公开(公告)号：US20070036997A1

公开(公告)日：2007-02-15

申请号：US11170836

申请日：2005-06-30

申请人： Margaret Floyd ,  Thomas Strangman ,  Derek Raybould ,  Paul Mravcak

发明人： Margaret Floyd ,  Thomas Strangman ,  Derek Raybould ,  Paul Mravcak

IPC分类号： B32B15/04 ,  B32B9/00

CPC分类号： F01D5/288 ,  C04B35/486 ,  C04B2235/3251 ,  C04B2235/762 ,  C04B2235/765 ,  C23C28/321 ,  C23C28/3215 ,  C23C28/325 ,  C23C28/345 ,  C23C28/3455 ,  F05D2230/313 ,  F05D2230/90 ,  F05D2300/2285 ,  F05D2300/611 ,  Y02T50/67 ,  Y02T50/671 ,  Y02T50/673

摘要： A turbine engine component includes an electron beam-physical vapor deposition thermal barrier coating covering at least a portion of a substrate. The thermal barrier coating includes an inner layer having a columnar-grained microstructure with inter-columnar gap porosity. The inner layer includes a stabilized ceramic material. The thermal barrier coating also includes a substantially non-porous outer layer, covering the inner layer and including the stabilized ceramic material. The outer layer is deposited with continuous line-of-sight exposure to the vapor source under oxygen deficient conditions. The outer layer may further comprise a dopant oxide that is more readily reducible than the stabilized ceramic material. During deposition, the outer layer may also have an oxygen deficient stoichiometry with respect to the inner layer. Oxygen stoichiometry in the outer layer may be restored by exposure of the coated component to an oxidizing environment.

摘要翻译： 涡轮发动机部件包括覆盖基板的至少一部分的电子束物理气相沉积热障涂层。 隔热涂层包括具有柱状间隙孔隙的柱状微结构的内层。 内层包括稳定的陶瓷材料。 热障涂层还包括基本上无孔的外层，覆盖内层并且包括稳定的陶瓷材料。 在缺氧条件下，外层沉积有连续的视线暴露于蒸汽源。 外层还可以包含比稳定的陶瓷材料更容易还原的掺杂剂氧化物。 在沉积期间，外层也可能具有相对于内层的缺氧化学计量。 可以通过将涂覆的组分暴露于氧化环境来恢复外层中的氧化学计量。

公开(公告)号：US20060246319A1

公开(公告)日：2006-11-02

申请号：US11119657

申请日：2005-05-02

申请人： Richard Bye ,  Malak Malak ,  Thomas Strangman ,  Derek Raybould

发明人： Richard Bye ,  Malak Malak ,  Thomas Strangman ,  Derek Raybould

IPC分类号： B05D1/08

CPC分类号： C23C28/04 ,  C04B41/009 ,  C04B41/52 ,  C04B41/89 ,  F01D5/286 ,  F01D5/288 ,  F05D2260/95 ,  F05D2300/2118 ,  F05D2300/2283 ,  Y02T50/67 ,  Y02T50/6765 ,  C04B41/5027 ,  C04B41/4582 ,  C04B41/5042 ,  C04B35/584

摘要： A component for a turbine engine component includes a ceramic substrate having a surface, an environmental barrier layer bonded to the substrate surface, and an impact-resistance layer bonded to the environmental barrier layer, the impact-resistance layer having a melting point higher than about 2700° F., and further having a between about 10 and about 30% porosity. The impact-resistance layer, environmental barrier layer, and interfaces at which the environmental layer is bound to the substrate surface and the impact-resistance layer are more readily shearable than the substrate. A method for protecting a turbine engine component from environmental and particle impact-related damage includes the steps of coating a substrate surface with the environmental barrier layer, and coating the environmental barrier layer with the impact-resistance layer.

