US2008292490A1PendingUtilityA1

High-temperature coatings and bulk alloys with pt metal modified gamma-ni + gamma'-ni3al alloys having hot-corrosion resistance

63
Assignee: UNIV IOWA STATE RES FOUND INCPriority: Aug 18, 2004Filed: May 4, 2007Published: Nov 27, 2008
Est. expiryAug 18, 2024(expired)· nominal 20-yr term from priority
Inventors:Brian GleesonDaniel J. Sordelet
C23C 4/02C22C 19/03C22C 19/056C22C 19/057C22C 19/058C23C 4/04C23C 4/08C23C 30/00C23C 28/321C23C 28/345C23C 28/3455C23C 28/325Y10T428/12944Y10T428/31678
63
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Claims

Abstract

An alloy including a Pt-group metal, Ni and Al, wherein the concentration of Al is limited with respect to the concentration of Ni and the Pt-group metal such that the alloy includes substantially no β-NiAl phase, and wherein the Pt-group metal is present in an amount sufficient to provide enhanced hot corrosion resistance.

Claims

exact text as granted — not AI-modified
1 - 21 . (canceled) 
   
   
       22 . A coating on a substrate, wherein the coating is an alloy which comprises:
 aluminum,   nickel,   at least one platinum group metal, wherein the alloy comprises less than about 10 at % of the at least one platinum group metal, and   hafnium,   wherein the alloy consists essentially of gamma prime Ni 3 Al phase and either beta NiAl phase or gamma Ni phase.   
   
   
       23 . The coating of  claim 22 , wherein the alloy comprises about 0.1 at % to about 2 at % hafnium. 
   
   
       24 . The coating of  claim 22 , wherein the coating has an outer surface region with a platinum group metal content of less than the average platinum group metal content in the coating. 
   
   
       25 . The coating of  claim 22 , wherein the coating comprises about 10 at % to about 23 at % aluminum. 
   
   
       26 . The coating of  claim 22 , wherein the coating comprises about 10 at % to about 22 at % aluminum. 
   
   
       27 . The coating of  claim 22 , wherein the coating consists essentially of the gamma prime Ni 3 Al phase and the gamma Ni phase. 
   
   
       28 . The coating of  claim 22 , wherein the alloy comprises about 3 at % to less than about 10 at % of the at least one platinum group metal. 
   
   
       29 . The coating of  claim 22 , wherein the alloy consists essentially of about 10 at % to about 23 at % aluminum,
 nickel,   at least one platinum group metal, wherein the alloy comprises less than about 10 at % of the at least one platinum group metal, and   about 0.5 at % to about 2 at % hafnium.   
   
   
       30 . The coating of  claim 22 , wherein the coating has an innermost region with a platinum group metal content of greater than the average platinum group metal content in the coating. 
   
   
       31 . The coating of  claim 22 , wherein the coating has an innermost region with an aluminum content of less than the average aluminum content in the coating. 
   
   
       32 . The coating of  claim 22 , wherein the innermost region of the coating has an aluminum content of less than the substrate. 
   
   
       33 . The coating of  claim 22 , wherein the alloy comprises about 0.5 at % to about 1 at % halfnium. 
   
   
       34 . The coating of  claim 22 , wherein the alloy is predominantly gamma prime Ni 3 Al phase. 
   
   
       35 . The coating of  claim 22 , wherein said coating is coated with a layer of ceramic. 
   
   
       36 . The coating of  claim 22 , wherein the substrate is composed of a superalloy. 
   
   
       37 . The coating of  claim 22 , wherein the substrate is a component for a gas turbine. 
   
   
       38 . The coating of  claim 22 , wherein the coating is an overlay coating. 
   
   
       39 . The coating of  claim 22 , wherein the platinum group metal is Pt, Pd, Ir, Rh, Ru or a mixture thereof. 
   
   
       40 . The coating of  claim 22 , wherein the at least one platinum group metal includes Pt. 
   
   
       41 . A method of making the coating of  claim 22 , comprising applying the alloy on the substrate. 
   
   
       42 . A coating on a superalloy substrate of a gas turbine, wherein the coating is an alloy which comprises:
 about 10 at % to about 23 at % aluminum,   nickel,   at least one platinum group metal, at least one platinum group metal, wherein the alloy comprises less than about 10 at % of the at least one platinum group metal and   hafnium,   
     wherein
 the alloy consists essentially of gamma prime Ni 3 Al phase and either beta NiAl phase or gamma Ni phase, and 
 the alloy is predominantly gamma prime Ni 3 Al phase. 
 
   
   
       43 . The coating of  claim 42 , wherein the alloy comprises about 0.1 at % to about 2 at % hafnium. 
   
   
       44 . The coating of  claim 42 , wherein the coating has an outer surface region with a platinum group metal content of less than the average platinum group metal content in the coating. 
   
   
       45 . The coating of  claim 42 , wherein the alloy comprises about 3 at % to less than about 10 at % of the at least one platinum group metal. 
   
   
       46 . The coating of  claim 42 , wherein the platinum group metal is Pt, Pd, Ir, Rh, Ru or a mixture thereof. 
   
   
       47 . The coating of  claim 42 , wherein the at least one platinum group metal includes Pt. 
   
