Wear resistant coating, method of manufacture thereof and articles comprising the same
Disclosed herein is an article comprising a substrate; an abrasive coating disposed on the substrate; where the abrasive coating comprises a matrix having abrasive grit particles dispersed therein; and a layer of material disposed on the abrasive coating; where the layer of material is a titanium nitride (TiN), boron nitride (BN), titanium-aluminum-nitrides [(TiAl)N], titanium-aluminum-silicon-nitrides [(TiAlSi)N], chromium nitrides (CrN), aluminum oxide (Al 2 O 3 ), titanium oxide (TiO 2 ), silicon carbo-nitride (SiCN), titanium carbo-nitride (TiCN), or a combination thereof.
1 . A method, comprising:
disposing an abrasive coating on a substrate, where the abrasive coating comprises a matrix;
pressing abrasive grit particles into the abrasive coating while the matrix is being deposited; and
disposing a layer of material on the abrasive coating to encapsulate the abrasive grit particles; where the layer of material is a boron nitride (BN), titanium-aluminum-silicon-nitrides [(TiAlSi)N], chromium nitrides (CrN), aluminum oxide (Al 2 O 3 ), titanium oxide (TiO 2 ), silicon carbo-nitride (SiCN), or a combination thereof.
2 . The method of claim 1 , where the disposing of the abrasive coating is accomplished by a method comprising electrolytic deposition.
3 . The method of claim 2 , where the disposing of the layer of material is conducted via physical vapor deposition, chemical vapor deposition, plasma enhanced vapor deposition, metal organic chemical vapor deposition, or a combination thereof.
4 . The method of claim 3 , where a precursor used in the physical vapor deposition comprises Ti, Al, Si, Cr or combination of thereof.
5 . The method of claim 4 , where the physical vapor deposition is conducted at a temperature 650° C. or less.
6 . The method of claim 4 , where the physical vapor deposition is conducted in a nitrogen atmosphere.
7 . The method of claim 6 , where the nitrogen atmosphere is comprises reactive nitrogen.
8 . The method of claim 1 , where the substrate comprises a tip of an airfoil.
9 . The method of claim 1 , where the abrasive grit particles comprise cubic boron nitride (CBN), coated silicon carbide (SiC), alumina, zirconia, or a combination thereof.
10 . The method of claim 1 , where the matrix is nickel, cobalt, or MCrAlY, where M represents nickel, cobalt, aluminum, titanium, copper, chrome, or a combination thereof.
11 . The method of claim 1 , where the abrasive grit particles are homogeneously dispersed and cover 15 to 60 percent of a blade tip surface area.
12 . The method of claim 1 , where the abrasive grit particles have an average particle size of 30 to 1000 micrometers.
13 . The method of claim 1 , where the abrasive is homogeneously dispersed and covers 15 to 60 percent of a blade tip surface area.
14 . The method of claim 1 , where the layer of material has a thickness of 0.1 to 50 micrometers measured from an interface between abrasive coating and the layer of material.
15 . The method of claim 1 , where the layer of material partially covers the abrasive coating.
16 . The method of claim 1 , further comprising pressing the grit into the matrix during one of: (i) after the matrix is deposited; and (ii) while the matrix is being deposited.