Combustion turbine component having rare earth CoNiCrAl coating and associated methods

1. A combustion turbine component comprising:

a combustion turbine component substrate; and

an alloy coating on said combustion turbine component substrate comprising

a first amount, by weight percent, of cobalt (Co), a second amount, by weight percent, of nickel (Ni), the first amount being greater than the first amount,

chromium (Cr), aluminum (Al), rhenium (Re),

at least one additional rare earth element, and

an oxide of the at least one additional rare earth element.

2. The combustion turbine component of claim 1 , wherein said alloy coating further comprises a third amount, by weight percent, of iron (Fe), the third amount being greater than the first amount.

3. The combustion turbine component of claim 2 , wherein said alloy coating comprises, by percentage of weight, 25% to 30% of Co; 20% to 25% Ni; 3% to 7% of Cr; 3% to 6% of Al; 0.1% to 5%, total, of at least one additional rare earth element; and a balance of Fe and O.

4. The combustion turbine component of claim 2 , wherein said alloy coating comprises, by percentage of weight, 27% to 29% of Co; 22% to 24% Ni; 4% to 6% of Cr; 4% to 5% of Al; 0.5% to 3%, total, of at least one additional rare earth element; and a balance of Fe and O.

5. The combustion turbine component of claim 1 , wherein said alloy coating further comprises yttrium (Y); and at least one of titanium (Ti), tantalum (Ta), and tungsten (W); and wherein said oxide comprises an oxide of at least one of the yttrium and the at least one additional rare earth element.

6. The combustion turbine component of claim 5 , wherein said alloy coating comprises, by percentage of weight, 25% to 35% of Ni; 15% to 25% of Cr; 6% to 15% of Al; and 0.05% to 5% of Y.

7. The combustion turbine component of claim 6 , wherein said alloy coating further comprises, by percentage of weight, 0.4% to 4%, total, of Re and at least one of Ti, Ta, and W; 0.1% to 5%, total, of at least one additional rare earth oxide; and a balance of Co and O.

8. The combustion turbine component of claim 5 , wherein said alloy coating comprises, by percentage of weight, 29% to 33% of Ni; 18% to 23% of Cr; 7% to 11% of Al; and 0.1% to 1% of Y.

9. The combustion turbine component of claim 8 , wherein said alloy coating further comprises, by percentage of weight, 0.5% to 3%, total, of Re and at least one of Ti, Ta, and W; 0.5% to 3%, total, of at least one additional rare earth oxide; and a balance of Co and O.

10. The combustion turbine component of claim 1 , further comprising a thermal barrier coating on said alloy coating.

11. The combustion turbine component of claim 1 , wherein said at least one additional rare earth element comprises at least one of lanthanum (La), cerium (Ce), praseodymium (Pr), neodymium (Nd), promethium (Pm), samarium (Sm), europium (Eu), gadolinium (Gd), terbium (Tb), dysprosium (Dy), holmium (Ho), erbium (Er), thulium (Tm), ytterbium (Yb), lutetium (Lu).

12. A combustion turbine component comprising:

a metallic combustion turbine component substrate; and

an alloy coating on said metallic combustion turbine component substrate comprising, by weight percent,

25% to 35% of Ni,

15% to 25% of Cr,

6% to 15% of Al,

0.05% to 5% of Y,

0.4% to 4%, total, of Re and at least one of Ti, Ta, and W,

0.1% to 5%, total, of at least one additional rare earth element, and

a balance of Co and O.

13. The combustion turbine component of claim 12 , wherein said alloy coating comprises, by percentage of weight, 29% to 33% of Ni; 18% to 23% of Cr; 7% to 11% of Al; 0.1% to 1% of Y; 0.5% to 3%, total, of Re and at least one of Ti, Ta, and W; 0.5% to 3%, total, of at least one additional rare earth element; and a balance of Co and O.

14. The combustion turbine component of claim 12 , further comprising a thermal barrier coating on said alloy coating.

15. The combustion turbine component of claim 12 , wherein said at least one additional rare earth element comprises at least one of lanthanum (La), cerium (Ce), praseodymium (Pr), neodymium (Nd), promethium (Pm), samarium (Sm), europium (Eu), gadolinium (Gd), terbium (Tb), dysprosium (Dy), holmium (Ho), erbium (Er), thulium (Tm), ytterbium (Yb), lutetium (Lu).

16. A method of making a combustion turbine component comprising:

forming a combustion turbine component substrate;

applying an alloy coating on the combustion turbine component substrate, the alloy coating comprising

a first amount, by weight percent, of cobalt (Co), a second amount, by weight percent, of nickel (Ni), the first amount being greater than the second amount,

chromium (Cr), aluminum (Al), rhenium (Re),

at least one additional rare earth element, and

an oxide of the at least one additional rare earth element.

