Material systems for repair of thermal barrier coating and methods thereof

Patent metadata

Field	Value
Publication number	US-2024084703-A1
Application number	US-202318239532-A
Country	US
Kind code	A1
Filing date	Aug 29, 2023
Priority date	Sep 8, 2022
Publication date	Mar 14, 2024
Grant date	—

Abstract

Methods for repairing a thermal barrier coating deposited on a component with localized spallation of the thermal barrier coating includes depositing a primer slurry on a thermally grown oxide of the component exposed by the localized spallation, depositing a ceramic slurry on the primer slurry, and heating the primer slurry and the ceramic slurry. The primer slurry includes a primer that includes at least one of a metal and a metal oxide. The ceramic slurry includes a ceramic material, a ceramic slurry binder material, and a ceramic slurry fluid carrier. Heating the primer slurry and the ceramic slurry forms a first chemical bond between the primer and the thermally grown oxide and a second chemical bond between the primer and the ceramic material.

First claim

What is claimed is:

1 . A method for repairing a thermal barrier coating deposited on a component with localized spallation of the thermal barrier coating, comprising:
depositing a primer slurry on a thermally grown oxide of the component exposed by the localized spallation, the primer slurry comprising a primer that includes at least one of a metal and a metal oxide; depositing a ceramic slurry on the primer slurry, the ceramic slurry comprising a ceramic material, a ceramic slurry binder material, and a ceramic slurry fluid carrier; and heating the primer slurry and the ceramic slurry to form a first chemical bond between the primer and the thermally grown oxide and a second chemical bond between the primer and the ceramic material.

2 . The method of claim 1 , wherein the ceramic material comprises yttria-stabilized zirconia particles.

3 . The method of claim 1 , wherein the ceramic slurry binder material is silicone based.

4 . The method of claim 1 , wherein the primer includes an organometallic precursor-derived metal oxide.

5 . The method of claim 1 , wherein the primer comprises Si.

6 . The method of claim 1 , wherein the primer comprises SiO 2 .

7 . The method of claim 1 , wherein the primer comprises MgO.

8 . The method of claim 1 , wherein the primer comprises Al.

9 . The method of claim 1 , wherein the primer comprises Cr 2 O 3 .

10 . The method of claim 1 , wherein the primer comprises Al 2 O 3 .

11 . The method of claim 1 , wherein the primer slurry comprises a primer slurry binder material having a different composition than the ceramic slurry binder material.

12 . The method of claim 1 , wherein the primer slurry comprises a first primer slurry and a second primer slurry having a different composition than the first primer slurry.

13 . The method of claim 12 , wherein the first primer slurry has a higher concentration of primer than the second primer slurry.

14 . The method of claim 1 , wherein:
the heating the primer slurry and the ceramic slurry forms a primer layer comprising the primer and a repair thermal barrier coating comprising the ceramic material; the first chemical bond bonds the primer layer to the thermally grown oxide and the second chemical bond bonds the primer layer to the repair thermal barrier coating; and the primer layer has a thickness between 0.1 and 4 mils.

15 . The method of claim 14 , wherein the primer layer has a thermal expansion coefficient between 4 PPM/K and 10 PPM/K.

16 . The method of claim 14 , wherein a thickness of the primer layer is between 0.2 and 0.6 mils.

17 . The method of claim 1 , wherein the method is performed on wing.

18 . A material system for in-situ repair of a thermal barrier coating deposited on a component with localized spallation of the thermal barrier coating, comprising:
a primer slurry comprising a primer chemically for bonding to a thermally grown oxide of the component exposed by the localized spallation, wherein the primer includes at least one of a metal and a metal oxide; and a ceramic slurry comprising a ceramic material, a binder material, and a fluid carrier, wherein the ceramic material is chemically for bonding to the primer and comprises yttria-stabilized zirconia particles.

19 . The material system of claim 18 , wherein the primer includes a metal and an oxide of the same metal.

20 . The material system of claim 18 , wherein the primer includes Ti.

Assignees

• Gen Electric

Inventors

• Saha Atanu
• Keshavan Hrishikesh
• Nagesh Mamatha
• Kulkarni Ambarish J
• Bewlay Bernard P

Classifications

• C04B2235/9607

  Thermal properties, e.g. thermal expansion coefficient · CPC title

• C04B2235/3246

  Stabilised zirconias, e.g. YSZ or cerium stabilised zirconia · CPC title

• C23C26/00

  Coating not provided for in groups C23C2/00 - C23C24/00 · CPC title

• C04B41/009

  characterised by the material treated · 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