US5683825A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Thermal barrier coating resistant to erosion and impact by particulate matter
Assignee: General Electric Co
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Filing: 1996-01-02
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Granted: 1997-11-04
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Expires: 2016-01-02
Abstract
Abstract A thermal barrier coating adapted to be formed on an article subjected to a hostile thermal environment while subjected to erosion by particles and debris, as is the case with turbine, combustor and augmentor components of a gas turbine engine. The thermal barrier coating is composed of a metallic bond layer deposited on the surface of the article, a ceramic layer overlaying the bond layer, and an erosion-resistant composition dispersed within or overlaying the ceramic layer. The bond layer serves to tenaciously adhere the thermal insulating ceramic layer to the article, while the erosion-resistant composition renders the ceramic layer more resistant to erosion. The erosion-resistant composition is either alumina (Al 2 O 3 ) or silicon carbide (SiC), while a preferred ceramic layer is yttria-stabilized zirconia (YSZ) deposited by a physical vapor deposition technique to have a columnar grain structure.
Inventors
- 👤 Robert W. Bruce
- 👤 Jon C. Schaeffer
- 👤 Mark A. Rosenzweig
- 👤 Rudolfo Viguie
- 👤 David V. Rigney
- 👤 Antonio F. Maricocchi
- 👤 David J. Wortman
- 👤 Bangalore A. Nagaraj
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-09 08:00
CPC Classifications
C; C23; C23C; C23C28/00
Claims Analysis
Total Claims: 24
Claim 1
Independent Claim
85 words
An erosion-resistant thermal barrier coating formed on an article subjected to particulate impact erosion and wear, the thermal barrier coating comprising: a metallic oxidation-resistant bond layer covering a surface of the article; a columnar ceramic layer formed on the bond layer by a physical vapor deposition technique; and an erosion-resistant composition present in the thermal barrier coating so as to inhibit erosion of the columnar ceramic layer, the erosion-resistant composition consisting essentially of a material chosen from the group consisting of silicon carbide and alumina.
Claim 2
Dependent Claim
85 words
An erosion-resistant thermal barrier coating formed on an article subjected to particulate impact erosion and wear, the thermal barrier coating comprising: a metallic oxidation-resistant bond layer covering a surface of the article; a columnar ceramic layer formed on the bond layer by a physical vapor deposition technique; and an erosion-resistant composition present in the thermal barrier coating so as to inhibit erosion of the columnar ceramic layer, the erosion-resistant composition consisting essentially of a material chosen from the group consisting of silicon carbide and alumina.
Claim 3
Dependent Claim
40 words
A thermal barrier coating as recited in claim 1 wherein the erosion-resistant composition is a wear coating overlaying the columnar ceramic layer so as to serve as a physical barrier to particulate impact and erosion of the columnar ceramic layer.
Claim 4
Dependent Claim
28 words
A thermal barrier coating as recited in claim 2 wherein the columnar ceramic layer consists essentially of zirconia stabilized by about 6 to about 8 weight percent yttria.
Claim 5
Dependent Claim
40 words
A thermal barrier coating as recited in claim 2 wherein the thermal barrier coating further comprises at least a second columnar ceramic layer overlaying the erosion-resistant composition and at least a second erosion-resistant composition overlaying the second columnar ceramic layer.
Claim 6
Dependent Claim
32 words
A thermal barrier coating as recited in claim 1 wherein the erosion-resistant composition is dispersed in the columnar ceramic layer so as to render the columnar ceramic layer more resistant to erosion.
Claim 7
Dependent Claim
41 words
A thermal barrier coating as recited in claim 5 wherein the columnar ceramic layer consists essentially of yttria-stabilized zirconia and the erosion-resistant composition, the erosion-resistant composition being alumina and constituting up to about 45 weight percent of the columnar ceramic layer.
Claim 8
Dependent Claim
27 words
A thermal barrier coating as recited in claim 1 wherein the bond layer has an average surface roughness R a of not more than about two micrometers.
Claim 9
Dependent Claim
23 words
A thermal barrier coating as recited in claim 1 wherein the erosion-resistant composition is deposited by a physical or chemical vapor deposition technique.
Claim 10
Dependent Claim
99 words
An impact and erosion-resistant thermal barrier coating formed on a superalloy article subjected to erosion and wear, the thermal barrier coating comprising: a metallic oxidation-resistant bond layer covering a surface of the superalloy article; a columnar ceramic layer formed on the bond layer by a physical vapor deposition technique, the columnar ceramic layer comprising yttria-stabilized zirconia; and an erosion-resistant coating formed on the columnar ceramic layer so as to serve as a physical barrier to erosion of the columnar ceramic layer, the erosion-resistant composition consisting essentially of a material chosen from the group consisting of silicon carbide and alumina.
