公开(公告)号：US6054184A

公开(公告)日：2000-04-25

申请号：US902490

申请日：1997-07-29

申请人： Robert W. Bruce ,  Mark A. Rosenzweig ,  Jon C. Schaeffer ,  David J. Wortman ,  Norman R. Lindblad

发明人： Robert W. Bruce ,  Mark A. Rosenzweig ,  Jon C. Schaeffer ,  David J. Wortman ,  Norman R. Lindblad

IPC分类号： C23C14/08 ,  C23C14/30 ,  C23C14/50 ,  C23C14/56 ,  C23C16/00

CPC分类号： C23C14/083 ,  C23C14/081 ,  C23C14/30 ,  C23C14/505 ,  C23C14/568

摘要： A method and apparatus for forming a multilayer thermal barrier coating such that the coating is composed of substantially homogeneous layers of different ceramic materials. The method entails supporting an article within a coating apparatus and in proximity to ceramic ingots of the different ceramic materials, and then simultaneously directing electron beams at both ingots so as to maintain a portion of each ingot in a molten state. According to a particular aspect of this invention, vapors of both ceramic materials coexist within the coating apparatus, yet each ceramic material is sequentially deposited onto the article by sequentially interrupting exposure of surfaces of the article to the vapors, such that the vapors form homogeneous successive layers on the surface. Exposure of the article to one or more of the vapors can be interrupted with a baffle, such that the vapor of only one of the ceramic ingots is directly deposited on a given surface of the article at any instant. The baffle can be employed in conjunction with the article being rotated at a constant or variable speed, and/or being translated above the members within the vessel to alter the relative thicknesses of the ceramic and an intermediate layer that is formed between adjacent layers and is composed of a mixture of the ceramic materials.

摘要翻译： 一种用于形成多层热障涂层的方法和装置，使得涂层由不同陶瓷材料的基本均匀的层组成。 该方法需要在涂覆装置内并且靠近不同陶瓷材料的陶瓷锭支撑制品，然后同时引导两个锭子处的电子束，以便将每个锭的一部分保持在熔融状态。 根据本发明的特定方面，两种陶瓷材料的蒸汽在涂覆设备中共存，但是每个陶瓷材料通过依次地将制品的表面暴露于蒸气而顺序地沉积到制品上，使得蒸气形成均匀的连续 表面上的层。 物品暴露于一个或多个蒸气可能会被挡板中断，使得只有一个陶瓷锭的蒸汽在任何时刻直接沉积在物品的给定表面上。 挡板可以与制品以恒定或可变速度一起旋转和/或在容器内的构件上方平移以改变陶瓷和相邻层之间形成的中间层的相对厚度，并且是 由陶瓷材料的混合物组成。

公开(公告)号：US5683825A

公开(公告)日：1997-11-04

申请号：US581819

申请日：1996-01-02

申请人： Robert W. Bruce ,  Jon C. Schaeffer ,  Mark A. Rosenzweig ,  Rudolfo Viguie ,  David V. Rigney ,  Antonio F. Maricocchi ,  David J. Wortman ,  Bangalore A. Nagaraj

发明人： Robert W. Bruce ,  Jon C. Schaeffer ,  Mark A. Rosenzweig ,  Rudolfo Viguie ,  David V. Rigney ,  Antonio F. Maricocchi ,  David J. Wortman ,  Bangalore A. Nagaraj

IPC分类号： C23C14/06 ,  C23C14/08 ,  C23C28/00 ,  C23C28/04 ,  B32B15/04

CPC分类号： C23C28/00

摘要： 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.sub.2 O.sub.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.

