WO2014151788A1 - Spallation-resistant thermal barrier coating - Google Patents
Spallation-resistant thermal barrier coating Download PDFInfo
- Publication number
- WO2014151788A1 WO2014151788A1 PCT/US2014/026452 US2014026452W WO2014151788A1 WO 2014151788 A1 WO2014151788 A1 WO 2014151788A1 US 2014026452 W US2014026452 W US 2014026452W WO 2014151788 A1 WO2014151788 A1 WO 2014151788A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- layer
- bondcoat
- cathode
- article
- deposition
- Prior art date
Links
- 239000012720 thermal barrier coating Substances 0.000 title claims abstract description 51
- 239000000758 substrate Substances 0.000 claims abstract description 31
- 239000011651 chromium Substances 0.000 claims description 43
- 238000000151 deposition Methods 0.000 claims description 32
- 238000000034 method Methods 0.000 claims description 28
- 239000000463 material Substances 0.000 claims description 23
- 239000000203 mixture Substances 0.000 claims description 23
- 230000008021 deposition Effects 0.000 claims description 22
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 20
- 229910052782 aluminium Inorganic materials 0.000 claims description 16
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 15
- 229910000601 superalloy Inorganic materials 0.000 claims description 13
- 229910001233 yttria-stabilized zirconia Inorganic materials 0.000 claims description 13
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 10
- 238000000541 cathodic arc deposition Methods 0.000 claims description 9
- 229910052804 chromium Inorganic materials 0.000 claims description 9
- 229910017052 cobalt Inorganic materials 0.000 claims description 9
- 239000010941 cobalt Substances 0.000 claims description 9
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 claims description 9
- 229910052759 nickel Inorganic materials 0.000 claims description 9
- 238000004519 manufacturing process Methods 0.000 claims description 7
- 229910002076 stabilized zirconia Inorganic materials 0.000 claims description 6
- 239000010410 layer Substances 0.000 description 85
- 239000000919 ceramic Substances 0.000 description 11
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 7
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 6
- 238000000576 coating method Methods 0.000 description 6
- 239000001301 oxygen Substances 0.000 description 6
- 229910052760 oxygen Inorganic materials 0.000 description 6
- 239000011248 coating agent Substances 0.000 description 5
- 238000005260 corrosion Methods 0.000 description 5
- 239000007789 gas Substances 0.000 description 5
- 238000005240 physical vapour deposition Methods 0.000 description 5
- 230000007797 corrosion Effects 0.000 description 4
- 239000007921 spray Substances 0.000 description 4
- 230000007704 transition Effects 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 3
- QDOXWKRWXJOMAK-UHFFFAOYSA-N dichromium trioxide Chemical compound O=[Cr]O[Cr]=O QDOXWKRWXJOMAK-UHFFFAOYSA-N 0.000 description 3
- 238000010894 electron beam technology Methods 0.000 description 3
- 230000008569 process Effects 0.000 description 3
- 230000008901 benefit Effects 0.000 description 2
- 238000005266 casting Methods 0.000 description 2
- 238000004140 cleaning Methods 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 238000005137 deposition process Methods 0.000 description 2
- 230000003647 oxidation Effects 0.000 description 2
- 238000007254 oxidation reaction Methods 0.000 description 2
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical group O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 2
- 239000012466 permeate Substances 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 238000000926 separation method Methods 0.000 description 2
- 239000002356 single layer Substances 0.000 description 2
- 238000004544 sputter deposition Methods 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 239000010953 base metal Substances 0.000 description 1
- 238000005422 blasting Methods 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 238000005056 compaction Methods 0.000 description 1
- 230000000295 complement effect Effects 0.000 description 1
- 230000003750 conditioning effect Effects 0.000 description 1
- 239000000356 contaminant Substances 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 238000005328 electron beam physical vapour deposition Methods 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 229910052735 hafnium Inorganic materials 0.000 description 1
- VBJZVLUMGGDVMO-UHFFFAOYSA-N hafnium atom Chemical compound [Hf] VBJZVLUMGGDVMO-UHFFFAOYSA-N 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000012212 insulator Substances 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000012811 non-conductive material Substances 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 description 1
- 230000037361 pathway Effects 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 238000007581 slurry coating method Methods 0.000 description 1
- 108010004034 stable plasma protein solution Proteins 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000000725 suspension Substances 0.000 description 1
- 238000012795 verification Methods 0.000 description 1
- 229910052727 yttrium Inorganic materials 0.000 description 1
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
- 229910001928 zirconium oxide Inorganic materials 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
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
- C23C14/08—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
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
- C23C14/14—Metallic material, boron or silicon
- C23C14/16—Metallic material, boron or silicon on metallic substrates or on substrates of boron or silicon
-
- 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
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
- C23C14/24—Vacuum evaporation
-
- 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
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
- C23C14/24—Vacuum evaporation
- C23C14/32—Vacuum evaporation by explosion; by evaporation and subsequent ionisation of the vapours, e.g. ion-plating
- C23C14/325—Electric arc evaporation
-
- 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
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2300/00—Materials; Properties thereof
- F05D2300/10—Metals, alloys or intermetallic compounds
- F05D2300/13—Refractory metals, i.e. Ti, V, Cr, Zr, Nb, Mo, Hf, Ta, W
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2300/00—Materials; Properties thereof
- F05D2300/10—Metals, alloys or intermetallic compounds
- F05D2300/17—Alloys
- F05D2300/175—Superalloys
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2300/00—Materials; Properties thereof
- F05D2300/20—Oxide or non-oxide ceramics
- F05D2300/21—Oxide ceramics
- F05D2300/2118—Zirconium oxides
-
- 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
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
- Y10T428/12535—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.] with additional, spatially distinct nonmetal component
- Y10T428/12611—Oxide-containing component
- Y10T428/12618—Plural oxides
Definitions
- the disclosure relates to gas turbine engines. More particularly, the disclosure relates to hot-corrosion
- Exemplary thermal barrier coating systems include two-layer thermal barrier coating systems.
- An exemplary system includes NiCoCrAlY bondcoat as the first layer (e.g., low pressure plasma sprayed (LPPS) ) and yttria-stabilized zirconia (YSZ) (or gadolinia-stabilized zirconia (GSZ) ) thermal barrier coating (TBC) (e.g., air plasma sprayed (APS), suspension plasma sprayed (SPS) or electron beam physical vapor deposited (EBPVD) ) as the second layer.
- a thermally grown oxide (TGO) layer e.g., alumina
- TGO interface layer grows in thickness.
- An exemplary YSZ is 7 weight percent
- Exemplary TBCs are applied to thicknesses of 1-40 mils ( 0.025-1. Omm) and can contribute to a temperature reduction of up to 300°F (167°C) at the base metal. This temperature reduction translates into improved part durability, or higher turbine operating temperatures and improved turbine
- One aspect of the disclosure involves a coated article having: a metallic substrate; a bondcoat; and a thermal barrier coating (TBC) .
- the bondcoat has a first layer and a second layer, the first layer having a lower Cr content than the second layer.
- single or multilayer TBC comprises material selected from the group consisting of
- the article consists essentially of the substrate, the bondcoat first layer, the bondcoat second layer, thermally grown oxide (TGO) and the TBC.
- the bondcoat second layer comprises 20-40 Cr, up to 30 Co, 5-13 Al, up to 2 Y, up to 2 Si, and up to 2 Hf; and the bondcoat first layer
- the bondcoat second layer comprises 20-40 Cr, up to 30 Co, 5-13 Al, up to 2 Y, up to 2 Si, and up to 2 Hf; and the bondcoat first layer
- the bondcoat second layer has a
- chromium content at least 10 weight percent higher than a chromium content of the bondcoat first layer; and the bondcoat first layer has an aluminum content at least 2 weight percent higher than an aluminum content of the bondcoat second layer.
- the bondcoat second layer comprises 20-40 Cr, up to 30 Co, 5-13 Al, up to 2 Y, up to 2 Si, and up to 2 Hf; and the bondcoat first layer
- the bondcoat second layer has a
- chromium content at least 10 weight percent higher than a chromium content of the bondcoat first layer.
- the bondcoat first layer has an aluminum content equal to or greater than than an aluminum content of the bondcoat second layer minus 2 weight percent.
- the substrate comprises a nickel or a cobalt based superalloy.
- the nickel based superalloy comprises, in weight %, 4.5-24 Cr, 4.5-20 Co, up to 4.5 Mo, 1.5-11 W, up to 5.5 Ti, up to 12.25 Ta, 1-6.2 Al, up to 0.05 B, up to 0.2 C, up to 0.2 Zr, up to 1.2 Nb, up to 2.0 Hf, and up to 3.5 Re.
- the cobalt based superalloy comprises, in weight %, 18-31 Cr, up to 15 Ni, up to 10 Mo, up to 12 W, up to 3 Ti, 1-10 Ta, up to 0.5 Al, up to 0.02 B, 0.1 to 0.9 C, 0.2 to 0.6 Zr, up to 2 Nb, and up to 2 Fe .
