US2007187005A1PendingUtilityA1

Alloy powders and coating compositions containing same

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Individually held — no corporate assignee on recordPriority: Feb 13, 2006Filed: Feb 7, 2007Published: Aug 16, 2007
Est. expiryFeb 13, 2026(expired)· nominal 20-yr term from priority
Inventors:Thomas Alan Taylor
C22C 32/0026C22C 33/0285C23C 4/073
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Claims

Abstract

This invention relates to alloy powders suitable for thermal spraying or other cladding methods comprising an alloy of MCrAlM′ wherein M is an element selected from nickel, cobalt, iron and mixtures thereof, and M′ is an element selected from yttrium, zirconium, hafnium, ytterbium and mixtures thereof, and wherein M comprises from about 35 to about 80 weight percent of said alloy, Cr comprises from about 15 to about 45 weight percent of said alloy, Al comprises from about 5 to about 30 weight percent of said alloy, and M′ comprises from about 0.01 to about 1.0 weight percent of said alloy, said alloy powder having a mean particle size of 50 percentile point in distribution of from about 5 microns to about 100 microns.

Claims

exact text as granted — not AI-modified
1 . An alloy powder suitable for thermal spraying or other cladding methods comprising an alloy of MCrAlM′ wherein M is an element selected from nickel, cobalt, iron and mixtures thereof, and M′ is an element selected from yttrium, zirconium, hafnium, ytterbium and mixtures thereof, and wherein M comprises from about 35 to about 80 weight percent of said alloy, Cr comprises from about 15 to about 45 weight percent of said alloy, Al comprises from about 5 to about 30 weight percent of said alloy, and M′ comprises from about 0.01 to about 1.0 weight percent of said alloy, said alloy powder having a mean particle size of 50 percentile point in distribution of from about 5 microns to about 100 microns.  
   
   
       2 . The alloy powder of  claim 1  wherein M is nickel and M′ is yttrium.  
   
   
       3 . The alloy powder of  claim 1  having a mean particle size of 50 percentile point in distribution of from about 5 microns to about 50 microns.  
   
   
       4 . The alloy powder of  claim 1  wherein M comprises from about 40 to about 70 weight percent of said alloy, Cr comprises from about 20 to about 40 weight percent of said alloy, Al comprises from about 10 to about 25 weight percent of said alloy, and M′ comprises from about 0.05 to about 0.95 weight percent of said alloy.  
   
   
       5 . The alloy powder of  claim 1  wherein an alpha-Cr phase is present up to a temperature of at least about 1000° C.  
   
   
       6 . The alloy powder of  claim 1  that is heat treated to stabilize equilibrium phases of said alloy.  
   
   
       7 . The alloy powder of  claim 1  wherein an alpha-Cr phase is in equilibrium in a thermally stabilized coating comprising said alloy at a temperature of about 800° C. and said alpha-Cr phase does not dissolve upon heating to a temperature of at least about 1000° C.  
   
   
       8 . The alloy powder of  claim 1  that falls within an alpha-Cr+beta-NiAl+gamma (FCC Ni alloy) phase field at a temperature of about 1150° C.  
   
   
       9 . A metal or non-metal substrate coated with the alloy powder of  claim 1 .  
   
   
       10 . The alloy powder of  claim 1  with the addition of up to about 10 volume percent stable oxide particles.  
   
   
       11 . The alloy powder of  claim 1  wherein the stable oxide particles are selected from yttria, hafnia or alumina.  
   
   
       12 . A coating made from the alloy powder of  claim 1 .  
   
   
       13 . A coating made from the alloy powder of  claim 1  wherein, during deposition of the coating, oxygen and/or carbon are intentionally added to the coating.  
   
   
       14 . A cast or wrought alloy article made from the alloy powder of  claim 1 .  
   
   
       15 . A coating composition suitable for thermal spraying or other cladding methods comprising an alloy powder of MCrAlM′ wherein M is an element selected from nickel, cobalt, iron and mixtures thereof, and M′ is an element selected from yttrium, zirconium, hafnium, ytterbium and mixtures thereof, and wherein M comprises from about 35 to about 80 weight percent of said alloy, Cr comprises from about 15 to about 45 weight percent of said alloy, Al comprises from about 5 to about 30 weight percent of said alloy, and M′ comprises from about 0.01 to about 1.0 weight percent of said alloy, said alloy powder having a mean particle size of 50 percentile point in distribution of from about 5 microns to about 100 microns.  
   
   
       16 . The coating composition of  claim 15  wherein M is nickel and M′ is yttrium.  
   
   
       17 . The coating composition of  claim 15  wherein said alloy powder has a mean particle size of 50 percentile point in distribution of from about 5 microns to about 50 microns.  
   
   
       18 . The coating composition of  claim 15  wherein M comprises from about 40 to about 70 weight percent of said alloy, Cr comprises from about 20 to about 40 weight percent of said alloy, Al comprises from about 10 to about 25 weight percent of said alloy, and M′ comprises from about 0.05 to about 0.95 weight percent of said alloy.  
   
   
       19 . The coating composition of  claim 15  wherein an alpha-Cr phase is present up to a temperature of at least about 1000° C.  
   
   
       20 . The coating composition of  claim 15  that is heat treated to stabilize equilibrium phases of said coating composition.  
   
   
       21 . The coating composition of  claim 15  wherein an alpha-Cr phase is in equilibrium in said coating composition that has been thermally stabilized at a temperature of about 800° C. and said alpha-Cr phase does not dissolve upon heating to a temperature of at least about 1000° C.  
   
   
       22 . The coating composition of  claim 15  that falls within an alpha-Cr+beta-NiAl+gamma (FCC Ni alloy) phase field at a temperature of about 1150° C.  
   
   
       23 . The coating composition of  claim 15  further comprising an oxide dispersion.  
   
   
       24 . The coating composition of  claim 15  wherein the oxide dispersion is selected from alumina, thoria, yttria and rare earth oxides, hafnia and zirconia.  
   
   
       25 . The coating composition of  claim 15  wherein the oxide dispersion comprises from about 5 to about 25 volume percent of said coating composition.  
   
   
       26 . A coating made from the coating composition of  claim 15 .  
   
   
       27 . A coating made from the coating composition of  claim 15  wherein, during deposition of the coating, oxygen and/or carbon are intentionally added to the coating.  
   
   
       28 . A metal or non-metal substrate coated with the coating composition of  claim 15.

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