摘要翻译： 一种隔热涂层，适于形成在经受恶劣热环境的制品上，同时受到颗粒和碎屑的侵蚀，如同燃气涡轮发动机的涡轮机，燃烧器和增压器部件的情况。 隔热涂层由沉积在物品表面上的金属粘合层，覆盖粘合层的陶瓷层和分散在陶瓷层内或覆盖陶瓷层的抗侵蚀组合物构成。 接合层用于将绝热陶瓷层牢固地粘附到制品上，而抗侵蚀组合物使得陶瓷层更耐侵蚀。 抗侵蚀组合物是氧化铝（Al 2 O 3）或碳化硅（SiC），而优选的陶瓷层是通过物理气相沉积技术沉积的具有柱状晶粒结构的氧化钇稳定的氧化锆（YSZ）。

公开(公告)号：US5683761A

公开(公告)日：1997-11-04

申请号：US450647

申请日：1995-05-25

申请人： Robert W. Bruce ,  Mark A. Rosenzweig ,  Bangalore A. Nagaraj ,  Jon C. Schaeffer ,  William B. Connor ,  David J. Wortman

发明人： Robert W. Bruce ,  Mark A. Rosenzweig ,  Bangalore A. Nagaraj ,  Jon C. Schaeffer ,  William B. Connor ,  David J. Wortman

IPC分类号： C23C4/02 ,  C23C14/02 ,  C23C14/08 ,  C23C28/00 ,  F01D5/28 ,  C23C16/40

CPC分类号： C23C28/345 ,  C23C14/025 ,  C23C14/081 ,  C23C28/321 ,  C23C28/3455 ,  C23C4/02 ,  F01D5/288 ,  Y02T50/67 ,  Y02T50/671

摘要： A bond-coated substrate is protected with an alpha alumina layer. The alpha alumina layer may be deposited as a relatively thick layer directly onto the bond-coated substrate. In this embodiment, no further ceramic layer overlies the alpha alumina layer. Other ceramics may be mixed into the alpha alumina layer, however. In another embodiment, a layer of a ceramic other than alpha alumina is deposited over the bond-coated substrate, and an alpha alumina layer is deposited over the ceramic layer.

摘要翻译： 用α氧化铝层保护键合的基底。 可以将α氧化铝层作为相对较厚的层直接沉积到粘结涂覆的基底上。 在该实施例中，没有另外的陶瓷层覆盖在α氧化铝层上。 然而，其他陶瓷可以混合到α氧化铝层中。 在另一个实施方案中，除了α氧化铝之外的陶瓷层沉积在粘合涂覆的基底上，并且在氧化铝层上沉积α氧化铝层。

公开(公告)号：US06391475B1

公开(公告)日：2002-05-21

申请号：US09522875

申请日：2000-03-10

申请人： Irene T. Spitsberg ,  David J. Wortman ,  Jon C. Schaeffer ,  Joseph D. Rigney

发明人： Irene T. Spitsberg ,  David J. Wortman ,  Jon C. Schaeffer ,  Joseph D. Rigney

IPC分类号： B32B1504

CPC分类号： F01D5/288 ,  C23C10/02 ,  C23C10/58 ,  C23C26/00 ,  C23C28/00 ,  Y02T50/67 ,  Y02T50/671 ,  Y10T428/12611 ,  Y10T428/1275 ,  Y10T428/12944

摘要： A nickel-base superalloy substrate has an overlying protective coating including a modified aluminum-containing protective layer. The modified aluminum-containing protective layer is formed of nickel, aluminum, calcium in an amount of from about 50 to about 300 parts per million by weight, and, optionally, elements interdiffused into the modified aluminum-containing protective layer from the substrate. Magnesium or barium may be used instead of or in addition to the calcium. A ceramic layer may overlie the modified aluminum-containing protective layer.

