Article and method of making thereof

Patent metadata

Field	Value
Publication number	US-9790587-B2
Application number	US-201414525586-A
Country	US
Kind code	B2
Filing date	Oct 28, 2014
Priority date	Oct 28, 2014
Publication date	Oct 17, 2017
Grant date	Oct 17, 2017

Abstract

An article including a substrate and a plurality of coatings disposed on the substrate is presented. The plurality of coatings includes a thermal barrier coating disposed on the substrate; and a protective coating including a calcium-magnesium-aluminum-silicon-oxide (CMAS)-reactive material disposed on the thermal barrier coating. The CMAS-reactive material has an orthorhombic weberite crystal structure. The CMAS-reactive material is present in the plurality of coatings in an effective amount to react with a CMAS composition at an operating temperature of the thermal barrier coating, thereby forming a reaction product having one or both of melting temperature and viscosity greater than that of the CMAS composition. A method of making the article and a related turbine engine component are also presented.

First claim

The invention claimed is:

1. An article, comprising:
a substrate; and
a plurality of coatings disposed on the substrate, the plurality of coatings comprising:
a thermal barrier coating disposed on the substrate; and
a protective overlaying coating comprising a calcium-magnesium-aluminum-silicon-oxide (CMAS)-reactive material disposed on the thermal barrier coating, the CMAS-reactive material having a formula Gd 3 BO 7 and an orthorhombic weberite crystal structure,
wherein B is at least one element selected from the group consisting of tantalum and niobium and wherein the CMAS-reactive material is present in the plurality of coatings in an effective amount to react with a CMAS composition at an operating temperature of the thermal barrier coating, thereby forming a reaction product having one or both of melting temperature and viscosity greater than that of the CMAS composition, and wherein the CMAS-reactive material is present in the plurality of coatings in an amount in a range from about 10 volume percent to about 75 volume percent of the plurality of coatings.

2. The article of claim 1 , wherein the protective coating has a thickness in a range from about 10 microns to about 1000 microns.

3. The article of claim 1 , wherein the protective coating consists essentially of the CMAS-reactive material.

4. The article of claim 1 , wherein the substrate comprises a superalloy material.

5. The article of claim 1 , further comprising a bond coating disposed between the substrate and the thermal barrier coating.

6. A turbine engine component comprising the article of claim 1 .

7. The turbine engine component of claim 6 , wherein the article is a combustor component, a turbine blade, a shroud, a nozzle, a heat shield, or a vane.

8. The article of claim 1 , wherein the protective coating has a thickness in a range from about 10 microns to about 1000 microns.

9. The article of claim 1 , wherein the thermal barrier coating comprises yttria-stabilized zirconia, scandia-stabilized zirconia, hafnia-stabilized zirconia, calcia-stabilized zirconia, magnesia-stabilized zirconia, or combinations thereof.

10. The article of claim 1 , wherein the CMAS-reactive material is present in the plurality of coatings in an amount in a range from about 10 volume percent to about 50 volume percent of the plurality of coatings.

11. The article of claim 1 , wherein the thermal barrier coating has a thickness in a range from about 50% to about 90% of the total thickness of the plurality of layers.

Assignees

• Gen Electric

Inventors

• Nayak Mohandas
• Sivaramakrishnan Shankar
• Venkataramani Venkat Subramaniam
• Srivastava Alok Mani
• Chatterjee Shahana

Classifications

• C23C28/042

  including a refractory ceramic layer, e.g. refractory metal oxides, ZrO2, rare earth oxides · CPC title

• C23C4/129

  Flame spraying · CPC title

• F05D2230/90

  Coating; Surface treatment · CPC title

• F01D5/288

  Protective coatings for blades · CPC title

• C23C28/3455

  with a refractory ceramic layer, e.g. refractory metal oxide, ZrO2, rare earth oxides or a thermal barrier system comprising at least one refractory oxide layer · CPC title