Thermal barrier coating with reduced edge crack initiation stress and high insulating factor

Patent metadata

Field	Value
Publication number	US-2021348562-A1
Application number	US-202016870449-A
Country	US
Kind code	A1
Filing date	May 8, 2020
Priority date	May 8, 2020
Publication date	Nov 11, 2021
Grant date	—

Abstract

A thermal barrier coating disposed on a substrate comprising a plurality of surface features formed on the substrate proximate an inner side of the substrate, each of the plurality of surface features comprising a metallic column having a top with rounded edges; a dense layer disposed in a valley located between each of the plurality of surface features, and the dense layer disposed on the top and covering the rounded edges; a thermally insulating topcoat disposed over the plurality of surface features.

First claim

What is claimed is:

1 . A thermal barrier coating disposed on a substrate comprising:
a plurality of surface features formed on said substrate proximate an inner side of said substrate, each of said plurality of surface features comprising a metallic column having a top with rounded edges; a dense ceramic layer disposed in a valley located between each of said plurality of surface features, and said dense ceramic layer disposed on said top and covering said rounded edges; a thermally insulating topcoat disposed over the plurality of surface features.

2 . The thermal barrier coating according to claim 1 , wherein said dense ceramic layer comprises a 5-10 mil thick YSZ coating.

3 . The thermal barrier coating according to claim 1 , wherein the metallic column top of each of the plurality of surface features comprises a radius from 1 to 5 times a thickness of the dense ceramic layer thickness.

4 . The thermal barrier coating according to claim 1 , further comprising:
a bond coat disposed between the dense ceramic layer and the substrate.

5 . The thermal barrier coating according to claim 4 , wherein said bond coat comprises a thickness of from 1-15 mills of MCrAlY.

6 . The thermal barrier coating according to claim 1 , wherein said thermally insulating topcoat comprises at least one of:
a porous material disposed over the dense ceramic layer between said plurality of surface features, and the porous material disposed over the dense ceramic layer at the top of the metallic column.

7 . The thermal barrier coating according to claim 6 , wherein said thermally insulating topcoat covers greater than 50 percent of a total area of the thermal barrier coating.

8 . A turbine engine component comprising:
a compressor section; a combustor fluidly connected with the compressor section; and a turbine section downstream from the combustor, the turbine section having a seal that includes a substrate extending between two circumferential sides, a leading edge, a trailing edge, an inner side for resisting hot engine exhaust gases from the combustor, and an outer side, a plurality of surface features formed in said substrate protruding from said substrate away from said outer side, said plurality of surface features comprising a metallic column structure having a rounded edge proximate a top of said column, a dense layer disposed in a valley between said plurality of surface features and disposed on said top of said column, a thermally insulating topcoat disposed over the plurality of surface features and disposed over the dense layer.

9 . The component according to claim 8 , wherein the surface features are configured as a pattern of rounded columns that define a cell structure therebetween; wherein the pattern provides the metallic column structure a spacing that results in the surface features making up less than or equal to fifty percent of a coating area.

10 . The component according to claim 9 , wherein said surface features comprise rounded edges at both the top and a bottom of the metallic column structure configured to reduce stress in the dense layer at both the top and a bottom of the metallic column structure of said plurality of surface features.

11 . The component according to claim 10 , further comprising:
a bond coat disposed between the dense layer and the substrate.

12 . The component according to claim 8 , wherein said thermally insulating topcoat comprises a porous material disposed over the dense layer between said plurality of surface features and disposed over the dense layer at the top of the metallic column structure.

13 . The component according to claim 8 , wherein said plurality of surface features include an aspect ratio of 0.5-2.5 height to width.

14 . A process of interrupting spallation for geometrically segmented coatings on a gas turbine engine component comprising:
said gas turbine engine component having a surface; forming a plurality of surface features protruding from said surface, said plurality of surface features comprising a metallic column structure having a rounded edge proximate a top of said column; disposing a dense ceramic layer on said surface in a valley between said plurality of surface features and disposing said dense ceramic layer on said rounded edge and said top of said column; and disposing a thermally insulating topcoat over said plurality of surface features.

15 . The process of claim 14 , further comprising:
disposing a bond coat layer between the surface and said dense ceramic layer.

16 . The process of claim 14 , further comprising:
configuring said plurality of surface features as a pattern of rounded columns that define a cell structure therebetween; wherein the pattern provides the metallic column structure a spacing that results in the surface features making up less than or equal to fifty percent of a coating area.

17 . The process of claim 14 , wherein said plurality of surface features include an aspect ratio of 0.5-2.5 height to width.

18 . The process of claim 14 , further comprising:
reducing stress in the dense ceramic layer at both the top and a bottom of the metallic column structure of said plurality of surface features.

19 . The process of claim 14 , wherein said thermally insulating topcoat comprises at least one of:
a porous material disposed over the dense ceramic layer between said plurality of surface features, and the porous material disposed over the dense ceramic layer at the top of the metallic column.

20 . The process of claim 19 , wherein the metallic column top of each of the plurality of surface features comprises a radius from 1 to 5 times a thickness of the thermally insulating topcoat thickness.

Assignees

• Raytheon Tech Corp

Inventors

• Strock Christopher W

Classifications

• C23C28/3215

  at least one MCrAlX layer · CPC title

• F05D2300/15

  Rare earth metals, i.e. Sc, Y, lanthanides · CPC title

• F05D2300/5023

  Thermal capacity · CPC title

• F05D2220/32

  in gas turbines · CPC title

• F01D11/12

  using a rubstrip, e.g. erodible. deformable or resiliently-biased part · CPC title