US2016214350A1PendingUtilityA1

Oxidation-Resistant Coated Superalloy

Assignee: PRATT & WHITNEY CANADAPriority: Aug 20, 2012Filed: Aug 19, 2013Published: Jul 28, 2016

Est. expiryAug 20, 2032(~6.1 yrs left)· nominal 20-yr term from priority

Inventors:Joel Larose Alan D. Cetel David A. Litton Brian S. Tryon

C22C 19/057C23C 14/5806B32B 15/01C23C 28/3215C23C 14/025C23C 14/58C22C 5/04C23C 28/3455C23C 28/321C22C 19/05C23C 28/32B32B 15/043C22C 19/03C23C 14/165C23C 30/00Y10T428/12937B32B 15/04Y10T428/12875Y10T428/12944C23C 28/022C22C 19/051C23C 14/14C22C 30/00F01D 5/28Y10T428/12931C23C 30/005F01D 5/288C23C 14/16

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References

Claims

Abstract

A coating-substrate combination includes: a Ni-based superalloy substrate comprising, by weight percent: 2.0-5.1 Cr; 0.9-3.3 Mo; 3.9-9.8 W; 2.2-6.8 Ta; 5.4-6.5 Al; 1.8-12.8 Co; 2.8-5.8 Re; 2.8-7.2 Ru; and a coating comprising, exclusive of Pt group elements, by weight percent: Ni as a largest content 5.8-9.3 Al; 4.4-25 Cr; 3.0-13.5 Co; up to 6.0 Ta, if any; up to 6.2 W, if any; up to 2.4 Mo, if any; 0.3-0.6 Hf; 0.1-0.4 Si; up to 0.6 Y, if any; up to 0.4 Zr, if any; up to 1.0 Re, if any.

Claims

exact text as granted — not AI-modified

What is claimed is: 
     
         1 . An article comprising:
 a Ni-based superalloy substrate comprising, by weight percent: 2.0-5.1 Cr; 0.9-3.3 Mo; 3.9-9.8 W; 2.2-6.8 Ta; 5.4-6.5 Al; 1.8-12.8 Co; 2.8-5.8 Re; 2.8-7.2 Ru; and   a coating comprising, exclusive of Pt group elements, by weight percent: Ni as a largest content 5.8-9.3 Al; 4.4-25 Cr; 3.0-13.5 Co; up to 6.0 Ta, if any; up to 6.2 W, if any; up to 2.4 Mo, if any; 0.3-0.6 Hf; 0.1-0.4 Si; up to 0.6 Y, if any; up to 0.4 Zr, if any; up to 1.0 Re, if any.   
     
     
         2 . The article of  claim 1  wherein:
 the substrate comprises 0.05-0.7 weight percent Hf. 
 
     
     
         3 . The article of  claim 1  wherein:
 the substrate has a 1800° F. &amp; 45 ksi (982° C. &amp; 310 MPa) rupture life of at least 120 hours. 
 
     
     
         4 . The article of  claim 1  wherein:
 the coating comprises exclusive of Pt group elements, by weight percent: 0.4-0.6 said Hf; 0.2-0.4 said Si. 
 
     
     
         5 . The article of  claim 1  wherein:
 the coating has less than 1.0 weight percent overall said platinum group elements combined. 
 
     
     
         6 . The article of  claim 1  wherein:
 in weight percent exclusive of platinum group elements, the coating has less than 1.0 weight percent individually other elements. 
 
     
     
         7 . The article of  claim 1  wherein:
 the substrate falls within one of the broader ranges of Table VI; and 
 the coating falls within the associated broader range of Table VII. 
 
     
     
         8 . The article of  claim 7  wherein:
 the coating and substrate fall within the narrower associated ranges. 
 
     
     
         9 . The article of  claim 1  wherein:
 in weight percent the coating has 6.0≦W+Ta≦13.0 or Ta+W≦0.05. 
 
     
     
         10 . The article of  claim 1  wherein:
 in weight percent the coating has 55.0≦Ni+Cr≦67.0 and Ni≦52; and 
 Cr weight percent in the coating is at least the same as Cr weight percent in the substrate. 
 
