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    • 专利摘要:
    METHOD FOR PRODUCING A CHROME DIFFUSION COATING, E, ONE STEP METHOD FOR PRODUCING A CHROME DIFFUSION COATING Unique and improved chromization processes are described. The processes involve forming chromizing coatings located over selected regions of a substrate. Chromium diffusion coatings are applied locally to selected regions of substrates in a controlled manner, compared to conventional chromization processes, and yet in a manner that produces less material scrap and does not require masking. A second coat can be selectively applied over other regions of the substrate.
    公开号:BR112016016203B1
    申请号:R112016016203-0
    申请日:2015-01-09
    公开日:2021-05-25
    发明作者:Zhihong Tang；Kevin E. Garing；Thomas D. Findlay；Thomas F. Lewis；James K. Knapp
    申请人:Praxair S.T. Technology, Inc；
    IPC主号:
    专利说明:

    Field of Invention
    [0001] The present invention generally relates to new and improved methods for applying chromium diffusion coatings on selective regions of a component. Fundamentals of the Invention
    [0002] A gas turbine engine consists of several components. During operation, gas turbine engine components are typically exposed to harsh environments that can damage turbine components. Environmental damage can occur in a variety of ways, including damage as a result of heat, oxidation, corrosion, hot corrosion, erosion, wear, fatigue, or a combination of various modes of degradation.
    [0003] Today's turbine engines are designed and operated in such a way that the environmental conditions and consequently the types of environmental damage in different regions of the various turbine components can vary significantly from one to another. As a result, an individual turbine engine component often requires multiple coating systems to protect the component's underlying base materials.
    [0004] As an example, Figure 1 shows the various sections of a typical turbine blade. The turbine blade has several sections, including a platform, an airfoil extending upwards from the platform, a shaft extending downwards from the platform, a root extending downwardly form the shaft, and passageways. internal cooling located inside the root, stem and airfoil. The platform has a top side adjacent to the airfoil and a bottom side adjacent to the shank.
    [005] In service, the airfoil and platform operate in the hottest regions of the turbine blades, and for this reason they are subjected to degradation by oxidation. Consequently, protection of base materials from the airfoil and top deck surface regions generally requires an oxidation resistant coating, such as a diffusion aluminum coating and/or an MCrAlY overlay coating. These oxidation resistant coatings are capable of forming a slow-growing, sticky alumina scale. The fouling provides a barrier between the metallic substrate and the environment. A thermal barrier coating can optionally be applied as a topcoat over the oxidation resistant coating to further reduce the metal temperature and extend the service life of the component.
    [006] In contrast to the airfoil and platform, the other regions of the turbine blade, including regions below the platform, stem, root and internal cooling passages, are exposed during service to relatively lower temperatures and to build up of corrosive particulates. Because these regions were previously exposed to temperatures and conditions where environmental damage does not have a tendency to occur, protective coatings were not required. However, as today's blades continue to be exposed to increasingly higher operating temperatures, particulates accumulated on the surface begin to fuse and cause Type II hot corrosion attack, which can lead to premature blade failure. of the turbine. Type II hot etch conditions generally require a chromium diffusion coating rather than an aluminum diffusion coating for protection.
    [007] The fans are subjected to attack similar to the blades, as the fans are generally made of materials similar to the blades, and may also have cooling channels.
    [008] As can be seen, different regions of a turbine blade are susceptible to different types of damage. Proper protection therefore requires selectively applying different protective coating systems on various turbine blade components. In particular, application of chromium coatings locally only over those regions of the turbine blade susceptible to hot corrosion attack is required.
    [009] However, conventional coating processes have their limitations for the successful application of chromizing coatings on only selected regions of the component. For example, conventional chromization processes, such as compression and vapor phase chromization, are not able to form a chromium diffusion coating over selective regions of a turbine component without using a custom masking apparatus or post-coating treatment. .
