Compliant layer for ceramic components and methods of forming the same

Patent metadata

Field	Value
Publication number	US-9527777-B2
Application number	US-201414205010-A
Country	US
Kind code	B2
Filing date	Mar 11, 2014
Priority date	Mar 11, 2013
Publication date	Dec 27, 2016
Grant date	Dec 27, 2016

Abstract

An apparatus includes a ceramic matrix composite (CMC) component and an interface coating on the CMC component, wherein the interface coating includes a layer of at least one of the following compositions: 100 wt % Ir; 90-95 wt % Ir, 5-10 wt % Co, 1-2 wt % Al, 1-2 wt % Si; 40-50 wt % Nb, 28-42 wt % Al, 4-15 wt % Cr, 1-2 wt % Si; 90-92 wt % Mo, 4-5 wt % Si, 4-5 wt % B; or 60-80 wt % V, 20-30 wt % Cr, 2-15 wt % Ti.

First claim

The invention claimed is:

1. An apparatus, comprising:
a ceramic matrix composite (CMC) component; and
an interface coating on the CMC component,
wherein the interface coating comprises a layer of
90-95 wt % Ir, 5-10 wt % Co, 1-2 wt % Al, 1-2 wt % Si.

2. The apparatus of claim 1 , wherein the interface coating further comprises a layer comprising at least one of Ti, Ni—Co—Fe, or Ni—Mo—Cr.

3. The apparatus of claim 1 , wherein the interface coating has a coefficient of thermal expansion (CTE) of about 4×10−6 to about 6×10−6/° F.

4. The apparatus of claim 1 , further comprising a bond layer between a surface of the CMC component and the interface coating.

5. The apparatus of claim 4 , wherein the bond layer comprises Si.

6. The apparatus of claim 4 , wherein the bond layer consists of Si.

7. The apparatus of claim 1 , further comprising a corrosion-resistant coating on the interface coating, wherein the corrosion-resistant coating comprises an alloy comprising at least one of Ti, Al, or V, an alloy comprising at least one of Ti, Al, Sn, Zr, or Mo, or an alloy comprising Ni and Cr.

8. The apparatus of claim 7 , wherein the corrosion-resistant coating comprises at least one of Ti—Al—V, Ti—Al—Sn—Zr—Mo, Ni—Cr, or Ni—Mo—Cr.

9. The apparatus of claim 1 , further comprising a compliance-enhancing coating on the interface coating, wherein the compliance-enhancing coating comprises at least one of Pt, Ag, Cu, Ni, Cr, Co, or Mo.

10. The apparatus of claim 9 , wherein the compliance-enhancing coating comprises at least one of a Cu alloy, an Ag alloy, or Co—Cr—Mo.

11. The apparatus of claim 1 , further comprising an outer coating on the interface coating, wherein the outer coating is selected from at least one of an environmental barrier coating or a thermal barrier coating.

12. A ceramic matrix composite (CMC) component with an interface coating system thereon, the interface coating system comprising;
a bond coating on a surface of the CMC component, wherein the bond coating comprises Si;
an interface coating on the bond coating,
wherein the interface coating comprises a layer of
90-95 wt % Ir, 5-10 wt % Co, 1-2 wt % Al, 1-2 wt % Si;
a corrosion-resistant coating on the interface coating, wherein the corrosion resistant coating comprises an alloy comprising at least one of Ti, Al, or V, an alloy comprising at least one of Ti, Al, Sn, Zr, or Mo, or an alloy comprising Ni and Cr; and
a compliance-enhancing coating on the corrosion-resistant coating, wherein the compliance-enhancing coating comprises at least one of Pt, Ag, Cu, Ni, Cr, Co, or Mo.

13. The apparatus of claim 12 , further comprising at least one outer coating on the compliance-enhancing coating.

14. The apparatus of claim 12 , wherein the bond coating consists of Si.

15. A method, comprising:
forming an interface coating on a ceramic matrix composite (CMC) component such that the interface coating is bonded to the ceramic component,
wherein the interface coating comprises a layer of
90-95 wt % Ir, 5-10 wt % Co, 1-2 wt % Al, 1-2 wt % Si.

16. The method of claim 15 , further comprising forming a bond coating on the CMC part prior to forming the interface coating, wherein the bond coating comprises Si.

17. The method of claim 16 , further comprising heat treating the bond coating and the interface coating to about 1100° C. to about 1325° C.

18. The method of claim 15 , further comprising forming a corrosion-resistant coating on the interface coating, wherein the corrosion resistant coating comprises an alloy comprising at least one of Ti, Al, or V, an alloy comprising at least one of Ti, Al, Sn, Zr, or Mo, or an alloy comprising Ni and Cr.

19. The method of claim 18 , further comprising heating the interface coating and the corrosion-resistant coating to a temperature of about 1100° C.

20. The method of claim 18 , further comprising forming a compliance-enhancing coating on the corrosion-resistant coating, wherein the compliance-enhancing coating comprises at least one of Pt, Ag, Cu, Ni, Cr, Co, or Mo.

21. The method of claim 20 , further comprising forming at least one outer coating on the compliance-enhancing coating.

22. A turbine engine component comprising a ceramic matrix composite (CMC) component, wherein the CMC component is loaded against a metal part, wherein the CMC component comprises an interface coating adjacent to the metal part,
the interface coating comprises a layer of
90-95 wt % Ir, 5-10 wt % Co, 1-2 wt % Al, 1-2 wt % Si.

Assignees

• Rolls Royce Corp

Inventors

• Chamberlain Adam Lee
• Lee Kang N
• Lazur Andrew Joseph

Classifications

• F01D5/282

  Selecting composite materials, e.g. blades with reinforcing filaments · CPC title

• F05D2300/10

  Metals, alloys or intermetallic compounds · CPC title

• C04B41/5127

  Cu, e.g. Cu-CuO eutectic · CPC title

• F01D5/3007

  of axial insertion type · CPC title

• C04B41/5105

  with a composition mainly composed of one or more of the noble metals or copper · CPC title