atoms of the yttrium-containing material are incorporated into the thickening aluminide layer 14 .
- the exposure to the yttrium-containing material is limited to the latter 25% of the total deposition time for aluminide layer 14 and yttrium atoms diffuse from the deposition environment into aluminide layer 14 to provide a concentration gradient having a peak concentration near the working surface 18 .
- the yttrium may be distributed with a uniform concentration through the aluminide layer 14 .
- An additional post-deposition heat treatment may be required to diffuse the yttrium into aluminide layer 14 .
- aluminide layer 14 permits a desired thickness of layer 14 to be formed in a reduced period of time as compared to a conventional deposition process.
- a thicker aluminide layer 14 may advantageously be formed where the cycle time is not substantially reduced with a pre-coated component 10 as compared to another component that was not pre-coated.
- Yttrium operates as a getter for the impurity or tramp element sulfur in the aluminide layer 14 , which originates from the donor material for forming the aluminide layer 14 . The gettering of sulfur by the yttrium is believed to reduce the likelihood that the aluminide layer 14 will spall.
- aluminide layer 14 may partially diffuse into the substrate 12 beneath the original surface 16 of the substrate 12 .
- the resulting aluminide layer 14 includes a diffusion region 20 that extends beneath the original surface 16 and an additive region 22 overlying the original surface 16 of substrate 12 .
- the outermost boundary of additive region 22 defines the working surface 18 of aluminide layer 14 when the jet engine component 10 is in service.
- Additive region 22 is an alloy that includes a relatively high concentration of the donor metal aluminum and a concentration of a metal, for example nickel, from substrate 12 outwardly diffusing from component 10 .
- diffusion region 20 has a lower concentration of aluminum and a relatively high concentration of the metal of substrate 12 .
- aluminide layer 14 may operate as a bond coat covered by a relatively thick ceramic thermal barrier coating or layer 24 of yttria stabilized zirconia (YSZ or Y 2 O 3 ).
- YSZ yttria stabilized zirconia
- the YSZ layer 24 may be applied to the jet engine component 10 by electron beam physical vapor deposition in a different deposition environment from the process forming aluminide layer 14 .
- the YSZ layer 24 typically has a porous columnar microstructure with individual grains oriented substantially perpendicular to the original surface 16 of substrate 12 .
- the YSZ layer 24 may be omitted if not required when the jet engine component 10 is in service.
- a thin layer 26 of zirconia is provided between the aluminide layer 14 and the YSZ layer 24 .
- the zirconia layer 26 operates to reduce the mismatch in atomic spacing between the aluminide layer 14 and the YSZ layer 24 .
- the zirconia layer 26 may be formed before YSZ layer 24 is applied, during application of YSZ layer 24 , or after YSZ layer 24 is formed by heating the jet engine component 10 in an oxidizing atmosphere at a suitable temperature.
- zirconia layer 26 may be formed by depositing metallic zirconium on aluminide layer 14 and then heating jet engine component 10 in air at a temperature of about 1100° F. to about 1200° F.
- a metallic zirconium layer may be anodized to form the zirconia layer 26 .
- the zirconium layer for forming zirconia layer 26 may be provided from an external receptacle 80 to a deposition environment suitable for growing the aluminide layer 14 , as described below in the context of FIG. 5 , or may be deposited in a different and distinct deposition environment from the aluminide layer 14 .
- the layer of metallic zirconium used to form the zirconia layer 26 may be deposited under conditions of rapid deposition so that the morphology of the parent zirconium layer is rough, rather than smooth.
- the rough zirconium layer is then transformed into zirconia. This roughening increases the effective surface area available for bonding with the YSZ layer 24 , which operates to enhance the adhesion of the YSZ layer 24 to the aluminide layer 14 .
- a CVD apparatus 40 suitable for use in the invention includes a main reaction chamber 42 enclosing an interior space 44 defining a deposition environment when purged of atmospheric gases, and evacuated.
- Inert gas such as argon
- An exhaust port 50 defined in the wall of the reaction chamber 42 is coupled with a vacuum pump 52 capable of evacuating the reaction chamber 42 to a vacuum pressure.
- One or more jet engine components 10 are introduced into the reaction chamber 42 and are situated away from a source of extrinsic metal, as explained below.
- a mass or charge of a solid donor material 54 Positioned within the reaction chamber 42 is a mass or charge of a solid donor material 54 , a mass or charge of an activator material 56 and several jet engine components 10 .
- the jet engine components 10 are fabricated from a nickel-based superalloy material.