    [0010] Compression chromization processes require a powder mixture including (a) a metallic source of chromium, (b) a vaporizable halide activator, and (c) an inert filler material such as aluminum oxide. The parts to be coated are completely enveloped in the compacted materials and then enclosed in a sealed or retorted chamber. The retort is then heated in a protective atmosphere to a temperature between about 1400-2100°F for about 2-10 hours to allow the Cr to diffuse into the surface. However, a complex and customized masking device is required to prevent deposition of the chrome coating at desired locations. In addition, compression chromization processes require a contact relationship between the chromium source and the metallic substrate. Compression chromization is generally not effective for coating inaccessible or hard-to-reach regions, such as the surfaces of internal cooling passageways of turbine blades. Also, unwanted residual coatings can form. These residual coatings are difficult to remove from cooling air holes and internal passages, and airflow restriction can occur. For this reason, compression chromization is not effective for selectively coating the surfaces of internal cooling passages.
    [0011] Vapor phase chromization processes are also problematic. A vapor phase chromization process involves placing the parts to be coated in a retort in a non-contact relationship with a chromium source and halide activator. Although a vapor phase process can effectively coat the surface of the internal cooling passages, the entire surface is undesirably coated. As a result, the turbine blade needs to be masked along those regions where no chromium coating is required. However, masking is challenging and often does not completely hide blade regions intended to be masked. Consequently, special post-coat treatments such as machining, grit blasting, or chemical treatments are required to remove excess chrome coating where no chrome coating is required. Such post-coat treatments are generally non-selective and result in undesirable loss of substrate material. Material loss can lead to changes in critical dimensions of turbine components and lead to premature structural dimension. Additionally, special care is typically required during post-coat treatments to avoid damage to the substrate or any unremoved chrome coating.
    [0012] The problems of using a compression or vapor phase chromization process are exacerbated as the geometry of certain components of the turbine component becomes more complex, such as regions below the platform, stem, root and passageways of internal cooling.
    [0013] In view of the disadvantages of existing chromizing processes, there is a need for a new generation chromizing process that can produce a chromizing coating in a controlled and accurate manner over selective regions of a component, thus minimizing masking requirements in areas where no coating is required, reducing material scrap and raw material consumption and minimizing exposure to hazardous materials in the workplace. Other advantages and applications of the present invention will become apparent to those skilled in the art. Invention Summary
    [0014] In a first aspect of the present invention, a method for producing a chromium diffusion coating over selected regions of a substrate is provided. A slurry containing chromium is provided. The slurry is applied to localized substrate surfaces. The slurry is cured. The slurry is heated in a protective atmosphere to a predetermined temperature for a predetermined duration. Chromium-containing vapors are generated. Chromium diffuses onto such localized surfaces to form the coating. The coating has a microstructure characterized by a substantial reduction in nitride and oxide inclusions and reduced α-Cr phase levels compared to conventional chromization processes.
    [0015] In a second aspect of the present invention, a one-step method for producing a localized chromium diffusion coating and a localized aluminum diffusion coating over selected regions of a substrate is provided. A slurry containing chromium is provided. The chromium-containing slurry is applied over a first region of the substrate, characterized by an absence of masking. An aluminum-containing material is provided. The chromium-containing slurry and aluminium-containing material are heated in a protective atmosphere to a predetermined temperature for a predetermined duration. Chromium diffuses into the first region. Aluminum diffuses into a second region in the absence of masking. Localized chromium diffusion coating forms along the first region. The chromium diffusion coating has a microstructure characterized by a substantial reduction in nitride and oxide inclusions and reduced α-Cr phase levels compared to conventional chromization processes. A localized aluminum diffusion coating forms along the second region.
    [0016] In a third aspect, a one-step method for producing a localized chromium diffusion coating and a localized aluminum diffusion coating over selected regions of a blade is provided. A slurry containing chromium is provided. The chromium-containing slurry is applied over a blade shaft, characterized by an absence of masking. An aluminum-containing material is provided within the retort. The partially coated blade is loaded into the retort. The partially coated blade is heated. Aluminum-containing vapors and chromium-containing vapors are generated. Chromium is diffused from vapors containing chromium within an outer surface of the blade shaft. Aluminum is diffused from vapors containing aluminum within an airfoil of the blade. Localized chromium diffusion coating is formed along the stem. The chromium diffusion coating has a microstructure characterized by a substantial reduction in nitride and oxide inclusions and reduced α-Cr phase levels compared to conventional chromization processes. Localized aluminum diffusion coating is formed along the airfoil.
