CPC C23C 16/56 (2013.01) [C22C 19/03 (2013.01); C23C 16/405 (2013.01)] | 20 Claims |
1. A method for producing a protective coating on an aerospace component, comprising:
depositing a metal oxide template layer comprising chromium oxide on the aerospace component comprising nickel and aluminum by an atomic layer deposition (ALD) process or a chemical vapor deposition (CVD) process, wherein the metal oxide template layer further comprises tungsten oxide, molybdenum oxide, vanadium oxide, or any combination thereof; and
heating the aerospace component containing the metal oxide template layer during a thermal process comprising:
diffusing aluminum contained within the aerospace component towards a surface of the aerospace component containing the metal oxide template layer;
oxidizing the diffused aluminum to produce an aluminum oxide layer disposed between the aerospace component and the metal oxide template layer, wherein the aluminum oxide layer comprises α-Al2O3, wherein the metal oxide template layer and the aluminum oxide layer have a corundum crystal structure, and wherein the metal oxide template layer and the aluminum oxide layer have crystal structures with a lattice mismatch of about 0.1% to about 10%; and
removing at least a portion of the metal oxide template layer while leaving the aluminum oxide layer by converting the chromium oxide to chromium oxide hydroxide during the thermal process.
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