Hybrid airfoil coatings

Patent metadata

Field	Value
Publication number	US-11739650-B2
Application number	US-201916286047-A
Country	US
Kind code	B2
Filing date	Feb 26, 2019
Priority date	Feb 27, 2018
Publication date	Aug 29, 2023
Grant date	Aug 29, 2023

Abstract

The disclosure describes articles and techniques that include an airfoil having a hybrid coating system to provide improved particle impact resistance and improve CMAS attack resistance on the pressure side of the airfoil and improved thermal load protection on the suction side of the airfoil. An example article for a gas turbine engine may include a substrate, and a hybrid environmental barrier coating (EBC) including a relatively dense EBC layer on a first portion of the substrate and a relatively porous EBC layer on a second portion of the substrate, where the first portion of the substrate is different from the second portion of the substrate, and wherein at least a portion of the relatively porous EBC layer overlaps at least a portion of the relatively dense EBC layer in an overlap region.

First claim

What is claimed is:

1. A turbine blade for a gas turbine engine, the turbine blade comprising:
a substrate comprising an airfoil having a leading edge, a suction side and a pressure side, each of the suction side and the pressure side extending from a stagnation point toward a trailing edge of the airfoil; and
a hybrid environmental barrier coating (EBC) on the substrate, the hybrid EBC comprising:
a first EBC layer having a first porosity; and
a second EBC layer having a second porosity, wherein the second porosity is greater than the first porosity, wherein at least a portion of the second EBC layer overlaps at least a portion of the first EBC layer in an overlap region between the stagnation point and an aerodynamic throat of the airfoil, wherein the first EBC layer extends from the overlap region, over the leading edge over the airfoil and along the pressure side, and wherein the second EBC layer extends from the overlap region along the suction side.

2. The turbine blade of claim 1 , wherein the hybrid EBC further comprises a bond layer between the substrate and at least one of the first EBC layer or the second EBC layer.

3. The gas turbine blade of claim 2 , further comprising an additional coating layer,
wherein at least one of the first EBC layer or the second EBC layer is disposed between the substrate and the additional coating layer.

4. The turbine blade of claim 1 , wherein a thickness of the hybrid EBC is substantially constant in the overlap region.

5. The turbine blade of claim 1 , wherein a width of the overlap region is between 0.3 millimeters and 13.0 millimeters.

6. The turbine blade of claim 1 , wherein the first EBC layer and the second EBC layer comprise the same EBC coating material.

7. A turbine blade for a gas turbine engine comprising:
an airfoil, wherein the airfoil comprises a leading edge, a suction side and a pressure side;
a hybrid environmental barrier coating (EBC) on the airfoil, the hybrid EBC comprising:
a first EBC layer defining a first porosity on at least a portion of the pressure side and extending over the leading edge onto at least a portion of the suction side; and
a second EBC layer defining a second porosity on at least a portion of the suction side, wherein at least a portion of the second EBC layer overlaps at least a portion of the first EBC layer in an overlap region, wherein the overlap region is between a point of stagnation and an aerodynamic throat of the airfoil, and
wherein the first porosity is less than the second porosity.

8. The turbine blade of claim 7 , further comprising a bond layer between the airfoil and at least one of the first EBC layer and the second EBC layer.

9. The gas turbine blade of claim 8 , wherein a bond coat is disposed between the hybrid EBC and the airfoil, and
the hybrid EBC is disposed between the airfoil and an additional coating layer.

10. The turbine blade of claim 7 , wherein a thickness of the hybrid EBC in the overlap region is substantially constant.

11. The turbine blade of claim 7 , wherein a width of the overlap region is between 0.3 millimeters and 13.0 millimeters.

12. The turbine blade of claim 7 , wherein the first EBC layer and the second EBC layer comprise the same EBC coating material.

Assignees

• Rolls Royce Corp
• Rolls Royce Nam Tech Inc

Inventors

• Shi Jun
• Weaver John Alan
• Li Li
• Bolcavage Ann
• Gold Matthew R

Classifications

• Y02T50/60

  Efficient propulsion technologies, e.g. for aircraft · CPC title

• F01D5/288 Primary

  Protective coatings for blades · 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

• C04B41/89

  for obtaining at least two superposed coatings having different compositions · CPC title

• F01D5/147

  Construction, i.e. structural features, e.g. of weight-saving hollow blades (F01D5/148, F01D5/16 and F01D5/20 take precedence; blade shape F01D5/141; blades with cooling or heating channels or cavities F01D5/18; heating, heat-insulating or cooling means on blades F01D5/18) · CPC title