    The invention may include any of the following aspects in various combinations and may also include any other aspect of the present invention described below in the written description. Brief Description of Drawings
    [0018] The objectives and advantages of the invention will be better understood from the following detailed description of the preferred embodiments thereof in connection with the accompanying figures in which like numbers denote the same characteristics from beginning to end and in which: Figure 1 shows a conventional turbine blade; Figure 2 shows a schematic diagram of selectively applying an aluminium-in-place coating and a chromizing-in-place coating over selective regions of a substrate; Figure 3 shows a block flow diagram according to with the principles of the present invention, for an approach of simultaneously forming a chromium diffusion coating on the surface of selected regions of one turbine blade while forming an aluminum coating on the surface of other regions of the turbine blade; Figure 4 shows a block flow diagram, in accordance with the principles of the present invention, of a 2-step approach that forms initially a chromium diffusion coating on the surface of selected regions of one turbine component and thereafter forms an aluminum coating on the surface of other regions of the component; Figure 5 shows a block flow diagram of a 2 approach steps to apply the chromium diffusion coating over the surface of selected regions of a turbine component and then applying an MCrAlY overlay coating over the surfaces of other selected regions of the component; and Figure 6a shows a transverse sectional microstructure of a locally applied aluminum coating on an airfoil, and Figure 6b shows a transverse sectional microstructure of a chromium diffusion coating applied locally on the stem, whereby both coatings were produced by the method described in Example 1 using the inventive approach shown in Figure 3. Detailed Description of the Invention
    [0019] The objectives and advantages of the invention will be better understood from the following detailed description of the preferred embodiments thereof in connection. The present description relates to new and improved methods for applying chromium diffusion coatings over selective regions of a component. The description is reported herein in the various embodiments and with reference to the various aspects and features of the invention.
    [0020] The relationship and functioning of the various elements of this invention are best understood from the following detailed description. The detailed description contemplates the characteristics, aspects and modalities of the various modifications and combinations as being within the scope of the description. The description may therefore be specified as comprising, consisting or consisting essentially of any such combinations and modifications of these specific features, aspects, and embodiments, or a selection of one or one of them.
    [0021] In all embodiments of the present invention, the terms "chromizing slurry" and "chromizing coating" will refer to those compositions containing chromium as more fully described in United States Provisional Patent Application 13603-US-P1, Serial No. 61/927,180, concurrently filed January 14, 2014, which is incorporated herein by reference in its entirety. As more fully described herein, the chromizing coatings produced from such a chromizing slurry composition are unique and characterized by significantly reduced levels of nitride and oxide inclusions, along with lower α-chromium phases, compared to those chromizing coatings produced by conventional chromization processes. As a result, the coatings have superior resistance to corrosion, erosion and fatigue compared to chromizing coatings produced by conventional compression, vapor phase or slurry processes.
    [0022] The improved formulation is based, at least in part, on the selected combination of halide activators and specific buffer materials within the slurry formulation. The slurry composition comprises a chromium source, a specific class of halide activator, a specific buffer material, a binder material and a solvent. The slurry composition of the present invention comprises a source of chromium in a range of from about 10% to about 90% of the slurry weight; a halide activator in a range of about 0.5% to about 50% by weight of the chromium source, a buffer material in the range of about 0.5% to about 100% of the chromium source; a binder solution in a range of about 5% to about 50% of the slurry weight wherein the binder solution includes a binder and a solvent. An optional inert filler material can be provided that is in the range of about 0% to about 50% of the slurry weight. In a preferred embodiment, the chromium source is in a range of about 30% to about 70%; the halide activator is in a range of about 2% to about 30% of the chromium source, the buffer material is in a range of about 3% to about 50% of the chromium source; the binder solution in a range of about 15% to about 40% of the slurry weight; and the optional inert filler material is in a range of about 5% to about 30% of the slurry weight.
