Methods for making high-temperature coatings having pt metal modified gamma-ni +gamma'-ni3al alloy compositions and a reactive element

Abstract

A method for making an oxidation resistant article, including (a) depositing a layer of a Pt group metal on a substrate to form a platinized substrate; and (b) depositing on the platinized substrate layer of Pt group metal a layer of a reactive element selected from the group consisting of Hf, Y, La, Ce and Zr and combinations thereof to form a surface modified region thereon, wherein the surface modified region includes the Pt-group metal, Ni, Al and the reactive element in relative concentration to provide a γ-Ni+γ-Ni3Al phase constitution.

1 - 63 . (canceled) 
     
     
         64 . A process of depositing a coating on a nickel based superalloy substrate, wherein the coating comprises an alloy comprising nickel, aluminum, at least one platinum group metal and a least one reactive element, wherein the principal phase of the alloy is gamma prime Ni 3 Al phase, comprising:
 forming on a surface of the substrate a layer of at least one platinum group metal and depositing on the layer of at least one platinum group metal a layer of at least one reactive element; and then   heating the substrate, the layer of at least one platinum group metal and the layer of at least one reactive element,   wherein the layer of at least one reactive element forms a surface-modified region comprising the at least one platinum group metal, and wherein the surface region comprises about 0.8 wt % to about 5 wt % of the at least one reactive element.   
     
     
         65 . The process of  claim 64 , wherein the layer of at least one reactive element forms a surface-modified region comprising the at least one platinum group metal, and wherein the surface region comprises greater than about 0.8 wt % of the at least one reactive element. 
     
     
         66 . The process of  claim 64 , wherein the layer of at least one reactive element forms a surface-modified region comprising the at least one platinum group metal, and wherein the surface region comprises about 0.8 wt % to about 3 wt % of the at least one reactive element. 
     
     
         67 . The process of  claim 64 , wherein the layer of at least one reactive element forms a surface-modified region comprising the at least one platinum group metal, and wherein the surface region comprises up to about 5 wt % of the at least one reactive element. 
     
     
         68 . The process of  claim 64 , wherein the alloy also contains gamma nickel phase. 
     
     
         69 . The process of  claim 64 , wherein the alloy comprises less than about 23 at % aluminum and about 10 at % to about 30 at % of the at least one platinum group metal. 
     
     
         70 . The process of  claim 64 , wherein the alloy further comprises chromium. 
     
     
         71 . The process of  claim 64 , wherein the alloy further comprises about 2 at % chromium. 
     
     
         72 . The process of  claim 64 , wherein the alloy further comprises about 2 at % to about 7 at % chromium. 
     
     
         73 . The process of  claim 64 , wherein the alloy further comprises about 2 at % to about 5 at % chromium. 
     
     
         74 . The process of  claim 64 , wherein the at least one reactive element is one or more of Hf, Y and Zr. 
     
     
         75 . The process of  claim 64 , wherein the at least one reactive element includes Hf. 
     
     
         76 . The process of  claim 64 , wherein the layer of at least one platinum group metal is formed by electrodeposition. 
     
     
         77 . The process of  claim 64 , wherein the layer of at least one reactive element is deposited by physical vapor deposition. 
     
     
         78 . The process of  claim 64 , wherein the at least one reactive element is deposited from a pack, wherein the pack contains up to about 2 wt % aluminum. 
     
     
         79 . The process of  claim 64 , wherein the at least one reactive element is deposited from a pack, wherein the pack contains 0 wt % aluminum. 
     
     
         80 . The process of  claim 64 , wherein the at least one reactive element is deposited from a pack heated at a temperature of about 650° C. to about 1100° C. 
     
     
         81 . The process of  claim 64 , further comprising depositing a thermal barrier ceramic topcoat on the coating. 
     
     
         82 . The process of  claim 64 , wherein the substrate contains at least one of Ta and Re. 
     
     
         83 . The process of  claim 64 , wherein the alloy contains the gamma prime phase as the sole phase. 
     
     
         84 . The process of  claim 64 , wherein the platinum group metal is Pt, Pd, Ir, Rh, Ru and mixtures thereof. 
     
     
         85 . The process of  claim 64 , wherein the at least one platinum group metal includes Pt. 
     
     
         86 . The process of  claim 64 , wherein the substrate is a nickel-based supperalloy. 
     
     
         87 . The process of  claim 64 , wherein the substrate is MAR-M 002, CMSX-4 or CMSX-10. 
     
     
         88 . The process of  claim 64 , wherein the at least one platinum group metal is deposited by chemical vapor deposition. 
     
     
         89 . The process of  claim 64 , wherein the heating is conducted at a temperature of about 900° C. to about 1200° C. 
     
     
         90 . A process of depositing a coating on a nickel based superalloy substrate, wherein the coating comprises an alloy comprising nickel, aluminum, at least one platinum group metal and a least one reactive element, wherein the alloy has predominantly gamma nickel and gamma prime Ni 3 Al phase constitution, comprising:
 forming on a surface of the substrate a layer of at least one platinum group metal and depositing on the layer of at least one platinum group metal a layer of at least one reactive element; and then   heating the substrate, the layer of at least one platinum group metal and the layer of at least one reactive element,   
       wherein the layer of at least one reactive element forms a surface-modified region comprising the at least one platinum group metal, and wherein the surface region comprises about 0.8 wt % to about 5 wt % of the at least one reactive element. 
     
     
         91 . A process of depositing a coating on a nickel based superalloy substrate, wherein the coating comprises an alloy comprising nickel, aluminum, at least one platinum group metal and a least one reactive element, wherein the aluminum and nickel are present in predominantly gamma prime phase, comprising:
 forming on a surface of the substrate a layer of at least one platinum group metal and depositing on the layer of at least one platinum group metal a layer of at least one reactive element; and then   heating the substrate, the layer of at least one platinum group metal and the layer of at least one reactive element,   wherein the layer of at least one reactive element forms a surface-modified region comprising the at least one platinum group metal, and wherein the surface region comprises about 0.8 wt % to about 5 wt % of the at least one reactive element.