US4532191A — MCrAlY cladding layers and method for making same

Claim 1

Independent Claim 119 words

A method for producing an oxidation resistant cladding of MCrAlY alloy having about six percent or less by weight Al content, said method comprising: providing a substrate; applying a coating layer of MCrAlY to at least a portion of said substrate; providing an inert ambient to engulf at least the coated portion of said substrate in an inert gas and simultaneously; irradiating at least a portion of the MCrAlY layer with a laser beam of sufficient power density to concurrently cause melting of the MCrAlY layer and a portion of the substrate contiguous to the molten MCrAlY to form a cladding of MCrAlY metallurgically bonded to the substrate, said MCrAlY cladding having uniform dispersoids of oxides of the alloy.

Claim 2

Independent Claim 119 words

A method for producing an oxidation resistant cladding of MCrAlY alloy having about six percent or less by weight Al content, said method comprising: providing a substrate; applying a coating layer of MCrAlY to at least a portion of said substrate; providing an inert ambient to engulf at least the coated portion of said substrate in an inert gas and simultaneously; irradiating at least a portion of the MCrAlY layer with a laser beam of sufficient power density to concurrently cause melting of the MCrAlY layer and a portion of the substrate contiguous to the molten MCrAlY to form a cladding of MCrAlY metallurgically bonded to the substrate, said MCrAlY cladding having uniform dispersoids of oxides of the alloy.

Claim 3

Dependent Claim 33 words

The method of claim 1 wherein said substrate is selected from the group consisting of ferritic or austenitic alloys of Fe, Ni or Co base having a carbon content less than about 0.2%.

Claim 4

Dependent Claim 13 words

The method of claim 1 wherein said substrate comprises an iron based alloy.

Claim 5

Dependent Claim 19 words

The method of claim 3 wherein said iron base alloy is characterized as having a relatively low carbon content.

Claim 6

Dependent Claim 19 words

The method of claim 1 wherein M in the MCrAlY cladding comprises iron, cobalt, nickel, or a combination thereof.

Claim 7

Dependent Claim 12 words

The method of claim 5 wherein said cladding of MCrAlY comprises FeCrAlY.

Claim 8

Dependent Claim 59 words

The method of claim 6 wherein said coating of FeCrAlY comprises: (a) from about 59 weight percent to about 81 weight percent iron; (b) from about 15 weight percent to about 30 weight percent chromium; (c) from about 4 weight percent to about 10 weight percent aluminum; (d) from about 0.1 weight percent to about 1.5 weight percent yittrium.

Claim 9

Dependent Claim 17 words

The method of claim 7 wherein said coating layer of MCrAlY comprises a particulate of the alloy.

Claim 10

Dependent Claim 12 words

The method of claim 8 wherein said particulate coating layer comprises FeCrAlY.

Claim 11

Dependent Claim 31 words

The method of claim 9 wherein said FeCrAlY comprises -325 mesh size powder of FeCrAlY uniformly spread upon a coating surface of the substrate to a thickness of about 0.035 inch.

Claim 12

Dependent Claim 13 words

The method of claim 10 wherein said substrate comprises type 304 stainless steel.

Claim 13

Dependent Claim 15 words

The method of claim 11 wherein said substrate has a thickness of about 1/4 inch.

Claim 14

Dependent Claim 40 words

The method of claim 1 or 6 wherein said irradiating laser beam is characterized as having an energy density ranging from about 4 kilowatts per cm 2 to about 12 kilowatts per cm 2 measured proximate to the FeCrAlY cladding.

Claim 15

Dependent Claim 13 words

The method of claim 13 wherein the laser is a CO 2 laser.

Claim 16

Dependent Claim 26 words

The method of claim 13 wherein the inert gas engulfing the coated substrate is selected to be substantially non-absorbing of the warelength of the laser beam.

Claim 17

Dependent Claim 41 words

The method of claim 13 wherein said irradiating continues for a period of time ranging from about 0.5 seconds to about 6.0 seconds to resulting in a FeCrAlY cladding layer ranging in thickness from about 0.02 inch to about 0.15 inch.

Claim 18

Dependent Claim 44 words

The method of claim 16 wherein said irradiation is further characterized as moving the coated substrate into and from said laser beam where with respect to any respective area of the coated substrate irradiation time ranges from about 0.5 seconds to about 6.0 seconds.

Claim 19

Dependent Claim 27 words

The method of claim 17 wherein said laser beam has an intensity of about 4.0 kilowatts per Cm 2 and the irradiation time is about 2.5 seconds.

