Methods for improving corrosion and oxidation resistance to the under platform region of a gas turbine blade

1. A method for providing corrosion and oxidation resistance to an under platform region of a gas turbine blade, the method comprising the steps of:

a) providing a gas turbine blade comprising a superalloy selected from the group consisting of nickel-base superalloys, cobalt-base superalloys, iron-base superalloys, and combinations thereof, the blade further comprising an under platform region having an exterior surface;

b) providing a slurry composition, wherein the slurry composition is substantially free of hexavalent chromium, and wherein the slurry composition comprises colloidal silica and aluminum-based powder;

c) applying the slurry composition to a pre-selected portion of the exterior surface of the under platform region;

d) subsequent to (c), heating the gas turbine blade under suitable diffusion conditions to form a silicon-modified aluminide coating on the pre-selected portion, wherein the cure conditions are operably selected to provide at least about 20% by weight aluminum and about 3% by weight silicon in the outer 25% of a coating thickness; and

e) subsequent to (c), pre-curing the slurry composition under ambient or elevated temperature conditions to form a pre-cured coating and inspecting the pre-cured coating for at least one surface defect selected from cracking, flaking, and excess buildup prior to (d).

2. The method according to claim 1 wherein in (b), providing a slurry composition includes:

providing a slurry composition including (a) colloidal silica and (b) particles of an aluminum-based powder wherein the colloidal silica is present in the range of about 5% by weight to about 20% by weight, based on silica solids, and wherein aluminum is present in the range of about 0.5% by weight to about 45% by weight of the total composition.

3. The method according to claim 1 wherein in (d), heating the gas turbine blade includes:

heating the gas turbine blade to a pre-selected temperature in the range of about 800° C. to about 920° C. in an environment selected from the group consisting of a vacuum and a protective atmosphere; and

holding the temperature of the gas turbine blade at the pre-selected temperature for a pre-selected length of time in the range of about 0.5 hours to about 8 hours to diffuse the aluminum and silicon into the pre-selected portion to form a corrosion and oxidation resistant coating.

4. The method according to claim 1 wherein in (a), providing the gas turbine blade includes providing a gas turbine blade selected from the group consisting of a new make blade, and a used blade needing repair in at least an under platform region thereof.

5. The method according to claim 4 wherein the gas turbine blade is a used blade in need of repair, the method further including:

removing a prior coating, if present, from at least the pre-selected portion.

6. The method according to claim 1 further including:

prior to (c), preparing at least the pre-selected portion for reception of the slurry composition.

7. The method according to claim 1 wherein in (c), applying the slurry composition includes utilizing at least one application technique selected from brushing, spraying, pouring, flowing, dipping, rolling.

8. The method according to claim 1 wherein in (c), applying the slurry composition includes utilizing robotic sprayers in an automated application system.

9. The method according to claim 1 including:

removing at least one portion of the pre-cured coating upon detection of the at least one surface defect.

10. The method according to claim 9 including:

replacing the removed pre-cured coating with additional slurry composition.