Coated article and method for producing coating

Abstract

A coated article and a method for producing a coating are disclosed. Producing the coating includes providing a substrate defining a substrate surface having a substrate erosion resistance and applying a matrix and ceramic particles to the substrate surface. The matrix includes an anodic material having an anodic erosion resistance. The ceramic particles include a first ceramic having a first ceramic erosion resistance and a second ceramic having a second ceramic erosion resistance. The first ceramic erosion resistance is greater than the second ceramic erosion resistance, greater than the anodic erosion resistance, and greater than the substrate erosion resistance. The second ceramic interacts inchoately with the anodic material during the applying to form modified ceramic particles and modified anodic material formations. The modified ceramic particles are capable of forming a passive oxide film. The coated article includes the substrate and the coating on the substrate surface.

1 . A method for producing a coating, comprising:
 providing a substrate defining a substrate surface having a substrate erosion resistance; and   applying a matrix and ceramic particles to the substrate surface, wherein:
 the matrix includes an anodic material having an anodic erosion resistance; and 
 the ceramic particles include:
 a first ceramic having a first ceramic erosion resistance; and 
 a second ceramic having a second ceramic erosion resistance, 
 
   wherein the first ceramic erosion resistance is:
 greater than the second ceramic erosion resistance; 
 greater than the anodic erosion resistance; and 
 greater than the substrate erosion resistance, 
   wherein the second ceramic interacts inchoately with the anodic material during the applying to form modified ceramic particles and modified anodic material formations, and   wherein the modified ceramic particles are capable of forming a passive oxide film.   
     
     
         2 . The method of  claim 1 , wherein the first ceramic erosion resistance yields erosion of the coating of less than about 76 μm over about 48,000 hours of operation under rear stage gas turbine compressor operating conditions. 
     
     
         3 . The method of  claim 1 , wherein the anodic material is selected from a group consisting of Cr 70% Ni 30%  (wt %), a mixture of Ni 80% Al 20%  (wt %) and Ni 95% Al 5%  (wt %), cobalt and aluminum particles in a sacrificial metallic undercoat with a ceramic overcoat, a metallurgically bonded aluminide with an aluminum surface layer, NiCrAl and combinations thereof. 
     
     
         4 . The method of  claim 3 , wherein the anodic material is Cr 70% Ni 30%  (wt %). 
     
     
         5 . The method of  claim 1 , wherein the first ceramic is tungsten carbide and the second ceramic is chromium carbide, chromium nitride or a combination of chromium carbide and chromium nitride. 
     
     
         6 . The method of  claim 5 , wherein:
 the anodic material contains chromium and nickel;   the second ceramic interacts inchoately with the chromium and nickel in the anodic material during the applying to form the modified ceramic particles and the modified anodic material formations; and   the modified ceramic particles include at least one of modified chromium carbide particles having a range of chromium carbide stoichiometries and modified chromium nitride particles having a range of chromium nitride stoichiometries.   
     
     
         7 . The method of  claim 5 , wherein the coating contains from about 30% to about 60% by weight tungsten carbide, from about 20% to about 50% by weight of one or both of chromium carbide and chromium nitride, and balance essentially anodic material. 
     
     
         8 . The method of  claim 1 , wherein the ceramic particles have an average particle diameter ranging from about 0.3 μm to about 5 μm, and the coating has an average distance between the ceramic particles ranging from about 0.2 μm to about 2 μm. 
     
     
         9 . The method of  claim 1 , wherein the substrate is selected from a group consisting of a compressor blade, a compressor vane, a centrifugal pump impeller, and a pipeline. 
     
     
         10 . The method of  claim 1 , wherein producing the coating consists essentially of applying a single matrix of anodic material with ceramic particles dispersed therein. 
     
     
         11 . A coated article, comprising:
 a substrate defining a substrate surface having a substrate erosion resistance; and   a coating on the substrate surface, wherein the coating includes:
 a matrix including an anodic material having an anodic erosion resistance; 
 ceramic particles including:
 a first ceramic having a first ceramic erosion resistance; and 
 a second ceramic having a second ceramic erosion resistance; and 
 
 modified ceramic particles and modified anodic material formations formed by an inchoate interaction between the second ceramic and the anodic material, 
   wherein the first ceramic erosion resistance is:
 greater than the second ceramic erosion resistance; 
 greater than the anodic erosion resistance; and 
 greater than the substrate erosion resistance, and 
   wherein the modified ceramic particles are capable of forming a passive oxide film.   
     
     
         12 . The coated article of  claim 11 , wherein the first ceramic erosion resistance yields erosion of the coating of less than about 76 μm over about 48,000 hours of operation under rear stage gas turbine compressor operating conditions. 
     
     
         13 . The coated article of  claim 11 , wherein the anodic material is selected from a group consisting of Cr 70% Ni 30%  (wt %), a mixture of Ni 80% Al 20%  (wt %) and Ni 95% Al 5%  (wt %), cobalt and aluminum particles in a sacrificial metallic undercoat with a ceramic overcoat, a metallurgically bonded aluminide with an aluminum surface layer, NiCrAl, and combinations thereof 
     
     
         14 . The coated article of  claim 12 , wherein the anodic material is Cr 70% Ni 30%  (wt %). 
     
     
         15 . The coated article of  claim 11 , wherein the first ceramic tungsten carbide and the second ceramic is chromium carbide, chromium nitride or a combination of chromium carbide and chromium nitride. 
     
     
         16 . The coated article of  claim 14 , wherein:
 the anodic material contains chromium and nickel;   the modified ceramic particles and the modified anodic material formations are formed by the inchoate interaction of the second ceramic with the chromium and nickel in the anodic material; and   the modified ceramic particles include at least one of modified chromium carbide particles having a range of chromium carbide stoichiometries and modified chromium nitride particles having a range of chromium nitride stoichiometries,   
     
     
         17 . The coated article of  claim 14 , wherein the coating contains from about 30% to about 60% by weight tungsten carbide, from about 20% to about 50% by weight of one or both of chromium carbide and chromium nitride, and balance essentially anodic material. 
     
     
         18 . The coated article of  claim 11 , wherein the ceramic particles have an average particle diameter ranging from about 0.3 μm to about μm, and the coating has an average distance between the ceramic particles ranging from about 0.2 μm to about 2 μm. 
     
     
         19 . The coated article of  claim 11  wherein the substrate is selected from a group consisting of a compressor blade, a compressor vane, a centrifugal pump impeller, and a pipeline. 
     
     
         20 . The coated article of  claim 11 , wherein the coating consists essentially of a single matrix of anodic material with ceramic particles dispersed therein.