US20070082131A1 - Optimized high purity coating for high temperature thermal cycling applications - Google Patents
Optimized high purity coating for high temperature thermal cycling applications Download PDFInfo
- Publication number
- US20070082131A1 US20070082131A1 US11/520,042 US52004206A US2007082131A1 US 20070082131 A1 US20070082131 A1 US 20070082131A1 US 52004206 A US52004206 A US 52004206A US 2007082131 A1 US2007082131 A1 US 2007082131A1
- Authority
- US
- United States
- Prior art keywords
- weight percent
- coating
- stabilizer
- zirconia
- hafnia
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/48—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on zirconium or hafnium oxides, zirconates, zircon or hafnates
- C04B35/486—Fine ceramics
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
- C23C14/08—Oxides
- C23C14/083—Oxides of refractory metals or yttrium
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
- C23C4/11—Oxides
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
- F01D5/288—Protective coatings for blades
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3224—Rare earth oxide or oxide forming salts thereof, e.g. scandium oxide
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3224—Rare earth oxide or oxide forming salts thereof, e.g. scandium oxide
- C04B2235/3225—Yttrium oxide or oxide-forming salts thereof
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3224—Rare earth oxide or oxide forming salts thereof, e.g. scandium oxide
- C04B2235/3227—Lanthanum oxide or oxide-forming salts thereof
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3231—Refractory metal oxides, their mixed metal oxides, or oxide-forming salts thereof
- C04B2235/3244—Zirconium oxides, zirconates, hafnium oxides, hafnates, or oxide-forming salts thereof
- C04B2235/3246—Stabilised zirconias, e.g. YSZ or cerium stabilised zirconia
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
- C04B2235/72—Products characterised by the absence or the low content of specific components, e.g. alkali metal free alumina ceramics
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T50/00—Aeronautics or air transport
- Y02T50/60—Efficient propulsion technologies, e.g. for aircraft
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
- Y10T428/12535—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.] with additional, spatially distinct nonmetal component
- Y10T428/12611—Oxide-containing component
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
- Y10T428/12535—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.] with additional, spatially distinct nonmetal component
- Y10T428/12611—Oxide-containing component
- Y10T428/12618—Plural oxides
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
- Y10T428/1266—O, S, or organic compound in metal component
- Y10T428/12667—Oxide of transition metal or Al
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
- Y10T428/24471—Crackled, crazed or slit
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
- Y10T428/249967—Inorganic matrix in void-containing component
- Y10T428/24997—Of metal-containing material
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
- Y10T428/252—Glass or ceramic [i.e., fired or glazed clay, cement, etc.] [porcelain, quartz, etc.]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/26—Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2982—Particulate matter [e.g., sphere, flake, etc.]
Definitions
- the invention relates to ceramic materials for thermal barriers and abradable coating systems in high temperature and high temperature cycling applications, and more particularly to ultra-pure zirconia and/or hafnia materials for use in thermal barrier and abradable coating applications.
- Superior high-temperature properties are required to improve the performance of heat resistant and corrosion resistant members.
- These members include, for example gas turbine blades, combustor cans, ducting and nozzle guide vanes in combustion turbines and combined cycle power plants.
- Turbine blades are driven by hot gasses, and the efficiency of the gas turbine increases with the rise in operational temperature. The demand for continued improvement in efficiency has driven the system designers to specify increasingly higher turbine operating temperatures. Thus, there is a continuing need for materials that can achieve higher operational temperatures.
- An additional design criteria for gas turbines is increased operating time between maintenance and repairs, meaning longer lifetime of the materials used in these applications.
- Thermal barrier coatings are used to insulate components, such as those in a gas turbine, operating at elevated temperatures. Thermal barriers allow increased operating temperature of gas turbines by protecting the coated part (or substrate) from direct exposure to the operating environment.
- An important consideration in the design of a thermal barrier is that the coating be a ceramic material having a crystalline structure containing beneficial cracks and voids, imparting strain tolerance. If there were no cracks in the coating, the thermal barrier would not function, because the differences in thermal expansion between the metal substrate system and the coating will cause interfacial stresses upon thermal cycling that are greater than the bond strength between them. By the creation of a crack network into the coating, a stress relief mechanism is introduced that allows the coating to survive numerous thermal cycles.
- crack networks are typically imparted into the coating on varying space scales by manipulating the thermodynamic and kinetic conditions of the manufacturing method, and different structures known to perform the coating task have been optimized likewise.
- cracks are also formed during service, so the structure formed upon coating manufacture changes with time, depending on the starting material phases in the manufactured coating and thermal conditions during service.
- Ceramic materials have been developed. These ceramic materials are used to protect the part and form a barrier so as to increase the thermal gradient, thereby reducing the temperature of the substrate.
- the ceramic material yttria stabilized zirconia (YSZ) has been commonly used as such a coating material. Materials with even lower thermal conductivity continue to be sought to serve as coatings.
- Another design factor determining coating lifetime is the sintering rate of the coating.
- the coating When the coating is cycled above half of its absolute melting temperature, the coating begins to sinter causing volume shrinkage. As the coating shrinks, the modulus increases, lowering the strain tolerance of the coating and it becomes detached. Decreasing the sintering rate of the thermal barrier slows down this failure mechanism. For high purity zirconia alloys, the onset of sintering commences at temperatures above 1000° C.
- zirconia is transparent to radiation in the infrared range.
- thermal barriers are sought for higher temperatures, zirconia becomes limited in its effectiveness.
- the main mechanism of heat transfer for zirconia changes from conduction to radiation at temperatures approaching 1500° C. Since zirconia is nearly transparent to the heat radiation (in the form of photons) above those temperatures, its main function as a heat barrier becomes reduced.
- zirconia-based thermal barrier material that remains optimized at temperatures from 1200° C. to above 1500° C.
- the invention is directed to blends of ceramic materials for use in thermal barriers for high temperature cycling applications and high temperature abradable coatings.
- the materials are alloys formed predominantly from ultra-pure stabilized zirconia (ZrO 2 ) and/or hafnia (HfO 2 ) alloys that have uncharacteristically high sintering resistance to achieve a high service lifetime.
- the invention provides the combinations of desired coating materials so that the changes in the coating microstructure over the in-service lifetime are retarded.
- Oxide impurities are defined as materials which, when combined with each other or with zirconia and/or hafnia, form phases with melting points much lower than that of pure zirconia and/or hafnia, especially but not limited to soda (Na 2 O), silica (SiO 2 ) and alumina (Al 2 O 3 ).
- One aspect of the invention is to provide a blend of ceramic materials for use in high-temperature thermal barriers or abradable seal coatings that have reduced sintering rates in addition to photon blocking or scattering characteristics.
- One material comprises of zirconia and/or hafnia and ytterbia (Yb 2 O 5 ) and/or yttria (Y 2 O 3 ), having a total amount of impurities of less than or equal to 0.15 weight percent, and preferably less than or equal to 0.10 percent.
- the zirconia and/or hafnia is partially stabilized by the ytterbia and/or yttria, and the specific oxide impurity concentrations of the material do not exceed 0.1 weight percent soda, 0.05 weight percent silica, and 0.01 weight percent alumina and 0.05 weight percent titania and preferably 0.01 weight percent soda, 0.01 weight percent silica, and 0.01 weight percent alumina and 0.01 weight percent titania.
- Another material comprises of zirconia and/or hafnia and neodymia (Nd 2 O 3 ) and/or europia (Eu 2 O 3 ), having a total amount of impurities of less than or equal to 0.15 weight percent, and preferably less than or equal to 0.10 percent.
- the zirconia and/or hafnia is partially stabilized by the neodymia and/or europia, and the specific oxide impurity concentrations of the material do not exceed 0.1 weight percent soda, 0.05 weight percent silica, and 0.01 weight percent alumina and 0.05 weight percent titania and preferably 0.01 weight percent soda, 0.01 weight percent silica, and 0.01 weight percent alumina and 0.01 weight percent titania.
- a blended high-purity coating that is suitable for high temperature cycling applications.
- the coating includes a first material and at least a second material.
- the first material is essentially about 4 to 20 weight percent of a stabilizer of one or more rare earth oxides, and a balance of at least one of zirconia (ZrO 2 ), hafnia (HfO 2 ) and combinations thereof, wherein the zirconia (ZrO 2 ) and/or hafnia (HfO 2 ) is partially stabilized by the stabilizer.
- the second material is of a different composition than the first material, and is also about 4 to 20 weight percent of a stabilizer of one or more rare earth oxides, and a balance of at least one of zirconia (ZrO 2 ), hafnia (HfO 2 ) and combinations thereof, wherein the zirconia (ZrO 2 ) and/or hafnia (HfO 2 ) is partially stabilized by the stabilizer.
- the first and second materials are blended together in the coating, and the total amount of impurities in the coating is less than or equal to 0.15 weight percent.
- a high-purity coating structure that is suitable for high temperature cycling applications is formed by a process of the following steps: providing a first material in a form suitable for use in thermal spraying applications, wherein said first material is about 4 to 20 weight percent of a stabilizer of one or more rare earth oxides, and a balance of at least one of zirconia (ZrO 2 ), hafnia (HfO 2 ) and combinations thereof, wherein the zirconia (ZrO 2 ) and/or hafnia (HfO 2 ) is partially stabilized by the stabilizer, and wherein the total amount of impurities in the first material is less than or equal to 0.15 weight percent; providing a second material of a different composition than the first material and in a form suitable for use in thermal spraying applications, said second material is about 4 to 20 weight percent of a stabilizer of one or more rare earth oxides, and a balance of at least one of zirconia (ZrO 2 ), hafnia (
- a method for producing a high-purity coating structure includes providing a first material consisting essentially of about 4 to 20 weight percent of a stabilizer of one or more rare earth oxides, and a balance of at least one of zirconia (ZrO 2 ), hafnia (HfO 2 ) and combinations thereof, wherein the zirconia (ZrO 2 ) and/or hafnia (HfO 2 ) is partially stabilized by the stabilizer, and wherein the total amount of impurities is less than or equal to 0.15 weight percent.
- Another step of the method includes providing a second material of a different composition than the first material, said second material consisting essentially of about 4 to 20 weight percent of a stabilizer of one or more rare earth oxides, and a balance of at least one of zirconia (ZrO 2 ), hafnia (HfO 2 ) and combinations thereof, wherein the zirconia (ZrO 2 ) and/or hafnia (HfO 2 ) is partially stabilized by the stabilizer, and wherein the total amount of impurities in second material is less than or equal to 0.15 weight percent.
- Yet another step of the method includes and applying said materials onto a metal substrate.
- a layered high-purity coating is provided.
- Each layer may contain different types of a high-purity zirconia- or hafnia-based material that is partially stabilized by one or more rare earth oxide.
- the total amount of impurities in each coating layer less than or equal to 0.15 weight percent.
- a gradated high-purity coating is provided.
- the coating is formed from two or more materials each of a high-purity zirconia- or hafnia-based material that is partially stabilized by one or more rare earth oxide.
- the first and one or more second materials form a compositional gradient through the thickness of the coating, and the total amount of impurities in the coating is less than or equal to 0.15 weight percent.
- FIG. 1 illustrates a perspective view of a turbine blade coated with a thermal barrier of ceramic material
- FIG. 2 provides a phase diagram for ZrO 2 ;
- FIG. 3 provides a phase diagram for ZrO 2 with stabilizer
- FIG. 4 provides a chart of composition vs. thermal cycles to failure for yttria stabilized zirconia
- FIG. 5 provides a chart showing the melting point of ZrO 2 vs. amount of stabilizer
- FIG. 6 provides a diagram showing a lamellar thermal barrier coating structure containing porosity and micro cracks
- FIG. 7 provides a diagram showing a lamellar thermal barrier coating structure containing macro cracks, porosity and micro cracks
- FIG. 8 provides a diagram showing a structure of thermal barrier coating deposited from the vapor phase
- FIG. 9 provides a diagram showing the Thornton model for predicting structure of a coating formed from the gas phase
- FIG. 10 provides a diagram showing a structure of thermal barrier coating deposited from both vapor and liquid phase
- FIG. 11A provides a diagram showing a lamellar thermal barrier coating structure formed from a blend of components containing porosity and micro cracks;
- FIG. 11B provides a diagram showing a dense solid thermal barrier coating structure formed from a blend of components, containing macro cracks, porosity and micro cracks;
- FIG. 11C provides a diagram showing a columnar thermal barrier coating structure formed from a blend of components
- FIG. 12 provides a diagram showing a thermal barrier coating structure formed from a blend of components and a placeholder
- FIG. 13 provides a diagram showing a thermal barrier coating containing a compositional gradient
- FIG. 14 provides a diagram showing a thermal barrier coating containing layers each of a different composition.
- FIG. 15 provides a diagram showing a thermal barrier coating containing a series of layers each of a different composition.
- FIG. 1 shows one component of a turbine.
- Turbine blade 100 has a leading edge 102 and an airfoil section 104 , against which hot combustion gases are directed during operation of the turbine, and which undergoes severe thermal stresses, oxidation and corrosion.
- a root end 106 of the blade anchors the blade 100 .
- Venting passages 108 may be included through the blade 100 to allow cooling air to transfer heat from the blade 100 .
- the blade 100 can be made from a high temperature resistant material.
- the surface of the blade 100 is coated with a thermal barrier coating 110 made of ultra-pure zirconia (ZrO 2 ) and/or hafnia (HfO 2 ) alloys in accordance with the invention.
- ZrO 2 ultra-pure zirconia
- HfO 2 hafnia
- the thermal barrier coating 110 may be applied on a MCrAlY bonding layer with an alumina scale (not shown) applied between the blade surface and the coating 110 .
- the coating 110 may be applied onto the bond coating surface through a variety of methods known in the art including thermal spray techniques such as powder flame spray and plasma spray and vapor deposition methods such as electron beam physical vapor deposition (EBPVD), high speed physical vapor deposition and low pressure plasma spraying (LPPS).
- thermal spray techniques such as powder flame spray and plasma spray and vapor deposition methods such as electron beam physical vapor deposition (EBPVD), high speed physical vapor deposition and low pressure plasma spraying (LPPS).
- EBPVD electron beam physical vapor deposition
- LPPS low pressure plasma spraying
- the coating 110 When applied, the coating 110 contains a crack network that allows it to survive numerous thermal cycles. As described in the above background section, the crack network is altered to a less desirable state by sintering and temperature cycling during service. Thus the structure formed upon coating manufacture changes with time, the rate depending on the starting material phases and service conditions. Decreasing the sintering rate increases the amount of time before the closing of microcracks and creation of massive cracks, increasing coating lifetime.
- zirconia (ZrO 2 )-based and/or hafnia (HfO 2 )-based systems have both a high coefficient of thermal expansion relative to other ceramics that is close to the coefficient of thermal expansion of the MCrAlY bond coat and the metal substrate system it protects. Also these material systems have a low thermal conductivity to give the highest level of thermal protection. Other ceramic systems do not possess both of these functions.
- Zirconia is currently a preferred system, primarily because of its comparatively lower cost.
- Hafnia offers equivalent or superior property advantages over zirconia, but has typically not been used in commercial applications due to its prohibitive cost. Nonetheless, hafnia is almost always present in zirconia due to the difficulty of their separation during mineral processing. While further discussion for convenience will address the zirconia-based system, the discussion below is also applicable to hafnia-based systems.
- the material purity of the starting materials must be as high as possible within economic reason.
- the zirconia and/or hafnia must have impurities of less than or equal to 0.15 weight percent, and preferably less than or equal to 0.10 weight percent.
- impurities such as silica and alumina and soda have a lower melting temperature than zirconia or hafnia and cause an increase in the sintering rate of the coating structure.
- the increased sintering rate is undesirable because any increase in sintering rate decreases the lifetime of the coating. Sintering decreases the surface area of the crack network within the coating, increasing the coating modulus over time until failure occurs.
- the material of the present invention contains zirconia (ZrO 2 ) and/or hafnia (HfO 2 ) and partially stabilized by a primary stabilizing oxide such as ytterbia and/or yttria, and possibly secondary stabilizers such as scandia or a lanthanide oxide having a total amount of impurities of less than or equal to 0.15 weight percent, and preferably less than or equal to 0.10 percent.
- a primary stabilizing oxide such as ytterbia and/or yttria
- secondary stabilizers such as scandia or a lanthanide oxide having a total amount of impurities of less than or equal to 0.15 weight percent, and preferably less than or equal to 0.10 percent.
- oxide impurities can be defined as materials which when combined with each other or with zirconia form phases with melting points much lower than that of pure zirconia, especially but not limited to soda (Na 2 O), silica (SiO 2 ), and alumina (Al 2 O 3 ).
- Other known impurities include titania (TiO 2 ), hematite (Fe 2 O 3 ), calcia (CaO), and magnesia (MgO).
- the limits for known impurities in order to achieve a desirable sintering rate and therefore increase service lifetime when used as a coating are:
- FIG. 2 provides a phase diagram for pure zirconia.
