WO2014092916A1 - Environmental barrier coatings and methods therefor - Google Patents
Environmental barrier coatings and methods therefor Download PDFInfo
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- WO2014092916A1 WO2014092916A1 PCT/US2013/069833 US2013069833W WO2014092916A1 WO 2014092916 A1 WO2014092916 A1 WO 2014092916A1 US 2013069833 W US2013069833 W US 2013069833W WO 2014092916 A1 WO2014092916 A1 WO 2014092916A1
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- WIPO (PCT)
- Prior art keywords
- silicon
- article according
- containing region
- surface features
- article
- Prior art date
Links
- 230000007613 environmental effect Effects 0.000 title description 14
- 238000000576 coating method Methods 0.000 title description 13
- 230000004888 barrier function Effects 0.000 title description 12
- 238000000034 method Methods 0.000 title description 11
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims abstract description 60
- 229910052710 silicon Inorganic materials 0.000 claims abstract description 60
- 239000010703 silicon Substances 0.000 claims abstract description 60
- 239000000470 constituent Substances 0.000 claims abstract description 46
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 37
- 239000000758 substrate Substances 0.000 claims description 29
- 239000000463 material Substances 0.000 claims description 13
- 239000000203 mixture Substances 0.000 claims description 13
- 239000000377 silicon dioxide Substances 0.000 claims description 13
- 229910000323 aluminium silicate Inorganic materials 0.000 claims description 8
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 8
- 229910052581 Si3N4 Inorganic materials 0.000 claims description 7
- 230000001788 irregular Effects 0.000 claims description 7
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 7
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 claims description 7
- 239000011159 matrix material Substances 0.000 claims description 6
- 229910021332 silicide Inorganic materials 0.000 claims description 6
- 239000011153 ceramic matrix composite Substances 0.000 claims description 5
- 239000002131 composite material Substances 0.000 claims description 5
- 229910052761 rare earth metal Inorganic materials 0.000 claims description 5
- 230000002787 reinforcement Effects 0.000 claims description 5
- FVBUAEGBCNSCDD-UHFFFAOYSA-N silicide(4-) Chemical class [Si-4] FVBUAEGBCNSCDD-UHFFFAOYSA-N 0.000 claims description 5
- 239000003870 refractory metal Substances 0.000 claims description 4
- 229910021350 transition metal silicide Inorganic materials 0.000 claims description 4
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 claims description 3
- 239000011521 glass Substances 0.000 claims description 3
- 150000002910 rare earth metals Chemical class 0.000 claims description 3
- -1 rare earth silicates Chemical class 0.000 claims description 3
- 229910000676 Si alloy Inorganic materials 0.000 claims description 2
- 238000004519 manufacturing process Methods 0.000 claims description 2
- 229910052750 molybdenum Inorganic materials 0.000 claims description 2
- 229910052758 niobium Inorganic materials 0.000 claims description 2
- 230000003746 surface roughness Effects 0.000 claims description 2
- 229910052727 yttrium Inorganic materials 0.000 claims description 2
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims 1
- 229910052692 Dysprosium Inorganic materials 0.000 claims 1
- 229910052691 Erbium Inorganic materials 0.000 claims 1
- 229910052688 Gadolinium Inorganic materials 0.000 claims 1
- 229910052689 Holmium Inorganic materials 0.000 claims 1
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 claims 1
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 claims 1
- KJTLSVCANCCWHF-UHFFFAOYSA-N Ruthenium Chemical compound [Ru] KJTLSVCANCCWHF-UHFFFAOYSA-N 0.000 claims 1
- 229910052771 Terbium Inorganic materials 0.000 claims 1
- 229910052775 Thulium Inorganic materials 0.000 claims 1
- 229910052769 Ytterbium Inorganic materials 0.000 claims 1
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 claims 1
- 229910052804 chromium Inorganic materials 0.000 claims 1
- 239000011651 chromium Substances 0.000 claims 1
- 150000001875 compounds Chemical class 0.000 claims 1
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 claims 1
- 229910052735 hafnium Inorganic materials 0.000 claims 1
- VBJZVLUMGGDVMO-UHFFFAOYSA-N hafnium atom Chemical compound [Hf] VBJZVLUMGGDVMO-UHFFFAOYSA-N 0.000 claims 1
- 229910052741 iridium Inorganic materials 0.000 claims 1
- GKOZUEZYRPOHIO-UHFFFAOYSA-N iridium atom Chemical compound [Ir] GKOZUEZYRPOHIO-UHFFFAOYSA-N 0.000 claims 1
- 239000011733 molybdenum Substances 0.000 claims 1
- 229910052863 mullite Inorganic materials 0.000 claims 1
- 239000010955 niobium Substances 0.000 claims 1
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 claims 1
- 229910052762 osmium Inorganic materials 0.000 claims 1
- SYQBFIAQOQZEGI-UHFFFAOYSA-N osmium atom Chemical compound [Os] SYQBFIAQOQZEGI-UHFFFAOYSA-N 0.000 claims 1
