SPRAY COATED MEMBER RESISTANT TO HIGH TEMPERATURE ENVIRONMENT AND METHOD OF PRODUCTION THEREOF

Abstract: In order to advantageously solve problems such as lowering of the productivity, contamination of alloy coating due to the adoption of different metal, increase of the cost due to the adoption of different coating process, a coating of MCrAlX alloy containing an oxide such as CoO, NiO or the like is directly formed at a thickness of 10∼500 µm through a low pressure plasma spraying process containing substantially no oxide and thereafter the same MCrAlX alloy xontaining no oxide is applied thereonto at a thickness of 100∼800 µm through a low pressure plasma spraying process in a non-oxidizing atmosphere to form a composite sprayed coating.

Description: TECHNICAL FIELD This invention relates to a spray coated member for use in high-temperature environment having an excellent high-temperature oxidation resistance as a high-temperature member such as boiler, gas turbine, jet engine, diesel engine or the like and a method of producing the same. BACKGROUND ART As to a high power generator such as a boiler, a gas turbine, a jet engine, a diesel engine or the like, there are many studies for mainly improving a heat efficiency. However, the improvement of heat efficiency forces a severe thermal load to a constructional part (material). As a metallic material used in a high temperature portion of the high power generator, therefore, it is required to have excellent high-temperature oxidation resistance and high-temperature corrosion resistance. Particularly, if it is intended to use a fuel containing impurities such as V, Na, S and the like, since inorganic compounds containing these impurities violently corrode and wear the metallic material at a high-temperature state, it is necessary to maintain the metallic material at a stable state for a long time under such an environment. In order to satisfy such a requirement, there have been developed many heat resistant alloys consisting essentially of nonferrous metallic elements such as Cr, Ni, Mo, Co, W, Ta, Al, Ti and the like from the old time, which are called as so-called super-alloys. In these heat resistant alloys, however, the high-temperature strength is most preferential, so that it tends to suppress an addition amount of a metal element not serving to the improvement of the strength as low as possible. A typical example of the metal element not serving to the improvement of the strength is Cr, Al, Si or the like, but these elements are excellent in the oxidation resistance and resistance to high-temperature corrosion. Therefore, it is ordinary that the super-alloy preferentially requiring the above high temperature strength is poor in the oxidation resistance and resistance to high-temperature corrosion. Heretofore, a metallic elements such as Cr, Al, Si or the like or an alloy thereof has previously been applied to a surface of a super-alloy member used under a high temperature environment through a spraying process, a diffusion treatment method or the like to compensate for the lowering of resistance force to chemical damage of the super-alloy. In the conventional spraying process, it is merit that the kind of the spraying material may optionally be selected, but there is a drawback that the resulting coating is porous and is poor in the corrosion resistance and adhesion property because the treatment is carried out in air. In this connection, there has recently been developed a method wherein plasma spraying is carried out in an argon gas atmosphere of a low pressure containing substantially no air (oxygen) (low-pressure plasma spraying process), whereby drawbacks inherent to the atmospheric-sprayed coating have largely been improved, but it can not be said that such a coating is still sufficient under recent environment exposed at higher temperature. On the other hand, the conventional diffusion treatment method is relatively easy when Cr, Al, Si and the like are treated individually, but it is hardly said that the oxidation resistance and the resistance to high-temperature corrosion are sufficient. And also, this treatment is required to be conducted at a higher temperature state of about 1000°C, so that it has a drawback that mechanical properties of super-alloy matrix lower. Under the above circumstances, JP-A-55-104471 proposes a method wherein Ni-Cr alloy as an oxidation-resistant metal is sprayed to conduct a diffusion treatment of Al, Cr or the like. In this method, however, the treatment at high temperature can not be avoided, so that it is inevitable to lower the mechanical properties of the matrix though the adhesion property and denseness of the sprayed coating are improved. On the other hand, the development of spraying materials is carried out for using under high-temperature environment. A typical material is a heat-resistant alloy material represented by MCrAlX (wherein M is a metal of Ni, Co or Fe or a mixture thereof. X is an element such as Y, Hf, Ta, Cs, Pt, Ce, Zr, La, Si, Th or the like). By plasma spraying the MCrAlX alloy under a low pressure, it is possible to form a sprayed coating having excellent oxidation resistance and resistance to high-temperature corrosion, and the performances of the high-temperature member are more improved. And also, there is proposed a method wherein the diffusion treatment of Cr, Al or the like is conducted after the formation of the MCrAlX alloy sprayed coating (e.g. JP-B-61-10034). The