Thermal and environmental barrier coating compositions and methods of deposition

Patent metadata

Field	Value
Publication number	US-11072566-B2
Application number	US-201916543836-A
Country	US
Kind code	B2
Filing date	Aug 19, 2019
Priority date	Jun 30, 2014
Publication date	Jul 27, 2021
Grant date	Jul 27, 2021

Abstract

A coated substrate is provided that comprises: a substrate; and a barrier coating comprising a compound having the formula: Ln2ABO8, where Ln comprises scandium, yttrium, lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, lutetium, or mixtures thereof; A comprises Si, Ti, Ge, Sn, Ce, Hf, Zr, or a combination thereof; and B comprises Mo, W, or a combination thereof. In one embodiment, B comprises Mo. A gas turbine is also provided that comprises the coated substrate described above.

First claim

What is claimed is:

1. A coated component, comprising:
a metal substrate;
a barrier coating comprising a compound having the formula:
Ln 2 AMo x W 1-x O 8

where Ln comprises scandium, yttrium, lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, lutetium, or mixtures thereof;
A comprises Si, Ti, Ge, Sn, Ce, Hf, Zr, or a combination thereof; and
0<x≤0.5.

2. The coated substrate as in claim 1 , wherein Ln is selected from the group consisting of scandium (Sc), yttrium (Y), lanthanum (La), cerium (Ce), praseodymium (Pr), neodymium (Nd), promethium (Pm), samarium (Sm), europium (Eu), gadolinium (Gd), terbium (Tb), dysprosium (Dy), holmium (Ho), erbium (Er), thulium (Tm), ytterbium (Yb), lutetium (Lu), and mixtures thereof.

3. The coated substrate as in claim 1 , wherein Ln comprises yttrium.

4. The coated substrate as in claim 1 , wherein A comprises Si.

5. The coated substrate as in claim 1 , wherein the compound has the formula:
Ln 2 Si y A 1-y Mo x W 1-x O 8
where
0<y≤0.5; and
A is Ti, Ge, Sn, Ce, Hf, Zr, or a combination thereof.

6. The coated substrate as in claim 1 , wherein A comprises Hf and/or Zr.

7. The coated substrate as in claim 1 , wherein the compound comprises a zircon crystal structure or a scheelite structure.

8. The coated substrate as in claim 1 , wherein the metal substrate comprises a nickel-based superalloy, a cobalt-based superalloy, a titanium-based superalloy, or an iron-based superalloy, and wherein the barrier coating defines an external surface of a multi-layer thermal barrier coating system formed on the metal substrate.

9. The coated substrate as in claim 8 , wherein the multi-layer thermal barrier coating system includes an aluminide or silicide bond coat layer on the metal substrate, an oxide layer, and the barrier coating as the outermost layer defining the external surface.

10. The coated substrate as in claim 1 , further comprising an outer coat layer on the barrier coating, and wherein the outer coat layer comprises Ln 2 SiO 5 , where Ln is scandium (Sc), yttrium (Y), lanthanum (La), cerium (Ce), praseodymium (Pr), neodymium (Nd), promethium (Pm), samarium (Sm), europium (Eu), gadolinium (Gd), terbium (Tb), dysprosium (Dy), holmium (Ho), erbium (Er), thulium (Tm), ytterbium (Yb), lutetium (Lu), or mixtures thereof.

11. The coated substrate as in claim 1 , wherein the coated substrate is a component of a gas turbine engine with the barrier coating facing a hot gas stream within the gas turbine engine.

12. A gas turbine engine defining a hot gas stream, the gas turbine engine comprising the coated substrate of claim 1 , wherein the barrier coating faces the hot gas stream within the gas turbine engine.

13. A method of forming a coated substrate, the method comprising:
applying a barrier coating over a substrate; wherein the barrier coating comprises a compound having the formula:
Ln 2 AMo x W 1-x O 8

where Ln comprises scandium, yttrium, lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, lutetium, or mixtures thereof;
A comprises Si, Ti, Ge, Sn, Ce, Hf, Zr, or a combination thereof; and
0<x≤0.5.

14. The method of claim 13 , wherein the barrier coating is applied to form the external exposed surface of the coated substrate.

15. The method of claim 14 , wherein the barrier coating is applied as a pattern of dense abradable ridges.

Assignees

• Gen Electric

Inventors

• Kirby Glen Harold
• Howell Thomas Grandfield

Classifications

• C23C28/345

  with at least one oxide layer · CPC title

• C23C28/3215

  at least one MCrAlX layer · CPC title

• C23C28/321

  with at least one metal alloy layer · CPC title

• C23C30/00

  Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process (C23C26/00, C23C28/00 take precedence) · CPC title

• 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