- a method for manufacturing the article comprises: applying the bondcoat first layer having an
- as-applied weight % composition comprising 1.0-30 Cr, up to 30 Co, 3-35 Al, 0.1-2 Y, 0.1 to 2 Hf, 0.1 to 7 Si, up to 8 Ta, up to 8 W, up to 2 Mo, and up to 2 Zr; and applying the bondcoat second layer atop the bondcoat first layer and having an as- applied weight % composition comprising 20-40 Cr, up to 30 Co, 5-13 Al, up to 2 Y, up to 2 Si, and up to 2 Hf.
- the article consists essentially of the substrate, the bondcoat first layer, the bondcoat second layer, and the TBC .
- a method for manufacturing the article comprises: applying the bondcoat first layer having an
- as-applied weight % composition comprising 5-30 Cr, up to 30 Co, 6-35 Al, 0.1-2 Y, 0.1 to 2 Hf, 0.1 to 7 Si, up to 8 Ta, up to 8 W, up to 2 Mo, and up to 2 Zr; and applying the bondcoat second layer atop the bondcoat first layer and having an as-applied weight % composition comprising 20-40 Cr, up to 30 Co, 5-13 Al, up to 2 Y, up to 2 Si, and up to 2 Hf.
- a method for manufacturing the article comprises: applying the bondcoat first layer having an
- the bondcoat first layer and the bondcoat second layer are applied by cathodic arc deposition. However, they could be applied by one or a combination of methods such as LPPS, HVOF, sputtering, EB-PVD or others known in industry.
- the bondcoat second layer is applied directly atop the bondcoat first layer; and the TBC is applied directly atop the bondcoat second layer.
- a characteristic thickness of the bondcoat first layer is 1 to 10 mils (0.02 mm to 0.25 mm); and a characteristic thickness of the bondcoat second layer is 1 to 10 mils (0.02 mm to 0.25 mm) .
- the TBC comprises yttria-stabilized zirconia or gadolinia-stabilized zirconia or combinations of the two .
- the substrate comprises a nickel based or a cobalt based superalloy.
- Another aspect of the disclosure involves a method for cathodic arc deposition from a first cathode and a second cathode.
- the method comprises: placing one or more
- the shifting comprises vertically moving the magnet from a first position to a second position.
- the method further comprises:
- the anode is a wall of the vacuum coating-chamber .
- the substrate comprises a nickel-based or a cobalt-based superalloy
- the first material is a first MCrAlY
- the second material is a second MCrAlY different from the first MCrAlY.
- the apparatus comprises: a chamber; a first cathode; a second cathode; a magnet; and an actuator for shifting a relative position of the magnet and the first and second cathodes shift from depositing from the first cathode to depositing from the second cathode.
- the shifting comprises vertically moving the magnet from a first position to a second position.
- the apparatus further comprises an actuator for vertically moving substrates from a first position associated with deposition from the first cathode to a second position associated with deposition from the second cathode .
- the anode is a wall of the chamber and the first cathode and second cathode surround a vertical axis one above the other.
- the first cathode comprises a first MCrAlY; and the second cathode comprises a second MCrAlY different from the first MCrAlY.
- FIG. 1 is a partially schematic sectional view of substrate having a thermal barrier coating (TBC) .
- TBC thermal barrier coating
- FIG. 2 is a partially schematic view of a vane bearing the TBC.
- FIG. 3 is a partially schematic view of a blade bearing the TBC.
- FIG. 4 is a flowchart of a process for coating the substrate of FIG. 1.
- FIG. 5 is a partially schematic view of a deposition apparatus .
- FIG. 6 is a table of alloy compositions.
- FIG. 7 is a table of high-Al and/or lower-Cr bondcoat compositions.
- FIG. 8 is a table of high-Cr bondcoat compositions.
- FIG. 1 shows a thermal barrier coating system 20 atop a metallic substrate 22.
- the thermal barrier coating system 20 atop a metallic substrate 22.
- substrate is a nickel-based superalloy or a cobalt-based superalloy such as a cast component (e.g., a single crystal casting) of a gas turbine engine.
- exemplary components are hot section components such as combustor panels, turbine blades, turbine vanes, and air seals.
- Exemplary substrate compositional ranges are shown in Table I of FIG. 6.
- the materials in Table I may consist essentially of the listed elements (e.g., with at most trace amounts of other elements) .
- other elements may be present in individual quantities less than 2.0 weight percent and/or aggregate quantities less than 5.0 weight percent, more narrowly 1.0 weight percent individually and 2.0 weight percent aggregate.
- the coating system 20 may include a bondcoat 30 atop a surface 26 of the substrate 22 and a thermal barrier coating (TBC) system 28 atop the bondcoat.
- TBC thermal barrier coating
- the bondcoat is a multi-layer bondcoat with at least two layers.
- a first layer 32 is a lower layer.
- a second layer 34 is over the first layer.
- the bondcoat consists of or consists essentially of the first and second layers (e.g., subject to relatively small
- the exemplary TBC is a single-layer TBC.
- Alternatives may involve a multi-layer TBC with at least two layers or a gradient TBC.
- the TBC consists of or consists essentially of the single layer.
- Multi-layer systems may be subject to relatively small gradation/transition or continuous transition with each other. Again, there may be a small transition involving the TGO.
- FIG. 2 shows a vane 50 comprising the cast metallic substrate 22.
- the vane includes an airfoil 52 having a surface comprising a leading edge 54, a trailing edge 56, a pressure side 58, and a suction side 60.
- the airfoil extends from an inboard end at a platform or band segment 62 to an outboard end and an outboard shroud or band segment 64.
- the segments 62 and 64 have respective gaspath surfaces 66 and 68. These are essentially normal to the airfoil surfaces.
- the TBC system extends at least along the surface of the airfoil and the surfaces 66 and 68.
- FIG. 3 shows a blade 100 having an airfoil 102
- the blade extending outward from a platform 104.
- the blade includes an attachment root 106 inboard of the platform.
- the platform 104 has an outboard gaspath surface 108.
- the exemplary bondcoat 30 is an overlay MCrAlY
- An exemplary MCrAlY overlay bondcoat is a
- Exemplary bondcoat thicknesses are 1-20 mils (0.02 to 0.5 mm), more narrowly, 2-15 mils (0.05 to 0.4 mm) or 3-8 mils (0.08 to 0.2 mm) on average, depending upon the application .—The layers 32 and 34 may differ in composition from each other and from more typical bondcoats in several manners.
- Exemplary layer 34 is a high chrome NiCoCrAlYHfSi , referred to as HiCrBC. This has a high Cr content (e.g., > 20 wt%, more particularly, 20- 40 wt% or 25-35 wt% or 29.5-34.5 wt% as applied). This
- Exemplary layer 32 may have one or more of several properties (either absolute or relative to the first
- layer is high-aluminum, having composition chosen to complement layer 34.
- the oxidation and spallation lives of the ceramic TBC may be, in some embodiments, enabled through the formation of an alumina (AI 2 O3) -based thermally grown oxide (TGO) or alumina scale 24 (discussed below) .
- Exemplary compositional ranges are shown in Table II of FIG. 7.
- the aluminum from the layer 32 is believed to diffuse through the layer 34.
- the as-applied Al content of the layer 32 may be less than that of the layer 34. In such situations, the layer 32 may still be a lower-Cr composition than the layer 34
- the alumina scale forms by high-temperature oxidation of the aluminum in the metallic coating, in particular usually during deposition (e.g., electron-beam physical vapor
- the aluminum diffuses outward from the
- an exemplary scale thickness may be in the range between 0.2 micrometers to 0.4 micrometers (8
- the oxygen remains available to build the oxide scale during ceramic deposition because it is present in the atmosphere of the coating chamber, but it also easily permeates through the ceramic topcoat being deposited while the oxide scale is forming/growing.
- the oxygen permeates between the columns of an electron-beam physically vapor deposited ceramic, as well as through the columns, because the zirconium oxide-based ceramic materials are, effectively, transparent (permeable) to the oxygen.
- the composition of the oxide scale is aluminum oxide, in the form of its alpha-phase, which will form at the temperature of interest of about 2000°F (1093°C), but will transform rapidly through some of its metastable forms (such as the theta aluminum oxide) as the part temperature rises during the pre ⁇ heat step of the coating process.
- the presence, in the bondcoat, of active elements such as yttrium, hafnium, silicon, and zirconium may, in various embodiments further improve the adherence of the thermally grown oxide to the ceramic top coat and bondcoat.
- the HiCrBC composition contains a moderate amount of aluminum
- its Al content is lower than in the high-Al (or, lower-Cr) composition (e.g., by at least 2 weight percent or by at least 3 weight percent or, more narrowly, by at least 5 weight percent) . This limits effectiveness of the HiCrBC used alone in an oxidizing
- the HiCrBC Al content may be more than that of the lower-Cr composition (e.g., in some examples up to 2 weight percent more) .