    [0023] Generally speaking, the chromium slurry comprises a chromium source, a halide activator and a specific binder solution. The chromium slurry further comprises a specific metallic powder or mixture of powders which can decrease the chemical activity of chromium in the slurry and absorb nitrogen and residual oxygen during the coating process. Additional details of the chromizing slurry and chromizing coating compositions are described in Provisional Patent Application 13603-US-P1, Serial No. 61/927,180, concurrently filed January 14, 2014.
    [0024] In accordance with the principles of the present invention, the chromium diffusion coatings of the present invention are locally applied to selected regions of metallic substrates in a controlled manner, compared to conventional chromization processes, and further in a manner that produces less scrap material and does not require masking. Unless otherwise indicated, it is to be understood that all compositions are expressed as percentages by weight (% by weight).
    [0025] The slurry chromization process is considered to be a chemical vapor deposition process. Upon heating to elevated temperature, the chromium source and the halide activator in the slurry mixture react to form volatile chromium halide vapor. The transport of chromium halide vapor from the slurry to the alloy surface to be coated takes place primarily by gaseous diffusion under the influence of the chemical potential gradient between the slurry and the alloy surface. When reaching the alloy surface, these chromium halide vapors react on the surface and deposit chromium, which diffuses into the alloy to form the coating.
    [0026] One embodiment of the present invention utilizes locally applying a chromium slurry composition onto a gas turbine blade (as shown in Figure 1). Appropriate methods include brushing, spraying, dipping, dip spinning or injection spinning. The specific method of application depends, at least in part, on the viscosity of the slurry composition as well as the geometry of the components. The chromizing slurry composition is applied over any one or more of the blade regions susceptible to Type II corrosion attack, such as a surface of the stem, root, below deck and internal cooling passages. Complex and customized tools and masking, which are typical and known to be used for many compression processes, are not required, thus simplifying the total chromization process. In general, application of approximately 0.02-0.1 inches of chromizing slurry ensures adequate coverage without using excessive amounts of slurry compositions, thus minimizing the use of raw materials. Having applied the chromizing slurry, the slurry is subjected to a heating cycle in a protective atmosphere for a predetermined duration and temperature to allow the chromium to diffuse into localized regions of the component. After the diffusion treatment, any remaining slurry residues along the localized regions can be removed by various methods, including wire brush, coarse oxide sand burnishing, glass bead, high pressure water jet, or other conventional methods. . Slurry residues typically comprise unreacted slurry compositional materials. Removal of any residue from the slurry is conducted in order to avoid damage to the underlying chromium surface layer. The resulting chromization coating contains insubstantial amounts of oxide and nitride inclusions along with lower levels of the alpha-chromium phase compared to a compression chromization process. The average chromium content in the chromium diffusion coating is about 15-50% by weight, and more preferably 25-40% by weight.
    [0027] Compared to compression chromization, the slurry method of the present invention allows the slurry to be applied locally over only those regions where the chromizing coating is required. Also, unlike compression chromization, no complex, custom tooling and masking is required.
    [0028] Another embodiment of the present invention provides for the application of different coatings on selective regions of a component. Specifically, an aluminum coating can be applied locally along with the chrome coating. Figure 2 shows the resulting coating system that is produced by the methods of the present invention. A chromium coating is located at the bottom region of the substrate where corrosion resistance is required, and an aluminum coating is located at the top region where corrosion resistance is required. Any conventional aluminum coating process such as vapor phase, slurry or chemical vapor deposition processes can be employed to produce the aluminum diffusion coating. As an example, an aluminum slurry coating process can be used with a conventional aluminium slurry such as SermAlcote™ 2525, which is commercially produced and sold by Praxair Surface Technologies, Inc. (Indianapolis, Indiana). The aluminide slurry can be applied in a manner as known in the art, and as described in United States Patent No. 6110262, which is incorporated herein by reference in its entirety.
    [0029] In a preferred embodiment of the present invention, Figure 3 shows a block flow diagram for simultaneously forming in a single step a chromium diffusion coating located on the surface of selected regions of the turbine blade while forming a coating of aluminum located on the surface of other regions of the turbine blade. One or more layers of chromium slurry is applied over selected regions of the blade that are susceptible to Type II corrosion attack, such as the surface of the stem, root, below deck and internal cooling passages. Brushing, spraying, dipping, dip spinning or injection spinning can be used to apply the chrome slurry of sufficient thickness to ensure adequate coverage of surfaces. Masking is not required due to the ability to selectively apply the chromizing slurry only to the desired blade surfaces.
