Method of forming a diffusion barrier for overlay coatings

Chemistry: electrical and wave energy – Processes and products – Coating – forming or etching by sputtering

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20419212, 20419222, 427226, 4273722, 427379, 427380, 4273831, C23C 1434

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active

061431419

ABSTRACT:
Superalloy substrates bearing a rhenium diffusion barrier, and a method of forming a rhenium diffusion barrier between a superalloy substrate and an overlay coating comprising aluminum. The method involves depositing a rhenium film onto the surface of a superalloy substrate and subjecting the rhenium film to first conditions effective to cause a minor portion of rhenium atoms to penetrate the surface of the superalloy substrate and second conditions effective to cause a minority of the rhenium atoms to diffuse into the substrate, forming a diffusion barrier comprising an interfacial zone comprising a mixture of rhenium atoms and atoms of the superalloy substrate covered by a rhenium film. The diffusion barrier is effective to suppress diffusion of aluminum from the overlay coating under static oxidation testing conditions.

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