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US 10,704,133 B2Granted
Coated article and method for making
AssigneeGeneral Electric Company
InventorsAndrew Joseph Detor, Richard DiDomizio, James Anthony Ruud, Soumya Nag
Life of this patent
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Abstract
A system and method described herein relate to applying an overlay metal-based coating to a metal-based substrate. An article is provided, which includes a metal-based substrate having an overlay metal-based coating disposed on the substrate at an interface. The interface is configured such that a crack formed within the overlay metal-based coating and approaching the interface has a propagation path that is more energetically favorable along the interface than through the interface and into the metal-based substrate.
Claims10
An article, comprising:
- a metal-based substrate having an overlay metal-based coating disposed on the substrate at an interface having an interface toughness, wherein the interface is configured such that a crack formed within the overlay metal-based coating and approaching the interface has a propagation path that is more energetically favorable along the interface than through the interface and into the metal-based substrate, wherein the interface toughness is in a range defined by an upper bound and a lower bound, wherein the lower bound is in a lower bound range from about 0.05 MPa√{square root over (m)} to about 0.2 MPa√{square root over (m)} and wherein the upper bound is 0.2*ΔKthMPa√{square root over (m)}, where ΔKth is the fatigue crack growth threshold stress intensity of the substrate.
An article, comprising:
- an overlay metal-based coating on a metal-based substrate, the overlay metal-based coating including a nickel-based alloy, a cobalt-based alloy, or any combination including one or more of these, the metal-based substrate including a nickel-based alloy, wherein the interface toughness between the overlay metal-based coating and the metal-based substrate is selected to have a lower bound of 0.1 MPa√{square root over (m)} and an upper bound of 0.25*ΔKthMPa√{square root over (m)}, where ΔKth is the fatigue crack growth threshold stress intensity of the substrate, and wherein responsive to a crack within the overlay metal-based coating, the interface toughness is configured such that the crack formed within the overlay metal-based coating and approaching an interface between the overlay metal-based coating and the metal-based substrate has a propagation path that is more energetically favorable along the interface than through the interface and into the metal-based substrate.
A method, comprising:
- applying an overlay metal-based coating on a metal-based substrate, wherein the interface between the overlay metal-based coating and metal-based substrate is configured such that a crack formed within the overlay metal-based coating and approaching the interface has a propagation path that is more energetically favorable along the interface than through the interface into the metal-based substrate, and wherein the overlay metal-based coating comprises a nickel-based alloy, a cobalt-based alloy, an iron-based alloy, or any combination including one or more of these wherein the metal-based substrate comprises a nickel-based alloy, a cobalt-based alloy, an iron-based alloy, or a combination including one or more of these, and wherein the interface between the overlay metal-based coating and the metal-based substrate has an interface toughness in a range defined by an upper bound and a lower bound, wherein the lower bound is in a lower bound range from about 0.05 MPa√{square root over (m)} to about 0.2 MPa√{square root over (m)}, and wherein the upper bound is 0.2*ΔKthMPa√{square root over (m)}, where ΔKth is the fatigue crack growth threshold stress intensity of the substrate.
A method, comprising:
- applying an overlay metal-based coating on a metal-based substrate using a high velocity air fuel (HVAF) spray gun, the overlay metal-based coating including a nickel-based alloy, a cobalt-based alloy, or any combination including one or more of these, the metal-based substrate including a nickel-based alloy, wherein the interface toughness between the overlay metal-based coating and the metal-based substrate is in a range defined by an upper bound and a lower bound, wherein the lower bound is in a lower bound range from about 0.05 MPa√{square root over (m)} to about 0.2 MPa√{square root over (m)}, and wherein the upper bound is 0.2*ΔKthMPa√{square root over (m)}, where ΔKth is the fatigue crack growth threshold stress intensity of the substrate, the interface toughness of the article being based on a stand off distance of the HVAF spray gun as the overlay metal-based coating is applied to the metal-based substrate, responsive to a crack within the overlay metal-based coating, the interface toughness of the article is configured such that the crack formed within the overlay metal-based coating and approaching an interface between the overlay metal-based coating and the metal-based substrate has a propagation path that is more energetically favorable along the interface than through the interface and into the metal-based substrate.
Dependencies are inferred from the claim text.