摘要翻译： 镍基超合金基板具有覆盖保护涂层，其包括改性的含铝保护层。 改性的含铝保护层由镍，铝，钙的重量百分比约为50〜300重量％，可选地，从基材相互扩散到改性含铝保护层中的元素形成。 可以使用镁或钡代替钙或除钙之外。 陶瓷层可以覆盖改性的含铝保护层。

公开(公告)号：US06458473B1

公开(公告)日：2002-10-01

申请号：US08786814

申请日：1997-01-21

申请人： Jeffrey A. Conner ,  Bangalore A. Nagaraj ,  Joseph A. Heaney, III ,  Nripendra N. Das ,  Patricia A. Zomcik ,  David J. Wortman ,  David V. Rigney ,  Jon C. Schaeffer

发明人： Jeffrey A. Conner ,  Bangalore A. Nagaraj ,  Joseph A. Heaney, III ,  Nripendra N. Das ,  Patricia A. Zomcik ,  David J. Wortman ,  David V. Rigney ,  Jon C. Schaeffer

IPC分类号： B21D3900

CPC分类号： C23C28/00 ,  C03C27/046 ,  C22C5/04 ,  C22C30/00 ,  C23C10/52 ,  F05B2230/90 ,  F05C2253/12 ,  Y10T428/12549 ,  Y10T428/12611 ,  Y10T428/12618 ,  Y10T428/12667

摘要： A thermal barrier coating system and a method for forming the coating system on a component designed for use in a hostile thermal environment, such as superalloy turbine, combustor and augmentor components of a gas turbine engine. The method is particularly directed to a thermal barrier coating system that includes a thermal insulating ceramic layer and a diffusion aluminide bond coat on which an aluminum oxide scale is grown to protect the underlying surface of the component and to chemically bond the ceramic layer. The bond coat is formed to contain an additive metal of platinum, palladium, rhodium, chromium and/or silicon, and an additive element of yttrium and/or zirconium, with possible additions of hafnium. The bond coat may be formed by codepositing aluminum with the active element, or by depositing the additive metal and active element on the surface of the component, and then aluminizing to form the diffusion aluminide bond coat.

摘要翻译： 一种热障涂层系统和一种在设计用于恶劣热环境的部件上形成涂层系统的方法，例如燃气涡轮发动机的超级合金涡轮机，燃烧器和增压器部件。 该方法特别涉及一种热障涂层系统，其包括绝热陶瓷层和扩散铝化物粘合涂层，其上生长氧化铝垢以保护部件的下表面并化学粘合陶瓷层。 形成粘合涂层以包含铂，钯，铑，铬和/或硅的添加金属和钇和/或锆的添加元素，可能添加铪。 粘结涂层可以通过将铝与活性元素共沉积，或者通过将添加剂金属和活性元素沉积在组分的表面上，然后镀铝以形成扩散铝化物粘合涂层而形成。

公开(公告)号：US5419971A

公开(公告)日：1995-05-30

申请号：US025455

申请日：1993-03-03

申请人： David W. Skelly ,  Bangalore A. Nagaraj ,  David J. Wortman ,  David V. Rigney ,  Seetha R. Mannava ,  Rudolfo Viguie ,  Robert W. Bruce ,  Warren A. Nelson ,  Curtis A. Johnson ,  Bhupendra K. Gupta

发明人： David W. Skelly ,  Bangalore A. Nagaraj ,  David J. Wortman ,  David V. Rigney ,  Seetha R. Mannava ,  Rudolfo Viguie ,  Robert W. Bruce ,  Warren A. Nelson ,  Curtis A. Johnson ,  Bhupendra K. Gupta

IPC分类号： C23C4/02 ,  F01D5/28 ,  B32B3/30

CPC分类号： F01D5/288 ,  C23C4/02 ,  Y02T50/67 ,  Y02T50/671 ,  Y10T428/12472 ,  Y10T428/12611 ,  Y10T428/12618 ,  Y10T428/12993 ,  Y10T428/24521 ,  Y10T428/24545 ,  Y10T428/24612

摘要： An article having a substrate is protected by a thermal barrier coating system. An interfacial layer contacts the upper surface of the substrate. The interfacial layer may comprise a bond coat only, or a bond coat and an overlay coat. The interfacial layer has on its upper surface a preselected, controllable pattern of three-dimensional features, such as grooves in a parallel array or in two angularly offset arrays. The features are formed by an ablation process using an ultraviolet laser such as an excimer laser. A ceramic thermal barrier coating is deposited over the pattern of features on the upper surface of the interfacial layer.