- Suitable solid donor materials 54 include alloys of chromium and aluminum, which are preferably low in sulfur content ( ⁇ 3 ppm sulfur).
- One suitable donor material 54 is 44 wt % aluminum and balance chromium.
- Appropriate activator materials 56 suitable for use in the invention include, but are not limited to, aluminum fluoride, aluminum chloride, ammonium fluoride, ammonium bifluoride, and ammonium chloride.
- the reaction chamber 42 is heated to a temperature effective to cause vaporization of the activator material 56 , which promotes the release of a vapor phase reactant from the solid donor material 54 .
- This vapor contains an extrinsic metal, typically aluminum, that contributes a first extrinsic metal for incorporation into aluminide layer 14 ( FIG. 1 ) formed on component 10 , as diagrammatically indicated by arrows 58 .
- the first extrinsic metal is separate and distinct from the jet engine component 10 .
- a receptacle 60 positioned outside the reaction chamber 42 is a receptacle 60 in which a second solid donor material 62 is provided.
- the solid donor material 62 furnishes a source of a second extrinsic metal separate and distinct from the jet engine component 10 .
- the second extrinsic metal combines with the first extrinsic metal supplied from donor material 54 to form the aluminide layer 14 on the jet engine component 10 .
- the receptacle 60 and a conduit 64 leading from the receptacle 60 to the reaction chamber 42 are heated with respective heaters 66 , 68 .
- the second solid donor material 62 provided in receptacle 60 may be any solid yttrium-halogen Lewis acid, such as YCl 3 .
- the yttrium-halogen Lewis acid may be ACS grade or reagent grade chemical that is high in purity and substantially free of contaminants, such as sulfur. Upon heating, such yttrium-halogen Lewis acids convert from a dry solid form to a liquid form and, when the temperature of the receptacle 60 is further increased, convert from the liquid form to a vapor to provide the vapor phase reactant containing yttrium.
- the vapor phase reactant from solid donor material 62 is conveyed or transported through the conduit 64 to the main reaction chamber 42 , as diagrammatically indicated by arrows 70 .
- the rate at which the vapor phase reactant from solid donor material 62 is provided to the main reaction chamber 42 is regulated by controlling the temperature of the receptacle 60 with the power to heaters 66 , 68 .
- the delivery vapor phase reactant from solid donor material 62 may be discontinued by sufficiently reducing the temperature of the receptacle 60 or with a valve (not shown) controlling flow in conduit 64 .
- a silicon-containing inoculant is applied to the original surface 16 of substrate 12 , preferably before jet engine component 10 is placed inside the main reaction chamber 42 .
- the inoculant is applied as a liquid and then dried to form a coating.
- Suitable liquid forms of the inoculant may be a mono-, bis- or tri-functional silane material provided in a solution.
- One particularly suitable silane solution is an organofunctional silane such as BTSE 1,2 bis(triethoxysilyl) ethane dissolved in a mixture of water, acetic acid and denatured alcohol with a silane concentration between about 1% and 10%.
- Innoculants like the silane solution, may be applied liberally by a brush, as if being painted, by dipping, by spraying, or by any other suitable conventional application technique.
- the jet engine component 10 bearing the inoculant is then introduced into the main reaction chamber 42 , a charge of the first donor material 54 , and a charge of the activator material 56 are introduced into the reaction chamber 42 , and a charge of the solid yttrium-halogen Lewis acid is introduced as the second donor material 62 into the receptacle 60 .
- the receptacle 60 and the reaction chamber 42 are purged of atmospheric gases by repeatedly admitting an inert gas from inert gas supply 46 through inlet port 48 and evacuating through exhaust port 50 with vacuum pump 52 .
- the main reaction chamber 42 is heated to a temperature effective to release activator material 56 , which interacts with first donor material 54 to release the first vapor phase reactant including metal from material 54 .
- Aluminum present in the vapor phase reactant begins to form the silicon-containing aluminide layer 14 ( FIG. 1 ) on the jet engine component 10 .
- receptacle 60 is heated by heater 66 to a temperature effective to form a second vapor phase reactant from solid donor material 62 , which is provided as a yttrium-containing vapor to the reaction chamber 42 through heated conduit 64 .
- the yttrium is incorporated into the thickening aluminide layer 14 .
- Additional steps, such as soaks and cleaning cycles may be involved in the coating process.
- the jet engine components 10 are removed from the reaction chamber 42 and, optionally, the YSZ layer 24 may be applied by a different process.
- another receptacle 71 may be positioned outside the reaction chamber 42 .
