WO1996031293A1 - Method and composite for protection of thermal barrier coating by a sacrificial surface coating - Google Patents

Method and composite for protection of thermal barrier coating by a sacrificial surface coating Download PDF

Info

Publication number
WO1996031293A1
WO1996031293A1 PCT/US1996/003684 US9603684W WO9631293A1 WO 1996031293 A1 WO1996031293 A1 WO 1996031293A1 US 9603684 W US9603684 W US 9603684W WO 9631293 A1 WO9631293 A1 WO 9631293A1
Authority
WO
WIPO (PCT)
Prior art keywords
thermal barrier
barrier coating
coating
oxide
stabilized zirconia
Prior art date
Application number
PCT/US1996/003684
Other languages
English (en)
French (fr)
Inventor
Wayne Charles Hasz
Curtis Alan Johnson
Marcus Preston Borom
Original Assignee
General Electric Company
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Priority claimed from US08/415,913 external-priority patent/US5660885A/en
Application filed by General Electric Company filed Critical General Electric Company
Priority to JP53031196A priority Critical patent/JP3995713B2/ja
Priority to DE19680223T priority patent/DE19680223B3/de
Publication of WO1996031293A1 publication Critical patent/WO1996031293A1/en

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/02Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by baking
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01DNON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D25/00Component parts, details, or accessories, not provided for in, or of interest apart from, other groups
    • F01D25/007Preventing corrosion
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00Processes for applying liquids or other fluent materials
    • B05D1/36Successively applying liquids or other fluent materials, e.g. without intermediate treatment
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00Layered products comprising a layer of metal
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00Layered products comprising a layer of metal
    • B32B15/01Layered products comprising a layer of metal all layers being exclusively metallic
    • CCHEMISTRY; METALLURGY
    • C23COATING 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
    • C23CCOATING 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
    • C23C28/00Coating 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
    • C23C28/04Coating 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
    • CCHEMISTRY; METALLURGY
    • C23COATING 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
    • C23CCOATING 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
    • C23C4/00Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/02Pretreatment of the material to be coated, e.g. for coating on selected surface areas
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01DNON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12Blades
    • F01D5/28Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/288Protective coatings for blades
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02CGAS-TURBINE PLANTS; AIR INTAKES FOR JET-PROPULSION PLANTS; CONTROLLING FUEL SUPPLY IN AIR-BREATHING JET-PROPULSION PLANTS
    • F02C7/00Features, components parts, details or accessories, not provided for in, or of interest apart form groups F02C1/00 - F02C6/00; Air intakes for jet-propulsion plants
    • F02C7/30Preventing corrosion or unwanted deposits in gas-swept spaces
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00Aeronautics or air transport
    • Y02T50/60Efficient propulsion technologies, e.g. for aircraft

