Zinc-diffused alloy coating for corrosion/heat protection
First Claim
1. A method for forming a corrosion and heat protective coating on a substrate comprising the steps of:
- forming a nickel base coating layer on said substrate;
applying a layer of zinc over said nickel base coating layer;
diffusing the zinc into said nickel base coating layer; and
said diffusing step comprising carrying out a thermal diffusion cycle in at least one of an atmospheric and an inert gas oven at a temperature in the range of 600 to 800°
F. for a time of at least 100 minutes.
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Accused Products
Abstract
The present invention relates to a zinc-diffused nickel alloy coating for corrosion and heat protection and to a method for forming such a coating. The coating method broadly comprises the steps of forming a plain nickel or nickel alloy coating layer on a substrate, applying a layer of zinc over the nickel or nickel alloy coating layer, and thermally diffusing the zinc into the nickel alloy coating layer. The coating method may further comprise immersing the coated substrate in a phosphated trivalent chromium conversion solution either before or after the diffusing step. The substrate may be a component used in a gas turbine engine, which component is formed from a steel material.
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Citations
21 Claims
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1. A method for forming a corrosion and heat protective coating on a substrate comprising the steps of:
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forming a nickel base coating layer on said substrate;
applying a layer of zinc over said nickel base coating layer;
diffusing the zinc into said nickel base coating layer; and
said diffusing step comprising carrying out a thermal diffusion cycle in at least one of an atmospheric and an inert gas oven at a temperature in the range of 600 to 800°
F. for a time of at least 100 minutes.- View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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17. A method for forming a corrosion and heat protective coating on a substrate comprising the steps of:
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forming a nickel base coating layer on said substrate;
applying a layer of zinc over said nickel base coating layer;
diffusing the zinc into said nickel base coating layer;
immersing said substrate in a phosphate trivalent chromium conversion solution; and
said immersing step being performed after said zinc layer applying step and before said diffusion step.
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- 18. A substrate having at least one surface and a zinc diffused nickel alloy coating on said at least one surface, said coating having a nickel or nickel alloy layer into which zinc atoms have diffused and a zinc layer into which nickel atoms have diffused, and said nickel alloy being formed from a nickel cobalt alloy having a cobalt content in the range of 7.0 to 40 wt %.
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20. A method for forming a corrosion and heat protective coating on a substrate comprising the steps of:
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forming a nickel base coating on said substrate;
applying a layer of zinc over said nickel base coating layer;
diffusing the zinc into said nickel base coating layer; and
atmospheric and an inert gas oven at a temperature of at least 600°
F. for a time sufficient to diffuse said zinc into said nickel base coating.- View Dependent Claims (21)
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Specification