High-entropy alloy-based compositions and adhesive coatings formed therefrom

Abstract

A high-entropy alloy-based composition having the formula: (M 1 a M 2 b M 3 c M 4 d M 5 e M 6 f )CrAlY 1‑x‑ z Zr x Mo z wherein each of M 1 , M 2 , M 3 , M 4 , M 5 , and M 6 is a different alloying element selected from Ni, Co, Fe, Si, Mn, and Cu, such that none of M 1 , M 2 , M 3 , M 4 , M 5 , and M 6 is the same alloying element; 0.05≤a≤0.35; 0.05≤b≤0.35; 0.05≤c≤0.35; 0.05≤d≤0.35; 0.05≤e≤0.35; 0≤f≤0.35; a+b+c+d+e+f=1; 0≤x≤1; 0≤z≤1; and 0≤x+z≤1.

Description

[0001] Priority Information

[0002] This application claims priority to Indian Provisional Patent Application No. 202211021535 filed on April 11, 2022. TECHNICAL FIELD

[0003] The present invention relates generally to compositions suitable for use in coating systems on components exposed to high temperature environments, such as through hot gas path of a gas turbine engine. More particularly, the present invention relates to compositions for use in thermal barrier coating (“TBC”) systems. BACKGROUND

[0004] Gas turbine engines generally include an inlet, a fan, one or more compressors, a combustor, and at least one turbine. The compressor(s) compress air that is passed to the combustor where it is mixed with fuel. The mixture is then ignited for producing hot combustion gases. The combustion gases are directed to the turbine which extracts energy from the combustion gases for driving the compressor(s), and for producing useful work to propel an aircraft in flight or drive a load such as an electrical generator.

[0005] The use of TBCs on components of gas turbine engines, such as combustor, high pressure turbine (“HPT”) blades and vanes, has increased. Generally, the thermal insulation of TBCs enables such components to withstand higher operating temperatures, increases component durability, and improves engine reliability. To keep the TBC effective throughout the planned life cycle of the component it protects, a bond coat is often present between the TBC and the substrate to help keep the TBC on the substrate during use. SUMMARY

[0006] The present invention provides a high-entropy alloy-based composition having the following formula:

[0007] (M 1 a M 2 b M 3 c M 4 d M 5 e M 6 f )CrAlY 1-x-z Zr x Mo z ,

[0008] wherein,

[0009] M 1 M 2 M 3 M 4 M 5 and M 6 Each of these elements is a different alloying element selected from Ni, Co, Fe, Si, Mn, and Cu, making M... 1 M 2 M 3 M 4 M 5 and M 6 None of them are the same alloying element; 0.05≤a≤0.35; 0.05≤b≤0.35; 0.05≤c≤0.35; 0.05≤d≤0.35; 0.05≤e≤0.35; 0≤f≤0.35; a+b+c+d+e+f=1; 0≤x≤1; 0≤z≤1; and 0≤x+z≤1.

[0010] Preferably, in the high-entropy alloy-based composition, 0.1≤a≤0.25; 0.1≤b≤0.25; 0.1≤c≤0.25; 0.1≤d≤0.25; and 0.1≤e≤0.25.

[0011] Preferably, in the high-entropy alloy-based composition, the alloy has the following formula:

[0012] (Cu 0.2 Mn 0.2 Fe 0.2 Co 0.2 Ni 0.2 )CrAlY 1-x-z Zr x Mo z ,

[0013] Where 0≤x≤1; 0≤z≤1; and 0≤x+z≤1.

[0014] Preferably, in the high-entropy alloy-based composition, the alloy has the following formula:

[0015] (Cu 0.2 Si 0.2 Fe 0.2 Co 0.2 Ni 0.2 )CrAlY 1-x-z Zr x Mo z ,

[0016] Among them, 0≤x≤1; 0≤z≤1; and 0≤x+z≤1.

[0017] On the other hand, the present invention relates to a coating component, comprising:

[0018] a substrate having a surface, wherein the substrate comprises a metal;

[0019] a bond coat on the surface of the substrate, wherein the bond coat comprises a layer comprising the high entropy alloy-based composition; and

[0020] a thermal barrier coating on the bond coat.

