Patent application number | Description | Published |
20080305264 | THERMAL BARRIER COATING AND PROCESS THEREFOR - A thermal barrier coating and deposition process for a component intended for use in a hostile thermal environment, such as the turbine, combustor and augmentor components of a gas turbine engine. The TBC has a first coating portion on at least a first surface portion of the component. The first coating portion is formed of a ceramic material to have at least an inner region, at least an outer region overlying the inner region, and a columnar microstructure whereby the inner and outer regions comprise columns of the ceramic material. The columns of the inner region are more closely spaced than the columns of the outer region so that the inner region of the first coating portion is denser than the outer region of the first coating portion, wherein the higher density of the inner region promotes the impact resistance of the first coating portion. | 12-11-2008 |
20090047135 | LAYERED CORROSION RESISTANT COATING FOR TURBINE BLADE ENVIRONMENTAL PROTECTION - The present invention is a gas turbine engine turbine blade comprising an airfoil section having at least an exterior surface, a platform section having an exterior surface, an under platform section having an exterior surface, and a dovetail section having an exterior surface. The blade further comprises a corrosion resistant coating on a surface of a turbine blade section selected from the group consisting of the exterior surface of the under platform section, the exterior surface of the dovetail section, and combinations thereof, the corrosion resistant coating comprising a particulate corrosion resistant component comprising from about 5 weight percent to about 100 weight percent corrosion resistant non-alumina particulates having a CTE greater than that of alumina particulates and balance alumina particulates, and a binder component. The present invention also includes methods for making such a gas turbine engine blade. | 02-19-2009 |
20090162562 | Methods for Applying Thermal Barrier Coating Systems - Methods for coating a substrate includes depositing on the substrate, a inner bond coat layer of a bond coat composition comprising, in weight percent, 14-20% Cr, 5-8% Al, 8-12% Co, 3-7% Ta, 0.1-0.6% Hf, 0.1-0.5% Y, up to about 1% Si, 0.005-0.020% Zr, 0.04-0.08% C, 0.01-0.02% B, with a remainder including nickel (Ni) and incidental impurities, wherein the bond coat composition is substantially free of rhenium; forming an aluminum-containing layer overlying the inner bond coat layer; and, optionally, depositing a thermal barrier coating composition overlying the aluminum-containing layer. | 06-25-2009 |
20090162690 | THERMAL BARRIER COATING SYSTEMS - Coating system for a metallic substrate includes a strengthened bond coat including a bond coat inner layer and an aluminum-containing layer overlying the bond coat inner layer. The bond coat inner layer is formed by deposition of a bond coat composition including, in weight percent, 14-20% Cr, 5-8% Al, 8-12% Co, 3-7% Ta, 0.1-0.6% Hf, 0.1-0.5% Y, up to about 1% Si, 0.005-0.020% Zr, 0.04-0.08% C, 0.01-0.02% B, with a remainder including Ni and incidental impurities, wherein the bond coat composition is substantially free of rhenium. The coating system includes an optional thermal barrier coating which may be a yttria-stabilized zirconia. | 06-25-2009 |
20090162692 | Coated Superalloy Articles - Coated superalloy article includes a bond coat comprising an inner bond coat layer disposed on the first surface being formed by deposition of a bond coat composition comprising, in weight percent, 14-20% Cr, 5-8% Al, 8-12% Co, 3-7% Ta, 0.1-0.6% Hf, 0.1-0.5% Y, up to about 1% Si, 0.005-0.020% Zr, 0.04-0.08% C, 0.01-0.02% B, with a remainder including nickel (Ni) and incidental impurities, wherein the bond coating composition is substantially free of rhenium. An aluminum-containing layer overlies the inner bond coat layer. Optionally, a thermal barrier coating overlies the aluminum-containing layer, wherein the thermal barrier coating, if present, is formed by deposition of a thermal barrier coating composition. | 06-25-2009 |
20090169752 | Method for Improving Resistance to CMAS Infiltration - Methods for providing improved resistance to CMAS infiltration for hot section components of a gas turbine engine. Exemplary methods include coating a substrate with a thermal barrier coating system by overlying a bond coated substrate with an inner thermal barrier layer comprised of a thermal barrier material such as yttria-stabilized zirconia. A top layer, including a rare-earth aluminate, is deposited so as to overlie at least a portion of the inner layer. Deposition processes and coating thicknesses may be tailored to the type of component to be coated. | 07-02-2009 |
