Abstract:
A ceramic material having particular utility as a thermal insulating or thermal barrier coating on metallic substrates is provided. The ceramic material broadly comprises at least one oxide and the balance comprising a first oxide selected from the group consisting of zirconia, ceria, and hafnia. The at least one has a formula A2O3 where A is selected from the group consisting of La, Pr, Nd, Sm, Eu, Tb, In, Sc, Y, Dy, Ho, Er, Tm, Yb, Lu, and mixtures thereof. The present invention also broadly relates to an article having a metal substrate and a thermal barrier coating as discussed above.
Abstract:
A turbine component has a substrate formed from a ceramic material selected from the group consisting of a monolithic ceramic material and a composite ceramic material and a thermal barrier coating bonded to the substrate. In one embodiment, the ceramic material forming the substrate is selected from the group of silicon nitride and self-reinforced silicon nitride. In another embodiment, the ceramic material forming the substrate is selected from the group consisting of a silicon carbide-silicon carbide material and a carbon-carbon material. At least one bond coat layer may be interposed between the substrate and the thermal barrier coating.
Abstract:
A method for use in a physical vapor deposition coating process includes depositing a ceramic coating material from a plume onto at least one substrate to form a ceramic coating thereon, and during the deposition, rotating the at least one substrate at rotational speed selected with respect to deposition rate of the ceramic coating material onto the at least one substrate.
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.
Abstract:
A method for use in a coating process includes pre-heating a substrate in the presence of a coating material and shielding the substrate during the pre-heating from premature deposition of the coating material by establishing a gas screen between the substrate and the coating material. An apparatus for use in a coating process includes a chamber, a crucible that is configured to hold a coating material in the chamber, an energy source operable to heat the interior of the chamber, a coating envelope situated with respect to the crucible, and at least one gas manifold located near the coating envelope. The at least one gas manifold is configured to provide a gas screen between the coating envelope and the crucible. A second manifold provides gas during a later coating deposition to compress a vapor plume of the coating material and focus the plume on the substrate to increase deposition rate.
Abstract:
A thermal barrier coating comprising from 0.5 to 1.0 mol% of at least one first oxide from the group consisting of CeO2, Pr203, Nd203, Eu2O3, Gd2O3, Dy203, Er2O3, Yb2O3, In2O3, Sc2O3, Y2O3, and mixtures thereof, combined with a second oxide selected from the group consisting of zirconia, hafnia, and ceria.
Abstract:
A superalloy article is disclosed having a thermal barrier coating. The article comprises a superalloy substrate (18), an adherent alumina layer (20) on the substrate, and a ceramic, thermally insulating layer (22) on the alumina layer. The ceramic layer has an overall thickness and comprises a relatively strain tolerant, columnar grain ceramic (24) on the alumina layer and relatively more thermally insulating ceramic (26) on the columnar grain ceramic. The alumina layer may be formed using an alumina forming layer such as an overlay or aluminide bond coat, or the superalloy may comprise a material that is capable of forming an alumina layer. The ceramic layers may be formed of a stabilized zirconia or other suitable material, and may have the same or different compositions.
Abstract:
A turbine component has a substrate formed from a ceramic material selected from the group consisting of a monolithic ceramic material and a composite ceramic material and a thermal barrier coating bonded to the substrate. In one embodiment, the ceramic material forming the substrate is selected from the group of silicon nitride and self-reinforced silicon nitride. In another embodiment, the ceramic material forming the substrate is selected from the group consisting of a silicon carbide-silicon carbide material and a carbon-carbon material. At least one bond coat layer may be interposed between the substrate and the thermal barrier coating.
Abstract:
A thermal barrier coating comprising at least 15 mol% of at least one lanthanide sesquioxide, each said lanthanide sesquioxide having a formula A2O3 where A is selected from the group consisting of La, Pr, Nd, Sm, Eu, Tb, and mixtures thereof, and the balance comprising a first oxide selected from the group consisting of zirconia, ceria, and hafnia, said first oxide being present in an amount of at least 50 mol%.