service life of the member for gas turbine is fairly improved by the above recent spraying process or the development of a technique combining the spraying process and the diffusion treatment method. However, the gas temperature of the gas turbine is anticipated to reach 1500-1700°C in future. In the gas turbine member contacting with such a high temperature gas, even if it is reinforced with a cooling mechanism through air or steam, it is anticipated that the temperature of the exposed member exceeds the existing 900°C and will be 950∼1050°C. For this end, it is studied to improve the high temperature strength of the member for the gas turbine (metal matrix). However, when the alloy sprayed coating is formed on such a high temperature member (metal substrate) by the conventional method, there is a fear of causing the following problems. (1) In the high temperature member (metal substrate), as the temperature becomes high, there is a strong tendency that an alloy component in a sprayed coating of, for example, MCrAlX alloy (wherein M is one or more of Ni, Co and Fe, X is one or more of Y, Hf, Ta, Cs, Pt, Ce, Zr, La, Si and Th) formed on the surface or a composite sprayed coating containing a diffusion layer therein diffuses and penetrates into the inside of the metal substrate and hence a thick brittle layer is created in a boundary portion between the sprayed coating and the substrate surface to easily peel the sprayed coating. (2) Among the components of the MCrAlX alloy penetrated into the inside of the metal substrate, Al particularly reacts with Ni included in the metal substrate to produce a brittle intermetallic compound such as AlNi, AlCo or the like and has an action disappearing a high temperature strength component or precipitate existing in the substrate. As a result, the high temperature strength of the substrate as a whole lowers and it is apt to cause crack or local breakage resulted from thermal fatigue. (3) Even in the MCrAlX alloy sprayed coating, Ni, Cr and the like being basic components diffuse to form a brittle layer, so that the resistance to thermal shock in the coating considerably lowers. It is said that these problems result from the feature that the components of the MCrAlX alloy sprayed coating applied to the surface of the substrate diffuse and penetrate into the substrate. As a countermeasure therefor, it is considered that the prevention of diffusing and penetrating the alloying components of the sprayed coating is an effective means. As such a means, there is a method wherein a high melting point metal (Nb, Ta) or a thin layer of (10∼100 µm) of an oxide film such as Al 2 O 3 is directly formed on the surface of the substrate through a spraying method or PVD method and the conventional MCrAlX alloy sprayed coating is formed thereon to control the internal diffusion of the MCrAlX alloying components. In this method, however, an expensive metal different from the MCrAlX alloying components is used, or the PVD method using an electron beam as a heat source is used in the formation of Al 2 O 3 film, so that the different film-forming process should be adopted and hence the lowering of the productivity is caused. And also, the prevention of the internal diffusion of the alloying components by this method loses the diffusion layer required for ensuring the adhesion property between the substrate and the sprayed coating and the adhesion property of the coating considerably lowers. It is, therefore, an object of the invention to solve the aforementioned problems of the conventional techniques and to propose a coating technique for advantageously solving problems such as lowering of productivity, contamination of alloy coating based on the adoption of different metal, cost up based on the adoption of different coating process and the like. US 4,451,496 (Gedwill et al) comprises a coated component comprising a base layer of an oxide dispersed, metallic alloy, plasma sprayed on to the substrate, and a top layer of an alloy of nickel, cobalt or iron, which is plasma sprayed on to the base layer. US 5,967,775 (Czech et al) discloses a coating for a body, the coating comprising a metallic covering layer applied directly on to the outside of the body, and a metallic enrichment layer covering a portion of the body. The metallic enrichment layer may be formed by the addition of aluminium or chromium to the material of the body, or the metallic covering layer. JP 61010034 (Mitsubishi Heavy Ind Ltd) discloses a method of manufacturing a metallic material having improved corrosion resistance and oxidation resistance at high temperature. The metallic material which may contain Cr, Ni, Al and/or Co, is melt sprayed or vapour deposited on the surface of the substrate to form a film. Additionally, diffusion or permeation of Al or Cr in the surface of the substrate is performed in order to improve oxidation and corrosion resistance. DISCLOSURE OF THE INVENTION According to a first aspect of the present invention, there is provided a spray coated member for use in a high-temperature environment, having a composite sprayed coating comprised of an oxide-containing undercoat sprayed coating obtained by spraying a MCrAlX alloy spraying material (wherein M is one or more of Ni, Co and Fe, and X is one or more of Y, Hf, Ta, Cs, Pt, Ce, Zr, La, Si and Th) containing one or more oxides selected from CoO, NiO, Cr 2 O 3 , Al 2 O 3 , Y 2 O 3 , MgO, SiO 2 , ZrO 2 and TiO 2 onto a surface