[0021] Optionally, the present invention relates to a coated component comprising:

[0022] a substrate having a surface, wherein the substrate comprises a metal;

[0023] a bond coat on the surface of the substrate, wherein the bond coat comprises a plurality of layers; and

[0024] a thermal barrier coating on the bond coat,

[0025] wherein each of the plurality of layers of the bond coat comprises 80 wt% or more of a high entropy alloy-based composition having the following formula:

[0026] (M 1 a M 2 b M 3 c M 4 d M 5 e M 6 f )CrAlY 1-x-z Zr x Mo z ,

[0027] wherein each of M 1 , M 2 , M 3 , M 4 , M 5 and M 6 is a different alloying element selected from Ni, Co, Fe, Si, Mn and Cu, such that M 1 , M 2 , M 3 , M 4 , M 5 and M 6None of them are the same alloying element; 0.05≤a≤0.35; 0.05≤b≤0.35; 0.05≤c≤0.35; 0.05≤d≤0.35; 0.05≤e≤0.35; 0≤f≤0.35; a+b+c+d+e+f=1; 0≤x≤1; 0≤z≤1; and 0≤x+z≤1.

[0028] Preferably, in the coating component, the adhesive coating includes an innermost layer adjacent to the substrate surface and comprising a first high-entropy alloy-based composition, and the adhesive coating includes an outermost layer adjacent to the thermal barrier coating and comprising a second high-entropy alloy-based composition, wherein the first high-entropy alloy-based composition and the second high-entropy alloy-based composition are located at their respective M... 1 a M 2 b M 3 c M 4 d M 5 e M 6 f At least one of them differs in composition.

[0029] Preferably, in the coated component, the adhesive coating has a compositional gradient from the innermost layer adjacent to the substrate surface to the outermost layer adjacent to the thermal barrier coating.

[0030] Preferably, M 1 a M 2 b M 3 c M 4 d M 5 e M 6 f At least one of them has the composition gradient.

[0031] Preferably, in the coated component, the alloy is a single-phase alloy.

[0032] Preferably, in the coated component, the thickness of the adhesive coating is 10μm to 100μm.

[0033] The present invention also relates to an engine component having the aforementioned coated component.

[0034] Preferably, the engine component includes at least one of HP turbine stator blades, HP turbine rotor blades, LP turbine stator blades, LP turbine rotor blades, or combustion liner. BRIEF DESCRIPTION OF DRAWINGS

[0035] A complete and enabling disclosure of the application, including the best mode thereof, to one of ordinary skill in the art is set forth in the specification, which makes specific reference to the drawings wherein:

[0036] Figure 1 is a schematic illustration of an exemplary coated component;

[0037] Figure 2 is a schematic illustration of an exemplary adhesive coating on a component surface; and

[0038] Figure 3 is a schematic cross-sectional view of an exemplary gas turbine engine in accordance with various embodiments of the present subject matter. DETAILED DESCRIPTION

[0039] Reference will now be made in detail to the presently preferred embodiments of the application, one or more examples of which are illustrated in the drawings. The detailed description uses numerical and letter designations

[0040] As used herein, the term "exemplary" means "serving as an example, instance, or illustration." Any implementation described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other implementations. Furthermore, unless otherwise noted, all implementations described herein are to be considered exemplary in nature. Indeed, the phrase "exemplary" is generally used herein to describe one or more implementations, but not to the exclusion of other implementations that can also be utilized in accordance with the present application. Accordingly, such terminology is not intended to limit or restrict the scope of the application. Furthermore, the term "or" as used herein means "and / or" unless otherwise indicated.

[0041] The singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0042] The term "at least one of," in the context of a list of items, means that at least one of the items, but not necessarily more than one, is included in the list. For example, the phrase "at least one of A, B, and C" means A alone, B alone, C alone, or any combination thereof.

[0043] The term "gas turbine engine" refers to an engine having a turbine machine as all or a portion of its power source. Exemplary gas turbine engines include turbofan engines, turboprop engines, turbojet engines, turboshaft engines, and the like, as well as hybrid-electric versions of one or more of these engines. The term "turbomachine" or "turbomachinery" refers to a machine that includes one or more compressors, a heat-generating section (e.g., a combustion section), and one or more turbine machines that together produce a torque output.

[0044] In the present disclosure, when a layer is described as being "on" or "over" another layer or substrate, it is to be understood that a layer can be directly on another layer or have another layer or feature between the layers unless explicitly stated to the contrary. Thus, these terms are merely describing the relative position of the layers to one another and do not necessarily mean "on top of" as the relative position of above or below depends on the orientation of the device relative to the viewer.

[0045] In the present disclosure, chemical elements are discussed using their common chemical abbreviations, such as are commonly found on the Periodic Table of the Elements. For example, hydrogen is represented by its common chemical abbreviation, H; helium is represented by its common chemical abbreviation, He; and so forth.

[0046] As used herein, the term "high-entropy alloy" ("HEA") refers to an alloy formed by mixing equal or relatively large proportions of five or more elements.

[0047] As used herein, "rare earth elements" refers to the rare earth elements of scandium (Sc), yttrium (Y), lanthanum (La), cerium (Ce), praseodymium (Pr), neodymium (Nd), promethium (Pm), samarium (Sm), europium (Eu), gadolinium (Gd), terbium (Tb), dysprosium (Dy), holmium (Ho), erbium (Er), thulium (Tm), ytterbium (Yb), lutetium (Lu), or mixtures thereof.

