Coating system including oxide nanoparticles in oxide matrix

Patent metadata

Field	Value
Publication number	US-2016102407-A1
Application number	US-201514879963-A
Country	US
Kind code	A1
Filing date	Oct 9, 2015
Priority date	Oct 9, 2014
Publication date	Apr 14, 2016
Grant date	—

Abstract

In some examples, an article may include a substrate and a coating on the substrate. The substrate may include a superalloy, a ceramic, or a ceramic matrix composite. The coating may include a layer comprising a matrix material and a plurality of nanoparticles. The matrix material may include at least one of silica, zirconia, alumina, titania, or chromia, and the plurality of nanoparticles may include nanoparticles including at least one of yttria, zirconia, alumina, or chromia. In some examples, an average diameter of the nanoparticles is less than about 400 nm.

First claim

1 . An article comprising:
a substrate; a coating on the substrate; wherein the coating comprises a layer comprising a matrix material and a plurality of nanoparticles; wherein the matrix material comprises at least one of silica, zirconia, alumina, titania, or chromia; wherein the plurality of nanoparticles comprises nanoparticles comprising at least one of yttria, zirconia, alumina, or chromia; and wherein an average diameter of the nanoparticles is less than about 400 nm.

2 . The article of claim 1 , wherein the article comprises a gas turbine engine disk, wherein the substrate defines at least one fir tree recess, and wherein the coating is on surfaces of the at least one fir tree recess.

3 . The article of claim 2 , wherein the coating is selectively not on surfaces of the gas turbine disk other than the surfaces of the at least one fir tree recess.

4 . (canceled)

5 . The article of claim 1 , wherein a mixture from which the layer is formed comprises between about 0.7 volume percent and about 13 volume percent of the nanoparticles.

6 . The article of claim 5 , wherein the mixture from which the layer is formed comprises between about 5 volume percent and about 7.5 volume percent of the nanoparticles.

7 . The article of claim 1 , wherein the matrix material comprises silica and zirconia.

8 . The article of claim 1 , wherein the nanoparticles comprise zirconia stabilized with at least one of yttria, alumina, or chromia.

9 . (canceled)

10 . The article of claim 1 , wherein the coating comprises a plurality of layers, each layer of the plurality comprises the matrix material and the plurality of nanoparticles.

11 . (canceled)

12 . The article of claim 10 , wherein the coating comprises between 3 and 10 layers.

13 . (canceled)

14 . The article of claim 1 , wherein the coating defines a thickness of between about 1 micrometers and about 10 micrometers.

15 . (canceled)

16 . A system comprising:
a first component comprising an alloy substrate; a second component comprising a ceramic or a CMC substrate; wherein at least a portion of the first component is in contact with at least a portion of the second component; wherein the at least a portion of the first component, the at least a portion of the second component, or both comprises a coating; wherein the coating comprises a layer comprising a matrix material and a plurality of nanoparticles; wherein the matrix material comprises at least one of silica, zirconia, alumina, titania, or chromia; wherein the plurality of nanoparticles comprises nanoparticles comprising at least one of yttria, zirconia, alumina, or chromia; and wherein an average diameter of the nanoparticles is less than about 400 nm.

17 - 18 . (canceled)

19 . The system of claim 16 , wherein a mixture from which the layer is formed comprises between about 0.7 volume percent and about 13 volume percent of the nanoparticles.

20 . (canceled)

21 . The system of claim 16 , wherein the matrix material comprises silica and zirconia.

22 . The system of claim 16 , wherein the nanoparticles comprise zirconia stabilized with at least one of yttria, alumina, or chromia.

23 . (canceled)

24 . The system of claim 16 , wherein the coating comprises a plurality of layers, each layer of the plurality comprises the matrix material and the plurality of nanoparticles.

25 . (canceled)

26 . The article of claim 24 , wherein the coating comprises between 3 and 10 layers.

27 . (canceled)

28 . The article of claim 16 , wherein the coating defines a thickness of between about 1 micrometers and about 10 micrometers.

29 . The article of claim 16 , wherein the first component comprises a gas turbine engine disk and the second component comprises a gas turbine engine blade.

30 . (canceled)

31 . A method comprising:
applying a layer of a sol comprising an oxide matrix precursor and a plurality of nanoparticles by at least one of air spraying, spin coating, or dip coating, wherein the oxide matrix precursor comprises a precursor of at least one of silica, zirconia, alumina, titania, or chromia, and wherein the plurality of nanoparticles comprise at least one of yttria, zirconia, alumina, or chromia; curing the layer to form a gel; and sintering the layer to form a layer comprising an oxide matrix and the plurality of nanoparticles, wherein the oxide matrix comprises at least one of silica, zirconia, alumina, titania, or chromia.

32 . The method of claim 31 , wherein:
applying the layer of the sol comprises applying a first layer of the sol; curing the layer to form the gel comprises curing the first layer to form a first gel, the method further comprises:
applying a second layer of a sol comprising an oxide matrix precursor and a plurality of nanoparticles by at least one of air spraying, spin coating, or dip coating, wherein the oxide matrix precursor comprises a precursor of at least one of silica, zirconia, alumina, titania, or chromia, and wherein the plurality of nanoparticles comprise at least one of yttria, zirconia, alumina, or chromia;
curing the second layer to form a second gel; and
sintering the layer to form the layer comprising the oxide matrix and the plurality of nanoparticles comprises sintering the first layer and the second layer to form a coating.

33 . (canceled)

Assignees

• Rolls Royce Corp
• Purdue Research Foundation

Inventors

• Shim Sungbo
• Landwehr Sean E
• Gong Stephanie
• Youngblood Jeffrey P
• Trice Rodney

Classifications

• F05D2300/2118

  Zirconium oxides · CPC title

• F05D2300/175

  Superalloys · CPC title

• F01D5/282

  Selecting composite materials, e.g. blades with reinforcing filaments · CPC title

• F01D5/284

  Selection of ceramic materials · CPC title

• C23C18/1216 Primary

  Metal oxides (C23C18/1212 takes precedence) · CPC title