Platinum modified NiCoCrAlY bondcoat for thermal barrier coating

Abstract

A turbine engine component has a substrate formed from a nickel based superalloy and a platinum modified NiCoCrAlY bondcoat applied to a surface of the substrate. Two methods for forming the platinum modified NiCoCrAlY bondcoat are described herein.

1 . A method for forming a coating on a substrate comprising the steps of:
 providing a substrate;   depositing a layer of platinum onto a surface of said substrate;   depositing a NiCoCrAlY layer onto said platinum layer; and   heat treating said substrate with said deposited layers to form a platinum modified NiCoCrAlY bondcoat.   
   
   
       2 . The method according to  claim 1 , wherein said substrate providing step comprises providing a substrate formed from a nickel based alloy. 
   
   
       3 . The method according to  claim 1 , wherein said platinum layer depositing step comprises electroplating said platinum layer on said substrate surface. 
   
   
       4 . The method according to  claim 1 , wherein said platinum depositing step comprises depositing a layer of platinum having a thickness in the range of from about 0.01 to 1.0 mil. 
   
   
       5 . The method according to  claim 1 , wherein said platinum in said bondcoat is present in an amount from about 5.0 to 70 wt %. 
   
   
       6 . The method according to  claim 1 , wherein said platinum in said bondcoat is present in an amount from about 10 to 60 wt %. 
   
   
       7 . The method according to  claim 1 , wherein said NiCoCrAlY depositing step comprises depositing said NiCoCrAlY coating using a cathodic arc deposition process. 
   
   
       8 . The method according to  claim 1 , wherein said NiCoCrAlY depositing step comprises depositing a NiCoCrAlY material comprising from about 4.0 to 25 wt % chromium, from about 2.0 to 28 wt % cobalt, from about 5.5 to 15 wt % aluminum, from about 0.1 to 1.6 wt % yttrium, up to about 2.0 wt % hafnium, up to about 2.0 wt % silicon, from about 3.0 to 12 wt % tantalum, from about 1.0 to 12 wt % tungsten, from about 1.0 to 10 wt % rhenium, up to about 2.0 wt % zirconium, up to about 4.0 wt % niobium, up to about 4.0 wt % titanium, from about 0.2 to 6.0 wt % molybdenum, and the balance nickel. 
   
   
       9 . The method according to  claim 1 , wherein said NiCoCrAlY depositing step comprises depositing a NiCoCrAlY material comprising from about 4.0 to 18 wt % chromium, from about 2.0 to 24 wt % cobalt, from about 5.5 to 13.5 wt % aluminum, from about 0.1 to 0.8 wt % yttrium, from about 0.001 to 0.4 wt % hafnium, from about 0.001 to 0.7 wt % silicon, from about 3.0 to 10 wt % tantalum, from about 1.0 to 9.0 wt % tungsten, from about 1.0 to 5.0 wt % rhenium, from about 0.001 to 1.0 wt % zirconium, from about 0.001 to 2.0 wt % niobium, from about 0.001 to 2.0 wt % titanium, from about 0.2 to 4.0 wt % molybdenum, and the balance nickel. 
   
   
       10 . The method according to  claim 1 , wherein said heat treating step comprises heating said substrate with said deposited layers at a temperature in the range of from about 1200 to about 2100 degrees Fahrenheit for a time period in the range of from about 2.0 to 15 hours to form said bondcoat. 
   
   
       11 . The method according to  claim 1 , further comprising applying a ceramic topcoat over said bondcoat having a thickness in the range of from about 1.0 to 50 mils. 
   
   
       12 . The method according to  claim 11 , wherein said ceramic topcoat applying step comprises applying a yttria stabilized zirconia topcoat. 
   
   
       13 . The method according to  claim 11 , wherein said ceramic topcoat applying step comprises applying a zirconia based pyrochlore topcoat. 
   
   
       14 . The method according to  claim 11 , wherein said ceramic topcoat applying step comprises applying a 5 to 60 mol % gadolinia stabilized zirconia topcoat. 
   
   
       15 . The method according to  claim 1 , further comprising applying a ceramic topcoat over said bondcoat having a thickness in the range of from about 3.0 to 15 mils. 
   
   
       16 . The method according to  claim 11 , wherein said ceramic topcoat applying step comprises applying said topcoat using an EB-PVD technique and thereby forming said topcoat with a columnar grained microstructure wherein columnar grains are oriented substantially perpendicular to said substrate surface and extend outwardly from the bondcoat. 
   
   
       17 . A method for forming a coating on a substrate comprising the steps of:
 providing a substrate;   depositing a NiCoCrAlY layer onto a surface of said substrate;   depositing a layer of platinum over said NiCoCrAlY layer; and   heat treating said substrate with said deposited layers to form a platinum modified NiCoCrAlY bondcoat.   
   
   
       18 . The method according to  claim 17 , wherein said substrate providing step comprises providing a substrate formed from a nickel based alloy. 
   
   
       19 . The method according to  claim 17 , wherein said platinum layer depositing step comprises electroplating said platinum layer on said substrate surface. 
   
   
       20 . The method according to  claim 17 , wherein said platinum depositing step comprises depositing a layer of platinum having a thickness in the range of from 0.01 to 1.0 mil. 
   