Definitions

  • the present invention relates to a method and composite for protecting thermal barrier coatings deposited on gas turbine and other heat engine parts from the deleterious effects of environmental contaminants.
  • the invention relates to a method and composite using a reactive sacrificial oxide coating which reacts with the contaminant composition formed from the environmental contaminants.
  • Thermal barrier coatings are deposited onto gas turbine and other heat engine parts to reduce heat flow and to limit the operating temperature of metal parts. These coatings generally are a ceramic material, such as chemically stabilized zirconia. Yttria-stabilized zirconia, scandia-stabilized zirconia, calcia-stabilized zirconia, and magnesia- stabilized zirconia are contemplated as thermal barrier coatings.
  • the thermal barrier coating of choice is a yttria-stabilized zirconia ceramic coating.
  • a typical thermal barrier coating comprises about 8 weight percent yttria-92 weight percent zirconia.
  • thermal barrier coating depends on the application, but generally ranges between about 5-60 mils thick for high temperature engine parts.
  • Metal parts provided with thermal barrier coatings can be made from nickel, cobalt, and iron based superalloys. The process is especially suited for parts and hardware used in turbines. Examples of turbine parts would be turbine blades, buckets, nozzles, combustion liners, and the like.
  • Thermal barrier coatings are a key element in current and future gas turbine engine designs expected to operate at high temperatures which produce high thermal barrier coating surface temperatures .
  • the ideal system for a hot high temperature engine part consists of a strain-tolerant thermal barrier ceramic layer deposited onto a bond coat which exhibits good corrosion resistance and closely matched thermal expansion coefficients.
  • thermal barrier coated engine parts can be susceptible to various modes of damage, including erosion, oxidation, and attack from environmental contaminants. At temperatures of engine operation adherence of these environmental contaminants on the hot thermal barrier coated surface can cause damage to the thermal barrier coating. Environmental contaminants form compositions, which are liquid at the surface temperatures of thermal barrier coatings .
  • Molten contaminant compositions can dissolve the thermal barrier coating or can infiltrate its pores and openings, initiating and propagating cracks causing delamination and loss of thermal barrier coating material.
  • Some environmental contaminant compositions that deposit on thermal barrier coated surfaces contain oxides of calcium, magnesium, aluminum, silicon, and mixtures thereof. These oxides combine to form contaminant compositions comprising calcium- magnesium-aluminum-silicon-oxide systems (Ca-Mg-Al-Si- 0), herein referred to as CMAS. Damage to thermal barrier coatings occurs when the molten CMAS infiltrates the thermal barrier coating. After infiltration and upon cooling, the molten CMAS, or other molten contaminant composition, solidifies. The stress build up in the thermal barrier coating is sufficient to cause spallation of the coating material and loss of the thermal protection that it provides to the underlying part.
  • CMAS calcium- magnesium-aluminum-silicon-oxide systems
  • the present invention satisfies this need by protecting a thermal barrier coating from degradation by environmental contaminant compositions which form on and adhere to a surface of a thermal barrier coated part.
  • the method of the invention comprises depositing a reactive or sacrificial oxide coating on the surface of thermal barrier coating, in an effective amount, so that the oxide coating reacts with the contaminant composition at the operating temperature of said thermal barrier coating and raises the melting temperature or viscosity of the contaminant composition as it forms on the surface.
  • the present invention also satisfies this need by providing a composite comprising a thermal barrier coating on a part with a continuous sacrificial oxide coating adjacent to an outer surface of the thermal barrier coating.
  • the invention also includes a protected thermal barrier coated part comprising a part with a thermal barrier coating on said part and a single protective layer of a sacrificial oxide coating on an outer surface of said thermal barrier coating.
  • the composite thermal barrier coating according to the present invention also comprises a substrate, bond coat, with a thermal barrier coating and a sacrificial oxide coating.
  • Environmental contaminants are materials that exist in the environment and are ingested into engines, from air and fuel sources, and impurities and oxidation products of engine components, such as iron oxide.
  • operating temperature means the surface temperature of the thermal barrier coating during its operation in a given application, such as a gas turbine engine. Such temperatures are above room temperature, and generally are above 500°C. High temperature operation of thermal barrier coating parts is usually above about 1000°C.
