Low sulfur nickel base substrate alloy and overlay coating system

1. A coated article having an improved coating oxidation life comprising:

a cast superalloy substrate material having a composition which includes sulfur, which sulfur is present in an amount less than 1 ppm, wherein said substrate material has a composition which includes cobalt, said cobalt being present in an amount as high as 7 wt %, from 2 to 30 wt % chromium, from 2 to 20 wt % tungsten, rhenium, said rhenium being present in an amount as high as 10 wt %, niobium, said niobium being present in an amount as high as 10 wt %, from 10.1 to 15 wt % tantalum, from 1.6 to 5 wt % titanium, from 3 to 7 wt % aluminum, from 2.6 to 10 wt % molybdenum, iron, said iron being present in an amount as high as 5 wt %, ruthenium, said ruthenium being present in an amount as high as 10 wt %, iridium, said iridium being present in an amount as high as 5 wt %, zirconium, said zirconium being present in an amount from 0.3 to 2.0 wt %, hafnium, said hafnium being present in an amount as high as 3.0 wt %, silicon, said silicon being present in an amount from 1.1 to 2.0 wt %, and the balance nickel;

an overlay coating containing nickel, cobalt, yttrium, chromium, and aluminum formed over a surface of said substrate material without any sulfur modifying element being pre-deposited onto said surface of the substrate; and

an interface between said surface of the substrate and said overlay coating having a high surface area configured to segregate said sulfur; wherein at least one of the surface area between the overlay coating and the superalloy substrate material has been at least doubled by mechanical techniques selected from the group consisting of rough polishing, grit blasting, oil honing, rough machining; and

results in a 50% enhanced sulfur segregation at the interface.

2. A coated article according to claim 1 , wherein said substrate material is cast into a shape of a turbine engine component.

3. A coated article according to claim 1 , wherein said substrate material has a single crystal microstructure.

4. A coated article according to claim 1 , wherein said substrate material has a directionally solidified (DS) or columnar grain, or an equiaxed microstructure.

5. A coated article according to claim 1 , wherein the superalloy substrate material has a gamma prime precipitate volume fraction anywhere from 20 to 75% and a dendrite size from 5 to 1000 microns.

6. A coated article according to claim 1 , wherein said overlay coating has a composition comprising cobalt, said cobalt being present in an amount as high as 30 wt %, from 10 to 40 wt % chromium, from 5 to 35 wt % aluminum, from 0.01 to 5.0 wt % yttrium, niobium, said niobium being present in an amount as high as 5.0 wt %, tantalum, said tantalum being present in an amount as high as 5.0 wt %, iron, said iron being present in an amount as high as 10 wt %, molybdenum, said molybdenum being present in an amount as high as 5.0 wt %, rhenium, said rhenium being present in an amount as high as 5.0 wt %, ruthenium, said ruthenium being present in an amount as high as 5.0 wt %, iridium, said iridium being present in an amount as high as 2.0 wt %, platinum, said platinum being present in an amount as high as 30 wt.%, zirconium, said zirconium being present in an amount from 0.3 to 1 wt. %, hafnium, said hafnium being present in an amount as high as 5.0 wt %, silicon, said silicon being present in an amount from 1.1 to 5.0 wt %, and the balance nickel.

7. A coated article according to claim 1 , wherein an outer surface of said overlay coating has a roughened surface between the outer surface and a thermally grown oxide (TGO) layer.

8. A coated article according to claim 1 , further comprising a thermal barrier coating deposited over said overlay coating.

9. A coated article according to claim 8 , wherein said thermal barrier coating comprises a ceramic coating.

10. A coated article according to claim 1 , wherein said sulfur is present in an amount less than 0.3 ppm.

11. A coated article having an improved coating oxidation life comprising:

a cast superalloy substrate material having a composition which includes sulfur, which sulfur is present in an amount less than 1 ppm, wherein said substrate material has a composition which includes cobalt, said cobalt being present in an amount as high as 7 wt %, from 2 to 30 wt % chromium, from 2 to 20 wt % tungsten, rhenium, said rhenium being present in an amount as high as 10 wt %, niobium, said niobium being present in an amount as high as 10 wt %, from 10.1 to 15 wt % tantalum, from 1.6 to 5 wt % titanium, from 3 to 7 wt % aluminum, from 2.6 to 10 wt % molybdenum, iron, said iron being present in an amount as high as 5 wt %, ruthenium, said ruthenium being present in an amount as high as 10 wt %, iridium, said iridium being present in an amount as high as 5 wt %, zirconium, said zirconium being present in an amount from 0.3 to 2 wt. %, hafnium, said hafnium being present in an amount as high as 3.0 wt %, silicon, said silicon being present in an amount from 1.1 to 2.0 wt %, and the balance nickel;

an overlay coating containing nickel, cobalt, yttrium, chromium, and aluminum formed over a surface of said substrate material without any sulfur modifying element being pre-deposited onto said surface of the substrate, wherein an outer surface of said overlay coating has a roughened surface between the outer surface and a thermally grown oxide (TGO) layer; and

an interface between said surface of the substrate and said overlay coating having a high surface area configured to segregate said sulfur; wherein at least one of the surface area between the overlay coating and the superalloy substrate material has been at least doubled by mechanical techniques selected from the group consisting of rough polishing, grit blasting, oil honing, rough machining; and

results in a 50% enhanced sulfur segregation at the interface.