US4447503A
Expired / Lapsed
US
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Superalloy coating composition with high temperature oxidation resistance
Assignee: Howmet Corp
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Filing: 1981-03-31
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Granted: 1984-05-08
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Expires: 2001-03-31
Abstract
Abstract Coatings for iron-, nickel- and cobalt-base superalloys and the resulting coated components having good high temperature oxidation resistance. The coatings consist essentially of, by weight, 5% to 50% chromium, 3% to 30% aluminum, 0.01% to 15% tantalum, up to 10% manganese, up to 5% tungsten, up to 12% silicon, up to 10% hafnium, up to 5% reactive metal from the group consisting of lanthanum, yttrium, and other rare earth elements, up to 5% of rare earth and/or refractory metal oxide particles, and the balance selected from the group consisting of nickel, cobalt and iron, and combinations thereof. Additions of titanium up to 5% and noble metals up to 15% are also contemplated.
Inventors
- 👤 Louis E. Dardi
- 👤 Srinivasan Shankar
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-29 19:33
CPC Classifications
C; C22; C22C; C22C19/00; C22C19/03; C22C19/05; C22C27/00; C22C27/06; C22C38/00; C22C38/18; C23; C23C; C23C30/00; C23C4/00; C23C4/04; C23C4/06; C23C4/073; F; F01; F01D; F01D25/00; F01D25/007; Y; Y02; Y02T; Y02T50/00; Y02T50/60; Y10; Y10S; Y10S428/00; Y10S428/922; Y10S428/9335; Y10S428/937; Y10T; Y10T428/00; Y10T428/12; Y10T428/12493; Y10T428/12535; Y10T428/12611; Y10T428/12639; Y10T428/1266; Y10T428/12771; Y10T428/12778; Y10T428/12861; Y10T428/12931
Claims Analysis
Total Claims: 45
Claim 1
Independent Claim
68 words
In a nickel, cobalt, or iron base superalloy component, the improvement comprising a coating composition on said component consisting essentially by weight of from 6 to 30% aluminum, 0.01 to 15% tantalum, 5 to 50% chromium, 0.1 to 10% manganese, up to 5% tungsten, up to 12% silicon, up to 10% hafnium, and the balance selected from the group consisting of nickel, cobalt, and iron and combinations thereof.
Claim 2
Dependent Claim
68 words
In a nickel, cobalt, or iron base superalloy component, the improvement comprising a coating composition on said component consisting essentially by weight of from 6 to 30% aluminum, 0.01 to 15% tantalum, 5 to 50% chromium, 0.1 to 10% manganese, up to 5% tungsten, up to 12% silicon, up to 10% hafnium, and the balance selected from the group consisting of nickel, cobalt, and iron and combinations thereof.
Claim 3
Dependent Claim
23 words
A component according to claim 1, wherein said composition includes 10 to 20% aluminum, 1 to 10% tantalum, and 10 to 40% chromium.
Claim 4
Dependent Claim
23 words
A component according to claim 2, wherein said composition includes 12 to 17% aluminum, 2 to 7% tantalum, and 15 to 20% chromium.
Claim 5
Dependent Claim
60 words
In a nickel, cobalt, or iron base superalloy component, the improvement comprising a coating composition on said component consisting essentially by weight of from 5 to 35% cobalt, 6 to 25% aluminum, 0.01 to 15% tantalum, 5 to 35% chromium, 0.1 to 10% manganese, up to 5% tungsten, up to 12% silicon, up to 10% hafnium and the balance nickel.
Claim 6
Dependent Claim
60 words
In a nickel, cobalt, or iron base superalloy component, the improvement comprising a coating composition on said component consisting essentially by weight of from 5 to 35% cobalt, 6 to 25% aluminum, 0.01 to 15% tantalum, 5 to 35% chromium, 0.1 to 10% manganese, up to 5% tungsten, up to 12% silicon, up to 10% hafnium and the balance nickel.
Claim 7
Dependent Claim
27 words
A component according to claim 4, wherein said composition includes 10 to 30% cobalt, 10 to 20% aluminum, 1 to 10% tantalum, and 10 to 30% chromium.
Claim 8
Dependent Claim
27 words
A component according to claim 5, wherein said composition includes 15 to 25% cobalt, 12 to 17% aluminum, 2 to 7% tantalum, and 15 to 20% chromium.
Claim 9
Dependent Claim
56 words
In a nickel, cobalt, or iron base superalloy component, the improvement comprising a coating composition on said component consisting essentially by weight of from 3 to 25% aluminum, 0.01 to 12% tantalum, 5 to 40% chromium, up to 10% manganese, up to 5% tungsten, up to 12% silicon, up to 10% hafnium, and the balance cobalt.
Claim 10
Dependent Claim
56 words
In a nickel, cobalt, or iron base superalloy component, the improvement comprising a coating composition on said component consisting essentially by weight of from 3 to 25% aluminum, 0.01 to 12% tantalum, 5 to 40% chromium, up to 10% manganese, up to 5% tungsten, up to 12% silicon, up to 10% hafnium, and the balance cobalt.