of a heat-resistant alloy substrate under a low pressure atmosphere containing substantially no oxygen, a non-oxide topcoat sprayed coating obtained by spraying a MCrAlX alloy spraying material (wherein M is one or more of Ni, Co and Fe, and X is one or more of Y, Hf, Ta, Cs, Pt, Ce, Zr, La, Si and Th) onto the undercoat under a low pressure atmosphere containing substantially no oxygen characterised in that an Al diffused layer is formed on the oxide containing undercoat and a heat shielding layer is formed on the surface of the topcoat sprayed coating and made of an oxide ceramic. According to a second aspect of the present invention, there is provided a method of producing a spray coated member for use in high-temperature environment, wherein (1) an oxide-containing undercoat sprayed coating is formed by spraying a MCrAlX alloy material (wherein M is one or more of Ni, Co and Fe, and X is one or more of Y, Hf, Ta, Cs, Pt, Ce, Zr, La, Si and Th) containing one or more oxides selected from CoO, NiO, Cr 2 O 3 , Al 2 O 3 , Y 2 O 3 , MgO, SiO 2 , ZrO 2 and TiO 2 onto a surface of a heat-resistant alloy substrate under a low pressure containing substantially no oxygen; (2) a non-oxide topcoat sprayed coating is formed thereon by spraying a MCrAlX alloy material (wherein M is one or more of Ni, Co and Fe, and X is one or more of Y, Hf, Ta, Cs, Pt, Ce, Zr, La, Si and Th) onto the undercoat under a low pressure containing substantially no oxygen; characterised in that the method further comprises the steps of (3) after the formation of the undercoat and topcoat, an Al diffusion treatment is further carried out on the oxide containing undercoat to increase the Al concentration in each surface layer portion; and (4) a heat shielding layer is formed by spraying an oxide ceramic after the formation of the topcoat in the spraying formation of the composite sprayed coating. The Al diffusion treatment of step (3) may be further carried out on the topcoat sprayed coating to form an Al diffused layer at its surface. The invention does not lie in a method adopting a different film-forming means and using a different metal as in the conventional technique, but lies in a technique forming a coating having an excellent resistance to high-temperature oxidation by using same film-forming means, same metal and same metal oxide. That is, preferred embodiments in accordance with the present invention provide techniques based on the following thoughts. (1) To prevent that the components in the MCrAlX alloy sprayed coating formed on the surface of the member exposed to high temperature rapidly diffuse into the inside of the substrate through with the rise of temperature in the gas turbine. (2) To maintain good mechanical properties over a long time by preventing the formation and growth of a modified layer having poor mechanical strength and low strength to thermal strength on the surface of high temperature substrate. (3) To eliminate an adoption of a different film-forming method such as formation of Al 2 O 3 underlayer thin film through PVD process or the like and formation of MCrAlX alloy sprayed coating through spraying process. (4) To eliminate the necessity of spraying a different high-melting point metal such as Nb, Ta or the like as an undercoat prior to the spraying of MCrAlX alloy. (5) To eliminate the degradation of resistance to high-temperature oxidation resulted from the metal such as Nb, Ta or the like included in the MCrAlX alloy when the cleaning in the line is insufficient. (6) In the conventional technique, the thin film such as Al 2 O 3 , Nb, Ta or the like formed as a lower layer is apt to bring about the lowering of the adhesion property of the MCrAlX alloy coating as an upper layer, so that it is difficult to form the film (when the internal diffusion of the MCrAlX alloy is prevented by Al 2 O 3 or the like, it is apt to cause the peeling due to the lowering of the adhesion property, while when the adhesion property is improved, the diffusion of the alloy into the inside of the substrate becomes deeper, which result in the lowering of the mechanical properties of the substrate itself). In the invention, the film can be formed by a simple method without requiring the above complicated control. Preferred embodiments developed under such thoughts are as follows (1) Composite sprayed coatings formed by directly applying a MCrAlX alloy containing an oxide such as CoO, NiO or the like on a surface of a substrate of a high-temperature exposed member at a thickness of 10-500 µm through a low pressure plasma spraying process containing substantially no oxygen and then applying the same MCrAlX alloy containing no oxide thereon at a thickness of 100∼800 µm through a low pressure plasma spraying process in a non-oxidizing atmosphere. (2) The oxide powder to be mixed with the MCrAlX alloy is used in an amount of 0.2∼20 wt% and the mixture is sprayed in a non-oxidizing atmosphere to form an undercoat having a thickness of 10∼500 µm onto the substrate of a high-temperature exposed member and then the MCrAlx alloy containing no oxide is sprayed thereonto in a non-oxidizing atmosphere to form a topcoat having a thickness of 10∼800 µm. (3) An Al diffusion is carried out on each surface of the sprayed coatings formed by the method of the item (1) and (2) to further provide a high resistance to high-temperature oxidation. (4) A heat shielding layer made of an oxide ceramic is further formed on the surface of the topcoat sprayed coating. In the invention, it is preferable that a total amount of the oxide powders included in the undercoat sprayed coating is within a range of 0.2-20% by weight. And also, so-called inclination compounding is favourable so as to gradually increase the compounding amount toward the substrate. In the invention, it is preferable that the undercoat sprayed coating has a thickness of 10-500 µm and the topcoat sprayed coating has a thickness of 100-800 µm. