Method for forming ternary alloys using precious metals and interdispersed phase

Claim 2

Method of forming on a nickel, cobalt or iron base metal structure a diffusion coating case of a preselected thickness and containing a precious metal ternary alloy and an interdispersed phase to impart improved corrosion, erosion and wear properties to a surface of said structure, which includes applying onto said structure surface an adherent layer of a precious metal in an amount less than normally required for a case of said preselected depth, applying a layer of an interdispersed phase-forming discrete particulate matter to said surface in a predetermined amount, forming a ternary alloy of said base metal, said precious metal and an alloying element by interdiffusing under nonoxidizing conditions said layer-applied structure surface from a diffusion pack containing said alloying element, and distributing said predetermined amount of interdispersed phase-forming matter as a separate entity comprising discrete particulate matter through said ternary alloy sufficient to increase the thickness of said ternary alloy containing case on said structure surface to said preselected thickness, whereby said case has the corrosion resistance properties characteristic of said ternary alloy, and the erosion and wear properties characteristic of said interdispersed phase matter.

Claim 3

The method according to claim 1, including also selecting an iron base alloy structure as said structure to be diffusion coated.

Claim 4

The method according to claim 1, including also selecting a cobalt base alloy structure as said structure to be diffusion coated.

Claim 5

The method according to claim 1, including also selecting a nickel base alloy structure as said structure to be diffusion coated.

Claim 6

The method according to claim 1, including also selecting aluminum as said alloying element.

Claim 7

The method according to claim 1, including also selecting rhodium as said precious metal.

Claim 8

The method according to claim 1, including also selecting platinum as said precious metal.

Claim 9

The method according to claim 1, including also selecting palladium as said precious metal.

Claim 10

The method according to claim 1, including also applying said precious metal to said surface by depositing from a bath thereof.

Claim 11

The method according to claim 1, including also applying said precious metal to said surface by vapor deposition.

Claim 12

The method according to claim 1, including also applying said precious metal to said surface by physical deposition.

Claim 13

The method according to claim 1, including also subjecting said surface applied precious metal to heating for a time and at a temperature prediffusing said precious metal into said surface.

Claim 14

The method according to claim 12, including maintaining a substantially oxygen-free atmosphere at said surface during said precious metal heating.

Claim 15

The method according to claim 1, including also maintaining said predetermined amount of interdispersed phase-forming discrete particulate matter separate from said pack constituents and relatively richly concentrated at said structure surface.

Claim 16

The method according to claim 14, including maintaining said discrete particulate matter as an adherent film on said structure surface.

Claim 17

The method according to claim 15, including also binding said discrete particulate matter into a film with an organic binder.

Claim 18

Method according to claim 1, including also selecting a refractory oxide, a hard carbide, a silicide, or nitride as said interdispersed phase-forming matter.

Claim 19

The method according to claim 17, including also selecting as the hard carbide, tungsten carbide, tantalum carbide, zirconium carbide, titanium carbide or chromium carbide, as the silicate, molybdenum disilicide, or as the nitride, silicon nitride.

Claim 20

Method according to claim 1, including also selecting a metal having an atomic number of 24 or higher and which does not form ternary alloys with said precious metal and said base metal as said interdispersed phase-forming matter.

Claim 21

The method according to claim 19, including also selecting as said interdispersed phase metal tungsten, tantalum, molybdenum, zirconium, titanium, hafnium, yttrium or chromium.

Claim 22

Method according to claim 1, including also selecting as said interdispersed phase-forming matter zirconia, alumina, titania, magnesia, yttria or hafnia refractory oxides having a particle size of less than about 25 microns.

Claim 23

Method of forming on a nickel or cobalt base metal structure a diffusion coating case of a preselected thickness and containing a rhodium or platinum ternary alloy and an interdispersed phase to impart improved corrosion, erosion and wear properties to a surface of said structure, which includes applying onto said structure surface a first adherent layer of rhodium and/or platinum in an amount less than normally required for a case of said preselected depth, applying over said first adherent layer a second adherent layer of an interdispersed phase-forming discrete particulate matter onto said surface in a predetermined amount, forming a ternary alloy of said base metal, said platinum or rhodium, and aluminum by immersing said layer-applied structure surface in an aluminizing pack containing a refractory oxide and aluminum and diffusing under non-oxidizing conditions and simultaneously distributing said predetermined amount of interdispersed phase-forming matter as discrete particulate matter through said ternary alloy sufficient to increase the thickness of said ternary alloy containing case on said structure surface to said preselected thickness, whereby said case has the corrosion resistance properties characteristic of said ternary alloy, and the erosion and wear properties characteristic of said interdispersed phase matter.