20090169914 | Thermal Barrier Coating Systems Including a Rare Earth Aluminate Layer for Improved Resistance to CMAS Infiltration and Coated Articles - Thermal barrier coating systems for use with hot section components of a gas turbine engine include an inner layer overlying a bond coated substrate and a top layer overlying at least a portion of the inner layer. The inner layer includes a thermal barrier material such as yttria-stabilized zirconia. The top layer includes a rare earth aluminate. The thicknesses and microstructures of the layers may be varied depending on the type of component to be coated. Articles incorporating the thermal barrier coating system exhibit improved resistance to CMAS infiltration | 07-02-2009 |
20090191347 | TURBINE COMPONENT OTHER THAN AIRFOIL HAVING CERAMIC CORROSION RESISTANT COATING AND METHODS FOR MAKING SAME - An article comprising a turbine component other than an airfoil having a metal substrate and a ceramic corrosion resistant coating overlaying the metal substrate. This coating has a thickness up to about 5 mils (127 microns) and comprises a ceramic metal oxide selected from the group consisting of zirconia, hafnia and mixtures thereof. This coating can be formed by a method comprising the following steps: (a) providing a turbine component other than an airfoil comprising the metal substrate; (b) providing a gel-forming solution comprising a ceramic metal oxide precursor; (c) heating the gel-forming solution to a first preselected temperature for a first preselected time to form a gel; (d) depositing the gel on the metal substrate; and (e) firing the gel at a second preselected temperature above the first preselected temperature to form the ceramic corrosion resistant coating comprising the ceramic metal oxide. This coating can also be formed by alternative methods wherein a ceramic composition comprising the ceramic metal oxide is deposited by physical vapor deposition on the metal substrate to provide a strain-tolerant columnar structure, or is thermal sprayed on the metal substrate. | 07-30-2009 |
20090191353 | TURBINE COMPONENT OTHER THAN AIRFOIL HAVING CERAMIC CORROSION RESISTANT COATING AND METHODS FOR MAKING SAME - An article comprising a turbine component other than an airfoil having a metal substrate and a ceramic corrosion resistant coating overlaying the metal substrate. This coating has a thickness up to about 5 mils (127 microns) and comprises a ceramic metal oxide selected from the group consisting of zirconia, hafnia and mixtures thereof. This coating can be formed by a method comprising the following steps: (a) providing a turbine component other than an airfoil comprising the metal substrate; (b) providing a gel-forming solution comprising a ceramic metal oxide precursor; (c) heating the gel-forming solution to a first preselected temperature for a first preselected time to form a gel; (d) depositing the gel on the metal substrate; and (e) firing the gel at a second preselected temperature above the first preselected temperature to form the ceramic corrosion resistant coating comprising the ceramic metal oxide. This coating can also be formed by alternative methods wherein a ceramic composition comprising the ceramic metal oxide is deposited by physical vapor deposition on the metal substrate to provide a strain-tolerant columnar structure, or is thermal sprayed on the metal substrate. | 07-30-2009 |
20090239061 | CERAMIC CORROSION RESISTANT COATING FOR OXIDATION RESISTANCE - A coating system and a method for forming the coating system, the method including coating a surface of a gas turbine engine turbine component having a metallic surface that is outside the combustion gas stream and exposed to cooling air during operation of the engine. A gel-forming solution including a ceramic metal oxide precursor is provided. The gel-forming solution is heated to a first preselected temperature for a first preselected time to form a gel. The gel is then deposited on the metallic surface. Thereafter the gel is fired at a second preselected temperature above the first preselected temperature to form a ceramic corrosion resistant coating comprising a ceramic metal oxide is selected from the group consisting of zirconia, hafnia and combinations thereof. The ceramic corrosion resistant coating having a thickness of up to about 127 microns and remaining adherent at temperatures greater than about 1000° F. | 09-24-2009 |
20100158680 | CMAS MITIGATION COMPOSITIONS, ENVIRONMENTAL BARRIER COATINGS COMPRISING THE SAME, AND CERAMIC COMPONENTS COMPRISING THE SAME - Calcium magnesium aluminosilicate (CMAS) mitigation compositions selected from rare earth elements, rare earth oxides, zirconia, hafnia partially or fully stabilized with alkaline earth or rare earth elements, zirconia partially or fully stabilized with alkaline earth or rare earth elements, magnesium oxide, cordierite, aluminum phosphate, magnesium silicate, and combinations thereof when the CMAS mitigation composition is included as a separate CMAS mitigation layer in an environmental barrier coating for a high temperature substrate component. | 06-24-2010 |