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a partial diagrammatic view of a sectional structure in a spray coated member according to the invention. Fig. 2 is a partial diagrammatic view of a sectional structure in another composite spray coated member according to the invention. Fig. 3 is a partial diagrammatic view of a sectional structure in the other composite spray coated member according to the invention. BEST MODE FOR CARRYING OUT THE INVENTION The invention proposes a composite coating of MCrAlX alloy having a good adhesion property and an excellent resistance to high-temperature oxidation though an amount of diffusion into an inside of a substrate and a surface coating method thereof. The details of the structure of the composite coating will be described below. A. Undercoat MCrAlX alloy sprayed coating and the formation thereof; As a substrate to be treated, there is used Ni-based alloy, Co-based alloy or the like frequently used as a gas turbine blade. The surface of the substrate is degreased and roughened by blast treatment. Thereafter, a mixture of MCrAlX alloy and one or more oxides selected from the group consisting of 1 ○ oxides of MCrALX alloy; Coo, NiO, Cr 2 O 3 , Al 2 O 3 , Y 2 O 3 and 2 ○ other oxides; MgO, SiO 2 , ZrO 2 and TiO 2 is applied at a thickness of 10∼500 µm in a non-oxidizing atmosphere containing substantially no oxide to form an undercoat coating. The particle size of the above oxide powder is preferable to be within a range of 0.1∼50 µm and also the amount added to the above MCrAlX alloy is within a range of 0.2∼20 wt%. When the particle size is less than 0.1 µm, the oxide frequently evaporates in a heat source for the spraying, while when it exceeds 50 µm, the fusion is difficult and the oxide is entered into the undercoat at a non-fused state and hence the coating is brittle and is apt to cause cracking. As to the addition amount of the oxide powder, when it is less than 0.2 wt%, the diffusion reaction of the MCrAlX alloy coating components into the inside of the substrate can not sufficiently be controlled if the member to be treated is exposed to a higher temperature, while when it exceeds 20 wt%, the diffusion amount into the inside of the substrate becomes small and the adhesion property of the alloy coating undesirably lowers. Moreover, the oxide powder added to the MCrAlX alloy can be produced by mechanically mixing (e.g. mechanical alloying process), or by granulating them with a tacking agent, or by a method wherein the oxide powder is mixed with molten alloy and then pulverized, or the like. As seen from the above, in the invention, the oxide powder is included in the undercoat sprayed coating formed on the surface of the substrate. As a property of this sprayed coating, the components of the MCrAlX alloy particles diffuse into the inside of the substrate, but the oxide powder does not diffuse. Therefore, it is said that the diffusion into the inside of the substrate becomes small as the oxide powder in the undercoat becomes large. According to the invention, in the formation of the undercoat sprayed coating of the oxide-containing MCrAlX alloy, it is favorable to conduct so-called slant concentration compounding of the oxide powder in such a manner that the content of the oxide powder is large in the side of the substrate and is made small in the surface layer portion. This is due to the fact that the undercoat sprayed coating having the slant compounded concentration of the oxide powder can effectively control the diffusion of the MCrAlX alloy components into the inside of the substrate and also is excellent in the adhesion property to the topcoat. As to the sprayed coating of the oxide-containing MCrAlX alloy for the undercoat, there are the following some problems from a viewpoint of the resistance to high-temperature oxidation. 1 ○ The oxide powder and MCrAlX alloy particles existing in the undercoat sprayed coating are not fused to each other at a state of forming the coating, so that microscopic gaps are produced. 2 ○ The corrosive components in the environment (corrosive components in combustion gas) penetrate into the inside of the coating through the microscopic gaps to lower the resistance to high-temperature oxidation in the coating. As a countermeasure, embodiments in accordance with the present invention adopt the following means. (a) The surface of the undercoat sprayed coating of the oxide-containing MCrAlX alloy is subjected to Al diffusion treatment. (b) The MCrAlX alloy coating containing no oxide is further formed on the surface of the undercoat sprayed coating of the oxide-containing MCrAlX alloy through a low pressure plasma spraying process. As to the Al diffusion treatment to the surface of undercoat sprayed coating of MCrAlX alloy containing oxide powder; As previously mentioned, the oxide powder and the MCrAlXalloy particles are not fused to each other, so that the resulting coating is poor in the resistance to high-temperature oxidation