High temperature coatings for gas turbines

• US 6,635,362 B2
• Filed: 06/04/2001
• Issued: 10/21/2003
• Est. Priority Date: 02/16/2001
• Status: Expired due to Fees

• Current Assignee: Xiaoci Maggie Zheng
• Original Assignee: Xiaoci Maggie Zheng
• Inventors: Zheng, Xiaoci Maggie
• Primary Examiner(s): Jones, Deborah
• Assistant Examiner(s): MCNEIL, JENNIFER C
• Application Number:
  US09/873,964
• Publication Number:
  US 20020155316A1
• Time in Patent Office: 869 Days
• Field of Search: 428/403, 428/546, 428/548, 428/570, 428/650, 428/651, 428/652, 428/323, 428/328, 428/332, 428/678, 428/680, 416/241.R, 420/442, 420/445, 420/455, 420/460, 420/550
• US Class Current: 428/678
• CPC Class Codes: C23C 30/00 Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process C23C26/00, C23C28/00 take precedence
• CPC Class Codes: F01D 5/288 Protective coatings for blades
• CPC Class Codes: Y10T 428/12028 Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, etc.]
• CPC Class Codes: Y10T 428/12181 Composite powder [e.g., coated, etc.]
• CPC Class Codes: Y10T 428/12458 having composition, density, or hardness gradient
• CPC Class Codes: Y10T 428/12736 Al-base component
• CPC Class Codes: Y10T 428/12931 Co-, Fe-, or Ni-base components, alternative to each other
• CPC Class Codes: Y10T 428/12944 Ni-base component
• CPC Class Codes: Y10T 428/25 Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
• CPC Class Codes: Y10T 428/256 Heavy metal or aluminum or compound thereof
• CPC Class Codes: Y10T 428/26 Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
• CPC Class Codes: Y10T 428/2991 Coated

Abstract

Coating for high temperature gas turbine components that include a MCrAlX phase, and an aluminum-rich phase, significantly increase oxidation and cracking resistance of the components, thereby increasing their useful life and reducing operating costs. The aluminum-rich phase includes aluminum at a higher concentration than aluminum concentration in the MCrAlX alloy, and an aluminum diffusion-retarding composition, which may include cobalt, nickel, yttrium, zirconium, niobium, molybdenum, rhodium, cadmium, indium, cerium, iron, chromium, tantalum, silicon, boron, carbon, titanium, tungsten, rhenium, platinum, and combinations thereof, and particularly nickel and/or rhenium. The aluminum-rich phase may be derived from a particulate aluminum composite that has a core comprising aluminum and a shell comprising the aluminum diffusion-retarding composition.

Claims

1. A high temperature coating composition comprising:

a MCrAlX phase;

an aluminum-rich phase comprising aluminum at a higher concentration than aluminum concentration in the MCrAlX alloy; and

an aluminum phase diffusion-retarding phase;

wherein

M is nickel, cobalt, iron, or a combination thereof; and

X is yttrium, hafnium, tantalum, molybdenum, tungsten, rhenium, rhodium, cadmium, indium, titanium, niobium, silicon, boron, carbon, zirconium, cerium, platinum, or a combination thereof.

2. A high temperature coating composition according to claim 1, wherein the aluminum-rich phase additionally comprises M.

3. A high temperature coating composition according to claim 1, wherein said aluminum diffusion-retarding phase comprises at least one metal selected from the group consisting of cobalt, nickel, yttrium, zirconium, niobium, molybdenum, rhodium, cadmium, indium, cerium, iron, chromium, tantalum, silicon, boron, carbon, titanium, tungsten, rhenium, platinum, hafnium, lanthanum, osmium, iridium, ruthenium, palladium, scandium, and combinations thereof.

4. A high temperature coating composition according to claim 1, wherein said aluminum diffusion-retarding phase comprises rhenium.

5. A high temperature coating composition according to claim 1, wherein said aluminum diffusion-retarding phase comprises nickel.

6. A high temperature coating composition according to claim 1, wherein said aluminum diffusion-retarding phase comprises a combination of nickel and rhenium.

7. A high temperature coating according to claim 1, wherein said at least one aluminum diffusion-retarding phase comprises 10-90 wt. % nickel and 90-10 wt. % rhenium.

8. A high temperature coating according to claim 1, wherein said at least one aluminum diffusion-retarding phase comprises 40-60 wt. % nickel and 60-40 wt. % rhenium.

