Thermal barrier coating for nickel and cobalt base super alloys

Abstract

Adherent, thermal shock-resistant protective coatings for nickel base super alloys are obtained by applying to the base metal a thin bond coat of an alloy of chromium aluminum and yttrium with materials selected from the group consisting of iron, cobalt, nickel and nickel-cobalt and applying thereover a continuously graded mixture of this material with a zirconia-based ceramic, the concentration of zirconia-based ceramic increasing from the bond coat to the outer layer. The zirconia ceramic may be stabilized by the addition thereto of amounts of magnesium oxide or other materials.

We claim: 
     
       1. .[.In a.]. .Iadd.A .Iaddend.thermally protected .[.superalloy structure.]. .Iadd.gas turbine engine combustion chamber .Iaddend.which comprises a substrate of a material selected from the group consisting of nickel and cobalt-base superalloys, a metal bond coat on said substrate and an oxide stabilized zirconia-base ceramic thermal barrier coating on said bond coat, .[.the improvement.]. wherein said bond coat is an alloy of chromium, aluminum and yttrium with a metal selected from the group consisting of iron, .[.cobalt,.]. nickel and a mixture of nickel and cobalt. 
     
     
       2. The .[.structure.]. .Iadd.combustion chamber .Iaddend.of claim 1 wherein said ceramic thermal barrier material is admixed with the bond coat alloy in a manner such that the concentration of the ceramic material increases continuously from the substrate to the finished surface. 
     
     
       3. .[.The structure of claim 1.]. .Iadd.A thermally protected gas turbine engine combustion chamber which comprises a substrate of a material selected from the group consisting of nickel and cobalt-base superalloys, a metal bond coat on said substrate and an oxide stabilized zirconia-base ceramic thermal barrier coating on said bond coat, wherein said bond coat is an alloy of chromium, aluminum and yttrium with a metal selected from the group consisting of iron, cobalt, nickel and a mixture of nickel and cobalt, and .Iaddend.wherein said bond coat alloy is 15-40 percent chromium, 10-25 percent aluminum and 0.01-1 percent yttrium. 
     
     
       4. The .[.structure.]. .Iadd.combustion chamber .Iaddend.of claim 3 wherein said alloy is .[.a nickel,.]. chromium, aluminum and yttrium .[.alloy.]..Iadd., with the balance a mixture of nickel and cobalt.Iaddend.. 
     
     
       5. The .[.structure.]. .Iadd.combustion chamber .Iaddend.of claim 1 wherein said alloy is .[.a nickel,.]. chromium, aluminum and yttrium .[.alloy.]..Iadd., with the balance a mixture of nickel and cobalt.Iaddend.. .[. 
     
     
       6.  A coated article of manufacture having a thermal barrier coating system comprising a substrate selected from the group consisting of nickel-base alloys and cobalt-base alloys,   a bond coating consisting essentially of a material selected from the group consisting of NiCrAlY, CoCrAlY and mixtures thereof covering said substrate, and   a thermal barrier coating consisting essentially of zirconia stabilized with another oxide..]. .[.7. The thermal barrier coating system of claim 6 wherein said oxide is selected from the group consisting of ZrO 2     
     
     
        --Y 2  O 3  and ZrO 2  --MgO..]. .[.8.  The article of claim 6 wherein said bond coating is 15 to 40 percent chromium, 10 to 25 percent aluminum, and 0.01 to 1 percent yttrium..]. .[.9. A method of coating surfaces of nickel-base and cobalt-base alloys comprising: a. coating said surfaces with a bond coating consisting essentially of a material selected from the group consisting of NiCrAlY and CoCrAlY and mixtures thereof; and   coating the coated surfaces formed in step (a) with a thermal barrier   
     
     
        coating consisting essentially of an oxide stabilized zirconia..]. .[.10. The method of coating a metal surface as claimed in claim 9 where said oxide is selected from the group consisting of ZrO 2  --Y 2  O 3  and ZrO 2  --MgO..]. .[.11. The method of claim 9 wherein said bond coating is 15 to 40 percent chromium, 10 to 25 percent aluminum and 0.01 
     
     
        to 1 percent yttrium..]. .Iadd.12.  A thermally protected gas turbine engine component which comprises a substrate of a nickel base superalloy, a metal bond coat on said substrate and an oxide stabilized zirconia-base ceramic thermal barrier coating on said bond coat, wherein said bond coat is an alloy of chromium, aluminum and yttrium, with the balance of a mixture of nickel and cobalt, and wherein said engine component is selected from the group consisting of combustion chambers, transition ducts, after burner liners, vane platforms and airfoils. .Iaddend. .Iadd.13. The component of claim 12 wherein said bond coat is 15-40 percent chromium, 10-25 percent aluminum, 0.01-1 percent yttrium, with the balance a mixture of nickel and cobalt. .Iaddend. .Iadd.14. The component of claim 13 wherein the concentration of bond coat and zirconia is continuously graded. .Iaddend. .Iadd.15. The component of claim 13 wherein the concentration of bond coat and zirconia is graded such that the engine component is characterized by more than one layer of discretely increasing concentrations of zirconia. .Iaddend. .Iadd.16. The component of claim 13 comprising one layer of 100 percent ceramic of the bond coat. .Iaddend.