摘要翻译： 涡轮发动机部件的部件包括具有表面的陶瓷基板，与基板表面接合的环境阻挡层，以及结合到环境阻挡层的耐冲击层，耐冲击层的熔点高于约 2700°F，并且进一步具有约10至约30％的孔隙率。 耐冲击层，环境阻挡层和环境层与基材表面和耐冲击层结合的界面比基材更容易剪切。 一种用于保护涡轮发动机部件免受环境和颗粒撞击相关损伤的方法包括以下步骤：用环境阻挡层涂覆基底表面，并用耐冲击层涂覆环境阻挡层。

公开(公告)号：US20060099358A1

公开(公告)日：2006-05-11

申请号：US10982445

申请日：2004-11-05

申请人： Derek Raybould ,  Chien-Wei Li ,  Bjoern Schenk ,  Thomas Strangman

发明人： Derek Raybould ,  Chien-Wei Li ,  Bjoern Schenk ,  Thomas Strangman

IPC分类号： B31B45/00

CPC分类号： C23C30/00 ,  C04B41/009 ,  C04B41/5027 ,  C04B41/52 ,  C04B41/87 ,  C04B41/89 ,  C04B2111/00982 ,  C23C26/00 ,  C23C28/042 ,  Y02T50/67 ,  Y10T428/13 ,  Y10T428/131 ,  Y10T428/1317 ,  C04B41/4527 ,  C04B41/5059 ,  C04B41/5066 ,  C04B41/522 ,  C04B41/4539 ,  C04B41/5024 ,  C04B41/5042 ,  C04B35/565 ,  C04B35/584 ,  C04B35/806

摘要： A protective coating for a component comprising a ceramic based substrate, and methods for protecting the component, the protective coating adapted for withstanding repeated thermal cycling. The substrate may comprise silicon nitride or silicon carbide, and the protective coating may comprise at least one tantalate of scandium, yttrium, or a rare earth element. The protective coating may further comprise one or more metal oxides. The coating protects the substrate from combustion gases in the high temperature turbine engine environment. The coating may be multi-layered and exhibits strong bonding to Si-based substrate materials and composites.

公开(公告)号：US20050042461A1

公开(公告)日：2005-02-24

申请号：US10644523

申请日：2003-08-18

申请人： Chien-Wei Li ,  Derek Raybould ,  Thomas Strangman ,  Bjoern Schenk

发明人： Chien-Wei Li ,  Derek Raybould ,  Thomas Strangman ,  Bjoern Schenk

IPC分类号： C04B41/50 ,  C04B41/51 ,  C04B41/52 ,  C04B41/89 ,  C23C28/04 ,  B32B9/04

CPC分类号： C04B41/009 ,  C04B41/52 ,  C04B41/89 ,  Y10T428/265 ,  C04B41/4531 ,  C04B41/5066 ,  C04B41/4558 ,  C04B41/5027 ,  C04B41/5035 ,  C04B41/5022 ,  C04B41/522 ,  C04B41/5042 ,  C04B35/565 ,  C04B35/58 ,  C04B35/584

摘要： A component comprising a silicon-based substrate and a diffusion barrier coating disposed on the silicon-based substrate. The diffusion barrier coating comprises an isolation layer disposed directly on the silicon-based substrate and at least one oxygen barrier layer disposed on the isolation layer. The oxygen barrier layer prevents the diffusion of oxygen therethrough, and prevents excessive oxidation of the silicon-based substrate. The isolation layer(s) prevent contaminants and impurities from reacting with the oxygen barrier layer. An environmental barrier coating may be disposed on the diffusion barrier coating, and a thermal barrier coating may be disposed on the environmental barrier coating. Methods for making a component having a diffusion barrier coating are also disclosed.

摘要翻译： 一种组件，包括硅基衬底和设置在硅基衬底上的扩散阻挡涂层。 扩散阻挡涂层包括直接设置在硅基衬底上的隔离层和设置在隔离层上的至少一个氧阻挡层。 氧阻隔层防止氧气扩散通过其中，并防止硅基衬底的过度氧化。 隔离层防止污染物和杂质与氧阻隔层反应。 可以在扩散阻挡涂层上设置环境屏障涂层，并且可以在环境屏障涂层上设置热障涂层。 还公开了制备具有扩散阻挡涂层的组分的方法。