- the high chromium content in the HiCrBC will favor the formation of chromia (Cr 2 0 3 ) at intermediate temperatures. While effective against corrosion products, chromia is less effective than alumina for top coat adherence.
- Exemplary as-applied Cr content in the HiCrBC will typically be at least 10 weight percent higher than in the high-Al or lower-Cr, more narrowly at least 15 weight percent or at least 20 weight percent.
- Exemplary thicknesses of each of the layers 32 and 34 is broadly 1 to 10 mils (0.02 to 0.25 mm); narrowly 1.5 to 4 mils (0.04 to 0.1mm) .
- Deposition techniques include air plasma spray (APS) , low pressure plasma spray (LPPS) , high velocity oxy fuel (HVOF) , sputtering, cathodic arc deposition and EB- PVD.
- Relative thicknesses may be about equal to each other (e.g., with both layers representing about 20-80% total thickness (locally or average) , more particularly 40-60%) . The relative importance of the respective properties of these two layers in a given application may influence which layer is thicker .
- An exemplary total thickness (local or average) of the one or more TBC layers 28 is in excess of 1 mil (0.02 mm), more particularly at least 3 mils (0.08 mm) or an exemplary 5 to 20 mils (0.13 to 0.50 mm) or 10 to 40 mils (0.25 to 1 mm) depending upon the application.
- Such layer (s) may be applied by techniques including APS, EB-PVD, SPS, SPPS, and slurry coating (with EB-PVD being particularly facilitative of the TGO formation) .
- the hot corrosion protective feature of the bondcoat should be most effective with the columnar form of the thermal barrier coating topcoat deposited by electron beam physical vapor deposition, because the contaminants/corrodants will infiltrate the ceramic TBC between its columns and potentially reach the TBC/bondcoat interface during engine operation.
- a similar columnar feature develops also with the TBC deposited by the solution plasma spray process of interest for combustor panel and blade outer air seal applications.
- air-plasma spray applied dense vertically cracked TBCs would also have a similar feature, these being of interest to the blade outer air seal, industrial gas turbine blades and vanes applications.
- the standard TBC chemical compositions are 7 to 8 wt .
- % yttria-stabilized zirconia as well as an exemplary 55 to 64 (nominal 59) wt . % gadolinia-stabilized zirconia topcoat with nearly 50% reduced thermal conductivity relative to the yttria-stabilized zirconia.
- FIG. 4 shows an exemplary process 200 for coating the substrate.
- initial substrate manufacture e.g., casting, finish machining, cleaning, and the like
- the bondcoat first layer 32 is applied 202 and the second layer 34 then applied 203. This may be done by cathodic arc deposition (or other methods as described above) . Both stages may be performed in a single chamber (not shown; or in two chambers with transfer in between) whereafter the substrate (s) are transferred 204 to a second chamber (not shown) for TBC deposition.
- a surface preparation 206 may comprise heat treatment, surface finishing/compaction, further cleaning and/or grit blasting (e.g., in yet other chambers) prior to reaching the second chamber. There may also be thermal conditioning via heater (not shown) .
- the TBC 28 or a first layer thereof may be applied 210 via EB-PVD in the second chamber.
- a further surface preparation (not shown) may follow and may require removal from the second chamber.
- a second or further TBC layer may be then applied 212 (e.g., by the same method in the same chamber but using at least a partially differing source (e.g., adding deposition from an ingot of an additive to deposition from an ingot of the base material (e.g., 7YSZ) or switching form an ingot of the 7YSZ to an ingot of the combined material) ) .
- a partially differing source e.g., adding deposition from an ingot of an additive to deposition from an ingot of the base material (e.g., 7YSZ) or switching form an ingot of the 7YSZ to an ingot of the combined material
- Additional layers may be deposited (whether in the aforementioned chambers or otherwise) .
- FIG. 5 shows an exemplary cathodic arc deposition system 300 for depositing the two bondcoat layers 32 and 34.
- the system 300 includes a chamber wall structure 302 having an interior surface 303 bounding a chamber interior space 304.
- a hollow cathode assembly 306 is centrally located in the chamber interior 304 and comprises at least two cathodes 308, 310.
- the exemplary cathodes 308 and 310 are axially aligned end-to-end or spaced apart circumscribing a central vertical axis 520.
- one of the two cathodes has composition selected to yield one of the layers while the other cathode has composition selected to yield the other layer.
- a cup structure 312 having a cover or lid 314 defines a vessel having an interior 316.
- the exemplary interior contains chilled water (cooling system not shown) for cooling a magnet 318.
- the exemplary magnet is a permanent magnet having vertically oriented polarity (e.g., with a north-up orientation in this particular example) .
- the water may also cool the cathodes which also cool by radiation.
- the exemplary lid 314 may be conductive to serve as a pathway for electrical transfer to the cathode (s) .
- at least a rim flange of the cup 312 is also
- the magnet 318 is carried via a shaft 320 or similar means for reciprocal movement at least between an upper condition/position (solid lines) and a lower
- condition/position (broken lines) .
- the magnet In the upper conditional position, the magnet facilitates deposition from the upper cathode 308. In the lower position, the magnet facilitates deposition from the lower cathode 310.
- An actuator 322 e.g., electric, pneumatic, or hydraulic
- a control system 324 e.g., a micro-controller, computer, or the like
- the shaft 320 passes freely through a
- cylindrical electrode 326 and is insulated relative to the electrode.
- a cathode power supply 330 creates a potential
- FIG. 5 further shows a conductive support plate 340 in contact with a lower rim of the lower cathode 310 to complete the electrical circuit thereacross.
- 340 is made from a highly conductive metal such as copper to help pull heat out of 310 (the lower cathode) and the 312 (cup structure) .
- 342 is a non-conductive material such as a ceramic that supports 340 (plate) and separates it from 344 (metallic plate) and 350 (platter) .
- the plate 340 is, in turn, supported by an
- insulator 342 e.g., a ceramic plate which, in turn, may be supported by an additional plate 344.
- additional plate 344 One, could manufacture a separation distance (where 344 resides) into the platter 350; however 344 can have its thickness easily modified by
- FIG. 5 further shows a part holder or platter 350.
- the part holder is connected to a power supply 352 for applying a bias voltage relative to ground.
- An actuator (370) may allow the part holder to be lifted or lift the parts between
- rotary or other actuators may be provided to rotate the parts about axes (e.g., rotation in directions 530 about axes 532 for evenness of deposition) .
- the magnet and parts are initially in the solid line raised positions associated with the upper cathode 308.
- FIG. 5 shows the magnetic field lines as 358.
- the cathodic arc extends between the associated negatively-charged cathode 308 and the positively-charged chamber wall 302 serving as an anode.
- a stream 362 of positively-charged atoms deposit on the part to form the associated layer 32 or 34.
- the residence time of the part and magnet in the first position will determine the thickness of the first layer 32. The appropriate thickness may be determined by experimental verification of deposition parameters.
- the position of the magnet 318 will determine the location of the cathodic arc.
- the magnet is downwardly shifted by the actuator 322 to the broken-line position.
- the parts are also shifted downwardly to remain at generally even level with the magnet .
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Metallurgy (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Engineering & Computer Science (AREA)
- Physical Vapour Deposition (AREA)
- Turbine Rotor Nozzle Sealing (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Analytical Chemistry (AREA)
Abstract
A coated article has: a metallic substrate (22); a bondcoat (30); and a thermal barrier coating (TBC) (28). The bondcoat has a first layer (32) and a second layer (34), the first layer having a lower Cr content than the second layer.
Description
SPALLATION-RESISTANT THERMAL BARRIER COATING
CROSS-REFERENCE TO RELATED APPLICATION
[0001] Benefit is claimed of U.S. Patent Application Ser. No. 61/800,594, filed March 15, 2013, and entitled
"Spallation-Resistant Thermal Barrier Coating", the disclosure of which is incorporated by reference herein in its entirety as if set forth at length. BACKGROUND
[0002] The disclosure relates to gas turbine engines. More particularly, the disclosure relates to hot-corrosion
resistant bondcoats for thermal barrier coatings for gas turbine engines.
[0003] Gas turbine engine gaspath components are exposed to extreme heat and thermal gradients during various phases of engine operation. Thermal-mechanical stresses and resulting fatigue contribute to component failure. Significant efforts are made to cool such components and provide thermal barrier coatings to improve durability.
[0004] Exemplary thermal barrier coating systems include two-layer thermal barrier coating systems. An exemplary system includes NiCoCrAlY bondcoat as the first layer (e.g., low pressure plasma sprayed (LPPS) ) and yttria-stabilized zirconia (YSZ) (or gadolinia-stabilized zirconia (GSZ) ) thermal barrier coating (TBC) (e.g., air plasma sprayed (APS), suspension plasma sprayed (SPS) or electron beam physical vapor deposited (EBPVD) ) as the second layer. Prior to and while the thermal barrier coat layer is being deposited, a thermally grown oxide (TGO) layer (e.g., alumina) forms atop the bondcoat layer. As time-at-temperature and the number of cycles increase during subsequent service exposure, this TGO interface layer grows in thickness. An exemplary YSZ is 7 weight percent
yttria-stabilized zirconia (7YSZ) .
