Thermal Barrier Coating with Lower Thermal Conductivity

Patent metadata

Field	Value
Publication number	US-2016333455-A1
Application number	US-201615223496-A
Country	US
Kind code	A1
Filing date	Jul 29, 2016
Priority date	Mar 6, 2009
Publication date	Nov 17, 2016
Grant date	—

Abstract

A thermal barrier coating includes a microstructure and a composition including: a ceramic based compound comprising gadolinia and zirconia. The coating includes a nano-structure having a porosity of at most 50% by volume of the coating.

First claim

What is claimed is:

1 . A thermal barrier coating for application to a substrate comprising:
a ceramic based compound comprising gadolinia and zirconia; and nano-structured porous inclusions in the compound, wherein the coating comprises a nano-structure having a porosity of at most 50% by volume.

2 . The coating of claim 1 , wherein said ceramic based compound consists essentially of GSZ.

3 . The coating of claim 1 , wherein the compound comprises zirconia with between about 5 to 60 mol. % gadolinia.

4 . The coating of claim 1 , wherein the porosity is at most 20% by volume of the coating.

5 . The coating of claim 1 , wherein the gadolinia and zirconia reacts with at least one silicate for form a reaction product.

6 . The coating of claim 1 , wherein the substrate is a surface of at least one of an airfoil, a seal, and a combustion chamber liner of a gas turbine engine.

7 . The coating of claim 6 , wherein the substrate includes at least the airfoil of a turbine vane of a gas turbine engine.

8 . The coating of claim 1 , wherein the substrate is composed of a material selected from the group consisting of nickel based alloy, cobalt based alloy, steel alloy, and molybdenum based alloy.

9 . The coating of claim 1 , further comprising a metallic bond coat disposed between the substrate and the thermal barrier coating.

10 . The coating of claim 9 , wherein the metallic bond coat has a thickness in the range of from about 0.5 to about 20 mils.

11 . The coating of claim 10 , wherein the metallic bond coat has a thickness in the range of from about 0.5 to about 10 mils.

12 . The coating of claim 1 , wherein the thermal barrier coating has a thickness in the range of from about 1.0 to about 50 mils.

13 . The coating of claim 12 , wherein the thermal barrier coating has a thickness in the range of from about 1.0 to about 15 mils.

14 . A process for applying a thermal barrier coating onto a substrate, the process comprising:
providing a particulate ceramic based compound comprising gadolinium zirconate; grading the particulate ceramic based compound to produce graded particles comprising nanosized particles, wherein the nanosized particles have an average diameter from 2nm to 400 nm, collecting the graded particles; at least partially melting an outer surface of a majority of the graded particles; and applying the partially melted graded particles onto the substrate to produce the coating comprising a porosity of at most 50% by volume of the coating.

15 . The process of claim 14 , further comprising applying the thermal barrier coating to a thickness in the range of from about 1.0 to about 50 mils.

16 . The process of claim 14 , wherein the applying is of partially melted agglomerated graded particles.

Assignees

• Pratt & Whitney Canada

Inventors

• Larose Joel

Classifications

• C23C4/134 Primary

  Plasma spraying · CPC title

• Y10T428/24997

  Of metal-containing material · CPC title

• F05D2300/2118

  Zirconium oxides · CPC title

• C23C4/11

  Oxides · CPC title

• C23C4/131

  Wire arc spraying · CPC title