  • a composite comprising a thermal barrier coated part with an outer sacrificial oxide coating has decreased damage from environmental contaminants that form molten contaminant compositions on the surface of the thermal barrier coating at operating temperatures. It has also been discovered that by applying a sacrificial oxide coating that reacts with environmental contaminants and resulting contaminant compositions encountered on surfaces of thermal barrier coated parts during service operation, the melting temperature or viscosity of the contaminant composition can be increased. As a result, the contaminant composition does not become molten and infiltration or viscous flow of the mixture into the thermal barrier coating is curtailed. This reduces damage to the thermal barrier coating.
  • Increasing the melting temperature and viscosity of the contaminant composition reduces infiltration into the thermal barrier coating, thereby decreasing the degradation of the thermal barrier coating.
  • the composition does not become liquid at the operating temperature of the thermal barrier coating. Infiltration or viscous flow of the contaminant composition into thermal barrier coating cracks, openings, and pores is diminished.
  • This invention also protects the thermal barrier coating from dissolution or spallation due to chemical and mechanical attack by the contaminant composition. This enhances the life of the thermal barrier coated part and thus, reduces thermal barrier coated part failure.
  • Sources of environmental contaminants include, but are not limited to, sand, dirt, volcanic ash, fly ash, cement, runway dust, substrate impurities, fuel and air sources, oxidation products from engine components, and the like.
  • the environmental contaminants adhere to the surfaces of thermal barrier coated parts. At the operating temperatures of the thermal barrier coating, the environmental contaminants then form contaminant compositions on surfaces of the thermal barrier coating which may have melting ranges or temperatures at or below the operating temperature.
  • the environmental contaminant may include magnesium, calcium, aluminum, silicon, chromium, iron, nickel, barium, titanium, alkali metals, and compounds thereof, to mention a few.
  • the environmental contaminants may be oxides, phosphates, carbonates, salts, and mixtures thereof.
  • the chemical composition of the contaminant composition corresponds to the composition of the environmental contaminants from which it is formed. For example, at operational temperatures of about 1000°C or higher, the contaminant composition corresponds to compositions in the calcium-magnesium- aluminum-silicon oxide systems or CMAS.
  • the environmental contaminant compositions known as CMAS comprise primarily a mixture of magnesium oxide (MgO) , calcium oxide (CaO) , aluminum oxide (Al 2 ⁇ 3 ), and silicon oxide (Si ⁇ 2 ..
  • MgO magnesium oxide
  • CaO calcium oxide
  • Al 2 ⁇ 3 aluminum oxide
  • Other elements, such as nickel, iron, titanium, and chromium, may be present in the CMAS in minor amounts when these elements or their compounds are present in the environmental contaminants.
  • a minor amount is an amount less than about ten weight percent of the total amount of contaminant composition present.
  • the protective coatings of this invention can be described as sacrificial or reactive in that they protect thermal barrier coatings by undergoing chemical or physical changes when in contact with a liquid contaminant composition.
  • the character of the protective coating is sacrificed.
  • the result of the change is to increase either the viscosity or the physical state of the contaminant composition, e.g., liquid CMAS, by dissolving in the composition or reacting with it, to form a by-product material which is not liquid or at least more viscous than the original CMAS.
  • Such a sacrificial or reactive coating is an outer oxide coating, usually of a metal oxide, deposited on the outer surface of the thermal barrier coating that reacts chemically with the contaminant composition at the surface temperature of the thermal barrier coating.
  • the chemical reaction is one in which the sacrificial oxide coating is consumed, at least partially, and elevates the melting temperature or viscosity of the contaminant composition.
  • the melting temperature of the contaminant composition is preferably increased by at least about 10°C, and most preferably about 50-100°C, above the surface temperature of the thermal barrier coating during its operation.
  • the composition of the sacrificial oxide coating is in part based on the composition of the environmental contaminants and the surface temperature of the thermal barrier coating during operation.
  • the sacrificial oxide coating contains an element or elements that are present in the liquid contaminant composition.
  • Suitable sacrificial oxide coatings that react with the CMAS composition to raise its melting temperature or viscosity include, but are not limited to, alumina, magnesia, chromia, calcia, scandia, calcium zirconate, silica, spinels such as magnesium aluminum oxide, and mixtures thereof.
  • a sacrificial oxide coating such as scandia
  • a sacrificial oxide coating such as scandia
  • to raise the CMAS melting temperature from 1190°C to greater than 1300°C about 10-20 weight percent of scandia is used for the sacrificial oxide coating.
  • the protective oxide coating is applied to the thermal barrier coating in an amount sufficient to effectively elevate the melting temperature or the viscosity of substantially all of the liquid contaminant formed.