公开(公告)号：US20050013993A1

公开(公告)日：2005-01-20

申请号：US10621719

申请日：2003-07-16

申请人： Chien-Wei Li ,  Derek Raybould ,  Bjoern Schenk ,  Thomas Strangman

发明人： Chien-Wei Li ,  Derek Raybould ,  Bjoern Schenk ,  Thomas Strangman

IPC分类号： C04B41/50 ,  C04B41/87 ,  C23C4/10 ,  C23C24/08 ,  C23C26/00 ,  C23C28/00 ,  C23C30/00 ,  B32B9/04

CPC分类号： C04B41/009 ,  C04B41/5027 ,  C04B41/87 ,  C23C4/11 ,  C23C24/08 ,  C23C26/00 ,  C23C30/00 ,  F05B2230/90 ,  F05C2203/0843 ,  F05C2253/12 ,  Y10T428/265 ,  C04B41/4527 ,  C04B41/455 ,  C04B41/5031 ,  C04B41/5045 ,  C04B35/565 ,  C04B35/584 ,  C04B35/806

摘要： An environmentally and thermally protected component comprising a silicon-based ceramic or composite substrate and an environmental and thermal barrier coating disposed on the substrate. The environmental and thermal barrier coating comprises at least about 50 mole % AlTaO4. The composition of the environmental and thermal barrier coating may be adapted to provide excellent CTE (coefficient of thermal expansion) match with a substrate, such as a SiC-based ceramic or composite. Coating compositions of the invention have a stable crystalline structure at a temperature up to at least about 1550° C. Methods for preparing an environmentally and thermally protected component are also disclosed.

摘要翻译： 环境和热保护的组分，其包含硅基陶瓷或复合衬底以及设置在衬底上的环境和热障涂层。 环境和隔热涂层包含至少约50摩尔％的Al Ta O 4。 环境和隔热涂层的组成可以适于提供优异的CTE（热膨胀系数）与诸如SiC基陶瓷或复合材料的基底匹配。 本发明的涂料组合物在高达至少约1550℃的温度下具有稳定的晶体结构。还公开了制备环境和热保护组分的方法。

公开(公告)号：US20060115660A1

公开(公告)日：2006-06-01

申请号：US11000743

申请日：2004-12-01

申请人： Thomas Strangman ,  Derek Raybould

发明人： Thomas Strangman ,  Derek Raybould

IPC分类号： C23C16/00

CPC分类号： C23C26/00 ,  C23C28/321 ,  C23C28/345 ,  C23C28/3455 ,  Y02T50/67

摘要： A durable protective coating may be formed by applying a thin layer of metastable alumina to a bond coating on a substrate. A thermal barrier coating may then be applied to the metastable alumina and the resulting part may be heat treated to transform the metastable alumina to a mixed alpha alumina having particles of the thermal barrier coating, such as zirconia in the case of an yttria stabilized zirconia thermal barrier coating, dispersed therein. The resulting thermal barrier coating may inhibit microbuckling of the thermally grown oxide scale that grows over time at the thermal barrier coating-bond coating interface.

摘要翻译： 可以通过将薄的亚稳态氧化铝涂覆在基底上的粘结涂层上来形成持久的保护涂层。 然后可以将热障涂层施加到亚稳态氧化铝上，并且所得到的部分可以被热处理以将亚稳态氧化铝转变成具有热障涂层颗粒的混合α氧化铝，例如在氧化钇稳定的氧化锆热的情况下的氧化锆 阻隔涂层，分散在其中。 所得到的热障涂层可以抑制在热障涂层 - 结合涂层界面处随时间增长的热生长氧化皮的微珠。

公开(公告)号：US08257559B2

公开(公告)日：2012-09-04

申请号：US12102186

申请日：2008-04-14

申请人： Margaret M. Floyd ,  Thomas Strangman ,  Derek Raybould ,  Paul J. Mravcak

发明人： Margaret M. Floyd ,  Thomas Strangman ,  Derek Raybould ,  Paul J. Mravcak

IPC分类号： C23C14/06 ,  C23C14/34

CPC分类号： F01D5/288 ,  C04B35/486 ,  C04B2235/3251 ,  C04B2235/762 ,  C04B2235/765 ,  C23C28/321 ,  C23C28/3215 ,  C23C28/325 ,  C23C28/345 ,  C23C28/3455 ,  F05D2230/313 ,  F05D2230/90 ,  F05D2300/2285 ,  F05D2300/611 ,  Y02T50/67 ,  Y02T50/671 ,  Y02T50/673

