Metal coat (variants) and method for coating thereof

FIELD: metal coats, in particular for gas turbine engines operating at high temperature.

SUBSTANCE: claimed metal coat contains (mass %) cobalt up to 18; chromium 3.0-18; aluminum 5.0-15; yttrium 0.1-1.0; hafnium up to 0.6; silicium up to 0.3; tantalum 3/0-10; tungsten up to 9.0; rhenium 1.0-6.0, molybdenum up to 10, and balance - nickel. Method of invention includes providing of support from at least one metal materials based on nickel, cobalt or iron followed by application of coating layer.

EFFECT: coats of high oxidation resistance and endurance strength.

33 cl, 1 tbl

 

The technical field to which the invention relates.

The present invention relates to metal coating having oxidation resistance and fatigue strength, intended for the protection of elements of gas turbine engines operating at high temperatures.

The level of technology

For protection against oxidation of the elements of gas turbine engines exposed to high temperatures, have developed various metallic coating. The basis of these coatings often are a variety of aluminide compositions, including metal materials based on Nickel or cobalt. In an alternative embodiment, the base composition may be a layer of deposited coating composition MCrAlY, where M stands for Nickel, cobalt, iron or a combination of these materials. These coatings have inherent weaknesses that do not allow you to use them for more new, advanced features of the gas turbine. Diffuse aluminides along with good fatigue strength (fatigue resistance) typically do not have the resistance to oxidation at very high temperatures over 1100° (2000°F). The application of the coating composition MCrAlY is limited due to their significantly low fatigue strength. The introduction of active elements in the coating composition MCrAlY allows not only activesky oxidation resistance, but also makes them quite suitable for use as a binder in ceramic coatings, creating a thermal barrier. As the closest analogue of the present invention is considered patent RU 2149202 published 20.05.2000, in which is disclosed a protective layer containing chromium, gallium, and optionally aluminum, silicon, yttrium, scandium, rare earth elements, and the basis, including the choice of iron, cobalt or Nickel. However, the known technical solution does not allow to minimize the difference in the degree of thermal expansion between the coating and the alloy used, in particular, for the manufacture of elements of gas turbine engines. While aluminides and coating composition MCrAlY used for a wide range of tasks, a new coating that can combine the advantages of both materials, directly intended for use in the promising elements of gas turbines, where fatigue, tensile load and oxidation should be kept to a minimum.

The invention

Accordingly, the present invention is the creation of a composition (composition) of the metallic coating having a high oxidation resistance and fatigue strength.

Another objective of the present invention is to provide a coating composition with a smaller difference in thermal expansion between the coating and the conventional alloy, used for the manufacture of turbines.

The above objectives are achieved by means of the totality of characteristics of the attached claims, describing the composition of the coatings and the method of coating a substrate of at least one of metallic materials based on Nickel, cobalt or iron in accordance with the present invention.

In General, in accordance with the present invention offers a metallic coating and method of applying on a substrate covering layer, which create through composition mainly of the following composition: up to 18 wt.% cobalt, from 3.0 to 18 wt.% chromium, 5.0 to 15 wt.% aluminum, from 0.1 to 1.0 wt.% yttrium, up to 0.6 wt.% hafnium, up to 0.3 wt.% silicon, from 3.0 to 10 wt.% tantalum, up to 9.0 wt.% tungsten, 1.0 to 6.0 wt.% rhenium, up to 10 wt.% molybdenum, and the remainder is Nickel. The total content of tantalum and tungsten in the coating composition in accordance with the present invention lies in the range from 3.0 to 16 wt.%.

Other features metallic coatings, resistant to corrosion and fatigue, in accordance with the present invention, as well as other objectives and advantages inherent in them, are set out in the following detailed description.

Information confirming the possibility of carrying out the invention

Elements of gas turbine engines are made of alloys based on Nickel, cobalt and iron. Because of the extremely high temperatures of operation of these elements, they need a protective coating. The composition of such coatings should minimize fatigue loads acting on these elements, and at the same time to provide maximum resistance to oxidation. The coating must also be such that the difference in the degree of thermal expansion between the coating and the alloy(s)used for manufacturing elements of gas turbine engines, was the lowest. Different degrees of thermal expansion and is one of the reasons of deterioration of the fatigue strength of the coating composition MCrAlY.

