Coating system including alternating layers of amorphous silica and amorphous silicon nitride

Patent metadata

Field	Value
Publication number	US-10047614-B2
Application number	US-201514879931-A
Country	US
Kind code	B2
Filing date	Oct 9, 2015
Priority date	Oct 9, 2014
Publication date	Aug 14, 2018
Grant date	Aug 14, 2018

Abstract

In some examples, an article may include a substrate and a coating on the substrate. The substrate may include a superalloy, a ceramic, or a ceramic matrix composite. The coating may include a first set of layers and a second set of layers. At least one layer of the first set of layers is between two layers of the second set of layers. The at least one layer of the first set of layers comprises one of amorphous silica or silicon nitride, and the at least two layers of the second set of layers comprises the other of amorphous silica or silicon nitride.

First claim

The invention claimed is:

1. A gas turbine engine comprising:
a turbine blade comprising a turbine blade root;
a gas turbine engine disk comprising:
a substrate defining at least one fir tree recess; and
a coating on surfaces of a fir tree recess of the at least one fir tree recess;

wherein the coating comprises a first set of layers and a second set of layers;
wherein at least one layer of the first set of layers is between two layers of the second set of layers;
wherein the at least one layer of the first set of layers comprises one of amorphous silica or amorphous silicon nitride;
wherein the at least two layers of the second set of layers comprises the other of amorphous silica or amorphous silicon nitride;
wherein at least one of amorphous silica or amorphous silicon nitride defines an outer surface of the coating; and
wherein the outer surface of the coating contacts a surface of the turbine blade root in the fir tree recess.

2. The article of claim 1 , wherein the coating is selectively not on surfaces of the gas turbine disk other than the surfaces of the fir tree recess of the at least one fir tree recess.

3. The article of claim 1 , wherein the at least one layer of the first set of layers comprises amorphous silica, and wherein the at least two layers of the second set of the layers comprise amorphous silicon nitride.

4. The article of claim 3 , wherein the at least one layer of the first set of layers does not include silicon nitride, and wherein the at least two layers of the second set of layers does not include silica.

5. The article of claim 1 , wherein the at least one layer of the first set of layers comprises amorphous silicon nitride, and wherein the at least two layers of the second set of the layers comprise amorphous silica.

6. The article of claim 5 , wherein the at least one layer of the first set of layers does not include silica, and wherein the at least two layers of the second set of layers does not include silicon nitride.

7. The article of claim 1 , wherein each layer of the first set of layers comprises a first, same composition, and wherein each layer of the second set of layers comprises a second, same composition.

8. The article of claim 1 , wherein each layer of the first set of layers and each layer of the second set of layers defines a thickness of between about 0.1 micrometers and about 10 micrometers.

9. A system comprising:
a first component comprising an alloy substrate, the first component defining at least a portion of a fir tree recess of a gas turbine engine disk; and
a second component comprising a ceramic or a CMC substrate, the second component defining at least a portion of a turbine blade root of a turbine blade;
wherein at least a portion of the first component, at least a portion of the second component, or both comprises a coating;
wherein the coating comprises a first set of layers and a second set of layers;
wherein at least one layer of the first set of layers is between two layers of the second set of layers;
wherein the at least one layer of the first set of layers comprises one of amorphous silica or amorphous silicon nitride;
wherein the at least two layers of the second set of layers comprises the other of amorphous silica or amorphous silicon nitride;
wherein at least one of amorphous silica or amorphous silicon nitride defines an outer surface of the coating; and
wherein the outer surface of the coating contacts the other of the first component or the second component.

10. The system of claim 9 , wherein the at least one layer of the first set of layers comprises amorphous silica, and wherein the at least two layers of the second set of the layers comprise amorphous silicon nitride.

11. The system of claim 10 , wherein the at least one layer of the first set of layers does not include silicon nitride, and wherein the at least two layers of the second set of layers does not include silica.

12. The system of claim 9 , wherein the at least one layer of the first set of layers comprises amorphous silicon nitride, and wherein the at least two layers of the second set of the layers comprise amorphous silica.

13. The system of claim 12 , wherein the at least one layer of the first set of layers does not include silica, and wherein the at least two layers of the second set of layers does not include silicon nitride.

14. The system of claim 9 , wherein each layer of the first set of layers comprises a first, same composition, and wherein each layer of the second set of layers comprises a second, same composition.

15. The system of claim 9 , wherein each layer of the first set of layers and each layer of the second set of layers defines a thickness of between about 0.1 micrometers and about 10 micrometers.

16. The system of claim 9 , wherein the portion of the first component comprises the coating.

17. The system of claim 9 , wherein the portion of the second component comprises the coating.

18. The system of claim 9 , wherein both the portion of the first component and the portion of the second component comprises the coating.

19. A method comprising:
depositing, using at least one of chemical vapor deposition or plasma-enhanced chemical vapor deposition, a plurality of layers comprising an amorphous microstructure on a surface of a fir tree recess of a gas turbine engine disk;
wherein the plurality of layers comprises a first set of layers and a second set of layers;
wherein at least one layer of the first set of layers is between two layers of the second set of layers;
wherein the at least one layer of the first set of layers comprises one of amorphous silica or amorphous silicon nitride;
wherein the at least two layers of the second set of layers comprises the other of amorphous silica or amorphous silicon nitride;
wherein at least one of amorphous silica or amorphous silicon nitride defines an outer surface of the coating; and
wherein the outer surface of the coating contacts a surface of a turbine blade root of a gas turbine engine blade in the fir tree recess.

Assignees

• Rolls Royce Corp

Inventors

• Shim Sungbo
• Landwehr Sean E

Classifications

• C04B41/52

  Multiple coating or impregnating {multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation} · CPC title

• C23C28/42

  characterized by the composition of the alternating layers · CPC title

• F05D2300/2283

  of silicon · CPC title

• F01D5/282

  Selecting composite materials, e.g. blades with reinforcing filaments · CPC title

• C04B41/89

  for obtaining at least two superposed coatings having different compositions · CPC title