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US-12624420-B2 - Oxidation and SRZ resistant coatings on nickel superalloys

US12624420B2US 12624420 B2US12624420 B2US 12624420B2US-12624420-B2

Abstract

An article has a nickel-based alloy substrate having, in weight percent: 5.4-7.4 Re; 4.1-5.9 Ru; 3.0-6.2 Cr; 3.0-10.0 Co; 0.5-3.8 Mo; 3.0-6.0 W; 4.6-8.6 Ta; 5.0-6.4 Al; 0.050-0.30 Hf; no more than 0.50 all other elements, if any, individually; and no more than 2.0 all other elements, if any, combined. A nickel-based coating is on the substrate and comprising, in weight percent: 6.0-10.0 Al; 4.0-15.0 Cr; 11.0-15.0 Co; 0.1-1.0 Hf; 0.1-1.0 Si; 0.1-1.0 Y; up to 1.0 Zr if any; up to 7.0 Ta if any; up to 6.0 W if any; no more than 1.0 all other elements, if any, individually; and no more than 4.0 all other elements, if any, combined.

Inventors

  • Joël Larose

Assignees

  • PRATT & WHITNEY CANADA CORP.

Dates

Publication Date
20260512
Application Date
20230612

Claims (20)

  1. 1 . An article comprising: a nickel-based alloy substrate consisting of, in weight percent: 6.2-6.6 Re; 4.7-5.2 Ru; 4.1-5.1 Cr; 5.3-6.8 Co; 0.9-2.7 Mo; 3.8-5.2 W; 5.4-7.9 Ta; 5.5-6.1 Al; 0.050-0.15 Hf; no more than 0.50 all other elements, if any, individually; and no more than 2.0 all other elements, if any, combined; and a nickel-based coating or layer thereof on the substrate consisting of, in weight percent: 6.0-8.0 Al; 4.0-6.0 Cr; 9.0-15.0 Co; 0.1-1.0 Hf; 0.1-1.0 Si; 0.1-1.0 Y; up to 1.0 Zr if any; 5.0-7.0 Ta; 4.0-6.0 W; no more than 0.50 all other elements, if any, individually; and no more than 2.0 all other elements, if any, combined.
  2. 2 . The article of claim 1 wherein: a secondary reaction zone, if any of the substrate is no more than 5.0 micrometers thick.
  3. 3 . The article of claim 1 wherein: the substrate lacks a secondary reaction zone.
  4. 4 . The article of claim 1 wherein: the coating comprises an additive layer and a diffusion layer; and the coating composition is measured in the additive layer.
  5. 5 . The article of claim 1 wherein: the substrate is a single crystal substrate.
  6. 6 . The article of claim 5 wherein: a secondary reaction zone, if any of the substrate is no more than 5.0 micrometers thick.
  7. 7 . The article of claim 6 wherein: the coating comprises an additive layer and a diffusion layer; and the coating composition is measured in the additive layer.
  8. 8 . The article of claim 1 wherein: the coating consists of, in weight percent: 6.3-7.7 Al; 4.1-5.3 Cr; 99.8-14.2 Co; 0.1-0.5 Hf; 0.2-0.8 Si; 0.2-0.8 Y; up to 0.8 Zr if any; 5.0-6.2 Ta; 4.3-5.3 W; no more than 0.50 all other elements, if any, individually; and no more than 2.0 all other elements, if any, combined.
  9. 9 . The article of claim 8 wherein: a secondary reaction zone, if any of the substrate is no more than 5.0 micrometers thick.
  10. 10 . The article of claim 8 wherein: the substrate lacks a secondary reaction zone.
  11. 11 . The article of claim 8 wherein: the coating comprises an additive layer and a diffusion layer; and the coating composition is measured in the additive layer.
  12. 12 . The article of claim 1 wherein: the substrate is a single crystal substrate.
  13. 13 . The article of claim 1 wherein: the nickel-based alloy substrate consists of, in weight percent: 6.2-6.6 Re; 4.7-5.2 Ru; 4.1-5.1 Cr; 5.3-5.9 Co; 2.2-2.7 Mo; 4.8-5.2 W; 5.4-5.8 Ta; 5.5-5.8 Al; 0.050-0.15 Hf; no more than 0.50 all other elements, if any, individually; and no more than 2.0 all other elements, if any, combined.
  14. 14 . The article of claim 13 wherein: the substrate is a single crystal substrate.
  15. 15 . The article of claim 1 wherein: the nickel-based alloy substrate consists of, in weight percent: 6.2-6.6 Re; 4.7-5.2 Ru; 4.1-5.1 Cr; 6.2-6.8 Co; 0.9-1.3 Mo; 3.8-4.2 W; 7.3-7.9 Ta; 5.7-6.1 Al; 0.050-0.15 Hf; no more than 0.50 all other elements, if any, individually; and no more than 2.0 all other elements, if any, combined.
  16. 16 . The article of claim 15 wherein: the coating consists of, in weight percent: 6.3-7.7 Al; 4.1-5.3 Cr; 11.8-14.2 Co; 0.1-0.5 Hf; 0.2-0.8 Si; 0.2-0.8 Y; up to 0.8 Zr if any; 5.0-6.2 Ta; 4.3-5.3 W; no more than 0.50 all other elements, if any, individually; and no more than 2.0 all other elements, if any, combined.
  17. 17 . The article of claim 16 wherein: a secondary reaction zone, if any of the substrate is no more than 5.0 micrometers thick.
  18. 18 . The article of claim 16 wherein: the substrate lacks a secondary reaction zone.
  19. 19 . The article of claim 16 wherein: the coating comprises an additive layer and a diffusion layer; and the coating composition is measured in the additive layer.
  20. 20 . The article of claim 1 wherein: the composition of the substrate is measured away from a diffusion zone with the coating; and the composition of the coating is measured away from a diffusion zone with the substrate.