as it is. In the invention, therefore, the undercoat sprayed coating is subjected to the Al diffusion treatment, whereby the fusion of the oxide powder and the MCrAlX alloy particles is attempted on the surface but also the Al content is increased to improve the resistance to high-temperature oxidation. As a process for the Al diffusion treatment, use may be made of a powder process (the member to be treated is embedded in powder made from Al metal, Al alloy powder, Al 2 O 3 , halide or the like and heated at 900∼1100°C for 3-10 hours), a chemical deposition process (metallic Al is precipitated by thermal decomposition of organic or inorganic Al compound or reduction reaction thereof with hydrogen and adhered onto the surface of the member to be treated), a physical deposition process (Al is evaporated by heat source such as electron beam or the like and adhered onto the surface of the member to be treated) and the like. The surface of the undercoat sprayed coating subjected to the Al diffusion treatment is excellent in the resistance to high-temperature oxidation and can be used as it is in accordance with the use environmental conditions. When the sprayed coating of the MCrAlX alloy containing the oxide as mentioned above is applied onto the surface of the substrate as an undercoat, even if the temperature of the use environment is not lower than 1000°C, the above oxide obstructs the diffusion of the MCrAlX alloy and hence the excessive diffusion into the inside of the substrate is eliminated. However, the oxide existing in the sprayed coating of the MCrAlX alloy is ununiformly distributed and the properties of the oxide itself become frequently incomplete state as compared with those of a stoichiometric oxide due to the flying in th eplasma heat source. On the other hand, many particles not oxidized are existent in the alloy. The thickness of the undercoat sprayed coating is within a range of 10∼500 µm, preferably a range of 50∼100 µm. When it is less than 10 µm, it is difficult to form the coating at an equal thickness by the spraying process, while when it exceeds 500 µm, the function as the diffusion obstruction is not improved and it is not economical. Therefore, when such a sprayed coating is heated to a higher temperature, the diffusion into the inside of the substrate somewhat occurs. In the invention, the topcoat is formed on the undercoat by spraying the MCrAlX alloy containing no oxide through a spraying process containing substantially no oxide as mentioned below. B. Topcoat MCrAlX alloy sprayed coating and the formation thereof; The undercoat sprayed coating of the MCrAlX alloy containing the oxide is small in the diffusion rate into the inside of the substrate, but is weak in the bonding force between the particles constituting the coating as it is and is porous, so that when it is used under an operating environment of gas turbine at a high temperature, there is caused a problem that the member to be treated (e.g. a turbine blade) is oxidized at a high temperature or subjected to a high-temperature corrosion by a combustion gas component invaded from pores of the coating. In order to solve this problem, according to the invention, a topcoat sprayed coating of MCrAlX alloy containing no oxide is further formed on the surface of the undercoat sprayed coating or the undercoat sprayed coating subjected to the Al diffusion treatment by a low pressure plasma spraying process in a non-oxidizing atmosphere. The topcoat sprayed coating is strong in the bonding force between the particles and good in the adhesion property to the undercoat sprayed coating. After the formation of the topcoat sprayed coating, when the heat treatment is carried out in air or argon atmosphere or under vacuum at 1000∼1170°C for 1∼5 hours, the pores of the topcoat sprayed coating are completely disappeared, whereby the resistance to high-temperature oxidation and the resistance to high-temperature corrosion can sufficiently be improved. In a preferable embodiment, the surface of the coating after the formation of the topcoat sprayed coating is subjected to the same Al diffusion treatment as mentioned above, whereby a layer of a high Al concentration having an excellent oxidation resistance is formed on the outermost surface layer portion of the topcoat sprayed coating and also a stronger bonding force between the particles constituting the topcoat is developed. As the Al diffusion treatment, the same process as mentioned above may be adapted. The thickness of the topcoat sprayed coating is within a range of 100∼800 µm, preferably a range of 200∼500 µm. When it is less than 100 µm, the resistance to high-temperature oxidation is insufficient, while when it exceeds 800 µm, the performances as the coating are not extremely improved and it is uneconomical. Although the formation of the undercoat sprayed coating and the topcoat sprayed coating is described by taking the low pressure plasma spraying process, the following process can be adopted as seen from the function and mechanism. That is, the low pressure plasma spraying process conducting the film formation in an atmosphere containing substantially no oxygen is optimum, but a pressure plasma spraying process or a spraying process using a laser as a heat source may be used if the atmosphere contains substantially no oxygen. And also, it can be said that it is possible to form the coating by a deposition process using an electron beam as a heat source in