EP2971240A1 - Hybrid thermal barrier coating and process of making same - Google Patents
Hybrid thermal barrier coating and process of making sameInfo
- Publication number
- EP2971240A1 EP2971240A1 EP13878078.8A EP13878078A EP2971240A1 EP 2971240 A1 EP2971240 A1 EP 2971240A1 EP 13878078 A EP13878078 A EP 13878078A EP 2971240 A1 EP2971240 A1 EP 2971240A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- layer
- barrier coating
- thermal barrier
- forming
- thermal
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 239000012720 thermal barrier coating Substances 0.000 title claims abstract description 41
- 238000000034 method Methods 0.000 title claims description 34
- 230000008569 process Effects 0.000 title claims description 22
- 239000000758 substrate Substances 0.000 claims abstract description 14
- 230000005855 radiation Effects 0.000 claims abstract description 9
- 239000007921 spray Substances 0.000 claims description 18
- 239000000203 mixture Substances 0.000 claims description 15
- 239000000463 material Substances 0.000 claims description 13
- 238000000576 coating method Methods 0.000 claims description 11
- 239000011248 coating agent Substances 0.000 claims description 9
- 229910001233 yttria-stabilized zirconia Inorganic materials 0.000 claims description 9
- CMIHHWBVHJVIGI-UHFFFAOYSA-N gadolinium(iii) oxide Chemical compound [O-2].[O-2].[O-2].[Gd+3].[Gd+3] CMIHHWBVHJVIGI-UHFFFAOYSA-N 0.000 claims description 8
- 239000000725 suspension Substances 0.000 claims description 8
- 239000002245 particle Substances 0.000 claims description 6
- 239000000843 powder Substances 0.000 claims description 4
- 229910002076 stabilized zirconia Inorganic materials 0.000 claims description 4
- 239000006194 liquid suspension Substances 0.000 claims description 3
- 238000005240 physical vapour deposition Methods 0.000 description 6
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 3
- 230000003628 erosive effect Effects 0.000 description 3
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 238000000151 deposition Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 229910000531 Co alloy Inorganic materials 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 150000001298 alcohols Chemical class 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 125000004122 cyclic group Chemical group 0.000 description 1
- 230000008021 deposition Effects 0.000 description 1
- 238000005328 electron beam physical vapour deposition Methods 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/134—Plasma spraying
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/04—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material
- C23C28/042—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material including a refractory ceramic layer, e.g. refractory metal oxides, ZrO2, rare earth oxides
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
- C23C4/11—Oxides
Definitions
- the present disclosure relates to a thermal barrier coating for use on a turbine engine component and to a process of making the thermal barrier coating.
- a thermal barrier coating (TBC) is created to meet one or more performance requirements including, but not liited to, spallation life, calcia-magnesia-alumina- silicate (CMAS) resistance, foreign object damage (FOD) resistance, erosion, and low conductivity.
- CMAS calcia-magnesia-alumina- silicate
- FOD foreign object damage
- a turbine barrier coating is applied to a turbine engine component, such as a turbine blade/vane, to help the component withstand the relatively high temperatures of its operational environment.
- TBCs are often formed using a singular coating process such as an electron beam physical vapor deposition
- a TBC may be formed from two separate EB-PVD layers formed from two different materials, such as 7 wt% yttria stabilized zirconia and gadolinia stabilized zirconia in order to improve the thermal conductivity properties of the coating.
- the strain-tolerant columnar structure of an EB-PVD coating helps to increase the TBC spallation life.
- a more porous TBC however may minimize the TBC thermal conductivity and possibly the thermal radiation through the coating.
- TBC there is a porous outer layer over a more dense inner layer made by an EB-PVD process.
- the two layers have diff rent porosity levels.
- Such a structure can be formed by changing the coating temperature. More power equals more density but also more temperature. It is also known to form a dense vertically cracked microstructure for the TBC where the deposition is conducted at a two inch stand-off for the dense layer and a six inch stand-off for the porous layer.
- thermal barrier coating which is applied to a turbine engine component having a substrate, which thermal barrier coating broadly comprises a first layer which has a strain tolerant columnar microstructure at an interface with the substrate for spallation resistance and a second layer which is porous conduction and radiation thermally resistant at an outer surface of the thermal barrier coating.
- the first and second layers are formed from the same material.
- the first and second layers are formed from different compositions.
- the second layer has a porosity in the range of from 10 to 40%.
- each of the first and second layers is formed from 7 wt% yttria stabilized zirconia.
- the first layer is formed from 7wt% yttria stabilized zirconia and the second layer is formed from gadolinia stabilized zirconia .
- the first layer has a first thermal conductivity and the second layer has a second thermal conductivity which is at least 10% lower than the first thermal conductivity.
