公开(公告)号：US20150167141A1

公开(公告)日：2015-06-18

申请号：US14107225

申请日：2013-12-16

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Larry Steven ROSENZWEIG ,  James Anthony RUUD ,  Shankar SIVARAMAKRISHNAN

IPC: C23C4/12 ,  C23C4/10 ,  F01D25/00

CPC classification number: C23C4/067 ,  C23C4/134 ,  F01D5/288 ,  Y02T50/6765 ,  Y10T428/24802

Abstract: The present application provides Calcia-Magnesia-Alumina-Silica (CMAS) (or molten silicate) resistant thermal barrier coatings (TBC). The coatings include elongate growth domains of non-equiaxed, randomly arranged overlapping grains or splats. The elongate growth domains include overlapping individual, randomly distributed splats of tough and soft phases. In some embodiments, the elongate growth domains are formed via air plasma spray. In some embodiments, the tough phases are at least partially stabilized zirconia and/or hafnia compositions, and the soft phases are CMAS (or molten silicate) reactive or resistant compositions. Within each elongate growth domain, the mixture of the tough and soft phases act together to limit penetration of CMAS and also provide sufficient domain toughness to minimize cracking forces produced during crystallization of infiltrated CMAS. The soft phases may react with the CMAS and increase its melting point, increase its viscosity, and reduce the destabilization of the tough phases.

Abstract translation: 本申请提供了氧化钙 - 氧化铝 - 二氧化硅（CMAS）（或熔融硅酸盐）耐热隔热涂层（TBC）。 涂层包括非等轴，随机排列的重叠晶粒或碎片的细长生长域。 细长的生长结构域包括重叠的，随机分布的韧性和软相的碎片。 在一些实施方案中，细长生长域通过空气等离子体喷涂形成。 在一些实施方案中，韧性相是至少部分稳定的氧化锆和/或铪组合物，并且软相是CMAS（或熔融硅酸盐）反应性或抗性组合物。 在每个细长生长区域内，韧性和软相的混合物共同作用以限制CMAS的渗透，并且还提供足够的结构域韧性以最小化渗透的CMAS结晶过程中产生的开裂力。 软相可能与CMAS反应并增加其熔点，增加其粘度，并减少韧性相的不稳定性。

公开(公告)号：US20180029928A1

公开(公告)日：2018-02-01

申请号：US15725889

申请日：2017-10-05

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Daniel Gene DUNN ,  James Anthony RUUD ,  Pierre-Andre BUI ,  Gregory Scot CORMAN ,  James Scott VARTULI

IPC: C03C17/00 ,  C04B35/80

CPC classification number: C03C17/001 ,  C04B35/80 ,  C04B35/806 ,  C04B2235/3826 ,  C04B2235/6028 ,  C04B2235/614 ,  C04B2235/616

Abstract: The present application provides methods and apparatus for processing ceramic fibers for the manufacture of ceramic matrix composites (CMCs). One method may include providing at least one frame including a planar array of unidirectional ceramic fibers extending across a void thereof. The method may further include depositing a coating on the ceramic fibers of the at least one frame via a chemical vapor deposition (CVD) process. The method may also include impregnating the coated ceramic fibers with a slurry including a ceramic matrix precursor composition to form at least one CMC prepreg, such as a prepreg tape. The ceramic fibers may be substantially SiC fibers, for example.

公开(公告)号：US20170144329A1

公开(公告)日：2017-05-25

申请号：US14951737

申请日：2015-11-25

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Daniel Gene DUNN ,  James Anthony RUUD ,  Pierre-Andre BUI ,  Gregory Scot CORMAN ,  James Scott VARTULI

IPC: B28B1/14 ,  C23C16/34 ,  C23C16/26 ,  C04B41/85

CPC classification number: B28B1/14 ,  C04B35/80 ,  C04B35/806 ,  C04B41/85 ,  C04B2235/3826 ,  C04B2235/6028 ,  C04B2235/614 ,  C04B2235/616 ,  C23C16/26 ,  C23C16/342 ,  C23C16/345

Abstract: The present application provides methods and apparatus for processing ceramic fibers for the manufacture of ceramic matrix composites (CMCs). One method may include providing at least one frame including a planar array of unidirectional ceramic fibers extending across a void thereof. The method may further include at least one of depositing a coating on the ceramic fibers of the at least one frame via a chemical vapor deposition (CVD) process and impregnating the ceramic fibers with a slurry including a ceramic matrix precursor composition to form at least one CMC prepreg. In some embodiments, the ceramic fibers of the planar array may include a coating, and the method may include impregnating the coated ceramic fibers with a slurry including a ceramic matrix precursor composition to form at least one CMC prepreg.

