Combustion turbine component having rare earth FeCrAI 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

iron (Fe), chromium (Cr), aluminum (Al), titanium (Ti), and molybdenum (Mo),

at least one rare earth element, and

an oxide of the at least one rare earth element.

2. The combustion turbine component of claim 1 , wherein said alloy coating further comprises at least one of manganese (Mn), silicon (Si), and carbon (C).

3. The combustion turbine component of claim 2 , wherein said alloy coating comprises, by percentage of weight, 18% to 25% Cr; 4-8% Al; and 0.4% to 4%, total, of Ti and Mo.

4. The combustion turbine component of claim 3 , wherein said alloy coating further comprises, by percentage of weight, 0.1% to 5%, total, of at least one rare earth element; up to 1%, total, of at least one of Mn, Si, and C; and a balance of Fe and O.

5. The combustion turbine component of claim 2 , wherein said alloy coating comprises, by percentage of weight, 20% to 23% Cr; 5-7% Al; and 0.5% to 3%, total, of Ti and Mo.

6. The combustion turbine component of claim 5 , wherein said alloy coating further comprises, by percentage of weight, 0.5% to 3%, total, of at least one rare earth element; from 0.05% to 0.8%, total, of at least one of Mn, Si, and C; and a balance of Fe and O.

7. The combustion turbine component of claim 2 , wherein the at least one rare earth element comprises yttrium (Y).

8. The combustion turbine component of claim 7 , wherein said alloy coating comprises, by percentage of weight, 18% to 25% Cr; 4-8% Al; 0.05% to 5% Y; and 0.4% to 4%, total, of Ti and Mo.

9. The combustion turbine component of claim 8 , wherein said alloy coating further comprises, by percentage of weight, 0.1% to 5%, total, of at least one rare earth element; up to 1%, total, of at least one of Mn, Si, and C; and a balance of Fe 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 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,

18% to 25% Cr,

4-8% Al,

0.4% to 4%, total, of Ti and Mo,

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

up to 1%, total, of at least one of Mn, Si and C, and

a balance of Fe and O.

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

14. The combustion turbine component of claim 12 , wherein said at least one 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).

15. The combustion turbine component of claim 12 , wherein said alloy coating comprises, by percentage of weight, 20% to 23% Cr; 5-7% Al; 0.5% to 3%, total, of Ti and Mo; 0.5% to 3%, total, of at least one rare earth element; from 0.05% to 0.8%, total, of at least one of Mn, Si, and C; and a balance of Fe and O.

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

iron (Fe), chromium (Cr), aluminum (Al), titanium (Ti), and molybdenum (Mo),

at least one rare earth element, and

an oxide of the at least one rare earth element.

17. The method of claim 16 , wherein the alloy coating further comprises at least one of manganese (Mn), silicon (Si), and carbon (C).

18. The method of claim 17 , wherein the alloy coating comprises, by percentage of weight, 18% to 25% Cr; 4-8% Al; and 0.4% to 4%, total, of Ti and Mo.

19. The method of claim 18 , wherein the alloy coating further comprises, by percentage of weight, 0.1% to 5%, total, of at least one rare earth element; up to 1%, total, of at least one of Mn, Si, and C; and a balance of Fe and O.

20. The method of claim 17 , wherein the alloy coating comprises, by percentage of weight, 20% to 23% Cr; 5-7% Al; and 0.5% to 3%, total, of Ti and Mo.

21. The method of claim 20 , wherein the alloy coating further comprises, by percentage of weight, 0.5% to 3%, total, of at least one rare earth element; 0.05% to 0.8%, total, of at least one of Mn, Si, and C; and a balance of Fe and O.

22. The method of claim 16 , wherein the at least one rare earth element comprises yttrium (Y).

23. The method of claim 22 , wherein the alloy coating comprises, by percentage of weight, 18% to 25% Cr; 4-8% Al; 0.05% to 5% Y; and 0.4% to 4%, total, of Ti and Mo.

24. The method of claim 23 , wherein the alloy coating further comprises, by percentage of weight, 0.1% to 5%, total, of at least one rare earth element; up to 1%, total, of at least one of Mn, Si, and C; and a balance of Fe 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

iron (Fe), chromium (Cr), aluminum (Al),

at least one of titanium (Ti) and molybdenum (Mo),

at least one rare earth element, and

an oxide of the at least one 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 perofrmed 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.