- a process for applying a thermal barrier coating to a turbine engine component which broadly comprises the steps of: forming a first layer which has a strain tolerant columnar microstructure at an interface of the first layer and a substrate using a suspension plasma spray technique; and forming a second layer which is porous and radiation thermally resistant at an outer surface of the thermal barrier coating using one of the suspension plasma spray technique and an air spray plasma technique.
- the process further comprises forming a continuously graded microstructure from the interface to the outer surface.
- the first layer forming step comprises suspending a powder feedstock in a liquid suspension and injecting the powder feedstock and the suspension into a plasma jet under conditions where the first layer is formed with the strain-tolerant columnar microstructure.
- the second layer forming step comprises changing spray parameters so as to form the porous and radiation thermally resistant second layer.
- the first and second layer forming steps comprises forming the first and second layers from the same material.
- the first layer is formed from a first material having a first composition and the second layer is formed from a second material having a second composition which is different from the first composition.
- the second layer is formed using the air spray plasma technique .
- the second layer forming step comprises forming the second layer so as to have a porosity of from 10 to 40%.
- the second layer forming step comprises forming the second layer so as to have a thermal conductivity which is at least 10% lower than a thermal conductivity of the first layer .
- the first and second layer forming steps comprise using a powdered feedstock having a particle size in the range of from lOnm to 10 microns.
- the first and second layer forming steps comprises using a powdered feedstock having a particle size in the range of from lOnm to 2.0 microns .
- FIG. 1 illustrates a turbine engine component having a thermal barrier coating in accordance with the present disclosure deposited thereon
- FIG. 2 illustrates a system for forming the coating on the turbine engine component.
- the turbine engine component may be any component which requires a thermal barrier coating such as a blade/vane.
- the turbine engine component 10 may have a substrate 12 formed from any suitable material known in the art including, but not limited to, a nickel based alloy, a cobalt based alloy, a titanium based alloy, a ceramic material, and an organo- matrix composite material.
- a thermal barrier coating 14 may be deposited on the substrate 12.
- the thermal barrier coating 14 may have a first layer 16 which interfaces with the surface 18 of the substrate 12 and an outer second layer 20.
- the first layer 16 may be formed so as to have a strain-tolerant columnar microstructure at the interface with the surface 18 of the substrate.
- the second layer 20 may be formed to have a porous thermal conduction and radiant heat transfer resistant microstructure at an outer surface 22 of the thermal barrier coating.
- the first layer 16 and the second layer 20 may formed from a material having the same composition.
- each of the layers 16 and 20 may be formed from a 7 wt% yttria stabilized zirconia (7YSZ) .
- the first layer 16 may be formed from a first material having a first composition and the second layer 20 may be formed from a second material having a second composition which is different from the first composition.
- the first layer 16 may be formed from 7YSZ, while the second layer 20 is formed from gadolinia stabilized zirconia.
- Each of the layers 16 and 20 may be formed using suspension plasma spray (SPS) technique such as that shown in FIG. 2.
- SPS suspension plasma spray
- a powdered feedstock is suspended in a liquid suspension 30.
- the powdered feedstock may be 7YSZ which may be suspended in ethanol, water, or other alcohols such as methanol.
- the powdered feedstock may have a particle size in the range of from 10 nm to 10 microns mean size diameter. In another non-limiting embodiment, the particles size may be in the range of from 10 nm to 2.0 microns.
- the powdered feedstock in the suspension is injected into a plasma jet 32 created by a plasma torch 34 and thus deposited onto the substrate 12. The spray conditions are such that the first layer 16 is formed to have the desired strain tolerant columnar microstructure .
- the deposition technique may have a short stand off (similar to that used in dense vertically cracked coatings) and high power/enthalpy plasma conditions.
- the spray conditions may be changed so as to form the second layer 20 with the porous thermal conduction and radiant heat transfer resistant microstructure.
- the angle of the spray nozzle could be changed from normal relative to the surface on which the layer 20 is being deposited; (2) the stand off may be increased; and/or (3) the plasma power/enthalpy may be reduced.
- More porosity in the second layer 20 than in the first layer 16 creates a reduction in thermal conductivity.
- the second layer 20 may have a reduction of at least 10% in thermal conductivity. This may come purely from a porosity increase or a change in the structure from columnar to more splat like. An increase in porosity increases the erosion rate.
- a useful limit may be 10 to 40% porosity in the second layer 20.
- the columnar structure SPS gives a thermal cyclic spallation resistance similar to EB-PVD (much higher than APS and higher than dense vertically cracked) .
- Erosion is a function of porosity content and can be greater or less than EB-PVD (generally higher than APS and more like dense vertically cracked) .
- Thermal conductivity as discussed above, follows the porosity content .
- the spray conditions may be discreetly or incrementally changed throughout the spray run.
- the spray conditions may be changed so that a continuously graded microstructure is formed where there is the strain-tolerant columnar microstructure at the interface with the substrate 12 for thermal barrier coating spallation resistance and a porous thermal conduction and radiation thermally resistant layer at the outer surface 22.