a vacuum vessel. Now, the chemical components of the sprayed coating used in the invention are called as a MCrAlX alloy as mentioned above, and a typical composition of the alloy is shown below. M component: Ni (0∼75 wt%), Co (0∼70 wt%), Fe (0∼30 wt%) Cr component: 5∼10 wt% Al component: 1∼29 wt% X component: Y (0∼5 wt%), Hf (0∼10 wt%) In the invention, Ta (1∼20 wt%), Si (0.1∼14 wt%), B (0∼0.1 wt%), C (0∼0.25 wt%), Mn (0∼10 wt%), Zr (0∼3 wt%), W (0∼5.5 wt%), Cs, Ce, La (0∼5 wt%, respectively), Pt (0∼20 wt%) and the like may be added, if necessary, in addition to the above components. Moreover, in the invention, the heat shielding layer formed on the surface of the topcoat sprayed coating is preferably an oxide ceramic mainly composed of ZrO2 and added with 4∼30 wt% of one or more of Y2O3, CaO, MgO, CeO2 and the like for stabilization or partial stabilization of ZrO2 crystal, or MgO-Al2O3, ZrO2-Al2O3 or the like may be used. Fig. 1 diagrammatically shows a sectional structure of a basic composite sprayed coating, in which an undercoat 2 of oxide-containing MCrAlX alloy is formed on a member 1 to be treated through a low pressure plasma spraying process and a topcoat 3 of MCrAlX alloy is formed thereon through a low pressure plasma spraying process. Further, Fig. 2 shows a sectional structure of the coating when the content of the oxide powder in the undercoat sprayed coating is slantly changed. When any coatings are exposed to a high-temperature environment, the oxide powder included in the undercoat sprayed coating controls the excessive diffusion of the MCrAlX alloy coating components into the inside of the member to be treated, while the dense topcoat sprayed coating develops the action of preventing the invasion of corrosive gas from an exterior. For this end, as shown in Fig. 3, when the heat shielding layer of ZrO2 oxide ceramic partly stabilized with CaO, MgO, Y2O3, CeO2 or the like is formed on the surface of the topcoat sprayed coating, the exposed temperature of the member to be treated can be lowered and the internal diffusion rate of the undercoat can be further decreased. EXAMPLES various kinds of the MCrAlX alloy spraying materials are used in the following examples and chemical compositions thereof are shown in Table 1. That is, the spraying materials can be roughly divided into an alloy spraying material containing no Ni (A), alloy spraying material containing no Co (B, C, D, E), alloy material containing Ni and Co (F, G) and a material obtained by adding 5 wt% of Ta, which is not included in the other alloys, to the alloy G. With regard to the following examples, in order to add a heat shielding layer, said heat shielding layer, which is made of an oxide ceramic, is formed on the surface of the topcoat sprayed coating. Example 1 In this example, the adhesion properties of the coatings are examined by subjecting the composite sprayed coating of MCrAlX alloy according to the invention formed on a Ni-based alloy substrate to a thermal shock test. A. Test specimen: (1) Composite sprayed coating MCrAlX alloy with oxide-containing undercoat. As a substrate to be sprayed, a test piece of 30 mm in width x 50 mm in length x 5 mm in thickness is prepared from the Ni-based alloy (15.3 wt% Ni-7 wt% Fe-2.5 wt% Ti-2 wt% Mo-10 wt% Co-remainder Ni). As a spraying material, a mixed powder of MCrAlX alloy (B, C, D, E, F - Table 1) added with 0.8 wt% of Al 2 O 3 , Y 2 O 3 ,or MgO is sprayed through a low pressure plasma spraying process to form an undercoat of 300 µm. And also, a part of the test specimens is subjected to Al diffusion treatment (900°C x 4h) through powder process, in accordance with present invention. Onto the surface of the undercoat sprayed coating is formed a topcoat sprayed coating having a thickness of 300 µm by using the MCrAlX alloy containing no oxide powder through the low pressure plasma spraying process (total thickness 600 µm). (2) MCrAlx alloy sprayed coating of Comparative Example without oxide-containing undercoat Onto the above Ni-based alloy substrate is formed the coating of the MCrAlx alloy containing no oxide at a thickness of 600 µm through the low pressure plasma spraying process. B. Thermal shock test method: An operation that the test specimen of the sprayed coating is heated in an electric furnace at 1000°C x 15 minutes and then charged into water of 25°C as a one cycle is repeated 25 times to observe the appearance state of the test specimen. C. Results: The experimental results are shown in Table 2. As seen from this table, the alloy sprayed coatings of the comparative example (Nos. 13∼17) show good resistance to thermal shock and do not show abnormal state in the appearance of the coating even after the 25 times repetition of the heating and water cooling. This is considered due to the fact that the coating formed by the MCrAlX alloy being dense through the low pressure plasma spraying process and good in the bonding force between particles strongly bonds to the substrate through the diffusion. In the coating of the comparative example, however, the layer considerably diffused into the inside of the substrate at a depth of 80∼120 µm is observed and hence the strength of the diffused portion in the substrate is considerably degraded, On the contrary, the test specimens provided with the undercoat of MCrAlX alloy containing the oxide powder (No. 1∼12) control the diffusion of the alloying components into the inside of the substrate and do not show