WO2014204480A1 - Systèmes de couche d'ancrage pour revêtement barrière environnemental - Google Patents
Systèmes de couche d'ancrage pour revêtement barrière environnemental Download PDFInfo
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- WO2014204480A1 WO2014204480A1 PCT/US2013/046946 US2013046946W WO2014204480A1 WO 2014204480 A1 WO2014204480 A1 WO 2014204480A1 US 2013046946 W US2013046946 W US 2013046946W WO 2014204480 A1 WO2014204480 A1 WO 2014204480A1
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- WIPO (PCT)
- Prior art keywords
- bond coat
- silicon
- component
- oxide
- substrate
- Prior art date
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- 238000000576 coating method Methods 0.000 title claims abstract description 64
- 230000007613 environmental effect Effects 0.000 title claims abstract description 47
- 239000011248 coating agent Substances 0.000 title claims abstract description 44
- 230000004888 barrier function Effects 0.000 title claims abstract description 42
- 229910052710 silicon Inorganic materials 0.000 claims abstract description 63
- 239000010703 silicon Substances 0.000 claims abstract description 63
- 229910021332 silicide Inorganic materials 0.000 claims abstract description 43
- 239000000758 substrate Substances 0.000 claims abstract description 29
- FVBUAEGBCNSCDD-UHFFFAOYSA-N silicide(4-) Chemical compound [Si-4] FVBUAEGBCNSCDD-UHFFFAOYSA-N 0.000 claims abstract description 26
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 claims abstract description 25
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 60
- 229910052761 rare earth metal Inorganic materials 0.000 claims description 49
- 239000000203 mixture Substances 0.000 claims description 22
- 239000010410 layer Substances 0.000 claims description 21
- -1 rare earth silicate Chemical class 0.000 claims description 18
- 238000000034 method Methods 0.000 claims description 15
- 239000002131 composite material Substances 0.000 claims description 12
- 229910000449 hafnium oxide Inorganic materials 0.000 claims description 11
- WIHZLLGSGQNAGK-UHFFFAOYSA-N hafnium(4+);oxygen(2-) Chemical compound [O-2].[O-2].[Hf+4] WIHZLLGSGQNAGK-UHFFFAOYSA-N 0.000 claims description 11
- 239000011229 interlayer Substances 0.000 claims description 11
- 230000000694 effects Effects 0.000 claims description 10
- 229910000323 aluminium silicate Inorganic materials 0.000 claims description 8
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 8
- 239000001301 oxygen Substances 0.000 claims description 8
- 229910052760 oxygen Inorganic materials 0.000 claims description 8
- 239000002019 doping agent Substances 0.000 claims description 4
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 claims description 4
- 229910001928 zirconium oxide Inorganic materials 0.000 claims description 4
- 229910001404 rare earth metal oxide Inorganic materials 0.000 claims description 3
- 230000007423 decrease Effects 0.000 claims 1
- 239000000919 ceramic Substances 0.000 abstract description 20
- 239000011153 ceramic matrix composite Substances 0.000 abstract description 20
- 150000002910 rare earth metals Chemical class 0.000 description 37
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 25
- CJNBYAVZURUTKZ-UHFFFAOYSA-N hafnium(IV) oxide Inorganic materials O=[Hf]=O CJNBYAVZURUTKZ-UHFFFAOYSA-N 0.000 description 11
- 229910052769 Ytterbium Inorganic materials 0.000 description 9
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 9
- 230000003647 oxidation Effects 0.000 description 9
- 238000007254 oxidation reaction Methods 0.000 description 9
- 239000000377 silicon dioxide Substances 0.000 description 9
- 229910052782 aluminium Inorganic materials 0.000 description 8
- 239000007789 gas Substances 0.000 description 8
- 239000010936 titanium Substances 0.000 description 8
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 7
- 150000001875 compounds Chemical class 0.000 description 7
- 238000005328 electron beam physical vapour deposition Methods 0.000 description 7
- CMIHHWBVHJVIGI-UHFFFAOYSA-N gadolinium(iii) oxide Chemical compound [O-2].[O-2].[O-2].[Gd+3].[Gd+3] CMIHHWBVHJVIGI-UHFFFAOYSA-N 0.000 description 7
- 239000000463 material Substances 0.000 description 7
- XQWQNVHACLGSBB-UHFFFAOYSA-N [Si]([O-])([O-])([O-])O.[Yb+3] Chemical compound [Si]([O-])([O-])([O-])O.[Yb+3] XQWQNVHACLGSBB-UHFFFAOYSA-N 0.000 description 6
- 238000000151 deposition Methods 0.000 description 6
- NAWDYIZEMPQZHO-UHFFFAOYSA-N ytterbium Chemical compound [Yb] NAWDYIZEMPQZHO-UHFFFAOYSA-N 0.000 description 6
- 229910052688 Gadolinium Inorganic materials 0.000 description 4
- 238000011161 development Methods 0.000 description 4
- 230000018109 developmental process Effects 0.000 description 4
- 238000009792 diffusion process Methods 0.000 description 4
- 229910052735 hafnium Inorganic materials 0.000 description 4
- 229910000676 Si alloy Inorganic materials 0.000 description 3