- 229910052702 rhenium Inorganic materials 0.000 claims 1
- WUAPFZMCVAUBPE-UHFFFAOYSA-N rhenium atom Chemical compound [Re] WUAPFZMCVAUBPE-UHFFFAOYSA-N 0.000 claims 1
- 229910052703 rhodium Inorganic materials 0.000 claims 1
- 239000010948 rhodium Substances 0.000 claims 1
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 claims 1
- 229910052707 ruthenium Inorganic materials 0.000 claims 1
- 229910052706 scandium Inorganic materials 0.000 claims 1
- 229910052715 tantalum Inorganic materials 0.000 claims 1
- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum atom Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 claims 1
- 229910021342 tungsten silicide Inorganic materials 0.000 claims 1
- 229910052726 zirconium Inorganic materials 0.000 claims 1
- 238000005516 engineering process Methods 0.000 description 19
- 239000011248 coating agent Substances 0.000 description 11
- 238000006073 displacement reaction Methods 0.000 description 9
- GLXWZXLWIAEWDJ-UHFFFAOYSA-N EBC-25 Natural products O1C(CC(CCCCCCCCCCCCC)OC(C)=O)CC(O)CC11OC2C=CC(=O)OC2C1 GLXWZXLWIAEWDJ-UHFFFAOYSA-N 0.000 description 7
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 7
- 239000001301 oxygen Substances 0.000 description 7
- 229910052760 oxygen Inorganic materials 0.000 description 7
- 230000003647 oxidation Effects 0.000 description 5
- 238000007254 oxidation reaction Methods 0.000 description 5
- 238000000151 deposition Methods 0.000 description 4
- 230000008021 deposition Effects 0.000 description 4
- 238000009826 distribution Methods 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- 238000006243 chemical reaction Methods 0.000 description 3
- 230000035699 permeability Effects 0.000 description 3
- 230000008569 process Effects 0.000 description 3
- 235000012239 silicon dioxide Nutrition 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 230000000996 additive effect Effects 0.000 description 2
- 230000015556 catabolic process Effects 0.000 description 2
- 238000005229 chemical vapour deposition Methods 0.000 description 2
- 229910052681 coesite Inorganic materials 0.000 description 2
- 229910052906 cristobalite Inorganic materials 0.000 description 2
- 229910002026 crystalline silica Inorganic materials 0.000 description 2
- 238000006731 degradation reaction Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 230000001681 protective effect Effects 0.000 description 2
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 description 2
- 229910052682 stishovite Inorganic materials 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 229910052905 tridymite Inorganic materials 0.000 description 2
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 230000003466 anti-cipated effect Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000005422 blasting Methods 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 238000003486 chemical etching Methods 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 230000006378 damage Effects 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 230000002401 inhibitory effect Effects 0.000 description 1
- 150000002500 ions Chemical class 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 230000000873 masking effect Effects 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 239000007800 oxidant agent Substances 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- 238000001020 plasma etching Methods 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 239000011253 protective coating Substances 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 230000009528 severe injury Effects 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000004901 spalling Methods 0.000 description 1
- 229910000601 superalloy Inorganic materials 0.000 description 1
- 238000005382 thermal cycling Methods 0.000 description 1
- 238000007751 thermal spraying Methods 0.000 description 1
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/52—Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
- C04B41/81—Coating or impregnation
- C04B41/89—Coating or impregnation for obtaining at least two superposed coatings having different compositions
-
- 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
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
- F01D5/288—Protective coatings for blades
-
- Y—GENERAL 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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
- Y10T428/24612—Composite web or sheet
Definitions
- the present technology generally relates to coating systems and methods suitable for protecting components exposed to high-temperature environments, such as the hostile thermal environment of a turbine engine. More particularly, this technology is directed to an environmental barrier coating (EBC) on a silicon-containing region of a component and to the incorporation of surface features in the silicon-containing region to inhibit creep displacement of the EBC when subjected to shear loading at elevated temperatures.
