Microstructure geometry for thermal barrier coatings to mitigate CMAS attack

Patent metadata

Field	Value
Publication number	US-11725523-B2
Application number	US-202017085105-A
Country	US
Kind code	B2
Filing date	Oct 30, 2020
Priority date	Jun 8, 2018
Publication date	Aug 15, 2023
Grant date	Aug 15, 2023

Abstract

Thermal barrier coatings and methods to make such coatings present improved resistance to CMAS infiltration. The method for forming a thermal barrier coating includes applying a layer of the thermal barrier coating to a component having a surface, forming a plurality of first channels in the thermal barrier coating, and forming a plurality of second channels in the thermal barrier coating. The first channels extend through a thickness of the thermal barrier coating from an interface with the surface of the component to a free surface opposite the interface. The second channels are disposed between the free surface and the interface and extending lengthwise generally parallel to the free surface of the thermal barrier coating, wherein the thermal barrier coating comprises a material comprising yttrium aluminum garnet (YAG) or yttria stabilized zirconia (YSZ).

First claim

What is claimed is:

1. A method for forming a thermal barrier coating, the method comprising:
applying a layer of the thermal barrier coating to a component having a surface; and
forming a plurality of first channels in the thermal barrier coating, wherein the first channels extend through a thickness of the thermal barrier coating from an interface with the surface of the component and a free surface opposite the interface; and
forming a plurality of second channels disposed between the free surface and the interface and extending lengthwise generally parallel to the free surface of the thermal barrier coating, wherein the thermal barrier coating comprises a material comprising yttrium aluminum garnet (YAG), wherein the plurality of second channels have an average cross-sectional span in a range of about 1 micron to 50 microns.

2. The method of claim 1 , further comprising forming the plurality of second channels to have an average cross-sectional span in a range of about 4 microns to 15 microns.

3. The method of claim 1 , further comprising forming the plurality of second channels by a solution precursor plasma spray process.

4. The method of claim 1 , further comprising forming the plurality of second channels by a thermal spray of powders and suspensions.

5. The method of claim 1 , further comprising forming the plurality of second channels by an electron beam physical vapor deposition process.

6. The method of claim 1 , further comprising forming the plurality of first channels and the plurality of second channels at locations for reactive blocking of calcium magnesium aluminum silicates (CMAS) infiltration.

7. The method of claim 1 , wherein forming the plurality of first channels further comprises spacing the plurality of first channels about 33 microns to 400 microns apart.

8. The method of claim 1 , wherein forming the plurality of second channels further comprises forming openings in at least some of the first channels and connecting some of the second channels to some of the first channels.

9. A method for forming a thermal barrier coating, the method comprising:
applying a layer of the thermal barrier coating to a component having a surface; and
forming a plurality of first channels in the thermal barrier coating, wherein the first channels extend through a thickness of the thermal barrier coating from an interface with the surface of the component and a free surface opposite the interface; and
forming a plurality of second channels disposed between the free surface and the interface and extending lengthwise generally parallel to the free surface of the thermal barrier coating, wherein the thermal barrier coating comprises a material comprising yttria stabilized zirconia (YSZ).

10. The method of claim 9 , wherein the material comprises yttria stabilized zirconia (YSZ).

11. The method of claim 9 , further comprising forming the plurality of second channels to have an average cross-sectional span in a range of about 1 micron to 50 microns.

12. The method of claim 9 , further comprising forming the plurality of second channels to have an average cross-sectional span in a range of about 4 microns to 15 microns.

13. The method of claim 9 , further comprising forming the plurality of second channels by a solution precursor plasma spray process.

14. The method of claim 9 , further comprising forming the plurality of second channels by a thermal spray of powders and suspensions.

15. The method of claim 9 , further comprising forming the plurality of second channels by an electron beam physical vapor deposition process.

16. The method of claim 9 , further comprising forming the plurality of first channels and the plurality of second channels at locations for reactive blocking of calcium magnesium aluminum silicates (CMAS) infiltration.

17. The method of claim 9 , wherein forming the plurality of first channels further comprises forming openings in the free surface of the thermal barrier coating.

18. The method of claim 9 , wherein forming the plurality of second channels further comprises forming openings in at least some of the first channels and connecting some of the second channels to some of the first channels.

19. A method for forming a thermal barrier coating, the method comprising:
applying a layer of the thermal barrier coating to a component having a surface; and
forming a plurality of first channels in the thermal barrier coating, wherein the first channels extend through a thickness of the thermal barrier coating from an interface with the surface of the component and a free surface opposite the interface; and
forming a plurality of second channels by a thermal spray of powders and suspensions, the plurality of second channels disposed between the free surface and the interface and extending lengthwise generally parallel to the free surface of the thermal barrier coating, wherein the thermal barrier coating comprises a material comprising yttrium aluminum garnet (YAG).

Assignees

• Univ Connecticut

Inventors

• Jordan Eric
• Kumar Rishi

Classifications

• F01D5/288 Primary

  Protective coatings for blades · CPC title

• C23C4/134

  Plasma spraying · CPC title

• C23C14/28

  by wave energy or particle radiation (C23C14/32 - C23C14/48 take precedence) · CPC title

• F05D2220/32

  in gas turbines · CPC title

• F05D2230/90

  Coating; Surface treatment · CPC title