Plasma sprayed MCrAlY coating and coating method

Chemistry: electrical and wave energy – Processes and products

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204 35N, 204 38B, 427 34, 427383D, 427405, 428667, 428668, C25D 548, B05D 108

Patent

active

041522230

ABSTRACT:
The oxidation-corrosion resistance of plasma sprayed MCrAlY overlay coatings is improved. The coating method involves plasma spraying the MCrAlY coating alloy onto a superalloy substrate, applying a chromium or aluminum envelope over the outer surface of the coating or mechanically working the outer surface to seal the surface against penetration by the high pressure isostatic atmosphere to be subsequently applied and then hot isostatically pressing the coated substrate to close the coating defects and diffuse at least a portion of the envelope, if present, into the overlay coating. The invention thus can provide an MCrAlY coating not only substantially free of pores, voids and the like defects but also having at least an outer zone enriched in chromium, aluminum or like metals.

REFERENCES:
patent: 3676085 (1972-07-01), Evans et al.
patent: 3866301 (1975-02-01), Salsgiver
patent: 3961098 (1976-06-01), Bessen
D. B. Arnold et al., "Process for High-Integrity Casting", Air Force Materials Lab, Air Force Systems Command, Wright-Patterson; IR-162-2(II), Nov. 1972.
Lou Frost, New Manufacturing Process & Techniques, Memo 33; North American Rockwell Aerospace & Systems Group.

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