Oxidation-Resistant Coated Superalloy
A coating-substrate combination includes: a Ni-based superalloy substrate comprising, by weight percent: 2.0-5.1 Cr; 0.9-3.3 Mo; 3.9-9.8 W; 2.2-6.8 Ta; 5.4-6.5 Al; 1.8-12.8 Co; 2.8-5.8 Re; 2.8-7.2 Ru; and a coating comprising, exclusive of Pt group elements, by weight percent: Ni as a largest content 5.8-9.3 Al; 4.4-25 Cr; 3.0-13.5 Co; up to 6.0 Ta, if any; up to 6.2 W, if any; up to 2.4 Mo, if any; 0.3-0.6 Hf; 0.1-0.4 Si; up to 0.6 Y, if any; up to 0.4 Zr, if any; up to 1.0 Re, if any.
1 . An article comprising:
a Ni-based superalloy substrate comprising, by weight percent: 2.0-5.1 Cr; 0.9-3.3 Mo; 3.9-9.8 W; 2.2-6.8 Ta; 5.4-6.5 Al; 1.8-12.8 Co; 2.8-5.8 Re; 2.8-7.2 Ru; and
a coating comprising, exclusive of Pt group elements, by weight percent: Ni as a largest content 5.8-9.3 Al; 4.4-25 Cr; 3.0-13.5 Co; up to 6.0 Ta, if any; up to 6.2 W, if any; up to 2.4 Mo, if any; 0.3-0.6 Hf; 0.1-0.4 Si; up to 0.6 Y, if any; up to 0.4 Zr, if any; up to 1.0 Re, if any.
2 . The article of claim 1 wherein:
the substrate comprises 0.05-0.7 weight percent Hf.
3 . The article of claim 1 wherein:
the substrate has a 1800° F. & 45 ksi (982° C. & 310 MPa) rupture life of at least 120 hours.
4 . The article of claim 1 wherein:
the coating comprises exclusive of Pt group elements, by weight percent: 0.4-0.6 said Hf; 0.2-0.4 said Si.
5 . The article of claim 1 wherein:
the coating has less than 1.0 weight percent overall said platinum group elements combined.
6 . The article of claim 1 wherein:
in weight percent exclusive of platinum group elements, the coating has less than 1.0 weight percent individually other elements.
7 . The article of claim 1 wherein:
the substrate falls within one of the broader ranges of Table VI; and
the coating falls within the associated broader range of Table VII.
8 . The article of claim 7 wherein:
the coating and substrate fall within the narrower associated ranges.
9 . The article of claim 1 wherein:
in weight percent the coating has 6.0≦W+Ta≦13.0 or Ta+W≦0.05.
10 . The article of claim 1 wherein:
in weight percent the coating has 55.0≦Ni+Cr≦67.0 and Ni≦52; and
Cr weight percent in the coating is at least the same as Cr weight percent in the substrate.
11 . The article of claim 1 wherein:
the coating has said weight percent combined of said Y, Hf, Zr, and Si of 0.5-1.5 weight percent.
12 . The article of claim 1 wherein:
the coating has 3.0-5.8 said weight percent Ta; and
the coating has combined contents, if any, of no more than 6.5% by weight Ru, said Ta, and said Re.
13 . The article of claim 1 wherein:
the coating has less than 0.50 weight percent Ru, if any.
14 . The article of claim 1 wherein:
the coating has less than 0.50 said weight percent Re, if any.
15 . The article of claim 1 wherein:
the coating has less than 0.10 said weight percent Re, if any.
16 . The article of claim 1 wherein:
a ratio of said substrate weight percent Re to said coating weight percent Re, if any, is in excess of 10.0.
17 . The article of claim 1 wherein:
a SRZ, if any, is less than 0.001 inch (0.025 mm) thick.
18 . The article of claim 1 being a turbine blade.
19 . The article of claim 1 wherein:
the substrate is a single crystal alloy.
20 . The article of claim 1 wherein:
the substrate has a density of 0.315-0.327 pounds per cubic inch (8.72-9.05 g/cm 3 ).
21 . The article of claim 1 wherein:
the substrate has a creep resistance of at least 50 F (28 C) greater than that of PWA1484.
22 . A method for using the article of claim 1 , comprising:
heating the article to a temperature of at least 2000 F (1093 C) for at least 400 hours while an SRZ, if any, remains less than 0.002 inch (0.05 mm) thick.
23 . A method for forming an article, the method comprising:
providing a substrate, the substrate comprising, by weight percent: nickel as a largest by weight constituent; 2.0-5.1 Cr; 0.9-3.3 Mo; 3.9-9.8 W; 2.2-6.8 Ta; 5.4-6.5 Al; 1.8-12.8 Co; 2.8-5.8 Re; 2.8-7.2 Ru and applying a coating material, the coating material comprising exclusive of Pt group elements, by weight percent:
nickel as a largest by weight constituent; Ni as a largest content 5.8-9.3 Al; 4.4-25 Cr; 3.0-13.5 Co; up to 6.0 Ta, if any; up to 6.2 W, if any; up to 2.4 Mo, if any; 0.3-0.6 Hf; 0.1-0.4 Si; up to 0.6 Y, if any; up to 0.4 Zr, if any; up to 1.0 Re, if any.
24 . The method of claim 23 further comprising at least one of:
applying a layer of one or more platinum group elements prior to applying the coating material; and
applying a ceramic coating after applying the coating material.