- 229910045601 alloy Inorganic materials 0.000 description 3
- 239000000956 alloy Substances 0.000 description 3
- 238000002485 combustion reaction Methods 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 3
- 238000002474 experimental method Methods 0.000 description 3
- UIWYJDYFSGRHKR-UHFFFAOYSA-N gadolinium atom Chemical compound [Gd] UIWYJDYFSGRHKR-UHFFFAOYSA-N 0.000 description 3
- VBJZVLUMGGDVMO-UHFFFAOYSA-N hafnium atom Chemical compound [Hf] VBJZVLUMGGDVMO-UHFFFAOYSA-N 0.000 description 3
- 238000005240 physical vapour deposition Methods 0.000 description 3
- 238000012545 processing Methods 0.000 description 3
- 150000004760 silicates Chemical class 0.000 description 3
- 239000007921 spray Substances 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- 229910052727 yttrium Inorganic materials 0.000 description 3
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 description 3
- 229910052726 zirconium Inorganic materials 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 2
- 229910052691 Erbium Inorganic materials 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 2
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 2
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 229910052796 boron Inorganic materials 0.000 description 2
- 238000005229 chemical vapour deposition Methods 0.000 description 2
- 239000000567 combustion gas Substances 0.000 description 2
- 125000004122 cyclic group Chemical group 0.000 description 2
- 230000008021 deposition Effects 0.000 description 2
- UYAHIZSMUZPPFV-UHFFFAOYSA-N erbium Chemical compound [Er] UYAHIZSMUZPPFV-UHFFFAOYSA-N 0.000 description 2
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 description 2
- 230000001681 protective effect Effects 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 229910052715 tantalum Inorganic materials 0.000 description 2
- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum atom Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 description 2
- 239000010409 thin film Substances 0.000 description 2
- 229910021350 transition metal silicide Inorganic materials 0.000 description 2
- 238000007740 vapor deposition Methods 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 229910052684 Cerium Inorganic materials 0.000 description 1
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- 229910052692 Dysprosium Inorganic materials 0.000 description 1
- 229910052693 Europium Inorganic materials 0.000 description 1
- 229910052689 Holmium Inorganic materials 0.000 description 1
- 229910052765 Lutetium Inorganic materials 0.000 description 1
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 1
- 229910052779 Neodymium Inorganic materials 0.000 description 1
- 229910052777 Praseodymium Inorganic materials 0.000 description 1
- 229910052773 Promethium Inorganic materials 0.000 description 1
- 229910052772 Samarium Inorganic materials 0.000 description 1
- 229910052771 Terbium Inorganic materials 0.000 description 1
- 229910052775 Thulium Inorganic materials 0.000 description 1
- XEDZPTDJMMNSIB-UHFFFAOYSA-N [Si]([O-])([O-])([O-])O.[Y+3] Chemical compound [Si]([O-])([O-])([O-])O.[Y+3] XEDZPTDJMMNSIB-UHFFFAOYSA-N 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- QVQLCTNNEUAWMS-UHFFFAOYSA-N barium oxide Chemical compound [Ba]=O QVQLCTNNEUAWMS-UHFFFAOYSA-N 0.000 description 1
- ZFXVRMSLJDYJCH-UHFFFAOYSA-N calcium magnesium Chemical compound [Mg].[Ca] ZFXVRMSLJDYJCH-UHFFFAOYSA-N 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 238000000541 cathodic arc deposition Methods 0.000 description 1
- ZMIGMASIKSOYAM-UHFFFAOYSA-N cerium Chemical compound [Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce] ZMIGMASIKSOYAM-UHFFFAOYSA-N 0.000 description 1
- 229910021357 chromium silicide Inorganic materials 0.000 description 1
- 239000008199 coating composition Substances 0.000 description 1
- 239000011247 coating layer Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 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 description 1
- KBQHZAAAGSGFKK-UHFFFAOYSA-N dysprosium atom Chemical compound [Dy] KBQHZAAAGSGFKK-UHFFFAOYSA-N 0.000 description 1
- 230000003628 erosive effect Effects 0.000 description 1
- OGPBJKLSAFTDLK-UHFFFAOYSA-N europium atom Chemical compound [Eu] OGPBJKLSAFTDLK-UHFFFAOYSA-N 0.000 description 1
- 229910001940 europium oxide Inorganic materials 0.000 description 1
- AEBZCFFCDTZXHP-UHFFFAOYSA-N europium(3+);oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[Eu+3].[Eu+3] AEBZCFFCDTZXHP-UHFFFAOYSA-N 0.000 description 1
- 238000009501 film coating Methods 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 229910001938 gadolinium oxide Inorganic materials 0.000 description 1
- 229940075613 gadolinium oxide Drugs 0.000 description 1
- 230000035876 healing Effects 0.000 description 1
- KJZYNXUDTRRSPN-UHFFFAOYSA-N holmium atom Chemical compound [Ho] KJZYNXUDTRRSPN-UHFFFAOYSA-N 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 229910052747 lanthanoid Inorganic materials 0.000 description 1