- Another solid donor material 72 provided in receptacle 71 furnishes a source of an extrinsic metal separate and distinct from the jet engine component 10 and separate and distinct from the yttrium-halogen Lewis acid comprising the second donor material 62 in receptacle 60 .
- this extrinsic metal from the donor material 72 may combine with the first extrinsic metal supplied from donor material 54 , may combine with yttrium material supplied to the jet engine component 10 from the second donor material, or may deposit separately on the jet engine component 10 .
- the receptacle 71 and a conduit 74 leading from the receptacle 71 to the reaction chamber 42 are heated with respective heaters 76 , 78 in order to release the vapor phase reactant from the donor material 72 and supply the vapor phase reactant to the main reaction chamber 42 .
- the solid donor material 72 provided in receptacle 71 may be any solid Lewis acid, such as AlCl 3 , CoCl 4 , CrCl 3 , CrF 3 , FeCl 3 , HfCl 3 , IrCl 3 , PtCl 4 , RhCl 3 , RuCl 3 , TiCl 4 , ZrCl 4 , and ZrF 4 .
- the Lewis acid may be ACS grade or reagent grade chemical that is high in purity and substantially free of contaminants, such as sulfur.
- Such Lewis acids Upon heating, such Lewis acids convert from a dry solid form to a liquid form and, when the temperature of the receptacle 71 is further increased, convert from the liquid form to a vapor to provide the vapor phase reactant containing the associated extrinsic metal.
- the vapor phase reactant from solid donor material 72 is conveyed or transported through the conduit 74 to the main reaction chamber 42 , as diagrammatically indicated by arrows 80 .
- the rate at which the vapor phase reactant from solid donor material 72 is provided to the main reaction chamber 42 is regulated by controlling the temperature of the receptacle 71 with variations in the power supplied to heaters 76 , 78 .
- the delivery of the vapor phase reactant from solid donor material 72 may be discontinued by sufficiently reducing the temperature of the receptacle 71 to halt vaporization or with a valve (not shown) controlling flow through conduit 74 .
- the vapor phase reactants from receptacles 60 and 72 are typically provided separately to the main reaction chamber 42 , so that the extrinsic metals from solid donor materials 62 , 72 are not co-deposited on jet engine component 10 .
- the separate control is achievable by, for example, lowering the temperature of each receptacle 60 , 71 , as required, so that the corresponding vapor phase reactant is not produced and, hence, not supplied to the main reaction chamber 42 .
- the temperature of the main reaction chamber 42 may be controlled so that the vapor phase reactant from donor material 54 is controllably present or absent while one or both of the receptacles 60 , 71 supplies the corresponding vapor phase reactant to the main reaction chamber 42 .
- a vapor phase reactant of, for example, zirconium to be independently supplied from receptacle 71 to the main reaction chamber 42 and to, for example, deposit over the aluminide layer 14 ( FIG. 3 ) previously formed on component 10 by a deposition process inside the main reaction chamber 42 .
- a deposition process may be used, as described above, for forming the zirconium layer that ultimately forms the zirconia layer 26 ( FIG. 3 ).
Abstract
Description
- The present invention relates to formation of an intermetallic layer on a metal component and, more particularly, to formation of an intermetallic layer on an airflow surface of a jet engine metal component.
- Intermetallic layers are often applied to a surface of a metal component for protecting the underlying metal substrate of the component and thereby extending its useful life during operation. For example, the aerospace industry coats many components having airflow surfaces in a jet engine, like turbine blades, vanes, and nozzle guides, with an aluminide layer to protect the underlying base metal from high temperature oxidation and corrosion.
- A ceramic thermal barrier coating may be applied over the aluminide layer to insulate the jet engine component from combustion and exhaust gases, permitting the combustion and exhaust gases from the engine to be hotter than would otherwise be possible with an aluminide layer alone. Increasing the temperature of the combustion and exhaust gases improves the efficiency of operation of the jet engine.
- However, such protective ceramic thermal barrier coatings may not adhere well directly to the superalloys commonly used to form jet engine components and, while in service, tend to spall.
- To improve adhesion and thereby provide resistance to spallation, a bond layer may be applied to the jet engine component before the ceramic thermal barrier coating is applied. Intermetallic aluminides, like platinum aluminide, are common examples of such bond coatings that have been in use for many years. However, platinum aluminides are expensive to produce, which contributes to increasing the cost of jet engine components and the cost of refurbishing used jet engine components.