[0048] As used herein, the term "substantially free" is to be understood as completely free of the recited component or containing trace amounts of the same component. "Trace amounts" are quantitative levels of chemical components that are nearly undetectable and do not provide a benefit to the functional or aesthetic properties of the subject composition. The term "substantially free" also includes completely free.

[0049] As used herein, the term "substantially (essentially) equal" shall be understood to include minor trace variations in quantitative levels that are not detectable and do not provide a benefit to the functional or aesthetic properties of the subject composition. For example, "substantially (essentially)" can mean within 1% (i.e., including values that differ from a stated value by up to 1%). The term "substantially (essentially) equal" also includes exactly equal.

[0050] It is generally desirable to improve the performance of bond coats to extend the effective life of TBCs.

[0051] The present disclosure generally relates to a composition comprising an alloy including a high-entropy alloy ("HEA") within an MCrAlY-based alloy to form a high-entropy alloy-based composition that is particularly suitable for a bond coat having superior performance. For example, the alloy can have improved oxidation resistance to help slow the formation of thermally grown oxides ("TGO") thereon.

[0052] Generally, the high-entropy alloy-based composition includes at least 5 different alloying elements (in place of the "M" in the MCrAlY-based alloy), wherein the at least 5 different alloying elements are selected from Ni, Co, Fe, Si, Mn, and Cu. Without wishing to be bound by any particular theory, it is believed that the at least 5 different alloying elements are selected such that each alloying element has an atomic radius that is within 15% of the atomic radius of nickel, which can allow for the formation of a desired crystal structure in the high-entropy alloy-based composition. Further, the use of the HEA allows for control of the coefficient of thermal expansion ("CTE") of the material as well as suppression of TGO formation on the high-entropy alloy-based composition.

[0053] In one embodiment, each of the at least 5 different alloying elements is present in an amount of 5 atomic % to 35 atomic %, wherein the sum of the atomic percentages of the at least 5 different alloying elements equals 1. For example, the high-entropy alloy-based composition can have a formula as shown in Formula 1:

[0054] Formula 1: (M 1 a M 2 b M 3 c M 4 d M 5 e M 6 f )CrAlY 1-x-z Zr x Mo z ,

[0055] wherein,

[0056] M 1 M 2 M 3 M 4 M 5 M 6 each of M 1 M 2 M 3 M 4 M 5 M 6 is not the same alloying element as any of M

[0057] 0.05 < a < 0.35 (e.g., 0.1 < a < 0.25);

[0058] 0.05 < b < 0.35 (e.g., 0.1 < b < 0.25);

[0059] 0.05 < c < 0.35 (e.g., 0.1 < c < 0.25);

[0060] 0.05 < d < 0.35 (e.g., 0.1 < d < 0.25);

[0061] 0.05 < e < 0.35 (e.g., 0.1 < e < 0.25);

[0062] 0 < f < 0.35;

[0063] a + b + c + d + e + f = 1;

[0064] 0 < x < 1 (e.g., 0 < x < 0.5, such as 0 < x < 0.25);

[0065] 0 < z < 1 (e.g., 0 < z < 0.5, such as 0 < z < 0.25); and

[0066] 0 < x + z < 1 (e.g., 0 < x + z < 1).

[0067] In one embodiment, f is no more than an insignificant trace amount (e.g., f is 0), such that there are only 5 alloying elements present in the high-entropy alloy-based composition. In one embodiment, the 5 alloying elements are present at different atomic weights from one another. In an alternative embodiment, the 5 alloying elements are present at substantially equal atomic weights from one another. For example, in this embodiment, when there are 5 alloying elements, a is substantially equal to b; b is substantially equal to c; c is substantially equal to d; d is substantially equal to e; f is no more than an insignificant trace amount (e.g., f is 0).

[0068] In one particular embodiment, the high-entropy alloy-based composition can have a formula as shown in Formula 2:

[0069] Formula 2: (Cu 0.2 Mn 0.2 Fe 0.2 Co 0.2 Ni 0.2 )CrAlY 1-x-z Zr x Mo z ,

[0070] wherein,

[0071] 0 < x < 1 ;

[0072] 0 < z < 1 ; and

[0073] 0 < x + z < 1.

[0074] In another particular embodiment, the high-entropy alloy-based composition can have a formula as shown in Formula 3:

[0075] Formula 3: (Cu 0.2 Si 0.2 Mn 0.2 Fe 0.2 Co 0.2 Ni 0.2 )CrAlY 1-x-z Zr x Mo z ,

[0076] wherein,

[0077] 0 < x < 1 ;

[0078] 0 < z < 1 ; and

[0079] 0 < x + z < 1.