[0005] Exemplary TBCs are applied to thicknesses of 1-40 mils ( 0.025-1. Omm) and can contribute to a temperature reduction of up to 300°F (167°C) at the base metal. This temperature reduction translates into improved part durability, or higher turbine operating temperatures and improved turbine
efficiency .
SUMMARY
[0006] One aspect of the disclosure involves a coated article having: a metallic substrate; a bondcoat; and a thermal barrier coating (TBC) . The bondcoat has a first layer and a second layer, the first layer having a lower Cr content than the second layer.
[0007] In additional or alternative embodiments of any of the foregoing embodiments single or multilayer TBC comprises material selected from the group consisting of
yttria-stabilized zirconia or gadolinia-stabilized zirconia or combinations thereof.
[0008] In additional or alternative embodiments of any of the foregoing embodiments, the article consists essentially of the substrate, the bondcoat first layer, the bondcoat second layer, thermally grown oxide (TGO) and the TBC.
[0009] In additional or alternative embodiments of any of the foregoing embodiments, by weight percent: the bondcoat second layer comprises 20-40 Cr, up to 30 Co, 5-13 Al, up to 2 Y, up to 2 Si, and up to 2 Hf; and the bondcoat first layer
comprises 5-30 Cr, up to 30 Co, 6-35 Al, 0.1-2 Y, 0.1 to 2 Hf, 0.1 to 7 Si, up to 8 Ta, up to 8 W, up to 2 Mo, and up to 2 Zr .
[0010] In additional or alternative embodiments of any of the foregoing embodiments, by weight percent: the bondcoat second layer comprises 20-40 Cr, up to 30 Co, 5-13 Al, up to 2 Y, up to 2 Si, and up to 2 Hf; and the bondcoat first layer
comprises 1.0-30 Cr, up to 30 Co, 3-35 Al, 0.1-2 Y, 0.1 to 2
Hf, 0.1 to 7 Si, up to 8 Ta, up to 8 W, up to 2 Mo, and up to 2 Zr.
[0011] In additional or alternative embodiments of any of the foregoing embodiments: the bondcoat second layer has a
chromium content at least 10 weight percent higher than a chromium content of the bondcoat first layer; and the bondcoat first layer has an aluminum content at least 2 weight percent higher than an aluminum content of the bondcoat second layer.
[0012] In additional or alternative embodiments of any of the foregoing embodiments, by weight percent: the bondcoat second layer comprises 20-40 Cr, up to 30 Co, 5-13 Al, up to 2 Y, up to 2 Si, and up to 2 Hf; and the bondcoat first layer
comprises 1.0-30 Cr, up to 30 Co, 3-35 Al, 0.1-2 Y, 0.1-2 Hf, 0.1-7 Si, up to 8 Ta, up to 8 W, up to 2 Mo, and up to 2 Zr.
[0013] In additional or alternative embodiments of any of the foregoing embodiments, the bondcoat second layer has a
chromium content at least 10 weight percent higher than a chromium content of the bondcoat first layer.
[0014] In additional or alternative embodiments of any of the foregoing embodiments, the bondcoat first layer has an aluminum content equal to or greater than than an aluminum content of the bondcoat second layer minus 2 weight percent.
[0015] In additional or alternative embodiments of any of the foregoing embodiments, the substrate comprises a nickel or a cobalt based superalloy.
[0016] In additional or alternative embodiments of any of the foregoing embodiments, the nickel based superalloy comprises, in weight %, 4.5-24 Cr, 4.5-20 Co, up to 4.5 Mo, 1.5-11 W, up to 5.5 Ti, up to 12.25 Ta, 1-6.2 Al, up to 0.05 B, up to 0.2 C, up to 0.2 Zr, up to 1.2 Nb, up to 2.0 Hf, and up to 3.5 Re.
[0017] In additional or alternative embodiments of any of the foregoing embodiments, the cobalt based superalloy comprises, in weight %, 18-31 Cr, up to 15 Ni, up to 10 Mo, up to 12 W,
up to 3 Ti, 1-10 Ta, up to 0.5 Al, up to 0.02 B, 0.1 to 0.9 C, 0.2 to 0.6 Zr, up to 2 Nb, and up to 2 Fe .
[0018] In additional or alternative embodiments of any of the foregoing embodiments, a method for manufacturing the article comprises: applying the bondcoat first layer having an
as-applied weight % composition comprising 1.0-30 Cr, up to 30 Co, 3-35 Al, 0.1-2 Y, 0.1 to 2 Hf, 0.1 to 7 Si, up to 8 Ta, up to 8 W, up to 2 Mo, and up to 2 Zr; and applying the bondcoat second layer atop the bondcoat first layer and having an as- applied weight % composition comprising 20-40 Cr, up to 30 Co, 5-13 Al, up to 2 Y, up to 2 Si, and up to 2 Hf.
[0019] In additional or alternative embodiments of any of the foregoing embodiments, the article consists essentially of the substrate, the bondcoat first layer, the bondcoat second layer, and the TBC .
[0020] In additional or alternative embodiments of any of the foregoing embodiments, a method for manufacturing the article comprises: applying the bondcoat first layer having an
as-applied weight % composition comprising 5-30 Cr, up to 30 Co, 6-35 Al, 0.1-2 Y, 0.1 to 2 Hf, 0.1 to 7 Si, up to 8 Ta, up to 8 W, up to 2 Mo, and up to 2 Zr; and applying the bondcoat second layer atop the bondcoat first layer and having an as-applied weight % composition comprising 20-40 Cr, up to 30 Co, 5-13 Al, up to 2 Y, up to 2 Si, and up to 2 Hf.
[0021] In additional or alternative embodiments of any of the foregoing embodiments, a method for manufacturing the article comprises: applying the bondcoat first layer having an
as-applied weight % composition comprising 1.0-30 Cr, up to 30 Co, 3-35 Al, 0.1-2 Y, 0.1 to 2 Hf, 0.1 to 7 Si, up to 8 Ta, up to 8 W, up to 2 Mo, and up to 2 Zr; and applying the bondcoat second layer atop the bondcoat first layer and having an as-applied weight % composition comprising 20-40 Cr, up to 30 Co, 5-13 Al, up to 2 Y, up to 2 Si, and up to 2 Hf.
[0022] In additional or alternative embodiments of any of the foregoing embodiments, the bondcoat first layer and the bondcoat second layer are applied by cathodic arc deposition. However, they could be applied by one or a combination of methods such as LPPS, HVOF, sputtering, EB-PVD or others known in industry.
[0023] In additional or alternative embodiments of any of the foregoing embodiments the bondcoat second layer is applied directly atop the bondcoat first layer; and the TBC is applied directly atop the bondcoat second layer.
[0024] In additional or alternative embodiments of any of the foregoing embodiments: a characteristic thickness of the bondcoat first layer is 1 to 10 mils (0.02 mm to 0.25 mm); and a characteristic thickness of the bondcoat second layer is 1 to 10 mils (0.02 mm to 0.25 mm) .
[0025] In additional or alternative embodiments of any of the foregoing embodiments, the TBC comprises yttria-stabilized zirconia or gadolinia-stabilized zirconia or combinations of the two .
[0026] In additional or alternative embodiments of any of the foregoing embodiments, the substrate comprises a nickel based or a cobalt based superalloy.
[0027] Another aspect of the disclosure involves a method for cathodic arc deposition from a first cathode and a second cathode. The method comprises: placing one or more
substrate (s) in a chamber; generating an arc between the first cathode and an anode to deposit a first material from the first cathode; and generating an arc between the second cathode and the anode to deposit a second material from the second cathode. A relative position of a magnet and the first and second cathodes is shifted to shift from depositing the first material to depositing the second material.
[0028] In additional or alternative embodiments of any of the foregoing embodiments, the shifting comprises vertically moving the magnet from a first position to a second position.
[0029] In additional or alternative embodiments of any of the foregoing embodiments, the method further comprises:
vertically moving substrates from a first position associated with deposition from the first cathode to a second position associated with deposition from the second cathode.
[0030] In additional or alternative embodiments of any of the foregoing embodiments, the anode is a wall of the vacuum coating-chamber .
[0031] In additional or alternative embodiments of any of the foregoing embodiments: the substrate comprises a nickel-based or a cobalt-based superalloy; the first material is a first MCrAlY; and the second material is a second MCrAlY different from the first MCrAlY.
[0032] Another aspect of the disclosure involves an apparatus for cathodic arc deposition. The apparatus comprises: a chamber; a first cathode; a second cathode; a magnet; and an actuator for shifting a relative position of the magnet and the first and second cathodes shift from depositing from the first cathode to depositing from the second cathode.
[0033] In additional or alternative embodiments of any of the foregoing embodiments, the shifting comprises vertically moving the magnet from a first position to a second position.
[0034] In additional or alternative embodiments of any of the foregoing embodiments, the apparatus further comprises an actuator for vertically moving substrates from a first position associated with deposition from the first cathode to a second position associated with deposition from the second cathode .