- Accordingly, there is a need for an aluminide coating competitive in performance with platinum aluminide and less expensive to produce than platinum aluminide.
- In one embodiment of the present invention, a jet engine component consists essentially of a substrate of a nickel-based superalloy material and an aluminide layer including silicon and yttrium, in which the aluminide layer defines a working surface exposed to the environment when the jet engine component in service.
- In another embodiment of the invention, a jet engine component comprises an aluminide layer including silicon and yttrium and disposed on the substrate of a nickel-based superalloy, and a zirconia layer disposed on the aluminide layer. The jet engine component may further include a ceramic thermal barrier layer disposed on the zirconia layer.
- In another aspect of the invention, a deposition process comprises applying a silicon-containing material to at least a portion of a surface of a jet engine component formed of a superalloy and exposing the jet engine component with the silicon-containing material to a donor material including a metal to begin forming an aluminide layer including metal from the donor material. The deposition process further includes exposing the thickening aluminide layer to a yttrium-containing material.
- By virtue of the foregoing, there is provided an improved environmental coating, bond coat, and method of forming such coatings that include an aluminide layer containing minor concentrations of silicon and yttrium. The aluminide coating of the invention is competitive in performance with platinum aluminide and less expensive to produce than platinum aluminide.
- These and other objects and advantages of the present invention shall be made apparent from the accompanying drawings and description thereof.
- The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate an embodiment of the invention and, together with a general description of the invention given above, and the detailed description of the embodiment given below, serve to explain the principles of the invention.
-
FIG. 1 is a diagrammatic cross-sectional view of a coated jet engine component of the invention; -
FIG. 1A is a diagrammatic cross-sectional view of a coated jet engine component similar toFIG. 1 ; -
FIG. 2 is a diagrammatic view of the coated jet engine component ofFIG. 1 coated with a ceramic thermal barrier coating; -
FIG. 3 is a diagrammatic cross-sectional view of a coated jet engine component in accordance with another alternative embodiment of the invention; -
FIG. 3A is a diagrammatic cross-sectional view of a coated jet engine component in accordance with yet another alternative embodiment of the invention; -
FIG. 4 is a schematic view showing jet engine components, such as that fromFIG. 1 orFIG. 1A , in a deposition environment of a simple CVD deposition system for purposes of explaining the principles of the present invention; and -
FIG. 5 is a schematic view showing jet engine components, such as that fromFIGS. 3 and 3 A, in a deposition environment of a simple CVD deposition system similar toFIG. 4 . - With reference to
FIG. 1 , a detailed view of a portion of a much larger jet engine component, generally indicated byreference numeral 10, is shown. Thejet engine component 10 includes ametallic substrate 12 and analuminide layer 14 coating anoriginal surface 16 of thesubstrate 12. Themetallic substrate 12 is made of any nickel-, cobalt-, or iron-based high temperature superalloy from which suchjet engine components 10 are commonly made. For example, thesubstrate 12 may be the nickel-based superalloy Inconel 795 Mod5 A. The present invention is not intended to be limited to any particularjet engine component 10, which may be a turbine blade, a vane, a nozzle guide, or any other part requiring protection from high temperature oxidation and corrosion while operating in a jet engine. Thesubstrate 12 may be masked to define areas across which thealuminide layer 14 is absent. - In this specific embodiment of the present invention,
aluminide layer 14 operates as an environmental coating having a workingsurface 18 exposed to the atmosphere with thejet engine component 10 in service. The general composition ofaluminide layer 14 is a chrome aluminide containing minor concentrations of silicon and a minor content of yttrium. The concentration of silicon in thealuminide layer 14 may be, for example, about 0.5 wt %. The concentration of yttrium in thealuminide layer 14 may be, for example, in a range of parts per million to less than about 0.5 wt %. -