- the diagram can be found, for example, in Ceramic Phase Diagrams vol. 3, FIG. 04259.
- pure zirconia exists in three crystal phases at different temperatures.
- very high temperatures >2370° C.
- intermediate temperatures (1200 to 2372° C.)
- relatively lower temperatures below 1200° C.
- the material transforms to the monoclinic structure.
- the transformation from tetragonal to monoclinic is accompanied by a 3 to 5 percent volume increase that causes extensive stress in the material.
- pure zirconia cannot fulfill the coating requirements for high-temperature cycling.
- the resulting strain difference between the coating and substrate caused by the phase transformation results in a stress that is greater than the bond strength between them, so the coating will detach.
- the stabilizing elements which are suitable for changing the amount and rate of phase transformation that occurs in the oxide coating, include the following: scandium, yttrium and the rare earths, particularly the lanthanides, since they have solubility in zirconia. Scandium is not typically used due to its rarity and resulting prohibitive cost. Rare earths metals from the actinide group such as uranium and thorium are not typically used due to their radioactivity. Thus, yttrium is a preferred stabilizing element. For purposes of the present invention, any of these elements used as stabilizing oxides (namely, any oxide from group IIIB (column 3) of the periodic table of elements) can be referred to as rare earth oxides.
- FIG. 3 provides a standard phase diagram for stabilized zirconia showing the general alloying trends for the zirconia stabilizers.
- the diagram can be found, for example, in Ceramic Phase Diagram, vol. Zirconia, FIG. Zr-157.
- Zirconia can be either partially or fully stabilized.
- Fully stabilized zirconia has an crystal structure that is cubic at all temperatures up to melting.
- Partially stabilized zirconia has an crystal structure that is tetragonal and has a phase transformation between tetragonal at higher temperatures and monoclinic plus cubic at lower temperatures.
- the temperature at which phase transformation occurs depends on the stabilizer material, as each stabilizer causes a different amount of suppression of the temperature of the onset of the tetragonal to monoclinic plus cubic phase transformation. At the suppressed temperatures, the rate of the phase transformation is greatly reduced. Over a large number of temperature cycles the phase transformation will slowly occur.
- phase transformation in partially stabilized zirconia causes localized stresses that lead to the formation of micron-sized micro-cracks in the coating upon thermal cycling that cancel out some of the massive stress caused by coating volume shrinkage.
- these two phenomena of the coating structure shrinking and cracking—work against each other and finding a balance between them will maximize coating lifetime.
- This mechanism implies then that the structure of the crack network of the coating is changing with time as the phase of the ceramic material changes. This mechanism is required for a thermal barrier or high temperature abradable coatings to survive thermal cycling.
- composition for which the best possible balance between sintering and phase transformation exists.
- the most desired composition can be found empirically by making thermal cycling tests with samples of differing composition and measuring the number of thermal cycles to failure.
- FIG. 4 shows the results for yttria-stabilized zirconia. From FIG. 4 it can be seen that a composition around 6.5 weight percent has the longest lifetime when similar coatings of varying composition were tested.
- the addition of a stabilizing element affects two main properties of the zirconia system in a positive manner.
- a thermal barrier coating can be further optimized by considering the effect of coating structure on lifetime.
- the ceramic coating in embodiments of the present invention has anisotropic sintering.
- high temperature shrinkage or sintering occurs less in the in-plane direction than in the through thickness direction.
- FIG. 6 provides a diagram showing a lamellar thermal barrier coating structure 120 containing porosity and micro cracks.
- the coating 120 is made up of frozen splats 111 applied over a substrate 100 and optional bond coat 112 .
- FIG. 7 provides a diagram showing a lamellar thermal barrier coating structure 130 containing macro cracks, porosity and micro cracks.
- the coating 120 is made up of frozen splats 131 applied over a substrate 100 and optional bond coat 112 .
- the coating 130 has vertical macro cracks 132 through the thickness of the coating
- This phenomenon can be explained by the structure that is formed.
- the coating has many more splat boundaries in the through thickness direction than in the in-plane direction, so it is the boundaries between splats sintering together that results in the shrinkage in the through-thickness.
- the sintering resistance of the coating can be improved by using ytterbia partially stabilized zirconia and/or hafnia and yttria stabilized zirconia and/or hafnia together.
- FIG. 11A shows a resulting coating 160 structure (applied over optional bond coat 112 and substrate 110 ), where the frozen droplets of ytterbia partially stabilized zirconia and/or hafnia 111 are interspersed with splats of yttria stabilized zirconia and/or hafnia 162 .
- FIG. 11B shows a resulting coating 170 structure (applied over optional bond coat 112 and substrate 110 ) including vertical cracks 132 , where the frozen droplets of ytterbia partially stabilized zirconia and/or hafnia 111 are interspersed with splats of yttria stabilized zirconia and/or hafnia 162 .
- One method of achieving this structure is by blending particles of each of the aforementioned in order to create some percentage splat boundaries that contain ytterbia stabilized zirconia on either one or both sides.
- An additional benefit of this coating will be that it has a lower thermal conductivity than a coating made from yttria stabilized zirconia and/or hafnia alone.
- zirconia is transparent to radiation in the infrared range.
- the effectiveness of typical zirconia barrier systems will decrease more rapidly at temperatures around 1500° C., when radiation becomes the dominant method of heat transfer.
- the material includes zirconia (ZrO 2 ) and/or hafnia (HfO 2 ) wherein the zirconia and/or hafnia is partially stabilized by the neodymium (Nd 2 O 3 ) and/or europia (Eu 2 O 5 ) and the total amount of impurities is less than or equal to 0.15 weight percent, and preferably less than or equal to 0.10 percent.
- the range of stabilizers is:
- Oxide impurities include soda (Na 2 O), silica (SiO 2 ), and alumina (Al 2 O 3 ), as well as titania (TiO 2 ) hematite (Fe 2 O 3 ), calcia (CaO), and magnesia (MgO).
- soda Na 2 O
- silica SiO 2
- alumina Al 2 O 3
- titania TiO 2
- TiO 2 hematite
- CaO calcia
- MgO magnesia
- a blend of two or more partially stabilized high-purity material compositions may also be used.
- a blended ceramic material for use in high-temperature thermal barriers is provided.
- the blended materials include a first material with a yttria (Y 2 O 3 ) stabilizer, and a balance of at least one of zirconia (ZrO 2 ) and hafnia (HfO 2 ) and combinations thereof, wherein the zirconia (ZrO 2 ) and/or hafnia (HfO 2 ) is partially stabilized by the yttria stabilizer, and wherein the total amount of impurities of the first material is less than or equal to 0.15 weight percent, and preferably less than or equal to 0.10 percent.
- the range of Y 2 O 3 stabilizer is about 4-12 weight percent, and preferably 6-9 weight percent.
- the second material of the blended material may contain a ytterbia (Yb 2 O 5 ) stabilizer and a balance of at least one of zirconia (ZrO 2 ) and hafnia (HfO 2 ) and combinations thereof, wherein the zirconia (ZrO 2 ) and/or hafnia (HfO 2 ) is partially stabilized by the ytterbia stabilizer, and wherein the total amount of impurities of the second material is less than or equal to 0.15 weight percent, and preferably less than or equal to 0.10 percent.
- the range of Yb 2 O 5 stabilizer is about 4-16 weight percent, and preferably 10-16 weight percent.
- the ytterbia (Yb 2 O 5 ) stabilized zirconia (ZrO 2 ) and/or hafnia (HfO 2 ) fraction may include about 5-50 weight percent of the total and preferably about 15-30 weight percent of the total.
- the yttria stabilized zirconia (ZrO 2 ) and/or hafnia (HfO 2 ) fraction may include about 50-95 weight percent of the total and preferably about 70-85 weight percent of the total blend.
- the blended material includes a first material with a ytterbia (Yb 2 O 5 ) stabilizer, and a balance of at least one of zirconia (ZrO 2 ) and hafnia (HfO 2 ) and combinations thereof, wherein the zirconia (ZrO 2 ) and/or hafnia (HfO 2 ) is partially stabilized by the ytterbia stabilizer, and wherein the total amount of impurities of the first material is less than or equal to 0.15 weight percent, and preferably less than or equal to 0.10 percent.
- the range of Yb 2 O 5 stabilizer is about 4-16 weight percent, and preferably 10-16 weight percent.
- the second material of the blended material may contain a stabilizer of at least one of neodymium (Nd 2 O 3 ), europia (Eu 2 O 5 ), and combinations thereof and a balance of at least one of zirconia (ZrO 2 ) and hafnia (HfO 2 ) and combinations thereof, wherein the balance is partially stabilized by the stabilizer, and wherein the total amount of impurities of the second material is less than or equal to 0.15 weight percent, and preferably less than or equal to 0.10 percent.
- the range of Nd 2 O 3 stabilizer is about 4-20 weight percent, and preferably 8-16 weight percent.
- the range of Eu 2 O 3 stabilizer is about 4-16 weight percent, and preferably 10-16 weight percent.
- the range of the combined Nd 2 O 3 and Eu 2 O 3 stabilizer is about 4-16 weight percent.
- the ytterbia (Y 2 O 3 ) stabilized zirconia (ZrO 2 ) and/or hafnia (HfO 2 ) fraction may include about 5-50 weight percent of the total and preferably about 15-30 weight percent of the total.
- the yttria stabilized zirconia (ZrO 2 ) and/or hafnia (HfO 2 ) fraction may include about 50-95 weight percent of the total and preferably about 70-85 weight percent of the total blend.
- the blended material includes a first material with a yttria (Y 2 O 3 ) stabilizer, and a balance of at least one of zirconia (ZrO 2 ) and hafnia (HfO 2 ) and combinations thereof, wherein the zirconia (ZrO 2 ) and/or hafnia (HfO 2 ) is partially stabilized by the yttria stabilizer, and wherein the total amount of impurities of the first material is less than or equal to 0.15 weight percent, and preferably less than or equal to 0.10 percent.
- the range of Y 2 O 3 stabilizer is about 4-12 weight percent, and preferably 6-9 weight percent.
- the second material of the blended material may contain a stabilizer of at least one of neodymium (Nd 2 O 3 ), europia (Eu 2 O 5 ), and combinations thereof and a balance of at least one of zirconia (ZrO 2 ) and hafnia (HfO 2 ) and combinations thereof, wherein the balance is partially stabilized by the stabilizer, and wherein the total amount of impurities of the second material is less than or equal to 0.15 weight percent, and preferably less than or equal to 0.10 percent.
- the range of Nd 2 O 3 stabilizer is about 4-20 weight percent, and preferably 8-16 weight percent.
- the range of Eu 2 O 3 stabilizer is about 4-16 weight percent, and preferably 10-16 weight percent.
- the range of the combined Nd 2 O 3 and Eu 2 O 3 stabilizer is about 4-16 weight percent.
- the neodymium (Nd 2 O 3 ) and/or europia (Eu 2 O 5 ) stabilized zirconia (ZrO 2 ) and/or hafnia (HfO 2 ) fraction may include about 5-50 weight percent of the total and preferably about 15-30 weight percent of the total.
- the yttria stabilized zirconia (ZrO 2 ) and/or hafnia (HfO 2 ) fraction may include about 50-95 weight percent of the total and preferably about 70-85 weight percent of the total blend.
- the blended material includes a blend of at least three materials.
- the first material may contain a yttria (Y 2 O 3 ) stabilizer, and a balance of at least one of zirconia (ZrO 2 ) and hafnia (HfO 2 ) and combinations thereof, wherein the zirconia (ZrO 2 ) and/or hafnia (HfO 2 ) is partially stabilized by the yttria stabilizer, and wherein the total amount of impurities of the first material is less than or equal to 0.15 weight percent, and preferably less than or equal to 0.10 percent.
- the range of Y 2 O 3 stabilizer is about 4-12 weight percent, and preferably 6-9 weight percent.
- the second material of the blend may contain a ytterbia (Yb 2 O 5 ) stabilizer, and a balance of at least one of zirconia (ZrO 2 ) and hafnia (HfO 2 ) and combinations thereof, wherein the zirconia (ZrO 2 ) and/or hafnia (HfO 2 ) is partially stabilized by the ytterbia stabilizer, and wherein the total amount of impurities of the second material is less than or equal to 0.15 weight percent, and preferably less than or equal to 0.10 percent.
- the range of Yb 2 O 5 stabilizer is about 4-16 weight percent, and preferably 10-16 weight percent.
- the third material of the blend may contain a stabilizer of at least one of neodymium (Nd 2 O 3 ), europia (Eu 2 O 5 ), and combinations thereof and a balance of at least one of zirconia (ZrO 2 ) and hafnia (HfO 2 ) and combinations thereof, wherein the balance is partially stabilized by the stabilizer, and wherein the total amount of impurities of the third material is less than or equal to 0.15 weight percent, and preferably less than or equal to 0.10 percent.
- the range of Nd 2 O 3 stabilizer is about 4-20 weight percent, and preferably 8-16 weight percent.
- the range of Eu 2 O 3 stabilizer is about 4-16 weight percent, and preferably 10-16 weight percent.
- the range of the combined Nd 2 O 3 and Eu 2 O 3 stabilizer is about 4-16 weight percent.
- the ytterbia (Y 2 O 3 ) stabilized zirconia (ZrO 2 ) and/or hafnia (HfO 2 ) fraction may include about 5-45 weight percent of the total, and preferably about 15-30 weight percent of the total.
- the neodymium (Nd 2 O 3 ) and/or europia (Eu 2 O 5 ) stabilized zirconia (ZrO 2 ) and/or hafnia (HfO 2 ) fraction may also include about 5-45 weight percent of the total and preferably about 15-30 weight percent of the total.
- the yttria stabilized zirconia (ZrO 2 ) and/or hafnia (HfO 2 ) fraction may include about 10-90 weight percent of the total, and preferably about 30-60 weight percent of the total blend.
- the partially stabilized high-purity materials and blends described above may be supplied in the form of a powder, solution, suspension, ingot or target.
- Powder may be in the form of a spray dried powder of the individual constituents and organic binder, spray dried powder of the combined individual constituents and organic binder, fused and crushed powder, agglomerated and sintered powder, plasma densified material or powder from chemical solution routes.
- Typical particle sizes may vary but are typically between about 5-150 microns when deposited by various thermal spray equipment, preferably between about 15-125 microns for air plasma spray.
- Particle sizes are typically less than about 45 microns, preferably less than about 30 microns, for low pressure plasma spray.
- FIG. 12 provides a diagram showing a thermal barrier coating structure 190 formed from a blend of components 111 , 162 and a placeholder 192 .
- the placeholder material 192 made of an organic powder material or an inorganic powder material, can be burned out subsequent to deposition.
- the organic or inorganic powder material has particle sizes typically between about 5-150 microns, and preferably between about 15-125 microns for plasma spray.
- the placeholder material 192 may be combined with the material blends described above to provide an material for an applied coating structure with porosity.
- the blended material is about 70-90 volume percent of the total material blended with 10-30 volume percent of the placeholder material, and preferably 15-30 volume percent.
- a high purity coating structure suitable for high temperature cycling applications may be formed by DC or RF plasma or combustion spraying in air or inert atmospheres at pressures between 1 Pa and 1 MPa.
- the materials may be co-sprayed in the ratios of the materials described above.
- FIGS. 6 and 11 A when the material are applied in accordance with these procedures, the resultant coating may contain a lamellar collection of frozen droplets and semi-molten droplets applied to a metal substrate forming a ceramic matrix, porosity and micro cracks.
- FIG. 6 provides a diagram showing a lamellar thermal barrier coating structure formed from liquid droplets
- FIG. 6 provides a diagram showing a lamellar thermal barrier coating structure formed from liquid droplets
- the porosity of the lamellar thermal barrier coating structure refers to a void with an aspect ratio (length divided by width) of less than about 10. Typical porosity is in the range of about 2 ⁇ 20 volume %, and preferably in the range of 7 ⁇ 15 volume %.
- the micro cracks refers to a void with an aspect ratio (length divided by width) of larger than about 10 and the length of the void is less than about 100 micrometers. Typical volume percentage of micro cracks is in the range of about 2 ⁇ 10 volume %, and preferably in the range of about 2 ⁇ 7 volume %.
- the material and material blends discussed above may also be applied as a lamellar collection of frozen droplets and semi-molten droplets applied to a heated metal substrate to form a ceramic matrix, porosity, macro cracks and micro cracks. These structures are shown in FIGS. 7 and 11 B.
- the porosity refers to a void with an aspect ratio (length divided by width) of less than about 10. Typical porosity for this structure is less than about 12 volume %, and preferably less than about 5 volume %.
- the macro cracks refer to a void with an aspect ratio (length divided by width) of larger than about 10 and the length of the void is longer than about 100 micrometers. More than about 90% of the macro cracks are arranged in the direction normal to the top coat and substrate interface.
- These macro cracks are referred to as vertical macro cracks, while the macro cracks parallel to the top coat and substrate interface are referred to as horizontal macro cracks.
