公开(公告)号：US11566531B2

公开(公告)日：2023-01-31

申请号：US17065127

申请日：2020-10-07

Applicant: Rolls-Royce Corporation ,  Rolls-Royce plc

Inventor： Jun Shi ,  Matthew Eric Hancock ,  Li Li

IPC: F01D11/12 ,  C23C4/11 ,  C23C4/134 ,  B32B18/00 ,  C23C14/08 ,  F01D5/20 ,  F01D5/28

Abstract: In one example, an article including a metallic substrate; and an abradable coating on the metallic substrate, the abradable coating including a plurality of abradable layers in an alternating arrangement with a plurality of CMAS resistant layers, wherein the plurality of CMAS resistant layers are configured to react with molten CMAS to form a stable phase.

公开(公告)号：US11326469B2

公开(公告)日：2022-05-10

申请号：US16887294

申请日：2020-05-29

Applicant: Rolls-Royce Corporation

Inventor： Li Li ,  Jun Shi

IPC: F01D21/00 ,  F01D21/14 ,  F01D25/00 ,  F01D5/28 ,  G01N21/64 ,  F01D11/12 ,  G01B11/06

Abstract: An article includes a substrate defining a surface, a bond coat on the surface of the substrate, a coating layer on the bond coat, and a wear indicator. The coating layer includes at least one of an environmental barrier coating (EBC) or an abradable coating. The wear indicator disposed in a first region of the coating layer and includes at least one chromophore dopant and a material of the EBC or the abradable coating. The wear indicator is configured to indicate wear of the coating layer.

公开(公告)号：US20220106888A1

公开(公告)日：2022-04-07

申请号：US17065127

申请日：2020-10-07

Applicant: Rolls-Royce Corporation ,  Rolls-Royce plc

Inventor： Jun Shi ,  Matthew Eric Hancock ,  Li Li

IPC: F01D11/12 ,  C23C14/08 ,  C23C4/134 ,  C23C4/11

Abstract: In one example, an article including a metallic substrate; and an abradable coating on the metallic substrate, the abradable coating including a plurality of abradable layers in an alternating arrangement with a plurality of CMAS resistant layers, wherein the plurality of CMAS resistant layers are configured to react with molten CMAS to form a stable phase.

公开(公告)号：US10851656B2

公开(公告)日：2020-12-01

申请号：US16141803

申请日：2018-09-25

Applicant: Rolls-Royce Corporation ,  Rolls-Royce PLC

Inventor： Stephanie Gong ,  Taylor K. Blair ,  Ngunjoh Lawrence Ndamka ,  Li Li ,  Sunny Chang ,  Ann Bolcavage

IPC: C04B41/52 ,  F01D5/28 ,  C23C28/04 ,  C23C28/00 ,  F01D25/00 ,  C04B41/89

Abstract: An article includes a substrate, a bond coat on the substrate, and a multilayer environmental barrier coating (EBC) on the bond coat. The multilayer EBC includes a first EBC layer defining a first thickness and a second EBC layer defining a second thickness. The first EBC layer includes a first rare earth disilicate and a first concentration of a sintering aid that includes alumina. The second EBC layer includes a second rare earth disilicate and a second concentration of the sintering aid that includes alumina, less than the first concentration of the sintering aid.

公开(公告)号：US10851026B2

公开(公告)日：2020-12-01

申请号：US16014660

申请日：2018-06-21

Applicant: Rolls-Royce Corporation ,  Rolls-Royce High Temperature Composites, Inc.

Inventor： Li Li ,  Sungbo Shim ,  Sunny Chang

IPC: C23C4/04 ,  C23C4/10 ,  C23C4/12 ,  C04B41/52 ,  C23C28/04 ,  B01J20/30

Abstract: A method of forming an impurity barrier layer on a CMC substrate may include introducing, to a heated plume of a thermal spray gun, a composite feedstock that includes a first coating material including a plurality of first particles; and a second coating material that may be different from the first coating material, where the second coating material at least partially encapsulates at least a portion of respective surfaces of the plurality of first particles; and directing, using the heated plume, at least the first coating material to a surface of a CMC substrate to deposit an impurity barrier layer including at least the first coating material.

公开(公告)号：US20190048475A1

公开(公告)日：2019-02-14

申请号：US16057984

申请日：2018-08-08

Applicant: Rolls-Royce Corporation ,  Rolls-Royce North American Technologies, Inc. ,  Rolls-Royce PLC

Inventor： Ngunjoh Lawrence Ndamka ,  Li Li ,  Ann Bolcavage ,  Bruce Edward Varney ,  Sean E. Landwehr

IPC: C23C28/04 ,  F01D5/28

Abstract: A method includes predicting a composition of calcium-magnesium-aluminum-silicate (CMAS) to be encountered by a high temperature mechanical system during use of the high temperature mechanical system. The method further includes selecting a composition of a CMAS-resistant barrier coating layer based at least in part on the predicted composition of CMAS. The CMAS-resistant barrier coating layer includes a base composition and at least one secondary oxide selected based on the predicted composition of CMAS. The at least one secondary oxide includes at least one of an oxide of a divalent element, an oxide of a trivalent element, or an oxide of a tetravalent element. The CMAS-resistant barrier coating layer comprises greater than 0 mol. % and less than about 7 mol. % of the at least one secondary oxide.