摘要翻译： 具有基底的制品由热障涂层系统保护。 界面层接触基板的上表面。 界面层可以仅包含粘结层，或者粘合涂层和覆盖层。 界面层在其上表面上具有三维特征的预选的可控模式，例如平行排列的凹槽或两个角度偏移的阵列。 特征通过使用诸如准分子激光器的紫外激光的消融处理形成。 陶瓷热障涂层沉积在界面层上表面上的特征图案上。

公开(公告)号：US06447854B1

公开(公告)日：2002-09-10

申请号：US09621422

申请日：2000-07-21

申请人： David V. Rigney ,  Antonio F. Maricocchi ,  David J. Wortman ,  Robert W. Bruce ,  Joseph D. Rigney

发明人： David V. Rigney ,  Antonio F. Maricocchi ,  David J. Wortman ,  Robert W. Bruce ,  Joseph D. Rigney

IPC分类号： C23C1430

CPC分类号： C23C14/083 ,  C23C14/566

摘要： A method for producing a thermal barrier coating system on an article that will be subjected to a hostile environment. The thermal barrier coating system is composed of a metallic bond coat and a ceramic thermal barrier coating having a columnar grain structure. The method generally entails forming the bond coat on the surface of a component, and then grit blasting the bond coat with an abrasive media having a particle size of greater than 80 mesh. The component is then supported within a coating chamber containing at least two ingots of the desired ceramic material. An absolute pressure of greater than 0.014 mbar is established within the chamber containing oxygen and an inert gas. Thereafter, the ceramic ingots are vaporized with an electron beam such that the vapor deposits on the surface of the component to form a layer of the ceramic material on the surface.

摘要翻译： 一种在受到恶劣环境的制品上制备热障涂层系统的方法。 热障涂层系统由金属粘合涂层和具有柱状晶粒结构的陶瓷热障涂层组成。 该方法通常需要在部件的表面上形成粘合涂层，然后用具有大于80目的粒度的研磨介质喷砂粘结涂层。 然后将该组分支撑在包含至少两个所需陶瓷材料锭的涂覆室内。 在含有氧气和惰性气体的室内建立大于0.014毫巴的绝对压力。 此后，陶瓷锭用电子束蒸发，使得蒸汽沉积在部件的表面上以在表面上形成陶瓷材料层。

公开(公告)号：US5981088A

公开(公告)日：1999-11-09

申请号：US912823

申请日：1997-08-18

申请人： Robert W. Bruce ,  David J. Wortman ,  Rudolfo Viguie ,  David W. Skelly

发明人： Robert W. Bruce ,  David J. Wortman ,  Rudolfo Viguie ,  David W. Skelly

IPC分类号： C23C14/08 ,  C23C28/00 ,  F01D5/28 ,  B32B15/04 ,  C23C14/02

CPC分类号： C23C28/3215 ,  C23C14/083 ,  C23C28/345 ,  C23C28/3455 ,  C23C28/36 ,  F01D5/288 ,  Y10T428/12618

摘要： A thermal insulating ceramic layer for use in a thermal barrier coating system on a component designed for use in a hostile thermal environment, such as turbine, combustor and augmentor components of a gas turbine engine. The ceramic layer is formed of zirconia stabilized by yttria and characterized by a columnar grain structure in which a monoclinic phase is present. To attain the monoclinic phase, the ceramic layer contains less than six weight percent yttria, with about two to five weight percent yttria being preferred. The ceramic layer is preferably part of a thermal barrier coating system that includes a substrate and a bond coat adhering the ceramic layer to the substrate. To obtain the desired columnar grain structure, the ceramic layer is deposited by a PVD technique, preferably EBPVD.