    [0030] After the application of the chromizing slurry, a conventional vapor phase, slurry or chemical vapor deposition process can be used with aluminum source materials as known in the art. The diffusion treatment can take place under an elevated temperature in the range of about 1000-1150 °C in a protective atmosphere for up to 24 hours, and more preferably about 2-16 hours. Upon heating to elevated temperature, aluminum halide vapors are generated from the aluminum source materials, transported to the alloy surface, and form aluminum coatings where no chromizing slurry is applied. These aluminum halide vapors can also reach the outer surface region of the chromizing slurry. However, these aluminum halide vapors react with the chromium source in the slurry mixture to form chromium halide vapors, thus leading to a substantial decrease in aluminum halide vapor partial pressure across the slurry thickness to the alloy surface. Meanwhile, within the chromization slurry, chromium halide vapors were partially generated by the chemical reactions of the chromium source and the halide activator in the slurry mixture. As a result, chromium halide vapors, as opposed to aluminum halide vapors, tend to prevail and preferentially occupy the localized regions where the chromizing slurry has been applied. The existence of chromium halide vapors in such regions allows the formation of a chromium coating that is thermodynamically favored over an aluminium coating. Consequently, the localized aluminum diffusion coating is produced locally in a controlled manner along those surfaces where no chromizing slurry has been applied, while a localized chromium diffusion coating is produced simultaneously along other regions.
    [0031] In a preferred embodiment, a chromium slurry is provided and applied over a region of the turbine blade susceptible to type II corrosion (ie, stem). No special masking tools are required. The partially slurry coated sheet is then loaded into a vapor phase aluminizing retort and heated in a protective atmosphere to carry out a vapor phase aluminizing process. The chromium and aluminizing coatings are formed simultaneously during the heating cycle. The aluminizing coating forms along regions susceptible to oxidation (ie, airfoil) while the chromizing coating forms along relatively cooler regions susceptible to corrosion (ie, rod) without employing masking. Any excess residue can be removed from the coated regions.
    [0032] Other variations are contemplated. For example, the aluminum coating can be applied separately after the formation of the chromizing coating. Prior to the aluminizing process, an aluminizing mask is applied to the chromizing region that was previously produced by the localized slurry chromization process of the present invention. This mask prevents the deposition of the aluminum coating onto the chromizing coating during the aluminizing process, as inadvertent deposition of the aluminum coating onto the chromizing coating can weaken the corrosion resistance of the chromizing coating. In this regard, Figure 4 shows a 2-step approach of a block flow diagram in accordance with the principles of the present invention. Alternatively the aluminum coating can be applied prior to formation of the chromizing coating.
    [0033] Still further, other types of coatings can be used in the present invention. As an example, after diffusion treatment of the coated part with the chromium slurry over those selected regions of the turbine blade susceptible to corrosion attack and removal of any residual coating, a second MCrAlY overlay coating can be applied to the airfoil by any conventional processes such as air plasma spraying, LPPS or HVOF. Prior to application of the MCrAlY coating, a mask is applied to the region of chromization that was previously produced by the localized slurry chromization process of the present invention. Figure 5 shows a block flow diagram of such a 2-step approach to the coating process. Example 1
    [0034] A turbine blade as shown in Figure 1 was selectively coated with a chromizing slurry composition and an aluminum coating using the one-step approach shown in Figure 3. The chromizing slurry composition was prepared comprising a aluminum fluoride activator, chromium powder, nickel powder, and an organic binder solution. The slurry was prepared by mixing the following: 75 g of 325 mesh chrome powder; 20 g of aluminum fluoride; 4 g of hydroxypropylcellulose klucel™; 51 g of deionized water; 25 g of nickel powder and 25 g of alumina powder.
