Nickel-chromium-aluminum composite by electrodeposition

1 . A coated article, comprising:

a turbine component;

a Ni—Cr—Al composite coated on a surface of the turbine component, the Ni—Cr—Al composite including a Ni—Cr coating on the turbine component and an aluminum coating on the Ni—Cr coating, wherein the Ni—Cr coating comprises from 2-50 wt % chromium and the balance of nickel; and

a bond coat on the aluminum coating;

wherein the Ni—Cr—Al composite coated on the surface comprises from 2 to 50 wt % chromium, from 0.1 to 6 wt % aluminum, and a remaining balance of nickel, wherein the Ni—Cr—Al composite is heat-treated to form a diffused Ni—Cr—Al alloy between the Ni—Cr coating and the aluminum coating that includes an aluminum compound formed between nickel and aluminum; and

wherein the heat-treated diffused Ni—Cr—Al alloy on the surface of the turbine component includes aluminum diffused from the aluminum coating to the Ni—Cr coating to form a Ni—Cr—Al zone, and chromium diffused from the Ni—Cr coating to the aluminum coating, and Ni and Cr from the Ni—Cr coating diffused through the aluminum coating and into the bond coat, and Ni and Cr diffused from the Ni—Cr coating into the surface of the turbine component; and

wherein the surface of the turbine component includes an Ni—Cr alloy and aluminum wherein the Ni—Cr—Al alloy is thicker than 250 μm.

2 . The coated article of claim 1 , wherein the Ni—Cr—Al composite coated on the surface comprises from 8 to 20 wt % chromium, from 0.1 to 6 wt % aluminum, and a remaining weight percentage of nickel.

3 . The coated article of claim 1 , wherein the turbine component is a vane, a rotor blade, or a stator.

4 . The coated article of claim 1 , wherein the turbine component is a repaired turbine component.

5 . The coated article of claim 1 , wherein the turbine component comprises a single crystal nickel-based superalloy.