摘要翻译： 一种用于热障涂层系统的隔热陶瓷层，其设计用于恶劣热环境中的部件，例如燃气涡轮发动机的涡轮机，燃烧器和增压器部件。 陶瓷层由氧化钇稳定的氧化锆形成，其特征在于存在单斜晶相的柱状晶粒结构。 为了获得单斜相，陶瓷层含有少于6重量％的氧化钇，优选约2至5重量％的氧化钇。 陶瓷层优选为热障涂层系统的一部分，其包括将陶瓷层粘附到基底上的基底和粘合涂层。 为了获得所需的柱状晶粒结构，通过PVD技术，优选EBPVD沉积陶瓷层。

公开(公告)号：US5418003A

公开(公告)日：1995-05-23

申请号：US120009

申请日：1993-09-10

申请人： Robert W. Bruce ,  David W. Skelly ,  William P. Minnear ,  Richard A. Nardi, Jr. ,  David J. Wortman ,  Antonio F. Maricocchi ,  Rudolfo Viguie ,  David V. Rigney

发明人： Robert W. Bruce ,  David W. Skelly ,  William P. Minnear ,  Richard A. Nardi, Jr. ,  David J. Wortman ,  Antonio F. Maricocchi ,  Rudolfo Viguie ,  David V. Rigney

IPC分类号： C23C14/08 ,  C23C14/24 ,  B05D3/06

CPC分类号： C23C14/083 ,  C23C14/24 ,  Y02T50/67

摘要： Evaporated ceramic coatings are prepared by furnishing an ingot of a ceramic material, treating the ingot to reduce sources of gas within the ingot, and evaporating the ceramic material in the ingot by melting the surface of the ingot with an intense heat source. The evaporated ceramic is deposited upon a substrate as the ceramic coating. The reduced gas content of the ingot decreases the incidence of spitting and eruptions from the molten surface of the ingot, thereby improving the quality of the deposited coating, and facilitating increases in evaporation rates and coatings process production rates.

摘要翻译： 蒸发的陶瓷涂层通过提供陶瓷材料锭，处理锭以减少锭内的气体源，并通过用强热源熔化锭的表面来蒸发锭中的陶瓷材料来制备。 蒸发的陶瓷作为陶瓷涂层沉积在基底上。 锭的气体含量降低会降低铸锭熔融表面的喷溅和喷发的发生率，从而提高沉积涂层的质量，并有利于蒸发速率和涂层工艺生产率的提高。

公开(公告)号：US06620465B2

公开(公告)日：2003-09-16

申请号：US09296632

申请日：1999-04-23

申请人： Joseph D. Rigney ,  David J. Wortman

发明人： Joseph D. Rigney ,  David J. Wortman

IPC分类号： C23C1430

CPC分类号： C23C14/30 ,  C23C14/22 ,  Y10T428/12549 ,  Y10T428/1259 ,  Y10T428/12618

摘要： An improved method for applying a ceramic material, such as a thermal barrier coating to an article. A method for applying a ceramic material as a coating to a substrate article in which the thermal conductivity of the ceramic material is reduced or lowered is provided. The thermal conductivity of a coating applied by a physical vapor deposition (PVD) method is dependent upon its distance from the source(s) of material used for the coating. The thermal conductivity of the applied coating is altered by adjusting the position of the article undergoing the PVD process by increasing the distances of the article or workpiece from the ingot or source of ceramic material to provide a coating of lower thermal conductivity. In accordance with the present invention, the article to be coated is positioned at a distance required to achieve at least a 10% reduction in the thermal conductivity of the applied coating.

摘要翻译： 一种用于将陶瓷材料（例如热障涂层）施加到制品上的改进方法。 提供了一种将陶瓷材料作为涂层施加到其中陶瓷材料的导热性降低或降低的基底制品的方法。 通过物理气相沉积（PVD）方法施加的涂层的导热性取决于其与用于涂层的材料源的距离。 通过增加制品或工件与铸块或陶瓷材料源的距离，通过调节经历PVD工艺的制品的位置来改变所涂覆的涂层的热导率，以提供较低热导率的涂层。 根据本发明，待涂覆的制品定位在实现涂覆涂层的热导率降低至少10％所需的距离处。