    [0035] The chromizing slurry composition was applied to selected surfaces of a rod as shown in Figure 1 by dipping the blade into the slurry. The turbine blade was made of a single crystal nickel pot superalloy which has a nominal composition of, by weight, about 7.5% Co, 7.0% Cr, 6.5% Ta, 6.2% Al, 5.0% W, 3.0% Re, 1.5% Mo, 0.015% Hf, 0.05% C, 0.004% B, 0.01% Y and the rest nickel. The slurry coating was then allowed to dry in an oven at 80°C for 30 minutes followed by curing at 135°C for 30 minutes.
    [0036] The slurry coated part was placed into a typical vapor phase aluminizing retort that contained a source of Cr-Al chunks and aluminum fluoride powder. The Cr-Al and aluminum fluoride powder pieces were located at the bottom of the coating retort. The piece coated with the slurry was placed without contact with either Cr-Al pieces or aluminum fluoride. After purging the retort with argon flow for 1 hour, the retort was heated to 2010°F in an argon atmosphere and held for 4 hours to allow the chromium and aluminum to selectively diffuse within the sample airfoil, respectively. Upon completion of the diffusion treatment, the sample was cooled to room temperature under an argon atmosphere and the slurry residues were removed from the sample by a smooth grain blasting operation.
    [0037] The coating results are shown in Figures 6a and 6b. The sample had its upper half or airfoil region coated with an aluminum coating, as shown in Fig. 6a, to resist high temperature oxidation and its bottom half or stem region coated with a layer enriched with chromium, such as shown in Fig.6b, to resist hot corrosion at low temperature. The chromium diffusion coating had an insignificant amount of oxide and nitride inclusions compared to conventional compression or vapor phase chromization processes. The coating was observed to be substantially free of the α-Cr phase and the average chromium concentration in the chromium diffusion coating was greater than 25% by weight.
    [0038] The chromization methods of the present invention represent a substantial improvement over conventional Cr diffusion coatings produced from compression processes, in the vapor or slurry phase. As seen, the present invention offers a unique method for locally applying chromizing slurry formulations with an optional second coating over other selected regions. The slurries of the present invention are advantageous because they can be selectively applied with control and accuracy over localized regions of the substrate by simple application methods, including brushing, spraying, dipping or injection. In addition, the control and accuracy of the application of chrome and other coatings can take place in a single step without masking. In contrast, conventional compression and vapor phase processes cannot locally generate chromium coatings along selected regions of a substrate. As a result, these conventional coatings require difficult masking techniques that typically are not effective in hiding those regions along the metallic substrate that are not desired to be coated.
    [0039] The ability of the present invention to locally apply slurry formulations to form coatings has the added benefit of significantly decreasing material scrap. As such, the present invention can keep all material in slurry and reduce scrap disposal, thus creating superior utilization of slurry constituents. The reduction in raw materials required for coating minimizes the exposure of hazardous materials in the workplace.
    [0040] Still further, unlike compression and vapor phase processes, the modified slurry formulations of the present invention can be used to form the improved chromium coatings on various parts having complex and intrinsic internal geometries. Compression processes have limited versatility, as they can only be applied to parts having a specific size and simplified geometry.
    [0041] It should be understood that in addition to gas turbine blades, the principles of the present invention can be used to coat any suitable substrate that requires the controlled application of chromizing coatings. In that regard, the methods of the present invention can protect a variety of different substrates that are used in other applications. For example, chromization coatings as used herein can be applied locally in accordance with the principles of the present invention on stainless steel substrates that do not contain sufficient chromium for oxidation resistance. Chromium coatings form a protective oxide inlay along the stainless steel substrate. Additionally, the present invention, unlike conventional processes, is effective in locally coating selected regions of substrates having internal sections with complex geometries.
    [0042] Although what is considered to be certain embodiments of the invention has been shown and described, it will, of course, be understood that various modifications and changes in form or details can be made quickly without departing from the spirit and scope of the invention. It is therefore intended that this invention is not limited to the exact form and details shown and described herein, nor to anything less than the entirety of the invention described herein and claimed in the following parts.