17. The method of claim 16 , wherein the alloy coating further comprises a third amount, by weight percent, of iron (Fe), the third amount being greater than the first amount.

18. The method of claim 17 , wherein the alloy coating comprises, by percentage of weight, 25% to 30% of Co; 20% to 25% Ni; 3% to 7% of Cr; 3% to 6% of Al; 0.1% to 5%, total, of at least one additional rare earth element; and a balance of Fe and O.

19. The method of claim 17 , wherein the alloy coating comprises, by percentage of weight, 27% to 29% of Co; 22% to 24% Ni; 4% to 6% of Cr; 4% to 5% of Al; 0.5% to 3%, total, of at least one additional rare earth element; and a balance of Fe and O.

20. The method of claim 16 , wherein the alloy coating further comprises yttrium (Y); and at least one of titanium (Ti), tantalum (Ta), and tungsten (W); and wherein the oxide comprises an oxide of at least one of the yttrium and the at least one additional rare earth element.

21. The method of claim 20 , wherein the alloy coating comprises, by percentage of weight, 25% to 35% of Ni; 15% to 25% of Cr; 6% to 15% of Al; and 0.05% to 5% of Y.

22. The method of claim 21 , wherein the alloy coating further comprises, by percentage of weight, 0.4% to 4%, total, of Re and at least one of Ti, Ta, and W; 0.1% to 5%, total, of at least one rare earth oxide; and a balance of Co and O.

23. The method of claim 20 , wherein the alloy coating comprises, by percentage of weight, 29% to 33% of Ni; 18% to 23% of Cr; 7% to 11% of Al; and 0.1% to 1% of Y.

24. The method of claim 23 , wherein the alloy coating further comprises, by percentage of weight, 0.5% to 3%, total, of Re and at least one of Ti, Ta, and W; 0.5% to 3%, total, of at least one rare earth oxide; and a balance of Co and O.

25. The method of claim 16 , wherein applying the alloy coating on the combustion turbine component substrate comprises:

atomizing a metallic liquid in an atmosphere to form a metallic powder;

milling the metallic powder to form a nanosized metallic powder; and

thermal spraying the nanosized metallic powder onto the combustion turbine component substrate.

26. The method of claim 25 , wherein the atmosphere comprises an oxidizing atmosphere.

27. The method of claim 25 , further comprising forming a thermal barrier coating on the combustion turbine component substrate after thermal spraying.

28. The method of claim 16 , wherein applying the alloy coating on the combustion turbine component substrate comprises:

atomizing a metallic liquid to form a metallic powder;

performing a series of heat treating steps on the metallic powder comprising

a first heat treating step performed in an oxidizing atmosphere,

a second heat treating step performed in an inert atmosphere, and

a third heat treating step performed in a reducing atmosphere to form a metallic power having an increased proportion of rare-earth oxides compared to non rare-earth oxides; and

thermal spraying the metallic powder having an increased proportion of rare-earth oxides compared to non rare-earth oxides onto the combustion turbine component substrate.

29. The method of claim 28 , wherein the first heat treating step is performed for a first period of time; and wherein the second heat treating step is performed for a second period of time; and wherein the second period of time is greater than the first period of time.

30. The method of claim 28 , further comprising forming a thermal barrier coating after the thermal spraying.

31. A method of making a combustion turbine component comprising:

forming a combustion turbine component substrate;

applying an alloy coating on the combustion turbine component substrate by at least

atomizing a metallic liquid to form a metallic powder;

performing a series of heat treating steps on the metallic powder comprising

a first heat treating step performed in an oxidizing atmosphere,

a second heat treating step performed in an inert atmosphere, and

a third heat treating step performed in a reducing atmosphere to form a metallic power having an increased proportion of rare-earth oxides compared to non rare-earth oxides; and

thermal spraying the metallic powder having an increased proportion of rare-earth oxides compared to non rare-earth oxides onto the combustion turbine component substrate,

the alloy coating comprising

a first amount, by weight percent, of cobalt (Co), a second amount, by weight percent, of nickel (Ni), the first amount being greater than the second amount,

chromium (Cr),

aluminum (Al),

at least one additional rare earth element, and

an oxide of the at least one additional rare earth element.

32. The method of claim 31 , wherein the first heat treating step is performed for a first period of time; and wherein the second heat treating step is performed for a second period of time; and wherein the second period of time is greater than the first period of time.

33. The method of claim 32 , further comprising forming a thermal barrier coating after the thermal spraying.

34. The method of claim 31 , further comprising milling the metallic powder to form a nanosized metallic powder after atomizing the metallic liquid; wherein the series of heat treating steps are performed on the nanosized metallic powder; and wherein the nanosized metallic powder is thermal sprayed.

35. The method of claim 31 , wherein the metallic powder is atomized in an oxidizing atmosphere.