- the first layer 16 may be formed using the above discussed SPS technique and the second layer 20 may be formed using a porous air plasma spray (APS) technique.
- APS porous air plasma spray
- thermal barrier coating can be formed using a single piece of equipment and in a single coating run .
- Another advantage is that one can easily change the composition of the second layer 20 so that it is different than the composition of the first layer 16. This can easily be done by changing the composition of the feedstock being injected into the plasma jet.
- a hybrid thermal barrier coating and a process for making same. While the coating and process have been described in the context of specific embodiments thereof, other unforeseen alternatives, modifications, and variations may become apparent to those skilled in the art having read the foregoing description. Accordingly, it is intended to embrace those alternatives, modifications, and variations as fall within the broad scope of the appended claims.
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Ceramic Engineering (AREA)
- Inorganic Chemistry (AREA)
- Coating By Spraying Or Casting (AREA)
Abstract
Description
Claims
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201361781656P | 2013-03-14 | 2013-03-14 | |
PCT/US2013/078186 WO2014143363A1 (en) | 2013-03-14 | 2013-12-30 | Hybrid thermal barrier coating and process of making same |
Publications (3)
Publication Number | Publication Date |
---|---|
EP2971240A1 true EP2971240A1 (en) | 2016-01-20 |
EP2971240A4 EP2971240A4 (en) | 2016-12-21 |
EP2971240B1 EP2971240B1 (en) | 2018-11-21 |
Family
ID=51537485
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP13878078.8A Active EP2971240B1 (en) | 2013-03-14 | 2013-12-30 | Hybrid thermal barrier coating and process of making the same |
Country Status (3)
Country | Link |
---|---|
US (2) | US20160017475A1 (en) |
EP (1) | EP2971240B1 (en) |
WO (1) | WO2014143363A1 (en) |
Families Citing this family (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR3043411B1 (en) * | 2015-11-09 | 2017-12-22 | Commissariat Energie Atomique | HIGH-TEMPERATURE THERMAL PROTECTION MULTI-LAYER CERAMIC COATING, IN PARTICULAR FOR AERONAUTICAL APPLICATION, AND PROCESS FOR PRODUCING THE SAME |
US10436042B2 (en) | 2015-12-01 | 2019-10-08 | United Technologies Corporation | Thermal barrier coatings and methods |
JP6908973B2 (en) * | 2016-06-08 | 2021-07-28 | 三菱重工業株式会社 | Manufacturing methods for thermal barrier coatings, turbine components, gas turbines, and thermal barrier coatings |
Family Cites Families (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP3872632B2 (en) * | 2000-06-09 | 2007-01-24 | 三菱重工業株式会社 | Thermal barrier coating material, gas turbine member and gas turbine using the same |
US20090110953A1 (en) * | 2007-10-29 | 2009-04-30 | General Electric Company | Method of treating a thermal barrier coating and related articles |
DE102008007870A1 (en) * | 2008-02-06 | 2009-08-13 | Forschungszentrum Jülich GmbH | Thermal barrier coating system and process for its preparation |
US20110143043A1 (en) * | 2009-12-15 | 2011-06-16 | United Technologies Corporation | Plasma application of thermal barrier coatings with reduced thermal conductivity on combustor hardware |
US20110151219A1 (en) * | 2009-12-21 | 2011-06-23 | Bangalore Nagaraj | Coating Systems for Protection of Substrates Exposed to Hot and Harsh Environments and Coated Articles |
EP2341166A1 (en) * | 2009-12-29 | 2011-07-06 | Siemens Aktiengesellschaft | Nano and micro structured ceramic thermal barrier coating |
JP2010255121A (en) * | 2010-07-20 | 2010-11-11 | Mitsubishi Heavy Ind Ltd | Film material |
EP2450465A1 (en) * | 2010-11-09 | 2012-05-09 | Siemens Aktiengesellschaft | Porous coating system with porous internal coating |
US9017792B2 (en) * | 2011-04-30 | 2015-04-28 | Chromalloy Gas Turbine Llc | Tri-barrier ceramic coating |
US20130260132A1 (en) * | 2012-04-02 | 2013-10-03 | United Technologies Corporation | Hybrid thermal barrier coating |
-
2013
- 2013-12-30 EP EP13878078.8A patent/EP2971240B1/en active Active
- 2013-12-30 WO PCT/US2013/078186 patent/WO2014143363A1/en active Application Filing
- 2013-12-30 US US14/775,031 patent/US20160017475A1/en not_active Abandoned
-
2018
- 2018-06-04 US US15/996,929 patent/US20180282853A1/en not_active Abandoned
Also Published As
Publication number | Publication date |
---|---|
US20180282853A1 (en) | 2018-10-04 |
US20160017475A1 (en) | 2016-01-21 |
EP2971240B1 (en) | 2018-11-21 |
EP2971240A4 (en) | 2016-12-21 |
WO2014143363A1 (en) | 2014-09-18 |
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