[0080] In alternative embodiments, f is greater than 0 and less than or equal to 0.35 (i.e., 0 < f < 0.35) such that each of Ni, Co, Fe, Si, Mn, and Cu is present in the high-entropy alloy-based composition. In one embodiment, the six alloying elements are present in atomic weights that are different from one another. In alternative embodiments, the six alloying elements are present in atomic weights that are substantially equal to one another. For example, in this embodiment, when the six alloying elements are present, a is substantially equal to b; b is substantially equal to c; c is substantially equal to d; d is substantially equal to e; and e is substantially equal to f.

[0081] In one particular embodiment, the high-entropy alloy-based composition can have a formula as shown in Formula 4:

[0082] Formula 4: (Cu 0.167 Si 0.167 Mn 0.167 Fe 0.167 Co 0.167 Ni0.167 ) CrAlY 1-x-z Zr x Mo z ,

[0083] wherein,

[0084] 0 < x < 1 ;

[0085] 0 < z < 1 ; and

[0086] 0 < x + z < 1.

[0087] It should be noted that Formula 4 rounds one sixth (i.e., 1 / 6) to 0.167, while recognizing that the sum of the six atomic percentages essentially equals 1.

[0088] Referring to each of Formulas 1-4, Y can be replaced or combined with other elements having similar atomic radii, such as Zr and / or Mo. In one embodiment, the high-entropy alloy-based composition can include Zr such that x is greater than 0 and less than or equal to 1 (e.g., 0 < x < 1), for example 0 < x < 0.25. In one embodiment, the high-entropy alloy-based composition can include Mo such that z is greater than 0 and less than or equal to 1 (e.g., 0 < z < 1), for example 0 < z < 0.25. In one particular embodiment, Y has an atomic concentration greater than the sum of the atomic concentrations of Zr and Mo, for example when 0 < x + z < 0.5.

[0089] In alternative embodiments, x does not exceed a trivial trace amount such that the high-entropy alloy-based composition is essentially free of Zr (e.g., x is 0). Similarly, in certain embodiments, z does not exceed a trivial trace amount such that the high-entropy alloy-based composition is essentially free of Mo (e.g., z is 0). In one particular embodiment, both x and z do not exceed a trivial trace amount such that Y is essentially free of any replacement (e.g., x + z is 0).

[0090] As noted above, the high-entropy alloy-based composition is particularly suitable for use in a bond coat between a component surface and a thermal barrier coating thereon.

[0091] For example, referring to Figure 1 , an exemplary coated component 100 is shown formed of a substrate 102 having a surface 103 and a coating system 106 on the surface. Generally, the coating system 106 includes a bond coat 104 on the surface 103 of the substrate 102 and a TBC 108 on an outermost surface 107 of the bond coat 104. In the embodiment shown, the bond coat 104 is directly on the surface 103 without any layers therebetween. The thickness of the bond coat 104 on the surface 103 of the substrate 102 can be 10 μιη to 100 μιη.

[0092] In one embodiment, the bond coat 104 can include at least 80 wt% of a high-entropy alloy-based composition (such as having a composition represented by any one of Formulas 1-4). The balance of the bond coat 104 can be any material suitable for a bond coat or TBC, such as silicon, silicides, rare earth silicates, etc. In one embodiment, the bond coat 104 can include 90 wt% to 100 wt% of a high-entropy alloy-based composition (such as having a composition represented by any one of Formulas 1-4). In one particular embodiment, the bond coat 104 consists essentially of a high-entropy alloy-based composition (such as having a composition represented by any one of Formulas 1-4).

[0093] In example embodiments, the bond coat 104 is substantially a single-phase alloy. That is, the bond coat 104 is at least 80 volume percent (vol%) (such as 80 vol% to 100 vol% (e.g., 95 vol% to 100 vol%)) of a single phase.

[0094] In certain embodiments, the bond coat 104 can have a composition gradient varying along the thickness of the bond coat 104. For example, referring to Figure 2 , an example bond coat 104 having a composition gradient is shown having a plurality of layers 120 spanning the thickness thereof from the surface 103 of the substrate 102 to the outermost surface 107 of the bond coat 104. Such a composition gradient can be formed within the bond coat 104 by applying individual layers 120 having different chemical compositions and then sintering / curing the bond coat 104 together.

