Method of deposition of metallic coatings using atomized spray

• Main Authors: MIGLIETTI, WARREN MARTIN, HARDWICKE, CANAN USLU, BUCCI, DAVID VINCENT, HANCE, KIVILCIM ONAL
• Format: Patent
• Language: English; French; German
• Published: 21.03.2012
• Subjects: CHEMICAL SURFACE TREATMENT; CHEMISTRY; CLADDING OR PLATING BY SOLDERING OR WELDING; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATIONOR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY IONIMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; COATING MATERIAL WITH METALLIC MATERIAL; COATING METALLIC MATERIAL; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; DIFFUSION TREATMENT OF METALLIC MATERIAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION INGENERAL; MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR; METALLURGY; PERFORMING OPERATIONS; SOLDERING OR UNSOLDERING; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THESURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; TRANSPORTING; WELDING; WORKING BY LASER BEAM

A method of coating a metal substrate (17) such as the components in second and third stages of gas turbine engines in order to increase the oxidation and corrosion resistance of the metal substrate (17) under high temperature operating conditions, the method including the steps of forming a powdered mixture of a high-melt superalloy or MCrAIY component (14), where M comprises Fe, Ni and/or Co, and a low-melt component (15) containing about 2-5 wt.% silicon, boron or hafnium, applying the powdered mixture to the surface of the metal substrate (17) at room temperature using an atomized spray to form a uniform surface coating, and then heating the coated substrate surface under vacuum conditions to a temperature in the range of about 1900°F to 2275°F to obtain a uniform coating composition (19) providing oxidation resistance to the underlying substrate.