摘要： A turbine engine component includes an electron beam-physical vapor deposition thermal barrier coating covering at least a portion of a substrate. The thermal barrier coating includes an inner layer having a columnar-grained microstructure with inter-columnar gap porosity. The inner layer includes a stabilized ceramic material. The thermal barrier coating also includes a substantially non-porous outer layer, covering the inner layer and including the stabilized ceramic material. The outer layer is deposited with continuous line-of-sight exposure to the vapor source under oxygen deficient conditions. The outer layer may further comprise a dopant oxide that is more readily reducible than the stabilized ceramic material. During deposition, the outer layer may also have an oxygen deficient stoichiometry with respect to the inner layer. Oxygen stoichiometry in the outer layer may be restored by exposure of the coated component to an oxidizing environment.

摘要翻译： 涡轮发动机部件包括覆盖基板的至少一部分的电子束物理气相沉积热障涂层。 隔热涂层包括具有柱状间隙孔隙的柱状微结构的内层。 内层包括稳定的陶瓷材料。 热障涂层还包括基本上无孔的外层，覆盖内层并且包括稳定的陶瓷材料。 在缺氧条件下，外层沉积有连续的视线暴露于蒸汽源。 外层还可以包含比稳定的陶瓷材料更容易还原的掺杂剂氧化物。 在沉积期间，外层也可能具有相对于内层的缺氧化学计量。 可以通过将涂覆的组分暴露于氧化环境来恢复外层中的氧化学计量。

公开(公告)号：US20060171813A1

公开(公告)日：2006-08-03

申请号：US11218074

申请日：2005-08-31

申请人： Malak Malak ,  Derek Raybould ,  Thomas Strangman

发明人： Malak Malak ,  Derek Raybould ,  Thomas Strangman

IPC分类号： F03B3/12

CPC分类号： F01D5/20 ,  C23C28/00 ,  C23C28/321 ,  C23C28/345 ,  C23C28/3455 ,  C23C28/347 ,  C23C28/42 ,  F01D11/125

摘要： A turbine blade tip and shroud clearance control coating system comprising a dense abrasive blade tip layer and an abradable shroud layer are provided. The dense abrasive coating may comprise cubic zirconia, hafnia or mixtures thereof and the abradable layer may be a nanolaminate thermal barrier coating that is softer than the dense abrasive layer.

公开(公告)号：US20060068189A1

公开(公告)日：2006-03-30

申请号：US10952110

申请日：2004-09-27

申请人： Derek Raybould ,  Thomas Strangman ,  Paul Chipko

发明人： Derek Raybould ,  Thomas Strangman ,  Paul Chipko

IPC分类号： B32B3/06 ,  B32B5/14 ,  B32B3/00 ,  B32B15/04

CPC分类号： F01D5/288 ,  C23C4/134 ,  C23C4/18 ,  F05D2230/312 ,  Y02T50/67 ,  Y02T50/671 ,  Y02T50/6765 ,  Y10T428/249956 ,  Y10T428/249957 ,  Y10T428/249967 ,  Y10T428/249969 ,  Y10T428/24997

摘要： A method for stabilizing a porous thermal barrier coating plasma sprayed on a substrate comprises the steps of immersing the porous thermal barrier coating in a sol gel comprising a metal oxide or precursor thereof, a solvent, and a surfactant, applying vacuum pressure to the sol gel to infiltrate the porous thermal barrier coating with the sol gel, and drying the sol gel to produce residual metal oxide particles in the porous thermal barrier coating.

