Thermal barrier coating system for superalloy components

Claim 2

A superalloy article of manufacture of the type having a ceramic thermal barrier coating on at least a portion of its surface, comprising: (a) a superalloy substrate; (b) an adherent, diffusion-aluminide coating applied to said portion of the substrate and adapted to be a reservoir of aluminum for the subsequent in situ formation of an alumina protective scale on said aluminide coated substrate; and (c) a columnar grained ceramic coating bonded directly to said aluminide coating and adapted to allow in situ oxidation of said aluminide to alumina.

Claim 3

The article of claim 1 wherein said diffusion aluminide coating is from 0.5 to 5 mils thick.

Claim 4

The article of claim 1 wherein the ceramic coating is from 0.5 to 50 mils thick.

Claim 5

The article of claim 1 wherein said diffusion aluminide coating is modified by at least one of the elements selected from the group consisting of Pt, Rh, Si, Hf, Cr, Mn, Ta, and Cb.

Claim 6

The article of claim 1 wherein said diffusion aluminide coating is modified by dispersed particles selected from the group consisting of alumina, yttria and hafnia.

Claim 7

The article of claim 1 having an MCrAlY overlay coating applied to the superalloy substrate under the diffusion aluminide coating.

Claim 8

The article of claim 1 wherein an adherent alumina layer has formed in situ due to oxygen transfer between said aluminide coating and said ceramic coating.

Claim 9

The article of claim 1 wherein said ceramic coating is yttria-stabilized zirconia.

Claim 10

The article of claim 1 wherein said ceramic coating is zirconia stabilized with at least one oxide selected from the group consisting of CaO, MgO, and CeO 2 .

Claim 11

The article of claim 1 wherein said ceramic coating is selected from the group consisting of alumina, ceria, yttria-stabilized hafnia, zirconium silicate and mullite.

Claim 12

The article of claim 1 wherein said ceramic coating is selected from the group consisting of borides and nitrides.

Claim 13

The article of claim 1 wherein up to 0.1 mil of the ceramic adjacent to the alumina scale has a denser microstructure, which may vary from equiaxed grains to columnar grains with the balance of the ceramic coating having a fully columnar grained microstructure.

Claim 14

A superalloy article having a ceramic thermal barrier coating, comprising: (a) a superalloy substrate; (b) an adherent, diffusion-aluminide coating applied to said substrate and forming a reservoir of aluminum for the formation of an alumina protective scale on said aluminide coated substrate; (c) a columnar grained ceramic coating bonded to said aluminide-alumina coating; and (d) wherein the exterior of the ceramic coating is densified by glazing.

Claim 15

A superalloy article having a ceramic thermal barrier coating, comprising: (a) a superalloy substrate; (b) an adherent, diffusion-aluminide coating applied to said substrate and forming a reservoir of aluminum for the formation of an alumina protective scale on said aluminide coated substrate; (c) a columnar grained ceramic coating bonded to said aluminide-alumina coating; and (d) wherein the exterior of the ceramic coating is densified by glazing.

Claim 18

The method of claim 14 including the further step of forming, in situ, an adherent alumina layer on said diffusion aluminide coating by oxidation thereof.

Claim 19

The method of claim 15 wherein said alumina layer is formed on said aluminide coating by heat treating the ceramic coated article in an oxygen containing atmosphere at a temperature of between 1600° and 2100° F.

Claim 20

The method of claim 14 including the step of modifying the substrate surface by applying a material selected from the group consisting of Pt, Rh, Si, Hf, Cr, Ta, Cb, alumina, yttria, hafnia, and a MCrAlY surface layer, prior to aluminiding.

Claim 21

The method of claim 14 wherein said columnar grained ceramic coating is applied by vapor deposition.

Claim 26

A superalloy article having a thermal barrier coating system thereon, comprising: a substrate made of a material selected from the group consisting of a nickel-based superalloy and a cobalt-based superalloy; and a thermal barrier coating system on the substrate, the thermal barrier coating system including an intermetallic bond coat overlying the substrate, the bond coat being selected from the group consisting of a nickel aluminide and a platinum aluminide intermetallic compound, a thermally grown aluminum oxide layer overlying the intermetallic bond coat, and a columnar grained ceramic topcoat overlying the aluminum oxide layer.

Claim 27

A superalloy article having a thermal barrier coating system thereon, comprising: a substrate made of a material selected from the group consisting of a nickel-based superalloy and a cobalt-based superalloy; and a thermal barrier coating system on the substrate, the thermal barrier coating system including an intermetallic bond coat overlying the substrate, the bond coat being selected from the group consisting of a nickel aluminide and a platinum aluminide intermetallic compound, a thermally grown aluminum oxide layer overlying the intermetallic bond coat, and a columnar grained ceramic topcoat overlying the aluminum oxide layer.

Claim 28

The article of claim 21, wherein the intermetallic bond coat is from about 0.001 to about 0.005 inches thick.

Claim 29

The article of claim 22, wherein the layer of aluminum oxide is less than about 1 micron thick.

Claim 30

The article of claim 21, wherein the ceramic topcoat is from about 1 to 1000 microns thick.

Claim 31

The article of claim 21, wherein the ceramic topcoat includes zirconium oxide and yttrium oxide.

Claim 32

The article of claim 21, wherein the ceramic topcoat is zirconium oxide plus from 0 to about 20 percent by weight yttrium oxide.

Claim 33

The article of claim 21, wherein the article is a gas turbine blade.

Claim 34

The article of claim 21, wherein the intermetallic coating includes at least one alloying element that does not alter the intermetallic character of the coating.