[0095] In one particular embodiment, an innermost layer 122 of the bond coat 104 adjacent the surface 103 of the substrate 102 can have a different composition than an outermost layer 124 defining the outermost surface 107 of the bond coat 104. For example, the innermost layer 122 can include a first high-entropy alloy-based composition and the outermost layer 124 can include a second high-entropy alloy-based composition, where the first and second high-entropy alloy-based compositions differ in their respective M 1 a M 2 b M 3 c M 4 d M 5 e M 6 fcomposition can include a particular alloying element, while the second high-entropy alloy-based composition is substantially free of the particular alloying element. Conversely, the first high-entropy alloy-based composition can be substantially free of another particular alloying element, while the second high-entropy alloy-based composition includes the other particular alloying element. Additionally or alternatively, in M 1 a M 2 b M 3 c M 4 d M 5 e M 6 f Additionally or alternatively, in at least one of M

[0096] The substrate 102 can be any suitable material, for example, a metal for withstanding high temperatures such as a steel or a superalloy (e.g., a nickel-based superalloy, a cobalt-based superalloy, or a iron-based superalloy such as Rene N5, N500, N4, N2, IN718, Hastelloy X, or Haynes 188) or other suitable material. The coating system 106 can be disposed along one or more portions of the substrate 102, or substantially on the entire exterior of the substrate 102. In particular embodiments, the coating system 106 can have a total thickness of 50 μιη (e.g., micrometers or μιη) to 2500 μιη (e.g., 100 μιη to 700 μιη).

[0097] TBC 108 can be formed from a plurality of individual layers 114. In particular embodiments, each of the layers 114 of TBC 108 can have a layer thickness of 25-100 μιη (e.g., 25-50 μιη). One or more of the individual layers 114 can be formed from a stable ceramic capable of sustaining a fairly high temperature gradient so that the coated metal component can operate at a gas temperature above the metal's melting point. For example, the stable ceramic material can be one or more of yttria-stabilized zirconia (YSZ) and other rare earth stabilized zirconia compositions, mullite (3AI2O3-2SiO2), alumina, ceria (CeO2), lanthanum zirconate, rare earth oxides (e.g., La2O3, Nb2O5, Pr2O3, CeO2), and metal-glass composites, and combinations thereof (e.g., alumina and YSZ, or ceria and YSZ). In addition to high temperature stability, YSZ also has high toughness and chemical inertness, and the coefficient of thermal expansion of YSZ is fairly well matched to the coefficient of thermal expansion of the metal component being coated. In one embodiment, TBC 108 can include a YSZ (e.g., 8YSZ)-based layer closest to the substrate 102 (such as directly on the bond coat 104).

[0098] Each individual layer 114 can be formed by any suitable process. For example, one or more of the individual layers 114 can be formed by air-plasma spray (APS), suspension plasma spray (SPS), solution precursor plasma spray (SPPS), electron beam physical vapor deposition (EBPVD), high velocity oxy-fuel (HVOF), electrostatic spray assisted vapor deposition (ESAVD), and direct vapor deposition.

[0099] The coated component 100 is particularly suitable for use as a component that is present in a high temperature environment, such as a component present in a gas turbine engine, for example, a combustor component, a turbine blade, a shroud, a nozzle, a heat shield, and a vane. In particular, the coated component 100 can be a component located within a hot gas path of a gas turbine engine, such that the coating system 106 forms a thermal barrier for the underlying substrate 102 to protect the component 100 within the gas turbine engine when exposed to the hot gas path.

[0100] Figure 3 is a schematic cross-sectional view of a gas turbine engine in accordance with an example embodiment of the present application. More particularly, for embodiments of Figure 3 The gas turbine engine is a high-bypass turbofan engine 10, referred to herein as "turbofan engine 10." As shown in Figure 3As shown, the turbofan engine 10 defines an axial direction A (extending parallel to the longitudinal axis 12 for reference) and a radial direction R. Generally, the turbofan engine 10 includes a fan section 14 and a core turbine engine 16 disposed downstream from the fan section 14. Although described below with reference to a turbofan engine 10, the present disclosure is generally applicable to turbomachinery, including turbojet engines, turboprop engines, and turboshaft gas turbine engines, including industrial and marine gas turbine engines and auxiliary power units. It can also be applicable to other high temperature applications involving water vapor in the gas phase, such as those resulting from the combustion of hydrocarbon fuels.

[0101] The exemplary core turbine engine 16 as shown generally includes a substantially tubular outer casing 18 defining an annular inlet 20. The outer casing 18 encloses, in serial flow relationship, a compressor section including a booster or low pressure (LP) compressor 22 and a high pressure (HP) compressor 24; a combustion section 26; a turbine section including a high pressure (HP) turbine 28 and a low pressure (LP) turbine 30; and a jet exhaust nozzle section 32. A high pressure (HP) shaft or spool 34 drivingly connects the HP turbine 28 to the HP compressor 24. A low pressure (LP) shaft or spool 36 drivingly connects the LP turbine 30 to the LP compressor 22.