Claim 11
Dependent Claim
23 words
A component according to claim 7, wherein said composition includes 10 to 20% aluminum, 1 to 10% tantalum, and 10 to 30% chromium.
Claim 12
Dependent Claim
23 words
A component according to claim 8, wherein said composition includes 12 to 17% aluminum, 2 to 7% tantalum, and 15 to 20% chromium.
Claim 13
Dependent Claim
35 words
A component according to claim 1, 4, or 7, wherein said composition includes up to 5% by weight of a reactive metal selected from the group consisting of lanthanum, yttrium, and the other rare earths.
Claim 14
Dependent Claim
24 words
A component according to claim 10, wherein said reactive metal is present in an amount between 1 and 3% by weight of the composition.
Claim 15
Dependent Claim
36 words
A component according to claim 1, 4, or 7, wherein said composition includes up to 5% by weight of a member selected from the group consisting of rare earth oxide particles and refractory metal oxide particles.
Claim 16
Dependent Claim
21 words
A component according to claim 12 wherein said oxide particles are present in an amount between 0.05 and 2.0% by weight.
Claim 17
Dependent Claim
39 words
A component according to claim 1, 4, or 7 wherein the tantalum is present in an amount between 2.0 and 5.0% by weight, and including from 2.0 to 5.0% by weight of tungsten or manganese or a combination thereof.
Claim 18
Dependent Claim
20 words
A component according to claim 14 wherein the amount of tungsten does not exceed 1.5% by weight of the coating.
Claim 19
Dependent Claim
32 words
A component according to claim 14, wherein said composition includes from 10 to 20% by weight cobalt, from 5 to 25% by weight chromium, and from 10 to 18% by weight aluminum.
Claim 20
Dependent Claim
36 words
A component according to claim 1, 4, or 7, wherein said composition includes from about 0.05 up to about 15% by weight of a noble metal selected from the group consisting of platinum rhodium, and palladium.
Claim 21
Dependent Claim
17 words
A component according to claim 1, wherein said composition includes up to about 5% by weight titanium.
Claim 22
Dependent Claim
68 words
A component according to claim 1, 4, or 7, wherein said composition includes at least one of tungsten and manganese, and the tantalum is present in an amount that is at least 20% by weight of the amount of tantalum, tungsten, and manganese, said composition containing at least about 0.5% by weight tantalum and at least about 0.5% by weight of tungsten or manganese or a combination thereof.
Claim 23
Dependent Claim
25 words
A component in accordance with claim 1, 4, or 7, wherein said manganese is present in said composition in an amount between 1 and 4%.
Claim 24
Dependent Claim
89 words
In a nickel, cobalt, or iron base superalloy component, the improvement comprising a coating composition on said component consisting essentially by weight of from 10 to 50% chromium, 6 to 15% aluminum, 1 to 15% of a metal mixture, and the balance selected from the group consisting of nickel, cobalt, and iron, and combinations thereof, said metal mixture consisting essentially of at least 20% by weight tantalum and the balance tungsten and manganese, said coating containing at least about 0.5% by weight tantalum and at least about 0.5% manganese.
Claim 25
Dependent Claim
89 words
In a nickel, cobalt, or iron base superalloy component, the improvement comprising a coating composition on said component consisting essentially by weight of from 10 to 50% chromium, 6 to 15% aluminum, 1 to 15% of a metal mixture, and the balance selected from the group consisting of nickel, cobalt, and iron, and combinations thereof, said metal mixture consisting essentially of at least 20% by weight tantalum and the balance tungsten and manganese, said coating containing at least about 0.5% by weight tantalum and at least about 0.5% manganese.
Claim 26
Dependent Claim
23 words
A component according to claim 21 wherein the amount of tungsten in said composition does not exceed 1.5% by weight of the coating.
Claim 27
Dependent Claim
68 words
In a nickel, cobalt, or iron base superalloy component, the improvement comprising a coating composition on said component consisting essentially by weight of from 10 to 50% chromium, 6 to 15% aluminum, 0.01 to 8% tantalum, 0.1 to 10% manganese, up to 5% tungsten, up to 12% silicon, up to 10% hafnium, and the balance selected from the group consisting of nickel, cobalt, and iron, and combinations thereof.
Claim 28
Dependent Claim
68 words
In a nickel, cobalt, or iron base superalloy component, the improvement comprising a coating composition on said component consisting essentially by weight of from 10 to 50% chromium, 6 to 15% aluminum, 0.01 to 8% tantalum, 0.1 to 10% manganese, up to 5% tungsten, up to 12% silicon, up to 10% hafnium, and the balance selected from the group consisting of nickel, cobalt, and iron, and combinations thereof.
Claim 29
Dependent Claim
60 words
In a nickel, cobalt, or iron base superalloy component, the improvement comprising a coating composition on said component consisting essentially by weight of from 5 to 35% cobalt, 10 to 35% chromium, 5 to 15% aluminum, 0.01 to 8% tantalum, 0.1 to 10% manganese, up to 5% tungsten, up to 12% silicon, up to 10% hafnium, and the balance nickel.