Claim 20

Dependent Claim 59 words

The method of claim 18 wherein said cladding of CoCrAlY comprises: (a) from about 59 weight percent to about 81 weight percent cobalt; (b) from about 15 weight percent to about 30 weight percent chromium; (c) from about 4 weight percent to about 10 weight percent aluminum; (d) from about 0.1 weight percent to about 1.5 weight percent yittrium.

Claim 21

Dependent Claim 12 words

The method of claim 19 wherein said coating layer comprises particulate CoCrAlY.

Claim 22

Dependent Claim 41 words

The method of claim 20 wherein said CoCrAlY comprises a powder of CoCrAlY ranging in granulation from about -80 mesh to about +270 mesh size, uniformly spread upon a coating surface of the substrate to a thickness of about 0.035 inch.

Claim 23

Dependent Claim 13 words

The method of claim 21 wherein said substrate comprises type 304 stainless steel.

Claim 24

Dependent Claim 15 words

The method of claim 22 wherein said substrate has a thickness of about 1/4 inch.

Claim 25

Dependent Claim 36 words

The method of claim 18 wherein said irradiating laser beam is characterized as having an energy density ranging from about 4.0 kilowatts per cm to about 12.0 kilowatts per cm measured proximate to the FeCrAlY cladding.

Claim 26

Dependent Claim 13 words

The method of claim 24 wherein the laser is a CO 2 laser.

Claim 27

Dependent Claim 26 words

The method of claim 24 wherein the inert gas engulfing the coated substrate is selected to be substantially non-absorbing of the wavelength of the laser beam.

Claim 28

Dependent Claim 13 words

The method of claim 26 or 15 wherein said inert gas comprises Argon.

Claim 29

Dependent Claim 18 words

The method of claim 26 or 15 wherein said inert gas comprises a mixture of Argon and Helium.

Claim 30

Dependent Claim 13 words

The method of claim 28 wherein said inert gas comprises about 20% Helium.

Claim 31

Dependent Claim 23 words

The method of claim 24 wherein said irradiating continues for a period of time ranging from about 0.5 seconds to about 6.0 seconds.

Claim 32

Dependent Claim 44 words

The method of claim 30 wherein said irradiating is further characterized as moving the coated substrate into and from said laser beam where with respect to any respective area of the coated substrate irradiation time ranges from about 0.5 seconds to about 6.0 seconds.

Claim 33

Dependent Claim 25 words

The method of claim 31 wherein said laser beam power density is about 4.0 kilowatts per cm and said irradiation time is about 2.1 seconds.

Claim 34

Dependent Claim 76 words

An oxidation resistant laser cladded substrate comprising: a metallic substrate having a carbon content of less that about 0.2%; an alloy layer of MCrAlY coating where M is iron, cobalt, nickel or a combination thereof and Al content is less than about 6.0%, said layer including a metallurgical bonding region adjacent to said substrate containing about 5% to about 50% of materials contained in said substrate whereby said alloy layer is metallurgically bonded to said substrate.

Claim 35

Dependent Claim 76 words

An oxidation resistant laser cladded substrate comprising: a metallic substrate having a carbon content of less that about 0.2%; an alloy layer of MCrAlY coating where M is iron, cobalt, nickel or a combination thereof and Al content is less than about 6.0%, said layer including a metallurgical bonding region adjacent to said substrate containing about 5% to about 50% of materials contained in said substrate whereby said alloy layer is metallurgically bonded to said substrate.

Claim 36

Dependent Claim 14 words

The cladded substrate of claim 33 wherein said substrate is an iron based alloy.

Claim 37

Dependent Claim 24 words

The cladded substrate of claim 34 wherein said iron based alloy comprises an alloy having Fe, Cr, Ni and less than about 0.2% C.

Claim 38

Dependent Claim 14 words

The cladded substrate of claim 34 wherein said substrate is type 304 stainless steel.

Claim 39

Dependent Claim 14 words

The cladded substrate of claim 33 or 36 wherein said MCrAlY coating comprises FeCrAlY.

Claim 40

Dependent Claim 15 words

The cladded substrate of claim 37 wherein the Al content comprises about 2.4 weight percent.

Claim 41

Dependent Claim 14 words

The cladded substrate of claim 33 or 36 wherein said MCrAlY layer comprises CoCrAlY.

Claim 42

Dependent Claim 15 words

The cladded substrate of claim 39 wherein the Al content comprises about 4.2 weight percent.

Claim 43

Dependent Claim 23 words

The cladded substrate of claim 33 wherein said metallurgical bonding region comprises about 10% to about 40% of materials contained in said substrate.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1988-07-29	1989-01-28	1989-07-30	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1992-07-29	1993-01-28	1993-07-30	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1996-07-29	1997-01-28	1997-07-30	$7700.00	Window Closed / Lapsed

MCrAlY cladding layers and method for making same

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