[0035] In additional or alternative embodiments of any of the foregoing embodiments, the anode is a wall of the chamber and
the first cathode and second cathode surround a vertical axis one above the other.
[0036] In additional or alternative embodiments of any of the foregoing embodiments: the first cathode comprises a first MCrAlY; and the second cathode comprises a second MCrAlY different from the first MCrAlY.
[0037] The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1 is a partially schematic sectional view of substrate having a thermal barrier coating (TBC) .
[0039] FIG. 2 is a partially schematic view of a vane bearing the TBC.
[0040] FIG. 3 is a partially schematic view of a blade bearing the TBC.
[0041] FIG. 4 is a flowchart of a process for coating the substrate of FIG. 1.
[0042] FIG. 5 is a partially schematic view of a deposition apparatus .
[0043] FIG. 6 is a table of alloy compositions.
[0044] FIG. 7 is a table of high-Al and/or lower-Cr bondcoat compositions.
[0045] FIG. 8 is a table of high-Cr bondcoat compositions.
[0046] Like reference numbers and designations in the various drawings indicate like elements.
DETAILED DESCRIPTION
[ 0047 ] FIG. 1 shows a thermal barrier coating system 20 atop a metallic substrate 22. In an exemplary embodiment, the
substrate is a nickel-based superalloy or a cobalt-based superalloy such as a cast component (e.g., a single crystal casting) of a gas turbine engine. Exemplary components are hot section components such as combustor panels, turbine blades, turbine vanes, and air seals.
[ 0048 ] Exemplary substrate compositional ranges are shown in Table I of FIG. 6. In some embodiments of the materials in Table I (and Tables II and III below) , the materials may consist essentially of the listed elements (e.g., with at most trace amounts of other elements) . In some embodiments, other elements may be present in individual quantities less than 2.0 weight percent and/or aggregate quantities less than 5.0 weight percent, more narrowly 1.0 weight percent individually and 2.0 weight percent aggregate.
[ 0049] The coating system 20 may include a bondcoat 30 atop a surface 26 of the substrate 22 and a thermal barrier coating (TBC) system 28 atop the bondcoat. A thermally grown oxide
(TGO) layer 24 will form at the interface of the bondcoat to the TBC. The bondcoat is a multi-layer bondcoat with at least two layers. A first layer 32 is a lower layer. A second layer 34 is over the first layer. In the exemplary system, the bondcoat consists of or consists essentially of the first and second layers (e.g., subject to relatively small
gradation/transition with each other (and with the TGO as noted above) .
[ 0050 ] The exemplary TBC is a single-layer TBC. Alternatives may involve a multi-layer TBC with at least two layers or a gradient TBC. In the exemplary system, the TBC consists of or consists essentially of the single layer. Multi-layer systems may be subject to relatively small gradation/transition or
continuous transition with each other. Again, there may be a small transition involving the TGO.
[0051] FIG. 2 shows a vane 50 comprising the cast metallic substrate 22. The vane includes an airfoil 52 having a surface comprising a leading edge 54, a trailing edge 56, a pressure side 58, and a suction side 60. The airfoil extends from an inboard end at a platform or band segment 62 to an outboard end and an outboard shroud or band segment 64. The segments 62 and 64 have respective gaspath surfaces 66 and 68. These are essentially normal to the airfoil surfaces. The TBC system extends at least along the surface of the airfoil and the surfaces 66 and 68.
[0052] FIG. 3 shows a blade 100 having an airfoil 102
extending outward from a platform 104. The blade includes an attachment root 106 inboard of the platform. The platform 104 has an outboard gaspath surface 108.
[0053] The exemplary bondcoat 30 is an overlay MCrAlY
bondcoat. An exemplary MCrAlY overlay bondcoat is a
NiCoCrAlYHfSi .
Exemplary bondcoat thicknesses are 1-20 mils (0.02 to 0.5 mm), more narrowly, 2-15 mils (0.05 to 0.4 mm) or 3-8 mils (0.08 to 0.2 mm) on average, depending upon the application .—The layers 32 and 34 may differ in composition from each other and from more typical bondcoats in several manners. Exemplary layer 34 is a high chrome NiCoCrAlYHfSi , referred to as HiCrBC. This has a high Cr content (e.g., > 20 wt%, more particularly, 20- 40 wt% or 25-35 wt% or 29.5-34.5 wt% as applied). This
bondcoat material provides excellent corrosion resistance at temperature below 1800°F. It was not developed for use as a traditional bondcoat. Its current application is targeted areas that show corrosion issues. HiCrBC has been tested at elevated temperatures and shows a debit in life vs. a typical NiCoCrAlY due to the lower aluminum content.
[0054] Exemplary layer 32 may have one or more of several properties (either absolute or relative to the first
substrate. In some examples, layer is high-aluminum, having composition chosen to complement layer 34. For example, the oxidation and spallation lives of the ceramic TBC may be, in some embodiments, enabled through the formation of an alumina (AI2O3) -based thermally grown oxide (TGO) or alumina scale 24 (discussed below) . Exemplary compositional ranges are shown in Table II of FIG. 7. The aluminum from the layer 32 is believed to diffuse through the layer 34. In some examples, while still significant, the as-applied Al content of the layer 32 may be less than that of the layer 34. In such situations, the layer 32 may still be a lower-Cr composition than the layer 34
[0055] The alumina scale forms by high-temperature oxidation of the aluminum in the metallic coating, in particular usually during deposition (e.g., electron-beam physical vapor
deposition) of the ceramic layer of the thermal barrier coating system. The aluminum diffuses outward from the
bondcoat, while the oxygen moves inward from the surrounding atmosphere. The aluminum and the oxygen combine to form an oxide scale, which initially builds up rapidly, with the thickness growing linearly with time. As the alumina scale grows in thickness, the aluminum has to diffuse through the scale to pick up the oxygen, and the thickness buildup slows down (curves downward) . At that point in time (perhaps two to three minutes into the ceramic deposition process at about 2000°F (1093°C)), the rate of thickness growth is no longer linear with time, but closer to parabolic. At the completion of the ceramic deposition process, perhaps at about 15 to 20 minutes or so, an exemplary scale thickness may be in the range between 0.2 micrometers to 0.4 micrometers (8
microinches to 16 microinches) . The oxygen remains available to build the oxide scale during ceramic deposition because it is present in the atmosphere of the coating chamber, but it
also easily permeates through the ceramic topcoat being deposited while the oxide scale is forming/growing. The oxygen permeates between the columns of an electron-beam physically vapor deposited ceramic, as well as through the columns, because the zirconium oxide-based ceramic materials are, effectively, transparent (permeable) to the oxygen. The composition of the oxide scale is aluminum oxide, in the form of its alpha-phase, which will form at the temperature of interest of about 2000°F (1093°C), but will transform rapidly through some of its metastable forms (such as the theta aluminum oxide) as the part temperature rises during the pre¬ heat step of the coating process.
[0056] The presence, in the bondcoat, of active elements such as yttrium, hafnium, silicon, and zirconium may, in various embodiments further improve the adherence of the thermally grown oxide to the ceramic top coat and bondcoat.
[0057] Whereas the HiCrBC composition contains a moderate amount of aluminum, in some examples its Al content is lower than in the high-Al (or, lower-Cr) composition (e.g., by at least 2 weight percent or by at least 3 weight percent or, more narrowly, by at least 5 weight percent) . This limits effectiveness of the HiCrBC used alone in an oxidizing
atmosphere. In others, the HiCrBC Al content may be more than that of the lower-Cr composition (e.g., in some examples up to 2 weight percent more) .
[0058] Additionally the high chromium content in the HiCrBC will favor the formation of chromia (Cr203) at intermediate temperatures. While effective against corrosion products, chromia is less effective than alumina for top coat adherence. Exemplary as-applied Cr content in the HiCrBC will typically be at least 10 weight percent higher than in the high-Al or lower-Cr, more narrowly at least 15 weight percent or at least 20 weight percent.
[0059] Exemplary thicknesses of each of the layers 32 and 34 is broadly 1 to 10 mils (0.02 to 0.25 mm); narrowly 1.5 to 4 mils (0.04 to 0.1mm) . Deposition techniques include air plasma spray (APS) , low pressure plasma spray (LPPS) , high velocity oxy fuel (HVOF) , sputtering, cathodic arc deposition and EB- PVD. Relative thicknesses may be about equal to each other (e.g., with both layers representing about 20-80% total thickness (locally or average) , more particularly 40-60%) . The relative importance of the respective properties of these two layers in a given application may influence which layer is thicker .
[0060] An exemplary total thickness (local or average) of the one or more TBC layers 28 is in excess of 1 mil (0.02 mm), more particularly at least 3 mils (0.08 mm) or an exemplary 5 to 20 mils (0.13 to 0.50 mm) or 10 to 40 mils (0.25 to 1 mm) depending upon the application.