- 150000002602 lanthanoids Chemical class 0.000 description 1
- 229910052746 lanthanum Inorganic materials 0.000 description 1
- FZLIPJUXYLNCLC-UHFFFAOYSA-N lanthanum atom Chemical compound [La] FZLIPJUXYLNCLC-UHFFFAOYSA-N 0.000 description 1
- OHSVLFRHMCKCQY-UHFFFAOYSA-N lutetium atom Chemical compound [Lu] OHSVLFRHMCKCQY-UHFFFAOYSA-N 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 229910021471 metal-silicon alloy Inorganic materials 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910021344 molybdenum silicide Inorganic materials 0.000 description 1
- 229910052863 mullite Inorganic materials 0.000 description 1
- QEFYFXOXNSNQGX-UHFFFAOYSA-N neodymium atom Chemical compound [Nd] QEFYFXOXNSNQGX-UHFFFAOYSA-N 0.000 description 1
- 229910052758 niobium Inorganic materials 0.000 description 1
- 239000010955 niobium Substances 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- SIWVEOZUMHYXCS-UHFFFAOYSA-N oxo(oxoyttriooxy)yttrium Chemical compound O=[Y]O[Y]=O SIWVEOZUMHYXCS-UHFFFAOYSA-N 0.000 description 1
- UFQXGXDIJMBKTC-UHFFFAOYSA-N oxostrontium Chemical compound [Sr]=O UFQXGXDIJMBKTC-UHFFFAOYSA-N 0.000 description 1
- UZLYXNNZYFBAQO-UHFFFAOYSA-N oxygen(2-);ytterbium(3+) Chemical compound [O-2].[O-2].[O-2].[Yb+3].[Yb+3] UZLYXNNZYFBAQO-UHFFFAOYSA-N 0.000 description 1
- 229910052763 palladium Inorganic materials 0.000 description 1
- 238000007750 plasma spraying Methods 0.000 description 1
- 229910021339 platinum silicide Inorganic materials 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000010248 power generation Methods 0.000 description 1
- PUDIUYLPXJFUGB-UHFFFAOYSA-N praseodymium atom Chemical compound [Pr] PUDIUYLPXJFUGB-UHFFFAOYSA-N 0.000 description 1
- 238000003672 processing method Methods 0.000 description 1
- VQMWBBYLQSCNPO-UHFFFAOYSA-N promethium atom Chemical compound [Pm] VQMWBBYLQSCNPO-UHFFFAOYSA-N 0.000 description 1
- 239000011253 protective coating Substances 0.000 description 1
- 239000003870 refractory metal Substances 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- KZUNJOHGWZRPMI-UHFFFAOYSA-N samarium atom Chemical compound [Sm] KZUNJOHGWZRPMI-UHFFFAOYSA-N 0.000 description 1
- 229910052706 scandium Inorganic materials 0.000 description 1
- SIXSYDAISGFNSX-UHFFFAOYSA-N scandium atom Chemical compound [Sc] SIXSYDAISGFNSX-UHFFFAOYSA-N 0.000 description 1
- 238000007581 slurry coating method Methods 0.000 description 1
- GZCRRIHWUXGPOV-UHFFFAOYSA-N terbium atom Chemical compound [Tb] GZCRRIHWUXGPOV-UHFFFAOYSA-N 0.000 description 1
- 238000005382 thermal cycling Methods 0.000 description 1
- 238000005050 thermomechanical fatigue Methods 0.000 description 1
- FRNOGLGSGLTDKL-UHFFFAOYSA-N thulium atom Chemical compound [Tm] FRNOGLGSGLTDKL-UHFFFAOYSA-N 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- 229910021341 titanium silicide Inorganic materials 0.000 description 1
- 229910052723 transition metal Inorganic materials 0.000 description 1
- 150000003624 transition metals Chemical class 0.000 description 1
- 229910003454 ytterbium oxide Inorganic materials 0.000 description 1
- 229940075624 ytterbium oxide Drugs 0.000 description 1
- 229910021355 zirconium silicide Inorganic materials 0.000 description 1
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/46—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on titanium oxides or titanates
- C04B35/462—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on titanium oxides or titanates based on titanates
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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- C04B35/46—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on titanium oxides or titanates
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- C04B35/478—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on titanium oxides or titanates based on titanates based on aluminium titanates
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- C04B35/48—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on zirconium or hafnium oxides, zirconates, zircon or hafnates
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- C04B35/584—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides based on silicon nitride
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- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
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- 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
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- 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
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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- F05D2300/211—Silica
Definitions
- the general field of this innovation is environmental barrier coatings, and embodiments relate more specifically to environmental barrier coatings for silicon-based ceramic components.
