Patent ID: 9279187
Filing Date: 2016-03-08
CPC Classification: C23C,F01D,H01J,Y10T

Claim Text:
1. A method of forming a diffusion barrier coating system between a substrate and coating comprising: depositing a diffusion barrier coating onto at least a portion of a substrate surface, wherein said diffusion barrier coating comprises at least two compositionally different layers, (i) a first layer having a composition selected from the group consisting of TaN, WN, Ti—Si—N, Zr—Si—N, Ta—Si—N, and Ti—Si—C—N; and (ii) a second layer having at least 50 at % aluminum selected from the group consisting of Al wherein said diffusion barrier coating layers are deposited by vapor deposition by providing a precursor gas including an element selected from the group consisting of O, N, C, and silicon at a flow rate of 1 sccm to 100 sccm, and providing a target including an element selected from the group consisting of tantalum, titanium, tungsten, zirconium, silicon, and aluminum and operating said target at a power in the range of 0.5 kW to 5kW for a deposition time in the range of 5 minutes to 100 minutes; and subsequently depositing [M M is selected from the group consisting of iron, cobalt, nickel, manganese, tungsten, and molybdenum, X is selected from the group consisting of a carbon and phosphorous, and “y” is in the range of 85 wt % to 95 wt % of the total composition, “a” is in the range of 70 wt % to 90 wt % of “y”, “b” is in the range of 5 wt % to 25 wt % of “y”, and “c” is in the range of 0.1 wt % to 5 wt % of “y”, wherein said [M wherein said [M