Methods of forming an article using electrophoretic deposition, and related article

Patent metadata

Field	Value
Publication number	US-2016160374-A1
Application number	US-201414563257-A
Country	US
Kind code	A1
Filing date	Dec 8, 2014
Priority date	Dec 8, 2014
Publication date	Jun 9, 2016
Grant date	—

Abstract

In one example of the present technology, a method for forming an article includes disposing an electrically conductive coating on a substrate. The method further includes disposing a layer stack on the electrically conductive coating by (i) disposing a first barrier coating by electrophoretic deposition; (ii) heat treating the first barrier coating; (iii) disposing an electrically conductive layer on the first barrier coating; and (iv) optionally repeating steps (i) to (iii). The method further includes disposing a second barrier coating on an outermost electrically conductive layer in the layer stack by electrophoretic deposition; and heat treating the second barrier coating.

First claim

What is claimed is:

1 . A method for forming an article, comprising:
(a) disposing an electrically conductive coating on a substrate; (b) disposing a layer stack on the electrically conductive coating by:
(i) disposing a first barrier coating by electrophoretic deposition;
(ii) heat treating the first barrier coating;
(iii) disposing an electrically conductive layer on the first barrier coating; and
(iv) optionally repeating steps (i) to (iii);
(c) disposing a second barrier coating on an outermost electrically conductive layer in the layer stack by electrophoretic deposition; and (d) heat treating the second barrier coating.

2 . The method of claim 1 , wherein the first barrier coating and the second barrier coating undergo at least partial densification during the heat treatment steps.

3 . The method of claim 1 , wherein the electrically conductive layer is disposed by electroless plating, spraying, dip coating, physical vapor deposition, chemical vapor deposition, or combinations thereof.

4 . The method of claim 1 , wherein the electrically conductive layer comprises a metal, an intermetallic, a metalloid, carbon, a conductive polymer, or combinations thereof.

5 . The method of claim 4 , wherein the electrically conductive layer comprises gold, silver, nickel, a conductive polymer, carbon, palladium, platinum, copper, iron, cobalt, boron, or combinations thereof.

6 . The method of claim 4 , wherein the electrically conductive layer comprises electroless-plated gold platinum, palladium, copper, nickel, cobalt, iron, boron, or combinations thereof.

7 . The method of claim 1 , wherein the first barrier coating comprises a rare earth silicate.

8 . The method of claim 7 , wherein the first barrier coating comprises a rare earth disilicate selected from the group consisting of ytterbium disilicate, yttrium disilicate, and combinations thereof.

9 . The method of claim 1 , wherein the second barrier coating comprises a rare earth silicate.

10 . The method of claim 9 , wherein the second barrier coating comprises a rare earth monosilicate selected from the group consisting of yttrium monosilicate, ytterbium monosilicate, and combinations thereof.

11 . The method of claim 1 , wherein the electrically conductive coating disposed on the substrate comprises silicon, metal silicide, silicon carbide, or combinations thereof.

12 . The method of claim 1 , wherein the electrically conductive coating disposed on the substrate further functions as a bond coating between the substrate and the first barrier coating.

13 . An article formed by the method of claim 1 .

14 . A turbine engine component comprising the article of claim 13 .

15 . A method for forming an article, comprising:
(a) disposing an electrically conductive coating on a substrate; (b) disposing a layer stack on the electrically conductive coating by:
(i) disposing a first barrier coating by electrophoretic deposition, wherein the first barrier coating comprises a rare earth disilicate;
(ii) heat treating the first barrier coating;
(iii) disposing an electrically conductive layer on the first barrier coating; and
(iv) optionally repeating steps (i) to (iii);
(c) disposing a second barrier coating on an outermost electrically conductive layer in the layer stack by electrophoretic deposition, wherein the second barrier coating comprises a rare earth monosilicate; and (d) heat treating the second barrier coating.

16 . The method of claim 15 , wherein the first barrier coating and the second barrier coating undergo at least partial densification during the heat treatment steps.

17 . The method of claim 15 , wherein the electrically conductive layer is disposed by electroless plating, spraying, dip coating, physical vapor deposition, chemical vapor deposition, or combinations thereof.

18 . The method of claim 15 , wherein the electrically conductive layer comprises a metal, an intermetallic, a metalloid, carbon, a conductive polymer, or combinations thereof.

19 . The method of claim 18 , wherein the electrically conductive layer comprises gold, silver, nickel, a conductive polymer, carbon, palladium, platinum, copper, iron, cobalt, boron, or combinations thereof.

20 . The method of claim 15 , wherein the electrically conductive coating comprises silicon, metal silicide, silicon carbide, or combinations thereof.

Assignees

• Gen Electric

Inventors

• Antolino Nicholas Edward
• Lipkin Don Mark
• Rutkowski Stephen Francis

Classifications

• C25D13/22 Primary

  Servicing or operating {apparatus or multistep processes} · CPC title

• C25D13/02

  with inorganic material · CPC title

• C25D13/12 Primary

  characterised by the article coated · CPC title

• F01D5/288

  Protective coatings for blades · CPC title

• C04B41/52

  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