Methods of forming a multilayer thermal barrier coating system

Patent metadata

Field	Value
Publication number	US-10378096-B2
Application number	US-201715487724-A
Country	US
Kind code	B2
Filing date	Apr 14, 2017
Priority date	Apr 28, 2016
Publication date	Aug 13, 2019
Grant date	Aug 13, 2019

Abstract

Methods are provided for forming a thermal barrier coating system on a surface of a component. The method can include introducing the component into a coating chamber, where a first ceramic source material and a second ceramic source material are positioned within the coating chamber of a physical vapor deposition apparatus. An energy source is directed onto the first ceramic source material to vaporize the first ceramic source material to deposit a first layer on the component. The energy source is alternated between the first ceramic source material and the second ceramic source material to form a blended layer on the first layer.

First claim

What is claimed is:

1. A method of forming a thermal barrier coating system on a surface of a component, the thermal barrier coating system comprising a thermal barrier coating that has columnar grains, the method comprising:
introducing the component into a coating chamber, wherein a first ceramic source material and a second ceramic source material are positioned within the coating chamber of a physical vapor deposition apparatus;
directing an energy source in the form of a laser onto the first ceramic source material to vaporize the first ceramic source material to deposit a first layer on the component; and
alternating the energy source between the first ceramic source material and the second ceramic source material to form a blended layer on the first layer, wherein the blended layer is formed from vapors from the first ceramic source material and the second ceramic source material, wherein the first ceramic source material and the second ceramic source material are different materials.

2. The method of claim 1 , wherein the laser has a first power when directed toward the first ceramic source material, and wherein the laser has a second power when alternating the laser between the first ceramic source material and the second ceramic source material.

3. The method of claim 2 , wherein the second power is higher than the first power.

4. The method of claim 1 , wherein the first ceramic source material comprises yttria-stabilized zirconia.

5. The method of claim 1 , wherein the second ceramic source material is configured to increase the resistance of the thermal barrier coating to infiltration by molten CMAS.

6. The method of claim 1 , wherein the second ceramic source material provides improved impact resistance to the component.

7. The method of claim 1 , further comprising:
depositing a bond coat on the surface of the component prior to forming the first layer.

8. A method of forming a thermal barrier coating system on a surface of a component, the thermal barrier coating system comprising a thermal barrier coating that has columnar grains, the method comprising:
introducing the component into a coating chamber, wherein a first ceramic source material and a second ceramic source material are positioned within the coating chamber of a physical vapor deposition apparatus;
directing an energy source in the form of a laser onto the first ceramic source material to vaporize the first ceramic source material to deposit a first layer on the component;
alternating the energy source between the first ceramic source material and the second ceramic source material to form a blended layer on the first layer, wherein the blended layer is formed from vapors from the first ceramic source material and the second ceramic source material; and
directing the laser onto the second ceramic source material to vaporize the second ceramic source material to deposit a second layer on the first layer.

Assignees

• Gen Electric

Inventors

• Clark Michael David
• Konitzer Douglas Gerard

Classifications

• C23C28/3455

  with a refractory ceramic layer, e.g. refractory metal oxide, ZrO2, rare earth oxides or a thermal barrier system comprising at least one refractory oxide layer · CPC title

• C23C28/00

  Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D · CPC title

• C23C28/321

  with at least one metal alloy layer · CPC title

• C23C14/06

  characterised by the coating material ({C23C14/0021} , C23C14/04 take precedence) · CPC title

• C23C28/3215

  at least one MCrAlX layer · CPC title