Method for applying a high-temperature bond coat on a metal substrate, and related compositions and articles
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B05D-007/14
B05D-001/34
B05D-001/00
B05D-003/02
출원번호
US-0747553
(2003-12-23)
발명자
/ 주소
Hasz,Wayne Charles
Sangeeta,D
출원인 / 주소
General Electric Company
인용정보
피인용 횟수 :
13인용 특허 :
10
초록▼
A method for applying a bond coat on a metal-based substrate is described. A slurry which contains braze material and a volatile component is deposited on the substrate. The slurry can also include bond coat material. Alternatively, the bond coat material can be applied afterward, in solid form or i
A method for applying a bond coat on a metal-based substrate is described. A slurry which contains braze material and a volatile component is deposited on the substrate. The slurry can also include bond coat material. Alternatively, the bond coat material can be applied afterward, in solid form or in the form of a second slurry. The slurry and bond coat are then dried and fused to the substrate. A repair technique using this slurry is also described, along with related compositions and articles.
대표청구항▼
What is claimed: 1. A method for applying a bond coat on a metal-based substrate, comprising the following steps: a) applying a slurry which comprises braze material to the substrate, wherein the slurry also contains a volatile component, and wherein the braze material has an avenge particle size i
What is claimed: 1. A method for applying a bond coat on a metal-based substrate, comprising the following steps: a) applying a slurry which comprises braze material to the substrate, wherein the slurry also contains a volatile component, and wherein the braze material has an avenge particle size in the range of about 20 microns to about 150 microns; b) applying bond coat material to the substrate, wherein the slurry comprising the braze material further comprises the bond coat material, so that the braze material and the bond coat material are applied to the substrate simultaneously, wherein said bond coat material comprises at least one material selected from the group consisting of aluminide; platinum-aluminide; nickel-aluminide; platinum-nickel-aluminide; an alloy of the formula MCrAlX, where M is selected from the group consisting of Fe, Ni, Co, and mixtures of any of the foregoing and where X is selected from the group consisting of Y, Ta, Si, Hf, Ti, Zr, B, C, and combinations thereof; and any combination of the foregoing; c) drying the slurry and bond coat material to remove at least a portion of the volatile component; and d) fusing the braze material and bond coat material to the substrate. 2. The method of claim 1, wherein the braze material comprises at least one metal selected from the group consisting of nickel, cobalt, iron, a precious metal, and a mixture which includes at least one of the foregoing. 3. The method of claim 2, wherein the braze material comprises at least about 40% by weight nickel. 4. The method of claim 2, wherein the braze material further comprises a constituent which lowers the melting point of the braze alloy. 5. The method of claim 4, wherein the constituent is silicon, boron, or mixtures thereof. 6. The method of claim 1, wherein the slurry further comprises at least one additive selected from the group consisting of binders, stabilizers, thickening agents, dispersants, deflocculants, anti-settling agents, plasticizers, emollients, lubricants, surfactants, anti-foam agents, and curing modifiers. 7. The method of claim 1, wherein the slurry is applied to the substrate by a technique selected from the group consisting of slip-casting, brushing, painting, dipping, flow-coating, roll-coating, spin coating, and spraying. 8. The method of claim 1, wherein the bond coat material has an average particle size of at least about 45 microns. 9. The method of claim 8, wherein the bond coat material has an average particle size in the range of about 150 microns to about 300 microns. 10. The method of claim 1, wherein the volatile component comprises at least one aqueous solvent or at least one organic solvent, or mixtures thereof. 11. The method of claim 1, wherein step (c) is carried out by air-drying. 12. The method of claim 1, wherein step (d) is carried out at a temperature in the range of about 525째 C. to about 1650째 C. 13. The method of claim 1, wherein the metal-based substrate is a superalloy. 14. The method of claim 13, wherein the superalloy is a nickel-base or cobalt-base material. 15. The method of claim 1, wherein the bond coat has a root mean square roughness (Ra) value of greater than about 200 micro-inches, after step (d). 