- the average number of vertical macro cracks in a length of 25.4 mm along the top coat and substrate interface is in the range of about 5 to 250, preferably in the range of about 50 to 150.
- the structure may be subsequently heat-treated and cooled to form additional macro cracks perpendicular to the coating and substrate interface.
- the material and material blends discussed above may also be applied to form a high purity coating structure having ceramic columns and gaps between the columns, as shown in FIG. 8 .
- the materials may be applied using a vapor deposition process such as low pressure plasma spraying or physical vapor deposition in air or inert atmospheres at pressures between 1 mPa and 1 kPa.
- a vapor deposition process such as low pressure plasma spraying or physical vapor deposition in air or inert atmospheres at pressures between 1 mPa and 1 kPa.
- the resulting coating has a unique columnar structure.
- the gaps between columns impart excellent strain tolerance to the coating.
- FIG. 8 if vapor deposition process was employed, another high purity coating structure 140 that comprises ceramic columns 143 and gaps 141 between them can be achieved.
- An optional bond coat 112 is shown between the substrate 100 and the coating 140 .
- the high purity coating structure 140 is formed by vaporizing the inventive high purity materials in a form of powder, ingot, target, solution or suspension. The formed vapor then deposited atomically on the substrate. By controlling processing temperature and pressure according to the Thornton's model ( FIG. 9 ), a coating with columnar structure is formed.
- ceramic columns 143 are basically a cluster of crystals. In low pressure (lower than ambient) plasma spraying process, if molten droplets are also generated during the vaporization of the invention high purity materials, then the entrapment and incorporation of these droplets into the coating results in the formation of another high purity coating structure.
- the ceramic columns are basically a cluster of crystals.
- more than about 90% of the crystals are oriented at an angle of about 45 to 135 degrees to the top coat and substrate interface.
- voids smaller than about 20 micrometers may be present.
- the gaps between the columns have an aspect ratio (length divided by width) of larger than about 10. More than about 90% of the gaps are oriented at an angle of about 45 to 135 degrees to the top coat and substrate interface.
- the frozen droplets distributing randomly in the gaps and columns are typically less than about 45 micrometers, and preferably less than 30 micrometers.
- the high purity coating structure 150 comprises ceramic columns 143 , gaps between the columns 141 , and nodules 142 distributing randomly in the gaps and columns.
- An optional bond coat 112 is shown between the substrate 100 and the coating 150 .
- the nodules 142 distributing randomly in the gaps and columns are frozen droplets.
- the size of these nodules 142 is typically less than about 45 micrometers, preferably less than about 30 micrometers.
- FIG. 11C provides a diagram showing a columnar thermal barrier coating structure 180 formed from a blend of components.
- the coating structure of FIG. 11C includes the same components as shown in FIG.
- the ceramic columns are basically a cluster of crystals. In this structure, more than about 90% of the crystals are oriented at an angle of about 45 to 135 degrees to the top coat and substrate interface. Within the cluster of crystals, voids smaller than about 20 micrometers may be present.
- the gaps 141 between the columns have an aspect ratio (length divided by width) of larger than about 10. More than about 90% of the gaps are oriented at an angle of about 45 to 135 degrees to the top coat 180 and substrate 100 interface.
- a thermal barrier or high temperature abradable seal coating can be further optimized by building the coating in layers with different compositions, or by introducing a compositional gradient through the thickness of the coating.
- the reason for this is that due to the relatively low thermal conductivity of the coating, a temperature gradient exists in the coating during high temperature surface, since the substrate is being cooled.
- the coating structure can be designed using the most optimal material at the surface, with less optimal materials towards the interface.
- Compositional gradients can be introduced into the coating during manufacture by using multiple feedstocks of different composition and varying their feed-rates during deposition. A coating with a compositional gradient is shown in FIG.
- the coating includes a starting material 261 most prominent along the surface of substrate 100 (or optional bond coat 112 ) and gradually giving way to starting material 262 , which makes up most of the exterior surface of the coating 260 .
- Materials 261 and 262 may be any of the materials described above with respect to embodiments of the present invention.
- Coating structures for the compositional gradients may include any of the structures described above.
- the coating can also be optimized by manufacturing it in layers with different compositions.
- the coating can have two or more layers, or multiple repeating layers.
- a material with optimized sintering resistance for example, ytterbia stabilized zirconia according to embodiments of the present invention
- a middle layer 272 with photon scattering capabilities for example, neodymia and/or europia stabilized zirconia according to embodiments of the present
- FIG. 15 Another example is FIG. 15 , showing a coating 280 with a repeating pattern of layers including a top layer 271 , middle layer 272 , and bottom layer 273 repeated, as shown.
- the combinations in FIGS. 14 and 15 serve only as examples.
- One skilled in the art will recognize numerous material combinations and coating structures as described herein may be layered to achieve optimal coating performance for various service conditions.
Abstract
The invention is directed to a blended material and method for obtaining thermal barriers for high temperature cycling applications that have both high sintering resistance to achieve a high service lifetime and low thermal conductivity to achieve high operating temperatures. These materials are additionally suited for use in high temperature abradable (rub seal) coatings. The invention provides desired coating structures so that the changes in the coating microstructure over the in-service lifetime are either limited or beneficial.
Description
- This application claims priority under 35 U.S.C. § 119(e) from U.S. Provisional Patent Application No. 60/724,286, filed on Oct. 7, 2005, which is incorporated herein by reference.
- Not Applicable
- Not Applicable
- 1. Field of the Invention
- The invention relates to ceramic materials for thermal barriers and abradable coating systems in high temperature and high temperature cycling applications, and more particularly to ultra-pure zirconia and/or hafnia materials for use in thermal barrier and abradable coating applications.
- 2. Description of the Related Art
- Superior high-temperature properties are required to improve the performance of heat resistant and corrosion resistant members. These members include, for example gas turbine blades, combustor cans, ducting and nozzle guide vanes in combustion turbines and combined cycle power plants. Turbine blades are driven by hot gasses, and the efficiency of the gas turbine increases with the rise in operational temperature. The demand for continued improvement in efficiency has driven the system designers to specify increasingly higher turbine operating temperatures. Thus, there is a continuing need for materials that can achieve higher operational temperatures. An additional design criteria for gas turbines is increased operating time between maintenance and repairs, meaning longer lifetime of the materials used in these applications.
- Thermal barrier coatings are used to insulate components, such as those in a gas turbine, operating at elevated temperatures. Thermal barriers allow increased operating temperature of gas turbines by protecting the coated part (or substrate) from direct exposure to the operating environment. An important consideration in the design of a thermal barrier is that the coating be a ceramic material having a crystalline structure containing beneficial cracks and voids, imparting strain tolerance. If there were no cracks in the coating, the thermal barrier would not function, because the differences in thermal expansion between the metal substrate system and the coating will cause interfacial stresses upon thermal cycling that are greater than the bond strength between them. By the creation of a crack network into the coating, a stress relief mechanism is introduced that allows the coating to survive numerous thermal cycles. Repeating crack networks are typically imparted into the coating on varying space scales by manipulating the thermodynamic and kinetic conditions of the manufacturing method, and different structures known to perform the coating task have been optimized likewise. In addition to this, cracks are also formed during service, so the structure formed upon coating manufacture changes with time, depending on the starting material phases in the manufactured coating and thermal conditions during service. There remains a need in the art for a coating material, coating material manufacturing method and coating manufacturing method that address the changes in the coating microstructure during its service lifetime.
- In an effort to meet this need for materials with higher temperature capabilities, certain ceramic materials have been developed. These ceramic materials are used to protect the part and form a barrier so as to increase the thermal gradient, thereby reducing the temperature of the substrate. For example, the ceramic material yttria stabilized zirconia (YSZ) has been commonly used as such a coating material. Materials with even lower thermal conductivity continue to be sought to serve as coatings.
- Another design factor determining coating lifetime is the sintering rate of the coating. When the coating is cycled above half of its absolute melting temperature, the coating begins to sinter causing volume shrinkage. As the coating shrinks, the modulus increases, lowering the strain tolerance of the coating and it becomes detached. Decreasing the sintering rate of the thermal barrier slows down this failure mechanism. For high purity zirconia alloys, the onset of sintering commences at temperatures above 1000° C.
- A major disadvantage brought about by using typical zirconia coating systems is that zirconia is transparent to radiation in the infrared range. As thermal barriers are sought for higher temperatures, zirconia becomes limited in its effectiveness. The main mechanism of heat transfer for zirconia changes from conduction to radiation at temperatures approaching 1500° C. Since zirconia is nearly transparent to the heat radiation (in the form of photons) above those temperatures, its main function as a heat barrier becomes reduced. Thus, there remains a need in the art for a zirconia-based thermal barrier material that remains optimized at temperatures from 1200° C. to above 1500° C.
- Accordingly, the invention is directed to blends of ceramic materials for use in thermal barriers for high temperature cycling applications and high temperature abradable coatings. The materials are alloys formed predominantly from ultra-pure stabilized zirconia (ZrO2) and/or hafnia (HfO2) alloys that have uncharacteristically high sintering resistance to achieve a high service lifetime. The invention provides the combinations of desired coating materials so that the changes in the coating microstructure over the in-service lifetime are retarded.
- The limits for impurities discovered to decrease sintering rate and therefore increase service lifetime compared with impurity concentrations present in current materials when used as a coating and stabilized for example, with yttria, are disclosed herein. Oxide impurities are defined as materials which, when combined with each other or with zirconia and/or hafnia, form phases with melting points much lower than that of pure zirconia and/or hafnia, especially but not limited to soda (Na2O), silica (SiO2) and alumina (Al2O3).
- One aspect of the invention is to provide a blend of ceramic materials for use in high-temperature thermal barriers or abradable seal coatings that have reduced sintering rates in addition to photon blocking or scattering characteristics. One material comprises of zirconia and/or hafnia and ytterbia (Yb2O5) and/or yttria (Y2O3), having a total amount of impurities of less than or equal to 0.15 weight percent, and preferably less than or equal to 0.10 percent. The zirconia and/or hafnia is partially stabilized by the ytterbia and/or yttria, and the specific oxide impurity concentrations of the material do not exceed 0.1 weight percent soda, 0.05 weight percent silica, and 0.01 weight percent alumina and 0.05 weight percent titania and preferably 0.01 weight percent soda, 0.01 weight percent silica, and 0.01 weight percent alumina and 0.01 weight percent titania. Another material comprises of zirconia and/or hafnia and neodymia (Nd2O3) and/or europia (Eu2O3), having a total amount of impurities of less than or equal to 0.15 weight percent, and preferably less than or equal to 0.10 percent. The zirconia and/or hafnia is partially stabilized by the neodymia and/or europia, and the specific oxide impurity concentrations of the material do not exceed 0.1 weight percent soda, 0.05 weight percent silica, and 0.01 weight percent alumina and 0.05 weight percent titania and preferably 0.01 weight percent soda, 0.01 weight percent silica, and 0.01 weight percent alumina and 0.01 weight percent titania.
- In one aspect of the invention, a blended high-purity coating that is suitable for high temperature cycling applications is provided. The coating includes a first material and at least a second material. The first material is essentially about 4 to 20 weight percent of a stabilizer of one or more rare earth oxides, and a balance of at least one of zirconia (ZrO2), hafnia (HfO2) and combinations thereof, wherein the zirconia (ZrO2) and/or hafnia (HfO2) is partially stabilized by the stabilizer. The second material is of a different composition than the first material, and is also about 4 to 20 weight percent of a stabilizer of one or more rare earth oxides, and a balance of at least one of zirconia (ZrO2), hafnia (HfO2) and combinations thereof, wherein the zirconia (ZrO2) and/or hafnia (HfO2) is partially stabilized by the stabilizer. The first and second materials are blended together in the coating, and the total amount of impurities in the coating is less than or equal to 0.15 weight percent.
- In another aspect of the invention, a high-purity coating structure that is suitable for high temperature cycling applications is formed by a process of the following steps: providing a first material in a form suitable for use in thermal spraying applications, wherein said first material is about 4 to 20 weight percent of a stabilizer of one or more rare earth oxides, and a balance of at least one of zirconia (ZrO2), hafnia (HfO2) and combinations thereof, wherein the zirconia (ZrO2) and/or hafnia (HfO2) is partially stabilized by the stabilizer, and wherein the total amount of impurities in the first material is less than or equal to 0.15 weight percent; providing a second material of a different composition than the first material and in a form suitable for use in thermal spraying applications, said second material is about 4 to 20 weight percent of a stabilizer of one or more rare earth oxides, and a balance of at least one of zirconia (ZrO2), hafnia (HfO2) and combinations thereof, wherein the zirconia (ZrO2) and/or hafnia (HfO2) is partially stabilized by the stabilizer, and wherein the total amount of impurities in second material is less than or equal to 0.15 weight percent; and applying each of the materials onto a metal substrate so that the materials are blended in the coating.
- In a further aspect of the invention, a method for producing a high-purity coating structure is provided. The method includes providing a first material consisting essentially of about 4 to 20 weight percent of a stabilizer of one or more rare earth oxides, and a balance of at least one of zirconia (ZrO2), hafnia (HfO2) and combinations thereof, wherein the zirconia (ZrO2) and/or hafnia (HfO2) is partially stabilized by the stabilizer, and wherein the total amount of impurities is less than or equal to 0.15 weight percent. Another step of the method includes providing a second material of a different composition than the first material, said second material consisting essentially of about 4 to 20 weight percent of a stabilizer of one or more rare earth oxides, and a balance of at least one of zirconia (ZrO2), hafnia (HfO2) and combinations thereof, wherein the zirconia (ZrO2) and/or hafnia (HfO2) is partially stabilized by the stabilizer, and wherein the total amount of impurities in second material is less than or equal to 0.15 weight percent. Yet another step of the method includes and applying said materials onto a metal substrate.
- According to another aspect of the invention, a layered high-purity coating is provided. Each layer may contain different types of a high-purity zirconia- or hafnia-based material that is partially stabilized by one or more rare earth oxide. The total amount of impurities in each coating layer less than or equal to 0.15 weight percent.
- According to different aspect of the invention, a gradated high-purity coating is provided. The coating is formed from two or more materials each of a high-purity zirconia- or hafnia-based material that is partially stabilized by one or more rare earth oxide. The first and one or more second materials form a compositional gradient through the thickness of the coating, and the total amount of impurities in the coating is less than or equal to 0.15 weight percent.
- The accompanying drawings are included to provide further understanding of the invention and are incorporated in and constitute a part of this specification. The accompanying drawings illustrate embodiments of the invention and together with the description serve to explain the principles of the invention. In the figures:
-
FIG. 1 illustrates a perspective view of a turbine blade coated with a thermal barrier of ceramic material; -
FIG. 2 provides a phase diagram for ZrO2; -
FIG. 3 provides a phase diagram for ZrO2 with stabilizer; -
FIG. 4 provides a chart of composition vs. thermal cycles to failure for yttria stabilized zirconia; -
FIG. 5 provides a chart showing the melting point of ZrO2 vs. amount of stabilizer; -
FIG. 6 provides a diagram showing a lamellar thermal barrier coating structure containing porosity and micro cracks; -
FIG. 7 provides a diagram showing a lamellar thermal barrier coating structure containing macro cracks, porosity and micro cracks; -
FIG. 8 provides a diagram showing a structure of thermal barrier coating deposited from the vapor phase; -
FIG. 9 provides a diagram showing the Thornton model for predicting structure of a coating formed from the gas phase; -
FIG. 10 provides a diagram showing a structure of thermal barrier coating deposited from both vapor and liquid phase; -
FIG. 11A provides a diagram showing a lamellar thermal barrier coating structure formed from a blend of components containing porosity and micro cracks; -
FIG. 11B provides a diagram showing a dense solid thermal barrier coating structure formed from a blend of components, containing macro cracks, porosity and micro cracks; -
FIG. 11C provides a diagram showing a columnar thermal barrier coating structure formed from a blend of components; -
FIG. 12 provides a diagram showing a thermal barrier coating structure formed from a blend of components and a placeholder; -
FIG. 13 provides a diagram showing a thermal barrier coating containing a compositional gradient; -
FIG. 14 provides a diagram showing a thermal barrier coating containing layers each of a different composition; and -
FIG. 15 provides a diagram showing a thermal barrier coating containing a series of layers each of a different composition. - Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
- In an exemplary use of a material of the invention,
FIG. 1 shows one component of a turbine.Turbine blade 100 has aleading edge 102 and anairfoil section 104, against which hot combustion gases are directed during operation of the turbine, and which undergoes severe thermal stresses, oxidation and corrosion. Aroot end 106 of the blade anchors theblade 100. Ventingpassages 108 may be included through theblade 100 to allow cooling air to transfer heat from theblade 100. Theblade 100 can be made from a high temperature resistant material. The surface of theblade 100 is coated with athermal barrier coating 110 made of ultra-pure zirconia (ZrO2) and/or hafnia (HfO2) alloys in accordance with the invention. Thethermal barrier coating 110 may be applied on a MCrAlY bonding layer with an alumina scale (not shown) applied between the blade surface and thecoating 110. Thecoating 110 may be applied onto the bond coating surface through a variety of methods known in the art including thermal spray techniques such as powder flame spray and plasma spray and vapor deposition methods such as electron beam physical vapor deposition (EBPVD), high speed physical vapor deposition and low pressure plasma spraying (LPPS). - When applied, the
coating 110 contains a crack network that allows it to survive numerous thermal cycles. As described in the above background section, the crack network is altered to a less desirable state by sintering and temperature cycling during service. Thus the structure formed upon coating manufacture changes with time, the rate depending on the starting material phases and service conditions. Decreasing the sintering rate increases the amount of time before the closing of microcracks and creation of massive cracks, increasing coating lifetime. - One feature of using zirconia (ZrO2)-based and/or hafnia (HfO2)-based systems is that they have both a high coefficient of thermal expansion relative to other ceramics that is close to the coefficient of thermal expansion of the MCrAlY bond coat and the metal substrate system it protects. Also these material systems have a low thermal conductivity to give the highest level of thermal protection. Other ceramic systems do not possess both of these functions. Zirconia is currently a preferred system, primarily because of its comparatively lower cost. Hafnia offers equivalent or superior property advantages over zirconia, but has typically not been used in commercial applications due to its prohibitive cost. Nonetheless, hafnia is almost always present in zirconia due to the difficulty of their separation during mineral processing. While further discussion for convenience will address the zirconia-based system, the discussion below is also applicable to hafnia-based systems.