- EBC Environmental barrier coating
- CMC monolithic ceramic or ceramic matrix composite
- a coating system consisting of a high temperature capable advanced zirconia-based (or hafhia-based) oxide top coat (thermal barrier) and a less temperature capable rare earth silicates and mullite/barium-strontium-aluminosilicate (BSASySi environmental barrier is a state-of-the-art protective T/EBC coating system for the Si-based ceramic applications.
- SiC/SiC turbine ceramic matrix composition applications including advanced
- the innovation disclosed and claimed herein in aspects thereof, comprises systems, methods and articles that can include environmental barrier coating bond coat systems.
- One example article can include a substrate, such as a SiC/SiC ceramic matrix composite substrate, and a bond coat system.
- the bond coat system can include a bond coat that can include one or more of a silicon/silicide component or an oxide/silicate component.
- interlayers can be included between the substrate and bond coat and external to the bond coat, and an optional environmental barrier coating top coat can be included external to the bond coat system.
- FIG. 1 illustrates a first example environmental barrier coating (EBC) bond coat system in accordance with aspects of the subject innovation.
- EBC environmental barrier coating
- FIG. 2 illustrates a second example EBC bond coat system in accordance with aspects of the subject innovation.
- FIG. 3 illustrates a third example EBC bond coat system in accordance with aspects of the subject innovation.
- FIG. 4 illustrates a fourth example EBC bond coat system in accordance with aspects of the subject innovation.
- FIG. 5 illustrates an example embodiment of an EBC bond coat system comprising a bond coat with a mixture phased region, in accordance with aspects of the subject innovation.
- FIG. 6 illustrates an example bond coat system with self-healing in accordance with aspects of the subject innovation.
- FIG. 7 illustrates the high temperature strength of several tested bond coat materials useable in aspects of the subject innovation.
- FIG. 8 illustrates the flexural strength and deflection of Hf0 2 -Si bond coat materials useable in aspects of the subject innovation at various temperatures.
- FIG. 9 illustrates testing results for RESi(0)-based bond coats.
- FIG. 10 illustrates flexural strength for various bond coats of the subject innovation at room temperature and elevated temperatures.
- FIGS. 1 1A, 1 IB, and 1 1C include specific examples of compositions useable in connection with various aspects of the subject innovation.
- embodiments of the subject innovation can include systems, articles, and methods that can employ an advanced high temperature capable, low expansion and low diffusion environmental barrier coating (EBC) bond coat system for Si-based ceramics and ceramic matrix composites (CMCs).
- EBC environmental barrier coating
- Various aspects of the subject innovation can provide coating compositions and architecture arrangements that can achieve exceptional environmental barrier coating bond coat adhesion, oxidation and fatigue resistance, and environmental protection performance, along with self-healing capabilities that can ensure log-term durability for Si-based turbine ceramic components.
- Environmental barrier coating bond coat systems, articles, and methods of the subject innovation can be employed in thin environmental barrier coating configurations, which can help enable the realization of ceramic turbine engine SiC/SiC CMC combustor and turbine airfoil applications.
- FIG. 1 illustrates a first example
- EBC bond coat system 100 in accordance with aspects of the subject innovation.
- the EBC bond coat systems, articles, and methods employed in various aspects of the subject innovation can utilize compositions and architecture designs disclosed herein to enhance the coating high temperature stability, high toughness and strength, and durability performance.
- the EBC bond coat system 100 is the coating layer directly adjacent to the substrate 102 (e.g., SiC/SiC ceramic matrix composite substrate, etc.), as shown in FIG. 1, which can improve environmental barrier coating adhesion and bonding strength, provide enhanced environmental protection, and, in various aspects of the subject innovation, can be designed to incorporate dynamic slow growth protective scale formation for oxidation resistance and seal healing.
- EBC bond coat system 100 can include a bond coat 104, which can be as described herein.
- environmental barrier bond coats 104 of the subject innovation can have any of a range of coating thicknesses, e.g., ranging from around 10 micrometers to around 200 micrometers.
- Layers 106 and 108 which can be included in some
- embodiments and can be excluded in other embodiments can be interlayers, e.g., diffusion barriers with crystalline and/or amorphous coatings as described herein, with the thickness ranging from around around 10 micrometers to around 200 micrometers .