摘要翻译： 用于稳定喷涂在基材上的多孔热障涂层等离子体的方法包括以下步骤：将多孔热障涂层浸入包含金属氧化物或其前体，溶剂和表面活性剂的溶胶凝胶中，向溶胶凝胶施加真空压力 用溶胶凝胶渗透多孔隔热涂层，并干燥溶胶凝胶以在多孔热障涂层中产生残留的金属氧化物颗粒。

公开(公告)号：US20050112381A1

公开(公告)日：2005-05-26

申请号：US10719629

申请日：2003-11-21

申请人： Derek Raybould ,  Chien-Wei Li ,  Bjoern Schenk ,  Thomas Strangman ,  Paul Chipko ,  Lee Poandl

发明人： Derek Raybould ,  Chien-Wei Li ,  Bjoern Schenk ,  Thomas Strangman ,  Paul Chipko ,  Lee Poandl

IPC分类号： C04B41/52 ,  C23C28/00 ,  C23C28/04 ,  F01D5/28 ,  F23R3/00 ,  B32B9/04 ,  B05D1/02 ,  B05D1/18 ,  B05D1/36

CPC分类号： F23R3/007 ,  C04B41/009 ,  C04B41/52 ,  C04B41/89 ,  C23C28/042 ,  C23C28/048 ,  F01D5/288 ,  F05D2230/312 ,  F05D2300/134 ,  F05D2300/21 ,  F23M2900/05004 ,  Y10T428/30 ,  C04B35/565 ,  C04B35/584 ,  C04B41/4531 ,  C04B41/5066 ,  C04B41/4529 ,  C04B41/5059 ,  C04B41/522 ,  C04B41/4556 ,  C04B41/5035 ,  C04B41/4535 ,  C04B41/5024 ,  C04B41/5027 ,  C04B41/5045 ,  C04B41/4527 ,  C04B41/5042

摘要： A protective barrier coating system including a diffusion barrier coating and an oxidation barrier coating and method for use in protecting silicon-based ceramic turbine engine components. A complete barrier coating system includes a thermal barrier coating of stabilized zirconia and an environmental barrier coating of an alloyed tantalum oxide. The oxidation barrier coating includes a layer of metallic silicates formed on a substrate of silicon nitride or silicon carbide to be protected. The oxidation barrier coating can include silicates of scandium, ytterbia or yttrium. The oxidation barrier coating may also include an inner layer of Si2ON2 between the diffusion barrier and the metallic silicate layer. The oxidation barrier coating can be applied to the substrate by spraying, slurry dipping and sintering, by a sol-gel process followed by sintering, by plasma spray, or by electron beam-physical vapor deposition. The diffusion layer of essentially pure Si3N4 can be applied to the substrate to prevent the migration of damaging cations from the protective layers to the substrate and is preferably formed by chemical vapor deposition. A method for protecting silicon based substrates can comprise a step of forming an oxidation barrier coating on a substrate, where a step of forming the oxidation barrier includes a step of sintering the oxidation barrier and substrate in a wet gas containing hydrogen.

摘要翻译： 一种包括扩散阻挡涂层和氧化屏障涂层的保护性屏障涂层系统以及用于保护硅基陶瓷涡轮发动机部件的方法。 完整的阻隔涂层系统包括稳定的氧化锆的隔热涂层和合金化氧化钽的环境屏障涂层。 氧化阻挡涂层包括在待保护的氮化硅或碳化硅的衬底上形成的金属硅酸盐层。 氧化屏障涂层可以包括钪，镱或钇的硅酸盐。 氧化阻隔涂层还可以包括扩散阻挡层和金属硅酸盐层之间的Si 2 2 2 N 2的内层。 通过喷雾，浆料浸渍和烧结，通过溶胶 - 凝胶法烧结，通过等离子体喷涂，或通过电子束 - 物理气相沉积，可将氧化阻隔涂层施加到基材上。 可以将基本上纯的Si 3 N 4 N 4的扩散层施加到基底上，以防止损伤的阳离子从保护层迁移到基底，并且优选地由化学 气相沉积。 用于保护硅基基板的方法可以包括在基板上形成氧化阻挡涂层的步骤，其中形成氧化屏障的步骤包括在含氢的湿气中烧结氧化阻挡层和基板的步骤。