公开(公告)号：US20170144925A1

公开(公告)日：2017-05-25

申请号：US14951650

申请日：2015-11-25

Applicant: GENERAL ELECTRIC COMPANY

Inventor： Daniel Gene DUNN ,  James Anthony RUUD ,  Pierre-Andre BUI ,  Gregory Scot CORMAN ,  James Scott VARTULI

IPC: C03C17/00

CPC classification number: C03C17/001 ,  C04B35/80 ,  C04B35/806 ,  C04B2235/3826 ,  C04B2235/6028 ,  C04B2235/614 ,  C04B2235/616

Abstract: The present application provides methods and apparatus for processing ceramic fibers for the manufacture of ceramic matrix composites (CMCs). One method may include providing at least one frame including a planar array of unidirectional ceramic fibers extending across a void thereof. The method may further include depositing a coating on the ceramic fibers of the at least one frame via a chemical vapor deposition (CVD) process. The method may also include impregnating the coated ceramic fibers with a slurry including a ceramic matrix precursor composition to form at least one CMC prepreg, such as a prepreg tape. The ceramic fibers may be substantially SiC fibers, for example.

公开(公告)号：US20160031186A1

公开(公告)日：2016-02-04

申请号：US14774998

申请日：2014-03-12

Applicant: GENERAL ELECTRIC COMPANY

Inventor： David Paul MOURER ,  Leonardo AJDELSZTAJN ,  Kenneth Rees BAIN ,  Andrew Joseph DETOR ,  Andrew William EMGE ,  James Anthony RUUD ,  Michael James WEIMER

IPC: B32B15/01 ,  F01D5/28 ,  C22C19/05

CPC classification number: B32B15/013 ,  B32B15/015 ,  C22C19/055 ,  C22C19/058 ,  C23C4/067 ,  C23C4/18 ,  C23C10/28 ,  F01D5/288 ,  F05D2300/175

Abstract: Coatings for substrates, such as superalloy substrates, are provided. The coating can include: 15 wt % to 45 wt % cobalt; 20 wt % to 40 wt % chromium; 2 wt % to 15 wt % aluminum; 0.1 wt % to 1 wt % yttrium; and nickel. The coatings may include nickel, cobalt, chromium and aluminum, and other optional additives to improve oxidation and corrosion resistance of the substrate without significant debit to its mechanical properties.

Abstract translation: 提供了用于基底的涂层，例如超耐热合金基底。 涂层可包括：15wt％至45wt％的钴; 20重量％至40重量％的铬; 2重量％至15重量％的铝; 0.1重量％至1重量％的钇; 和镍。 涂层可以包括镍，钴，铬和铝以及其它任选的添加剂，以改善衬底的抗氧化和耐腐蚀性，而不会对其机械性能造成重大损失。

公开(公告)号：US20150233256A1

公开(公告)日：2015-08-20

申请号：US13741848

申请日：2013-01-15

Applicant: General Electric Company

Inventor： Krishnamurthy ANAND ,  James Anthony RUUD ,  Surinder Singh PABLA ,  Joshua Lee MARGOLIES ,  Padmaja PARAKALA ,  Larry Steven ROSENZWEIG

IPC: F01D5/28 ,  C23C4/02 ,  C23C4/10 ,  C23C4/12

CPC classification number: F01D5/284 ,  C23C4/02 ,  C23C4/11 ,  C23C4/134 ,  F01D5/28 ,  F01D5/288 ,  F05D2300/2118 ,  Y10T428/12549 ,  Y10T428/12618

Abstract: A thermal barrier coating system for metal components in a gas turbine engine having an ultra low thermal conductivity and high erosion resistance, comprising an oxidation-resistant bond coat formed from an aluminum rich material such as MCrAlY and a thermal insulating ceramic layer over the bond coat comprising a zirconium or hafnium oxide lattice structure (ZrO2 or HfO2) and an oxide stabilizer compound comprising one or more of the compounds ytterbium oxide (Yb2O3), yttria oxide (Y2O3), hafnium oxide (HfO2), lanthanum Oxide (La2O3), tantalum oxide (Ta2O5) or zirconium oxide (ZrO2). The invention includes a new method of forming the ceramic-based thermal barrier coatings using a liquid-based suspension containing microparticles comprised of at least one of the above compounds ranging in size between about 0.1 and 5 microns. The coatings form a tortuous path of ceramic interfaces that increase the coating toughness while preserving the ultra low thermal conductivity.

Abstract translation: 一种用于具有超低热导率和高耐侵蚀性的燃气轮机中的金属部件的隔热涂层系统，包括由富铝材料如MCrAlY形成的抗氧化粘合涂层和粘结涂层上的绝热陶瓷层 包括锆或铪氧化物晶格结构（ZrO 2或HfO 2）和包含一种或多种化合物氧化镱（Yb 2 O 3），氧化钇（Y 2 O 3），氧化铪（HfO 2），氧化镧（La 2 O 3），钽 氧化物（Ta2O5）或氧化锆（ZrO2）。 本发明包括使用包含由至少一种上述化合物构成的微粒的液体基悬浮液形成陶瓷基热障涂层的新方法，其尺寸范围为约0.1至5微米。 涂层形成陶瓷界面的曲折路径，从而提高涂层韧性，同时保持超低热导率。