Aluminide layer 14 may be formed by coating thesubstrate 12 with a layer of a silicon-containing material and placing it into a chemical vapor deposition environment suitable for forming an aluminide layer onjet engine component 10. An exemplary procedure for coating jet engine components with a silicon-coating material prior to aluminiding is described in commonly-owned U.S. Pat. No. 6,605,161, issued on Aug. 12, 2003. After the growth ofaluminide layer 14 is initiated, the deposition environment is modified to include a vapor of a yttrium-containing material. An exemplary method for introducing additional elements from a separate receptacle to a main reaction chamber defining the bulk of the chemical vapor deposition environment is described in commonly-owned U.S. application Ser. No. 10/613,620, entitled “Simple Chemical Vapor Deposition System and Methods for Depositing Multiple-metal Aluminide Coatings.” When the vapor of the yttrium-containing material is proximate to thejet engine component 10, atoms of the yttrium-containing material are incorporated into the thickeningaluminide layer 14. Preferably, the exposure to the yttrium-containing material is limited to the latter 25% of the total deposition time foraluminide layer 14 and yttrium atoms diffuse from the deposition environment intoaluminide layer 14 to provide a concentration gradient having a peak concentration near the workingsurface 18. Alternatively, the yttrium may be distributed with a uniform concentration through thealuminide layer 14. An additional post-deposition heat treatment may be required to diffuse the yttrium intoaluminide layer 14. - The presence of silicon in the
aluminide layer 14 permits a desired thickness oflayer 14 to be formed in a reduced period of time as compared to a conventional deposition process. Alternatively, athicker aluminide layer 14 may advantageously be formed where the cycle time is not substantially reduced with apre-coated component 10 as compared to another component that was not pre-coated. Yttrium operates as a getter for the impurity or tramp element sulfur in thealuminide layer 14, which originates from the donor material for forming thealuminide layer 14. The gettering of sulfur by the yttrium is believed to reduce the likelihood that thealuminide layer 14 will spall. - With reference to
FIG. 1A in which like reference numerals refer to like features inFIG. 1 ,aluminide layer 14 may partially diffuse into thesubstrate 12 beneath theoriginal surface 16 of thesubstrate 12. The resultingaluminide layer 14 includes adiffusion region 20 that extends beneath theoriginal surface 16 and anadditive region 22 overlying theoriginal surface 16 ofsubstrate 12. The outermost boundary ofadditive region 22 defines the workingsurface 18 ofaluminide layer 14 when thejet engine component 10 is in service.Additive region 22 is an alloy that includes a relatively high concentration of the donor metal aluminum and a concentration of a metal, for example nickel, fromsubstrate 12 outwardly diffusing fromcomponent 10. By contrast,diffusion region 20 has a lower concentration of aluminum and a relatively high concentration of the metal ofsubstrate 12. - With reference to
FIG. 2 in which like reference numerals refer to like features inFIG. 1 ,aluminide layer 14 may operate as a bond coat covered by a relatively thick ceramic thermal barrier coating orlayer 24 of yttria stabilized zirconia (YSZ or Y2O3). Such thermal barrier coatings and methods for the application thereof are familiar to those of ordinary skill in the art. TheYSZ layer 24 may be applied to thejet engine component 10 by electron beam physical vapor deposition in a different deposition environment from the process formingaluminide layer 14. When applied by this deposition technique, theYSZ layer 24 typically has a porous columnar microstructure with individual grains oriented substantially perpendicular to theoriginal surface 16 ofsubstrate 12. Of course, theYSZ layer 24 may be omitted if not required when thejet engine component 10 is in service. - With reference to
FIG. 3 in which like reference numerals refer to like features inFIG. 1 , athin layer 26 of zirconia is provided between thealuminide layer 14 and theYSZ layer 24. Thezirconia layer 26 operates to reduce the mismatch in atomic spacing between thealuminide layer 14 and theYSZ layer 24. Thezirconia layer 26 may be formed beforeYSZ layer 24 is applied, during application ofYSZ layer 24, or afterYSZ layer 24 is formed by heating thejet engine component 10 in an oxidizing atmosphere at a suitable temperature. In one specific embodiment,zirconia layer 26 may be formed by depositing metallic zirconium onaluminide layer 14 and then heatingjet engine component 10 in air at a temperature of about 1100° F. to about 1200° F. Alternatively, a metallic zirconium layer may be anodized to form thezirconia layer 26. The zirconium layer for formingzirconia layer 26 may be provided from an external receptacle 80 to a deposition environment suitable for growing thealuminide layer 14, as described below in the context ofFIG. 5 , or may be deposited in a different and distinct deposition environment from thealuminide layer 14. - As shown in