- EBC bond coat systems in accordance with the subject innovation can comprise one or both of two composition categories, referred to herein as Group A (also referred to herein as an "silicon/silicide component”) and Group B (also referred to herein as a “oxide/silicate component”).
- Group A and Group B have low oxygen activities (or called “oxgen getter”) and higher oxygen but lower silica activities, respectively.
- Members of Group A generally have superior oxidation resistance, while members of Group B generally have superior temperature resistance and combustion environmental resistance.
- Group A (the "silicon/silicide component") can be an advanced silicon based alloy system as described herein, e.g., a rare earth (RE) based or doped silicon alloy or compound.
- RE rare earth
- Rare earth metals that can be employed in connection with group A include Ytterbium, Gadolinium, Neodymium, Samarium, Lutetium, Erbium, Europium, Terbium, Dysprosium, Holmium, Lanthanum, Cerium, Praseodymium, Promethium, Thulium (i.e., lanthanides), plus Yttrium and Scandium; Group A can also include doped Carbide-Nitrides of these.
- Group B (the "oxide/silicate component”) can include highly stable Oxide and Silicate based material systems described herein.
- bond coats of the subject innovation can include Hf0 2 (or Zr0 2 , etc.) and
- Si/alloyed/doped Si optionally with various dopants as described herein.
- Various embodiments of bond coats of the subject innovation incorporating Hf0 2 and Si or their alloys have been demonstrated to have excellent temperature and environmental resistance, including resistance to CMAS (Calcium Magnesium Alumino-Silicate) attack.
- CMAS Calcium Magnesium Alumino-Silicate
- EBC bond coats in accordance with the subject innovation can have advanced multi-component compositions, which can be arranged to form thermodynamically stable, multi-scale composites that have superior performance as compared to the current state of the art silicon bond coat.
- Bond coat systems and articles in accordance with the subject innovation can have thermal expansion co-efficients in a range from 4-6 10 "6 m/nvK, comparable to the Si-based ceramics, and conventional Silicon bond coats.
- Coatings of the subject innovation can be processed consistent with any of the current state-of-the-art coating processing methods.
- embodiments of the subject innovation can comprise systems articles and methods that can utilize multi-component bond coat systems, which can include one or more of alloy doped Silicon; alloy-doped or silicon- rich Rare Earth (RE) Silicides; Rare Earth (RE) doped transition metal Silicides;
- Embodiments of the subject innovation can form highly stable bond coat systems useable in connection with SiC/SiC CMC components.
- Group A (the "silicon/silicide component") useable in connection with bond coat systems disclosed herein, can include (a) Rare Earth doped or alloyed Silicon, (b) Rare Earth (RE) Silicides (e.g., any of various stoichiometry compounds, such as RE5S13, RE5S14, RESi, RE3S15, RES-2, etc. and also particularly non-stoichiometry silicide compound compositions disclosed herein for optimum performance enhancement), which can include Ytterbium Silicides, Yttrium Silicides, Gadolinium Silicides, Erbium
- RE Rare Earth
- the Group A can be doped or oxidized with minor "oxygen" dopant or with oxygen gradients.
- Group B (the "oxide/silicate component”) useable in connection with bond coat systems disclosed herein can significantly improve the temperature capability, environmental stability and strength capability, and can include (a) Rare Earth (RE) oxides (e.g., RE2O3), which can include Ytterbium Oxide, Yttrium Oxide, Gadolinium Oxide, Europium Oxide, etc.; (b) Rare Earth Mono-Silicates (RE 2 Si05) or Di-Silicates (RE2S12O7) such as Yb 2 Si0 5 , Yb 2 Si 2 0 7 , Y 2 SiO s , Gd 2 Si 2 0 7 , Gd 2 SiO s and Gd 2 Si 2 0 7 ; (c) other oxides such as Barium Oxide (BaO), Strontium Oxide (SrO), etc.; (d) Titanium and Tantalum-doped and un-doped Rare Earth Zirconium and Hafnium Pyrochlore
- each of layer 106 and layer 108 can be a diffusion barrier, which in one embodiment can be a thin crystalline and/or amorphous coating of a silicon/silicide component (e.g., a member of Group A), which can have the capability of operating at temperatures of at least 1600°C (2912°F), and can have ultra low oxygen and water vapor diffusivity.
- a silicon/silicide component e.g., a member of Group A
- a silicon/silicide component e.g., a member of Group A
- either or both of 106 (near the EBC top coats/bond coat interface) and layer 108 (near the bond coat/CMC interface) can comprise an extremely thin layered low diffusional coating, and can incorporate, utilizing a higher silicon content than bond coat 104, high temperature capable amorphous or crystalline phased Ta x SiCN, RETa x SiCN, Ti x (AlCrTa) y SiCN, or other compositions from Groups A or B.