Claim 11
Dependent Claim
99 words
An impact and erosion-resistant thermal barrier coating formed on a superalloy article subjected to erosion and wear, the thermal barrier coating comprising: a metallic oxidation-resistant bond layer covering a surface of the superalloy article; a columnar ceramic layer formed on the bond layer by a physical vapor deposition technique, the columnar ceramic layer comprising yttria-stabilized zirconia; and an erosion-resistant coating formed on the columnar ceramic layer so as to serve as a physical barrier to erosion of the columnar ceramic layer, the erosion-resistant composition consisting essentially of a material chosen from the group consisting of silicon carbide and alumina.
Claim 12
Dependent Claim
28 words
A thermal barrier coating as recited in claim 9 wherein the columnar ceramic layer consists essentially of zirconia stabilized by about 6 to about 8 weight percent yttria.
Claim 13
Dependent Claim
40 words
A thermal barrier coating as recited in claim 9 wherein the thermal barrier coating further comprises at least a second columnar ceramic layer overlaying the erosion-resistant composition and at least a second erosion-resistant composition overlaying the second columnar ceramic layer.
Claim 14
Dependent Claim
27 words
A thermal barrier coating as recited in claim 9 wherein the bond layer has an average surface roughness R a of not more than about two micrometers.
Claim 15
Dependent Claim
84 words
An impact and erosion-resistant thermal barrier coating formed on a superalloy article subjected to erosion and wear, the thermal barrier coating comprising: a metallic oxidation-resistant bond layer covering a surface of the superalloy article; a columnar ceramic layer formed on the bond layer by a physical vapor deposition technique, the columnar ceramic layer comprising zirconia; and an erosion-resistant composition dispersed in the columnar ceramic layer so as to render the columnar ceramic layer more resistant to erosion, the erosion-resistant composition consisting essentially of alumina.
Claim 16
Dependent Claim
84 words
An impact and erosion-resistant thermal barrier coating formed on a superalloy article subjected to erosion and wear, the thermal barrier coating comprising: a metallic oxidation-resistant bond layer covering a surface of the superalloy article; a columnar ceramic layer formed on the bond layer by a physical vapor deposition technique, the columnar ceramic layer comprising zirconia; and an erosion-resistant composition dispersed in the columnar ceramic layer so as to render the columnar ceramic layer more resistant to erosion, the erosion-resistant composition consisting essentially of alumina.
Claim 17
Dependent Claim
37 words
A thermal barrier coating as recited in claim 13 wherein the zirconia of the columnar ceramic layer is stabilized with yttria, and the erosion-resistant composition constitutes up to about 45 weight percent of the columnar ceramic layer.
Claim 18
Dependent Claim
27 words
A thermal barrier coating as recited in claim 13 wherein the bond layer has an average surface roughness R a of not more than about two micrometers.
Claim 19
Independent Claim
85 words
A method for forming an impact and erosion-resistant thermal barrier layer on an article, the method comprising the steps of: forming a metallic oxidation-resistant bond layer on a surface of the article; forming a columnar ceramic layer on the bond layer by a physical vapor deposition technique; and providing an erosion-resistant composition in the thermal barrier coating so as to inhibit erosion of the columnar ceramic layer, the erosion-resistant composition consisting essentially of a material chosen from the group consisting of silicon carbide and alumina.
Claim 20
Independent Claim
85 words
A method for forming an impact and erosion-resistant thermal barrier layer on an article, the method comprising the steps of: forming a metallic oxidation-resistant bond layer on a surface of the article; forming a columnar ceramic layer on the bond layer by a physical vapor deposition technique; and providing an erosion-resistant composition in the thermal barrier coating so as to inhibit erosion of the columnar ceramic layer, the erosion-resistant composition consisting essentially of a material chosen from the group consisting of silicon carbide and alumina.
Claim 21
Dependent Claim
34 words
A method as recited in claim 16 wherein the step of forming the bond layer results in the bond layer having an average surface roughness R a of not more than about two micrometers.
Claim 22
Dependent Claim
33 words
A method as recited in claim 16 wherein the step of forming the columnar ceramic layer includes maintaining the article stationary while depositing the columnar ceramic layer using the physical vapor deposition technique.
Claim 23
Dependent Claim
28 words
A method as recited in claim 16 wherein the step of providing the erosion-resistant composition entails forming a layer of the erosion-resistant composition over the columnar ceramic layer.
Claim 24
Dependent Claim
30 words
A method as recited in claim 16 wherein the step of providing the erosion-resistant composition entails forming a dispersion of particles of the erosion-resistant composition in the columnar ceramic layer.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
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| 3.5 Years (Year 4) | 2000-11-03 | 2001-05-05 | 2001-11-04 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2004-11-03 | 2005-05-05 | 2005-11-04 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2008-11-03 | 2009-05-05 | 2009-11-04 | $7700.00 | Window Closed / Lapsed |