FIG. 3A , the layer of metallic zirconium used to form thezirconia layer 26 may be deposited under conditions of rapid deposition so that the morphology of the parent zirconium layer is rough, rather than smooth. The rough zirconium layer is then transformed into zirconia. This roughening increases the effective surface area available for bonding with theYSZ layer 24, which operates to enhance the adhesion of theYSZ layer 24 to thealuminide layer 14. - With reference to
FIG. 4 , aCVD apparatus 40 suitable for use in the invention includes amain reaction chamber 42 enclosing aninterior space 44 defining a deposition environment when purged of atmospheric gases, and evacuated. Inert gas, such as argon, is supplied from agas supply 46 to thereaction chamber 42 through aninlet port 48 defined in the wall ofchamber 42. Anexhaust port 50 defined in the wall of thereaction chamber 42 is coupled with avacuum pump 52 capable of evacuating thereaction chamber 42 to a vacuum pressure. One or morejet engine components 10 are introduced into thereaction chamber 42 and are situated away from a source of extrinsic metal, as explained below. - Positioned within the
reaction chamber 42 is a mass or charge of asolid donor material 54, a mass or charge of anactivator material 56 and severaljet engine components 10. Thejet engine components 10 are fabricated from a nickel-based superalloy material. Suitablesolid donor materials 54 include alloys of chromium and aluminum, which are preferably low in sulfur content (<3 ppm sulfur). Onesuitable donor material 54 is 44 wt % aluminum and balance chromium.Appropriate activator materials 56 suitable for use in the invention include, but are not limited to, aluminum fluoride, aluminum chloride, ammonium fluoride, ammonium bifluoride, and ammonium chloride. Thereaction chamber 42 is heated to a temperature effective to cause vaporization of theactivator material 56, which promotes the release of a vapor phase reactant from thesolid donor material 54. This vapor contains an extrinsic metal, typically aluminum, that contributes a first extrinsic metal for incorporation into aluminide layer 14 (FIG. 1 ) formed oncomponent 10, as diagrammatically indicated byarrows 58. The first extrinsic metal is separate and distinct from thejet engine component 10. - With continued reference to
FIG. 4 , positioned outside thereaction chamber 42 is areceptacle 60 in which a secondsolid donor material 62 is provided. Thesolid donor material 62 furnishes a source of a second extrinsic metal separate and distinct from thejet engine component 10. The second extrinsic metal combines with the first extrinsic metal supplied fromdonor material 54 to form thealuminide layer 14 on thejet engine component 10. Thereceptacle 60 and aconduit 64 leading from thereceptacle 60 to thereaction chamber 42 are heated withrespective heaters - The second
solid donor material 62 provided inreceptacle 60 may be any solid yttrium-halogen Lewis acid, such as YCl3. The yttrium-halogen Lewis acid may be ACS grade or reagent grade chemical that is high in purity and substantially free of contaminants, such as sulfur. Upon heating, such yttrium-halogen Lewis acids convert from a dry solid form to a liquid form and, when the temperature of thereceptacle 60 is further increased, convert from the liquid form to a vapor to provide the vapor phase reactant containing yttrium. The vapor phase reactant fromsolid donor material 62 is conveyed or transported through theconduit 64 to themain reaction chamber 42, as diagrammatically indicated byarrows 70. The rate at which the vapor phase reactant fromsolid donor material 62 is provided to themain reaction chamber 42 is regulated by controlling the temperature of thereceptacle 60 with the power toheaters solid donor material 62 may be discontinued by sufficiently reducing the temperature of thereceptacle 60 or with a valve (not shown) controlling flow inconduit 64. - In use and with continued reference to
FIG. 4 , a silicon-containing inoculant is applied to theoriginal surface 16 ofsubstrate 12, preferably beforejet engine component 10 is placed inside themain reaction chamber 42. The inoculant is applied as a liquid and then dried to form a coating. Suitable liquid forms of the inoculant may be a mono-, bis- or tri-functional silane material provided in a solution. One particularly suitable silane solution is an organofunctional silane such as BTSE 1,2 bis(triethoxysilyl) ethane dissolved in a mixture of water, acetic acid and denatured alcohol with a silane concentration between about 1% and 10%. Innoculants, like the silane solution, may be applied liberally by a brush, as if being painted, by dipping, by spraying, or by any other suitable conventional application technique. - The