abnormal state even in the thermal shock test of 25 times under the above test conditions and have been confirmed to have a good adhesion property. And also, the coatings in accordance with the present invention, after the Al diffusion treatment of the undercoat (No. 1, 5, 9, 12), show a good resistance to thermal shock. Example 2 In this example, test for high-temperature corrosion and test for high-temperature sulfurization are made with respect to products obtained by forming the composite sprayed coating of MCrAlX alloy according to the invention onto Co-based alloy substrate, whereby the resistance to high-temperature environment is examined. A. Test specimen: 1 ○ Composite sprayed coating of MCrAlX alloy with oxide-containing undercoat. A test specimen of 30 mm width x 50 mm length x 5 mm thickness is prepared by using the following Co-based alloy as a substrate to be sprayed. Co-based alloy: 29.5 wt% Cr-10.5 wt% Ni-7.0 wt% W-2 wt% Fe-remainder Co An undercoat of 300 µm in thickness is formed by using MCrAlX alloy (A, C) added with 1.0 wt% of Al 2 O 3 , SiO 2 , TiO 2 or ZrO 2 as a spraying material through the low pressure plasma spraying process. On some test specimens, a topcoat of 300 µm in thickness is formed on the undercoat sprayed coating by using the MCrAlX alloy containing no oxide powder (A, C) through the low pressure plasma spraying process. Further, there are provided products in accordance with the present invention obtained by subjecting each of the undercoat and topcoat to Al diffusion treatment through powder process. 2 ○ sprayed coating of MCrAlX alloy of Comparative Example a. A coating of 300 µm in thickness is formed on each of the above Ni-based alloy substrate and Co-based alloy substrate by using the MCrAlX alloys (A, C) through the atmospheric plasma spraying process. b. There are provided products obtained by subjecting the sprayed coating of the above item a to the Al diffusion treatment under the same conditions as in the acceptable example of the invention. B. High-temperature corrosion test method: The high-temperature corrosion test method shown in Table 4 is carried out under the following conditions. 3 ○ Vanadium corrosion test: composition of chemical agents: 80% V 2 O 5 ∼20% NaCl temperature · time: 900° x 3 h 4 ○ Test of high-temperature sulfurization corrosion: composition of chemical agents: 90% Na 2 SO 4 -10% NaCl temperature time: 1000°C x 4 h Moreover, the amount of the agents applied in both tests is 25 mg per 1 cm 2 of the sprayed coating (25 mg/cm 2 ), and the test specimen is maintained in an electric furnace at given temperature and time and taken out therefrom and thereafter the section of the coating corresponding to the corroded portion is observed by a microscope and the depth of the corrosion component penetrated is observed by an X-ray microanalyzer to examine the resistance to high-temperature corrosion in the coating. C. Results: In Table 3 are summarized the above test results for high-temperature corrosion. In the section of the atmospheric plasma sprayed coating of the comparative examples (No. 9, 10), corrosion components (V and S in vanadium corrosion, S and Cl in high-temperature sulfurization corrosion) very deeply penetrate into the inside of the coating (75∼135 µm), while the penetration of the corrosion components stops to a range of 23-57 µm in the composite sprayed coatings according to the invention (No. 4 and 7), and the resistance to high-temperature corrosion is excellent. On the other hand, in the coating of the comparative example (No. 9), the penetration depth is observed to be 2-3 times that of the composite sprayed coating according to the invention (Nos. 4 and 7) though it is subjected to the Al diffusion treatment, from which it is considered that the effect is less to the coating in which the surfaces of the spraying particles are covered with thin oxide film and gaps are existent between the particles as in the atmospheric plasma sprayed coating. In this point, it is considered that in the composite sprayed coating according to the invention, the oxide powder is included, but the content thereof is small, so that MCrAlX alloy particles being rich in the chemical activity are existent at a dense state and metallurgically reacts with Al in the Al diffusion treatment to form a more dense coating having an excellent corrosion resistance. INDUSTRIAL APPLICABILITY As seen from the above explanations and the results of the examples, the composite sprayed coating of MCrAlX alloy consisting of the oxide sprayed coating and non-oxide sprayed coating with Al diffusion according to the invention is small in the thickness of the diffusion layer into the inside of the member to be exposed even if the environment temperature becomes higher, so that it shows a good resistance to thermal shock and develops an excellent performance to the resistance to high-temperature corrosion. As a result, the member sprayed with MCrAlX alloy according to the invention is possible to be produced in a good productivity and a low cost by using the same kind of the spraying process and the same kind of metal in a field of gas turbine anticipating the rise of the temperature in future and hence it contributes to reduce the cost of power generation. And also, the invention is suitable as a high temperature member used in a blast furnace, a heat treating furnace or the like, or a heat-resistant member used in rocket, space shuttle or the like.