    权利要求:
    Claims (16)
    [0001]
    1. Method for producing a chromium diffusion coating on selected regions of a substrate, characterized in that it comprises the steps of: providing a chromium-containing slurry; applying the chromium-containing slurry to localized substrate surfaces; curing the slurry slurry; heat the slurry in a protective atmosphere to a predetermined temperature for a predetermined duration; generate chromium-containing vapors; diffuse the chromium within said localized surfaces to form the coating, said coating having a microstructure distinguished by a reduction in nitride inclusions and oxide and reduced α-Cr phase levels.
    [0002]
    2. Method according to claim 1, characterized in that said method comprises locally applying a second coating on the substrate.
    [0003]
    3. Method according to claim 2, characterized in that said second coating comprises an aluminum coating.
    [0004]
    4. Method according to claim 2, characterized in that said second coating comprises a MCrAlY coating.
    [0005]
    5. Method according to claim 1, characterized in that the step of applying the slurry comprises brushing, spraying, dipping, dip spinning, injection, or any combination thereof.
    [0006]
    6. Method according to claim 1, characterized in that said localized surfaces are subjected to corrosion attack.
    [0007]
    7. Method for producing a localized chromium diffusion coating and an aluminium diffusion coating located over selected regions of a substrate simultaneously, characterized in that it comprises the steps of: providing a slurry containing chromium; applying the slurry containing chromium over a first region of the substrate, distinguished by an absence of masking; provide an aluminium-containing material; heat the chromium-containing slurry and the aluminium-containing material in a protective atmosphere to a predetermined temperature for a predetermined duration; diffuse chromium within the first region; diffuse aluminum within a second region in the absence of masking; form the chromium diffusion coating located along the first region, said chromium diffusion coating having a microstructure distinguished by a reduction in nitride and oxide inclusions and reduced levels α-Cr phase; and form an aluminum diffusion coating located along the second region.
    [0008]
    8. Method according to claim 7, characterized in that said first region is subjected to corrosion attack.
    [0009]
    9. Method according to claim 7, characterized in that said second region is subjected to oxidation attack.
    [0010]
    10. Method according to claim 7, characterized in that the step of applying the chromium slurry comprises brushing, spraying, dipping, dipping or injection spinning, or any combination thereof.
    [0011]
    11. Method according to claim 7, characterized in that said chromium diffusion coating and alumina diffusion coating are formed simultaneously during diffusion treatment.
    [0012]
    12. Method according to claim 7, characterized in that the substrate is a gas turbine blade and said first region comprises a rod.
    [0013]
    13. Method according to claim 12, characterized in that said second region comprises an airfoil.
    [0014]
    14. Method for producing a localized chromium diffusion coating and an aluminium diffusion coating located over selected regions of a blade simultaneously, characterized in that it comprises the steps of: providing a slurry containing chromium; applying the slurry containing chromium on a blade rod, distinguished by an absence of masking; provide material containing aluminum within the retort; load the partially coated blade into the retort; heat the partially coated blade; generate vapors containing aluminum and vapors containing chromium; diffuse chromium from the vapors containing chromium within an outer region of the blade stem; diffuse aluminum from aluminum containing vapors within an airfoil of the blade; form the chromium diffusion coating located along the stem, said chromium diffusion coating having a microstructure distinguished by a reduction in nitride and oxide inclusions and reduced α-Cr phase levels; eform the aluminum diffusion coating located along the airfoil.
    [0015]
    15. Method according to claim 14, characterized in that said slurry containing chromium is applied locally on the rod.
    [0016]
    16. Method according to claim 14, characterized in that said localized diffusion coating forms in the absence of masking.
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    法律状态:
    2019-12-24| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2020-11-17| B06A| Notification to applicant to reply to the report for non-patentability or inadequacy of the application [chapter 6.1 patent gazette]|
    2021-03-09| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2021-05-25| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 09/01/2015, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US201461927210P| true| 2014-01-14|2014-01-14|
    US61/927,210|2014-01-14|
    US14/592,382|US9587302B2|2014-01-14|2015-01-08|Methods of applying chromium diffusion coatings onto selective regions of a component|
    US14/592,382|2015-01-08|
    PCT/US2015/010734|WO2015108766A1|2014-01-14|2015-01-09|Methods of applying chromium diffusion coatings onto selective regions of a component|
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