[0102] For the embodiment described, the fan section 14 includes a variable pitch fan 38 having a plurality of fan blades 40 connected in spaced relation to a disk 42. As shown, the fan blades 40 generally extend outwardly from the disk 42 along the radial direction R. As the fan blades 40 are operatively connected to a suitable actuation member 44 (configured to collectively change the pitch of the fan blades 40 in unison), each fan blade 40 is rotatable about a pitch axis P relative to the disk 42. The fan blades 40, disk 42, and actuation member 44 are rotatable together about the longitudinal axis 12 by the LP spool 36 over an optional power gear box 46. The power gear box 46 includes a plurality of gears for reducing the rotational speed of the LP spool 36 to a more efficient rotational fan speed.

[0103] Still referring to Figure 3In exemplary embodiments of the present application, the disk 42 is covered by a rotatable front nacelle 48 having an aerodynamic profile to facilitate airflow through the plurality of fan blades 40. Further, the exemplary fan section 14 includes an annular fan casing or outer nacelle 50 circumferentially surrounding the fan 38 and / or at least a portion of the core turbine engine 16. It should be appreciated that the nacelle 50 can be configured to be supported relative to the core turbine engine 16 by a plurality of circumferentially spaced apart outlet guide vanes 52. Further, a downstream section 54 of the nacelle 50 can extend over an exterior of the core turbine engine 16 so as to define a bypass airflow passage 56 therebetween.

[0104] During operation of the turbofan engine 10, a volume of air 58 enters the turbofan engine 10 through an associated inlet 60 of the nacelle 50 and / or fan section 14. As the volume of air 58 passes through the fan blades 40, a first portion 62 of the air 58 is directed or routed into the bypass airflow passage 56 as indicated by the arrow, and a second portion 64 of the air 58 is directed or routed into the LP compressor 22 as indicated by the arrow. The ratio between the first portion 62 of air and the second portion 64 of air is commonly referred to as the bypass ratio. The pressure of the second portion 64 of air is then subsequently increased as it is passed through the high pressure (HP) compressor 24 and into the combustion section 26 where it is mixed with fuel and combusted to provide combustion gases 66.

[0105] The combustion gases 66 are directed through the HP turbine 28 where a portion of the thermal and / or kinetic energy from the combustion gases 66 is sequentially extracted via stages of HP turbine stator vanes 68 (coupled to the outer casing 18) and HP turbine rotor blades 70 (coupled to the HP shaft or spool 34), causing the HP shaft or spool 34 to rotate, thereby supporting the operation of the HP compressor 24. The combustion gases 66 are then directed through the LP turbine 30 where a second portion of the thermal and kinetic energy is sequentially extracted from the combustion gases 66 via stages of LP turbine stator vanes 72 (coupled to the outer casing 18) and LP turbine rotor blades 74 (coupled to the LP shaft or spool 36), causing the LP shaft or spool 36 to rotate, thereby supporting the operation of the LP compressor 22 and / or the rotation of the fan 38.

[0106] The combustion gases 66 are then directed through the injection exhaust nozzle section 32 of the core turbine engine 16 to provide propulsive thrust. At the same time, the first portion of air 62 is significantly increased in pressure as it is directed through the bypass airflow passage 56 (also providing propulsive thrust) before it is exhausted from the fan nozzle exhaust section 76 of the turbofan engine 10. The HP turbine 28, the LP turbine 30, and the injection exhaust nozzle section 32 at least partially define a hot gas path 78 for directing the combustion gases 66 through the core turbine engine 16. For example, coating components 100 Figure 1 and Figure 2 may be particularly suitable as components in contact with the combustion gases 66, including but not limited to the HP turbine stator vanes 68, the HP turbine rotor blades 70, the LP turbine stator vanes 72, the LP turbine rotor blades 74, components within the combustion section 26 (such as a combustion liner), and the like.

[0107] Other aspects of the application are provided by the subject matter of the following clauses:

[0108] 1. A high-entropy alloy-based composition having the formula:

[0109] (M 1 a M 2 b M 3 c M 4 d M 5 e M 6 f )CrAlY 1-x-z Zr x Mo z ,

[0110] wherein,

[0111] M 1 , M 2 , M 3 , M 4 , M 5 , and M 6 each are a different alloying element selected from Ni, Co, Fe, Si, Mn, and Cu, such that M 1 , M 2 , M 3 , M 4 , M 5 , and M 6None of the alloying elements are the same; 0.05 < a < 0.35; 0.05 < b < 0.35; 0.05 < c < 0.35; 0.05 < d < 0.35; 0.05 < e < 0.35; 0 < f < 0.35; a + b + c + d + e + f = 1; 0 < x < 1; 0 < z < 1; and 0 < x + z < 1.