- layers 106 and 108 can be included, while in other embodiments they can be omitted.
- bond coat 104 can be a multicomponent doped bond coat, comprising a silicon/silicide component (e.g., from Group A).
- FIG. 2 illustrates a second example EBC bond coat system 200 in accordance with aspects of the subject innovation.
- Substrate 202 and layers 206 and 208 (which can be optional, as with EBC bond coat system 100) can be as described elsewhere herein in connection with analogous components, e.g., those of FIG. 1.
- Bond coat 204 can be a multicomponent doped bond coat, comprising an oxide/silicate component (e.g., from Group B).
- an oxide/silicate component e.g., from Group B
- members of Group A or Group B either individual members or combination thereof, can be used for EBC bond coats, as shown in FIGS. 1 and 2.
- FIG. 3 illustrated is a third example of an EBC bond coat system 300 comprising a composite bond coat 304 in accordance with aspects of the subject innovation.
- Substrate 302 and layers 306 and 308 can be as described above in connection with FIGS. 1 and 2 (with layers 306 and 308 again optional).
- Bond coat 304 can comprise a composite of both a silicon/silicide component (e.g., from Group A) and an oxide/silicate component (e.g., from Group B), such as an oxide/silicate component (e.g., from Group B) as reinforcements 310 and embedded in a layer 312 composed of a silicon/silicide component (e.g., from Group A) or vice versa, as shown in bond coat 304.
- silicon/silicide components useable in connection with bond coat 304, of the Rare Earth Silicides, dopants such as Aluminum can ensure superior cyclic and oxidation resistance under lower temperature conditions, which can prevent "pesting" from occurring.
- the combination of components from both Group A and Group B can provide superior integrity and performance for the bond coat, via the sophisticated composite system of an Oxide-Silicate in combination with a Silicon alloy.
- An extremely thin layered low diffusional coating near the bond coat/substrate (e.g., CMC) interface at 308, and a similar layer near the EBC top coat/bond coat interface at 306, can be incorporated, and can utilize a higher silicon content, high temperature capable amorphous or crystalline phased Ta x SiCN, RETa x SiCN, Ti x (AlCrTa) y SiCN, for example, or other members or combinations thereof selected from Groups A and B.
- FIG. 4 illustrates a fourth example embodiment of an EBC bond coat system 400 comprising a layered composite bond coat 404 in accordance with aspects of the subject innovation.
- Substrate 402 and layers 406 and 408 can be as described in connection with similar components of FIGS. 1, 2, and 3.
- Bond coat 404 can be arranged in a layered composite configuration with alternating layers 410 and 412 of a
- EBCs when included, can be as described herein, for example, comprising a high stability multicomponent Hf0 2 - RE 2 03-Si02 RE2Si2.x07.2 X ; in other embodiments, other components described herein can be used additionally or alternatively in connection with environmental barrier coats.
- silicon/silicide components e.g., from Group A
- silicon/silicide components can be employed that can have relatively high silicon content designs (silicon-rich, off-stoichiometry silicide compositions) to provide superior oxidation resistance.
- silicon-rich silicides such as RE3S15 and RES12 can provide such a relatively high silicon content, for example, and also RE3Sis+ x and RES12 where the "x" indicates a modified composition with the silicon rich silicides for superior performance.
- FIG. 5 illustrates an example embodiment of an EBC bond coat system 500 comprising a bond coat 504 with a mixture phased region, in accordance with aspects of the subject innovation.
- Substrate 502 and layers 506 and 508 can be as described in connection with other embodiments (again, layers 506 and 508 can be optional).
- FIG. 5 also shows a thermal and environmental barrier coating (T/EBC) 510, which can be optionally included in any embodiments described herein.
- Bond coat 504 can comprise a mixture phased region 512-516 of increasing silicon or silica content or silica activity at portions of bond coat 504 closer to the substrate 502 (e.g., CMC) when compared with portions more distant from substrate 502.
- the mixture phased region is indicated in FIG.
- RESi mixture phased region of RESi, or RESi(O), RE 3 Si 5 or RE 3 Si 5 (0) and RESi 2 (0), with the silicon concentration between 50 and 67 molar%, and can provide excellent temperature capability and oxidation resistance.
- Various embodiments can have a silicon molar concentration in the range from 62 to 70%.
- Other embodiments of the subject innovation can have atomic percentages for silicon between 55 and 95%, or between 60 and 90%, or between 65 and 95%, etc.
- Silicon-rich bonded Silicide composites can provide coatings with excellent temperature capability and durability.
- Ti x (AlCrTa) y Si-(C)N type coating systems high silicon concentration (e.g., up to 60 molar%) can produce coatings with extremely high temperature capability (1600- 1700°C), exceptional mechanical properties, and low diffusivity amorphous coating formation.