   
       48 . A coating on a superalloy substrate of a gas turbine, wherein the coating is an alloy which comprises:
 about 10 at % to about 23 at % aluminum,   nickel,   at least one platinum group metal, at least one platinum group metal, wherein the alloy comprises less than about 10 at % of the at least one platinum group metal, and   hafnium,   wherein the alloy consists essentially of gamma prime and beta NiAl phase or gamma Ni phase.   
   
   
       49 . The coating of  claim 48 , wherein the alloy comprises about 0.1 at % to about 2 at % hafnium. 
   
   
       50 . The coating of  claim 48 , wherein the alloy comprises about 3 at % to less than about 10 at % of the at least one platinum group metal. 
   
   
       51 . The coating of  claim 48 , wherein the coating has an outer surface region with a platinum group metal content of less than the average platinum group metal content in the coating. 
   
   
       52 . A coating on a substrate, wherein the coating is an alloy which comprises:
 about 10 at % to about 23 at % aluminum,   nickel,   at least one platinum group metal, at least one platinum group metal, wherein the alloy comprises less than about 10 at % of the at least one platinum group metal, and   hafnium,   wherein the alloy consists essentially of gamma prime Ni 3 Al phase and either beta NiAl phase or gamma Ni phase.   
   
   
       53 . The coating of  claim 52 , wherein the alloy comprises about 0.5 at % to about 2 at % hafnium. 
   
   
       54 . The coating of  claim 52 , wherein the coating has an outer surface region with a platinum group metal content of less than the average platinum group metal content in the coating. 
   
   
       55 . The coating of  claim 52 , wherein the alloy comprises about 3 at % to less than about 10 at % of the at least one platinum group metal. 
   
   
       56 . A coating on a substrate, wherein the coating is an alloy which comprises:
 aluminum,   nickel,   at least one platinum group metal, wherein the alloy comprises less than about 10 at % of the at least one platinum group metal, and   hafnium,   wherein the alloy comprises gamma prime Ni 3 Al phase and either beta NiAl phase or gamma Ni phase.   
   
   
       57 . The coating of  claim 56 , wherein the alloy comprises about 0.5 at % to about 2 at % hafnium. 
   
   
       58 . The coating of  claim 57 , wherein the coating has an outer surface region with a platinum group metal content of less than the average platinum group metal content in the coating. 
   
   
       59 . A coating on a superalloy substrate of a gas turbine, wherein the coating is an alloy which comprises:
 about 10 at % to about 23 at % aluminum,   nickel,   at least one platinum group metal, at least one platinum group metal, wherein the alloy comprises less than about 10 at % of the at least one platinum group metal and   hafnium,   
     wherein
 the alloy comprises gamma prime Ni 3 Al phase and either beta NiAl phase or gamma Ni phase, and 
 the alloy is predominantly gamma prime Ni 3 Al phase. 
 
   
   
       60 . The coating of  claim 59 , wherein the alloy comprises about 0.5 at % to about 2 at % hafnium. 
   
   
       61 . The coating of  claim 59 , wherein the coating has an outer surface region with a platinum group metal content of less than the average platinum group metal content in the coating. 
   
   
       62 . A coating on a superalloy substrate of a gas turbine, wherein the coating comprises:
 about 10 at % to about 23 at % aluminum,   nickel,   at least one platinum group metal, at least one platinum group metal, wherein the alloy comprises less than about 10 at % of the at least one platinum group metal, and   hafnium,   wherein the alloy comprises gamma prime and beta NiAl phase or gamma Ni phase.   
   
   
       63 . The coating of  claim 62 , wherein the alloy comprises about 0.5 at % to about 2 at % hafnium. 
   
   
       64 . The coating of  claim 62 , wherein the coating has an outer surface region with a platinum group metal content of less than the average platinum group metal content in the coating. 
   
   
       65 . A coating on a substrate, wherein the coating is an alloy which comprises:
 about 10 at % to about 23 at % aluminum,   nickel,   at least one platinum group metal, at least one platinum group metal, wherein the alloy comprises less than about 10 at % of the at least one platinum group metal, and   hafnium,   wherein the alloy comprises gamma prime Ni 3 Al phase and either beta NiAl phase or gamma Ni phase.   
   
   
       66 . The coating of  claim 65 , wherein the alloy comprises about 0.1 at % to about 2 at % hafnium. 
   
   
       67 . The coating of  claim 65 , wherein the coating has an outer surface region with a platinum group metal content of less than the average platinum group metal content in the coating. 
   
   
       68 . A coating on a substrate, wherein the coating is an alloy which comprises:
 aluminum,   nickel,   at least one platinum group metal, wherein the alloy comprises less than about 10 at % of the at least one platinum group metal, and   hafnium,   wherein the alloy is predominantly gamma prime Ni 3 Al phase and also contains either beta NiAl phase or gamma Ni phase.   
   
   
       69 . The coating of  claim 68 , wherein the alloy comprises about 0.1 at % to about 2 at % hafnium. 
   
   
       70 . The coating of  claim 68 , wherein the alloy contains the gamma Ni phase. 
   
   
       71 . A coating on a substrate, wherein the coating is an alloy which comprises:
 aluminum,   nickel,   at least one platinum group metal, wherein the alloy comprises less than about 10 at % of the at least one platinum group metal, and   hafnium,   wherein the alloy has predominantly gamma prime Ni 3 Al phase and gamma nickel phase constitution.   
   
   
       72 . The coating of  claim 71 , wherein the alloy comprises about 0.1 at % to about 2 at % hafnium.

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