[0112] 2. The composition of any of the preceding clauses, wherein 0.1 < a < 0.25; 0.1 < b < 0.25; 0.1 < c < 0.25; 0.1 < d < 0.25; and 0.1 < e < 0.25.

[0113] 3. The composition of any of the preceding clauses, wherein f is 0.

[0114] 4. The composition of any of the preceding clauses, wherein a is substantially equal to b; b is substantially equal to c; c is substantially equal to d; and d is substantially equal to e.

[0115] 5. The composition of any of the preceding clauses, wherein a is substantially equal to b; b is substantially equal to c; c is substantially equal to d; d is substantially equal to e; and e is substantially equal to f.

[0116] 6. The composition of any of the preceding clauses, wherein x is 0.

[0117] 7. The composition of any of the preceding clauses, wherein z is 0.

[0118] 8. The composition of any of the preceding clauses, wherein 0 < x < 0.5 and 0 < z < 0.5.

[0119] 9. The composition of any of the preceding clauses, wherein 0 < x < 0.25.

[0120] 10. The composition of any of the preceding clauses, wherein 0 < z < 0.25.

[0121] 11. The composition of any of the preceding clauses, wherein 0 < x + z < 0.5, such that the atomic concentration of Y is greater than Zr and Mo.

[0122] 12. The composition of any of the preceding clauses, wherein the alloy has the following formula:

[0123] (Cu 0.2 Mn 0.2 Fe 0.2 Co 0.2 Ni 0.2 )CrAlY 1-x-z Zr xMo z ,

[0124] wherein 0 < x < 1 ; 0 < z < 1 ; and 0 < x + z < 1.

[0125] 13. The composition of any of the preceding clauses, wherein the alloy has the following formula:

[0126] (Cu 0.2 Si 0.2 Fe 0.2 Co 0.2 Ni 0.2 )CrAlY 1-x-z Zr x Mo z ,

[0127] wherein 0 < x < 1 ; 0 < z < 1 ; and 0 < x + z < 1.

[0128] 14. A coated component comprising:

[0129] a substrate having a surface, wherein the substrate comprises a metal;

[0130] a bond coat on the surface of the substrate, wherein the bond coat comprises a layer comprising the composition of any of the preceding clauses; and

[0131] a thermal barrier coating on the bond coat.

[0132] 15. A coated component comprising:

[0133] a substrate having a surface, wherein the substrate comprises a metal;

[0134] a bond coat on the surface of the substrate, wherein the bond coat comprises a plurality of layers; and

[0135] a thermal barrier coating on the bond coat,

[0136] wherein each of the plurality of layers of the bond coat comprises a high entropy alloy-based composition of 80 wt% or more, the high entropy alloy-based composition having the following formula:

[0137] (M 1 a M 2 b M 3 c M 4 d M 5 e M 6 f )CrAlY 1-x-z Zrx Mo z ,

[0138] wherein M 1 , M 2 , M 3 , M 4 , M 5 , and M 6 are each a different alloying element selected from Ni, Co, Fe, Si, Mn, and Cu, such that none of M 1 , M 2 , M 3 , M 4 , M 5 , and M 6 are the same alloying element; 0.05 < a < 0.35; 0.05 < b < 0.35; 0.05 < c < 0.35; 0.05 < d < 0.35; 0.05 < e < 0.35; 0 < f < 0.35; a + b + c + d + e + f = 1; 0 < x < 1; 0 < z < 1; and 0 < x + z < 1.

[0139] 16. The coated component of any of the preceding clauses, wherein the bond coat includes an innermost layer adjacent to a surface of the substrate and comprising a first high-entropy alloy-based composition, and the bond coat includes an outermost layer adjacent to the thermal barrier coating and comprising a second high-entropy alloy-based composition, wherein the first and second high-entropy alloy-based compositions differ in their respective compositions of at least one of M 1 a M 2 b M 3 c M 4 d M 5 e M 6 f .

[0140] 17. The coated component of any of the preceding clauses, wherein the bond coat has a composition gradient from the innermost layer adjacent to the surface of the substrate to the outermost layer adjacent to the thermal barrier coating.

[0141] 18. The coated component of any of the preceding clauses, wherein M 1 a M 2 b M 3 c M 4 d M 5 eM 6 f at least one of the compositions has a gradient.

[0142] 19. The coated component of any of the preceding clauses, wherein the alloy is a single phase alloy.

[0143] 20. The coated component of any of the preceding clauses, wherein the bond coat has a thickness of 10 pm to 100 pm.

[0144] 21. An engine component comprising the coated component of any of the preceding clauses.

[0145] 22. The engine component of any of the preceding clauses, wherein the engine component comprises at least one of a HP turbine stator vane, a HP turbine rotor blade, a LP turbine stator vane, a LP turbine rotor blade, or a combustion liner.