jet engine component 10 bearing the inoculant is then introduced into themain reaction chamber 42, a charge of thefirst donor material 54, and a charge of theactivator material 56 are introduced into thereaction chamber 42, and a charge of the solid yttrium-halogen Lewis acid is introduced as thesecond donor material 62 into thereceptacle 60. Thereceptacle 60 and thereaction chamber 42 are purged of atmospheric gases by repeatedly admitting an inert gas frominert gas supply 46 throughinlet port 48 and evacuating throughexhaust port 50 withvacuum pump 52. - The
main reaction chamber 42 is heated to a temperature effective to releaseactivator material 56, which interacts withfirst donor material 54 to release the first vapor phase reactant including metal frommaterial 54. Aluminum present in the vapor phase reactant begins to form the silicon-containing aluminide layer 14 (FIG. 1 ) on thejet engine component 10. After thealuminide layer 14 begins to form,receptacle 60 is heated byheater 66 to a temperature effective to form a second vapor phase reactant fromsolid donor material 62, which is provided as a yttrium-containing vapor to thereaction chamber 42 throughheated conduit 64. The yttrium is incorporated into the thickeningaluminide layer 14. Persons of ordinary skill in the art will recognize that additional steps, such as soaks and cleaning cycles, may be involved in the coating process. Thejet engine components 10 are removed from thereaction chamber 42 and, optionally, theYSZ layer 24 may be applied by a different process. - With reference to
FIG. 5 in which like reference numerals refer to like features inFIG. 4 , anotherreceptacle 71 may be positioned outside thereaction chamber 42. Anothersolid donor material 72 provided inreceptacle 71 furnishes a source of an extrinsic metal separate and distinct from thejet engine component 10 and separate and distinct from the yttrium-halogen Lewis acid comprising thesecond donor material 62 inreceptacle 60. Depending upon the deposition process, this extrinsic metal from thedonor material 72 may combine with the first extrinsic metal supplied fromdonor material 54, may combine with yttrium material supplied to thejet engine component 10 from the second donor material, or may deposit separately on thejet engine component 10. Thereceptacle 71 and a conduit 74 leading from thereceptacle 71 to thereaction chamber 42 are heated withrespective heaters donor material 72 and supply the vapor phase reactant to themain reaction chamber 42. - The
solid donor material 72 provided inreceptacle 71 may be any solid Lewis acid, such as AlCl3, CoCl4, CrCl3, CrF3, FeCl3, HfCl3, IrCl3, PtCl4, RhCl3, RuCl3, TiCl4, ZrCl4, and ZrF4. The Lewis acid may be ACS grade or reagent grade chemical that is high in purity and substantially free of contaminants, such as sulfur. Upon heating, such Lewis acids convert from a dry solid form to a liquid form and, when the temperature of thereceptacle 71 is further increased, convert from the liquid form to a vapor to provide the vapor phase reactant containing the associated extrinsic metal. The vapor phase reactant fromsolid donor material 72 is conveyed or transported through the conduit 74 to themain reaction chamber 42, as diagrammatically indicated by arrows 80. The rate at which the vapor phase reactant fromsolid donor material 72 is provided to themain reaction chamber 42 is regulated by controlling the temperature of thereceptacle 71 with variations in the power supplied toheaters solid donor material 72 may be discontinued by sufficiently reducing the temperature of thereceptacle 71 to halt vaporization or with a valve (not shown) controlling flow through conduit 74. - The vapor phase reactants from
receptacles main reaction chamber 42, so that the extrinsic metals fromsolid donor materials jet engine component 10. The separate control is achievable by, for example, lowering the temperature of eachreceptacle main reaction chamber 42. In addition, the temperature of themain reaction chamber 42 may be controlled so that the vapor phase reactant fromdonor material 54 is controllably present or absent while one or both of thereceptacles main reaction chamber 42. These capabilities permit a vapor phase reactant of, for example, zirconium to be independently supplied fromreceptacle 71 to themain reaction chamber 42 and to, for example, deposit over the aluminide layer 14 (FIG. 3 ) previously formed oncomponent 10 by a deposition process inside themain reaction chamber 42. Such a process may be used, as described above, for forming the zirconium layer that ultimately forms the zirconia layer 26 (FIG. 3 ). - While the present invention has been illustrated by the description of an embodiment thereof and specific examples, and while the embodiment has been described in considerable detail, it is not intended to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and methods and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the scope or spirit of applicant's general inventive concept.
