Apparatus and method for introducing small amounts of refractory elements into a vapor deposition coating

A vapor deposition apparatus (10) adapted to deposit a vapor-deposited coating (71) containing a refractory element in greater than trace amounts, said vapor deposition apparatus comprising:

• a) a vapor deposition source material, said vapor deposition source material comprising a first material (20), said first material comprising a refractory material, said refractory material being alloyed with at least two elements, and a second material (30) comprising at least two elements to be evaporated to form a vapor-deposited material, wherein said two elements in said second material (30) that are to be evaporated are the same as said two elements contained in said first material (20);
• b) a crucible (45) having an open top, said crucible being capable of containing said vapor deposition source, wherein said first material (20) and said second material (30) are disposed in said chamber such that said first material is positioned over said second material and at least partially covers said second material;
• c) a base material (50) located vertically above said open top;
• and
• d) at least one heating means (60), said heating means being capable of supplying sufficient heat to create a molten zone (55) in said first material (20), wherein said molten zone (55) contacts said second material, thereby creating a second molten zone (56) in said second material (30),
• whereby said two elements in said second material (30) and said refractory material are evaporated from said crucible (45), thereby forming a vapor stream that impinges upon said base material (50) and condenses thereon, thereby forming said vapor-deposited coating (71) containing said refractory material in greater than trace amounts, said third material, and said fourth material.

A method of vapor-depositing a coating on a base material (50), said coating comprising at least two elements and a refractory material, wherein said refractory material comprising greater than 0.05 atomic percent of said vapor-deposited coating, the method comprising the steps of:

• a) providing a source material, said source material comprising a first material (20), said first material comprising at least two elements, said refractory element being alloyed therewith, and a second material, said second material (30) comprising at least two elements;
• b) placing said source material in a crucible (45) such that said first material is positioned over said second material and at least partially covers said second material;
• c) providing a base (50) upon which said vapor-deposited coating is to be deposited;
• d) positioning said base vertically above an opening in the crucible (45);
• and
• e) heating said first material (20), thereby creating a molten zone (55) in said first material (20), wherein said molten zone contacts said second material (30), thereby creating a second molten zone (56) within said second material (30),
• wherein said two elements in said second material (30) are transported through said molten zone (55), wherein said refractory material and said two elements in said second material (30) are evaporated from said source material and are condensed upon said base material (50), thereby forming said vapor-deposited coating (71).

A method of vapor-depositing (71) a coating on a base material (50), said coating comprising at least two elements and a refractory material, wherein said refractory material comprising greater than 0.05 atomic percent of said vapor-deposited coating, the method comprising the steps of:

• a) selecting a vapor-deposition source material, wherein said vapor deposition source material comprises a first material (20), said first material comprising a refractory material, said refractory material being alloyed with at least two elements, and a second material (30) comprising at least two elements to be evaporated to form a vapor-deposited material, wherein said two elements in said second material (30) that are to be evaporated are the same as said two elements contained in said first material (20);
• b) placing said vapor-deposition source material in a crucible (45) such that said first material (20) is positioned over said second material (30) and at least partially covers said second material (30);
• c) providing a base (50) upon which said vapor-deposited coating (71) is to be deposited;
• d) positioning said base (50) vertically above an opening in the crucible (45);
• and
• e) heating said first material (20), thereby creating a molten zone (55) in said first material (20), wherein said molten zone (55) contacts said second material (30), thereby creating a second molten zone (55) within said second material (30),
• wherein said two elements in said second material (30) are transported through said molten zone (55), wherein said refractory material and said two elements in said second material (30) are evaporated from said source material and are condensed upon said base material (50), thereby forming said vapor-deposited coating (71).