Compositions for erosion and molten dust resistant environmental barrier coatings

Patent metadata

Field	Value
Publication number	US-10822285-B2
Application number	US-201715689382-A
Country	US
Kind code	B2
Filing date	Aug 29, 2017
Priority date	Aug 29, 2017
Publication date	Nov 3, 2020
Grant date	Nov 3, 2020

Abstract

Coating systems are provided for positioning on a surface of a substrate, along with the resulting coated components and methods of their formation. The coating system may include a layer having a compound of the formula: A 1−b B b Z 1−d D d MO 6 where: A is Al, Ga, In, Sc, Y, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Fe, Cr, Co, Mn, Bi, or a mixture thereof; b is 0 to about 0.5; Z is Hf, Ti, or a mixture thereof; D is Zr, Ce, Ge, Si, or a mixture thereof; d is 0 to about 0.5; and M is Ta, Nb, or a mixture thereof.

First claim

What is claimed is:

1. A coating system on a surface of a substrate, the coating system comprising:
a layer of a compound having the formula:
A 1−b B b Z 1−d D d MO 6

where:
A is Al, Ga, In, Sc, Y, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Fe, Cr, Co, Mn, Bi, or a mixture thereof;
b is 0 to 0.5;
Z is Hf, Ti, or a mixture thereof;
D is Zr, Ce, Ge, Si, or a mixture thereof;
d is 0 to 0.5; and
M is Ta, Nb, or a mixture thereof;

wherein the substrate is a ceramic matrix composite.

2. The coating system as in claim 1 , further comprising:
a bond coat on the surface of the substrate and positioned between the substrate and the layer.

3. The coating system as in claim 2 , wherein the bond coating comprises silicon metal or a silicide, and further wherein a transition layer is positioned between the bond coat and the layer.

4. The coating system as in claim 1 , wherein the layer has a thickness of 1 μm to 1 mm.

5. The coating system as in claim 1 , wherein the layer is an external layer of the coating system.

6. The coating system of claim 1 , wherein b is 0, and wherein A consists of an element selected from the group consisting of Al, Ga, In, Sc, Y, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Fe, Cr, Co, Mn, and Bi.

7. The coating system of claim 1 , wherein b is 0, and wherein A consists of an element selected from the group consisting of Al, Er, and Y.

8. The coating system of claim 1 , wherein b is greater than 0 to 0.5.

9. The coating system of claim 1 , wherein d is 0.

10. The coating system of claim 1 , wherein Z includes Hf.

11. The coating system of claim 1 , wherein M includes Ta.

12. The coating system of claim 1 , wherein A includes Al in combination with another element and wherein Z includes Hf such that the compound has the formula:
Al x A′ a B b Ln 1−x−a−b Hf 1−t−d Ti t D d MO 6

where:
x is 0.01 to 0.99 such that Al is present in the compound;
A′ is Ga, In, Sc, Y, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Fe, Cr, Co, Mn, Bi, or a mixture thereof;
a is 0 to 0.99;
b is 0 to 0.5, with 1−x−a−b being greater than 0 to 0.99 such that Ln is present in the compound;
Ln is Sc, Y, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, ytterbium Yb, Lu, or a mixture thereof, and wherein Ln is different than A in terms of composition;
t is 0 to 0.99;
D is Zr, Ce, Ge, Si, or a mixture thereof;
d is 0 to 0.5;
the sum oft and d is less than 1 such that Hf is present in the compound; and
M is Ta, Nb, or a mixture thereof.

13. The coating system of claim 12 , where b is 0, and where t is 0.

14. The coating system of claim 13 , where d is 0, and where M is Ta.

15. The coating system of claim 1 , wherein A includes Al and Ga in combination with another element and wherein Z includes Hf such that the compound has the formula:
Al x Ga y B b Ln 1−x−y−b Hf 1−t−d Ti t D d MO 6

where:
x is 0.01 to 0.99 such that Al is present in the compound;
y is 0.01 to 0.99 such that Ga is present in the compound;
b is 0 to 0.5, with 1−x−y−b being greater than 0 to 0.99 such that Ln is present in the compound;
Ln is Sc, Y, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, ytterbium Yb, Lu, or a mixture thereof, and wherein Ln is different than A in terms of composition;
t is 0 to 0.99;
D is Zr, Ce, Ge, Si, or a mixture thereof;
d is 0 to 0.5;
the sum oft and d is less than 1 such that Hf is present in the compound; and
M is Ta, Nb, or a mixture thereof.

16. A coated component, comprising:
a ceramic substrate having a surface; and
a coating system on the surface of the ceramic substrate, wherein the coating system comprises a layer of a compound having the formula:
A 1−b B b Z 1−d D d MO 6

where:
A is Al, Ga, In, Sc, Y, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Fe, Cr, Co, Mn, Bi, or a mixture thereof;
b is 0 to 0.5;
Z is Hf, Ti, or a mixture thereof;
D is Zr, Ce, Ge, Si, or a mixture thereof;
d is 0 to 0.5; and
M is Ta, Nb, or a mixture thereof;

wherein the ceramic substrate is a ceramic matrix composite.

17. The coated component as in claim 16 , wherein the layer has a thickness of about 1 μm to 1 mm, and further wherein the layer is an external layer of the coating system.

18. The coated component as in claim 16 , where b is 0, d is 0, Z is Hf, and M is Ta.

19. The coated component as in claim 16 , wherein A includes Al in combination with another element and wherein Z includes Hf such that the compound has the formula:
Al x A′ a B b Ln 1−x−a−b Hf 1−t−d Ti t D d MO 6

where:
x is 0.01 to 0.99 such that Al is present in the compound;
A′ is Ga, In, Sc, Y, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Fe, Cr, Co, Mn, Bi, or a mixture thereof;
a is 0 to 0.99;
b is 0 to 0.5, with 1−x−a−b being greater than 0 to 0.99 such that Ln is present in the compound;
Ln is Sc, Y, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, ytterbium Yb, Lu, or a mixture thereof, and wherein Ln is different than A in terms of composition;
t is 0 to 0.99;
D is Zr, Ce, Ge, Si, or a mixture thereof;
d is 0 to 0.5;
the sum oft and d is less than 1 such that Hf is present in the compound; and
M is Ta, Nb, or a mixture thereof.

20. A method of forming the coating system of claim 1 , the method comprising:
applying a slurry onto the surface of the substrate, wherein the slurry comprises the compound dispersed within a substrate.

Assignees

• Gen Electric

Inventors

• Kirby Glen Harold

Classifications

• C23C28/32

  including at least one pure metallic layer · CPC title

• F01D5/288

  Protective coatings for blades · CPC title

• C04B35/495 Primary

  based on vanadium, niobium, tantalum, molybdenum or tungsten oxides or solid solutions thereof with other oxides, e.g. vanadates, niobates, tantalates, molybdates or tungstates · CPC title

• C04B2235/3232

  Titanium oxides or titanates, e.g. rutile or anatase · CPC title

• 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