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A highly oxidation and corrosion resistant silicon and hafnium modified NiCoCrAlY coating has been developed to protect the external surfaces of advanced single crystal turbine airfoils. This significant technical advance was made possible in part through the use of the low pressure chamber plasma spray process in fabricating this type of coating alloy which has been very difficult to deposit using conventional electron beam physical vapor deposition methods. The addition of silicon and hafnium to the NiCoCrAlY coating improved its surface oxide scale (primarily alumina) adherence and also increased its capability to reform alumina (once the oxide had spalled) during cyclic exposure. These improvements increased the durability of this new coating by at least two-fold vis-a-vis baseline NiCoCrAlY on single crystal PWA 1480 alloy samples in cyclic burner rig tests. Recently completed experimental JT9D endurance testing has confirmed the laboratory data and this coating has recently entered production for PW2037 commercial engine applications.

A Silicon and Hafnium Modified Plasma Sprayed MCrAlY Coating for Single Crystal Superalloys