- To achieve optimal performance, the material purity of the starting materials (zirconia and/or hafnia) must be as high as possible within economic reason. For the present invention the zirconia and/or hafnia must have impurities of less than or equal to 0.15 weight percent, and preferably less than or equal to 0.10 weight percent. The reason for this is that impurities such as silica and alumina and soda have a lower melting temperature than zirconia or hafnia and cause an increase in the sintering rate of the coating structure. The increased sintering rate is undesirable because any increase in sintering rate decreases the lifetime of the coating. Sintering decreases the surface area of the crack network within the coating, increasing the coating modulus over time until failure occurs.
- In certain embodiments, the material of the present invention contains zirconia (ZrO2) and/or hafnia (HfO2) and partially stabilized by a primary stabilizing oxide such as ytterbia and/or yttria, and possibly secondary stabilizers such as scandia or a lanthanide oxide having a total amount of impurities of less than or equal to 0.15 weight percent, and preferably less than or equal to 0.10 percent. For purposes of the present invention, oxide impurities can be defined as materials which when combined with each other or with zirconia form phases with melting points much lower than that of pure zirconia, especially but not limited to soda (Na2O), silica (SiO2), and alumina (Al2O3). Other known impurities include titania (TiO2), hematite (Fe2O3), calcia (CaO), and magnesia (MgO). In accordance with the invention, the limits for known impurities in order to achieve a desirable sintering rate and therefore increase service lifetime when used as a coating are:
-
- Na2O—0.1 weight percent
- SiO2—0.05 weight percent
- Al2O3—0.01 weight percent
- TiO2—0.05 weight percent
- Fe2O3—0.05 weight percent
- CaO—0.05 weight percent
- MgO—0.05 weight percent;
and preferably: - Na2O—0.01 weight percent
- SiO2—0.01 weight percent
- Al2O3—0.01 weight percent
- TiO2—0.01 weight percent
- Fe2O3—0.01 weight percent
- CaO—0.025 weight percent
- MgO—0.025 weight percent.
Other specific concentration ranges of stabilizers are provided in co-pending and commonly assigned U.S. patent applications entitled “CERAMIC MATERIAL FOR HIGH TEMPERATURE SERVICE,” “OPTIMIZED HIGH TEMPERATURE THERMAL BARRIER,” and “HIGH PURITY CERAMIC ABRADABLE COATINGS,” each filed on Sep. 12, 2006 and each incorporated herein by reference.
-
FIG. 2 provides a phase diagram for pure zirconia. (The diagram can be found, for example, in Ceramic Phase Diagrams vol. 3, FIG. 04259.) As shown inFIG. 3 , pure zirconia exists in three crystal phases at different temperatures. At very high temperatures (>2370° C.) the material has a cubic structure. At intermediate temperatures (1200 to 2372° C.) it has a tetragonal structure. At relatively lower temperatures (below 1200° C.) the material transforms to the monoclinic structure. The transformation from tetragonal to monoclinic is accompanied by a 3 to 5 percent volume increase that causes extensive stress in the material. Thus, pure zirconia cannot fulfill the coating requirements for high-temperature cycling. The resulting strain difference between the coating and substrate caused by the phase transformation results in a stress that is greater than the bond strength between them, so the coating will detach. - In order to overcome the volume change caused by the undesired phase transformation described above, one or more elements are added to the zirconia to modify the amount of phase transformation that occurs. The stabilizing elements, which are suitable for changing the amount and rate of phase transformation that occurs in the oxide coating, include the following: scandium, yttrium and the rare earths, particularly the lanthanides, since they have solubility in zirconia. Scandium is not typically used due to its rarity and resulting prohibitive cost. Rare earths metals from the actinide group such as uranium and thorium are not typically used due to their radioactivity. Thus, yttrium is a preferred stabilizing element. For purposes of the present invention, any of these elements used as stabilizing oxides (namely, any oxide from group IIIB (column 3) of the periodic table of elements) can be referred to as rare earth oxides.
-
FIG. 3 provides a standard phase diagram for stabilized zirconia showing the general alloying trends for the zirconia stabilizers. (The diagram can be found, for example, in Ceramic Phase Diagram, vol. Zirconia, FIG. Zr-157.) Zirconia can be either partially or fully stabilized. Fully stabilized zirconia has an crystal structure that is cubic at all temperatures up to melting. Partially stabilized zirconia has an crystal structure that is tetragonal and has a phase transformation between tetragonal at higher temperatures and monoclinic plus cubic at lower temperatures. The temperature at which phase transformation occurs depends on the stabilizer material, as each stabilizer causes a different amount of suppression of the temperature of the onset of the tetragonal to monoclinic plus cubic phase transformation. At the suppressed temperatures, the rate of the phase transformation is greatly reduced. Over a large number of temperature cycles the phase transformation will slowly occur. - One possible theory is that the phase transformation in partially stabilized zirconia causes localized stresses that lead to the formation of micron-sized micro-cracks in the coating upon thermal cycling that cancel out some of the massive stress caused by coating volume shrinkage. Thus, these two phenomena of the coating structure—shrinking and cracking—work against each other and finding a balance between them will maximize coating lifetime. This mechanism implies then that the structure of the crack network of the coating is changing with time as the phase of the ceramic material changes. This mechanism is required for a thermal barrier or high temperature abradable coatings to survive thermal cycling.
- From this theory, the composition for which the best possible balance between sintering and phase transformation exists. The most desired composition can be found empirically by making thermal cycling tests with samples of differing composition and measuring the number of thermal cycles to failure.
FIG. 4 shows the results for yttria-stabilized zirconia. FromFIG. 4 it can be seen that a composition around 6.5 weight percent has the longest lifetime when similar coatings of varying composition were tested. - The addition of a stabilizing element affects two main properties of the zirconia system in a positive manner. First, the addition of a stabilizer generally increases the melting temperature of the zirconia (in the partially stabilized composition ranges). Second, the addition of a stabilizer generally decreases the thermal conductivity. From the phase diagram in
FIG. 5 , which plots melting temperature versus composition, it can be seen that ytterbia stabilized zirconia (ZrYb2O5) and yttria stabilized zirconia (ZrY2O5) have the highest melting temperatures respectively for zirconia stabilizers (excluding actinides such as thoria that are radioactive and not fit for service). These stabilized compositions therefore have the greatest sintering resistance and, consequently, the greatest potential coating lifetime. - Rising fuel cost and other factors continue to drive the need for improved operational efficiency, and thus higher operating temperatures, of gas turbines. While yttria stabilized zirconia is the material of choice for stabilization, greater operational temperatures can be achieved using ytterbia, for example, as shown in
FIG. 4 . Zirconia partially stabilized by ytterbia provides a better composition, since it also has one of the lowest thermal conductivities of the potential stabilizers when alloyed with zirconia. As the need for higher operating temperatures increases, a higher coating material cost may be tolerated, so ytterbia partially stabilized zirconia may become a preferred thermal barrier. Given then the trade-offs of cost and performance, a combination of both yttria and ytterbia stabilizers is expected to have optimum performance to cost ratio - A thermal barrier coating can be further optimized by considering the effect of coating structure on lifetime. Three types of structures exist depending on coating manufacturing method. Even though the general structures described herein have different complexities and are defined by differently sized spaces, they have one thing in common: they are physically made up of cracks, whose initial structure is defined by the manufacturing method of the material and coating and whose crack structure changes with time. These structures can be formed using the partially stabilized zirconia and/or hafnia material variants of the present invention, as described above with respect to
FIGS. 2-5 . - The ceramic coating in embodiments of the present invention has anisotropic sintering. For the coating made up of frozen splats with respect to
FIGS. 6 and 7 , high temperature shrinkage or sintering occurs less in the in-plane direction than in the through thickness direction.FIG. 6 provides a diagram showing a lamellar thermalbarrier coating structure 120 containing porosity and micro cracks. Thecoating 120 is made up offrozen splats 111 applied over asubstrate 100 andoptional bond coat 112.FIG. 7 provides a diagram showing a lamellar thermal barrier coating structure 130 containing macro cracks, porosity and micro cracks. Thecoating 120 is made up offrozen splats 131 applied over asubstrate 100 andoptional bond coat 112. The coating 130 has verticalmacro cracks 132 through the thickness of the coating For a coating made up of frozen splats, as shown inFIGS. 6 and 7 , this phenomenon can be explained by the structure that is formed. The coating has many more splat boundaries in the through thickness direction than in the in-plane direction, so it is the boundaries between splats sintering together that results in the shrinkage in the through-thickness. Thus, the sintering resistance of the coating can be improved by using ytterbia partially stabilized zirconia and/or hafnia and yttria stabilized zirconia and/or hafnia together.FIG. 11A shows a resultingcoating 160 structure (applied overoptional bond coat 112 and substrate 110), where the frozen droplets of ytterbia partially stabilized zirconia and/orhafnia 111 are interspersed with splats of yttria stabilized zirconia and/orhafnia 162.FIG. 11B shows a resulting coating 170 structure (applied overoptional bond coat 112 and substrate 110) includingvertical cracks 132, where the frozen droplets of ytterbia partially stabilized zirconia and/orhafnia 111 are interspersed with splats of yttria stabilized zirconia and/orhafnia 162. One method of achieving this structure is by blending particles of each of the aforementioned in order to create some percentage splat boundaries that contain ytterbia stabilized zirconia on either one or both sides. An additional benefit of this coating will be that it has a lower thermal conductivity than a coating made from yttria stabilized zirconia and/or hafnia alone. - As previously noted, zirconia is transparent to radiation in the infrared range. Thus the effectiveness of typical zirconia barrier systems will decrease more rapidly at temperatures around 1500° C., when radiation becomes the dominant method of heat transfer. There are two stabilizers for zirconia from the lanthanide series that, when added to zirconia, form an atomic oxide structure that serves to scatter photons in the infrared range. These stabilizers are europia (Eu2O3) and neodymia (Nd2O3). Both neodymia and europia are effective stabilizers, but neodymia may be the more preferable due to its lower cost. The europia and neodymia can also be combined. In order to further optimize the thermal barrier coating at high temperatures, europia or neodymia are specifically added to the zirconia-based powder material, so that the thermal conductivity of the coating is optimized at high temperatures.
- Thus, in embodiments of the invention the material includes zirconia (ZrO2) and/or hafnia (HfO2) wherein the zirconia and/or hafnia is partially stabilized by the neodymium (Nd2O3) and/or europia (Eu2O5) and the total amount of impurities is less than or equal to 0.15 weight percent, and preferably less than or equal to 0.10 percent. The range of stabilizers is:
-
- Nd2O3—4-20 weight percent
- Eu2O3—4-16 weight percent
- Nd2O3 and Eu2O3—4-16 weight percent
and preferably: - Nd2O3—8-16 weight percent
- Eu2O3—10-16 weight percent
- Nd2O3 and Eu2O3—4-16 weight percent
- Oxide impurities include soda (Na2O), silica (SiO2), and alumina (Al2O3), as well as titania (TiO2) hematite (Fe2O3), calcia (CaO), and magnesia (MgO). The limits for these known oxide impurities in order to achieve a desirable sintering rate and therefore increase service lifetime when used as a coating are the same as those listed above with respect to previous compositions.
- A blend of two or more partially stabilized high-purity material compositions may also be used. For example, in another embodiment, a blended ceramic material for use in high-temperature thermal barriers is provided. The blended materials include a first material with a yttria (Y2O3) stabilizer, and a balance of at least one of zirconia (ZrO2) and hafnia (HfO2) and combinations thereof, wherein the zirconia (ZrO2) and/or hafnia (HfO2) is partially stabilized by the yttria stabilizer, and wherein the total amount of impurities of the first material is less than or equal to 0.15 weight percent, and preferably less than or equal to 0.10 percent. The range of Y2O3 stabilizer is about 4-12 weight percent, and preferably 6-9 weight percent. The second material of the blended material may contain a ytterbia (Yb2O5) stabilizer and a balance of at least one of zirconia (ZrO2) and hafnia (HfO2) and combinations thereof, wherein the zirconia (ZrO2) and/or hafnia (HfO2) is partially stabilized by the ytterbia stabilizer, and wherein the total amount of impurities of the second material is less than or equal to 0.15 weight percent, and preferably less than or equal to 0.10 percent. The range of Yb2O5 stabilizer is about 4-16 weight percent, and preferably 10-16 weight percent. In the blended material, the ytterbia (Yb2O5) stabilized zirconia (ZrO2) and/or hafnia (HfO2) fraction may include about 5-50 weight percent of the total and preferably about 15-30 weight percent of the total. The yttria stabilized zirconia (ZrO2) and/or hafnia (HfO2) fraction may include about 50-95 weight percent of the total and preferably about 70-85 weight percent of the total blend.
- In another embodiment the blended material includes a first material with a ytterbia (Yb2O5) stabilizer, and a balance of at least one of zirconia (ZrO2) and hafnia (HfO2) and combinations thereof, wherein the zirconia (ZrO2) and/or hafnia (HfO2) is partially stabilized by the ytterbia stabilizer, and wherein the total amount of impurities of the first material is less than or equal to 0.15 weight percent, and preferably less than or equal to 0.10 percent. The range of Yb2O5 stabilizer is about 4-16 weight percent, and preferably 10-16 weight percent. The second material of the blended material may contain a stabilizer of at least one of neodymium (Nd2O3), europia (Eu2O5), and combinations thereof and a balance of at least one of zirconia (ZrO2) and hafnia (HfO2) and combinations thereof, wherein the balance is partially stabilized by the stabilizer, and wherein the total amount of impurities of the second material is less than or equal to 0.15 weight percent, and preferably less than or equal to 0.10 percent. The range of Nd2O3 stabilizer is about 4-20 weight percent, and preferably 8-16 weight percent. The range of Eu2O3 stabilizer is about 4-16 weight percent, and preferably 10-16 weight percent. The range of the combined Nd2O3 and Eu2O3 stabilizer is about 4-16 weight percent. In the blended material, the ytterbia (Y2O3) stabilized zirconia (ZrO2) and/or hafnia (HfO2) fraction may include about 5-50 weight percent of the total and preferably about 15-30 weight percent of the total. The yttria stabilized zirconia (ZrO2) and/or hafnia (HfO2) fraction may include about 50-95 weight percent of the total and preferably about 70-85 weight percent of the total blend.
- In another embodiment of the invention the blended material includes a first material with a yttria (Y2O3) stabilizer, and a balance of at least one of zirconia (ZrO2) and hafnia (HfO2) and combinations thereof, wherein the zirconia (ZrO2) and/or hafnia (HfO2) is partially stabilized by the yttria stabilizer, and wherein the total amount of impurities of the first material is less than or equal to 0.15 weight percent, and preferably less than or equal to 0.10 percent. The range of Y2O3 stabilizer is about 4-12 weight percent, and preferably 6-9 weight percent. The second material of the blended material may contain a stabilizer of at least one of neodymium (Nd2O3), europia (Eu2O5), and combinations thereof and a balance of at least one of zirconia (ZrO2) and hafnia (HfO2) and combinations thereof, wherein the balance is partially stabilized by the stabilizer, and wherein the total amount of impurities of the second material is less than or equal to 0.15 weight percent, and preferably less than or equal to 0.10 percent. The range of Nd2O3 stabilizer is about 4-20 weight percent, and preferably 8-16 weight percent. The range of Eu2O3 stabilizer is about 4-16 weight percent, and preferably 10-16 weight percent. The range of the combined Nd2O3 and Eu2O3 stabilizer is about 4-16 weight percent. In the blended material, the neodymium (Nd2O3) and/or europia (Eu2O5) stabilized zirconia (ZrO2) and/or hafnia (HfO2) fraction may include about 5-50 weight percent of the total and preferably about 15-30 weight percent of the total. The yttria stabilized zirconia (ZrO2) and/or hafnia (HfO2) fraction may include about 50-95 weight percent of the total and preferably about 70-85 weight percent of the total blend.
