US6258467B1
Expired / Lapsed
US
⏱️ 0.0 years remaining
Thermal barrier coating having high phase stability
Assignee: United States Department of Energy
•
Filing: 2000-08-17
•
Granted: 2001-07-10
•
Expires: 2020-08-17
Abstract
Abstract A device (10) comprising a substrate (22) having a deposited ceramic thermal barrier coating layer (20) characterized by a microstructure having gaps (28) where the thermal barrier coating (20) consists essentially of a pyrochlore crystal structure having a chemical formula consisting essentially of An+2-xBm+2+xO7-y, where A is selected from the group of elements selected from La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, and mixtures thereof; where B is selected from the group of elements selected from Zr, Hf, Ti and mixtures thereof; n and m are the valence of A and B respectively, and for -0.5<=x<=0.5,and excluding the following combinations for x=0, y=0: A=La and B=Zr; A=La and B=Hf; A=Gd and B=Hf; and A=Yb and B=Ti.
Inventors
- 👤 Ramesh Subramanian
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-09 01:24
CPC Classifications
C; C04; C04B; C04B35/00; C04B35/01; C04B35/48; C04B35/486; C23; C23C; C23C28/00; C23C28/30; C23C28/32; C23C28/321; C23C28/3215; C23C28/34; C23C28/345; C23C28/3455; C23C28/36; C04B2235/00; C04B2235/02; C04B2235/30; C04B2235/32; C04B2235/3224; C04B2235/3227; C04B2235/3231; C04B2235/3244; C04B2235/3248; C04B2235/70; C04B2235/74; C04B2235/76; Y; Y02; Y02T; Y02T50/00; Y02T50/60; Y10; Y10T; Y10T428/00; Y10T428/12; Y10T428/12493; Y10T428/12535; Y10T428/12542; Y10T428/12549; Y10T428/12611; Y10T428/12618; Y10T428/12771; Y10T428/12861; Y10T428/12889; Y10T428/12931; Y10T428/12944
Claims Analysis
Total Claims: 20
Claim 1
Independent Claim
168 words
A device operating over a range of temperatures and having a deposited thermal barrier coating on at least a portion of its surface, the device comprising: a substrate with a base coat; and then a deposited ceramic thermal barrier layer, said ceramic thermal barrier layer consisting essentially of a pyrochlore crystal structure having a chemical formula consisting essentially of A n+ 2−x B m+ 2+x O 7−y where A is selected from the group of elements consisting of La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, and mixtures thereof; where B is selected from the group of elements consisting of Zr, Hf, Ti and mixtures thereof; n and m are the valence of A and B respectively; and for −0.5≦x≦0.5, y = 7 - ( ( 2 - x ) n + ( 2 + x ) m ) 2 , and excluding the following combinations for x=0, y=0:A=La and B=Zr; A=La and B=Hf; A=Gd and B=Hf; and A=Yb and B=Ti.
Claim 2
Independent Claim
168 words
A device operating over a range of temperatures and having a deposited thermal barrier coating on at least a portion of its surface, the device comprising: a substrate with a base coat; and then a deposited ceramic thermal barrier layer, said ceramic thermal barrier layer consisting essentially of a pyrochlore crystal structure having a chemical formula consisting essentially of A n+ 2−x B m+ 2+x O 7−y where A is selected from the group of elements consisting of La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, and mixtures thereof; where B is selected from the group of elements consisting of Zr, Hf, Ti and mixtures thereof; n and m are the valence of A and B respectively; and for −0.5≦x≦0.5, y = 7 - ( ( 2 - x ) n + ( 2 + x ) m ) 2 , and excluding the following combinations for x=0, y=0:A=La and B=Zr; A=La and B=Hf; A=Gd and B=Hf; and A=Yb and B=Ti.
Claim 3
Dependent Claim
25 words
The device of claim 1 , wherein the microstructure of the thermal barrier layer is characterized by a plurality of gaps extending through the thickness.
Claim 4
Dependent Claim
23 words
The device of claim 1 , wherein said ceramic thermal barrier is stable over a range of temperatures up to about 1500° C.
Claim 5
Dependent Claim
47 words
The device of claim 1 , wherein said ceramic thermal barrier coating consists essentially of Sm 2−x Zr 2+x O 7−y where −0.5≦X≦0.5 and y = 7 - [ ( 2 - x ) 3 + ( 2 + x ) 4 ) 2 .
Claim 6
Dependent Claim
15 words
The device of claim 1 , wherein said ceramic thermal barrier is resistant to sintering.
Claim 7
Dependent Claim
27 words
The device of claim 1 , wherein said ceramic thermal barrier is resistant to sintering and contains gaps within its structure generally parallel to the substrate surface.