  • the thermal barrier coating As little as about one weight percent of the oxide coating based on the total weight of the contaminant composition present on the surface of the thermal barrier coating can help prevent infiltration of molten contaminant compositions into the thermal barrier coating.
  • about 10-20 weight percent of the sacrificial oxide coating is deposited on the thermal barrier coating.
  • the amount of the sacrificial oxide coating deposited may be up to fifty weight percent or a 1:1 ratio of oxide coating to liquid contaminant.
  • the sacrificial oxide coating can be deposited on the thermal barrier coating by coating methods known in the art, such as sol-gel, sputtering, air plasma spray, organo-metallic chemical vapor deposition, physical vapor deposition, chemical vapor deposition, and the like. Thicknesses of the sacrificial oxide coating can vary from about 0.2 micrometers to about 250 micrometers. The preferred thickness is about 2-125 micrometers. The thickness of the oxide coating is at least in part, determined by the chemistry of the particular oxide coating, the operating temperature of the thermal barrier coating, and the amount and composition of the contaminant. If thick sacrificial oxide coatings are required, i.e., about 125 micrometers or more, a compositionally graded deposit can be used to keep internal stresses minimized in order that delamination of the sacrificial coating does not occur.
  • CMAS composition For purposes of illustrating the use of a specific sacrificial oxide coating, as well as imparting an understanding of the present invention, the reaction of CMAS composition with the sacrificial oxide coating on a thermal barrier coating is described at operating temperatures of about 1200°C or higher.
  • the chemical composition of the CMAS composition was determined by electron microprobe analysis of infiltrated deposits found on thermal barrier coated engine parts where deposit-induced damage to the thermal barrier coating had been observed. Analysis indicated that 127 micron (5 mils) of CMAS-like deposits (-34 mg/cm-2 assuming a density of 2.7 g/cm ⁇ ) can form on thermal barrier coating surfaces.
  • the CMAS deposits evaluated were typically in the compositional range (weight %) : 5-35% CaO, 2- 35% MgO, 5-15% AI2O3, 5-55% Si ⁇ 2, 0-5% NiO, 5-10%
  • An average composition for such deposits (weight %: 28.7% CaO, 6.4% MgO, 11.1% AI2O3, 43.7% Si ⁇ 2, 1.9% NiO, 8.3% Fe 2 03> was synthesized in the laboratory and used as a standard CMAS for the purpose of evaluating protective coatings. Differential thermal analysis of actual CMAS deposits and the synthesized CMAS indicated that the onset of melting occurs at about 1190°C with the maximum of the melting peak occurring at about 1260°C. Thermal testing of candidate protective coatings for thermal barrier coatings against the laboratory synthesized CMAS composition were carried out at about 1260°C.
  • Viscosity data on a similar CMAS composition indicates that the viscosity of CMAS is about 4 Pa»s (Pascal second) at 1260°C. This fluid phase infiltrates the thermal barrier coating and causes damage either by freezing-induced spallation or by high temperature chemical attack induced destabilization. Laboratory experiments with unprotected thermal barrier coatings indicate that, under isothermal conditions, 8mg CMAS/c ⁇ .2 is sufficient to cause entire thermal barrier coating layers to spall off.
  • the surface temperature of the thermal barrier coating during operation is about 1200°C
  • the melting temperature of the CMAS composition should be raised at least 10°C higher than the surface temperature of the thermal barrier coating during its operation.
  • DTA differential thermal analysis
  • thermodynamic calculation to assess the ability of candidate sacrificial materials to react with CMAS and increase the melting temperature such that infiltration of the CMAS does not occur into the thermal barrier coating during service.
  • Viscosity measurements were used to assess the ability of sacrificial oxide coatings to react with CMAS, to increase the liquid phase viscosity, and thereby, to limit physical infiltration into the thermal barrier coating microstrueture.
  • Candidate sacrificial oxide coating compositions were deposited on thermal barrier coatings and assessed for CMAS infiltration resistance using metallography, SEM and electron microprobe chemical analysis. The above testing was conducted under laboratory furnace test conditions (isothermal) .
  • Sacrificial reactive oxide coatings that were deposited by the sol-gel, air plasma spray, sputtering, and MOCVD methods were: scandia, calcium zirconate, calcium oxide (CaO) , aluminum oxide (AI 2 O 3 ), magnesium oxide (MgO), and silicon oxide (Si0 2 ) .
  • the effectiveness of protective coatings in preventing CMAS-infiltration-induced thermal barrier coating damage was tested by comparing the infiltration resistance of protected and non-protected thermal barrier coated substrates which were thermally cycled in the presence of surface deposits of CMAS.
  • 8mg/cm*2 of ground pre-reacted CMAS was deposited on masked areas of the thermal barrier coated substrates.