Claim 35

A superalloy article having a thermal barrier coating system thereon, comprising: a substrate made of superalloy selected from the group consisting of a nickel-based superalloy and a cobalt-based superalloy; and a thermal barrier coating system on the substrate, the thermal barrier coating system including an aluminide intermetallic bond coat upon the substrate, the bond coat being selected from the group consisting of a nickel aluminide and a platinum aluminide, the bond coat having a thickness of from about 0.001 to about 0.005 inches thick, a layer of a thermally grown aluminum oxide upon the intermetallic bond coat, the layer of aluminum oxide being less than about 1 micron thick, and a ceramic topcoat upon the layer of aluminum oxide, the ceramic topcoat having a composition of zirconium oxide plus from 0 to about 20 weight percent yttrium oxide and a columnar grain structure wherein the columnar axis is substantially perpendicular to the surface of the intermetallic bond coat.

Claim 36

A superalloy article having a thermal barrier coating system thereon, comprising: a substrate made of superalloy selected from the group consisting of a nickel-based superalloy and a cobalt-based superalloy; and a thermal barrier coating system on the substrate, the thermal barrier coating system including an aluminide intermetallic bond coat upon the substrate, the bond coat being selected from the group consisting of a nickel aluminide and a platinum aluminide, the bond coat having a thickness of from about 0.001 to about 0.005 inches thick, a layer of a thermally grown aluminum oxide upon the intermetallic bond coat, the layer of aluminum oxide being less than about 1 micron thick, and a ceramic topcoat upon the layer of aluminum oxide, the ceramic topcoat having a composition of zirconium oxide plus from 0 to about 20 weight percent yttrium oxide and a columnar grain structure wherein the columnar axis is substantially perpendicular to the surface of the intermetallic bond coat.

Claim 37

The article of claim 29, wherein the nickel aluminide is NiAl.

Claim 38

A process for preparing a superalloy article having a thermal barrier coating system thereon, comprising: furnishing a substrate made of a nickel-based superalloy; depositing upon the surface of the substrate an aluminide intermetallic coating that has a substantially smooth upper surface, said aluminide intermetallic coating being selected from the group consisting of a nickel aluminide and a platinum aluminide intermetallic compound; thermally oxidizing the upper surface of the intermetallic coating to form an aluminum oxide layer; and depositing upon the surface of the aluminum oxide layer a columnar grained ceramic topcoat by physical vapor deposition.

Claim 39

A process for preparing a superalloy article having a thermal barrier coating system thereon, comprising: furnishing a substrate made of a nickel-based superalloy; depositing upon the surface of the substrate an aluminide intermetallic coating that has a substantially smooth upper surface, said aluminide intermetallic coating being selected from the group consisting of a nickel aluminide and a platinum aluminide intermetallic compound; thermally oxidizing the upper surface of the intermetallic coating to form an aluminum oxide layer; and depositing upon the surface of the aluminum oxide layer a columnar grained ceramic topcoat by physical vapor deposition.

Claim 40

The process of claim 31, wherein the temperature of the substrate during the step of depositing the intermetallic coating is less than about 2100° F.

Claim 41

The process of claim 31, wherein the temperature of the substrate during the step of depositing the ceramic topcoat is from about 1500° F. to about 2100° F.

Claim 42

The process of claim 31, wherein the aluminide is platinum rhodium aluminide.

Claim 43

A thermal barrier coating system for metallic substrates, comprising: an intermetallic bond coat overlying a substrate selected from the group consisting of nickel-based, cobalt-based and iron-based superalloys, the bond coat being selected from the group consisting of a nickel aluminide and a platinum aluminide intermetallic compound, and a columnar grained ceramic topcoat overlying the intermetallic coating.

Claim 44

A thermal barrier coating system for metallic substrates, comprising: an intermetallic bond coat overlying a substrate selected from the group consisting of nickel-based, cobalt-based and iron-based superalloys, the bond coat being selected from the group consisting of a nickel aluminide and a platinum aluminide intermetallic compound, and a columnar grained ceramic topcoat overlying the intermetallic coating.

Claim 45

The coating system of claim 35, wherein the bond coat is oxidized to form an aluminum oxide layer between the bond coat and the topcoat.

Claim 46

A superalloy article having a thermal barrier coating system thereon, comprising: a substrate made of a material selected from the group consisting of a nickel-based superalloy and a cobalt-based superalloy; and a thermal barrier coating system on the substrate, the thermal barrier coating system including an intermetallic bond coat overlying the substrate, the bond coat being selected from the group consisting of a nickel aluminide and a platinum aluminide intermetallic compound, a thermally grown aluminum oxide layer overlying the intermetallic bond coat, and a ceramic topcoat overlying the aluminum oxide layer.

Claim 47

A superalloy article having a thermal barrier coating system thereon, comprising: a substrate made of a material selected from the group consisting of a nickel-based superalloy and a cobalt-based superalloy; and a thermal barrier coating system on the substrate, the thermal barrier coating system including an intermetallic bond coat overlying the substrate, the bond coat being selected from the group consisting of a nickel aluminide and a platinum aluminide intermetallic compound, a thermally grown aluminum oxide layer overlying the intermetallic bond coat, and a ceramic topcoat overlying the aluminum oxide layer.

Claim 48

A thermal barrier coating system for metallic substrates, comprising: an intermetallic bond coat overlying a substrate selected from the group consisting of nickel-based, cobalt-based and iron-based superalloys, the bond coat being selected from the group consisting of a nickel aluminide and a platinum aluminide intermetallic compound, and a ceramic topcoat overlying the intermetallic coating.

Claim 49

A thermal barrier coating system for metallic substrates, comprising: an intermetallic bond coat overlying a substrate selected from the group consisting of nickel-based, cobalt-based and iron-based superalloys, the bond coat being selected from the group consisting of a nickel aluminide and a platinum aluminide intermetallic compound, and a ceramic topcoat overlying the intermetallic coating.