Long life low cost environmental barrier coating for ceramic matrix composites

Patent metadata

Field	Value
Publication number	US-2016362557-A1
Application number	US-201414193467-A
Country	US
Kind code	A1
Filing date	Feb 28, 2014
Priority date	Mar 5, 2013
Publication date	Dec 15, 2016
Grant date	—

Abstract

An environmental barrier coating composition for a ceramic matrix composite is provided that includes a doped rare earth disilicate layer over the ceramic matrix composite. The doped rare earth disilicate includes a disilicate having a composition of RE 2 Si 2 O 7 . The RE is selected from the group consisting of at least one of lutetium, ytterbium, thulium, erbium, holmium, dysprosium, terbium, gadolinium, europium, samarium, promethium, neodymium, praseodymium, cerium, lanthanum, yttrium, and scandium.

First claim

1 . An environmental barrier coating for a ceramic matrix composite, the environmental barrier coating comprising:
a calcium-magnesium aluminosilicate-resistant layer; a doped rare earth disilicate layer; wherein the calcium-magnesium aluminosilicate-resistant layer is located over the doped rare earth disilicate layer; wherein the doped rare earth disilicate layer is located between the calcium-magnesium aluminosilicate-resistant layer and the ceramic matrix composite; wherein the doped rare earth disilicate layer includes a rare earth disilicate that has a composition of RE 2 Si 2 O 7 , wherein RE comprises at least one of lutetium, ytterbium, thulium, erbium, holmium, dysprosium, terbium, gadolinium, europium, samarium, promethium, neodymium, praseodymium, cerium, lanthanum, yttrium, or scandium; wherein the doped rare earth disilicate layer includes a dopant that includes at least one of Al 2 O 3 , an alkali earth oxide, or an alkali oxide; wherein the dopant is present in an amount between about 0.1 weight percent (wt. %) and about 5 wt. %, the balance of the doped rare earth disilicate layer being the rare earth disilicate; wherein the calcium-magnesium aluminosilicate-resistant layer comprises a rare earth oxide, wherein the rare earth oxide has a composition of RE 2 O 3 , wherein RE comprises at least one of lutetium, ytterbium, thulium, erbium, holmium, dysprosium, terbium, gadolinium, europium, samarium, promethium, neodymium, praseodymium, cerium, lanthanum, yttrium, or scandium; wherein the calcium-magnesium aluminosilicate-resistant layer further includes Al 2 O 3 and SiO 2 ; wherein the Al 2 O 3 in the calcium-magnesium aluminosilicate-resistant layer is present in an amount between about 0.1 wt. % and about 5 wt. %; and wherein the SiO 2 in the calcium-magnesium aluminosilicate-resistant layer is present in an amount between about 5 wt. % and about 25 wt. %, with the balance of the CMAS-resistant layer being the rare earth oxide.

2 . The environmental barrier coating of claim 1 , wherein the calcium-magnesium aluminosilicate-resistant layer further comprises at least one of Ta 2 O 5 , TiO 2 , or HfSiO 4 .

3 . The environmental barrier coating of claim 1 , wherein the Al 2 O 3 in the calcium-magnesium aluminosilicate-resistant layer is present in an amount between about 0.5 wt. % and about 3 wt. % and the SiO 2 in the calcium-magnesium aluminosilicate resistant layer is present in an amount between about 5 wt. % and about 20 wt. %.

4 . The environmental barrier coating of claim 1 , wherein the Al 2 O 3 in the calcium-magnesium aluminosilicate-resistant layer is present in an amount between about 0.5 wt. % and about 1 wt. % and the SiO 2 in the calcium-magnesium aluminosilicate-resistant layer is present in an amount between about 10 wt. % and about 20 wt. %.

5 . The environmental barrier coating of claim 1 , wherein the calcium-magnesium aluminosilicate-resistant layer has a thickness of between about 0.5 mils and about 10 mils.

6 . The environmental barrier coating of claim 1 , wherein the doped rare earth disilicate layer comprises Al 2 O 3 and wherein the Al 2 O 3 in the doped rare earth disilicate layer is present in an amount between about 0.5 wt. % and about 3 wt. %

7 . The environmental barrier coating of claim 1 , wherein the doped rare earth disilicate layer comprises the alkali oxide, and wherein the alkali oxide in the doped rare earth disilicate layer is present in an amount between about 0.1 wt. % and about 1 wt. %.

8 . The environmental barrier coating of claim 1 , wherein the doped rare earth disilicate layer has a thickness of between about 0.5 mils to and about 10 mils.

9 . The environmental barrier coating of claim 1 , further comprising an uppermost top coat comprising at least one of a rare earth disilicate layer, a rare earth monosilicate layer, a dual-layered coat including a rare earth monosilicate layer over a rare earth disilicate layer, or a rare earth disilicate and rare earth monosilicate layer; wherein the rare earth disilicate has a composition of RE 2 Si 2 O 7 , wherein RE comprises at least one of lutetium, ytterbium, thulium, erbium, holmium, dysprosium, terbium, gadolinium, europium, samarium, promethium, neodymium, praseodymium, cerium, lanthanum, yttrium, or scandium; and the rare earth monosilicate has a composition of RE 2 SiO 5 , wherein RE comprises at least one of lutetium, ytterbium, thulium, erbium, holmium, dysprosium, terbium, gadolinium, europium, samarium, promethium, neodymium, praseodymium, cerium, lanthanum, yttrium, or scandium.

10 . The environmental barrier coating of claim 1 , wherein the calcium-magnesium aluminosilicate-resistant layer further includes an alkali oxide.

11 . The environmental barrier coating of claim 10 , wherein the alkali oxide in the calcium-magnesium aluminosilicate-resistant layer is present in an amount between about 0.1 wt. % and about 1 wt. %.

12 . The environmental barrier coating of claim 1 , wherein the doped rare earth disilicate layer comprises the alkali earth oxide, and wherein the alkali earth oxide is present in an amount between about 0.1 wt. % and about 1 wt. %.

13 . The environmental barrier coating of claim 1 , further comprising a silicon coat layer, wherein the silicon coat layer is located between the doped rare earth disilicate layer and the ceramic matrix composite.

14 . The environmental barrier coating of claim 2 , wherein the at least one of Ta 2 O 5 , TiO 2 , or HfSiO 4 is present in an amount between about 0.1 wt. % and about 3 wt. %.

Assignees

• Rolls Royce Corp

Inventors

• Lee Kang N

Classifications

• C09D1/02 Primary

  alkali metal silicates · CPC title

• C04B41/87 Primary

  Ceramics · CPC title

• C09D1/00

  Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances · CPC title

• C04B41/89

  for obtaining at least two superposed coatings having different compositions · CPC title

• Y10T428/264

  Up to 3 mils · CPC title