  • a thermal cycle consisted of heating the samples to 1260°C in 10 minutes, holding it at 1260°C for 10 minutes, followed by cooling it to room temperature in 30 minutes. After each cycle the samples were inspected with the unaided eye and at 50x using a stereo microscope. This cycle was repeated several times. After completion of thermal testing, the samples were sectioned, metallographically polished, and inspected using bright field and dark field optical microscopy.
  • Example 1 demonstrates the effect of CMAS on a thermal barrier coated part without a sacrificial oxide protective coating.
  • Non-protected thermal barrier coating samples tested in the above-mentioned fashion exhibit visible CMAS induced thermal barrier coating swelling and cracking (visible on sample edges under the stereomicroscope) .
  • Metallographic preparation and inspection of the non-protected samples shows CMAS induced thermal barrier coating densification, cracking and exfoliation.
  • EXAMPLE 3 Differential thermal analysis found that magnesia or calcia additions increased the melting temperatures for CMAS compositions when 1:1 by weight additions were made. Twenty weight percent additions - 13 - of magnesia or calcia cause the differential thermal analysis curves for CMAS compositions to exhibit two separate melting peaks: at 1254°C and at 1318°C for magnesia, and 1230°C and 1331°C for calcia. Thermal barrier coatings protected with magnesia or calcia coatings exhibited less CMAS composition-induced exfoliation than unprotected thermal barrier coating samples when exposed to 8 mg/cm 2 CMAS compositions during furnace cycle testing. A 5 mil thick magnesium oxide coating was air plasma spray coated on a thermal barrier coating sample and tested using the above described method.
  • EAMPLE 4 A 3 mil thick calcium zirconate coating was air plasma spray coated on a thermal barrier coating sample and tested using the method described in example 1. After thermally cycling the coating with the addition of 8 mg/cm 2 CMAS to 1260°C, metallography showed that CMAS composition was retained on top of the thermal barrier coating, and there was no apparent infiltration into the thermal barrier coating.
  • alumina additions increase the CMAS composition melting temperature upon heating when 1:1 by weight additions of alumina to the CMAS composition are made.
  • One to one additions elevate the onset of melting for CMAS compositions to a temperature greater than 1345°C.
  • a 5 mil air plasma spray deposited film of alumina minimized the infiltration of 8 mg/cm 2 CMAS composition after heat treatment at 1260°C for 1 hour.
  • EXAMPLE 6 The ability of secondary protective oxides to increase the viscosity was tested. For a given exposure time, an increase in CMAS viscosity will decrease the infiltration depth into the thermal barrier coating. Survey studies of viscosity changes in CMAS resulting from oxide additions were made. Simplistic viscosity type measurements utilized in testing of porcelain enamels were employed for ranking purposes. In the enameling test, pellets made from mixtures of CMAS with varying amounts of candidate oxides were placed on a horizontal platinum sheet and melted. The platinum sheet was rotated to a vertical position for a precise amount of time (to allow viscous flow) and then rotated back to a horizontal position (to stop viscous flow) and removed from the furnace.
  • the approximate viscosity can be calculated from the length of the flow line and the flow time.
  • the relative change in CMAS viscosity with oxide addition can be determined by measuring the change in flow line length with the addition of various oxides.
  • Candidate oxides which increased the CMAS viscosity (among them alumina, magnesia, calcia, and calcium zirconate) were then deposited on thermal barrier coated substrates and thermally tested with CMAS deposits. The results of the alumina, magnesia, and calcium zirconate protective coatings are described in examples 2, 3 and 4.
  • this invention also is a method for protecting a thermal barrier coating against damage caused by a liquid composition formed from environmental contaminants at operating temperatures of the thermal barrier coating which comprises forming on a surface of the thermal barrier coating a sacrificial metal oxide coating comprising at least one metal oxide that reacts with said liquid composition and upon contact with said liquid composition raises a melting temperature or viscosity of said liquid composition above a surface temperature of the thermal barrier coating. The melting point of the liquid composition is increased.
  • the practice of this invention makes it possible to extend the effective life of gas turbine engine thermal barrier coatings at a specific set of operating parameters including operating temperature and operating environment. It also provides a means to provide for engine designs which impose increased thermal burdens on thermal barrier coatings such as reduced cooling of thermal barrier coated parts or exposure of such parts to higher temperature input, i.e., effective increase of operating temperatures for the engine system. Accordingly, the practice of this invention provides for substantial enhancement of the functions of currently available thermal barrier coatings under more rigorous thermal assault as demands for performance escalate.

