Thermal protection methods using barrier coatings with strain tolerance grooves

Patent metadata

Field	Value
Publication number	US-2025059895-A1
Application number	US-202318449768-A
Country	US
Kind code	A1
Filing date	Aug 15, 2023
Priority date	Aug 15, 2023
Publication date	Feb 20, 2025
Grant date	—

Abstract

A method of forming a component. The method includes applying a thermal barrier coating to the component to facilitate decreasing heat transfer to the component, wherein the thermal barrier coating includes at least one thermal insulating layer and a metallic bond coat layer in contact with an outer surface of the component. The method also includes forming a plurality of grooves in the at least one thermal insulating layer of the thermal barrier coating to facilitate increasing a strain tolerance of the thermal barrier coating, wherein each of the plurality of grooves extends a depth into the at least one thermal insulating layer. The method further includes depositing a material within the plurality of grooves to facilitate increasing an amount of thermal protection of the metallic bond coat layer within those areas of the thermal barrier coating in which the plurality of grooves are formed.

First claim

What is claimed is:

1 . A method of forming a component, the method comprising:
applying a thermal barrier coating to the component to facilitate decreasing heat transfer to the component, wherein the thermal barrier coating comprises at least one thermal insulating layer and a metallic bond coat layer, wherein the at least one thermal insulating layer extends across the metallic bond coat layer and wherein the metallic bond coat layer is in contact with an outer surface of the component; forming a plurality of grooves in the at least one thermal insulating layer of the thermal barrier coating to facilitate increasing a strain tolerance of the thermal barrier coating, wherein each of the plurality of grooves extends a depth into the at least one thermal insulating layer; and depositing a material within the plurality of grooves to facilitate increasing an amount of thermal protection of the metallic bond coat layer within those areas of the thermal barrier coating in which the plurality of grooves are formed.

2 . The method of claim 1 , wherein depositing the material within the plurality of grooves comprises depositing the material in a slurry form.

3 . The method of claim 1 , wherein depositing the material within the plurality of grooves comprises depositing the material in a spray form.

4 . The method of claim 1 , wherein applying the thermal barrier coating to the component comprises applying a first thermal insulating layer across the component and a second thermal insulating layer across at least a portion of the first thermal insulating layer.

5 . The method of claim 4 , wherein forming the plurality of grooves comprises forming the plurality of grooves such that at least some of the grooves extend into the second thermal insulating layer.

6 . The method of claim 4 , wherein forming the plurality of grooves comprises forming the plurality of grooves such that at least some of the grooves extend through the second thermal insulating layer and at least partially into the first thermal insulating layer.

7 . The method of claim 4 , wherein forming the plurality of grooves comprises forming the plurality of grooves such that at least some of the grooves extend through the second and first thermal insulating layers to contact the metallic bond coat layer.

8 . The method of claim 7 , wherein depositing the material within the plurality of grooves further comprises depositing the material within the plurality of grooves to facilitate decreasing an amount of degradation of the component within those areas of the thermal barrier coating including the plurality of grooves.

9 . The method of claim 1 , wherein depositing the material within the plurality of grooves further comprises depositing the material to fill an entirety of each of the plurality of grooves.

10 . The method of claim 1 , wherein depositing the material within the plurality of grooves further comprises depositing the material to fill only a portion of the plurality of grooves.

11 . The method of claim 1 , wherein depositing the material within the plurality of grooves further comprises depositing the material within the plurality of grooves to facilitate decreasing an amount of oxidation of the component within those areas of the thermal barrier coating including the plurality of grooves.

12 . The method of claim 1 , wherein forming the plurality of grooves comprises forming each groove with a bottom surface that is defined by a radius.

13 . A method of fabricating a turbine engine component, the method comprising:
applying a thermal barrier coating to the component to facilitate decreasing heat transfer to the component, wherein the thermal barrier coating comprises at least one thermal insulating layer and a metallic bond coat layer, wherein the at least one thermal insulating layer extends across the metallic bond coat layer and wherein the metallic bond coat layer is in contact with an outer surface of the component; forming a plurality of grooves in the at least one thermal insulating layer of the applied thermal barrier coating to facilitate increasing a strain tolerance of the thermal barrier coating, wherein each of the plurality of grooves extends into a depth into the at least one thermal insulating layer to a groove bottom along a line perpendicular to the metallic bond coat layer; and depositing a material within the plurality of grooves to facilitate increasing an amount of thermal protection of the metallic bond coat layer that is proximate to the line of extension of each of the plurality of grooves.

14 . The method of claim 13 , wherein applying the thermal barrier coating to the component comprises applying a first thermal insulating layer across the component and a second thermal insulating layer across at least a portion of the first thermal insulating layer.

15 . The method of claim 14 , wherein forming the plurality of grooves comprises forming the plurality of grooves such that at least some of the grooves extend into the second thermal insulating layer.

16 . The method of claim 14 , wherein forming the plurality of grooves comprises forming the plurality of grooves such that at least some of the grooves extend through the second thermal insulating layer and at least partially into the first thermal insulating layer.

17 . The method of claim 14 , wherein forming the plurality of grooves comprises forming the plurality of grooves such that at least some of the grooves extend through the second and first thermal insulating layers to contact the metallic bond coat layer.

18 . The method of claim 17 , wherein depositing the material within the plurality of grooves further comprises depositing the material within the plurality of grooves to facilitate decreasing an amount of degradation of the component that is proximate to the line of extension of each of the plurality of grooves.

19 . The method of claim 13 , wherein depositing the material within the plurality of grooves further comprises depositing the material to fill an entirety of each of the plurality of grooves.

20 . The method of claim 13 , wherein depositing the material within the plurality of grooves further comprises depositing the material to fill only a portion of the plurality of grooves.

Assignees

• Ge Infrastructure Technology Llc

Inventors

• Schaeffer Jon C
• Kottilingam Srikanth C

Classifications

• F01D25/08

  Cooling (of machines or engines in general F01P); Heating; Heat-insulation (of blade-carrying members, of blades F01D5/00) · CPC title

• F01D25/005 Primary

  Selecting particular materials · CPC title

• C23C24/04 Primary

  Impact or kinetic deposition of particles · CPC title

• F05D2230/90

  Coating; Surface treatment · CPC title

• F01D25/007

  Preventing corrosion · CPC title