In accordance with the present invention is the development of metallic coatings was aimed at reducing the difference in the degree of thermal expansion and providing the most close to the desired level of resistance to oxidation and fatigue. Moreover, the data of the metal coating, which is applied in the form of a covering layer on a substrate, generated from at least one of metallic materials based on Nickel, cobalt or iron, contain mostly in the General case up to 18 wt.% cobalt, from 3.0 to 18 wt.% chromium, 5.0 to 15 wt.% aluminum, from 0.1 to 1.0 wt.% yttrium, up to 0.6 wt.% hafnium, up to 0.3 wt.% silicon, from 3.0 to 10 wt.% tantalum, up to 9.0 wt.% tungsten, 1.0 to 6.0 wt.% rhenium, up to 10 wt.% molybdenum, and the rest is Nickel. The content of tantalum and tungsten in the overall composition of these coatings is in the range from 3.0 to 16 wt.%.

In accordance with the above generic composition of the coatings, which are in accordance with the invention is applied on a substrate, the first of their family, especially suitable for application to the elements of gas turbine engines, mainly contains up to 15 wt.%, preferably up to 2.0 wt.%, cobalt; from 5.0 to 18 wt.%, preferably from 10 to 15 wt.%, chromium; from 5.0 to 12 wt.%, preferably from 6.0 to 10 wt.%, aluminum, 0.1 to 1.0 wt.%, preferably from 0.2 to 0.7 wt.%, yttrium; up to 0.6 wt.%, preferably from 0.2 to 0.6 wt.%, hafnium; up to 0.3 wt.%, preferably 0.1 wt.% or less of silicon; from 3.0 to 10 wt.%, preferably from 5.0 to 7.0 wt.%, tantalum; up to 5.0 wt.%, preferably from 1.0 to 4.0 wt.%, tungsten; from 1.0 to 6.0 wt.%, preferably from 1.0 to 3.5 wt.%, rhenium, up to 10 wt.%, preferably 4.0 wt.% or less, molybdenum, and the remainder is Nickel. The total content of tantalum and tungsten in the data metal coating lies in the range from 3.0 to 12 wt.% and preferably in the range from 5.0 to 9.0 wt.%.

Among the coatings of the first family are particularly suitable coating composition contains a 12.5 wt.% chromium, 8 wt.% aluminum, from 0.4 to 0.7 wt.% yttrium, 0.4 wt.% hafnium, 6.0 wt.% tantalum, 2.0 wt.% tungsten, 2.0 wt.% rhenium, and the rest of sostavlenie.

The second family of compounds for metal coatings, which are in accordance with the invention is applied to the substrate, contains from 2.0 to 18 wt.%, preferably from 8.0 to 12 wt.%, cobalt; from 3.0 to 10 wt.%, preferably from 4.0 to 6.5 wt.%, chromium; from 5.5 to 15 wt.%, preferably from 7.5 to 12.5 wt.%, aluminum, 0.1 to 1.0 wt.%, preferably from 0.2 to 0.7 wt.%, yttrium; up to 0.6 wt.%, preferably from 0.2 to 0.6 wt.%, hafnium; up to 0.3 wt.% silicon; from 3.0 to 10 wt.%, preferably from 5.0 to 7.0 wt.%, tantalum; from 1.0 to 9.0 wt.%, preferably from 4.2 to 5.8 wt.%, tungsten; from 1.0 to 5.0 wt.%, preferably from 2.3 to 3.7 wt.%, rhenium; from 0.2 to 4.0 wt.%, preferably from 1.4 to 2.0 wt.%, molybdenum, and the remainder is Nickel. The total content of tantalum and tungsten in the data metal coating lies in the range from 3.0 to 12 wt.% and preferably in the range from 5.0 to 9.0 wt.%.

Among the coatings of the second family are particularly suitable coating composition contains 10.5 wt.% cobalt, 5.0 wt.% chromium, and 9.0 wt.% aluminum, 0.4 to 0.7 wt.% yttrium, 0.4 wt.% hafnium, 0.1 wt.% silicon, 6.0 wt.% tantalum, 5.0 wt.% tungsten, 3.0 wt.% rhenium, 1.7 wt.% molybdenum, and the remainder is Nickel.