Claims (23)
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AT05851165T ATE545717T1 (en) | 2004-09-16 | 2005-04-13 | ALUMINIDE-COATED TURBO ENGINE COMPONENTS AND METHOD FOR APPLYING SUCH ALUMINIDE COATINGS TO TURBO ENGINE COMPONENTS |
US11/575,105 US7901739B2 (en) | 2004-09-16 | 2005-04-13 | Gas turbine engine components with aluminide coatings and method of forming such aluminide coatings on gas turbine engine components |
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PCT/US2005/012527 WO2006052277A2 (en) | 2004-09-16 | 2005-04-13 | Gas turbine engine components with aluminide coatings and method of forming such aluminide coatings on gas turbine engine components |
EP05851165A EP1802784B1 (en) | 2004-09-16 | 2005-04-13 | Gas turbine engine components with aluminide coatings and method of forming such aluminide coatings on gas turbine engine components |
US11/721,564 US8623461B2 (en) | 2004-09-16 | 2005-12-12 | Metal components with silicon-containing protective coatings substantially free of chromium and methods of forming such protective coatings |
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AT05858676T ATE513939T1 (en) | 2004-09-16 | 2005-12-12 | TURBO ENGINE COMPONENTS COATED WITH SILICON AND CHROME NON-ALUMINIDE COATINGS AND METHOD FOR PRODUCING SUCH NON-ALUMINIDE COATINGS |
US14/147,818 US9157140B2 (en) | 2004-09-16 | 2014-01-06 | Metal components with silicon-containing protective coatings substantially free of chromium and methods of forming such protective coatings |
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US11/575,105 Division US7901739B2 (en) | 2004-09-16 | 2005-04-13 | Gas turbine engine components with aluminide coatings and method of forming such aluminide coatings on gas turbine engine components |
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US11/721,564 Active 2029-05-22 US8623461B2 (en) | 2004-09-16 | 2005-12-12 | Metal components with silicon-containing protective coatings substantially free of chromium and methods of forming such protective coatings |
US14/147,818 Active 2024-12-23 US9157140B2 (en) | 2004-09-16 | 2014-01-06 | Metal components with silicon-containing protective coatings substantially free of chromium and methods of forming such protective coatings |
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US7394136B2 (en) * | 2003-10-10 | 2008-07-01 | Taiwan Semiconductor Manufacturing Co., Ltd. | High performance semiconductor devices fabricated with strain-induced processes and methods for making same |
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US7901739B2 (en) | 2004-09-16 | 2011-03-08 | Mt Coatings, Llc | Gas turbine engine components with aluminide coatings and method of forming such aluminide coatings on gas turbine engine components |
US20080220165A1 (en) * | 2004-09-16 | 2008-09-11 | Aeromet Technologies, Inc. | Gas Turbine Engine Components With Aluminide Coatings And Method Of Forming Such Aluminide Coatings On Gas Turbine Engine Components |
US20080274290A1 (en) * | 2004-09-16 | 2008-11-06 | Aeromet Technologies, Inc. | Metal Components With Silicon-Containing Protective Coatings Substantially Free of Chromium and Methods of Forming Such Protective Coatings |
US8623461B2 (en) | 2004-09-16 | 2014-01-07 | Mt Coatings Llc | Metal components with silicon-containing protective coatings substantially free of chromium and methods of forming such protective coatings |
US20080096045A1 (en) * | 2004-12-13 | 2008-04-24 | Aeromet Technologies, Inc. | Turbine Engine Components With Non-Aluminide Silicon-Containing and Chromium-Containing Protective Coatings and Methods of Forming Such Non-Aluminide Protective Coatings |
US9133718B2 (en) | 2004-12-13 | 2015-09-15 | Mt Coatings, Llc | Turbine engine components with non-aluminide silicon-containing and chromium-containing protective coatings and methods of forming such non-aluminide protective coatings |
US20080193663A1 (en) * | 2007-02-08 | 2008-08-14 | Honeywell International, Inc. | Method of forming bond coating for a thermal barrier coating |
US7989020B2 (en) | 2007-02-08 | 2011-08-02 | Honeywell International Inc. | Method of forming bond coating for a thermal barrier coating |
EP2199424A1 (en) * | 2008-12-19 | 2010-06-23 | Rolls-Royce Corporation | Static chemical vapor deposition of gamma-Ni + gamma'-Ni3Al coatings |
US20100159136A1 (en) * | 2008-12-19 | 2010-06-24 | Rolls-Royce Corporation | STATIC CHEMICAL VAPOR DEPOSITION OF y-Ni + y'-Ni3AI COATINGS |
US20120177908A1 (en) * | 2010-07-14 | 2012-07-12 | Christopher Petorak | Thermal spray coatings for semiconductor applications |
Also Published As
Publication number | Publication date |
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PL1834009T3 (en) | 2017-08-31 |
WO2006036171A1 (en) | 2006-04-06 |
US20080274290A1 (en) | 2008-11-06 |
US20140120266A1 (en) | 2014-05-01 |
US20080220165A1 (en) | 2008-09-11 |
US7901739B2 (en) | 2011-03-08 |
ATE513939T1 (en) | 2011-07-15 |
US8623461B2 (en) | 2014-01-07 |
US9157140B2 (en) | 2015-10-13 |
ATE545717T1 (en) | 2012-03-15 |
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