[0061] Such layer (s) may be applied by techniques including APS, EB-PVD, SPS, SPPS, and slurry coating (with EB-PVD being particularly facilitative of the TGO formation) .
[0062] The hot corrosion protective feature of the bondcoat should be most effective with the columnar form of the thermal barrier coating topcoat deposited by electron beam physical vapor deposition, because the contaminants/corrodants will infiltrate the ceramic TBC between its columns and potentially reach the TBC/bondcoat interface during engine operation. A similar columnar feature develops also with the TBC deposited by the solution plasma spray process of interest for combustor panel and blade outer air seal applications. Moreover, air-plasma spray applied dense vertically cracked TBCs would also have a similar feature, these being of interest to the blade outer air seal, industrial gas turbine blades and vanes applications. The standard TBC chemical compositions are 7 to 8 wt . % yttria-stabilized zirconia, as well as an exemplary 55 to 64 (nominal 59) wt . % gadolinia-stabilized zirconia topcoat
with nearly 50% reduced thermal conductivity relative to the yttria-stabilized zirconia.
[0063] FIG. 4 shows an exemplary process 200 for coating the substrate. After initial substrate manufacture (e.g., casting, finish machining, cleaning, and the like) the bondcoat first layer 32 is applied 202 and the second layer 34 then applied 203. This may be done by cathodic arc deposition (or other methods as described above) . Both stages may be performed in a single chamber (not shown; or in two chambers with transfer in between) whereafter the substrate (s) are transferred 204 to a second chamber (not shown) for TBC deposition.
[0064] A surface preparation 206 may comprise heat treatment, surface finishing/compaction, further cleaning and/or grit blasting (e.g., in yet other chambers) prior to reaching the second chamber. There may also be thermal conditioning via heater (not shown) . The TBC 28 or a first layer thereof may be applied 210 via EB-PVD in the second chamber. A further surface preparation (not shown) may follow and may require removal from the second chamber.
[0065] After application of the first layer, a second or further TBC layer may be then applied 212 (e.g., by the same method in the same chamber but using at least a partially differing source (e.g., adding deposition from an ingot of an additive to deposition from an ingot of the base material (e.g., 7YSZ) or switching form an ingot of the 7YSZ to an ingot of the combined material) ) .
[0066] Additional layers may be deposited (whether in the aforementioned chambers or otherwise) .
[0067] FIG. 5 shows an exemplary cathodic arc deposition system 300 for depositing the two bondcoat layers 32 and 34.
The system 300 includes a chamber wall structure 302 having an interior surface 303 bounding a chamber interior space 304.
[0068] A hollow cathode assembly 306 is centrally located in the chamber interior 304 and comprises at least two cathodes
308, 310. The exemplary cathodes 308 and 310 are axially aligned end-to-end or spaced apart circumscribing a central vertical axis 520. When used to deposit the present bondcoat, one of the two cathodes has composition selected to yield one of the layers while the other cathode has composition selected to yield the other layer. A cup structure 312 having a cover or lid 314 defines a vessel having an interior 316. The exemplary interior contains chilled water (cooling system not shown) for cooling a magnet 318. The exemplary magnet is a permanent magnet having vertically oriented polarity (e.g., with a north-up orientation in this particular example) . The water may also cool the cathodes which also cool by radiation. The exemplary lid 314 may be conductive to serve as a pathway for electrical transfer to the cathode (s) . In this particular example, at least a rim flange of the cup 312 is also
conductive and intervenes between the lid 314 and the upper cathode 308 to establish electrical connection therebetween.
[0069] The magnet 318 is carried via a shaft 320 or similar means for reciprocal movement at least between an upper condition/position (solid lines) and a lower
condition/position (broken lines) . In the upper conditional position, the magnet facilitates deposition from the upper cathode 308. In the lower position, the magnet facilitates deposition from the lower cathode 310. An actuator 322 (e.g., electric, pneumatic, or hydraulic) may drive the reciprocal movement under the control of a control system 324 (e.g., a micro-controller, computer, or the like) . In the exemplary implementation, the shaft 320 passes freely through a
cylindrical electrode 326 and is insulated relative to the electrode.
[0070] A cathode power supply 330 creates a potential
difference between the electrode 326 (and thus the cathodes) and the chamber wall 302.
[0071] FIG. 5 further shows a conductive support plate 340 in contact with a lower rim of the lower cathode 310 to complete the electrical circuit thereacross. 340 is made from a highly conductive metal such as copper to help pull heat out of 310 (the lower cathode) and the 312 (cup structure) . 342 is a non-conductive material such as a ceramic that supports 340 (plate) and separates it from 344 (metallic plate) and 350 (platter) . The plate 340 is, in turn, supported by an
insulator 342 (e.g., a ceramic plate) which, in turn, may be supported by an additional plate 344. One, could manufacture a separation distance (where 344 resides) into the platter 350; however 344 can have its thickness easily modified by
exchanging separation plates instead of building a new platter 350.
[0072] FIG. 5 further shows a part holder or platter 350. The part holder is connected to a power supply 352 for applying a bias voltage relative to ground. An actuator (370) may allow the part holder to be lifted or lift the parts between
respective positions for deposition from the two cathodes.
Additionally, rotary or other actuators may be provided to rotate the parts about axes (e.g., rotation in directions 530 about axes 532 for evenness of deposition) .
[0073] In the exemplary embodiment, for purposes of
illustration, the upper cathode will be assumed to be
associated with the bondcoat material 32 and the lower cathode with the bondcoat material 34. These cathodes may be formed of the respective materials or may have slightly altered
combinations to account for species attrition during
deposition. Accordingly, the magnet and parts are initially in the solid line raised positions associated with the upper cathode 308.
[0074] With the power supplies 330 and 352 powered, a cathodic arc 360 is formed. FIG. 5 shows the magnetic field lines as 358. The cathodic arc extends between the associated
negatively-charged cathode 308 and the positively-charged chamber wall 302 serving as an anode. With the part(s) maintained at negative potential by the power supply or voltage source 352, a stream 362 of positively-charged atoms deposit on the part to form the associated layer 32 or 34. The residence time of the part and magnet in the first position will determine the thickness of the first layer 32. The appropriate thickness may be determined by experimental verification of deposition parameters.
[0075] The position of the magnet 318 will determine the location of the cathodic arc. To shift from deposition of material from the cathode 308 to the cathode 310, the magnet is downwardly shifted by the actuator 322 to the broken-line position. In the exemplary embodiment, the parts are also shifted downwardly to remain at generally even level with the magnet .
[0076] One or more embodiments have been described.
Nevertheless, it will be understood that various modifications may be made. For example, implemented in the remanufacture of a given article for the reengineering of the configuration of such article, details of the baseline and its use may
influence details of any particular implementation.
Accordingly, other embodiments are within the scope of the following claims.
Claims
1. A coated article comprising:
a metallic substrate (22);
a bondcoat (30) comprising:
a first layer (32); and
a second layer (34), the first layer having a lower Cr content than the second layer; and
a thermal barrier coating (TBC) (28) .
2. The article of claim 1 wherein:
the TBC comprises material selected from the group consisting of yttria-stabilized zirconia or
gadolinia-stabilized zirconia or combinations thereof.
3. The article of claim 2 consisting essentially of the substrate, the bondcoat first layer, the bondcoat second layer, and the TBC.
4. The article of claim 1 wherein by weight percent:
the bondcoat second layer comprises 20-40 Cr, up to 30 Co, 5-13 Al, up to 2 Y, up to 2 Si, and up to 2 Hf; and
the bondcoat first layer comprises 5-30 Cr, up to 30 Co, 6-35 Al, 0.1-2 Y, 0.1-2 Hf, 0.1-7 Si, up to 8 Ta, up to 8 W, up to 2 Mo, and up to 2 Zr.
5. The article of claim 4 wherein:
the bondcoat second layer has a chromium content at least 10 weight percent higher than a chromium content of the bondcoat first layer; and
the bondcoat first layer has an aluminum content at least 2 weight percent higher than an aluminum content of the bondcoat second layer.
6. The article of claim 1 wherein by weight percent:
the bondcoat second layer comprises 20-40 Cr, up to 30
Co, 5-13 Al, up to 2 Y, up to 2 Si, and up to 2 Hf; and
the bondcoat first layer comprises 1.0-30 Cr, up to 30 Co, 3-35 Al, 0.1-2 Y, 0.1-2 Hf, 0.1-7 Si, up to 8 Ta, up to 8
W, up to 2 Mo, and up to 2 Zr.
7. The article of claim 1 wherein:
the bondcoat second layer has a chromium content at least 10 weight percent higher than a chromium content of the bondcoat first layer.
8. The article of claim 1 wherein:
the bondcoat first layer has an aluminum content equal to or greater than than an aluminum content of the bondcoat second layer minus 2 weight percent.
9. The article of claim 1 wherein:
the substrate comprises a nickel-based or a cobalt-based superalloy.