[0146] This written description uses examples to disclose the application, including the best mode, and also to enable any person skilled in the art to practice the application, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the application is defined by the claims, and can include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include insubstantial changes to the literal languages of the claims.

Claims

1. A high-entropy alloy-based composition having the following formula: (I 1 a From b I 3 c I 4 d I 5 e I 6 f )CrAlY 1-x-z Zr x My soul z , in, M 1 M 3 M 4 M 5 and M 6 Each of these elements is a different alloying element selected from Ni, Co, Fe, Mn, and Cu, making M... 1 M 3 M 4 M 5 and M 6 None of them are the same alloying element; 0.05 ≤ a ≤ 0.35； b = 0.2； 0.05 ≤ c ≤ 0.35； 0.05 ≤ d ≤ 0.35； 0.05 ≤ e ≤ 0.35； 0 ≤ f ≤ 0.35； a + b + c + d + e + f = 1; 0 ≤ x ≤ 1； 0 ≤ z ≤ 1； as well as 0 ≤ x + z ≤ 1.

2. The composition according to claim 1, wherein, 0.1 ≤ a ≤ 0.25； 0.1 ≤ c ≤ 0.25； 0.1 ≤ d ≤ 0.25； as well as 0.1 ≤ e ≤ 0.25。 3. The composition according to claim 1, wherein, f is 0.

4. The composition according to claim 1, wherein, a equals b; b equals c; c equals d; and d equals e.

5. The composition according to claim 1, wherein, a equals b; b equals c; c equals d; d equals e; and e equals f.

6. The composition according to claim 1, wherein, x is 0.

7. The composition according to claim 1, wherein, z is 0.

8. The composition according to claim 1, wherein, 0≤x≤0.5 and 0≤z≤0.

5.

9. The composition according to claim 1, wherein, 0<x≤0.25。 10. The composition according to claim 1, wherein, 0<z≤0.25。 11. The composition according to claim 1, wherein, 0 ≤ x + z < 0.5, which makes the atomic concentration of Y greater than that of Zr and Mo.

12. The composition according to claim 1, wherein, The alloy has the following formula: (Cu 0.2 Yes 0.2 Faith 0.2 Co 0.2 Nose 0.2 )CrAlY 1-x-z Zr x Mo z , in, 0 ≤ x ≤ 1； 0 ≤ z ≤ 1; and 0 ≤ x + z ≤ 1.

13. A coated component, comprising: A substrate having a surface, wherein the substrate comprises a metal; An adhesive coating on the surface of a substrate, wherein the adhesive coating comprises a layer containing the composition of claim 1; and Thermal barrier coating on adhesive coating.

14. A coated component, comprising: A substrate having a surface, wherein the substrate comprises a metal; An adhesive coating on the surface of a substrate, wherein the adhesive coating comprises multiple layers; and Thermal barrier coating on adhesive coating Each of the multiple layers of the adhesive coating comprises more than 80% by weight of a high-entropy alloy-based composition, said high-entropy alloy-based composition having the following formula: (I 1 a From b I 3 c I 4 d I 5 e I 6 f )CrAlY 1-x-z Zr x My soul z , in, M 1 M 3 M 4 M 5 and M 6 Each of these elements is a different alloying element selected from Ni, Co, Fe, Mn, and Cu, making M... 1 M 3 M 4 M 5 and M 6 None of them are the same alloying element; 0.05 ≤ a ≤ 0.35； b = 0.2； 0.05 ≤ c ≤ 0.35； 0.05 ≤ d ≤ 0.35； 0.05 ≤ e ≤ 0.35； 0 ≤ f ≤ 0.35； a + b + c + d + e + f = 1; 0 ≤ x ≤ 1； 0 ≤ z ≤ 1; and 0 ≤ x + z ≤ 1.

15. The coated component according to claim 14, wherein, The adhesive coating includes an innermost layer adjacent to the surface of the substrate and comprising a first high-entropy alloy-based composition, and an outermost layer adjacent to the thermal barrier coating and comprising a second high-entropy alloy-based composition, wherein the first high-entropy alloy-based composition and the second high-entropy alloy-based composition are respectively located at their respective M... 1 a Si b M 3 c M 4 d M 5 e M 6 f At least one of them is different in composition.

16. The coated component according to claim 14, wherein, The adhesive coating has a compositional gradient from the innermost layer adjacent to the surface of the substrate to the outermost layer adjacent to the thermal barrier coating.

17. The coated component according to claim 16, wherein, M 1 a M 3 c M 4 d M 5 e M 6 f At least one of them has the composition gradient.

18. The coated component according to claim 14, wherein, The alloy is a single-phase alloy.

19. The coated component according to claim 14, wherein, The thickness of the adhesive coating is 10μm to 100μm.

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