Cause deterioration of the fatigue strength of the coating lies in its excessive thickness. Common methods of applying the covering layer include thermal spraying processes, such as the plasma spraying under low pressure (PNND), when the thickness of the coating lies in the range from 0.1 to 0.3 mm (0.004 to a 0.012 inch). Using the processes of the cathode plasma-arc spraying is possible coating of the above composition with a thickness of 0.05 mm (0.002 inches). Methods of coating in accordance with the present invention by means of cathode plasma-arc spraying is described in U.S. patent No. 5972185; 5932078; 6036828; 5792267 and 6224726, the common feature of which is a reference to this method. Can also be used and other methods of coating, including other processes, plasma deposition, such as magnetron sputtering and electron-beam plasma spraying. When the coating thickness is not critical, can be applied to the processes of thermal spraying such as plasma spraying under low pressure, and the processes of deposition, high velocity oxy-fuel stream.

The coating having the composition in accordance with the present invention, showed resistance to thermal fatigue at the level of the most advanced diffuse aluminide coatings. The table below shows comparative test results of samples of the coating compositions according to the present invention and other compounds in the process of cyclic oxidation in the flame of the burner at a temperature of 1150°With (2100°F).

Test cyclic oxidation in the flame of the burner at a temperature of 1150°With (2100°F)
Sample NThickness (mm)The time to failure of the coating (hours)The time to failure of the coating (hours)**The time between system failures (hours)The time between system failures (hours)**
      
7010,0752320157327131839
7020,0794105264862854055
7030,0691591117919321431
6990,0843060185536222195
7000,0551170108813991301
6970,069828181045871
6950,0718265901315939
6960,062676552805 657
PWA 2750,05115115366366
Notes:

** When making the coating thickness of 0.05 mm (2 mil).

The samples made from a material 701, had the following composition: 12.5 wt.% chromium, 8.0 wt.% aluminum, from 0.4 to 0.7 wt.% yttrium, 0.4 wt.% hafnium, 6.0 wt.% tantalum, 2.0 wt.% tungsten, 2.0 wt.% rhenium, the rest was a Nickel. The samples made from a material 702, had the following composition: 10.5 wt.% cobalt, 5.0 wt.% chromium, and 9.0 wt.% aluminum, from 0.4 to 0.7 wt.% yttrium, 0.4 wt.% hafnium, 0.1 wt.% silicon, 6.0 wt.% tantalum, 5.0 wt.% tungsten, 3.0 wt.% rhenium, 1.7 wt.% molybdenum, and the rest was a Nickel.

The samples indicated by the number 703, had the following composition: 7.0 wt.% chromium, 6.0 wt.% aluminum, 5.5 wt.% tungsten, 4.0 wt.% tantalum, 2.0 wt.% rhenium, about 4.0 wt.% ruthenium, 0.5 wt.% molybdenum, 0.4 wt.% hafnium, 0.25 wt.% yttrium, and the rest was a Nickel.

Samples marked with number 699, had a NiCoCrAlY composition containing rhenium and tantalum. Samples marked with numbers 700, 697, 695, and 696, had the composition of NiAl containing from 2 to 4 wt.% chromium, from 0.2 to 0.6 wt.% yttrium and 0.4 wt.% hafnium. Samples denoted by PWA 275, was the standard aluminides NiAl with low activity.

Under the terms of the test samples was for 57 minutes at a temperature of 1150#x000B0; (2100°F) and every hour, was cooled with compressed air for 3 minutes. The burner was supplied pre-heated compressed air is mixed with jet fuel JP8 for heating samples under dynamic conditions.

Thus, in accordance with the present invention offers a metallic coating having oxidation resistance and fatigue strength, which fully meets the above objectives can be obtained the above-mentioned means, and has the aforementioned advantages. Since the description of the present invention was covered by a special version of its implementation, specialists in the art will become apparent and other alternative embodiments, variations and modifications of the invention upon reading the foregoing description. Accordingly, the invention was created in order to cover these alternative embodiments, variations and modifications lying within the scope of the claims defined by the attached claims.