20100159150 | METHODS FOR MAKING ENVIRONMENTAL BARRIER COATINGS AND CERAMIC COMPONENTS HAVING CMAS MITIGATION CAPABILITY - Methods of making components having calcium magnesium aluminosilicate (CMAS) mitigation capability involving providing a component; applying an environmental barrier coating to the component, the environmental barrier coating having a separate CMAS mitigation layer including a CMAS mitigation composition selected from rare earth elements, rare earth oxides, zirconia, hafnia partially or fully stabilized with alkaline earth or rare earth elements, zirconia partially or fully stabilized with alkaline earth or rare earth elements, magnesium oxide, cordierite, aluminum phosphate, magnesium silicate, and combinations thereof. | 06-24-2010 |
20100162715 | METHOD AND SYSTEM FOR ENHANCING HEAT TRANSFER OF TURBINE ENGINE COMPONENTS - A method and system for enhancing the heat transfer of turbine engine components is disclosed that includes applying a metallic coating having a high thermal conductivity to the cold side of a turbine component to enhance heat transfer away from the component. The metallic coating may be roughened to improve heat transfer. The metal coating may be a Ni—Al bond coating having an aluminum content greater than about 50 weight percent. | 07-01-2010 |
20100279018 | CERAMIC CORROSION RESISTANT COATING FOR OXIDATION RESISTANCE - A coating system and a method for forming the coating system, the method including coating a surface of a gas turbine engine turbine component having a metallic surface that is outside the combustion gas stream and exposed to cooling air during operation of the engine. A gel-forming solution including a ceramic metal oxide precursor is provided. The gel-forming solution is heated to a first preselected temperature for a first preselected time to form a gel. The gel is then deposited on the metallic surface. Thereafter the gel is fired at a second preselected temperature above the first preselected temperature to form a ceramic corrosion resistant coating comprising a ceramic metal oxide is selected from the group consisting of zirconia, hafnia and combinations thereof. The ceramic corrosion resistant coating having a thickness of up to about 127 microns and remaining adherent at temperatures greater than about 1000° F. | 11-04-2010 |
20130095344 | THERMAL BARRIER COATING SYSTEMS AND PROCESSES THEREFOR - Coating systems and processes by which the coating systems can be deposited to be resistant to contaminants, and particularly resistant to infiltration and damage caused by CMAS. The coating systems include inner and outer ceramic layers, each having a microstructure characterized by splats and horizontal porosity. The inner ceramic layer consists essentially of zirconia stabilized by about 6 to about 9 weight percent yttria. The outer ceramic layer overlies and contacts the inner ceramic layer to define the outermost surface of the coating system. The outer ceramic layer consists essentially of zirconia stabilized by about 25 to about 75 weight percent yttria, has a thickness that is less than the thickness of the inner ceramic layer, and has a porosity level that is lower than that of the inner ceramic layer. | 04-18-2013 |
20140220378 | THERMAL BARRIER COATING SYSTEMS AND PROCESSES THEREFOR - Coating systems and processes by which the coating systems can be deposited to be resistant to contaminants, and particularly resistant to infiltration and damage caused by CMAS. The coating systems include inner and outer ceramic layers. The inner ceramic layer consists essentially of zirconia stabilized by about 6 to about 9 weight percent yttria and optionally contains greater than 0.5 to 10 weight percent hafnium oxide. The outer ceramic layer overlies and contacts the inner ceramic layer to define the outermost surface of the coating system. The outer ceramic layer consists essentially of zirconia stabilized by about 25 to about 75 weight percent yttria, has a thickness that is less than the thickness of the inner ceramic layer and further contains greater than 0.5 to 10 weight percent hafnium oxide and optionally 1 to 10 weight percent tantalum oxide. The outer ceramic layer has a porosity level that is lower than that of the inner ceramic layer. | 08-07-2014 |
20140377473 | THERMAL BARRIER COATING SYSTEMS AND PROCESSES THEREFOR - Coating systems and processes by which the coating systems can be deposited to be resistant to contaminants, and particularly resistant to infiltration and damage caused by CMAS. The coating systems include inner and outer ceramic layers, each having a microstructure characterized by splats and horizontal porosity. The inner ceramic layer consists essentially of zirconia stabilized by about 6 to about 9 weight percent yttria. The outer ceramic layer overlies and contacts the inner ceramic layer to define the outermost surface of the coating system. The outer ceramic layer consists essentially of zirconia stabilized by about 25 to about 75 weight percent yttria, has a thickness that is less than the thickness of the inner ceramic layer, and has a porosity level that is lower than that of the inner ceramic layer. | 12-25-2014 |