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Combustion & Propulsion (AREA)
  • Plasma & Fusion (AREA)
  • Physics & Mathematics (AREA)
  • Inorganic Chemistry (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
  • Coating By Spraying Or Casting (AREA)
PCT/US1996/003684 1995-04-03 1996-03-18 Method and composite for protection of thermal barrier coating by a sacrificial surface coating WO1996031293A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
JP53031196A JP3995713B2 (ja) 1995-04-03 1996-03-18 犠牲的な表面被膜によりサーマルバリアコーティングを保護するための方法および複合材
DE19680223T DE19680223B3 (de) 1995-04-03 1996-03-18 Verfahren zum Schutz eines Wärmesperren-Überzuges und entsprechendes Bauteil

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US08/415,913 US5660885A (en) 1995-04-03 1995-04-03 Protection of thermal barrier coating by a sacrificial surface coating
US41757795A 1995-04-06 1995-04-06
US08/415,913 1995-04-06
US08/417,577 1995-04-06

Publications (1)

Publication Number Publication Date
WO1996031293A1 true WO1996031293A1 (en) 1996-10-10

Family

ID=27023168

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1996/003684 WO1996031293A1 (en) 1995-04-03 1996-03-18 Method and composite for protection of thermal barrier coating by a sacrificial surface coating

Country Status (6)

Country Link
JP (1) JP3995713B2 (ko)
KR (1) KR100436256B1 (ko)
CH (1) CH690581A5 (ko)
DE (1) DE19680223B3 (ko)
IN (1) IN188355B (ko)
WO (1) WO1996031293A1 (ko)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1998026110A1 (de) * 1996-12-10 1998-06-18 Siemens Aktiengesellschaft Erzeugnis, welches einem heissen gas aussetzbar ist, mit einer wärmedämmschicht sowie verfahren zur herstellung
WO1999023278A1 (de) 1997-11-03 1999-05-14 Siemens Aktiengesellschaft Erzeugnis, insbesondere bauteil einer gasturbine, mit keramischer wärmedämmschicht
EP1382715A1 (en) * 2002-07-19 2004-01-21 General Electric Company Protection of a gas turbine component by a vapor-deposited oxide coating
WO2010080240A1 (en) * 2008-12-19 2010-07-15 General Electric Company Cmas mitigation compositions, environmental barrier coatings comprising the same, and ceramic components comprising the same
WO2010080241A1 (en) * 2008-12-19 2010-07-15 General Electric Company Methods for making environmental barrier coatings and ceramic components having cmas mitigation capability
EP2233600A1 (en) 2009-03-26 2010-09-29 Alstom Technology Ltd Method for the protection of a thermal barrier coating system and a method for the renewal of such a protection
US7875370B2 (en) 2006-08-18 2011-01-25 United Technologies Corporation Thermal barrier coating with a plasma spray top layer
US11174557B2 (en) 2017-01-30 2021-11-16 Siemens Energy Global GmbH & Co. KG Thermal barrier coating system compatible with overlay