1. Metallic coating having oxidation resistance and fatigue resistance, characterized in that it has the following composition, wt.%:

Cobalt under 18

Chrome 3,0-18

Aluminum 5,0 - 15

Yttrium 0,1 - 1,0

Hafnium-0.6

Silicon 0.3

Tantalum 3,0 - 10

The tungsten To 9.0

Rhenium 1,0 - 6,0

Molybdenum Up to 10

Nickel Else

2. Metallic coating according to claim 1, characterized in that the total content of tantalum and tungsten is from 3.0 to 16 wt.%.

3. Metallic coating according to claim 1, characterized in that the content of cobalt is less than 15 wt.%, the chromium content ranges from 5.0 to 18 wt.%, the aluminum content ranges from 5.0 to 12 wt.%, and the tungsten content is less than 5.0 wt.%.

4. Metallic coating according to claim 1, characterized in that the content of cobalt is from 2.0 to 18 wt.%, containing chromium is from 3.0 to 10 wt.%, the aluminum content ranges from 5.5 to 15 wt.%, the content of rhenium is from 1.0 to 5.0 wt.%, and the molybdenum content is from 2.0 to 4.0 wt.%.

5. Metallic coating according to claim 1, characterized in that the total content of tantalum and tungsten is from 4.0 to 16 wt.%.

6. Metal coating, characterized in that it has basically the following composition, wt.%:

Cobalt 15

Chrome 5,0 - 18

Aluminum 5,0 - 12

Yttrium 0,1 - 1,0

Hafnium-0.6

Silicon 0.3

Tantalum 3,0 - 10

The tungsten To 5.0

Rhenium 1,0 - 6,0

Molybdenum Up to 10

Nickel Else

7. Metallic coating according to claim 6, characterized in that the total content of tantalum and tungsten composition is employed, from 3.0 to 12 wt.%.

8. Metallic coating according to claim 6, characterized in that the total content of tantalum and tungsten is from 5.0 to 9.0 wt.%.

9. Metallic coating according to claim 6, characterized in that the content of cobalt is less than 2.0 wt.%, the chromium content is from 10 to 15 wt.%, the aluminum content is from 6.0 to 10 wt.%, the yttrium content is from 0.2 to 0.7 wt.%, the content of hafnium is from 0.2 to 0.6 wt.%, the silicon content is less than 0.1 wt.%, and the content of tantalum is from 5.0 to 7.0 wt.%.

10. Metallic coating according to claim 6, characterized in that the chromium content of 12.5 wt.%, as the aluminum content is 8.0 wt.%.

11. Metallic coating according to claim 9, characterized in that the yttrium content is from 0.4 to 0.7 wt.%, and the content of hafnium is 0.4 wt.%.

12. Metallic coating according to claim 6, characterized in that the content of rhenium is from 1.0 to 3.5 wt.%, preferably 2.0 wt.%.

