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Intermetallic alloy development in the early 1990’s suggested that zirconium additions to the NiAl system could significantly strengthen the bond coat and prevent surface rumpling that leads to failure of the thermal barrier coating (TBC) system. A new overlay bond coat based on NiAl that incorporates zirconium and chromium has been developed. Additions of both zirconium and chromium were found to be beneficial for TBC adherence and environmental resistance of the bond coat. Overlay processing methods were used to produce the coating in order to accurately control the zirconium and chromium content. Furthermore, the overlay coating incorporated substrate elements, like nickel, to reduce interdiffusion with the substrate. This reduced interdiffusion resulted in greater retention of the load bearing area of the substrate after extended time at temperature. A gas turbine engine was run with both the new overlay bond coat and current diffusion platinum aluminide bond coat for direct comparison. The new NiAl+Cr+Zr overlay bond coat demonstrated improved durability and better protection of the underlying substrate in comparison with the current state of the art diffusion platinum aluminide bond coat.

Development of Improved Bond Coat for Enhanced Turbine Durability