- EBC environmental barrier coating
- Ceramic composite materials are being developed for such high temperature applications as combustor liners, vanes, shrouds, blades, and other hot section components of turbine engines.
- Some examples of composite materials include silicon-based composites, for example, composite materials in which silicon, silicon carbide (SiC), silicon nitride (Si 3 N 4 ), and/or a metal silicide serves as a reinforcement phase and/or a matrix phase.
- a protective coating is beneficial or required for a Si-containing material.
- Such coatings should provide environmental protection by inhibiting the formation of volatile silicon hydroxide (for example, Si(OH) ) products and, desirably, preventing ingress of water vapor to the oxidizing surface.
- a coating system having these functions will be referred to below as an environmental barrier coating (EBC) system.
- Desirable properties for the coating material include a coefficient of thermal expansion (CTE) compatible with the Si-containing substrate material, low permeability for oxidants, low thermal conductivity, low silica chemical activity and chemical compatibility with the underlying Si-containing material and thermally grown silica scale.
- CTE coefficient of thermal expansion
- the silicon content of a silicon-containing bondcoat reacts with oxygen and/or water vapor at high temperatures to form an oxide product, predominantly an amorphous silica (S1O 2 ) scale, though a fraction of the oxide product may be crystalline silica or the (solid or gaseous) oxides of other constituents of the bondcoat.
- the amorphous silica product exhibits low oxygen permeability.
- the silica product that thermally grows on the bondcoat is able to form a protective barrier layer that deters permeation of oxygen into the substrate.
- the amorphous silica product that forms on a silicon-containing bondcoat in service has a relatively low viscosity and consequently a high creep rate under shear loading at the operating temperatures.
- High shear loads can be imposed by g forces resulting from rotation of parts, such as blades (buckets) of turbine engines. Such shear loading may cause creep displacements of the EBC relative to the substrate, which can result in severe EBC damage and even direct loss of EBC protection of the underlying substrate.
- the present technology provides an environmental barrier coating (EBC) system and a method of fabricating the EBC system on an article formed of a silicon-containing material, such as a ceramic matrix composite (CMC) in which a silicon-containing material serves as a reinforcement phase and/or a matrix phase.
- EBC environmental barrier coating
- CMC ceramic matrix composite
- the EBC system and method are particularly well suited for protecting silicon-containing articles exposed to high temperatures, including the hostile thermal environment of a turbine engine.
- an article comprises a silicon- containing region comprising surface features on a surface thereof, the surface features comprising depressions, protuberances, or combinations thereof; at least one outer layer overlying the surface of the silicon-containing region; and a constituent layer on the surface of the silicon-containing region and between and contacting the silicon-containing region and the at least one outer layer, the constituent layer being formed by oxidation of constituents of the silicon-containing region and being susceptible to creep within an operating environment of the article, the surface features physically interlocking the at least one outer layer with the silicon-containing region through the constituent layer.
- a method of coating a silicon- containing region of an article comprises forming surface features on a surface of the silicon-containing region, the surface features comprising depressions, protuberances, or combinations thereof; forming at least one outer layer overlying the surface of the silicon- containing region; and forming a constituent layer on the surface of the silicon-containing region between the silicon-containing region and the at least one outer layer, the
- constituent layer being formed by oxidation of constituents of the silicon-containing region and being susceptible to creep within an operating environment of the article, and the surface features physically interlocking the at least one outer layer with the silicon- containing region through the constituent layer.
- FIG. 1 schematically represents an EBC system containing a bondcoat whose surface is configured to have a regular distribution of surface features in accordance with an example of the present technology
- FIG. 2 schematically represents an EBC system containing a bondcoat whose surface is configured to have an irregular distribution of surface features in accordance with another example of the present technology.
- the present technology is generally applicable to components that operate within environments characterized by high temperatures, thermal cycling, thermal and mechanical stresses, and oxidation.