13. Metallic coating according to claim 6, characterized in that the molybdenum content is not more than 4.0 wt.%.

14. Metal coating, characterized in that mostly has the following composition, wt.%:

Cobalt-2.0

Chrome 10 - 15

Aluminum 6,0 - 10

Yttrium 0,2 - 0,7

Hafnium 0,2 - 0,6

Silicon 0,001 - 0,1

Tantalum 5,0 - 7,0

Tungsten 1,0 - 4,0

Rhenium 1,0 - 3,5

Molybdenum Up to 4.0

Nickel Else

15. The metal coating 14, characterized in that the total content of tantalum and tungsten is from 6.0 to 9.0 wt.%.

16. Metal coating, characterized in that it has the following composition, wt.%:

Chrome 12,5

Aluminum 8,0

Yttrium 4,0 - 0,7

Hafnium 0,4

Tantalum 6,0

Tungsten 2,0

Rhenium 2,0

Nickel Else

17. Metal coating, characterized in that it has basically the following composition, wt.%:

Cobalt 2,0 - 18

Chrome 3,0 - 10

Aluminum 5,5 - 15

Yttrium 0,1 - 1,0

Hafnium-0.6

Silicon 0.3

Tantalum 3,0 - 10

Tungsten 1,0 - 9,0

Rhenium 1,0 - 5,0

Molybdenum 0,2 - 4,0

Nickel Else

18. The metal coating 17, characterized in that the total content of tantalum and tungsten is from 4.0 to 16 wt.%.

19. The metal coating 17, characterized in that the total content of tantalum and tungsten is from 7.0 to 12 wt.%.

20. The metal coating 17, characterized in that the total content of tantalum and tungsten is 11 wt.%.

21. The metal coating 17, wherein the content of cobalt is from 8.0 to 12 wt.%, the chromium content is from 4.0 to 6.5 wt.%, the aluminum content is from 7.5 to 12.5 wt., the yttrium content is from 0.2 to 0.7 wt.%, the content of hafnium is from 0.2 to 0.6 wt.%, the silicon content is less than 0.1 wt.%, and the content of tantalum is from 5.0 to 7.0 wt.%.

22. The metal coating 17, wherein the content of cobalt is 10.5 wt.%, the chromium content is 5.0 wt.%, the aluminium content is 9.0 wt.%, the yttrium content is from 0.4 to 0.7 wt.%, the hafnium content of 0.4 wt.%, and the content of tantalum is 6.0 wt.%.

23. The metal coating 17, wherein the tungsten content is from 4.2 to 5.8 wt.%, the content of rhenium is from 2.3 to 3.7 wt.%, and the molybdenum content ranges from 1.4 to 2.0 wt.%.

24. The metal coating 17, wherein the tungsten content is 5.0 wt.%, the content of rhenium is 3.0 wt.%, and the molybdenum content is 1.7 wt.%.

25. Metal coating, characterized in that it has basically the following composition, wt.%:

Cobalt 8,0 - 12

Chrome 4,0 - 6,5

Aluminum 7,5 - 12,5

Yttrium 0,2 - 0,7

Hafnium 0,2 - 0,6

Silicon 0.3

Tantalum 5,0 - 7,0

Tungsten is 4.2 to 5.8

Rhenium 2,3 - 3,7

Molybdenum 1,4 - 2,0

Nickel Else

26. The metallic coating on A.25, characterized in that the total content of tantalum and wolf the mA ranges from 9.2 to 12 wt.%.

27. Metal coating, characterized in that it has the following composition, wt.%:

Cobalt 10,5

Chrome 5,0

Aluminum 9,0

Yttrium 0,4 - 0,7

Hafnium 0,4

Silicon 0,1

Tantalum 6,0

Tungsten 5,0

Rhenium 3,0

Molybdenum 1,7

Nickel Else

28. The method of coating in which first create a substrate of at least one of metallic materials based on Nickel, cobalt, or iron, and then applied on the substrate covering layer, characterized in that the covering layer creates through composition mainly of the following composition: up to 18 wt.% cobalt, from 3.0 to 18 wt.% chromium, 5.0 to 15 wt.% aluminum, from 0.1 to 1.0 wt.% yttrium, up to 0.6 wt.% hafnium, up to 0.3 wt.% silicon, from 3.0 to 10 wt.% tantalum, up to 9.0 wt.% tungsten, 1.0 to 6.0 wt.% rhenium, up to 10 wt.% molybdenum, and the remainder is Nickel.

29. The method according to p, characterized in that the application of the covering layer is realized by means of cathodic arc process or plasma spraying process under a low pressure.

30. The method according to p, characterized in that the covering layer creates through composition mainly of the following composition: up to 15.0 wt.% cobalt, from 5.0 to 18 wt.% chromium, 5.0 to 12 wt.% aluminum, from 0.1 to 1.0 wt.% yttrium, up to 0.6 wt.% hafnium, up to 0.3 wt.% silicon, from 3.0 to 10 wt.% tan is Ala, to 5.0 wt.% tungsten, 1.0 to 6.0 wt.% rhenium, up to 10 wt.% molybdenum, and the remainder is Nickel.

31. The method according to p, characterized in that the covering layer is mainly made of the following composition: up to 2.0 wt.% cobalt, 10 to 15 wt.% chromium, from 6.0 to 10 wt.% aluminum, 0.2 to 0.7 wt.% yttrium, from 0.2 to 0.6 wt.% hafnium, up to 0.1 wt.% silicon, from 5.0 to 7.0 wt.% tantalum, from 1.0 to 4.0 wt.% tungsten, 1.0 to 3.5 wt.% rhenium, up to 4.0 wt.% molybdenum, and the remainder is Nickel.

