Article and method of making thereof

Patent metadata

Field	Value
Publication number	US-2016115818-A1
Application number	US-201414524072-A
Country	US
Kind code	A1
Filing date	Oct 27, 2014
Priority date	Oct 27, 2014
Publication date	Apr 28, 2016
Grant date	—

Abstract

An article including a substrate and a plurality of coatings disposed on the substrate is presented. The plurality of coatings includes a thermal barrier coating disposed on the substrate; and a protective coating including a calcium-magnesium-aluminum-silicon-oxide (CMAS)-reactive material disposed on the thermal barrier coating. The CMAS-reactive material includes an NZP-type material. The CMAS-reactive material is present in the plurality of coatings in an effective amount to react with a CMAS composition at an operating temperature of the thermal barrier coating, thereby forming a reaction product having one or both of melting temperature and viscosity greater than that of the CMAS composition. A method of making the article and a related turbine engine component are also presented.

First claim

1 . An article, comprising:
a substrate; a plurality of coatings disposed on the substrate, the plurality of coatings comprising:
a thermal barrier coating disposed on the substrate; and
a protective coating comprising a calcium-magnesium-aluminum-silicon-oxide (CMAS)-reactive material disposed on the thermal barrier coating, the CMAS-reactive material comprising an NZP-type material, and
wherein the CMAS-reactive material is present in the plurality of coatings in an effective amount to react with a CMAS composition at an operating temperature of the thermal barrier coating, thereby forming a reaction product having one or both of melting temperature and viscosity greater than that of the CMAS composition.

2 . The article of claim 1 , wherein the CMAS-reactive material comprises:
A 1−x B x Zr 4−y D y (PO 4 ) z wherein A and B are selected from the group consisting of alkaline earth metals and rare earth metals, D is hafnium or titanium; x is a number from 0 to 1; y is a number from 0 to 4; and z is 3 or 6.

3 . The article of claim 1 , wherein the CMAS-reactive material comprises MZr 4 (PO 4 ) 6 , wherein M comprises at least one alkaline earth metal.

4 . The article of claim 1 , wherein the CMAS-reactive material comprises Ca x Sr 1−x Zr 4 (PO 4 ) 6 , wherein x is a number from 0 to 1.

5 . The article of claim 1 , wherein the CMAS-reactive material comprises CaZr 4 (PO 4 ) 6 , SrZr 4 (PO 4 ) 6 , Ca 0.5 Sr 0.5 Zr 4 (PO 4 ) 6 , or combinations thereof.

6 . The article of claim 1 , wherein the protective coating has a thickness in a range from about 25 micron to about 1000 microns.

7 . The article of claim 1 , wherein the CMAS-reactive material is present in the plurality of coatings in an amount in a range from about 10 weight percent to about 75 volume percent.

8 . The article of claim 1 , wherein the CMAS-reactive material is present in the protective coating in an amount in a range from about 10 weight percent to about 100 volume percent.

9 . The article of claim 1 , wherein the thermal barrier coating comprises a ceramic thermal barrier material.

10 . The article of claim 9 , wherein the ceramic thermal barrier material comprises yttria-stabilized zirconia, scandia-stabilized zirconia, calcia-stabilized zirconia, magnesia-stabilized zirconia, or combinations thereof.

11 . The article of claim 1 , wherein the substrate comprises a superalloy material.

12 . A turbine engine component comprising the article of claim 1 .

13 . The turbine engine component of claim 12 , wherein the article is a combustor component, a turbine blade, a shroud, a nozzle, a heat shield, or a vane.

14 . A turbine engine component, comprising:
a plurality of coatings disposed on a superalloy substrate, the plurality of coatings comprising:
a thermal barrier coating disposed on the superalloy substrate; and
a protective coating comprising a calcium-magnesium-aluminum-silicon-oxide (CMAS)-reactive material disposed on the thermal barrier coating, the CMAS-reactive material comprising Ca x Sr 1−x Zr 4 (PO 4 ) 6 , wherein x is an integer in a range from about 0 to about 1, and
wherein the CMAS-reactive material is present in the plurality of coatings in an effective amount to react with a CMAS composition at an operating temperature of the thermal barrier coating, thereby forming a reaction product having one or both of melting temperature and viscosity greater than that of the CMAS composition.

15 . A method of manufacturing an article, comprising:
forming a plurality of coatings by:
disposing a thermal barrier coating on a substrate; and
disposing a protective coating comprising a calcium-magnesium-aluminum- silicon-oxide (CMAS)-reactive material on the thermal barrier coating, the CMAS-reactive material comprising an NZP-type material, and
wherein the CMAS-reactive material is present in the plurality of coatings in an effective amount to react with a CMAS composition at an operating temperature of the thermal barrier coating, thereby forming a reaction product having one or both of melting temperature and viscosity greater than that of the CMAS composition.

16 . The method of claim 15 , wherein the CMAS-reactive material comprises:
A 1−x B x Zr 4−y D y (PO 4 ) z wherein A and B are selected from the group consisting of alkaline earth metals and rare earth metals, D is hafnium or titanium; x is a number from 0 to 1; y is a number from 0 to 4; and z is 3 or 6.

17 . The method of claim 15 , wherein the CMAS-reactive material comprises MZr 4 (PO 4 ) 6 , wherein M comprises at least one alkaline earth metal.

18 . The method of claim 15 , wherein the CMAS-reactive material comprises CaZr 4 (PO 4 ) 6 , SrZr 4 (PO 4 ) 6 , Ca 0.5 Sr 0.5 Zr 4 (PO 4 ) 6 , or combinations thereof.

19 . The method of claim 15 , wherein the thermal barrier coating comprises yttria-stabilized zirconia, scandia-stabilized zirconia, calcia-stabilized zirconia, magnesia-stabilized zirconia, or combinations thereof.

20 . The method of claim 15 , wherein the substrate comprises a superalloy material.

21 . The method of claim 15 , wherein disposing the protective coating on the thermal barrier coating comprises plasma spraying, physical vapor deposition, electron beam physical vapor deposition, sol-gel method, or combinations thereof.

Assignees

• Gen Electric

Inventors

• Porob Digamber Gurudas
• Sivaramakrishnan Shankar
• Venkataramani Venkat Subramaniam
• Nayak Mohandas
• Ramachandran Gopi Chandran

Classifications

• C23C14/08 Primary

  Oxides (C23C14/10 takes precedence) · CPC title

• F01D25/005 Primary

  Selecting particular materials · CPC title

• C23C4/127

  Chemistry & Metallurgy · mapped topic

• C23C14/22

  characterised by the process of coating · CPC title

• C04B35/16 Primary

  based on silicates other than clay {(zircon C04B35/48)} · CPC title