Families Citing this family (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6231998B1 (en) * 1999-05-04 2001-05-15 Siemens Westinghouse Power Corporation Thermal barrier coating
US7927722B2 (en) * 2004-07-30 2011-04-19 United Technologies Corporation Dispersion strengthened rare earth stabilized zirconia
US7579087B2 (en) * 2006-01-10 2009-08-25 United Technologies Corporation Thermal barrier coating compositions, processes for applying same and articles coated with same
EP2128299B1 (en) * 2008-05-29 2016-12-28 General Electric Technology GmbH Multilayer thermal barrier coating
US8337996B2 (en) * 2010-11-22 2012-12-25 General Electric Company Vanadium resistant coating system
US11047033B2 (en) 2012-09-05 2021-06-29 Raytheon Technologies Corporation Thermal barrier coating for gas turbine engine components
US9995169B2 (en) 2013-03-13 2018-06-12 General Electric Company Calcium-magnesium-aluminosilicate resistant coating and process of forming a calcium-magnesium-aluminosilicate resistant coating
WO2014184906A1 (ja) * 2013-05-15 2014-11-20 株式会社日立製作所 遮熱コーティング部材
DE102014205491A1 (de) * 2014-03-25 2015-10-01 Siemens Aktiengesellschaft Keramisches Wärmedämmschichtsystem mit Schutzschicht gegen CMAS
DE102015221751A1 (de) * 2015-11-05 2017-05-11 Siemens Aktiengesellschaft Verfahren zur Herstellung einer Korrosionsschutzschicht für Wärmedämmschichten aus hohlen Aluminiumoxidkugeln und äußerster Glasschicht und Bauteil sowie Materialmischung

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4399199A (en) * 1979-02-01 1983-08-16 Johnson, Matthey & Co., Limited Protective layer
US5080977A (en) * 1990-07-31 1992-01-14 United States Of America, As Represented By The Administrator, Nat'l. Aero. And Space Admin. Composite thermal barrier coating
US5223045A (en) * 1987-08-17 1993-06-29 Barson Corporation Refractory metal composite coated article
US5338577A (en) * 1993-05-14 1994-08-16 Kemira, Inc. Metal with ceramic coating and method

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4399199A (en) * 1979-02-01 1983-08-16 Johnson, Matthey & Co., Limited Protective layer
US5223045A (en) * 1987-08-17 1993-06-29 Barson Corporation Refractory metal composite coated article
US5080977A (en) * 1990-07-31 1992-01-14 United States Of America, As Represented By The Administrator, Nat'l. Aero. And Space Admin. Composite thermal barrier coating
US5338577A (en) * 1993-05-14 1994-08-16 Kemira, Inc. Metal with ceramic coating and method

Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1998026110A1 (de) * 1996-12-10 1998-06-18 Siemens Aktiengesellschaft Erzeugnis, welches einem heissen gas aussetzbar ist, mit einer wärmedämmschicht sowie verfahren zur herstellung
WO1999023278A1 (de) 1997-11-03 1999-05-14 Siemens Aktiengesellschaft Erzeugnis, insbesondere bauteil einer gasturbine, mit keramischer wärmedämmschicht
EP1382715A1 (en) * 2002-07-19 2004-01-21 General Electric Company Protection of a gas turbine component by a vapor-deposited oxide coating
US6926928B2 (en) * 2002-07-19 2005-08-09 General Electric Company Protection of a gas turbine component by a vapor-deposited oxide coating
US7875370B2 (en) 2006-08-18 2011-01-25 United Technologies Corporation Thermal barrier coating with a plasma spray top layer
US8343589B2 (en) 2008-12-19 2013-01-01 General Electric Company Methods for making environmental barrier coatings and ceramic components having CMAS mitigation capability
WO2010080241A1 (en) * 2008-12-19 2010-07-15 General Electric Company Methods for making environmental barrier coatings and ceramic components having cmas mitigation capability
JP2012512966A (ja) * 2008-12-19 2012-06-07 ゼネラル・エレクトリック・カンパニイ 環境バリアコーティングおよびcmas緩和能力を有するセラミック構成部品を作製する方法
WO2010080240A1 (en) * 2008-12-19 2010-07-15 General Electric Company Cmas mitigation compositions, environmental barrier coatings comprising the same, and ceramic components comprising the same
US8859052B2 (en) 2008-12-19 2014-10-14 General Electric Company Methods for making environmental barrier coatings and ceramic components having CMAS mitigation capability
EP2233600A1 (en) 2009-03-26 2010-09-29 Alstom Technology Ltd Method for the protection of a thermal barrier coating system and a method for the renewal of such a protection
US8356482B2 (en) 2009-03-26 2013-01-22 Alstom Technology Ltd. Methods for the protection of a thermal barrier coating system and methods for the renewal of such a protection
US11174557B2 (en) 2017-01-30 2021-11-16 Siemens Energy Global GmbH & Co. KG Thermal barrier coating system compatible with overlay

Also Published As

Publication number Publication date
IN188355B (ko) 2002-09-14
JP3995713B2 (ja) 2007-10-24
CH690581A5 (de) 2000-10-31
DE19680223B3 (de) 2013-01-17
KR100436256B1 (ko) 2004-07-16
DE19680223T1 (de) 1997-06-05
KR970703205A (ko) 1997-07-03
JPH10502310A (ja) 1998-03-03

Similar Documents

Publication Publication Date Title
US5660885A (en) Protection of thermal barrier coating by a sacrificial surface coating
US5773141A (en) Protected thermal barrier coating composite
US5871820A (en) Protection of thermal barrier coating with an impermeable barrier coating
US5851678A (en) Composite thermal barrier coating with impermeable coating
US5914189A (en) Protected thermal barrier coating composite with multiple coatings
US6261643B1 (en) Protected thermal barrier coating composite with multiple coatings
EP2766504B1 (en) Thermal barrier coating systems and processes therefor
US6558814B2 (en) Low thermal conductivity thermal barrier coating system and method therefor
US9023486B2 (en) Thermal barrier coating systems and processes therefor
US6465090B1 (en) Protective coating for thermal barrier coatings and coating method therefor
CA1167329A (en) Columnar grain ceramic thermal barrier coatings
US8062759B2 (en) Thermal barrier coating systems including a rare earth aluminate layer for improved resistance to CMAS infiltration and coated articles
JP3825114B2 (ja) 粒状物によるエロージョン及び衝撃に対して耐性の断熱皮膜
WO1996031293A1 (en) Method and composite for protection of thermal barrier coating by a sacrificial surface coating
JP3727948B2 (ja) 不浸透性バリアコーティングによりサーマルバリアコーティングを保護するための方法および複合材
US20070224411A1 (en) Protection of thermal barrier coating by impermeable barrier coating
US20090169752A1 (en) Method for Improving Resistance to CMAS Infiltration
US6929868B2 (en) SRZ-susceptible superalloy article having a protective layer thereon
JP3353035B2 (ja) 断熱皮膜系

Legal Events

Date Code Title Description
AK Designated states

Kind code of ref document: A1

Designated state(s): CH DE JP KR

WWE Wipo information: entry into national phase

Ref document number: 1019960706851

Country of ref document: KR

RET De translation (de og part 6b)

Ref document number: 19680223

Country of ref document: DE

Date of ref document: 19970605

WWE Wipo information: entry into national phase

Ref document number: 19680223

Country of ref document: DE

WWE Wipo information: entry into national phase

Ref document number: 09091692

Country of ref document: US

REG Reference to national code

Ref country code: DE

Ref legal event code: 8607