Gas turbine engine component coating with self-healing barrier layer

Patent metadata

Field	Value
Publication number	US-11149338-B2
Application number	US-201916397092-A
Country	US
Kind code	B2
Filing date	Apr 29, 2019
Priority date	Nov 26, 2013
Publication date	Oct 19, 2021
Grant date	Oct 19, 2021

Abstract

A method of providing a self-healing coating includes providing substrate, applying a layer of an aluminum-containing MAX phase material and another material to the substrate. The method includes exposing the layer to a temperature greater than 2000° F. to form alpha aluminum.

First claim

What is claimed is:

1. A method of providing a self-healing coating, comprising:
providing a substrate;
applying a layer to the substrate, the layer comprising aluminum-containing MAX phase material and another material, wherein the layer provides a MAX phase/metal matrix composite, and wherein the MAX phase material has a particle size pf between 1 and 3 microns; and
exposing the layer to a temperature greater than 2000° F. to form alpha aluminum.

2. The method according to, wherein the substrate is at least one of a nickel based alloy, an iron-nickel based alloy, a cobalt based alloy, a molybdenum based alloy, or a niobium based alloy.

3. The method according to claim 1 , comprising applying a thermal barrier coating to the layer.

4. The method according to claim 3 , wherein the layer is a bond coat, and the other material is at least one of a MCrAlY material (where M is nickel, iron and/or cobalt), an aluminide material, a platinum aluminide material, or a ceramic-based material.

5. The method according to claim 3 , wherein the aluminum-containing MAX phase material has an aluminum ratio of 0.6-1.4 times a stoichiometric aluminum value of the MAX phase material.

6. The method according to claim 3 , wherein the thermal barrier coating includes at least one of an yttria stabilized zirconia material and a gadolinia stabilized zirconia material.

7. The method according to claim 1 , wherein the substrate is a non-oxide ceramic including at least one of a ceramic based substrate or a ceramic matrix composite substrate.

8. The method according to claim 7 , wherein the non-oxide ceramic is SiC or SiN.

9. The method according to claim 7 , wherein the layer is an environmental barrier coating, and the other material is at least one of an alumina-containing ceramic, mullite, zircon, or rare earth silicates.

10. The method according to claim 9 , wherein the aluminum-containing MAX phase material has an aluminum ratio of 0.6-1.4 times a stoichiometric aluminum value of the MAX phase material.

11. The method according to claim 1 , wherein the metal matrix is formed from particles having a particle size of 0.02 and 0.5 microns.

12. The method according to claim 11 , wherein the particles of the metal matrix composite are formed via ball milling.

13. The method according to claim 1 , wherein the applying step comprises co-spraying individual constituent MAX phase and metal matrix composite particles.

Assignees

• United Technologies Corp
• Raytheon Tech Corp

Inventors

• Strock Christopher W
• Amini Shahram

Classifications

• C23C4/06 Primary

  Metallic material · CPC title

• C04B41/5061

  Titanium carbide · CPC title

• F05D2300/2283

  of silicon · CPC title

• F01D5/288

  Protective coatings for blades · CPC title

• C23C4/10

  Oxides, borides, carbides, nitrides or silicides; Mixtures thereof · CPC title