Claim 30
Dependent Claim
60 words
In a nickel, cobalt, or iron base superalloy component, the improvement comprising a coating composition on said component consisting essentially by weight of from 5 to 35% cobalt, 10 to 35% chromium, 5 to 15% aluminum, 0.01 to 8% tantalum, 0.1 to 10% manganese, up to 5% tungsten, up to 12% silicon, up to 10% hafnium, and the balance nickel.
Claim 31
Dependent Claim
23 words
A component according to claim 1, 4, or 7 wherein said coating consists essentially of a single phased microstructure of alloyed beta phase.
Claim 32
Dependent Claim
55 words
A component according to claim 4 wherein said composition includes 10 to 30% cobalt, 10 to 30% chromium, 10 to 20% aluminum, 1 to 10% tantalum, 0.1 to 2% hafnium, up to 5% manganese, and up to 2% of a reactive metal selected from the group consisting of lanthanum, yttrium, and the other rare earths.
Claim 33
Dependent Claim
55 words
A component according to claim 26 wherein said composition includes 20 to 24% cobalt, 17 to 19% chromium, 13 to 15% aluminum, 2 to 4% tantalum, 0.3 to 0.8% hafnium, 1.0 to 1.5% manganese, and 0.2 to 1.0% of a reactive metal selected from the group consisting of lanthanum, yttrium, and the other rare earths.
Claim 34
Dependent Claim
22 words
A component according to claim 1, 4, or 7 wherein said coating is present in a thickness between 0.0001 and 0.1 inches.
Claim 35
Dependent Claim
32 words
A component according to claim 1, 4, or 7, including a superalloy substrate, and at least two coating layers applied to said substrate, said composition comprising either or both of said layers.
Claim 36
Dependent Claim
21 words
A component according to claim 1, 4, or 7 wherein said coating comprises a bond coat for a thermal barrier coating.
Claim 37
Dependent Claim
17 words
A component according to claim 28, 31, or 34 wherein said coating is deposited by plasma spraying.
Claim 38
Dependent Claim
27 words
A component in accordance with claim 26, wherein said superalloy component to which said coating composition is applied is selected from directionally solidified and single crystal substrates.
Claim 39
Dependent Claim
60 words
In a nickel, cobalt, or iron base superalloy component, the improvement comprising a coating composition on said component consisting essentially by weight of from 6 to 30% aluminum, 0.01 to 15% tantalum, 5 to 50% chromium, 16 to 35% cobalt, up to 10% manganese, up to 5% tungsten, up to 12% silicon, up to 10% hafnium, and the balance nickel.
Claim 40
Dependent Claim
60 words
In a nickel, cobalt, or iron base superalloy component, the improvement comprising a coating composition on said component consisting essentially by weight of from 6 to 30% aluminum, 0.01 to 15% tantalum, 5 to 50% chromium, 16 to 35% cobalt, up to 10% manganese, up to 5% tungsten, up to 12% silicon, up to 10% hafnium, and the balance nickel.
Claim 41
Dependent Claim
19 words
A component according to claim 33, wherein said composition includes 6 to 25% aluminum and 5 to 35% chromium.
Claim 42
Dependent Claim
66 words
In a nickel, cobalt, or iron base superalloy component, the improvement comprising a coating composition on said component consisting essentially by weight of from 6 to 30% aluminum, 0.01 to 15% tantalum, 15% chromium, up to 10% manganese, up to 5% tungsten, up to 12% silicon, up to 10% hafnium, and the balance selected from the group consisting of nickel, cobalt, and iron and combinations thereof.
Claim 43
Dependent Claim
66 words
In a nickel, cobalt, or iron base superalloy component, the improvement comprising a coating composition on said component consisting essentially by weight of from 6 to 30% aluminum, 0.01 to 15% tantalum, 15% chromium, up to 10% manganese, up to 5% tungsten, up to 12% silicon, up to 10% hafnium, and the balance selected from the group consisting of nickel, cobalt, and iron and combinations thereof.
Claim 44
Dependent Claim
49 words
A component according to claim 7, wherein said composition includes 28 to 30% chromium, 8 to 10% aluminum, 2 to 4% tantalum, 1.5 to 2% manganese, and up to 1.5% by weight of a reactive metal selected from the group consisting of lanthanum, yttrium, and the other rare earths.
Claim 45
Dependent Claim
49 words
A component according to claim 4, wherein said composition includes 32 to 35% chromium, 6 to 8% aluminum, 1.5 to 3.5% tantalum, 1.5 to 2% manganese, and up to 1.5% by weight of a reactive metal selected from the group consisting of lanthanum, yttrium, and the other rare earths.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1987-05-08 | 1987-11-07 | 1988-05-08 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1991-05-08 | 1991-11-07 | 1992-05-08 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1995-05-08 | 1995-11-07 | 1996-05-08 | $7700.00 | Window Closed / Lapsed |