Methods for depositing sacrificial coatings on aerospace components

Abstract

Embodiments of the present disclosure generally relate to protective coatings on aerospace components and methods for depositing the protective coatings. In one or more embodiments, an aerospace component has a body containing a nickel superalloy, a metal oxide template layer disposed on the body, and an aluminum oxide layer disposed between the body of the aerospace component and the metal oxide template layer. The metal oxide template layer contains chromium oxide, chromium oxide hydroxide, or a combination thereof. The aluminum oxide layer contains α-Al 2 O 3 . The metal oxide template layer and the aluminum oxide layer have a corundum crystal structure and have crystal structures with a lattice mismatch of about 0.1% to about 10%.

What is claimed is: 
     
         1 . An aerospace component, comprising:
 a body comprising a nickel superalloy;   a metal oxide template layer disposed on the body, wherein the metal oxide template layer comprises chromium oxide, chromium oxide hydroxide, or a combination thereof; and   an aluminum oxide layer disposed between the body of the aerospace component and the metal oxide template layer, wherein the aluminum oxide layer comprises α-Al 2 O 3 , wherein the metal oxide template layer and the aluminum oxide layer have a corundum crystal structure, and wherein the metal oxide template layer and the aluminum oxide layer have crystal structures with a lattice mismatch of about 0.1% to about 10%.   
     
     
         2 . The aerospace component of  claim 1 , wherein the metal oxide template layer has a thickness of about 10 nm to about 2,000 nm. 
     
     
         3 . The aerospace component of  claim 2 , wherein the aluminum oxide layer has a thickness of about 10 nm to about 1,000 nm. 
     
     
         4 . The aerospace component of  claim 1 , wherein the metal oxide template layer and the aluminum oxide layer have crystal structures with a lattice mismatch of about 1% to about 8%. 
     
     
         5 . The aerospace component of  claim 1 , wherein the metal oxide template layer is a material deposited on the aerospace component by an atomic layer deposition (ALD) process or a chemical vapor deposition (CVD) process. 
     
     
         6 . The aerospace component of  claim 1 , wherein the aerospace component is a turbine blade, a turbine vane, a support member, a frame, a rib, a fin, a pin fin, a combustor fuel nozzle, a combustor shield, an internal cooling channel, or any combination thereof. 
     
     
         7 . The aerospace component of  claim 1 , wherein the nickel superalloy comprises nickel, aluminum, and one or more metals selected from chromium, cobalt, titanium, molybdenum, tungsten, or alloys thereof. 
     
     
         8 . The aerospace component of  claim 7 , wherein the nickel superalloy comprises about 40 wt % or greater of nickel and about 0.5 wt % to about 15 wt % of aluminum. 
     
     
         9 . The aerospace component of  claim 1 , wherein the nickel superalloy comprises about 50 wt % or greater of nickel and about 1 wt % to about 10 wt % of aluminum. 
     
     
         10 . An aerospace component, comprising:
 a body comprising a nickel superalloy, the superalloy comprises nickel, aluminum, and one or more metals selected from chromium, cobalt, titanium, molybdenum, tungsten, or alloys thereof;   a metal oxide template layer disposed on the body, wherein the metal oxide template layer comprises chromium oxide, tungsten oxide, molybdenum oxide, vanadium oxide, or any combination thereof; and   an aluminum oxide layer disposed between the body of the aerospace component and the metal oxide template layer, wherein the aluminum oxide layer comprises α-Al 2 O 3 , wherein the metal oxide template layer and the aluminum oxide layer have a corundum crystal structure, and wherein the metal oxide template layer and the aluminum oxide layer have crystal structures with a lattice mismatch of about 0.1% to about 10%.   
     
     
         11 . The aerospace component of  claim 10 , wherein the metal oxide template layer comprises chromium oxide. 
     
     
         12 . The aerospace component of  claim 11 , wherein the metal oxide template layer further comprises chromium oxide hydroxide. 
     
     
         13 . The aerospace component of  claim 10 , wherein the metal oxide template layer has a thickness of about 10 nm to about 2,000 nm. 
     
     
         14 . The aerospace component of  claim 13 , wherein the metal oxide template layer has a thickness of about 100 nm to about 1,000 nm. 
     
     
         15 . The aerospace component of  claim 10 , wherein the aluminum oxide layer has a thickness of about 10 nm to about 1,000 nm. 
     
     
         16 . The aerospace component of  claim 15 , wherein the aluminum oxide layer has a thickness of about 20 nm to about 500 nm. 
     
     
         17 . The aerospace component of  claim 10 , wherein the metal oxide template layer and the aluminum oxide layer have crystal structures with a lattice mismatch of about 1% to about 8%. 
     
     
         18 . The aerospace component of  claim 10 , wherein the aerospace component is a turbine blade, a turbine vane, a support member, a frame, a rib, a fin, a pin fin, a combustor fuel nozzle, a combustor shield, an internal cooling channel, or any combination thereof. 
     
     
         19 . The aerospace component of  claim 10 , wherein the nickel superalloy comprises about 50 wt % or greater of nickel and about 1 wt % to about 10 wt % of aluminum. 
     
     
         20 . An aerospace component, comprising:
 a body comprising a nickel superalloy, wherein the nickel superalloy comprises about 40 wt % or greater of nickel and about 0.5 wt % to about 15 wt % of aluminum, and wherein the aerospace component is a turbine blade, a turbine vane, a support member, a frame, a rib, a fin, a pin fin, a combustor fuel nozzle, a combustor shield, an internal cooling channel, or any combination thereof;   a metal oxide template layer disposed on the body, wherein the metal oxide template layer comprises chromium oxide, chromium oxide hydroxide, or a combination thereof; and   an aluminum oxide layer disposed between the body of the aerospace component and the metal oxide template layer, wherein the aluminum oxide layer comprises α-Al 2 O 3 , wherein the metal oxide template layer and the aluminum oxide layer have a corundum crystal structure, and wherein the metal oxide template layer and the aluminum oxide layer have crystal structures with a lattice mismatch of about 2% to about 8%.