Claim 24

Method of forming on a nickel or cobalt base metal structure a diffusion coating case of a preselected thickness and containing a rhodium or platinum ternary alloy and an interdispersed phase to impart improved corrosion, erosion and wear properties to a surface of said structure, which includes applying onto said structure surface a first adherent layer of rhodium and/or platinum in an amount less than normally required for a case of said preselected depth, applying over said first adherent layer a second adherent layer of an interdispersed phase-forming discrete particulate matter onto said surface in a predetermined amount, forming a ternary alloy of said base metal, said platinum or rhodium, and aluminum by immersing said layer-applied structure surface in an aluminizing pack containing a refractory oxide and aluminum and diffusing under non-oxidizing conditions and simultaneously distributing said predetermined amount of interdispersed phase-forming matter as discrete particulate matter through said ternary alloy sufficient to increase the thickness of said ternary alloy containing case on said structure surface to said preselected thickness, whereby said case has the corrosion resistance properties characteristic of said ternary alloy, and the erosion and wear properties characteristic of said interdispersed phase matter.

Claim 25

The method according to claim 22, including also applying said rhodium or platinum metal to said surface by depositing from a bath or vapor thereof.

Claim 26

The method according to claim 23, including also applying said rhodium or platinum to said surface by physical deposition.

Claim 27

The method according to claim 23, including also maintaining said predetermined amount of interdispersed phase-forming discrete particulate matter and relatively richly concentrated at said structure surface.

Claim 28

The method according to claim 25, including binding said discrete particulate matter into an adherent layer on said structure surface with a binding agent.

Claim 29

The method according to claim 26, including also binding said discrete particulate matter with an organic binder as binding agent.

Claim 30

The method according to claim 27, including also selecting as said discrete particulate matter tungsten carbide, tantalum carbide, zirconium carbide, titanium carbide or chromium carbide.

Claim 31

The method according to claim 27, including also selecting as said discrete particulate matter tungsten, tantalum, molybdenum, zirconium, titanium, hafnium, yttrium or chromium.

Claim 32

The method according to claim 27, including also selecting as said discrete particulate matter zirconia, alumina, titania, magnesia, yttria or hafnia refractory oxides having a particle size of less than about 25 microns.

Claim 33

Method of forming on a nickel or cobalt base metal structure a diffusion coating case of a preselected thickness and containing a rhodium or platinum ternary alloy and an interdispersed phase to impart improved corrosion, erosion and wear properties to a surface of said structure, which includes depositing onto said structure surface a first adherent layer of rhodium and/or platinum to a depth equal to from 2.5 to 17% of the ultimate case depth and less than normally required for a case of said preselected depth, applying over said first adherent layer a second adherent layer of an interdispersed phase-forming discrete particulate matter and an organic binder onto said surface in a predetermined amount, forming a ternary alloy of said base metal, said platinum or rhodium, and aluminum by immersing said layer-applied structure surface in an aluminizing pack containing a refractory oxide and aluminum and diffusing under non-oxidizing conditions and simultaneously distributing said predetermined amount of interdispersed phase-forming matter as discrete particulate matter through said ternary alloy sufficient to increase the thickness of said ternary alloy containing case on said structure surface to said preselected thickness, whereby said case has the corrosion resistance properties characteristic of said ternary alloy, and the erosion and wear properties characteristic of said interdispersed phase matter.

Claim 34

Method of forming on a nickel or cobalt base metal structure a diffusion coating case of a preselected thickness and containing a rhodium or platinum ternary alloy and an interdispersed phase to impart improved corrosion, erosion and wear properties to a surface of said structure, which includes depositing onto said structure surface a first adherent layer of rhodium and/or platinum to a depth equal to from 2.5 to 17% of the ultimate case depth and less than normally required for a case of said preselected depth, applying over said first adherent layer a second adherent layer of an interdispersed phase-forming discrete particulate matter and an organic binder onto said surface in a predetermined amount, forming a ternary alloy of said base metal, said platinum or rhodium, and aluminum by immersing said layer-applied structure surface in an aluminizing pack containing a refractory oxide and aluminum and diffusing under non-oxidizing conditions and simultaneously distributing said predetermined amount of interdispersed phase-forming matter as discrete particulate matter through said ternary alloy sufficient to increase the thickness of said ternary alloy containing case on said structure surface to said preselected thickness, whereby said case has the corrosion resistance properties characteristic of said ternary alloy, and the erosion and wear properties characteristic of said interdispersed phase matter.