     
     
         11 . The article of  claim 1  wherein:
 the coating has said weight percent combined of said Y, Hf, Zr, and Si of 0.5-1.5 weight percent. 
 
     
     
         12 . The article of  claim 1  wherein:
 the coating has 3.0-5.8 said weight percent Ta; and 
 the coating has combined contents, if any, of no more than 6.5% by weight Ru, said Ta, and said Re. 
 
     
     
         13 . The article of  claim 1  wherein:
 the coating has less than 0.50 weight percent Ru, if any. 
 
     
     
         14 . The article of  claim 1  wherein:
 the coating has less than 0.50 said weight percent Re, if any. 
 
     
     
         15 . The article of  claim 1  wherein:
 the coating has less than 0.10 said weight percent Re, if any. 
 
     
     
         16 . The article of  claim 1  wherein:
 a ratio of said substrate weight percent Re to said coating weight percent Re, if any, is in excess of 10.0. 
 
     
     
         17 . The article of  claim 1  wherein:
 a SRZ, if any, is less than 0.001 inch (0.025 mm) thick. 
 
     
     
         18 . The article of  claim 1  being a turbine blade. 
     
     
         19 . The article of  claim 1  wherein:
 the substrate is a single crystal alloy. 
 
     
     
         20 . The article of  claim 1  wherein:
 the substrate has a density of 0.315-0.327 pounds per cubic inch (8.72-9.05 g/cm 3 ). 
 
     
     
         21 . The article of  claim 1  wherein:
 the substrate has a creep resistance of at least 50 F (28 C) greater than that of PWA1484. 
 
     
     
         22 . A method for using the article of  claim 1 , comprising:
 heating the article to a temperature of at least 2000 F (1093 C) for at least 400 hours while an SRZ, if any, remains less than 0.002 inch (0.05 mm) thick.   
     
     
         23 . A method for forming an article, the method comprising:
 providing a substrate, the substrate comprising, by weight percent: nickel as a largest by weight constituent; 2.0-5.1 Cr; 0.9-3.3 Mo; 3.9-9.8 W; 2.2-6.8 Ta; 5.4-6.5 Al; 1.8-12.8 Co; 2.8-5.8 Re; 2.8-7.2 Ru and applying a coating material, the coating material comprising exclusive of Pt group elements, by weight percent:   nickel as a largest by weight constituent; Ni as a largest content 5.8-9.3 Al; 4.4-25 Cr; 3.0-13.5 Co; up to 6.0 Ta, if any; up to 6.2 W, if any; up to 2.4 Mo, if any; 0.3-0.6 Hf; 0.1-0.4 Si; up to 0.6 Y, if any; up to 0.4 Zr, if any; up to 1.0 Re, if any.   
     
     
         24 . The method of  claim 23  further comprising at least one of:
 applying a layer of one or more platinum group elements prior to applying the coating material; and 
 applying a ceramic coating after applying the coating material. 
 
     
     
         25 . The method of  claim 23  wherein:
 the applying is PVD. 
 
     
     
         26 . The method of  claim 23  wherein:
 heating the article to a temperature of at least 2000 F (1093 C) for at least 400 hours while an SRZ, if any, remains less than 0.002 (0.05 mm) inch thick. 
 
     
     
         27 . An article comprising:
 a Ni-based superalloy substrate comprising, by weight percent: 4.0-6.0 Cr; 1.0-2.0 Mo; 4.0-6.0 W; 3.0-7.0 Ta; 5.0-7.0 Al; 11.0-13.0 Co; 4.0-6.0 Re; 1.0-3.0 Ru; 0.1-0.5 Hf; and   a coating comprising, exclusive of Pt group elements, by weight percent: Ni as a largest content 5-11 Al; 3-13 Cr; 9-16 Co; up to 7 Ta, if any; up to 6 W, if any; up to 3 Mo, if any; 0.05-0.7 Hf; 0.1-0.5 Si; up to 0.7 Y, if any; up to 0.7 Zr, if any; up to 0 Re, if any.   
     
