High-temperature articles and method for making
AssigneeGeneral Electric Company One Reserach Circle
InventorsJi-Cheng Zhao, Don Mark Lipkin
Life of this patent
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Abstract
A coated article, a coating for protecting an article, and a method for protecting an article are provided. The article comprises a metallic substrate and a substantially single-phase coating disposed on the substrate, wherein the coating comprises nickel (Ni) and at least about 30 atomic percent aluminum (Al); the coating further comprises a gradient in Al composition, the gradient extending from a first Al concentration level at an outer surface of the coating to a second Al concentration level at an interface between the substantially single-phase coating and the substrate, wherein the first Al concentration level is greater than the second Al concentration level and the second concentration level is at least about 30 atomic percent Al.
Claims62
An article comprising:
- a metallic substrate;
- and
- a substantially single-phase coating disposed on said substrate, wherein said coating comprises nickel (Ni) and at least about 30 atomic percent aluminum (Al), wherein said coating further comprises a gradient in Al composition, said gradient extending from a first Al concentration level at an outer surface of said coating to a second Al concentration level at an interface between said substantially single-phase coating and said substrate;
- wherein said first Al concentration level is greater than said second Al concentration level and said second concentration level is at least about 30 atomic percent Al.
An article comprising:
- a metallic substrate;
- a substantially single-phase B2-structured nickel aluminide coating disposed on said substrate, wherein said coating comprises Ni, Cr, Zr, up to about 20 atomic percent Co, up to about 20 atomic percent Fe, and at least about 30 atomic percent Al, wherein said coating further comprises a gradient in Al composition, said gradient extending from a first Al concentration level at an outer surface of said coating to a second Al concentration level at an interface between said substantially single-phase coating and said substrate;
- wherein said first Al concentration level is greater than said second Al concentration level and said second concentration level is at least about 30 atomic percent Al.
A coating for protecting an article, said coating comprising:
- a substantially single-phase coating disposed on a substrate, wherein said coating comprises nickel (Ni) and at least about 30 atomic percent aluminum (Al), wherein said coating further comprises a gradient in Al composition, said gradient extending from a first Al concentration level at an outer surface of said coating to a second Al concentration level at an interface between said substantially single-phase coating and said substrate;
- wherein said first Al concentration level is greater than said second Al concentration level and said second concentration level is at least about 30 atomic percent Al.
A coating for protecting an article, said coating comprising:
- a substantially single-phase B2-structured nickel aluminide coating disposed on a substrate, wherein said coating comprises Ni, Cr, Zr, up to about 20 atomic percent Co, up to about 20 atomic percent Fe, and at least about 30 atomic percent Al, wherein said coating further comprises a gradient in Al composition, said gradient extending from a first Al concentration level at an outer surface of said coating to a second Al concentration level at an interface between said substantially single-phase coating and said substrate;
- wherein said first Al concentration level is greater than said second Al concentration level and said second concentration level is at least about 30 atomic percent Al.
A method for protecting an article from a high-temperature oxidative environment, said method comprising:
- providing a substrate;
- disposing a first coating layer onto said substrate, wherein said first coating layer comprises nickel (Ni) and aluminum (Al);
- and
- disposing a second coating layer onto said first coating layer, wherein said second coating layer comprises at least about 90 atomic percent aluminum.
The method of claim 33, wherein disposing said second coating layer comprises disposing said second layer using a physical vapor deposition technique selected from the group consisting of electron beam physical vapor deposition and ion plasma deposition.
The method of claim 33, wherein disposing said second coating layer comprises disposing a layer comprising at least about 95 atomic percent aluminum.
The method of claim 33, wherein disposing said second coating layer comprises disposing a layer consisting essentially of aluminum.
The method of claim 33, wherein disposing said second coating layer comprises disposing a layer having a thickness of at least about 5 micrometers.
The method of claim 33, wherein disposing said first layer comprises disposing said first layer using a technique selected from the group consisting of ion plasma deposition, electron beam physical vapor deposition, thermal spray deposition, and plasma spray deposition.
The method of claim 33, wherein disposing said first layer comprises disposing a first layer further comprising at least one of chromium (Cr), zirconium (Zr), up to about 20 atomic percent cobalt (Co), and up to about 20 atomic percent iron (Fe).
The method of claim 33, wherein disposing said first coating layer comprises disposing a layer having a thickness of greater than about 10 micrometers.
The method of claim 33, further comprising reacting said first coating layer with said second coating layer to form a reacted coating layer.
The method of claim 33, wherein providing said substrate comprises providing at least one of a nickel-based alloy, a cobalt-based alloy, and an iron-based alloy.
The method of claim 33, further comprising disposing a thermal barrier coating over one of said second coating layer and said reacted coating layer.
A method for protecting an article from a high-temperature, oxidative environment, said method comprising:
- providing a metallic substrate;
- disposing a first coating layer onto said substrate, wherein said first coating layer comprises nickel (Ni), aluminum (Al), chromium (Cr), zirconium (Zr), up to about 20 atomic percent cobalt (Co), and up to about 20 atomic percent iron (Fe);
- disposing a second coating layer onto said first coating layer using a physical vapor deposition technique selected from the group consisting of electron beam physical vapor deposition and ion plasma deposition, wherein said second coating layer consists essentially of aluminum;
- and
- reacting said first coating layer with said second coating layer to form a substantially single-phase reacted coating layer comprising a B2-structured nickel aluminide and further comprising a gradient in Al composition, said gradient extending from a first Al concentration level at an outer surface of said reacted coating layer to a second Al concentration level at an interface between said substantially single-phase coating and said substrate, wherein said first Al concentration level is greater than said second Al concentration level and said second concentration level is at least about 30 atomic percent Al.
Dependencies are inferred from the claim text.