Composite coating layer for ceramic matrix composite substrate

Patent metadata

Field	Value
Publication number	US-11976013-B2
Application number	US-201816138580-A
Country	US
Kind code	B2
Filing date	Sep 21, 2018
Priority date	Sep 27, 2017
Publication date	May 7, 2024
Grant date	May 7, 2024

Abstract

An article may include a substrate including a ceramic matrix composite (CMC); a composite coating layer including a first coating material that includes a rare-earth disilicate and a second coating material that includes at least one of a rare-earth monosilicate, a CMAS-resistant material, or a high-temperature dislocating material, where the second coating material forms a substantially continuous phase in the composite coating layer.

First claim

What is claimed is:

1. An article comprising:
a substrate including a ceramic matrix composite (CMC);
a single composite coating layer formed from a composite feedstock, the composite feedstock comprising:
a first coating material comprising a rare-earth disilicate; and
a second coating material comprising at least one of a calcium-magnesium-alumino-silicate (CMAS)-resistant material or a high-temperature dislocating material,
wherein the second coating material forms a substantially continuous phase in the single composite coating layer, and wherein the single composite coating layer comprises splats of the first coating material evenly distributed throughout the substantially continuous phase of the second coating material and substantially fully encapsulated by the second coating material.

2. The article of claim 1 , wherein the second coating material comprises the CMAS-resistant material, and wherein the CMAS-resistant material comprises at least one of a rare-earth zirconate, a rare-earth oxide, calcia, alumina, or silica.

3. The article of claim 1 , wherein the second coating material comprises the high-temperature dislocating material, and wherein the high-temperature dislocating material comprises at least one of hafnium diboride, zirconium diboride, tantalum nitride, or tantalum carbide.

4. The article of claim 1 , wherein the single composite coating layer is substantially dense having a porosity of less than about 10 vol. %.

5. The article of claim 1 , wherein the single composite coating layer is a porous abradable coating having a porosity of greater than about 10 vol. %.

6. The article of claim 1 , further comprising an environmental barrier coating, wherein the environmental barrier coating is between the substrate and the single composite coating layer.

7. The article of claim 1 , further comprising an overlayer on the single composite coating layer, wherein the single composite coating layer is a compositional transition layer between one of the substrate, a bond coat, or an environmental barrier coating and the overlayer.

8. The article of claim 1 , wherein the single composite coating layer comprises about 5 vol. % to about 50 vol. % of the second coating material.

9. A composite feedstock comprising:
a core comprising a first coating material comprising a rare-earth disilicate; and
an outer layer at least partially encapsulating the core, wherein the outer layer comprises a second coating material comprising at least one of a rare-earth monosilicate, a CMAS-resistant material, or a high-temperature dislocating material, wherein the second coating material at least partially encapsulates respective surfaces of the core.

10. The composite feedstock of claim 9 , wherein the second coating material comprises the CMAS-resistant material, and wherein the CMAS-resistant material comprises at least one of a rare-earth zirconate, a rare-earth oxide, calcia, alumina, or silica.

11. The composite feedstock of claim 9 , wherein the second coating material comprises the high-temperature dislocating material, and wherein the high-temperature dislocating material comprises at least one of hafnium diboride, zirconium diboride, tantalum nitride, or tantalum carbide.

12. The composite feedstock of claim 9 , wherein the composite feedstock is formed by at least one of a physical blending, a sol-gel process, chemical vapor deposition, a cladding process, or refractory precursor coating.

13. An article comprising:
a substrate including a ceramic matrix composite (CMC);
a single composite coating layer comprising:
a first coating material comprising a rare-earth disilicate; and
a second coating material comprising at least one of a calcium-magnesium-alumino-silicate (CMAS)-resistant material or a high-temperature dislocating material,
wherein the second coating material forms a substantially continuous phase in the single composite coating layer, and wherein the single composite coating layer comprises splats of the first coating material evenly distributed throughout the substantially continuous phase of the second coating material and substantially fully encapsulated by the second coating material.

Assignees

• Rolls Royce Corp
• Rolls Royce Plc

Inventors

• Gong Stephanie
• Ndamka Ngunjoh Lawrence
• Gold Matthew R
• Li Li
• Blair Taylor K
• Chang Sunny
• Bolcavage Ann

Classifications

• C04B41/52 Primary

  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

• B05B7/205

  the material to be sprayed being originally a particulate material · CPC title

• C04B35/62807

  Silica or silicates · CPC title

• C04B35/6281

  Alkaline earth metal oxides · CPC title

• C04B35/62813

  Alumina or aluminates · CPC title