- components include high and low pressure turbine vanes (nozzles) and blades (buckets), shrouds, combustor liners, augmentor hardware, and other hot section components of turbine engines, though the technology has application to other components.
- nozzles high and low pressure turbine vanes
- buckets blades
- shrouds shrouds
- combustor liners combustor liners
- augmentor hardware augmentor hardware
- the present technology is applicable to rotating components of turbine engines, such as blades (buckets).
- Multilayer environmental barrier coating (EBC) systems 14 in accordance with examples of this technology are schematically represented in FIGS. 1 and 2 as protecting a substrate 12 of a component or article 10.
- the substrate 12 may include a silicon- containing region.
- silicon-containing materials include those with a silicon carbide, silicon nitride, a silicide (for example, a refractory metal or transition metal silicide, including, but not limited to, for example Mo, Nb, or W silicides) and/or silicon as a matrix or second phase.
- Further examples include ceramic matrix composites (CMC) that contain silicon carbide as the reinforcement and/or matrix phase.
- the EBC systems 14 of FIGS. 1 and 2 represent one of a variety of different EBC systems that can incorporate a silicon-containing bondcoat 16, shown in FIGS. 1 and 2 as being directly applied to a surface 34 of the substrate 12.
- An example of a silicon- containing bondcoat is disclosed in, for example, U.S. 6,299,988.
- the bondcoat 16 is further represented as bonding a first EBC layer 20 to the substrate 12, and optionally at least one additional layer 22, 24, 18 of the EBC system 14.
- the EBC system 14 is intended to provide environmental protection to the underlying substrate 12, as well as to potentially reduce the operating temperature of the component 10, thereby enabling the component 10 to operate at higher gas temperatures than otherwise possible. While FIGS.
- 1 and 2 represent the EBC system 14 as including the silicon-containing bondcoat 16, in which case the first EBC layer 20 is deposited directly on a silicon-containing surface region formed by the bondcoat 16, the technology is also applicable to an EBC system 14 that does not include a bondcoat 16 as described herein, in which case the first EBC layer 20 is deposited directly on a silicon-containing surface region formed by the substrate 12. It should be appreciated that a constituent layer 30, or a portion of the constituent layer 30, described in more detail below, may be present prior to application of the first EBC layer 20.
- EBC silicon hydroxide
- the EBC layers 25, hereafter referred to as EBC may serve to resist recession by chemical reaction of the bondcoat 16 and/or substrate 12 with water vapor, provide a temperature gradient to reduce the operating temperature of the component 10, or both.
- Suitable EBC's usable with the present technology include, but are not limited to, those disclosed in, for example, U.S. 6,296,941 and U.S. 6,410,148.
- the EBC may perform a multitude of sealing, reaction barrier, recession resistance, and/or thermal barrier functions.
- each of the bondcoat 16 and substrate 12 may define a surface region of the component 10 that contains silicon.
- the bondcoat 16 may comprise or consist essentially of elemental silicon.
- the bondcoat 16 may contain silicon carbide, silicon nitride, metal silicides, elemental silicon, silicon alloys, or mixtures thereof.
- Bondcoat 16 may further contain oxide phases, such as silica, rare earth silicates, rare earth aluminosilicates, and/or alkaline earth aluminosilicates.
- oxide phases such as silica, rare earth silicates, rare earth aluminosilicates, and/or alkaline earth aluminosilicates.
- a thickness of the bondcoat 16 may be, for example, about 25 to about 350 ⁇ , for example about 50 to about 250 ⁇ , for example about 100 to 200 ⁇ , for example about 125 to 175 ⁇ , for example about 150 ⁇ .
- the silicon of the bondcoat 16 reacts with oxygen at elevated temperatures to thermally grow a constituent layer 30 of predominantly amorphous silica (SiO 2 ) on its surface 32, as schematically represented in FIGS. 1 and 2.
- the resulting amorphous silica exhibits low oxygen permeability.
- the constituent layer 30 is able to deter permeation of oxygen into the bondcoat 16 and substrate 12.
- some of the amorphous silica may crystallize into crystalline silica.
- the constituent layer 30 may have a composition other than pure silica, yet contain silica as a constituent derived from oxidation of the bondcoat 16.
