Thermal barrier coating, turbine member, gas turbine, and method for producing thermal barrier coating

Patent metadata

Field	Value
Publication number	US-11946147-B2
Application number	US-201916979971-A
Country	US
Kind code	B2
Filing date	Feb 6, 2019
Priority date	Mar 26, 2018
Publication date	Apr 2, 2024
Grant date	Apr 2, 2024

Abstract

A thermal barrier coating includes a bond coat layer deposited on a substrate, and a ceramic layer deposited on the bond coat layer. The ceramic layer includes a first layer having a porosity of 10% or more and 15% or less, and a second layer having a porosity of 0.5% or more and 9.0% or less and deposited on the first layer.

First claim

The invention claimed is:

1. A thermal barrier coating comprising:
a bond coat layer deposited on a substrate; and
a ceramic layer deposited on the bond coat layer,
the ceramic layer including
a first layer having a porosity of 10% or more and 15% or less, and
a second layer having a porosity of 0.5% or more and less than 9.0%, and having a thickness of 50 μm or more and 100 μm or less, the second layer being deposited on the first layer,

wherein a thickness of the second layer is 10% or more and 100% or less of a thickness of the first layer,
wherein the first layer and the second layer are each composed of ytterbium-stabilized zirconia (“YbSZ”),
wherein the second layer is formed by thermally spraying first spray particles having a particle size distribution with a D10 particle size of 30 μm or more and 40 μm or less, a D50 particle size of 40 μm or more and 60 μm or less, and a D90 particle size of 70 μm or more and 80 μm or less,
wherein the first layer is formed by thermally spraying second spray particles having a particle size distribution with a D10 particle size of 40 μm or more and 50 μm or less, a D50 particle size of 60 μm or more and 70 μm or less, and a D90 particle size of 80 μm or more and 100 μm or less, and
wherein a ratio of the D10 particle size of the first spray particles to the D10 particle size of the second spray particles is larger than a ratio of the D50 particle size of the first spray particles to the D50 particle size of the second spray particles and a ratio of the D90 particle size of the first spray particles to the D90 particle size of the second spray particles.

2. The thermal barrier coating according to claim 1 ,
wherein the first layer and the second layer are thermal spray layers formed by atmospheric plasma spraying.

3. A turbine member comprising the thermal barrier coating according to claim 1 .

4. A gas turbine comprising the turbine member according to claim 3 .

5. The thermal barrier coating according to claim 1 , wherein the porosity of the second layer is 1.0% or more and 7.5% or less.

6. The thermal barrier coating according to claim 1 , wherein the first layer has no vertical cracks extending along a thickness direction of the first layer, and
wherein the porosity of the second layer is 0.5% or more and less than 4.0%.

7. The thermal barrier coating according to claim 1 , wherein the porosity of the second layer is 0.5% or more and less than 3.0%.

Assignees

• Mitsubishi Heavy Ind Ltd

Inventors

• Torigoe Taiji
• Okajima Yoshifumi
• Kudo Daisuke
• Mega Masahiko
• Tanigawa Shuji

Classifications

• C23C4/04 Primary

  characterised by the coating material · CPC title

• B32B15/04

  comprising metal as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a bituminous or tarry layer B32B11/08; next to a water-setting substance layer B32B13/06; next to a glass layer B32B17/061; next to a cellulosic plastic layer B32B23/042)} · CPC title

• C23C4/02 Primary

  Pretreatment of the material to be coated, e.g. for coating on selected surface areas · CPC title

• C23C4/134

  Plasma spraying · CPC title

• C23C28/30

  Coatings combining at least one metallic layer and at least one inorganic non-metallic layer · CPC title