32. The method according to p, characterized in that the covering layer is mainly made of the following composition: from 2.0 to 18 wt.% cobalt, from 3.0 to 10 wt.% chromium, from about 5.5 to 15 wt.% aluminum, from 0.1 to 1.0 wt.% yttrium, up to 0.6 wt.% hafnium, up to 0.3 wt.% silicon, from 3.0 to 10 wt.% tantalum, from 1.0 to 9.0 wt.% tungsten, 1.0 to 5.0 wt.% rhenium, from 0.2 to 4.0 wt.% molybdenum, and the remainder is Nickel.

33. The method according to p, characterized in that the covering layer is mainly made of the following composition: from 8.0 to 12 wt.% cobalt, from 4.0 to 6.5 wt.% chromium, from 7.5 to 12.5 wt.% aluminum, 0.2 to 0.7 wt.% yttrium, from 0.2 to 0.6 wt.% hafnium, up to 0.3 wt.% silicon, from 5.0 to 7.0 wt.% tantalum, from 4.2 to 5.8 wt.% tungsten, from 2.3 to 3.7 wt.% rhenium, from 1.4 to 2.0 wt.% molybdenum, and the remainder is Nickel.



 

Same patents:

The invention relates to new chemical compounds, in particular chromium-cobalt-yttrium to aluminide low yttrium content of the composition Cr0,180Co0,215Al0,60Y0,005that can be used as a material for heat-resistant plasma coatings of Nickel alloys operating at 900-1000oIn long mode
The invention relates to mechanical engineering and can be used, for example, to increase the durability of turbine blades of gas turbine engines or stationary gas turbines

The invention relates to mechanical engineering and can be used, for example, to increase the durability of turbine blades of gas turbine engines or stationary gas turbines

The invention relates to mechanical engineering and can be used in the coating thermal spray methods

The invention relates to the field of coating and can be used in mechanical engineering, nuclear energy, metallurgy during recovery of parts from various metals and alloys, or restoring large stamps in places of local wear

The invention relates to mechanical engineering and can be used in the aviation and energy gazoturbostroenie for protection of parts of the CCD and GTU (nozzles, heating pipes, etc.,) from high temperature oxidation and corrosion
The invention relates to mechanical engineering and can be used when restoring a worn cast iron cylinder liners

The invention relates to the field of corrosion protection and can be used to obtain a heat-resistant alloys based on aluminum for plasma coatings heat resistant alloys Nickel-based

The invention relates to the coating of metallic materials and can be used to protect the surface of slabs of titanium alloys from gas saturating when heated under hot deformation

FIELD: production of antifriction materials.

SUBSTANCE: the invention is dealt with production of antifriction materials, which are used in plain bearers. The invention offers a multilayer laminate for plain bearers with a base layer, a layer of a bearing alloy, the first interlayer made out of nickel, the second interlayer made out of tin and nickel, and also a sliding layer made out of copper and tin. At that the sliding layer(4) has a mould (5) made out of tin and including the copper-stannic particles (6) consisting by 39-55 mass % out of copper and the rest - tin. The technical result of the invention is an increase of wear-resistance of the material at an increased specific loading on it.

EFFECT: the invention ensures an increase of wear-resistance of the material at an increased specific loading on it.

9 cl, 4 dwg, 1 ex

The invention relates to the field of materials for microelectronics

The invention relates to a method of wear-resistant coatings on cutting tools and can be used in Metalworking
The invention relates to rolling production, in particular to a protective anti-corrosion coating steel

The invention relates to the field of decorative coatings on products fabricated from aluminum alloy in an atmosphere of reactive gases, and can be used on parts operating in instrument making and electronics industries

The invention relates to structural elements for channels of hot gases, in particular turbine blades, arozamena screens, etc. containing a metal base of oversplash based on Nickel, cobalt or iron

The invention relates to metallurgy, in particular to compositions used for coating products from metals and alloys, such as high-temperature alloys, applied to the turbine blades of gas turbine engines or stationary gas turbines

The invention relates to mechanical engineering and can be used in the manufacture of extrusion presses continuous action intended to obtain products with the cavities of the plastic mixtures
The invention relates to a steel sheet, in particular of stainless steel, suitable for the manufacture of the discharge element

 // 2246684
Up!