25 . The method of claim 23 wherein:
the applying is PVD.
26 . The method of claim 23 wherein:
heating the article to a temperature of at least 2000 F (1093 C) for at least 400 hours while an SRZ, if any, remains less than 0.002 (0.05 mm) inch thick.
27 . An article comprising:
a Ni-based superalloy substrate comprising, by weight percent: 4.0-6.0 Cr; 1.0-2.0 Mo; 4.0-6.0 W; 3.0-7.0 Ta; 5.0-7.0 Al; 11.0-13.0 Co; 4.0-6.0 Re; 1.0-3.0 Ru; 0.1-0.5 Hf; and
a coating comprising, exclusive of Pt group elements, by weight percent: Ni as a largest content 5-11 Al; 3-13 Cr; 9-16 Co; up to 7 Ta, if any; up to 6 W, if any; up to 3 Mo, if any; 0.05-0.7 Hf; 0.1-0.5 Si; up to 0.7 Y, if any; up to 0.7 Zr, if any; up to 0 Re, if any.
28 . An article comprising:
a Ni-based superalloy substrate comprising, by weight percent: 4.0-6.0 Cr; 1.0-2.0 Mo; 5.0-6.0 W; 5.0-6.0 Ta; 5.0-6.0 Al; 5.0-7.0 Co; 5.0-6.0 Re; 2.0-3.0 Ru; and
a coating comprising, exclusive of Pt group elements, by weight percent: Ni as a largest content 5-11 Al; 3-15 Cr; 9-16 Co; up to 7 Ta, if any; up to 6 W, if any; up to 3 Mo, if any; 0.05-0.7 Hf; 0.1-0.5 Si; up to 0.7 Y, if any; up to 0.7 Zr, if any; up to 0 Re, if any.
29 . An article comprising:
a Ni-based superalloy substrate comprising, by weight percent: 2.0-3.0 Cr; 2.0-4.0 Mo; 8.0-10.0 W; 2.0-3.0 Ta; 6.0-7.0 Al; 6.0-8.0 Co; 4.0-5.0 Re; 6.0-8.0 Ru; and
a coating comprising, exclusive of Pt group elements, by weight percent: Ni as a largest content 5-11 Al; 3-15 Cr; 9-17 Co; up to 7 Ta, if any; up to 6 W, if any; up to 3 Mo, if any; 0.05-0.7 Hf; 0.1-0.5 Si; up to 0.7 Y, if any; up to 0.7 Zr, if any; up to 0 Re, if any.
30 . An article comprising:
a Ni-based superalloy substrate comprising, by weight percent: 2.0-3.0 Cr; 1.0-3.0 Mo; 3.0-5.0 W; 3.0-4.0 Ta; 5.0-7.0 Al; 1.0-3.0 Co; 2.0-4.0 Re; 4.0-6.0 Ru; and
a coating comprising, exclusive of Pt group elements, by weight percent: Ni as a largest content 5-11 Al; 3-15 Cr; 9-16 Co; up to 7 Ta, if any; up to 6 W, if any; up to 3 Mo, if any; 0.05-0.7 Hf; 0.1-0.5 Si; up to 0.7 Y, if any; up to 0.7 Zr, if any; up to 0 Re, if any.
31 . An article comprising:
a Ni-based superalloy substrate comprising, by weight percent: 2.0-3.0 Cr; 2.0-3.0 Mo; 7.0-9.0 W; 2.0-4.0 Ta; 5.0-6.0 Al; 7.0-9.0 Co; 3.0-5.0 Re; 4.0-6.0 Ru; and
a coating comprising, exclusive of Pt group elements, by weight percent: Ni as a largest content 5-11 Al; 3-15 Cr; 9-17 Co; up to 7 Ta, if any; up to 6 W, if any; up to 3 Mo, if any; 0.05-0.7 Hf; 0.1-0.5 Si; up to 0.7 Y, if any; up to 0.7 Zr, if any; up to 0 Re, if any.
32 . An article comprising:
a Ni-based superalloy substrate comprising, by weight percent: 3.0-4.0 Cr; 0.5-2.0 Mo; 6.0-8.0 W; 4.0-5.0 Ta; 5.0-7.0 Al; 1.0-3.0 Co; 4.0-5.0 Re; 3.0-5.0 Ru; and
a coating comprising, exclusive of Pt group elements, by weight percent: Ni as a largest content 5-11 Al; 3-15 Cr; 9-17 Co; up to 7 Ta, if any; up to 6 W, if any; up to 3 Mo, if any; 0.05-0.7 Hf; 0.1-0.5 Si; up to 0.7 Y, if any; up to 0.7 Zr, if any; up to 0 Re, if any.
33 . An article comprising:
a Ni-based superalloy substrate comprising, by weight percent: 4.0-6.0 Cr; 1.0-2.0 Mo; 4.0-6.0 W; 6.0-7.0 Ta; 5.0-6.0 Al; 11.0-14.0 Co; 5.0-6.0 Re; 2.0-4.0 Ru; and
a coating comprising, exclusive of Pt group elements, by weight percent: Ni as a largest content 5-11 Al; 3-9 Cr; 9-15 Co; up to 7 Ta, if any; up to 6 W, if any; up to 3 Mo, if any; 0.05-0.7 Hf; 0.1-0.5 Si; up to 0.7 Y, if any; up to 0.7 Zr, if any; up to 0 Re, if any.