- In a further embodiment of the invention the blended material includes a blend of at least three materials. The first material may contain a yttria (Y2O3) stabilizer, and a balance of at least one of zirconia (ZrO2) and hafnia (HfO2) and combinations thereof, wherein the zirconia (ZrO2) and/or hafnia (HfO2) is partially stabilized by the yttria stabilizer, and wherein the total amount of impurities of the first material is less than or equal to 0.15 weight percent, and preferably less than or equal to 0.10 percent. The range of Y2O3 stabilizer is about 4-12 weight percent, and preferably 6-9 weight percent. The second material of the blend may contain a ytterbia (Yb2O5) stabilizer, and a balance of at least one of zirconia (ZrO2) and hafnia (HfO2) and combinations thereof, wherein the zirconia (ZrO2) and/or hafnia (HfO2) is partially stabilized by the ytterbia stabilizer, and wherein the total amount of impurities of the second material is less than or equal to 0.15 weight percent, and preferably less than or equal to 0.10 percent. The range of Yb2O5 stabilizer is about 4-16 weight percent, and preferably 10-16 weight percent. The third material of the blend may contain a stabilizer of at least one of neodymium (Nd2O3), europia (Eu2O5), and combinations thereof and a balance of at least one of zirconia (ZrO2) and hafnia (HfO2) and combinations thereof, wherein the balance is partially stabilized by the stabilizer, and wherein the total amount of impurities of the third material is less than or equal to 0.15 weight percent, and preferably less than or equal to 0.10 percent. The range of Nd2O3 stabilizer is about 4-20 weight percent, and preferably 8-16 weight percent. The range of Eu2O3 stabilizer is about 4-16 weight percent, and preferably 10-16 weight percent. The range of the combined Nd2O3 and Eu2O3 stabilizer is about 4-16 weight percent. In the blended material, the ytterbia (Y2O3) stabilized zirconia (ZrO2) and/or hafnia (HfO2) fraction may include about 5-45 weight percent of the total, and preferably about 15-30 weight percent of the total. The neodymium (Nd2O3) and/or europia (Eu2O5) stabilized zirconia (ZrO2) and/or hafnia (HfO2) fraction may also include about 5-45 weight percent of the total and preferably about 15-30 weight percent of the total. The yttria stabilized zirconia (ZrO2) and/or hafnia (HfO2) fraction may include about 10-90 weight percent of the total, and preferably about 30-60 weight percent of the total blend.
- The partially stabilized high-purity materials and blends described above may be supplied in the form of a powder, solution, suspension, ingot or target. Powder may be in the form of a spray dried powder of the individual constituents and organic binder, spray dried powder of the combined individual constituents and organic binder, fused and crushed powder, agglomerated and sintered powder, plasma densified material or powder from chemical solution routes. Typical particle sizes may vary but are typically between about 5-150 microns when deposited by various thermal spray equipment, preferably between about 15-125 microns for air plasma spray. Particle sizes are typically less than about 45 microns, preferably less than about 30 microns, for low pressure plasma spray.
-
FIG. 12 provides a diagram showing a thermalbarrier coating structure 190 formed from a blend ofcomponents placeholder 192. Theplaceholder material 192, made of an organic powder material or an inorganic powder material, can be burned out subsequent to deposition. The organic or inorganic powder material has particle sizes typically between about 5-150 microns, and preferably between about 15-125 microns for plasma spray. Theplaceholder material 192 may be combined with the material blends described above to provide an material for an applied coating structure with porosity. In certain embodiments, the blended material is about 70-90 volume percent of the total material blended with 10-30 volume percent of the placeholder material, and preferably 15-30 volume percent. - Using the materials and the material blends described above, a high purity coating structure suitable for high temperature cycling applications may be formed by DC or RF plasma or combustion spraying in air or inert atmospheres at pressures between 1 Pa and 1 MPa. Alternatively, the materials may be co-sprayed in the ratios of the materials described above. As shown in
FIGS. 6 and 11 A, when the material are applied in accordance with these procedures, the resultant coating may contain a lamellar collection of frozen droplets and semi-molten droplets applied to a metal substrate forming a ceramic matrix, porosity and micro cracks.FIG. 6 provides a diagram showing a lamellar thermal barrier coating structure formed from liquid droplets, andFIG. 11A provides a diagram showing a lamellar thermal barrier coating structure formed from a blend of components. The porosity of the lamellar thermal barrier coating structure refers to a void with an aspect ratio (length divided by width) of less than about 10. Typical porosity is in the range of about 2˜20 volume %, and preferably in the range of 7˜15 volume %. The micro cracks refers to a void with an aspect ratio (length divided by width) of larger than about 10 and the length of the void is less than about 100 micrometers. Typical volume percentage of micro cracks is in the range of about 2˜10 volume %, and preferably in the range of about 2˜7 volume %. - The material and material blends discussed above may also be applied as a lamellar collection of frozen droplets and semi-molten droplets applied to a heated metal substrate to form a ceramic matrix, porosity, macro cracks and micro cracks. These structures are shown in
FIGS. 7 and 11 B. The porosity refers to a void with an aspect ratio (length divided by width) of less than about 10. Typical porosity for this structure is less than about 12 volume %, and preferably less than about 5 volume %. The macro cracks refer to a void with an aspect ratio (length divided by width) of larger than about 10 and the length of the void is longer than about 100 micrometers. More than about 90% of the macro cracks are arranged in the direction normal to the top coat and substrate interface. These macro cracks are referred to as vertical macro cracks, while the macro cracks parallel to the top coat and substrate interface are referred to as horizontal macro cracks. The average number of vertical macro cracks in a length of 25.4 mm along the top coat and substrate interface is in the range of about 5 to 250, preferably in the range of about 50 to 150. The structure may be subsequently heat-treated and cooled to form additional macro cracks perpendicular to the coating and substrate interface. - Using a different application process, the material and material blends discussed above may also be applied to form a high purity coating structure having ceramic columns and gaps between the columns, as shown in
FIG. 8 . The materials may be applied using a vapor deposition process such as low pressure plasma spraying or physical vapor deposition in air or inert atmospheres at pressures between 1 mPa and 1 kPa. When coatings are produced using a vapor deposition process, the resulting coating has a unique columnar structure. The gaps between columns impart excellent strain tolerance to the coating. As illustrated inFIG. 8 , if vapor deposition process was employed, another highpurity coating structure 140 that comprisesceramic columns 143 andgaps 141 between them can be achieved. Anoptional bond coat 112 is shown between thesubstrate 100 and thecoating 140. The highpurity coating structure 140 is formed by vaporizing the inventive high purity materials in a form of powder, ingot, target, solution or suspension. The formed vapor then deposited atomically on the substrate. By controlling processing temperature and pressure according to the Thornton's model (FIG. 9 ), a coating with columnar structure is formed. Herein,ceramic columns 143 are basically a cluster of crystals. In low pressure (lower than ambient) plasma spraying process, if molten droplets are also generated during the vaporization of the invention high purity materials, then the entrapment and incorporation of these droplets into the coating results in the formation of another high purity coating structure. The ceramic columns are basically a cluster of crystals. In this structure, more than about 90% of the crystals are oriented at an angle of about 45 to 135 degrees to the top coat and substrate interface. Within the cluster of crystals, voids smaller than about 20 micrometers may be present. The gaps between the columns have an aspect ratio (length divided by width) of larger than about 10. More than about 90% of the gaps are oriented at an angle of about 45 to 135 degrees to the top coat and substrate interface. The frozen droplets distributing randomly in the gaps and columns are typically less than about 45 micrometers, and preferably less than 30 micrometers. - The material and material blends discussed above may also be applied to form a structure with ceramic columns, gaps between the columns and frozen droplets distributing randomly in the gaps and columns. As illustrated in
FIG. 10 , the highpurity coating structure 150 comprisesceramic columns 143, gaps between thecolumns 141, andnodules 142 distributing randomly in the gaps and columns. Anoptional bond coat 112 is shown between thesubstrate 100 and thecoating 150. Thenodules 142 distributing randomly in the gaps and columns are frozen droplets. The size of thesenodules 142 is typically less than about 45 micrometers, preferably less than about 30 micrometers.FIG. 11C provides a diagram showing a columnar thermal barrier coating structure 180 formed from a blend of components. The coating structure ofFIG. 11C includes the same components as shown inFIG. 10 and further includes asecond coating material 182 interspersed throughout theceramic columns 143. The ceramic columns are basically a cluster of crystals. In this structure, more than about 90% of the crystals are oriented at an angle of about 45 to 135 degrees to the top coat and substrate interface. Within the cluster of crystals, voids smaller than about 20 micrometers may be present. Thegaps 141 between the columns have an aspect ratio (length divided by width) of larger than about 10. More than about 90% of the gaps are oriented at an angle of about 45 to 135 degrees to the top coat 180 andsubstrate 100 interface. - In accordance with the invention, a thermal barrier or high temperature abradable seal coating can be further optimized by building the coating in layers with different compositions, or by introducing a compositional gradient through the thickness of the coating. The reason for this is that due to the relatively low thermal conductivity of the coating, a temperature gradient exists in the coating during high temperature surface, since the substrate is being cooled. Thus there is a variation in the sintering rate through the thickness of the coating, and this means that the coating structure can be designed using the most optimal material at the surface, with less optimal materials towards the interface. Compositional gradients can be introduced into the coating during manufacture by using multiple feedstocks of different composition and varying their feed-rates during deposition. A coating with a compositional gradient is shown in
FIG. 13 , where the coating includes a startingmaterial 261 most prominent along the surface of substrate 100 (or optional bond coat 112) and gradually giving way to startingmaterial 262, which makes up most of the exterior surface of thecoating 260.Materials - In addition to optimizing the coating by using compositional gradients, the coating can also be optimized by manufacturing it in layers with different compositions. The coating can have two or more layers, or multiple repeating layers. For example of one embodiment, as shown in
FIG. 14 , acoating 270 with atop layer 271 made from a material with optimized sintering resistance (for example, ytterbia stabilized zirconia according to embodiments of the present invention), amiddle layer 272 with photon scattering capabilities (for example, neodymia and/or europia stabilized zirconia according to embodiments of the present invention) and abottom layer 273 made from a third composition (for example, zirconia stabilized with yttria or scandia or a lanthanide oxide according to embodiments of the present invention). Another example isFIG. 15 , showing acoating 280 with a repeating pattern of layers including atop layer 271,middle layer 272, andbottom layer 273 repeated, as shown. The combinations inFIGS. 14 and 15 serve only as examples. One skilled in the art will recognize numerous material combinations and coating structures as described herein may be layered to achieve optimal coating performance for various service conditions. - While exemplary embodiments of the invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous insubstantial variations, changes, and substitutions will now be apparent to those skilled in the art without departing from the scope of the invention disclosed herein by the Applicants. Accordingly, it is intended that the invention be limited only by the spirit and scope of the claims, as they will be allowed.
Claims (38)
1. A blended high-purity coating that is suitable for high temperature cycling applications, said coating comprising:
a first material consisting essentially of about 4 to 20 weight percent of a stabilizer of one or more rare earth oxides, and a balance of at least one of zirconia (ZrO2), hafnia (HfO2) and combinations thereof, wherein the zirconia (ZrO2) and/or hafnia (HfO2) is partially stabilized by the stabilizer; and
a second material of a different composition than the first material, said second material consisting essentially of about 4 to 20 weight percent of a stabilizer of one or more rare earth oxides, and a balance of at least one of zirconia (ZrO2), hafnia (HfO2) and combinations thereof, wherein the zirconia (ZrO2) and/or hafnia (HfO2) is partially stabilized by the stabilizer;
wherein the first and second materials are blended together in the coating, and wherein the total amount of impurities in the coating is less than or equal to 0.15 weight percent.
2. The blended high-purity coating of claim 1 , wherein said first material is about 5 to 50 weight percent of the total coating and the stabilizer of said first material is about 4 to 12 weight percent yttria, and wherein said second material is about 50 to 95 weight percent of the total coating and the stabilizer of said second material is about 4 to 16 weight percent ytterbia.
3. The blended high-purity coating of claim 1 , wherein said first material is about 5 to 50 weight percent of the total coating and the stabilizer of said first material is about 4 to 12 weight percent yttria, and wherein said second material is about 50 to 95 weight percent of the total coating and the stabilizer of said second material is about 4 to 20 weight percent of at least one of neodymium (Nd2O3), europia (Eu2O5), and combinations thereof.
4. The blended high-purity coating of claim 1 , wherein said first material is about 5 to 50 weight percent of the total coating and the stabilizer of said first material is about 4 to 16 weight percent ytterbia (Yb2O5), and wherein said second material is about 50 to 95 weight percent of the total coating and the stabilizer of said second material is about 4 to 20 weight percent of at least one of neodymium (Nd2O3), europia (Eu2O5), and combinations thereof.
5. The blended high-purity coating of claim 1 , further comprising a third material of a different composition than the first and second materials, said third material consisting essentially of about 4 to 20 weight percent of a stabilizer of one or more rare earth oxides, and a balance of at least one of zirconia (ZrO2), hafnia (HfO2) and combinations thereof, wherein the zirconia (ZrO2) and/or hafnia (HfO2) is partially stabilized by the stabilizer.
6. The blended high-purity coating of claim 1 , further comprising a placeholder material made of an organic powder material or an inorganic powder material that can be burned out subsequent to deposition of the blended material, said placeholder material comprising about 10-30 volume percent of the total materials.
7. The blended high-purity coating of claim 1 , wherein the total amount of impurities in the coating is less than or equal to 0.10 weight percent.
8. The blended high-purity coating of claim 1 , wherein the coating has a structure including a ceramic matrix, porosity, and micro cracks.
9. The blended high-purity coating of claim 1 , wherein the coating has a structure including a ceramic matrix, porosity, macro cracks, and micro cracks.
10. The blended high-purity coating of claim 1 , wherein the coating has a structure including ceramic columns and gaps between the columns.
11. A high-purity coating structure that is suitable for high temperature cycling applications, said coating structure formed by the process comprising the steps of:
providing a first material in a form suitable for use in thermal spraying applications, wherein said first material consists essentially of about 4 to 20 weight percent of a stabilizer of one or more rare earth oxides, and a balance of at least one of zirconia (ZrO2), hafnia (HfO2) and combinations thereof, wherein the zirconia (ZrO2) and/or hafnia (HfO2) is partially stabilized by the stabilizer, and wherein the total amount of impurities in the first material is less than or equal to 0.15 weight percent;
providing a second material of a different composition than the first material and in a form suitable for use in thermal spraying applications, said second material consisting essentially of about 4 to 20 weight percent of a stabilizer of one or more rare earth oxides, and a balance of at least one of zirconia (ZrO2), hafnia (HfO2) and combinations thereof, wherein the zirconia (ZrO2) and/or hafnia (HfO2) is partially stabilized by the stabilizer, and wherein the total amount of impurities in second material is less than or equal to 0.15 weight percent; and
applying each of said materials onto a metal substrate so that the materials are blended in the coating.
12. The high-purity coating structure of claim 11 , wherein the applying step is accomplished using a thermal spray process conducted at pressures between 1 Pa and 1 MPa, so as to form a stream of molten and/or semi-molten droplets that build up a coating of frozen lamellar splats subsequent to impact with the substrate.
13. The high-purity coating structure of claim 12 , wherein the coating has a structure including a ceramic matrix, porosity, and micro cracks.
14. The high-purity coating structure of claim 12 , wherein the coating has a structure including a ceramic matrix, porosity, macro cracks, and micro cracks.
15. The high-purity coating structure of claim 11 , wherein the applying step is accomplished using a vapor deposition process conducted at pressures between 1 mPa and 1 kPa, so as to form a coating with ceramic columns and gaps between the columns.
16. The high-purity coating structure of claim 11 , wherein the applying step is accomplished using a low pressure plasma spray process conducted at pressures between 1 Pa and 10 kPa, so as to form ceramic columns, gaps between the columns, and frozen droplets distributed randomly in the gaps and columns.
17. The high-purity coating structure of claim 11 , wherein the formation process further comprises the step of providing a placeholder material made of an inorganic powder material or an organic powder material that can be burned out subsequent to deposition of the blended material, said placeholder material comprising about 10-30 volume percent of the total materials.
18. The high-purity coating structure of claim 11 , wherein said first material is about 5 to 50 weight percent of the total coating and the stabilizer of said first material is about 4 to 12 weight percent yttria, and wherein said second material is about 50 to 95 weight percent of the total coating and the stabilizer of said second material is about 4 to 16 weight percent ytterbia.