- the constituent layer 30 may contain other elements in solution, such as, but not limited to, boron, aluminum, and/or nitrogen.
- the constituent layer 30 may also contain other phases, such as yttrium aluminosilicate (YAS) or rare earth disilicate (REDS).
- YAS yttrium aluminosilicate
- RDS rare earth disilicate
- the various possible compositions for the constituent layer 30 may be derived at least in part from the
- composition of the bondcoat 16 16.
- the first layer 20 of the EBC 25 can be deposited directly on a silicon-containing surface region of the component 10 defined by the substrate 12, in which case the substrate 12 is formed to have a composition whose silicon content is sufficient to react with oxygen at elevated temperatures and form a protective silica constituent layer 30 described above. Furthermore, depending on the composition of the substrate 12, this layer may be a predominantly amorphous silica product, a silica-rich glass, or a multi-phase mixture wherein one of the phases is silica- rich. As a matter of convenience, the remaining disclosure will make reference to
- the constituent layer 30 may have a relatively low viscosity and
- Creep of the constituent layer 30 that forms on the surface 32 of the silicon- containing bondcoat 16 may be inhibited by making the surface 32 of the bondcoat 16 to contain surface features, schematically represented in FIGS. 1 and 2 in the form of depressions (recesses) 26 and/or protuberances (protrusions) 28, respectively. While the depressions 26 and protuberances 28 are represented in FIGS. 1 and 2 as being only on the surface 32 of the bondcoat 16, it should be appreciated that similar surface features may be provided at the surface of the substrate 12.
- the surface features preferably extend from the bondcoat surface 32 by a thickness about equal to or greater than that of the constituent layer 30 that grows on the surface 32 over the service interval of component 10.
- the surface features 26, 28 may extend from or into the surface 32 of the bondcoat 16 by, for example, about 10 to about 200 ⁇ , for example about 40 to about 160 ⁇ , for example about 80 to about 120 ⁇ , for example about 100 ⁇ , though the dimensions may depend on the maximum anticipated thickness of the constituent layer 30 and other factors associated with the particular application.
- depressions 26 having a mean depth of about 50 to about 100 ⁇ may be effective, and protuberances 28 having a mean height of about 50 to about 100 ⁇ may be effective.
- Lateral dimensions for the depressions 26 and protuberances 28 may depend on the allowable displacement that the EBC 25 may experience as a result of creep of the constituent layer 30. The relative displacement of the EBC 25 will be limited by the depths and lateral dimensions of the depressions 26 and/or the heights of and mean distances between the protuberances 28.
- lateral dimensions for the depressions 26 and protuberances 28 may depend on the particular composition and construction of the EBC system 14 and the particular application of the component 10 protected by the EBC system 14, lateral dimensions may be from a minimum of about 10 m to a maximum of about equivalent to the dimensions of the article 10.
- protuberances 28 may be of the same size and shape (homogeneous or uniform) as shown in FIG. 1 or may have different sizes and/or shapes (heterogeneous or irregular) as shown in FIG. 2.
- Potential shapes for the depressions 26 and protuberances 28 include, but are not limited to, rectilinear shapes such as squares, rectangles and triangles and curvilinear shapes such as circles and ovals.
- Such depressions 26 and protuberances 28 may be discontinuous or continuous and defined by square waves, sine or random waves, tapered trenches, and irregular surface roughness generated as a result of the process by which the bondcoat 16 is deposited.
- the depressions 26 and/or protuberances 28 may be arranged to define a uniform or regular (homogeneous) array or pattern as represented by the depressions 26 of FIG. 1 , or arranged to define a non-uniform or irregular (heterogeneous) distribution or pattern as represented by the protuberances 28 of FIG. 2, or a combination of both.
- the depressions 26 and/or protuberances 28 may be roughly equally spaced from each other and may have roughly equal dimensions, whereas an irregular pattern may be characterized by depressions 26 and/or protuberances 28 that are unequally spaced from each other and/or have unequal dimensions.
- Suitable spacing between adjacent surface features 26/28 may be at least about 10 ⁇ , with more preferred ranges being about 20 to about 2000 ⁇ and particularly about 50 to about 1000 ⁇ .
