Al-Co-Cr-Fe-Ni-Si Alloy Cladding for Wear and Corrosion Resistance
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Solution Overview
Problem
Current metal bonding layers in nickel-based superalloys for engine turbines face issues with thermal barrier coating peeling due to thermally grown oxide thickness and corrosion from high halogen-free glass fiber plastics, leading to wear and corrosion of injection components.
Innovation Solution
An aluminum-cobalt-chromium-iron-nickel-silicon alloy powder with specific atomic percentages is produced using inert gas spray atomization and cladded onto substrates via thermal spray technology, forming a high-temperature, wear-resistant, and corrosion-resistant layer that reduces reaction rates and improves bonding strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal bonding layer is used between nickel-based superalloy and ceramic thermal barrier layer, then bonding strength is improved, but thermally grown oxide thickness increases causing thermal barrier coating to peel off
Solution Approach 1:
The patent modifies the chemical composition parameters of the bonding layer by incorporating specific elements (Al, Si, Ti, B) in controlled amounts to optimize both bonding strength and oxidation resistance, preventing TGO overgrowth while maintaining interface stability
Solution Approach 2:
The bonding layer is designed as a composite material system combining nickel-based superalloy with specific alloying elements (Al, Si, Ti, B) to achieve multiple functions: strong bonding to both substrate and ceramic, controlled oxidation resistance, and thermal barrier properties
2Reliability
If halogen-free high glass fiber plastic parts are produced with inorganic flame retardants, then fire safety is improved, but injection components suffer severe corrosion
Solution Approach 1:
The alloy cladding layer acts as an intermediary protective barrier between the injection component and the corrosive halogen-free plastic environment, preventing direct contact and chemical interaction while allowing the plastic to maintain its fire safety properties
3Strength
If glass fiber is added to plastic parts to improve strength, then mechanical strength is improved, but injection components suffer severe wear
Solution Approach 1:
The alloy cladding layer serves as a protective intermediary layer that prevents direct contact between the injection component and glass fibers in the plastic, thereby preventing wear while allowing the plastic parts to maintain their enhanced mechanical strength
4Reliability
If aluminum content in the alloy is increased to improve oxidation resistance, then high-temperature oxidation resistance is improved, but hot cracking tendency increases
Solution Approach 1:
The patent optimizes the aluminum content within a specific range (3-13 at%) rather than maximizing it, and balances it with other alloying elements (Si, Ti, B) to achieve both oxidation resistance and hot cracking resistance through controlled compositional parameters
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting alloy cladding exhibits enhanced high-temperature hardness, wear resistance, and corrosion resistance, extending the service life of injection components and maintaining high bonding strength with substrates.
Implementation Method 1
cladded onto substrates via thermal spray technology
Data Source
AI summary
An aluminum-cobalt-chromium-iron-nickel-silicon alloy has atomic percentages of 4-12 at % aluminum, 15-25 at % cobalt, 25-35 at % chromium, 4-8 at % iron, 15-25 at % nickel, 10-25 at % silicon, wherein the atomic percentage of aluminum plus silicon is between 18-32 at %. The disclosure applies the alloy design to develop a low-aluminum Al—Co—Cr—Fe—Ni—Si alloy composition, and has high-temperature hardness, high wear resistance, corrosion resistance and high temperature oxidation resistance.