9. A high temperature coating according to claim 1, wherein the amount of the MCrAlX phase ranges from 50-95 parts by weight, and the amount of the aluminum-rich phase ranges from 5-50 parts by weight.

10. A high temperature coating according to claim 1, wherein the amount of the MCrAlX phase ranges from 70-90 parts by weight, and the amount of the aluminum-rich phase ranges from 10-30 parts by weight.

11. A high temperature coating according to claim 1, wherein the amount of the MCrAlX phase ranges from 85-90 parts by weight, and the amount of the aluminum-rich phase ranges from 10-15 parts by weight.

12. A high temperature coating according to claim 1, wherein the MCrAlX phase comprises no more than 10 wt. % aluminum, and the aluminum-rich phase comprises at least 15 wt. % aluminum.

13. A high temperature coating according to claim 1, wherein the aluminum-rich phase comprises at least 40 wt. % aluminum.

14. A high temperature coating according to claim 1, wherein said aluminum-rich phase comprises 30 wt. % nickel, 20 wt. % rhenium and 50 wt. % aluminum.

15. A high temperature coating composition according to claim 1, wherein said aluminum-rich phase is derived from a particulate aluminum composite comprising:

a core comprising aluminum metal; and

a shell comprising at least one aluminum diffusion-retarding metal.

16. A high temperature coating composition according to claim 15, wherein the core comprises at least 15 wt. % aluminum.

17. A high temperature coating according to claim 15, wherein the core comprises at least 40 wt. % aluminum.

18. A high temperature coating composition according to claim 15, wherein the shell comprises at least one metal selected from the group consisting of rhenium, nickel, lanthanum, hafnium, tantalum, cobalt, chromium, iron, niobium, titanium molybdenum, rhodium, cadmium, indium, silicon, boron, carbon, platinum, osmium, cerium, and combinations thereof.

19. A high temperature coating composition according to claim 15, wherein the shell comprises nickel, rhenium, or a combination thereof.

20. A high temperature coating composition according to claim 15, wherein the shell comprises nickel.

21. A high temperature coating composition according to claim 15, wherein the shell comprises rhenium.

22. A high temperature coating composition according to claim 15, wherein the shell comprises a combination or nickel and rhenium.

23. A high temperature coating composition according to claim 15, wherein the shell comprises a first inner layer and a second outer layer.

24. A high temperature coating composition according to claim 23, wherein the first inner layer comprises rhenium and the second outer layer comprises nickel.

25. A high temperature coating composition according to claim 15, wherein said shell comprises:

10-90 parts by weight nickel; and

90-10 parts by weight rhenium.

26. A high temperature coating composition according to claim 15, wherein said shell comprises:

40-60 parts by weight nickel; and

60-40 parts by weight rhenium.

34. A high temperature coating composition according to claim 1, comprising overall 25-100 wt % M, 5-55 wt % aluminum, and 0.025-36 wt % rhenium.

27. A particulate aluminum composite comprising

a core comprising aluminum metal;

and

a shell comprising rhenium.

28. A particulate aluminum composite according to claim 27, wherein the shell comprises a combination of nickel and rhenium.

29. A particulate aluminum composite according to claim 27, wherein the shell comprises a first inner layer comprising rhenium and a second layer outer comprising nickel.

30. A particulate aluminum composite according to claim 27, wherein said shell comprises:

10-90 parts by weight nickel; and

90-10 parts by weight rhenium.

31. A particulate aluminum composite according to claim 27, wherein said shell comprises:

40-60 parts by weight nickel; and

60-40 parts by weight rhenium.

32. A particulate aluminum composite according to claim 27 comprising overall 30 wt. % nickel, 20 wt. % rhenium and 50 wt. % aluminum.

33. A crack-resistant gas turbine component comprising:

a high temperature coating composition; and

a superalloy substrate,

wherein said high temperature coating composition comprises;

a MCrAlX phase;

an aluminum-rich phase comprising aluminum at a higher concentration than aluminum concentration in the MCrAlX alloy; and

an aluminum diffusion-retarding phase;

M is iron, cobalt nickel, or a combination thereof; and

X is yttrium, hafnium, tantalum, molybdenum, tungsten, rhenium, rhodium, cadmium, indium, titanium, niobium, silicon, boron, carbon, zirconium, cerium, platinum, or a combination thereof.