Claims: A spray coated member for use in high-temperature environment, having a composite sprayed coating comprised of an oxide-containing undercoat sprayed coating obtained by spraying a MCrAlX alloy spraying material (wherein M is one or more of Ni, Co and Fe, and X is one or more of Y, Hf, Ta, Cs, Pt, Ce, Zr, La, Si and Th) containing one or more oxides selected from CoO, NiO, Cr 2 O 3 , Al 2 O 3 , Y 2 O 3 , MgO, SiO 2 , ZrO 2 and TiO 2 onto a surface of a heat-resistant alloy substrate under a low pressure atmosphere containing substantially no oxygen, a non-oxide topcoat sprayed coating obtained by spraying a MCrAlX alloy spraying material (wherein M is one or more of Ni, Co and Fe, and X is one or more of Y, Hf, Ta, Cs, Pt, Ce, Zr, La, Si and Th) onto the undercoat under a low pressure atmosphere containing substantially no oxygen characterised in that an Al diffused layer is formed on the oxide containing undercoat, and a heat shielding layer is formed on the surface of the topcoat sprayed coating and made of an oxide ceramic. A spray coated member according to claim 1, wherein a total amount of the oxide powder included in the undercoat sprayed coating is within a range of 0.2-20% by weight. A spray coated member according to claim 1, wherein the topcoat sprayed coating has further an Al diffused layer at its surface. A spray coated member according to claim 1, wherein the undercoat sprayed coating has a thickness within a range of 10-500 µm. A spray coated member according to claim 1, wherein the topcoat sprayed coating has a thickness within a range of 100-800 µm. A method of producing a spray coated member for use in high-temperature environment, wherein (1) an oxide-containing undercoat sprayed coating is formed by spraying a MCrAlX alloy material (wherein M is one or more of Ni, Co and Fe, and X is one or more of Y, Hf, Ta, Cs, Pt, Ce, Zr, La, Si and Th) containing one or more oxides selected from CoO, NiO, Cr 2 O 3 , Al 2 O 3 , Y 2 O 3 , MgO, SiO 2 , ZrO 2 and TiO 2 onto a surface of a heat-resistant alloy substrate under a low pressure atmosphere containing substantially no oxygen; (2) a non-oxide topcoat sprayed coating is formed thereon by spraying a MCrAlX alloy material (wherein M is one or more of Ni, Co and Fe, and X is one or more of Y, Hf, Ta, Cs, Pt, Ce, Zr, La, Si and Th) onto the undercoat under a low pressure containing substantially no oxygen; characterised in that the method further comprises the steps of (3) after the formation of the undercoat and topcoat, an Al diffusion treatment is further carried out on the oxide containing undercoat to increase the Al concentration in each surface layer portion; and (4) a heat shielding layer is formed by spraying an oxide ceramic after the formation of the topcoat in the spraying formation of the composite sprayed coating. A method according to claim 6, wherein the Al diffusion treatment of step (3) is further carried out on the topcoat sprayed coating to form an Al diffused layer at its surface.

Inventors: HARADA YOSHIO, SUIZU TATSUO, TERATANI TAKEMA, HARADA, YOSHIO, SUIZU, TATSUO, TERATANI, TAKEMA
Applicants: TOCALO CO LTD, TOCALO CO. LTD.
Application year: 1998
Main classification: C23C4
IPC codes: C23C28, C23C4, C23C10