Novel Architectures For Ultra Low Thermal Conductivity Thermal Barrier Coatings With Improved Erosion And Impact Properties

• Main Authors: LARRY STEVEN ROSENZWEIG, JAMES ANTHONY RUUD, JOSHUA LEE MARGOLIES, SURINDER SINGH PABLA, PADMAJA PARAKALA, KRISHNAMURTHY ANAND
• Format: Patent
• Language: Chinese; English
• Published: 16.07.2014
• Subjects: CHEMICAL SURFACE TREATMENT; CHEMISTRY; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATIONOR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY IONIMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; COATING MATERIAL WITH METALLIC MATERIAL; COATING METALLIC MATERIAL; DIFFUSION TREATMENT OF METALLIC MATERIAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION INGENERAL; LAYERED PRODUCTS; LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT ORNON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM; METALLURGY; PERFORMING OPERATIONS; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THESURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; TRANSPORTING

A thermal barrier coating system for metal components in a gas turbine engine having an ultra low thermal conductivity and high erosion resistance, comprising an oxidation-resistant bond coat formed from an aluminum rich material such as MCrAlY and a thermal insulating ceramic layer over the bond coat comprising a zirconium or hafnium oxide lattice structure (ZrO2 or HfO2) and an oxide stabilizer compound comprising one or more of the compounds ytterbium oxide (Yb2O3 ), yttrium oxide (Y2O3), hafnium oxide (HfO2), lanthanum oxide (La2O3), tantalum oxide (Ta2O5) or zirconium oxide (ZrO2). The invention includes a new method of forming the ceramic-based thermal barrier coatings using a liquid-based suspension containing microparticles comprised of at least one of the above compounds ranging in size between about 0.1 and 5 microns. The coatings form a tortuous path of ceramic interfaces that increase the coating toughness while preserving the ultra low thermal conductivity.