Method for applying a high-temperature bond coat on a metal substrate, and related compositions and articles
AssigneeGeneral Electric Company
InventorsWayne Charles Hasz, D Sangeeta
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Abstract
A method for applying a bond coat on a metal-based substrate is described. A slurry which contains braze material and a volatile component is deposited on the substrate. The slurry can also include bond coat material. Alternatively, the bond coat material can be applied afterward, in solid form or in the form of a second slurry. The slurry and bond coat are then dried and fused to the substrate. A repair technique using this slurry is also described, along with related compositions and articles.
Claims30
A method for applying a bond coat on a metal-based substrate, comprising the following steps:
- a) applying a slurry which comprises braze material to the substrate, wherein the slurry also contains a volatile component, and wherein the braze material has an avenge particle size in the range of about 20 microns to about 150 microns;
- b) applying bond coat material to the substrate, wherein the slurry comprising the braze material further comprises the bond coat material, so that the braze material and the bond coat material are applied to the substrate simultaneously, wherein said bond coat material comprises at least one material selected from the group consisting of aluminide;
- platinum-aluminide;
- nickel-aluminide;
- platinum-nickel-aluminide;
- an alloy of the formula MCrAlX, where M is selected from the group consisting of Fe, Ni, Co, and mixtures of any of the foregoing and where X is selected from the group consisting of Y, Ta, Si, Hf, Ti, Zr, B, C, and combinations thereof;
- and any combination of the foregoing;
- c) drying the slurry and bond coat material to remove at least a portion of the volatile component;
- and
- d) fusing the braze material and bond coat material to the substrate.
A method for applying a metal aluminide- or MCrAlY-based bond coat on a superalloy substrate, where M is nickel, cobalt, or a mixture thereof, comprising the following steps:
- (I) applying a slurry which comprises a volatile component and a mixture of braze material and bond coat material to the substrate, wherein the braze material contains at least about 40% by weight nickel, and wherein the braze material has an average particle size in the range of about 40 microns to about 80 microns and the bond coat material has an average particle size in the range of about 150 microns to about 300 microns;
- (II) drying the slurry under conditions sufficient to remove at least a portion of the volatile component, forming a green coating;
- and
- (III) brazing the green coating to the substrate;
- wherein said bond coat material comprises at least one material selected from the group consisting of aluminide;
- platinum-aluminide;
- nickel-aluminide;
- platinum-nickel-aluminide;
- an alloy of the formula MCrAlX, where M is selected from the group consisting of Fe, Ni, Co, and mixtures of any of the foregoing and where X is selected from the group consisting of Y, Ta, Si, Hf, Ti, Zr, B, C, and combinations thereof;
- and any combination of the foregoing.
A method for replacing a bond coat applied over a metal-based substrate, comprising the following steps:
- (i) removing the existing bond coat from a selected area on the substrate;
- (ii) applying a slurry which comprises braze material to the selected area, wherein the slurry also contains a volatile component, and wherein the braze material has an average particle size in the range of about 20 microns to about 150 microns;
- (iii) applying additional bond coat material to the selected area, wherein the slurry comprising the braze material further comprises the bond coat material, so that the braze material and the bond coat material are applied to the substrate simultaneously, wherein said bond coat material comprises at least one material selected from the group consisting of aluminide;
- platinum-aluminide;
- nickel-aluminide;
- platinum-nickel-aluminide;
- an alloy of the formula MCralX, where M is selected from the group consisting of Fe, Ni, Co, and mixtures of any of the foregoing and where X is selected from the group consisting of Y, Ta, Si, Hf, Ti, Zr, B, C, and combinations thereof;
- and any combination of the foregoing;
- and
- (iv) fusing the braze material and bond coat material to the selected area.
Dependencies are inferred from the claim text.