10. The article of claim 9 wherein:
if the substrate is the nickel-based superalloy it comprises in weight % 4.5-24 Cr, 4.5-20 Co, up to 4.5 Mo, 1.5-11 W, up to 5.5 Ti, up to 12.5 Ta, 1-6.2 Al, up to 0.05 B, up to 0.2 C, up to 0.2 Zr, up to 1.2 Nb, up to 2.0 Hf, and up to 3.5 Re; and
if the substrate is the cobalt based superalloy it comprises, in weight %, 18-31 Cr, up to 15 Ni, up to 10 Mo, up to 12 W, up to 3 Ti, 1-10 Ta, up to 0.5 Al, up to 0.02 B, 0.1 to 0.9 C, 0.2 to 0.6 Zr, up to 2 Nb, and up to 2 Fe .
11. A method for manufacturing the article of claim 1, the method comprising:
applying (202) the bondcoat first layer having an
as-applied weight % composition comprising 5-30 Cr, up to 30 Co, 6-35 Al, 0.1-2 Y, 0.1 to 2 Hf, and 0.1 to 7 Si, up to 8 Ta, up to 8 W, up to 2 Mo, and up to 2 Zr; and
applying (203) the bondcoat second layer atop the
bondcoat first layer and having an as-applied weight %
composition comprising 20-40 Cr, up to 30 Co, 5-13 Al, up to 2 Y, up to 2 Si, and up to 2 Hf.
12. A method for manufacturing the article of claim 1, the method comprising:
applying (202) the bondcoat first layer having an
as-applied weight % composition comprising 1.0-30 Cr, up to 30 Co, 3-35 Al, 0.1-2 Y, 0.1 to 2 Hf, 0.1 to 7 Si, up to 8 Ta, up to 8 W, up to 2 Mo, and up to 2 Zr; and
applying (203) the bondcoat second layer atop the
bondcoat first layer and having an as-applied weight %
composition comprising 20-40 Cr, up to 30 Co, 5-13 Al, up to 2 Y, up to 2 Si, and up to 2 Hf.
13. The method of claim 12 wherein:
the applying of the bondcoat first layer and the applying of the bondcoat second layer are accomplished by cathodic arc deposition .
14. The method of claim 12 wherein:
the bondcoat second layer is applied directly atop the bondcoat first layer; and
the TBC is applied directly atop the bondcoat second layer.
15. The method of claim 12 wherein:
a characteristic thickness of the bondcoat first layer is 1-10 mils (0.02 mm to 0.25 mm); and
a characteristic thickness of the bondcoat second layer is 1-10 mils (0.02 mm to 0.25 mm) .
The method of claim 12, wherein
the TBC comprises yttria-stabilized zirconia or
gadolinia-stabilized zirconia or combinations therof.
17. The method of claim 12, wherein:
the substrate comprises a nickel-based superalloy or a cobalt-based superalloy.
18. A method for cathodic arc deposition from a first cathode (308) and a second cathode (310), the method comprising:
placing one or more substrates in a chamber (304);
generating an arc (360) between the first cathode (308) and an anode (302) to deposit a first material from the first cathode ;
generating an arc between the second cathode and the anode to deposit a second material from the second cathode; and
shifting a relative position of a magnet (318) and the first and second cathodes to shift from depositing the first material to depositing the second material.
19. The method of claim 18 wherein:
the shifting comprises vertically moving the magnet from a first position to a second position.
20. The method of claim 18 further comprising:
vertically moving substrates from a first position associated with deposition from the first cathode to a second position associated with deposition from the second cathode.
21. The method of claim 18 wherein:
the anode is a wall of the chamber.
22. The method of claim 18 wherein:
the substrate comprises a nickel-based or cobalt-based superalloy;
the first material is a first MCrAlY; and
the second material is a second MCrAlY different from the first MCrAlY.
23. An apparatus (300) for cathodic arc deposition, the apparatus comprising:
a chamber (302) ;
a first cathode (308);
a second cathode (310);
a magnet (318); and
an actuator (322) for shifting a relative position of the magnet and the first and second cathodes shift from depositing from the first cathode to depositing from the second cathode.
24. The apparatus of claim 23 wherein:
the shifting comprises vertically moving the magnet from a first position to a second position.
25. The apparatus of claim 24 further comprising:
an actuator (380) for vertically moving substrates from a first position associated with deposition from the first cathode to a second position associated with deposition from the second cathode.
26. The apparatus of claim 23 wherein:
the anode is a wall (302) of the chamber (304); and the first cathode and second cathode surround a vertical axis (520) one above the other.
27. The apparatus of claim 23 wherein:
the first cathode comprises a first MCrAlY; and the second cathode comprises a second MCrAlY different from the first MCrAlY.
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP14767987.2A EP2971239B1 (en) | 2013-03-15 | 2014-03-13 | Spallation-resistant thermal barrier coating |
EP22181358.7A EP4130332A3 (en) | 2013-03-15 | 2014-03-13 | Spallation resistant thermal barrier coating |
US14/773,781 US10113226B2 (en) | 2013-03-15 | 2014-03-13 | Spallation-resistant thermal barrier coating |
EP18166188.5A EP3372707B1 (en) | 2013-03-15 | 2014-03-13 | Spallation resistant thermal barrier coating |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201361800594P | 2013-03-15 | 2013-03-15 | |
US61/800,594 | 2013-03-15 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2014151788A1 true WO2014151788A1 (en) | 2014-09-25 |
Family
ID=51528406
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2014/026452 WO2014151788A1 (en) | 2013-03-15 | 2014-03-13 | Spallation-resistant thermal barrier coating |
Country Status (3)
Country | Link |
---|---|
US (2) | US9506140B2 (en) |
EP (3) | EP4130332A3 (en) |
WO (1) | WO2014151788A1 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102018112353A1 (en) * | 2018-05-23 | 2019-11-28 | Forschungszentrum Jülich GmbH | Process for coating a substrate with a cavity structure |
EP3080329B1 (en) * | 2013-12-10 | 2023-04-05 | Raytheon Technologies Corporation | Chromizing over cathodic arc coating |
Families Citing this family (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US9834835B2 (en) * | 2015-02-18 | 2017-12-05 | United Technologies Corporation | Fire containment coating system for titanium |
US10436042B2 (en) | 2015-12-01 | 2019-10-08 | United Technologies Corporation | Thermal barrier coatings and methods |
EP3784815A4 (en) * | 2018-04-27 | 2021-11-03 | Applied Materials, Inc. | Protection of components from corrosion |
DE102018218018A1 (en) * | 2018-10-22 | 2020-04-23 | Siemens Aktiengesellschaft | Deposition welding of nickel-based superalloys using two powders, powder mixture and process |
US10711621B1 (en) | 2019-02-01 | 2020-07-14 | Rolls-Royce Plc | Turbine vane assembly with ceramic matrix composite components and temperature management features |
US10767495B2 (en) | 2019-02-01 | 2020-09-08 | Rolls-Royce Plc | Turbine vane assembly with cooling feature |
CN110735117B (en) * | 2019-11-29 | 2021-06-29 | 中国航发沈阳黎明航空发动机有限责任公司 | Preparation method of thermal barrier coating of duplex guide blade |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5972185A (en) * | 1997-08-30 | 1999-10-26 | United Technologies Corporation | Cathodic arc vapor deposition apparatus (annular cathode) |
US20080138529A1 (en) * | 2006-12-11 | 2008-06-12 | Ge Global Research Center | Method and apparatus for cathodic arc ion plasma deposition |
US20080261069A1 (en) * | 2007-04-18 | 2008-10-23 | Hitachi Ltd. | High temperature component with thermal barrier coating |
WO2011103927A1 (en) * | 2010-02-26 | 2011-09-01 | Siemens Aktiengesellschaft | Two layered metallic bondcoat |
US20120164473A1 (en) * | 2009-02-25 | 2012-06-28 | Mary Taylor | Thermal barrier coatings |
Family Cites Families (31)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4109061A (en) | 1977-12-08 | 1978-08-22 | United Technologies Corporation | Method for altering the composition and structure of aluminum bearing overlay alloy coatings during deposition from metallic vapor |
NL8700620A (en) * | 1987-03-16 | 1988-10-17 | Hauzer Holding | CATHODE ARC VAPORIZATION DEVICE AND METHOD FOR ITS OPERATION. |
US4944858A (en) * | 1988-12-08 | 1990-07-31 | United Technologies Corporation | Method for applying diffusion aluminide coating |
JP3370676B2 (en) * | 1994-10-14 | 2003-01-27 | シーメンス アクチエンゲゼルシヤフト | Protective layer for protecting members against corrosion, oxidation and thermal overload, and method of manufacturing the same |