     
         28 . An article comprising:
 a Ni-based superalloy substrate comprising, by weight percent: 4.0-6.0 Cr; 1.0-2.0 Mo; 5.0-6.0 W; 5.0-6.0 Ta; 5.0-6.0 Al; 5.0-7.0 Co; 5.0-6.0 Re; 2.0-3.0 Ru; and   a coating comprising, exclusive of Pt group elements, by weight percent: Ni as a largest content 5-11 Al; 3-15 Cr; 9-16 Co; up to 7 Ta, if any; up to 6 W, if any; up to 3 Mo, if any; 0.05-0.7 Hf; 0.1-0.5 Si; up to 0.7 Y, if any; up to 0.7 Zr, if any; up to 0 Re, if any.   
     
     
         29 . An article comprising:
 a Ni-based superalloy substrate comprising, by weight percent: 2.0-3.0 Cr; 2.0-4.0 Mo; 8.0-10.0 W; 2.0-3.0 Ta; 6.0-7.0 Al; 6.0-8.0 Co; 4.0-5.0 Re; 6.0-8.0 Ru; and   a coating comprising, exclusive of Pt group elements, by weight percent: Ni as a largest content 5-11 Al; 3-15 Cr; 9-17 Co; up to 7 Ta, if any; up to 6 W, if any; up to 3 Mo, if any; 0.05-0.7 Hf; 0.1-0.5 Si; up to 0.7 Y, if any; up to 0.7 Zr, if any; up to 0 Re, if any.   
     
     
         30 . An article comprising:
 a Ni-based superalloy substrate comprising, by weight percent: 2.0-3.0 Cr; 1.0-3.0 Mo; 3.0-5.0 W; 3.0-4.0 Ta; 5.0-7.0 Al; 1.0-3.0 Co; 2.0-4.0 Re; 4.0-6.0 Ru; and   a coating comprising, exclusive of Pt group elements, by weight percent: Ni as a largest content 5-11 Al; 3-15 Cr; 9-16 Co; up to 7 Ta, if any; up to 6 W, if any; up to 3 Mo, if any; 0.05-0.7 Hf; 0.1-0.5 Si; up to 0.7 Y, if any; up to 0.7 Zr, if any; up to 0 Re, if any.   
     
     
         31 . An article comprising:
 a Ni-based superalloy substrate comprising, by weight percent: 2.0-3.0 Cr; 2.0-3.0 Mo; 7.0-9.0 W; 2.0-4.0 Ta; 5.0-6.0 Al; 7.0-9.0 Co; 3.0-5.0 Re; 4.0-6.0 Ru; and   a coating comprising, exclusive of Pt group elements, by weight percent: Ni as a largest content 5-11 Al; 3-15 Cr; 9-17 Co; up to 7 Ta, if any; up to 6 W, if any; up to 3 Mo, if any; 0.05-0.7 Hf; 0.1-0.5 Si; up to 0.7 Y, if any; up to 0.7 Zr, if any; up to 0 Re, if any.   
     
     
         32 . An article comprising:
 a Ni-based superalloy substrate comprising, by weight percent: 3.0-4.0 Cr; 0.5-2.0 Mo; 6.0-8.0 W; 4.0-5.0 Ta; 5.0-7.0 Al; 1.0-3.0 Co; 4.0-5.0 Re; 3.0-5.0 Ru; and   a coating comprising, exclusive of Pt group elements, by weight percent: Ni as a largest content 5-11 Al; 3-15 Cr; 9-17 Co; up to 7 Ta, if any; up to 6 W, if any; up to 3 Mo, if any; 0.05-0.7 Hf; 0.1-0.5 Si; up to 0.7 Y, if any; up to 0.7 Zr, if any; up to 0 Re, if any.   
     
     
         33 . An article comprising:
 a Ni-based superalloy substrate comprising, by weight percent: 4.0-6.0 Cr; 1.0-2.0 Mo; 4.0-6.0 W; 6.0-7.0 Ta; 5.0-6.0 Al; 11.0-14.0 Co; 5.0-6.0 Re; 2.0-4.0 Ru; and   a coating comprising, exclusive of Pt group elements, by weight percent: Ni as a largest content 5-11 Al; 3-9 Cr; 9-15 Co; up to 7 Ta, if any; up to 6 W, if any; up to 3 Mo, if any; 0.05-0.7 Hf; 0.1-0.5 Si; up to 0.7 Y, if any; up to 0.7 Zr, if any; up to 0 Re, if any.

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