- Densities for the depressions 26 and/or protuberances 28, as measured by discrete surface features per square centimeter of surface area of the bondcoat 16, may depend in part on the height/depth, shape and/or lateral dimensions of the surface features and the operating environment (e.g time, temperature and shear stress) of component 10.
- the depressions 26 and/or protuberances 28 may be formed during or following the deposition of the bondcoat 16 and prior to the deposition of the first layer 20.
- the depressions 26 and/or protuberances 28 may be fabricated by various processes.
- depressions 26 can be produced by various material removal (subtractive) methods, such as but not limited to grit blasting, chemical etching, plasma etching, and laser machining
- protuberances 28 may be produced by material deposition (additive) methods, such as chemical vapor deposition (CVD), ion plasma deposition (IPD), and thermal spraying. Sizes and distributions of depressions 26 and/or protuberances 28 may be controlled by suitable methods, such as masking.
- the depressions 26 and/or protuberances 28 on the bondcoat 16 provide a means by which the constituent layer 30 that grows on the bondcoat 16 and a first EBC layer 20 deposited on the bondcoat 16 may be physically interlocked with the bondcoat 16, even as the constituent layer 30 continues to grow on the surface 32 of the bondcoat 16, including within its depressions 26 and/or over its protrusions 28.
- the depressions 26 and/or protuberances 28 on the bondcoat 16 limit displacement of the constituent layer 30 and, therefore, the relative displacement of the EBC 25.
- the depressions 26 and/or protuberances 28 are able to inhibit long-range sliding of the EBC 25 that can occur with respect to the bondcoat 16 and substrate 12 if the surface 32 of the bondcoat 16 were microscopically smooth, particularly if the component 10 is a rotating component, such as a bucket/blade of a turbine engine. If not inhibited by the depressions 26 and/or protuberances 28, such sliding would cause cracking and spalling of the overlying EBC 25 with subsequent loss of the environmental protection provided by the multilayer EBC system 14. In an extreme case, loss of the EBC system 14 over large surface regions of the component 10 can lead to rapid environmental degradation and ultimate failure of the component 10.
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- General Engineering & Computer Science (AREA)
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- Wood Science & Technology (AREA)
- Turbine Rotor Nozzle Sealing (AREA)
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- Other Surface Treatments For Metallic Materials (AREA)
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Abstract
Description
Claims
Priority Applications (6)
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EP13808287.0A EP2931939B1 (en) | 2012-12-11 | 2013-11-13 | Environmental barrier coatings and methods therefor |
BR112015012655A BR112015012655A2 (en) | 2012-12-11 | 2013-11-13 | article and method for making a coated article |
CA2893872A CA2893872C (en) | 2012-12-11 | 2013-11-13 | Environmental barrier coatings and methods therefor |
CN201380064866.2A CN104838039B (en) | 2012-12-11 | 2013-11-13 | Environment barrier coating and its method |
EP21166780.3A EP3865603A1 (en) | 2012-12-11 | 2013-11-13 | Environmental barrier coatings and methods therefor |
JP2015546488A JP6405315B2 (en) | 2012-12-11 | 2013-11-13 | Environmental barrier coating and method thereof |
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US13/711,250 | 2012-12-11 | ||
US13/711,250 US9428650B2 (en) | 2012-12-11 | 2012-12-11 | Environmental barrier coatings and methods therefor |
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US (1) | US9428650B2 (en) |
EP (2) | EP2931939B1 (en) |
JP (1) | JP6405315B2 (en) |
CN (1) | CN104838039B (en) |
BR (1) | BR112015012655A2 (en) |
CA (1) | CA2893872C (en) |
WO (1) | WO2014092916A1 (en) |
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Also Published As
Publication number | Publication date |
---|---|
EP2931939A1 (en) | 2015-10-21 |
CA2893872A1 (en) | 2014-06-19 |
CA2893872C (en) | 2018-11-06 |
JP2016506315A (en) | 2016-03-03 |
US20140162027A1 (en) | 2014-06-12 |
CN104838039A (en) | 2015-08-12 |
BR112015012655A2 (en) | 2017-07-11 |
EP3865603A1 (en) | 2021-08-18 |
US9428650B2 (en) | 2016-08-30 |
EP2931939B1 (en) | 2021-04-07 |
JP6405315B2 (en) | 2018-10-17 |
CN104838039B (en) | 2018-03-30 |
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