Dislocator chemistries for turbine abradable or machinable coating systems

Patent metadata

Field	Value
Publication number	US-12359586-B2
Application number	US-202118013959-A
Country	US
Kind code	B2
Filing date	Jul 1, 2021
Priority date	Jul 3, 2020
Publication date	Jul 15, 2025
Grant date	Jul 15, 2025

Abstract

A coated article (20;60) includes a substrate (22) and a coating (24;62) on the substrate. The coating includes at least a first layer (30). The first layer has: a matrix (50); and a filler (52) at 2.0% to 40% by volume in the first layer. The first layer is selected from alkaline earth or transition metal (M) tungstates (MWO4); alkaline earth molybdates (MMoO4); rare earth (RE) phosphates (REPO4); and combinations thereof.

First claim

What is claimed is:

1. A coated article being a blade outer air seal comprising:
a substrate having a concave inner diameter (ID) surface; and
a coating on the substrate ID surface including at least a first layer,

wherein the first layer comprises:
a matrix; and
a filler at 2.0% to 40% by volume in the first layer selected from:
alkaline earth or transition metal tungstates;
alkaline earth molybdates;
rare earth phosphates; and
combinations thereof,

wherein the filler comprises at 5.0% to 30% by volume in the first layer one or a combination of:
CaWO 4 ;
BaWO 4 ;
BaMoO 4 ; and
SrMoO 4 .

2. The coated article of claim 1 wherein:
the filler is at 5.0% to 30.0% by volume in the first layer.

3. The coated article of claim 1 wherein:
the first layer has 5.0% to 20% porosity.

4. The coated article of claim 1 wherein:
the filler comprises at 5.0% to 30% by volume in the first layer:
CaWO 4 .

5. The coated article of claim 1 wherein:
the matrix comprises at least 50% by volume one or more rare earth, zirconium, or hafnium silicates.

6. The coated article of claim 5 wherein:
the rare earth silicate comprises at least one of yttrium monosilicate, yttrium disilicate, ytterbium monosilicate, and ytterbium disilicate.

7. The coated article of claim 6 further comprising:
an environmental barrier layer between the substrate and the first layer and comprising at least 50% by volume hafnium monosilicate.

8. The coated article of claim 1 wherein:
the substrate is a ceramic matrix composite.

9. The coated article of claim 1 further comprising:
a bond coat comprising a SiOC-BMAS mixture.

10. The coated article of claim 1 further comprising:
an environmental barrier layer between the substrate and the first layer and comprising at least 50% by volume one or more rare earth, zirconium, or hafnium silicates.

11. The coated article of claim 1 wherein:
the filler has a melting point of 1450° C. to 2100° C.

12. The coated article of claim 1 wherein:
the filler has a melting point within 400° C. of melting points of a majority of the matrix by weight.

13. The coated article of claim 1 wherein:
the coating includes a bond coat between the substrate and the first layer.

14. An engine comprising the blade outer air seal of claim 1 and further comprising:
a stage of blades adjacent the ID surface.

15. A method for manufacturing the blade outer air seal of claim 1 , the method comprising:
co-spraying:
a matrix-forming powder;
the filler as a powder; and
a fugitive powder; and

heating to remove the fugitive.

16. The method of claim 15 wherein one or more of:
the method comprises applying a bond coat prior to the spraying;
the spraying is dry powder; and
the matrix-forming powder and the filler powder are pre-blended.

17. A coated article being a blade outer air seal comprising:
a substrate having a concave inner diameter (ID) surface; and
a coating on the substrate ID surface including at least a bond coat and a first layer,

wherein:
the bond coat comprises a SiOC-BMAS mixture; and
the first layer comprises:
a matrix; and
a filler at 2.0% to 40% by volume in the first layer selected from:
alkaline earth or transition metal tungstates;
alkaline earth molybdates;
rare earth phosphates; and
combinations thereof.

18. The coated article of claim 17 wherein:
the coating includes a bond coat between the substrate and the first layer.

19. The coated article of claim 17 wherein:
the substrate is a ceramic matrix composite.

Assignees

• Raytheon Tech Corp
• Rtx Corp

Inventors

• Joost William J
• Bridges Kara J
• Strock Christopher W
• Smyth Imelda P
• Jackson Richard Wesley

Classifications

• F05D2230/90

  Coating; Surface treatment · CPC title

• C23C4/10

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

• C23C4/02

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

• C04B41/522

  Multiple coatings, for one of the coatings of which at least one alternative is described · CPC title

• C04B41/5096

  Silicon (C04B35/573 takes precedence) · CPC title