Description

CROSS-REFERENCE TO RELATED APPLICATION Benefit is claimed of U.S. Patent Application No. 63/351,419, filed Jun. 12, 2022, and entitled “Oxidation and SRZ Resistant Coatings on Nickel Superalloys”, the disclosure of which is incorporated by reference herein in its entirety as if set forth at length. BACKGROUND The disclosure relates to high temperature nickel-based superalloys. More particularly, the disclosure relates to oxidation resistant superalloy coatings for such superalloys. Gas turbine engines (used in propulsion and power applications and broadly inclusive of turbojets, turboprops, turbofans, turboshafts, industrial gas turbines, and the like) often include cast single-crystal nickel-based superalloys are used for turbine section blades. Such alloys are notoriously subject to oxidation and require oxidation-resistant coatings. Example coatings include diffusion aluminides and vapor deposited MCrAlY coatings. Such coatings may be used alone (commonly on components that are not internally cooled) or may be used as bondcoats for ceramic coatings (commonly on components that are internally cooled). However, many coatings exhibit excessive secondary reaction zone (SRZ) formation with the substrate material. Prior blade substrate and coating combinations that have been proposed include those in US Pub. Nos. 2006/0093851 A1, 2009/0075115 A1, and 2009/0274928 A1. Metallic coatings may be the outermost layer (subject to oxidation layers, etc.) or may be bond coats for ceramic thermal barrier coatings (TBC) deposited thereatop. US Pub. No. 2021/0001603 A1 (the '603 publication), of Larose et al., published Jan. 7, 2021 and entitled “Oxidation-Resistant Coated Superalloy” the disclosure of which is incorporated by reference herein in its entirety as if set forth at length, discloses a series of castable Ru-containing single-crystal (SX) nickel based (Ni largest element content by weight) superalloys designated CPW-V 1 through CPW-V 11 and MCrAlY overlay coatings designated CPW-C1 through CPW-C6. Various combinations presented particularly advantageous oxidation and SRZ resistance. The substrate alloys were purported to have advantageous creep properties relative to Ru-free PWA1484. Additionally, the Japan National Institute for Materials Science (NIMS) has developed an Ru-containing alloy designated TMS-196 and a subsequent derivative designated as TMS-238. These are respectively designated as 5th and 6th generation alloys. TMS-196 and TMS-238 are disclosed in Kawagishi, Kyoko, An-Chou Yeh, Tadaharu Yokokawa, Toshiharu Kobayashi, Yutaka Koizumi and Hiroshi Harada, “Development of an Oxidation-Resistant High-Strength Sixth-Generation Single-Crystal Superalloy TMS-238”, Superalloys 2012: 12th International Symposium on Superalloys, October, 2012, pp 189-195, The Minerals, Metals & Materials Society (TMS), McCandless, Pennsylvania (Kawagishi et al. 2012). Also see US Pub. No. 2011/0142714 A1 (the '714 publication) (Ex. 1 re. TMS-238 and Ref. Ex. 9 re. TMS-196) and US Pub. No. 2011/171057 A1 (the '057 publication) (disclosing deeper background art). A coating for TMS-196 is disclosed in U.S. Pat. No. 8,221,901B2 (the '901 patent). Coatings for TMS-238 are disclosed in Matsumoto, Kazuhide & Kawagishi, Kyoko & Harada, Hiroshi, “Development of Thermal Barrier Coating System Using EQ Coating for Advanced Single Crystal Superalloys: Proceedings of the 13th Interational Symposium of Superalloys”, July, 2016, pp. 279-284, TMS (The Minerals, Metals & Materials Society), Warrendale, PA (Matsumoto et al. 2016). Other coatings are seen in US Pub. No. 2013/202913 A1 (the '913 publication). In the '901 patent, Table 6 Example 28 TMS-196 exhibits 25 micrometers SRZ thickness with Coating H. This is lower than the '901 patent reference examples, but still higher than the best performing '901 patent examples (1 micrometer or less) for other substrates. SUMMARY One aspect of the disclosure involves an article comprising a nickel-based alloy substrate comprising (or alternatively consisting of or consisting essentially of), in weight percent: 5.4-7.4 Re; 4.1-5.9 Ru; 3.0-6.2 Cr; 3.0-10.0 Co; 0.5-3.8 Mo; 3.0-6.0 W; 4.6-8.6 Ta; 5.0-6.4 Al; 0.050-0.30 Hf; no more than 1.0 (optionally more narrowly 0.50) all other elements, if any, individually; and no more than 4.0 (optionally more narrowly 2.0) all other elements, if any, combined. A nickel-based coating is on the substrate and comprising (or alternatively consisting of or consisting essentially of), in weight percent: 6.0-10.0 Al; 4.0-15.0 Cr; 11.0-15.0 Co; 0.1-1.0 Hf; 0.1-1.0 Si; 0.1-1.0 Y; up to 1.0 Zr if any; up to 7.0 Ta if any; up to 6.0 W if any; no more than 1.0 (optionally more narrowly 0.50) all other elements, if any, individually; and no more than 4.0 (optionally more narrowly 2.0) all other elements, if any, combined. In a further embodiment of any of the foregoing embodiments, additionally and/or alternatively, a secondary reaction zone, if any of the substrate is no mo