DE59801544D1 (en) | 1997-11-03 | 2001-10-25 | Siemens Ag | PRODUCT WITH A LAYER PROTECTION AGAINST A HOT AGGRESSIVE GAS |
DE19815473A1 (en) | 1998-04-07 | 1999-10-14 | Ghh Borsig Turbomaschinen Gmbh | Hot gas-carrying gas manifold of a gas turbine |
GB9821903D0 (en) | 1998-10-09 | 1998-12-02 | Rolls Royce Plc | A method of applying a coating to a metallic article and an apparatus for applying a coating to a metallic article |
US6207297B1 (en) | 1999-09-29 | 2001-03-27 | Siemens Westinghouse Power Corporation | Barrier layer for a MCrAlY basecoat superalloy combination |
US6435830B1 (en) | 1999-12-20 | 2002-08-20 | United Technologies Corporation | Article having corrosion resistant coating |
US6270318B1 (en) | 1999-12-20 | 2001-08-07 | United Technologies Corporation | Article having corrosion resistant coating |
US6435835B1 (en) | 1999-12-20 | 2002-08-20 | United Technologies Corporation | Article having corrosion resistant coating |
ES2300396T3 (en) | 2002-04-22 | 2008-06-16 | Pivot A.S. | PROCEDURE FOR COVERING THE ELECTRIC ARC WITH ROTATING CATHETS. |
US7060366B2 (en) | 2003-02-19 | 2006-06-13 | General Electric Company | Article including a substrate with a metallic coating and a chromium-aluminide protective coating thereon, and its preparation and use in component restoration |
JP3865705B2 (en) | 2003-03-24 | 2007-01-10 | トーカロ株式会社 | Heat shielding coating material excellent in corrosion resistance and heat resistance, and method for producing the same |
EP1700932A1 (en) | 2005-03-08 | 2006-09-13 | Siemens Aktiengesellschaft | Layer system with diffusion inhibiting layer |
DE102005060243A1 (en) | 2005-12-14 | 2007-06-21 | Man Turbo Ag | Process for coating hollow internally cooled gas turbine blades with adhesive-, zirconium oxide ceramic- and Cr diffusion layers useful in gas turbine engine technology has adhesive layer applied by plasma or high rate spraying method |
US20070138019A1 (en) * | 2005-12-21 | 2007-06-21 | United Technologies Corporation | Platinum modified NiCoCrAlY bondcoat for thermal barrier coating |
US20070231589A1 (en) | 2006-04-04 | 2007-10-04 | United Technologies Corporation | Thermal barrier coatings and processes for applying same |
EP1925687A1 (en) | 2006-11-24 | 2008-05-28 | Siemens Aktiengesellschaft | NICoCrAl-layer and metallic layer system |
US20100254820A1 (en) | 2006-12-29 | 2010-10-07 | Michael Patrick Maly | Article with restored or regenerated structure |
US20090075115A1 (en) | 2007-04-30 | 2009-03-19 | Tryon Brian S | Multi-layered thermal barrier coating |
US7858205B2 (en) | 2007-09-19 | 2010-12-28 | Siemens Energy, Inc. | Bimetallic bond layer for thermal barrier coating on superalloy |
EP2128285A1 (en) | 2008-05-20 | 2009-12-02 | Siemens Aktiengesellschaft | Two-layer MCrAIX coating with different cobalt and nickel contents |
EP2206806A1 (en) | 2009-01-09 | 2010-07-14 | Siemens Aktiengesellschaft | Two-layer MCrAIX coating with different cobalt and nickel contents |
EP2206805A1 (en) | 2009-01-08 | 2010-07-14 | Siemens Aktiengesellschaft | MCrAIX coating with different chrome and aluminium contents |
US20120193226A1 (en) * | 2011-02-02 | 2012-08-02 | Beers Russell A | Physical vapor deposition system |
US20120193217A1 (en) | 2011-02-02 | 2012-08-02 | Tryon Brian S | Segmented post cathode |
RU2566693C2 (en) | 2011-07-08 | 2015-10-27 | Сименс Акциенгезелльшафт | System of layers with two-layer metal layer |
EP2729302A1 (en) | 2011-09-12 | 2014-05-14 | Siemens Aktiengesellschaft | LAYER SYSTEM WITH DOUBLE MCrAlX METALLIC LAYER |
EP2639336A1 (en) | 2012-03-16 | 2013-09-18 | Siemens Aktiengesellschaft | Coating system with NiCoCrAlY double-protection coat with varying chromium content and alloy |
EP2682488A1 (en) | 2012-07-05 | 2014-01-08 | Siemens Aktiengesellschaft | Coating system with NiCoCrAlY double-protection coat with varying chromium content and alloy |
-
2014
- 2014-03-13 EP EP22181358.7A patent/EP4130332A3/en active Pending
- 2014-03-13 EP EP18166188.5A patent/EP3372707B1/en active Active
- 2014-03-13 EP EP14767987.2A patent/EP2971239B1/en active Active
- 2014-03-13 WO PCT/US2014/026452 patent/WO2014151788A1/en active Application Filing
- 2014-03-13 US US14/209,761 patent/US9506140B2/en active Active
- 2014-03-13 US US14/773,781 patent/US10113226B2/en active Active
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5972185A (en) * | 1997-08-30 | 1999-10-26 | United Technologies Corporation | Cathodic arc vapor deposition apparatus (annular cathode) |
US20080138529A1 (en) * | 2006-12-11 | 2008-06-12 | Ge Global Research Center | Method and apparatus for cathodic arc ion plasma deposition |
US20080261069A1 (en) * | 2007-04-18 | 2008-10-23 | Hitachi Ltd. | High temperature component with thermal barrier coating |
US20120164473A1 (en) * | 2009-02-25 | 2012-06-28 | Mary Taylor | Thermal barrier coatings |
WO2011103927A1 (en) * | 2010-02-26 | 2011-09-01 | Siemens Aktiengesellschaft | Two layered metallic bondcoat |
Non-Patent Citations (1)
Title |
---|
See also references of EP2971239A4 * |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP3080329B1 (en) * | 2013-12-10 | 2023-04-05 | Raytheon Technologies Corporation | Chromizing over cathodic arc coating |
DE102018112353A1 (en) * | 2018-05-23 | 2019-11-28 | Forschungszentrum Jülich GmbH | Process for coating a substrate with a cavity structure |
Also Published As
Publication number | Publication date |
---|---|
US10113226B2 (en) | 2018-10-30 |
EP2971239A4 (en) | 2017-03-29 |
EP2971239A1 (en) | 2016-01-20 |
EP2971239B1 (en) | 2018-05-16 |
US9506140B2 (en) | 2016-11-29 |
US20160040281A1 (en) | 2016-02-11 |
EP4130332A2 (en) | 2023-02-08 |
EP3372707A1 (en) | 2018-09-12 |
EP4130332A3 (en) | 2023-05-31 |
EP3372707B1 (en) | 2022-06-29 |
US20140272456A1 (en) | 2014-09-18 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
EP2971239B1 (en) | Spallation-resistant thermal barrier coating | |
EP1591550B2 (en) | Thermal barrier coating having an interfacial layer for spallation life enhancement and low conductivity | |
US9511572B2 (en) | Nanocrystalline interlayer coating for increasing service life of thermal barrier coating on high temperature components | |
EP1254967B1 (en) | Improved plasma sprayed thermal bond coat system | |
US6255001B1 (en) | Bond coat for a thermal barrier coating system and method therefor | |
EP2607510B1 (en) | Nickel-cobalt-based alloy and bond coat and bond coated articles incorporating the same | |
EP2258889B1 (en) | Method and apparatus for applying a thermal barrier coating | |
JPH09296702A (en) | Heat insulating coated product and coating method | |
EP1340833A1 (en) | Hybrid thermal barrier coating and method of making the same | |
JP2011074494A (en) | Single layer bond coat and method of application | |
EP2093307B1 (en) | Cathodic arc deposition coatings for turbine engine components | |
EP0985745B1 (en) | Bond coat for a thermal barrier coating system | |
US20140186656A1 (en) | Spallation-Resistant Thermal Barrier Coating | |
EP2213760B1 (en) | Oxide coating foundation for promoting TBC adherence | |
Li et al. | Thermal shock behavior of EB-PVD thermal barrier coatings | |
CN117328014A (en) | Abradable seal coating, preparation method thereof, turbine outer ring and application | |
EP3055444A1 (en) | Thermal barrier coating with improved adhesion | |
US20070087210A1 (en) | High temperature insulative coating (XTR) | |
Ali et al. | Intermediate PVD layers as diffusion barriers in turbine coating systems | |
Rai | Development of Protective Coatings for Single Crystal Turbine Blades | |
Zhu et al. | A Comparison of Thermal Shock Behavior between APS and Low-Energy VLPPS ZrO2-7% Y2O3 Thermal Barrier Coatings | |
Lima et al. | A Comparison of Thermal Shock Behavior between APS and Low-Energy VLPPS ZrO2-7% Y2O3 Thermal Barrier Coatings |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
121 | Ep: the epo has been informed by wipo that ep was designated in this application |
Ref document number: 14767987 Country of ref document: EP Kind code of ref document: A1 |
|
WWE | Wipo information: entry into national phase |
Ref document number: 14773781 Country of ref document: US |
|
NENP | Non-entry into the national phase |
Ref country code: DE |
|
WWE | Wipo information: entry into national phase |
Ref document number: 2014767987 Country of ref document: EP |