公开(公告)号：US12071382B2

公开(公告)日：2024-08-27

申请号：US16726553

申请日：2019-12-24

Applicant: Rolls-Royce Corporation

Inventor： Jun Shi ,  Li Li ,  Gregory John Kenneth Harrington

IPC: C04B41/00 ,  C04B41/50 ,  C04B41/89 ,  C23C4/18 ,  F01D5/28

CPC classification number: C04B41/009 ,  C04B41/0072 ,  C04B41/5024 ,  C04B41/89 ,  C23C4/18 ,  F01D5/282 ,  F01D5/288 ,  F05D2230/31 ,  F05D2230/40 ,  F05D2230/90 ,  F05D2300/15 ,  F05D2300/6033 ,  F05D2300/611

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

公开(公告)号：US11851770B2

公开(公告)日：2023-12-26

申请号：US17002203

申请日：2020-08-25

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

Inventor： Matthew R. Gold ,  Michael Cybulsky ,  Stephanie Gong ,  Li Li

IPC: C23C28/04 ,  C23C4/11 ,  C23C4/134 ,  F01D5/28 ,  C23C28/00 ,  C04B41/87 ,  C04B41/50 ,  C04B41/00 ,  C23C4/073 ,  B32B18/00 ,  C23C24/08 ,  C04B111/00 ,  B32B15/16

CPC classification number: C23C28/042 ,  B32B18/00 ,  C04B41/009 ,  C04B41/5042 ,  C04B41/87 ,  C23C4/073 ,  C23C4/11 ,  C23C4/134 ,  C23C24/08 ,  C23C28/3215 ,  C23C28/345 ,  C23C28/3455 ,  F01D5/288 ,  B32B15/16 ,  C04B2111/0025 ,  C04B2111/00577 ,  C04B2235/3224 ,  C04B2235/5436 ,  C04B2235/5445 ,  C04B2235/76 ,  C04B2237/343 ,  C04B2237/348 ,  C04B2237/586 ,  C04B2237/588 ,  C04B2237/704 ,  F05D2230/312 ,  F05D2230/90 ,  F05D2300/15 ,  F05D2300/2112 ,  F05D2300/2118 ,  C04B41/5042 ,  C04B41/4527 ,  C04B41/5045 ,  C04B41/526

Abstract: An article that includes a substrate; a first layer including yttria and zirconia or hafnia, where the first layer has a columnar microstructure and includes predominately the zirconia or hafnia; a second layer on the first layer, the second layer including zirconia or hafnia, ytterbia, samaria, and at least one of lutetia, scandia, ceria, neodymia, europia, and gadolinia, where the second layer includes predominately zirconia or hafnia, and where the second layer has a columnar microstructure; and a third layer on the second layer, the third layer including zirconia or hafnia, ytterbia, samaria, and a rare earth oxide including at least one of lutetia, scandia, ceria, neodymia, europia, and gadolinia, where the third layer has a dense microstructure and has a lower porosity than the second layer.

公开(公告)号：US20220002857A1

公开(公告)日：2022-01-06

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：US20210372293A1

公开(公告)日：2021-12-02

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

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：US20210188723A1

公开(公告)日：2021-06-24

申请号：US17119345

申请日：2020-12-11

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

Inventor： Robert Alexander Sean Golden ,  Sungbo Shim ,  Li Li ,  Taylor K. Blair

IPC: C04B41/52 ,  C04B35/80 ,  C04B41/00 ,  C04B41/45 ,  C04B41/50 ,  C04B41/87 ,  C04B41/89

Abstract: The disclosure describes braze tape coatings and technique to form articles with differing physical properties in different layers or regions of the article. An example method includes forming a braze tape defining at least one layer that includes a first segment and a second segment. A portion of the second segment in the plane is adjacent to a portion of the first segment in a plane of the layer. The method also includes positioning the braze tape on a surface of a substrate, the plane of the layer of the braze tape being parallel to the surface of the substrate. The method also includes heating the braze tape to melt a constituent of at least one of the first coating material and the second coating material to form a densified coating on the surface of the substrate.

公开(公告)号：US20200377990A1

公开(公告)日：2020-12-03

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 ,  C04B41/00 ,  C04B41/45 ,  C04B41/50 ,  C04B41/86

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：US20200024977A1

公开(公告)日：2020-01-23

申请号：US16286047

申请日：2019-02-26

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

Inventor： Jun Shi ,  John Alan Weaver ,  Li Li ,  Ann Bolcavage ,  Matthew R. Gold

IPC: F01D5/28 ,  F01D5/14

Abstract: The disclosure describes articles and techniques that include an airfoil having a hybrid coating system to provide improved particle impact resistance and improve CMAS attack resistance on the pressure side of the airfoil and improved thermal load protection on the suction side of the airfoil. An example article for a gas turbine engine may include a substrate, and a hybrid environmental barrier coating (EBC) including a relatively dense EBC layer on a first portion of the substrate and a relatively porous EBC layer on a second portion of the substrate, where the first portion of the substrate is different from the second portion of the substrate, and wherein at least a portion of the relatively porous EBC layer overlaps at least a portion of the relatively dense EBC layer in an overlap region.

公开(公告)号：US20190323112A1

公开(公告)日：2019-10-24

申请号：US16388087

申请日：2019-04-18

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

Inventor： Sungbo Shim ,  Li Li

IPC: C23C4/10 ,  C23C4/134 ,  C04B35/622 ,  C04B35/565 ,  C04B35/587 ,  C04B41/50 ,  C04B41/87 ,  C04B41/00 ,  C04B41/45

Abstract: A composite bond coat may include a matrix and a reinforcing component. The matrix may be formed from silicon-based particles, and the reinforcing component includes silicon-based ceramic particles. The composite bond coat may be formed by introducing a precursor composition into a plume generated by a thermal spray gun to generate a thermal spray stream. The thermal spray stream may be directed at a major surface defined by a substrate of the component to form the composite bond coat. The precursor composition includes the matrix component and the reinforcing component.

公开(公告)号：US20190032503A1

公开(公告)日：2019-01-31

申请号：US16043708

申请日：2018-07-24

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

Inventor： Jun Shi ,  Li Li ,  Ted J. Freeman

IPC: F01D11/12 ,  F01D25/00 ,  F01D25/24

Abstract: An example high-performance system may include an example high-performance component. The high-performance component may include a substrate defining a channel. The channel defines a leading ramp and a trailing ramp. The example high-performance component includes an abradable track between the leading and the trailing ramps. The abradable track includes a porous abradable composition. The example high-performance system may include a rotating component configured to contact and abrade the abradable track. An example technique for forming the abradable track includes thermal spraying a precursor composition at the channel to form the abradable track.

公开(公告)号：US20180371600A1

公开(公告)日：2018-12-27

申请号：US16017448

申请日：2018-06-25

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

Inventor： Li Li ,  Stephanie Gong ,  Matthew R. Gold ,  Ann Bolcavage

IPC: C23C4/10 ,  F01D25/00 ,  C23C4/134

Abstract: A method that includes introducing a suspension comprising a coating material and a carrier into a heated plume of a thermal spray device. The coating material may include silicon or a silicon alloy. The method further includes directing the coating material using the heated plume toward a substrate that includes a ceramic or a ceramic matrix composite and depositing the coating material to form a bond coat directly on the substrate such that the bond coat defines a porosity of less than about 3 percent by volume.