- Bond coats that comprise both a silicon/silicide component (e.g., from Group A) and an oxide/silicate component (e.g., from Group B) can provide for a coating with capability.
- the oxide/silicate component e.g., refractory metal or rare earth oxides or silicates, etc.
- the advanced RE and RE doped Silicon or Silicide of Group A and the oxide-silicate compositions of Group B can also enhance the bond coat self-healing in the event cracking develops, and can also provide excellent oxidation and combustion environment protection under extreme environments.
- FIG. 6 illustrates an example bond coat system 600 with self-healing in accordance with aspects of the subject innovation.
- the substrate 602 can be as described elsewhere herein, and thin layers diffusion barriers can be included, although not shown in FIG. 6.
- Bond coat 604 can be any of a variety of bond coats as described herein, although the bond coat illustrated is similar to that illustrated in connection with FIG. 5.
- Bond coat 604 can comprise a silicon/silicide component, an oxide/silicate component, or a combination of the two, and can have a graded composition as described above in connection with mixture phased region 512-516 of FIG.
- Bond coat 604 is capable of self-healing cracks and self-growth of a low silica activity and high stability EBC, as shown at 606.
- a thermal and environmental barrier coating (T/EBC) top coat 608 can be included, but it need not be included in all embodiments, due to the ability of bond coat 604 to self-grow an EBC for superior stress and fatigue resistance.
- environmental barrier coating bond coat systems described herein can employ any of a variety of compositions and architectures described herein. Experimental results obtained in connection with embodiments of EBC bond coat systems useable in connection with Si-based ceramic and CMC component applications have demonstrated higher temperature capabilities and durability than state-of-the-art coatings in laboratory simulated engine environments. Various aspects and embodiments of bond coating systems disclosed herein have been successfully tested and demonstrated at the sub-element and sub-component levels. 10039) In various aspects, embodiments can employ an oxide-Si bond coat as described herein, in combination with an RE silicate or RE aluminosilicate EBC.
- Interlayers in such an embodiment can comprise RE-Hf02/Zr02-aluminosilicate layered coatings.
- Various high stability coatings can be employed in various aspects of the innovation, which can include one or more of RE oxide doped HfCVZrC , pyrochlores (RE 2 Zr 2 07- RE 2 Zr207), perovskites (e.g., RE-SrZr03, etc.), magnetoplumbites (e.g., REMgAlnOi9, etc.), or RE-Hafhia plus RE aluminosilicate composite coatings.
- embodiments of the subject innovation can also comprise other coats that can form an EBC system, such as top coats described herein.
- top coats of the subject innovation can employ various materials, such as those of the form RE-Hf0 2 -X, RE-Hf0 2 -graded Silica, RE-Hf0 2 -Alumino Silicate, etc.
- Top coats can be applied via EB-PVD or other suitable techniques, such as EB-PVD Hf0 2 -RE 2 0 2 , etc.
- coats and coat systems of the subject innovation can be applied via a variety of techniques, such as applied by Electron Beam-Physical Vapor Deposition (EB-PVD), Plasma-Spray Physical Vapor Deposition (PS-PVD), Plasma- Spray - Thin Film (PS-TF), High temperature Vacuum Vapor Deposition, Chemical vapor Deposition, etc.
- EB-PVD Electron Beam-Physical Vapor Deposition
- PS-PVD Plasma-Spray Physical Vapor Deposition
- PS-TF Plasma- Spray - Thin Film
- High temperature Vacuum Vapor Deposition Chemical vapor Deposition, etc.
- silicate/HfC -RE-Silicate with distinct vapor pressures can be applied via EB-PVD with co-deposition.
- PS-PVD and/or PS-TF coating processes can be employed, with PVD splat coating processing at low pressure (e.g., around 1 torr, etc.).
- high velocity vapor and non-line-of-sight coating processing can be employed.
- PS techniques used herein can employ a high enthalpy plasma vapor stream for efficient and complex thin film coating processing.
- FIG. 7 illustrates the high temperature strength of several tested bond coat materials useable in aspects of the subject innovation.
- FIG. 8 illustrates the flexural strength and deflection of HfC>2-Si bond coat materials useable in aspects of the subject innovation at various temperatures.
- the bond coat systems of the subject innovation have excellent strength and toughness.
- Other tested bond coats included RESiO+X (Ta, Al, Hf, Zr, etc.) bond coats, RESi+X bond coats, Zr/Hf-RE-Si bond coats, etc.
- FIG. 9 illustrates testing results for RESiO-based bond coats, showing a Silicon concentration range that can provide for improved oxidation resistance at 1500°C.