公开(公告)号：US11702728B2

公开(公告)日：2023-07-18

申请号：US16884841

申请日：2020-05-27

Applicant: Rolls-Royce Corporation

Inventor： Li Li ,  Gregory John Kenneth Harrington ,  Robert Alexander Sean Golden

IPC: C23C4/18 ,  C23C4/11 ,  C23C4/134 ,  C04B41/86 ,  C04B41/45 ,  C04B41/50 ,  C04B41/00

CPC classification number: C23C4/18 ,  C04B41/009 ,  C04B41/4539 ,  C04B41/4543 ,  C04B41/5024 ,  C04B41/86 ,  C23C4/11 ,  C23C4/134

Abstract: In one example, a method for forming an environmental barrier coating (EBC) and/or abradable coating on a substrate. The method may include depositing a coating on a ceramic or ceramic matrix composite (CMC) substrate to form an as-deposited coating, wherein the coating includes at least one of an environmental barrier coating (EBC) and an abradable coating. The method further comprises heat treating the as-deposited coating at or above a first temperature for a first period of time following the deposition of the as-deposited coating on the substrate, wherein heat treating the as-deposited coating includes heating the as-deposited coating to or above the first temperature at a controlled rate. The heat treatment may be configured to at least one of decrease the open pores and/or microcracks of the heat-treated coating compared to the as-deposited coating or control a grain size of the heat-treated coating.

公开(公告)号：US11655543B2

公开(公告)日：2023-05-23

申请号：US16057984

申请日：2018-08-08

Applicant: Rolls-Royce Corporation ,  Rolls-Royce North American Technologies, Inc. ,  Rolls-Royce PLC

Inventor： Ngunjoh Lawrence Ndamka ,  Li Li ,  Ann Bolcavage ,  Bruce Edward Varney ,  Sean E. Landwehr

IPC: C23C28/04 ,  F01D5/28 ,  C23C28/00

CPC classification number: C23C28/042 ,  C23C28/321 ,  C23C28/3215 ,  C23C28/345 ,  C23C28/347 ,  C23C28/3455 ,  F01D5/288 ,  F05D2220/323 ,  F05D2240/12 ,  F05D2240/30 ,  F05D2300/21 ,  F05D2300/611

Abstract: A method includes predicting a composition of calcium-magnesium-aluminum-silicate (CMAS) to be encountered by a high temperature mechanical system during use of the high temperature mechanical system. The method further includes selecting a composition of a CMAS-resistant barrier coating layer based at least in part on the predicted composition of CMAS. The CMAS-resistant barrier coating layer includes a base composition and at least one secondary oxide selected based on the predicted composition of CMAS. The at least one secondary oxide includes at least one of an oxide of a divalent element, an oxide of a trivalent element, or an oxide of a tetravalent element. The CMAS-resistant barrier coating layer comprises greater than 0 mol. % and less than about 7 mol. % of the at least one secondary oxide.

公开(公告)号：US11512379B2

公开(公告)日：2022-11-29

申请号：US17360375

申请日：2021-06-28

Applicant: Rolls-Royce Corporation

Inventor： Li Li ,  Taylor K. Blair ,  Stephanie Gong

IPC: C23C4/18 ,  C23C4/02

Abstract: In one example, a method for forming a coating system including a bond coat and an environmental barrier coating on a ceramic or CMC substrate, e.g., with an abradable coating on the environmental barrier coating. The method may include depositing a bond coat on a ceramic or ceramic matrix composite (CMC) substrate to form an as-deposited bond coat; heat treating the as-deposited bond coat following the deposition of the as-deposited bond coat on the substrate to form a heat treated bond coat; depositing an environment barrier coating (EBC) layer on the heat treated bond coat to form as deposited EBC layer; and heat treating the as-deposited EBC layer to form a heat treated EBC layer.

公开(公告)号：US20220371967A1

公开(公告)日：2022-11-24

申请号：US17302996

申请日：2021-05-18

Applicant: Rolls-Royce Corporation ,  Rolls-Royce North American Technologies, Inc.

Inventor： Li Li ,  Matthew T. Kush ,  Robert Alexander Sean Golden ,  Jun Shi

IPC: C04B41/52 ,  C04B35/80 ,  C04B41/00 ,  C04B41/50 ,  C04B41/89 ,  C04B41/87

Abstract: An article may include a substrate, such as a silicon-containing ceramic matrix composite, an environmental barrier coating (EBC) layer on the substrate, and a CMAS-resistant EBC layer on the EBC layer. The EBC layer may include at least one rare-earth disilicate (REDS). The CMAS-resistant EBC layer may include at least one rare-earth monosilicate (REMS) configured to react with CMAS to form crystalline reaction products. The CMAS-resistant EBC layer may include a plurality of vertical cracks extending from a surface of the CMAS-resistant EBC layer at least partially into the CMAS-resistant EBC layer. Additionally, or alternatively, the EBC layer may include a plurality of vertical cracks extending from a surface of the EBC layer into at least a portion of the EBC layer.