19. The high-purity coating structure of claim 11 , wherein said first material is about 5 to 50 weight percent of the total coating and the stabilizer of said first material is about 4 to 12 weight percent yttria, and wherein said second material is about 50 to 95 weight percent of the total coating and the stabilizer of said second material is about 4 to 20 weight percent of at least one of neodymium (Nd2O3), europia (Eu2O5), and combinations thereof.
20. The high-purity coating structure of claim 11 , wherein said first material is about 5 to 50 weight percent of the total coating and the stabilizer of said first material is about 4 to 16 weight percent ytterbia (Yb2O5), and wherein said second material is about 50 to 95 weight percent of the total coating and the stabilizer of said second material is about 4 to 20 weight percent of at least one of neodymium (Nd2O3), europia (Eu2O5), and combinations thereof.
21. The high-purity coating structure of claim 11 , further comprising a third material of a different composition than the first and second materials, said third material consisting essentially of about 4 to 20 weight percent of a stabilizer of one or more rare earth oxides, and a balance of at least one of zirconia (ZrO2), hafnia (HfO2) and combinations thereof, wherein the zirconia (ZrO2) and/or hafnia (HfO2) is partially stabilized by the stabilizer.
22. A method for producing a high-purity coating structure suitable for high temperature cycling applications, said method comprising the steps of:
providing a first material consisting essentially of about 4 to 20 weight percent of a stabilizer of one or more rare earth oxides, and a balance of at least one of zirconia (ZrO2), hafnia (HfO2) and combinations thereof, wherein the zirconia (ZrO2) and/or hafnia (HfO2) is partially stabilized by the stabilizer, and wherein the total amount of impurities is less than or equal to 0.15 weight percent;
providing a second material of a different composition than the first material, said second material consisting essentially of about 4 to 20 weight percent of a stabilizer of one or more rare earth oxides, and a balance of at least one of zirconia (ZrO2), hafnia (HfO2) and combinations thereof, wherein the zirconia (ZrO2) and/or hafnia (HfO2) is partially stabilized by the stabilizer, and wherein the total amount of impurities in second material is less than or equal to 0.15 weight percent; and
applying said materials onto a metal substrate.
23. The method of claim 22 , wherein the first and second materials are be supplied in the form of a powder or a slurry of partially stabilized powder, and wherein said step of applying uses a thermal spray process.
24. The method of claim 23 , wherein said thermal spray process is conducted at pressures between about 1 Pa and 1 MPa, so as to form a stream of molten and/or semi-molten droplets that build up a coating of frozen lamellar splats subsequent to impact with the substrate.
25. The method of claim 24 , wherein the thermal spray process results in a coating having a structure including a ceramic matrix, porosity, and micro cracks.
26. The method of claim 24 , wherein the thermal spray process results in a coating having a structure including a ceramic matrix, porosity, macro cracks, and micro cracks.
27. The method of claim 22 , wherein the first and second materials are applied using a vapor deposition process.
28. The method of claim 27 , wherein said vapor deposition process is conducted at pressures between 1 mPa and 1 kPa, so as to form a coating with ceramic columns and gaps between the columns.
29. The method of claim 27 , wherein said vapor deposition process is a low pressure plasma spray process conducted at pressures between 1 Pa and 10 kPa, so as to form ceramic columns, gaps between the columns, and frozen droplets distributed randomly in the gaps and columns.
30. The method of claim 22 , wherein further comprising providing a placeholder material made of an inorganic powder material or an organic powder material that is burned out subsequent to deposition of the blended material, said placeholder material comprising about 10-30 volume percent of the total materials.
31. The method of claim 22 , wherein said first material is about 5 to 50 weight percent of the total coating and the stabilizer of said first material is about 4 to 12 weight percent yttria, and wherein said second material is about 50 to 95 weight percent of the total coating and the stabilizer of said second material is about 4 to 16 weight percent ytterbia.
32. The method of claim 22 , wherein said first material is about 5 to 50 weight percent of the total coating and the stabilizer of said first material is about 4 to 12 weight percent yttria, and wherein said second material is about 50 to 95 weight percent of the total coating and the stabilizer of said second material is about 4 to 20 weight percent of at least one of neodymium (Nd2O3), europia (Eu2O5), and combinations thereof.
33. The method of claim 22 , wherein said first material is about 5 to 50 weight percent of the total coating and the stabilizer of said first material is about 4 to 16 weight percent ytterbia (Yb2O5), and wherein said second material is about 50 to 95 weight percent of the total coating and the stabilizer of said second material is about 4 to 20 weight percent of at least one of neodymium (Nd2O3), europia (Eu2O5), and combinations thereof.
34. The method of claim 22 , further comprising providing a third material of a different composition than the first and second materials, said third material consisting essentially of about 4 to 20 weight percent of a stabilizer of one or more rare earth oxides, and a balance of at least one of zirconia (ZrO2), hafnia (HfO2) and combinations thereof, wherein the zirconia (ZrO2) and/or hafnia (HfO2) is partially stabilized by the stabilizer.
35. The method of claim 22 wherein said step of applying comprises co-spraying said first material and said second material.
36. A gradated high-purity coating that is suitable for high temperature cycling applications, said coating comprising:
a first material consisting essentially of about 4 to 20 weight percent of a stabilizer of one or more rare earth oxides, and a balance of at least one of zirconia (ZrO2), hafnia (HfO2) and combinations thereof, wherein the zirconia (ZrO2) and/or hafnia (HfO2) is partially stabilized by the stabilizer; and
one or more second material of a different composition than the first material, said one or more second material consisting essentially of about 4 to 20 weight percent of a stabilizer of one or more rare earth oxides, and a balance of at least one of zirconia (ZrO2), hafnia (HfO2) and combinations thereof, wherein the zirconia (ZrO2) and/or hafnia (HfO2) is partially stabilized by the stabilizer;
wherein the first and one or more second materials form a compositional gradient through the thickness of the coating, and wherein the total amount of impurities in the coating is less than or equal to 0.15 weight percent.
37. A layered high-purity coating that is suitable for high temperature cycling applications, said coating comprising:
a first material consisting essentially of about 4 to 20 weight percent of a stabilizer of one or more rare earth oxides, and a balance of at least one of zirconia (ZrO2), hafnia (HfO2) and combinations thereof, wherein the zirconia (ZrO2) and/or hafnia (HfO2) is partially stabilized by the stabilizer; and
one or more second material of a different composition than the first material, said one or more second material consisting essentially of about 4 to 20 weight percent of a stabilizer of one or more rare earth oxides, and a balance of at least one of zirconia (ZrO2), hafnia (HfO2) and combinations thereof, wherein the zirconia (ZrO2) and/or hafnia (HfO2) is partially stabilized by the stabilizer;
wherein the first and one or more second materials are layered through the thickness of the coating, and wherein the total amount of impurities in each coating layer less than or equal to 0.15 weight percent.
38. The method of claim 37 , wherein the stabilizer of said first material is about 4 to 12 weight percent yttria; wherein the stabilizer of said second material is about 4 to 20 weight percent of at least one of neodymium (Nd2O3), europia (Eu2O5), and combinations thereof; and wherein the stabilizer of a third material is about 4 to 16 weight percent ytterbia.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/520,042 US20070082131A1 (en) | 2005-10-07 | 2006-09-13 | Optimized high purity coating for high temperature thermal cycling applications |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US72426805P | 2005-10-07 | 2005-10-07 | |
US11/520,042 US20070082131A1 (en) | 2005-10-07 | 2006-09-13 | Optimized high purity coating for high temperature thermal cycling applications |
Publications (1)
Publication Number | Publication Date |
---|---|
US20070082131A1 true US20070082131A1 (en) | 2007-04-12 |
Family
ID=37689568
Family Applications (5)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/520,041 Active 2027-08-25 US7955707B2 (en) | 2005-10-07 | 2006-09-13 | High purity ceramic abradable coatings |
US11/520,042 Abandoned US20070082131A1 (en) | 2005-10-07 | 2006-09-13 | Optimized high purity coating for high temperature thermal cycling applications |
US11/520,043 Active US7723249B2 (en) | 2005-10-07 | 2006-09-13 | Ceramic material for high temperature service |
US11/520,044 Active 2029-05-08 US7955708B2 (en) | 2005-10-07 | 2006-09-13 | Optimized high temperature thermal barrier |
US12/960,107 Active US8187717B1 (en) | 2005-10-07 | 2010-12-03 | High purity ceramic abradable coatings |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/520,041 Active 2027-08-25 US7955707B2 (en) | 2005-10-07 | 2006-09-13 | High purity ceramic abradable coatings |
Family Applications After (3)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/520,043 Active US7723249B2 (en) | 2005-10-07 | 2006-09-13 | Ceramic material for high temperature service |
US11/520,044 Active 2029-05-08 US7955708B2 (en) | 2005-10-07 | 2006-09-13 | Optimized high temperature thermal barrier |
US12/960,107 Active US8187717B1 (en) | 2005-10-07 | 2010-12-03 | High purity ceramic abradable coatings |
Country Status (7)
Country | Link |
---|---|
US (5) | US7955707B2 (en) |
EP (1) | EP1772441B1 (en) |
JP (3) | JP2007107098A (en) |
CN (1) | CN101081735B (en) |
AT (1) | ATE535504T1 (en) |
CA (1) | CA2562668C (en) |
ES (1) | ES2374636T3 (en) |
Cited By (31)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20070274837A1 (en) * | 2006-05-26 | 2007-11-29 | Thomas Alan Taylor | Blade tip coatings |
US20080026160A1 (en) * | 2006-05-26 | 2008-01-31 | Thomas Alan Taylor | Blade tip coating processes |
US20080160172A1 (en) * | 2006-05-26 | 2008-07-03 | Thomas Alan Taylor | Thermal spray coating processes |
US20080226837A1 (en) * | 2006-10-02 | 2008-09-18 | Sulzer Metco Ag | Method for the manufacture of a coating having a columnar structure |
US20090074961A1 (en) * | 2007-09-19 | 2009-03-19 | Siemens Power Generation, Inc. | Engine portions with functional ceramic coatings and methods of making same |
US20090136781A1 (en) * | 2007-08-16 | 2009-05-28 | Damani Rajiv J | Method For The Generation Of A Functional Layer |
US20090184280A1 (en) * | 2008-01-18 | 2009-07-23 | Rolls-Royce Corp. | Low Thermal Conductivity, CMAS-Resistant Thermal Barrier Coatings |
US20100080984A1 (en) * | 2008-09-30 | 2010-04-01 | Rolls-Royce Corp. | Coating including a rare earth silicate-based layer including a second phase |
US20100086757A1 (en) * | 2006-12-15 | 2010-04-08 | Thomas Berndt | Method for coating a component |
US7722246B1 (en) * | 2005-04-20 | 2010-05-25 | Carty William M | Method for determining the thermal expansion coefficient of ceramic bodies and glazes |
US20100129636A1 (en) * | 2008-11-25 | 2010-05-27 | Rolls-Royce Corporation | Abradable layer including a rare earth silicate |
US20100311562A1 (en) * | 2005-10-07 | 2010-12-09 | Sulzer Metco (Us), Inc. | High purity ceramic abradable coatings |
US20110033630A1 (en) * | 2009-08-05 | 2011-02-10 | Rolls-Royce Corporation | Techniques for depositing coating on ceramic substrate |
US20120148769A1 (en) * | 2010-12-13 | 2012-06-14 | General Electric Company | Method of fabricating a component using a two-layer structural coating |
US8337989B2 (en) * | 2010-05-17 | 2012-12-25 | United Technologies Corporation | Layered thermal barrier coating with blended transition |
US8470460B2 (en) | 2008-11-25 | 2013-06-25 | Rolls-Royce Corporation | Multilayer thermal barrier coatings |
CN103290352A (en) * | 2013-06-18 | 2013-09-11 | 张关莲 | Method for preparing zirconium oxide thermal barrier coating by spraying process |
US20130260119A1 (en) * | 2012-03-27 | 2013-10-03 | United Technologies Corporation | Multi-Material Thermal Barrier Coating System |
US20150084245A1 (en) * | 2013-09-20 | 2015-03-26 | Alstom Technology Ltd | Method for producing means with thermal resist for applying at a surface of a heat exposed component |
US9194242B2 (en) | 2010-07-23 | 2015-11-24 | Rolls-Royce Corporation | Thermal barrier coatings including CMAS-resistant thermal barrier coating layers |
US9975812B2 (en) | 2005-10-07 | 2018-05-22 | Oerlikon Metco (Us) Inc. | Ceramic material for high temperature service |
US10125618B2 (en) | 2010-08-27 | 2018-11-13 | Rolls-Royce Corporation | Vapor deposition of rare earth silicate environmental barrier coatings |
US10233760B2 (en) | 2008-01-18 | 2019-03-19 | Rolls-Royce Corporation | CMAS-resistant thermal barrier coatings |
US10329205B2 (en) | 2014-11-24 | 2019-06-25 | Rolls-Royce Corporation | Bond layer for silicon-containing substrates |
US10808308B2 (en) | 2016-06-08 | 2020-10-20 | Mitsubishi Heavy Industries, Ltd. | Thermal barrier coating, turbine member, and gas turbine |
US10851656B2 (en) | 2017-09-27 | 2020-12-01 | Rolls-Royce Corporation | Multilayer environmental barrier coating |
US11292748B2 (en) | 2017-06-21 | 2022-04-05 | Höganäs Germany GmbH | Zirconium oxide powder for thermal spraying |
US20220371966A1 (en) * | 2019-11-12 | 2022-11-24 | Siemens Energy Global GmbH & Co. KG | Ceramic material, powder, and layer system comprising the ceramic material |
US11655543B2 (en) | 2017-08-08 | 2023-05-23 | Rolls-Royce Corporation | CMAS-resistant barrier coatings |
US11851770B2 (en) | 2017-07-17 | 2023-12-26 | Rolls-Royce Corporation | Thermal barrier coatings for components in high-temperature mechanical systems |
US11946147B2 (en) | 2018-03-26 | 2024-04-02 | Mitsubishi Heavy Industries, Ltd. | Thermal barrier coating, turbine member, gas turbine, and method for producing thermal barrier coating |
Families Citing this family (78)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP1777302B1 (en) | 2005-10-21 | 2009-07-15 | Sulzer Metco (US) Inc. | Plasma remelting method for making high purity and free flowing metal oxides powder |
US7799716B2 (en) * | 2006-03-03 | 2010-09-21 | Sulzer Metco (Us), Inc. | Partially-alloyed zirconia powder |
CA2653492C (en) * | 2006-05-26 | 2015-04-14 | Praxair Technology, Inc. | High purity powders and coatings prepared therefrom |
CA2585992C (en) * | 2006-06-08 | 2014-06-17 | Sulzer Metco (Us) Inc. | Dysprosia stabilized zirconia abradable |
US7776459B2 (en) * | 2006-08-18 | 2010-08-17 | United Technologies Corporation | High sodium containing thermal barrier coating |
FR2910465B1 (en) | 2006-12-21 | 2011-03-04 | Commissariat Energie Atomique | REFRACTORY CERAMIC MATERIAL HAVING HIGH TEMPERATURE OF SOLIDUS, METHOD FOR MANUFACTURING THE SAME, AND STRUCTURE PIECE INCORPORATING SAID MATERIAL. |