- FIG. 10 illustrates flexural strength for various environmental barrier bond coats of the subject innovation at room temperature and elevated
- coatings in accordance with various aspects of the subject innovation can comprise (a) Silicon cladded ⁇ 2 (e.g., agglomerated or sinter crushed ⁇ 1 ⁇ 2 powders, which can be at or near a 30:70 weight ratio of Si:HfC>2); (b) Yttrium monosilicate, with approximately a 50:50 molar ratio of Y2O3 and Si0 2 (i.e., around 78.984% weight and 21.016% weight, respectively); (c) Silicon cladded ytterbium monosilicate plus minor t' HfC> 2 (e.g., in a weight ratio of approximately 30:60:10 of Si : Ytterbium monosilicate : t' Hf0 2 ); (d) Silicon cladded ytterbium monosilicate (e.g., in a weight ratio of approximately 30:70 of Si: Ytterbium monosilicate
- bond coats in certain embodiments can comprise (a) Silicon with 30% atomic weight of Ytterbium; (b) alternating and co- deposition of 50% Gd 2 0 3 with Si plus 30 at.% Yb and 50% Yb 2 0 3 with Si plus 30 at.% Yb; or (c) a composite bond coat of HfO 2 with Si plus 30 at.% Yb.
- the thickness of these example bond coats can be in the range of 3 to 5 mils, although greater or lesser thicknesses can be used in various embodiments.
- certain embodiments of bond coat systems can comprise (a) Silicon with 15% atomic weight of Gadolinium; (b) alternating and co-deposition of 50% Gd 2 0 3 with Si and 50% ⁇ 13 ⁇ 40 3 with Si; or (c) a composite bond coat of Hf0 2 with Si plus 15 at.% Gd.
- an alternating layer system can be employed with a total thickness of around 10 mils.
- a bottom system (of thickness around 5 mils) can be included that alternates between (a) Hf0 2 (5% molar, 6.086% weight), Y 2 0 3 (5% molar, 6.529% weight), Gd 2 0 3 (5% molar, 20.962% weight), Yb 2 0 3 (25% molar, 45.576% weight), with co-deposition of Si0 2 (60% molar, 20.847% weight) and (b) Hf0 2 (96% molar, 90.7333% weight), Y 2 0 3 (2% molar, 3.464% weight), Gd 2 0 3 (1% molar, 2.780% weight), and Yb 2 0 3 (1% molar, 3.023% weight).
- a top system can be included (also of thickness around 5 mils) that alternates between (a) HfO 2 (30% molar, 27.598% weight), Y 2 0 3 (5% molar, 4.934% weight), Gd 2 0 3 (5% molar, 7.921% weight), Yb 2 0 3 (30% molar, 51.669% weight), with co- deposition of Si0 2 (30% molar, 7.878% weight) and (b) Hf0 2 (96% molar, 90.7333% weight), Y 2 0 3 (2% molar, 3.464% weight), Gd 2 0 3 (1% molar, 2.780% weight), and Yb 2 0 3 (1% molar, 3.023% weight).
- Si0 2 grading can be used with both.
- the chemical compositions can vary from the specific ratios provided, while remaining within the scope of the subject innovation.
- FIGS. 1 1 A, 1 IB, and 1 1C include other specific examples of compositions useable in connection with various aspects of the subject innovation; again, these examples are provided for purposes of illustration, and are not intended to be limiting.
- the subject innovation in various embodiments, can provide bond coat systems that can be critical for future development of advanced high performance gas turbine engine applications.
- the environmental barrier bond coating system is one of the most critical technologies that can lead to the future realization of SiC/SiC CMC turbine engine combustor liners and vanes, and turbine blades, allowing the engines to be operated at much higher temperatures with significantly reduced cooling requirements.
- This technology can be also used in a variety of other settings in which ceramic components will be subjected to extreme temperature or environmental conditions, such as land-based stationary gas turbines for power generation, and other energy related heat engine systems.
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Abstract
La présente invention concerne des systèmes avancés de couches d'ancrage pour revêtement barrière environnemental présentant de meilleures caractéristiques thermiques et une meilleure résistance environnementale. Ces systèmes de couches d'ancrage peuvent être appliqués à des substrats céramiques tels que les substrats composites de matrice céramique SiC/SiC, et peuvent conférer une protection vis-à-vis des températures extrêmes, des charges mécaniques et des conditions environnementales, comme dans les turbines à gaz à haute température. Les exemples de systèmes de couches d'ancrage peuvent inclure soit un composant avancé silicium/siliciure, soit un composant oxyde/silicate, soit l'une de leurs combinaisons.
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EP3604257A1 (fr) * | 2018-08-03 | 2020-02-05 | United Technologies Corporation | Revêtement de liaison auto-réparateur renforcé de fibres |
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CN115894081A (zh) * | 2022-12-15 | 2023-04-04 | 西安交通大学 | 一种高熔点、长寿命环境障涂层粘接层的制备方法及材料 |
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