Multi-component deposition

• US 20050249888A1
• Filed: 05/07/2004
• Published: 11/10/2005
• Est. Priority Date: 05/07/2004
• Status: Active Grant

• Current Assignee: Rtx Corporation
• Original Assignee: United Technologies Corporation (Raytheon Technologies Corporation d/b/a RTX)
• Inventors: Malashenko, Igor S., Belousov, Igor V., Makhotkin, Alexander V.
• Granted Patent: US 7,404,986 B2
• Time in Patent Office: Days
• US Class Current: 427/585
• CPC Class Codes: B23P 6/007 using only additive methods, e.g. build-up welding
• CPC Class Codes: C23C 14/042 using masks
• CPC Class Codes: C23C 14/16 on metallic substrates or on substrates of boron or silicon
• CPC Class Codes: C23C 14/22 characterised by the process of coating
• CPC Class Codes: C23C 14/24 Vacuum evaporation
• CPC Class Codes: C23C 14/54 Controlling or regulating the coating process
• CPC Class Codes: C23C 16/44 characterised by the method of coating C23C16/04 takes precedence

Abstract

Physical vapor deposition is augmented by chemical vapor deposition from one or more organometallic compounds to deposit multi-component materials. The organometallic compounds may be carbonyls. The process may be used to deposit coatings and repair material on superalloy turbine engine parts.

Claims

1. A method for depositing a deposition material on a part comprising:

placing the part in a deposition chamber;

vaporizing one or more first components for forming the deposition material by electron beam heating; and

vaporizing one or more organometallic compounds for providing one or more second components of the deposition material being codeposited on the part with the first components.

2. The method of claim 1 wherein:

the vaporizing one or more organometallic compounds is via a chemical vapor deposition process.

3. The method of claim 1 wherein:

the one or more first components and one or more second components condense on the part.

4. The method of claim 1 further comprising:

actively controlling a temperature of the part to, in turn, control dissociation of the one or more organometallic compounds.

5. The method of claim 4 wherein:

the temperature of the part is maintained between 600 C and 1050 C; and

the vaporizing of the one or more organometallic compounds comprises heating to between 45 C and 120 C.

6. The method of claim 4 further comprising:

heat treating the part so as to homogenize the deposited deposition material.

7. The method of claim 1 wherein:

the one or more organometallic compounds comprise, at least 50% by weight, carbonyls of one or more refractory elements.

8. The method of claim 1 wherein:

the vaporizing of the one or more first components comprises vaporizing at least one M-Cr—

Al—

Ti alloy; and

the deposition material consists essentially of a nickel- or cobalt-based superalloy.

9. The method of claim 1 wherein:

the one or more first components consist in major part of Ti; and

the one or more second components consist essentially of Mo.

10. The method of claim 1 wherein the deposition material consists essentially of:

at least one of a nickel-or cobalt-based superalloy with 1-20%, by weight, refractory metal addition.

11. The method of claim 1 wherein the deposition material consists essentially of:

at least one M-Cr—

Al—

Ti alloy;

2-20%, by weight, combined of one or more of W, Mo, Re, Pt, Rh, Ru, Os, Ir, Te, and V; and

0-0.3%, by weight, C.

12. The method of claim 1 wherein:

the part has lost first material from a site; and

the deposition material is deposited to the site so as to replace the lost first material.

13. The method of claim 12 wherein:

the deposition material has a first interface with a substrate of the part, a bond strength between the deposition material and the substrate being in excess of 50 ksi.

14. The method of claim 12 wherein:

the part and the deposition material comprise nickel- or cobalt-based superalloys of like nominal composition and having 2-20%, by weight, refractory metal;

the bond strength is between 60 ksi and 90 ksi;

the deposition material has a depth of at least 2.0 mm at the site on the part;

the substrate has a thickness in excess of the depth of the deposition material; and

the substrate comprises original unrepaired material.

15. The method of claim 12 wherein:

the part and the deposition material comprise nickel- or cobalt-based superalloys of like nominal composition and having 2-20%, by weight, refractory metal;

the bond strength is between 60 ksi and 90 ksi;

the deposition material has an average depth of less than 0.75 mm;

the substrate has a thickness in excess of the depth of the deposition material; and

the substrate comprises original unrepaired material.

16. The method of claim 12 further comprising:

applying a mask to a portion of the part surrounding the site prior to deposition; and

removing the mask after the deposition.

17. The method of claim 1 wherein:

the vaporized one or more organometallic compounds are permitted to condense on the part and the deposition material deposited on the part is irradiated via an electron beam to cause electron beam-induced dissociation of the one or more organometallic compounds leaving one or more refractory metals as said one or more second components.

18. An apparatus for depositing material on a workpiece comprising:

a deposition chamber;

means for vaporizing one or more first deposition material components;

means for vaporizing one or more organometallic compounds for providing one or more second deposition material components; and

a control system coupled to the means for vaporizing one or more first deposition material components and the means for vaporizing one or more organometallic compounds and programmed so as to provide feedback loop control of codeposition of the first and second deposition material components to the workpiece.

19. The apparatus of claim 18 further comprising:

means for monitoring a temperature of the workpiece.

20. The apparatus of claim 18 wherein:

the means for vaporizing the one or more first deposition material components comprises an electron beam source directing an electron beam toward an ingot comprising the one or more first deposition material components; and

the means for vaporizing the one or more organometallic compounds comprises a conductive heater for heating the one or more organometallic compounds.

21. The apparatus of claim 18 wherein:

the control system is programmed to provide a varying balance between the one or more first deposition material components and the one or more second deposition material components across a thickness of the deposited material so as to form a predetermined graded composition in the deposited material.

22. An apparatus for depositing deposition material on a workpiece comprising:

a deposition chamber;

a first source of one or more first components of the deposition material heated so as to vaporize the first components; and

a second source comprising one or more organometallic compounds providing one or more second components of the deposition material.

23. The apparatus of claim 22 wherein:

the one or more first components include, by weight;

at least 50% of one or a combination of Ni, Co and Fe;

at least 12% Cr;

at least 6% Al; and

at least 0.5% Ti; and

the one or more second components consist essentially of;

one or more refractory metals and up to 0.3%, by weight, C.

24. The apparatus of claim 22 wherein:

the one or more first components include;

at least 50%, by weight, Ti; and

the one or more second components consist essentially of;

one or more refractory metals and up to 0.1%, by weight, C.

25. A method for codepositing one or more first components and one or more second components comprising:

electron beam physical vapor deposition of the one or more first components; and

chemical vapor deposition of the one or more second components from an organometallic compound.

26. The method of claim 25 wherein the one or more first components comprise, by weight:

at least 50% of one or a combination of Ni, Co, and Fe;

at least 12% Cr;

at least 6% Al; and

at least 0.5% Ti.

27. The method of claim 25 wherein:

the one or more first components are from a single ingot; and

the one or more second components are at least two refractory metal components from at least two different sources of different composition.