Claim 8
Dependent Claim
32 words
The device of claim 1 , wherein said ceramic thermal barrier consists of a material selected from the group consisting essentially of A=Sm and B=Zr; A=Eu and B=Zr; and A=Gd and B=Zr.
Claim 9
Dependent Claim
21 words
The device of claim 1 , wherein said ceramic thermal barrier consists essentially of Sm 2 Zr 2 O 7 .
Claim 10
Dependent Claim
13 words
The device of claim 1 , wherein said substrate is a turbine component.
Claim 11
Dependent Claim
18 words
The device of claim 1 wherein said substrate is selected from turbine blades, turbine vanes and turbine transitions.
Claim 12
Dependent Claim
53 words
The device of claim 1 also containing a MCrAlY alloy base coat layer between the substrate and the ceramic thermal barrier layer, wherein M is selected from the group consisting of Ni, Co, Fe, and mixtures, and where the substrate is selected from the group consisting of metallic superalloy materials and ceramic materials.
Claim 13
Dependent Claim
16 words
The device of claim 1 , operating in a turbine at temperatures up to 1500° C.
Claim 14
Independent Claim
164 words
A method for producing a device operable over a range of temperatures, the method comprising the steps of: providing a substrate; and depositing a ceramic thermal barrier layer over the substrate in a manner that provides a deposited ceramic layer consisting essentially of a pyrochlore crystal structure having a chemical formula consisting essentially of A n+ 2−x B m+ 2+x O 7−y , where A is selected from the group of elements consisting of La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, and mixtures thereof; where B is selected from the group of elements consisting of Zr, Hf, Ti and mixtures thereof; n and m are the valence of A and B respectively; and for −0.5≦x≦0.5, y = 7 - ( ( 2 - x ) n + ( 2 + x ) m ) 2 , and excluding the following combinations for x=0, y=0:A=La and B=Zr; A=La and B=Hf; A=Gd and B=Hf; and A=Yb and B=Ti.
Claim 15
Independent Claim
164 words
A method for producing a device operable over a range of temperatures, the method comprising the steps of: providing a substrate; and depositing a ceramic thermal barrier layer over the substrate in a manner that provides a deposited ceramic layer consisting essentially of a pyrochlore crystal structure having a chemical formula consisting essentially of A n+ 2−x B m+ 2+x O 7−y , where A is selected from the group of elements consisting of La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, and mixtures thereof; where B is selected from the group of elements consisting of Zr, Hf, Ti and mixtures thereof; n and m are the valence of A and B respectively; and for −0.5≦x≦0.5, y = 7 - ( ( 2 - x ) n + ( 2 + x ) m ) 2 , and excluding the following combinations for x=0, y=0:A=La and B=Zr; A=La and B=Hf; A=Gd and B=Hf; and A=Yb and B=Ti.
Claim 16
Dependent Claim
31 words
The method of claim 13 , where the microstructure of the thermal barrier layer is characterized by a plurality of gaps of the thermal barrier layer is extending through the thickness.
Claim 17
Dependent Claim
47 words
The method of claim 13 , wherein the step of depositing further comprises the step of depositing a MCrAlY alloy base coat layer on the substrate before depositing the ceramic thermal barrier layer, wherein M is selected from the group consisting of Ni, Co, Fe, and mixtures.
Claim 18
Dependent Claim
45 words
The method of claim 13 , wherein the step of depositing the thermal barrier coating is selected from plasma spray techniques, electron beam physical vapor deposition, D-gun techniques, high velocity oxygen fuel deposition techniques, inductively coupled deposition processes, and electron beam directed vapor deposition techniques.
Claim 19
Dependent Claim
47 words
The method of claim 13 , wherein said ceramic thermal barrier coating consists essentially of Sm 2−x Zr 2+x O 7−y where −0.5≦X≦0.5 and y = 7 - [ ( 2 - x ) 3 + ( 2 + x ) 4 ) 2 .
Claim 20
Dependent Claim
52 words
The method of claim 13 , wherein said ceramic thermal barrier consists essentially of Sm 2 Zr 2 O 7 deposited as an admixture of Sm 2 O 3 plus ZrO 2 where the mole % of Sm 2 O 3 ranges from about 15 mole % to about 40 mole %.
References Cited (Backward Citations)
US4321310A
Cited
US5304519A
Cited
US5562998A
Cited
US5683825A
Cited
US5789330A
Cited
US6127048A
Cited
US6177200B1
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2004-07-09 | 2005-01-08 | 2005-07-10 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2008-07-09 | 2009-01-08 | 2009-07-10 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2012-07-09 | 2013-01-08 | 2013-07-10 | $7700.00 | Window Closed / Lapsed |