16. The method of claim 1, wherein the slurry is prepared by combining the bond coat material and the braze material with a solvent and at least one additive selected from the group consisting of binders, stabilizers, thickening agents, dispersants, deflocculants, anti-settling agents, plasticizers, emollients, lubricants, surfactants, anti-foam agents, and curing modifiers. 17. The method of claim 1, wherein the braze material has an average particle size in the range of about 20 microns to about 150 microns, and the bond coat material has an average particle size of at least about 45 microns. 18. The method of claim 1, wherein the bond coat is in the form of a second slurry, and the second slurry is pre-mixed with the first slurry to form a pre-mixture, said pre-mixture being applied to the substrate prior to step (c). 19. The method of claim 18, wherein the pre-mixture is applied to the substrate by a technique selected from the group consisting of slip-casting, brushing, painting, dipping, flow-coating, roll-coating, spin coating, and spraying. 20. The method of claim 1, wherein an overcoat is applied over the bond coat after step (d). 21. The method of claim 20, wherein the overcoat is a thermal barrier coating. 22. The method of claim 21, wherein the thermal barrier coating is zirconia-based. 23. The method of claim 21, wherein the thermal barrier coating is applied by a thermal spray technique. 24. The method of claim 23, wherein the thermal spray technique is a plasma spray process. 25. The method of claim 20, wherein the overcoat is a wear-resistant coating. 26. The method of claim 20, wherein the overcoat comprises a material selected from the group consisting of metal carbides; alumina, mullite, zircon, cobalt-molybdenum-chromium-silicon; strontium-calcium-zirconate glass; and mixtures thereof. 27. A method for applying a metal aluminide-or MCrAlY-based bond coat on a superalloy substrate, where M is nickel, cobalt, or a mixture thereof, comprising the following steps: (I) applying a slurry which comprises a volatile component and a mixture of braze material and bond coat material to the substrate, wherein the braze material contains at least about 40% by weight nickel, and wherein the braze material has an average particle size in the range of about 40 microns to about 80 microns and the bond coat material has an average particle size in the range of about 150 microns to about 300 microns; (II) drying the slurry under conditions sufficient to remove at least a portion of the volatile component, forming a green coating; and (III) brazing the green coating to the substrate; wherein said bond coat material comprises at least one material selected from the group consisting of aluminide; platinum-aluminide; nickel-aluminide; platinum-nickel-aluminide; an alloy of the formula MCrAlX, where M is selected from the group consisting of Fe, Ni, Co, and mixtures of any of the foregoing and where X is selected from the group consisting of Y, Ta, Si, Hf, Ti, Zr, B, C, and combinations thereof; and any combination of the foregoing. 28. The method of claim 27, wherein a zirconia-based thermal barrier coating is applied over the bond coat. 29. A method for replacing a bond coat applied over a metal-based substrate, comprising the following steps: (i) removing the existing bond coat from a selected area on the substrate; (ii) applying a slurry which comprises braze material to the selected area, wherein the slurry also contains a volatile component, and wherein the braze material has an average particle size in the range of about 20 microns to about 150 microns; (iii) applying additional bond coat material to the selected area, wherein the slurry comprising the braze material further comprises the bond coat material, so that the braze material and the bond coat material are applied to the substrate simultaneously, wherein said bond coat material comprises at least one material selected from the group consisting of aluminide; platinum-aluminide; nickel-aluminide; platinum-nickel-aluminide; an alloy of the formula MCralX, where M is selected from the group consisting of Fe, Ni, Co, and mixtures of any of the foregoing and where X is selected from the group consisting of Y, Ta, Si, Hf, Ti, Zr, B, C, and combinations thereof; and any combination of the foregoing; and (iv) fusing the braze material and bond coat material to the selected area. 30. The method of claim 29, wherein the metal-based substrate is a portion of a turbine engine.
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