   
       21 . The method according to  claim 17 , wherein said heat treating step comprises forming said bondcoat so that said platinum in said bondcoat is present in an amount from about 5.0 to 70 wt %. 
   
   
       22 . The method according to  claim 17 , wherein said heat treating step comprises forming said bondcoat so that said platinum in said bondcoat is present in an amount from about 10 to 60 wt %. 
   
   
       23 . The method according to  claim 17 , wherein said NiCoCrAlY depositing step comprises depositing said NiCoCrAlY coating using an cathodic arc deposition process. 
   
   
       24 . The method according to  claim 17 , wherein said NiCoCrAlY depositing step comprises depositing a NiCoCrAlY material comprising from about 4.0 to 25 wt % chromium, from about 2.0 to 28 wt % cobalt, from about 5.5 to 15 wt % aluminum, from about 0.1 to 1.6 wt % yttrium, up to about 2.0 wt % hafnium, up to about 2.0 wt % silicon, from about 3.0 to 12 wt % tantalum, from about 1.0 to 12 wt % tungsten, from about 1.0 to 10 wt % rhenium, up to about 2.0 wt % zirconium, up to about 4.0 wt % niobium, up to about 4.0 wt % titanium, from about 0.2 to 6.0 wt % molybdenum, and the balance nickel. 
   
   
       25 . The method according to  claim 17 , wherein said NiCoCrAlY depositing step comprises depositing a NiCoCrAlY material comprising from about 4.0 to 18 wt % chromium, from about 2.0 to 24 wt % cobalt, from about 5.5 to 13.5 wt % aluminum, from about 0.1 to 0.8 wt % yttrium, from about 0.001 to 0.4 wt % hafnium, from about 0.001 to 0.7 wt % silicon, from about 3.0 to 10 wt % tantalum, from about 1.0 to 9.0 wt % tungsten, from about 1.0 to 5.0 wt % rhenium, from about 0.001 to 1.0 wt % zirconium, from about 0.001 to 2.0 wt % niobium, from about 0.001 to 2.0 wt % titanium, from about 0.2 to 4.0 wt % molybdenum, and the balance nickel. 
   
   
       26 . The method according to  claim 17 , wherein said heat treating step comprises heating said substrate with said deposited layers at a temperature in the range of from about 1200 to about 2100 degrees Fahrenheit for a time period in the range of from about 2.0 to 15 hours to form said bondcoat. 
   
   
       27 . The method according to  claim 17 , further comprising applying a ceramic topcoat over said bondcoat having a thickness in the range of from about 1.0 to 50 mils. 
   
   
       28 . The method according to  claim 17 , further comprising applying a ceramic topcoat over said bondcoat having a thickness in the range of from about 3.0 to 15 mils. 
   
   
       29 . The method according to  claim 27 , wherein said ceramic topcoat applying step comprises applying a yttria stabilized zirconia topcoat. 
   
   
       30 . The method according to  claim 27 , wherein said ceramic topcoat applying step comprises applying a zirconia based pyrochlore topcoat. 
   
   
       31 . The method according to  claim 27 , wherein said ceramic topcoat applying step comprises applying a 5.0 to 60 mol % gadolinia stabilized zirconia. 
   
   
       32 . The method according to  claim 27 , wherein said ceramic topcoat applying step comprises applying said topcoat using an EB-PVD technique and thereby forming said topcoat with a columnar grained microstructure wherein columnar grains are oriented substantially perpendicular to said substrate surface and extend outwardly from the bondcoat. 
   
   
       33 . A turbine engine component comprising:
 a substrate formed from a nickel based superalloy; and   a platinum modified NiCoCrAlY bondcoat applied to a surface of said substrate.   
   
   
       34 . A turbine engine component according to  claim 33 , wherein said bondcoat has a thickness in the range of from 1.0 to 5.0 mils. 
   
   
       35 . A turbine engine component according to  claim 33 , further comprising a ceramic topcoat and a layer of aluminum oxide scale between said ceramic topcoat and said bondcoat, whereby said bondcoat improves adherence of said aluminum oxide scale. 
   
   
       36 . A turbine engine component according to  claim 35 , wherein said ceramic topcoat comprises a yttria stabilized zirconia. 
   
   
       37 . A turbine engine component according to  claim 35 , wherein said ceramic topcoat comprises a zirconia based pyrochlore topcoat. 
   
   
       38 . A turbine engine component according to  claim 35 , wherein said ceramic topcoat comprises a 5 to 60 mol % gadolinia stabilized zirconia. 
   
   
       39 . A turbine engine component according to  claim 35 , wherein said ceramic topcoat has a thickness in the range of from 1.0 to 50 mils and a columnar grained microstructure with columnar grains oriented substantially perpendicular to the surface of the substrate and extending outwardly from the bondcoat and alumina scale. 
   
   
       40 . The turbine engine component according to  claim 39 , wherein said thickness in the range of from 3.0 to 15 mils. 
   
   
       41 . The turbine engine component according to  claim 33 , wherein said bondcoat has a three-dimensional interconnected two-phase microstructure with grain sizes from 0.5 to 30 microns. 
   
   
       42 . The turbine engine component according to  claim 33 , wherein said bondcoat contains from about 5.0 to 70 wt % platinum. 
   
   
       43 . The turbine engine component according to  claim 33 , wherein said bondcoat contains from about 10 to 60 wt % platinum.