FR2910466A1 (en) | 2006-12-21 | 2008-06-27 | Commissariat Energie Atomique | Preparation of refractory ceramic material powder comprises e.g. obtaining hafnium dioxide and yttrium oxide powder dry mixture, granulating, drying, filling mold with the mixture, isostatic/semi-isostatic pressing and sintering |
FR2927997A1 (en) * | 2008-02-25 | 2009-08-28 | Snecma Sa | METHOD FOR TESTING A WAVE FOOT COATING |
KR20090093819A (en) * | 2008-02-28 | 2009-09-02 | 코바렌트 마테리얼 가부시키가이샤 | Sintered body and member used in plasma treatment device |
EP2098606A1 (en) * | 2008-03-04 | 2009-09-09 | Siemens Aktiengesellschaft | A MCrAlY alloy, methods to produce a MCrAlY layer and a honeycomb seal |
GB0809440D0 (en) * | 2008-05-23 | 2008-07-02 | Southside Thermal Sciences Sts | Multi-functional material compositions, structures incorporating the same and methods for detecting ageing in luminescent material compositions |
EP2141328A1 (en) * | 2008-07-03 | 2010-01-06 | Siemens Aktiengesellschaft | Sealing system between a shroud segment and a rotor blade tip and manufacturing method for such a segment |
US8506243B2 (en) * | 2009-11-19 | 2013-08-13 | United Technologies Corporation | Segmented thermally insulating coating |
CN101831602B (en) * | 2010-02-09 | 2011-12-21 | 江苏大学 | Method for preparing thermal expansion matching composite thermal barrier coating |
JP4593683B1 (en) * | 2010-02-16 | 2010-12-08 | 昭和電工株式会社 | Surface-coated cermet member and manufacturing method thereof |
US9598972B2 (en) * | 2010-03-30 | 2017-03-21 | United Technologies Corporation | Abradable turbine air seal |
CN102094165B (en) * | 2010-12-27 | 2012-07-04 | 北京工业大学 | Highly wear-resistant mechanical seal moving ring and manufacturing method thereof |
EP2683844B1 (en) * | 2011-03-09 | 2019-05-08 | Rolls-Royce Corporation | Abradable layer |
US9719353B2 (en) | 2011-04-13 | 2017-08-01 | Rolls-Royce Corporation | Interfacial diffusion barrier layer including iridium on a metallic substrate |
RU2463279C1 (en) * | 2011-04-26 | 2012-10-10 | Государственное образовательное учреждение высшего профессионального образования "Российский химико-технологический университет им. Д.И. Менделеева" (РХТУ им. Д.И. Менделеева) | PROTECTIVE GLASSCERAMIC COATING FOR SiC-CONTAINING MATERIALS AND METHOD OF MAKING SAID COATING |
CN102390996B (en) * | 2011-08-11 | 2013-05-15 | 九江嘉远科技有限公司 | Manufacturing process of suction nozzle |
DE102011081323B3 (en) * | 2011-08-22 | 2012-06-21 | Siemens Aktiengesellschaft | Fluid-flow machine i.e. axial-flow gas turbine, has abradable abrasion layer arranged at blade tip adjacent to radial inner side of housing and made of specific mass percent of zirconium oxide stabilized ytterbium oxide |
US9034479B2 (en) * | 2011-10-13 | 2015-05-19 | General Electric Company | Thermal barrier coating systems and processes therefor |
US9023486B2 (en) * | 2011-10-13 | 2015-05-05 | General Electric Company | Thermal barrier coating systems and processes therefor |
CN103102716B (en) * | 2011-11-11 | 2015-11-04 | 神华集团有限责任公司 | Coating composition, coating system and component with coating system |
US20130177772A1 (en) * | 2012-01-05 | 2013-07-11 | General Electric Company | Radiation mitigated articles and methods of making the same |
US9988309B2 (en) * | 2012-05-20 | 2018-06-05 | Skyworks Solutions, Inc. | Thermal barrier coating material with enhanced toughness |
US9204109B1 (en) * | 2012-10-31 | 2015-12-01 | Florida Turbine Technologies, Inc. | IR detection of small cracks during fatigue testing |
WO2014149097A2 (en) * | 2013-03-15 | 2014-09-25 | United Technologies Corporation | Maxmet composites for turbine engine component tips |
US9816392B2 (en) | 2013-04-10 | 2017-11-14 | General Electric Company | Architectures for high temperature TBCs with ultra low thermal conductivity and abradability and method of making |
US9289917B2 (en) * | 2013-10-01 | 2016-03-22 | General Electric Company | Method for 3-D printing a pattern for the surface of a turbine shroud |
US20150118441A1 (en) * | 2013-10-25 | 2015-04-30 | General Electric Company | Thermo-photo-shielding for high temperature thermal management |
EP3916121A1 (en) * | 2013-11-14 | 2021-12-01 | Raytheon Technologies Corporation | Ceramic coated articles and manufacture methods |
FR3013360B1 (en) * | 2013-11-19 | 2015-12-04 | Snecma | INTEGRATED SINTERING PROCESS FOR MICROFILERATION AND EROSION PROTECTION OF THERMAL BARRIERS |
US20150147524A1 (en) * | 2013-11-26 | 2015-05-28 | Christopher A. Petorak | Modified thermal barrier composite coatings |
US11479846B2 (en) | 2014-01-07 | 2022-10-25 | Honeywell International Inc. | Thermal barrier coatings for turbine engine components |
EP3111049A1 (en) | 2014-02-25 | 2017-01-04 | Siemens Aktiengesellschaft | Turbine abradable layer with airflow directing pixelated surface feature patterns |
US8939716B1 (en) | 2014-02-25 | 2015-01-27 | Siemens Aktiengesellschaft | Turbine abradable layer with nested loop groove pattern |
US9243511B2 (en) | 2014-02-25 | 2016-01-26 | Siemens Aktiengesellschaft | Turbine abradable layer with zig zag groove pattern |
WO2016133987A2 (en) | 2015-02-18 | 2016-08-25 | Siemens Aktiengesellschaft | Forming cooling passages in combustion turbine superalloy castings |
US9151175B2 (en) | 2014-02-25 | 2015-10-06 | Siemens Aktiengesellschaft | Turbine abradable layer with progressive wear zone multi level ridge arrays |
US8939705B1 (en) | 2014-02-25 | 2015-01-27 | Siemens Energy, Inc. | Turbine abradable layer with progressive wear zone multi depth grooves |
US8939707B1 (en) | 2014-02-25 | 2015-01-27 | Siemens Energy, Inc. | Turbine abradable layer with progressive wear zone terraced ridges |
US9249680B2 (en) | 2014-02-25 | 2016-02-02 | Siemens Energy, Inc. | Turbine abradable layer with asymmetric ridges or grooves |
US8939706B1 (en) | 2014-02-25 | 2015-01-27 | Siemens Energy, Inc. | Turbine abradable layer with progressive wear zone having a frangible or pixelated nib surface |
EP2918705B1 (en) | 2014-03-12 | 2017-05-03 | Rolls-Royce Corporation | Coating including diffusion barrier layer including iridium and oxide layer and method of coating |
US11098399B2 (en) | 2014-08-06 | 2021-08-24 | Raytheon Technologies Corporation | Ceramic coating system and method |
TWI588116B (en) * | 2014-11-11 | 2017-06-21 | 三菱日立電力系統股份有限公司 | Turbine member |
CN104446458A (en) * | 2014-12-03 | 2015-03-25 | 山东理工大学 | Method for preparing yttrium-oxide-stabilized hafnium oxide vacuum coating material |
US20160265367A1 (en) * | 2014-12-22 | 2016-09-15 | General Electric Company | Environmental barrier coating with abradable coating for ceramic matrix composites |
US20160236994A1 (en) * | 2015-02-17 | 2016-08-18 | Rolls-Royce Corporation | Patterned abradable coatings and methods for the manufacture thereof |
US10190435B2 (en) | 2015-02-18 | 2019-01-29 | Siemens Aktiengesellschaft | Turbine shroud with abradable layer having ridges with holes |
JP6411931B2 (en) * | 2015-03-26 | 2018-10-24 | 太平洋セメント株式会社 | Composite hollow particles |
US20170122560A1 (en) * | 2015-10-28 | 2017-05-04 | General Electric Company | Gas turbine component with improved thermal barrier coating system |
US10995624B2 (en) * | 2016-08-01 | 2021-05-04 | General Electric Company | Article for high temperature service |
JP6415780B2 (en) * | 2016-08-26 | 2018-10-31 | 日本碍子株式会社 | Insulation material |
US10513463B2 (en) | 2016-09-27 | 2019-12-24 | Skyworks Solutions, Inc. | Enhanced fracture toughness thermal barrier coating material |
US10415579B2 (en) | 2016-09-28 | 2019-09-17 | General Electric Company | Ceramic coating compositions for compressor blade and methods for forming the same |
DK201600605A1 (en) * | 2016-10-07 | 2018-04-16 | Haldor Topsoe As | Combustion Chamber Hot Face Refractory Lining |
FR3058469B1 (en) * | 2016-11-09 | 2020-08-21 | Safran | TURBOMACHINE PART COATED WITH A THERMAL BARRIER AND PROCEDURE TO OBTAIN IT |
US10428727B2 (en) * | 2017-04-14 | 2019-10-01 | Ford Motor Company | Bonding strength enhancement for ceramic coating on high temperature alloy |
FR3067391B1 (en) * | 2017-06-12 | 2020-12-04 | Safran | REINFORCED ANTI-CMAS COATING |
US11597991B2 (en) * | 2017-06-26 | 2023-03-07 | Raytheon Technologies Corporation | Alumina seal coating with interlayer |
US10947625B2 (en) | 2017-09-08 | 2021-03-16 | Raytheon Technologies Corporation | CMAS-resistant thermal barrier coating and method of making a coating thereof |
CN107604299B (en) * | 2017-09-11 | 2020-03-13 | 北京工业大学 | Composite material for heat-insulating coating and preparation method of coating |
DE102017216756A1 (en) * | 2017-09-21 | 2019-03-21 | Siemens Aktiengesellschaft | Pure zirconia powder, layer and layer system |
DE102018204498A1 (en) * | 2018-03-23 | 2019-09-26 | Siemens Aktiengesellschaft | Ceramic material based on zirconium oxide with other oxides |
US11261750B2 (en) | 2018-03-26 | 2022-03-01 | Rolls-Royce North American Technologies Inc. | CMC blade track with integral abradable |
JP7015199B2 (en) * | 2018-03-28 | 2022-02-02 | 株式会社フジミインコーポレーテッド | Method for manufacturing thermal spray material and coating film |
CN108439977B (en) * | 2018-04-23 | 2021-01-19 | 北京航空航天大学 | High-temperature low-thermal-conductivity hafnium oxide-based thermal barrier coating material and preparation method thereof |
EP3863990A4 (en) * | 2018-10-09 | 2022-10-12 | Oerlikon Metco (US) Inc. | High-entropy oxides for thermal barrier coating (tbc) top coats |
CN110129709B (en) * | 2019-06-11 | 2021-09-10 | 华东理工大学 | Preparation method of ceramic layer, ceramic layer obtained by preparation method and thermal barrier coating of ceramic layer |
CN110791734A (en) * | 2019-11-29 | 2020-02-14 | 中国航发沈阳黎明航空发动机有限责任公司 | Preparation method of thermal barrier coating of turbine working blade |
CN110735117B (en) * | 2019-11-29 | 2021-06-29 | 中国航发沈阳黎明航空发动机有限责任公司 | Preparation method of thermal barrier coating of duplex guide blade |
US11339671B2 (en) | 2019-12-20 | 2022-05-24 | Honeywell International Inc. | Methods for manufacturing porous barrier coatings using air plasma spray techniques |
US20210340388A1 (en) * | 2020-05-01 | 2021-11-04 | General Electric Company | Composition for thermal barrier coating |
WO2023091283A1 (en) * | 2021-11-18 | 2023-05-25 | Oerlikon Metco (Us) Inc. | Porous agglomerates and encapsulated agglomerates for abradable sealant materials and methods of manufacturing the same |
CN117568737A (en) * | 2024-01-12 | 2024-02-20 | 北矿新材科技有限公司 | Coating with high thermal shock resistance and high abrasion resistance, preparation method thereof, engine and aircraft |
Citations (11)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4520114A (en) * | 1983-09-26 | 1985-05-28 | Celanese Corporation | Production of metastable tetragonal zirconia |
US4535033A (en) * | 1983-08-16 | 1985-08-13 | The United States Of America As Represented By The Administrator Of The National Aeronautics And Space Administration | Thermal barrier coating system |
US4996068A (en) * | 1987-12-02 | 1991-02-26 | Mitsubishi Gas Chemical Company | Methods for treating food and a deoxodizer package in a microwave oven |
US5073433A (en) * | 1989-10-20 | 1991-12-17 | Technology Corporation | Thermal barrier coating for substrates and process for producing it |
US5705231A (en) * | 1995-09-26 | 1998-01-06 | United Technologies Corporation | Method of producing a segmented abradable ceramic coating system |
US6358002B1 (en) * | 1998-06-18 | 2002-03-19 | United Technologies Corporation | Article having durable ceramic coating with localized abradable portion |
US20020094448A1 (en) * | 2001-01-18 | 2002-07-18 | Rigney Joseph David | Thermally-stabilized thermal barrier coating |
US20040033884A1 (en) * | 2002-08-13 | 2004-02-19 | Howard Wallar | Plasma spheroidized ceramic powder |
US20040146613A1 (en) * | 2003-01-28 | 2004-07-29 | Paul Diebel | Shelf stable, dehydrated, heat-treated meat protein product and method of preparing same |
US20040229031A1 (en) * | 2003-01-10 | 2004-11-18 | Maurice Gell | Coatings, materials, articles, and methods of making thereof |
US20050074532A1 (en) * | 2000-12-22 | 2005-04-07 | Mcmaster Gayle Edith | Automated production of packaged cooked meals |
Family Cites Families (48)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4360598A (en) | 1980-03-26 | 1982-11-23 | Ngk Insulators, Ltd. | Zirconia ceramics and a method of producing the same |
US4565792A (en) * | 1983-06-20 | 1986-01-21 | Norton Company | Partially stabilized zirconia bodies |
JPS6141757A (en) * | 1984-08-01 | 1986-02-28 | Hitachi Ltd | Zro2-base powder for heat insulating coating |
FR2578241B1 (en) * | 1985-03-01 | 1990-03-30 | Rhone Poulenc Spec Chim | STABILIZED ZIRCONIA, ITS PREPARATION PROCESS AND ITS APPLICATION IN CERAMIC COMPOSITIONS |
US4639356A (en) | 1985-11-05 | 1987-01-27 | American Cyanamid Company | High technology ceramics with partially stabilized zirconia |
US4849142A (en) | 1986-01-03 | 1989-07-18 | Jupiter Technologies, Inc. | Superplastic forging of zirconia ceramics |
JPS62207884A (en) * | 1986-03-07 | 1987-09-12 | Toshiba Corp | High temperature heat resistant member |
JPH01179725A (en) * | 1988-01-08 | 1989-07-17 | Daido Steel Co Ltd | Production of partially stabilized zirconia having extremely high purity |
JPH01317167A (en) * | 1988-03-15 | 1989-12-21 | Tosoh Corp | Calcined zirconium oxide compact for forming thin film and production thereof |
US4898368A (en) * | 1988-08-26 | 1990-02-06 | Union Carbide Corporation | Wear resistant metallurgical tuyere |
US5015502A (en) | 1988-11-03 | 1991-05-14 | Allied-Signal Inc. | Ceramic thermal barrier coating with alumina interlayer |
US4936745A (en) * | 1988-12-16 | 1990-06-26 | United Technologies Corporation | Thin abradable ceramic air seal |
JPH03223455A (en) * | 1990-01-29 | 1991-10-02 | Sugitani Kinzoku Kogyo Kk | Ceramic thermal spraying material |
US5418003A (en) * | 1993-09-10 | 1995-05-23 | General Electric Company | Vapor deposition of ceramic materials |
US6182176B1 (en) * | 1994-02-24 | 2001-01-30 | Hewlett-Packard Company | Queue-based predictive flow control mechanism |
US5670270A (en) * | 1995-11-16 | 1997-09-23 | The Dow Chemical Company | Electrode structure for solid state electrochemical devices |
DE69615517T2 (en) * | 1995-12-22 | 2002-05-16 | Gen Electric | Body with high temperature protective layer and method for coating |
US6123997A (en) * | 1995-12-22 | 2000-09-26 | General Electric Company | Method for forming a thermal barrier coating |
CN1225079A (en) * | 1996-07-05 | 1999-08-04 | 福塞科国际有限公司 | Ceramic compositions |
JPH1025578A (en) * | 1996-07-10 | 1998-01-27 | Toshiba Corp | Heat resistant member and its production |
US6042878A (en) | 1996-12-31 | 2000-03-28 | General Electric Company | Method for depositing a ceramic coating |
ATE420272T1 (en) * | 1999-12-20 | 2009-01-15 | Sulzer Metco Ag | PROFILED SURFACE USED AS A SCRUB COATING IN FLOW MACHINES |
EP1126044A1 (en) | 2000-02-16 | 2001-08-22 | General Electric Company | High purity yttria stabilized zirconia for physical vapor deposition |
US6352788B1 (en) * | 2000-02-22 | 2002-03-05 | General Electric Company | Thermal barrier coating |
JP3631982B2 (en) * | 2000-06-16 | 2005-03-23 | 三菱重工業株式会社 | Manufacturing method of thermal barrier coating material |
JP3825231B2 (en) * | 2000-07-24 | 2006-09-27 | 三菱重工業株式会社 | Method for producing hollow ceramic powder for thermal spraying |
ES2384236T3 (en) * | 2000-12-08 | 2012-07-02 | Sulzer Metco (Us) Inc. | Improved thermal barrier coating and pre-alloyed stabilized zirconia powder |
US7001859B2 (en) * | 2001-01-22 | 2006-02-21 | Ohio Aerospace Institute | Low conductivity and sintering-resistant thermal barrier coatings |
US6812176B1 (en) * | 2001-01-22 | 2004-11-02 | Ohio Aerospace Institute | Low conductivity and sintering-resistant thermal barrier coatings |
JP4091275B2 (en) * | 2001-06-29 | 2008-05-28 | 株式会社東芝 | Metal ceramic laminated structure member and method for manufacturing the same |
JP2003160852A (en) * | 2001-11-26 | 2003-06-06 | Mitsubishi Heavy Ind Ltd | Thermal insulating coating material, manufacturing method therefor, turbine member and gas turbine |
US20040005452A1 (en) * | 2002-01-14 | 2004-01-08 | Dorfman Mitchell R. | High temperature spray dried composite abradable powder for combustion spraying and abradable barrier coating produced using same |
US20030138658A1 (en) * | 2002-01-22 | 2003-07-24 | Taylor Thomas Alan | Multilayer thermal barrier coating |
CN1229304C (en) * | 2002-11-16 | 2005-11-30 | 太原理工大学 | Nano tetragonal phase zirconium oxide powder and preparation thereof |
FR2854072B1 (en) * | 2003-04-23 | 2006-08-04 | Centre Nat Rech Scient | VECTOR FOR ORAL ADMINISTRATION |
JP2005002409A (en) | 2003-06-11 | 2005-01-06 | Toshiba Corp | Ceramic-coated member, method for manufacturing the same, and thermal-barrier coated high-temperature component using the ceramic-coated member |
CN1203830C (en) * | 2003-09-05 | 2005-06-01 | 清华大学 | Polycrystal zirconium oxide ceramic dental material and preparation thereof |
US6960395B2 (en) * | 2003-12-30 | 2005-11-01 | General Electric Company | Ceramic compositions useful for thermal barrier coatings having reduced thermal conductivity |
US20050142393A1 (en) * | 2003-12-30 | 2005-06-30 | Boutwell Brett A. | Ceramic compositions for thermal barrier coatings stabilized in the cubic crystalline phase |
US7291403B2 (en) * | 2004-02-03 | 2007-11-06 | General Electric Company | Thermal barrier coating system |
US20050238894A1 (en) * | 2004-04-22 | 2005-10-27 | Gorman Mark D | Mixed metal oxide ceramic compositions for reduced conductivity thermal barrier coatings |
US7955707B2 (en) * | 2005-10-07 | 2011-06-07 | Sulzer Metco (Us), Inc. | High purity ceramic abradable coatings |
US7773459B2 (en) * | 2006-01-13 | 2010-08-10 | Furuno Electric Co., Ltd. | Underwater sounding method and apparatus |
US20070274837A1 (en) * | 2006-05-26 | 2007-11-29 | Thomas Alan Taylor | Blade tip coatings |
US8021762B2 (en) * | 2006-05-26 | 2011-09-20 | Praxair Technology, Inc. | Coated articles |
US7776459B2 (en) | 2006-08-18 | 2010-08-17 | United Technologies Corporation | High sodium containing thermal barrier coating |
FR2910466A1 (en) * | 2006-12-21 | 2008-06-27 | Commissariat Energie Atomique | Preparation of refractory ceramic material powder comprises e.g. obtaining hafnium dioxide and yttrium oxide powder dry mixture, granulating, drying, filling mold with the mixture, isostatic/semi-isostatic pressing and sintering |
US7846561B2 (en) * | 2007-09-19 | 2010-12-07 | Siemens Energy, Inc. | Engine portions with functional ceramic coatings and methods of making same |
-
2006
- 2006-09-13 US US11/520,041 patent/US7955707B2/en active Active
- 2006-09-13 US US11/520,042 patent/US20070082131A1/en not_active Abandoned
- 2006-09-13 US US11/520,043 patent/US7723249B2/en active Active
- 2006-09-13 US US11/520,044 patent/US7955708B2/en active Active
- 2006-10-02 EP EP20060121639 patent/EP1772441B1/en not_active Revoked
- 2006-10-02 ES ES06121639T patent/ES2374636T3/en active Active
- 2006-10-02 AT AT06121639T patent/ATE535504T1/en active
- 2006-10-05 CA CA 2562668 patent/CA2562668C/en active Active
- 2006-10-06 JP JP2006275678A patent/JP2007107098A/en active Pending
- 2006-10-06 CN CN2006101495026A patent/CN101081735B/en active Active
-
2010
- 2010-12-03 US US12/960,107 patent/US8187717B1/en active Active
-
2013
- 2013-05-20 JP JP2013105886A patent/JP2013166695A/en active Pending
-
2015
- 2015-01-22 JP JP2015010171A patent/JP5893180B2/en active Active
Patent Citations (15)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4535033A (en) * | 1983-08-16 | 1985-08-13 | The United States Of America As Represented By The Administrator Of The National Aeronautics And Space Administration | Thermal barrier coating system |
US4520114A (en) * | 1983-09-26 | 1985-05-28 | Celanese Corporation | Production of metastable tetragonal zirconia |
US4996068A (en) * | 1987-12-02 | 1991-02-26 | Mitsubishi Gas Chemical Company | Methods for treating food and a deoxodizer package in a microwave oven |
US5073433A (en) * | 1989-10-20 | 1991-12-17 | Technology Corporation | Thermal barrier coating for substrates and process for producing it |
US5073433B1 (en) * | 1989-10-20 | 1995-10-31 | Praxair Technology Inc | Thermal barrier coating for substrates and process for producing it |
US5780171A (en) * | 1995-09-26 | 1998-07-14 | United Technologies Corporation | Gas turbine engine component |
US5705231A (en) * | 1995-09-26 | 1998-01-06 | United Technologies Corporation | Method of producing a segmented abradable ceramic coating system |
US6102656A (en) * | 1995-09-26 | 2000-08-15 | United Technologies Corporation | Segmented abradable ceramic coating |
US6358002B1 (en) * | 1998-06-18 | 2002-03-19 | United Technologies Corporation | Article having durable ceramic coating with localized abradable portion |
US20050074532A1 (en) * | 2000-12-22 | 2005-04-07 | Mcmaster Gayle Edith | Automated production of packaged cooked meals |
US20020094448A1 (en) * | 2001-01-18 | 2002-07-18 | Rigney Joseph David | Thermally-stabilized thermal barrier coating |
US20040033884A1 (en) * | 2002-08-13 | 2004-02-19 | Howard Wallar | Plasma spheroidized ceramic powder |
US6893994B2 (en) * | 2002-08-13 | 2005-05-17 | Saint-Gobain Ceramics & Plastics, Inc. | Plasma spheroidized ceramic powder |
US20040229031A1 (en) * | 2003-01-10 | 2004-11-18 | Maurice Gell | Coatings, materials, articles, and methods of making thereof |
US20040146613A1 (en) * | 2003-01-28 | 2004-07-29 | Paul Diebel | Shelf stable, dehydrated, heat-treated meat protein product and method of preparing same |
Cited By (54)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US7722246B1 (en) * | 2005-04-20 | 2010-05-25 | Carty William M | Method for determining the thermal expansion coefficient of ceramic bodies and glazes |
US20110003119A1 (en) * | 2005-10-07 | 2011-01-06 | Sulzer Metco (Us), Inc. | Optimized high temperature thermal barrier |
US20100311562A1 (en) * | 2005-10-07 | 2010-12-09 | Sulzer Metco (Us), Inc. | High purity ceramic abradable coatings |
US9975812B2 (en) | 2005-10-07 | 2018-05-22 | Oerlikon Metco (Us) Inc. | Ceramic material for high temperature service |
US11046614B2 (en) | 2005-10-07 | 2021-06-29 | Oerlikon Metco (Us) Inc. | Ceramic material for high temperature service |
US7955708B2 (en) | 2005-10-07 | 2011-06-07 | Sulzer Metco (Us), Inc. | Optimized high temperature thermal barrier |
US7955707B2 (en) | 2005-10-07 | 2011-06-07 | Sulzer Metco (Us), Inc. | High purity ceramic abradable coatings |
US8187717B1 (en) | 2005-10-07 | 2012-05-29 | Sulzer Metco (Us) Inc. | High purity ceramic abradable coatings |
US20140178632A1 (en) * | 2006-05-26 | 2014-06-26 | Thomas Alan Taylor | High purity zirconia-based thermally sprayed coatings and processes for the preparation thereof |
US8021762B2 (en) * | 2006-05-26 | 2011-09-20 | Praxair Technology, Inc. | Coated articles |
US8197950B2 (en) * | 2006-05-26 | 2012-06-12 | Praxair S.T. Technology, Inc. | Dense vertically cracked thermal barrier coatings |
US20070274837A1 (en) * | 2006-05-26 | 2007-11-29 | Thomas Alan Taylor | Blade tip coatings |
US20080220209A1 (en) * | 2006-05-26 | 2008-09-11 | Thomas Alan Taylor | Thermally sprayed coatings |
US8394484B2 (en) * | 2006-05-26 | 2013-03-12 | Praxair Technology, Inc. | High purity zirconia-based thermally sprayed coatings |
US20080213617A1 (en) * | 2006-05-26 | 2008-09-04 | Thomas Alan Taylor | Coated articles |
US20080160172A1 (en) * | 2006-05-26 | 2008-07-03 | Thomas Alan Taylor | Thermal spray coating processes |
US9085490B2 (en) | 2006-05-26 | 2015-07-21 | Praxair S.T. Technology, Inc. | High purity zirconia-based thermally sprayed coatings and processes for the preparation thereof |
US20080026160A1 (en) * | 2006-05-26 | 2008-01-31 | Thomas Alan Taylor | Blade tip coating processes |
US20080226837A1 (en) * | 2006-10-02 | 2008-09-18 | Sulzer Metco Ag | Method for the manufacture of a coating having a columnar structure |
US20100086757A1 (en) * | 2006-12-15 | 2010-04-08 | Thomas Berndt | Method for coating a component |
US20090136781A1 (en) * | 2007-08-16 | 2009-05-28 | Damani Rajiv J | Method For The Generation Of A Functional Layer |
US7846561B2 (en) | 2007-09-19 | 2010-12-07 | Siemens Energy, Inc. | Engine portions with functional ceramic coatings and methods of making same |
WO2009038785A3 (en) * | 2007-09-19 | 2009-06-04 | Siemens Energy Inc | Engine portions with functional ceramic coatings and methods of making same |
WO2009038785A2 (en) * | 2007-09-19 | 2009-03-26 | Siemens Energy, Inc. | Engine portions with functional ceramic coatings and methods of making same |
WO2009038749A1 (en) | 2007-09-19 | 2009-03-26 | Siemens Energy, Inc. | Imparting functional characteristics to engine portions |
US8153204B2 (en) | 2007-09-19 | 2012-04-10 | Siemens Energy, Inc. | Imparting functional characteristics to engine portions |
US20090075057A1 (en) * | 2007-09-19 | 2009-03-19 | Siemens Power Generation, Inc. | Imparting functional characteristics to engine portions |
US20090074961A1 (en) * | 2007-09-19 | 2009-03-19 | Siemens Power Generation, Inc. | Engine portions with functional ceramic coatings and methods of making same |
US20090184280A1 (en) * | 2008-01-18 | 2009-07-23 | Rolls-Royce Corp. | Low Thermal Conductivity, CMAS-Resistant Thermal Barrier Coatings |
US10233760B2 (en) | 2008-01-18 | 2019-03-19 | Rolls-Royce Corporation | CMAS-resistant thermal barrier coatings |
US20100080984A1 (en) * | 2008-09-30 | 2010-04-01 | Rolls-Royce Corp. | Coating including a rare earth silicate-based layer including a second phase |
US10717678B2 (en) | 2008-09-30 | 2020-07-21 | Rolls-Royce Corporation | Coating including a rare earth silicate-based layer including a second phase |
US20100129636A1 (en) * | 2008-11-25 | 2010-05-27 | Rolls-Royce Corporation | Abradable layer including a rare earth silicate |
US8124252B2 (en) | 2008-11-25 | 2012-02-28 | Rolls-Royce Corporation | Abradable layer including a rare earth silicate |
US8470460B2 (en) | 2008-11-25 | 2013-06-25 | Rolls-Royce Corporation | Multilayer thermal barrier coatings |
US20110033630A1 (en) * | 2009-08-05 | 2011-02-10 | Rolls-Royce Corporation | Techniques for depositing coating on ceramic substrate |
US8337989B2 (en) * | 2010-05-17 | 2012-12-25 | United Technologies Corporation | Layered thermal barrier coating with blended transition |
US8574721B2 (en) | 2010-05-17 | 2013-11-05 | United Technologies Corporation | Layered thermal barrier coating with blended transition and method of application |
US9194242B2 (en) | 2010-07-23 | 2015-11-24 | Rolls-Royce Corporation | Thermal barrier coatings including CMAS-resistant thermal barrier coating layers |
US10125618B2 (en) | 2010-08-27 | 2018-11-13 | Rolls-Royce Corporation | Vapor deposition of rare earth silicate environmental barrier coatings |
US20120148769A1 (en) * | 2010-12-13 | 2012-06-14 | General Electric Company | Method of fabricating a component using a two-layer structural coating |
US9428837B2 (en) * | 2012-03-27 | 2016-08-30 | United Technologies Corporation | Multi-material thermal barrier coating system |
US20130260119A1 (en) * | 2012-03-27 | 2013-10-03 | United Technologies Corporation | Multi-Material Thermal Barrier Coating System |
CN103290352A (en) * | 2013-06-18 | 2013-09-11 | 张关莲 | Method for preparing zirconium oxide thermal barrier coating by spraying process |
US20150084245A1 (en) * | 2013-09-20 | 2015-03-26 | Alstom Technology Ltd | Method for producing means with thermal resist for applying at a surface of a heat exposed component |
US9862647B2 (en) * | 2013-09-20 | 2018-01-09 | Ansaldo Energia Ip Uk Limited | Method for producing means with thermal resistance for applying at a surface of a heat exposed component |
US10329205B2 (en) | 2014-11-24 | 2019-06-25 | Rolls-Royce Corporation | Bond layer for silicon-containing substrates |
US10808308B2 (en) | 2016-06-08 | 2020-10-20 | Mitsubishi Heavy Industries, Ltd. | Thermal barrier coating, turbine member, and gas turbine |
US11292748B2 (en) | 2017-06-21 | 2022-04-05 | Höganäs Germany GmbH | Zirconium oxide powder for thermal spraying |
US11851770B2 (en) | 2017-07-17 | 2023-12-26 | Rolls-Royce Corporation | Thermal barrier coatings for components in high-temperature mechanical systems |
US11655543B2 (en) | 2017-08-08 | 2023-05-23 | Rolls-Royce Corporation | CMAS-resistant barrier coatings |
US10851656B2 (en) | 2017-09-27 | 2020-12-01 | Rolls-Royce Corporation | Multilayer environmental barrier coating |
US11946147B2 (en) | 2018-03-26 | 2024-04-02 | Mitsubishi Heavy Industries, Ltd. | Thermal barrier coating, turbine member, gas turbine, and method for producing thermal barrier coating |
US20220371966A1 (en) * | 2019-11-12 | 2022-11-24 | Siemens Energy Global GmbH & Co. KG | Ceramic material, powder, and layer system comprising the ceramic material |
Also Published As
Publication number | Publication date |
---|---|
US8187717B1 (en) | 2012-05-29 |
CN101081735A (en) | 2007-12-05 |
ATE535504T1 (en) | 2011-12-15 |
CA2562668A1 (en) | 2007-04-07 |
US20100311562A1 (en) | 2010-12-09 |
ES2374636T3 (en) | 2012-02-20 |
US20120114929A1 (en) | 2012-05-10 |
US7955707B2 (en) | 2011-06-07 |
US7723249B2 (en) | 2010-05-25 |
EP1772441B1 (en) | 2011-11-30 |
US20100075147A1 (en) | 2010-03-25 |
JP2015108196A (en) | 2015-06-11 |
JP2013166695A (en) | 2013-08-29 |
US20110003119A1 (en) | 2011-01-06 |
CA2562668C (en) | 2013-12-10 |
EP1772441A1 (en) | 2007-04-11 |
US7955708B2 (en) | 2011-06-07 |
JP2007107098A (en) | 2007-04-26 |
JP5893180B2 (en) | 2016-03-23 |
CN101081735B (en) | 2013-03-13 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US20210261465A1 (en) | Ceramic material for high temperature service | |
US20070082131A1 (en) | Optimized high purity coating for high temperature thermal cycling applications | |
US7867575B2 (en) | Sintering resistant, low conductivity, high stability thermal barrier coating/environmental barrier coating system for a ceramic-matrix composite (CMC) article to improve high temperature capability | |
EP1666438B1 (en) | Thermal barrier coating/environmental barrier coating system for a silicon containing substrate to improve high temperature capability | |
EP1577499B1 (en) | Turbine components with thermal barrier coatings | |
US20180354858A1 (en) | Thermal barrier coating material with enhanced toughness | |
US10807912B1 (en) | Advanced high temperature environmental barrier coating systems for SiC/SiC ceramic matrix composites | |
US10513463B2 (en) | Enhanced fracture toughness thermal barrier coating material | |
EP2767525B1 (en) | Ceramic powders and methods therefor | |
WO2019199678A1 (en) | Cmas resistant, high strain tolerant and low thermal conductivity thermal barrier coatings and thermal spray coating method | |
WO2023200720A1 (en) | Environmental barrier materials and coatings containing low melting temperature phases | |
EP2851356A1 (en) | Method for producing means with thermal resist for applying at a surface of a heat exposed component |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: SULZER METCO (US), INC., NEW YORK Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:DOESBURG, JACOBUS C.;XIE, LIANGDE;SCHMID, RICHARD;AND OTHERS;REEL/FRAME:018617/0895 Effective date: 20061006 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |