U.S. patent application number 15/110819 was filed with the patent office on 2016-11-17 for silicon oxycarbide-based environmental barrier coating.
The applicant listed for this patent is UNITED TECHNOLOGIES CORPORATION. Invention is credited to Daniel G. Goberman, Tania Bhatia Kashyap, Wayde R. Schmidt, Paul Sheedy, Xia Tang.
Application Number | 20160333454 15/110819 |
Document ID | / |
Family ID | 53543337 |
Filed Date | 2016-11-17 |
United States Patent
Application |
20160333454 |
Kind Code |
A1 |
Tang; Xia ; et al. |
November 17, 2016 |
SILICON OXYCARBIDE-BASED ENVIRONMENTAL BARRIER COATING
Abstract
An article includes a silicon oxycarbide-based layer that has
Si, O, and C in a covalently bonded network. The silicon
oxycarbide-based layer has first and second opposed surfaces. A
calcium-magnesium alumino-silicate-based layer is interfaced with
the first surface of the silicon oxycarbide-based layer.
Inventors: |
Tang; Xia; (West Hartford,
CT) ; Sheedy; Paul; (Bolton, CT) ; Kashyap;
Tania Bhatia; (West Hartford, CT) ; Schmidt; Wayde
R.; (Pomfret Center, CT) ; Goberman; Daniel G.;
(East Granby, CT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
UNITED TECHNOLOGIES CORPORATION |
Hartford |
CT |
US |
|
|
Family ID: |
53543337 |
Appl. No.: |
15/110819 |
Filed: |
January 8, 2015 |
PCT Filed: |
January 8, 2015 |
PCT NO: |
PCT/US15/10554 |
371 Date: |
July 11, 2016 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
61927079 |
Jan 14, 2014 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C23C 28/044 20130101;
C23C 4/02 20130101; F05D 2300/611 20130101; F05D 2240/12 20130101;
F05D 2300/2261 20130101; F05D 2300/211 20130101; C23C 28/04
20130101; F05D 2240/35 20130101; C23C 4/12 20130101; F05D 2240/30
20130101; C23C 16/32 20130101; F05D 2240/11 20130101; F01D 5/288
20130101; F16J 15/453 20130101; C23C 4/04 20130101; F05D 2300/21
20130101; C23C 16/401 20130101 |
International
Class: |
C23C 4/12 20060101
C23C004/12; F01D 5/28 20060101 F01D005/28; C23C 4/04 20060101
C23C004/04 |
Goverment Interests
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] This invention was made with government support under
contract number N00014-09-C-0201 awarded by the United States Navy.
The government has certain rights in the invention.
Claims
1. An article comprising: a silicon oxycarbide-based layer having
Si, O, and C in a covalently bonded network, the silicon
oxycarbide-based layer having first and second opposed surfaces;
and a calcium-magnesium alumino-silicate-based layer interfaced
with the first surface of the silicon oxycarbide-based layer.
2. The article as recited in claim 1, wherein the silicon
oxycarbide-based layer further includes SiO.sub.2.
3. The article as recited in claim 2, wherein the silicon
oxycarbide-based layer includes, by volume, 5-65% of the SiO.sub.2
with a remainder of silicon oxycarbide.
4. The article as recited in claim 2, wherein the SiO.sub.2 is a
continuous matrix phase with regions of the silicon oxycarbide
dispersed there through.
5. The article as recited in claim 1, wherein the silicon
oxycarbide-based layer further includes a dispersed phase of
barium-magnesium alumino-silicate.
6. The article as recited in claim 5, wherein the silicon
oxycarbide-based layer includes, by volume, 1-30% of the dispersed
phase of barium-magnesium alumino-silicate.
7. The article as recited in claim 1, wherein the silicon
oxycarbide-based layer further includes a continuous matrix phase
of SiO.sub.2 and a dispersed phase of barium-magnesium
alumino-silicate.
8. The article as recited in claim 1, wherein the silicon
oxycarbide-based layer further includes a continuous matrix phase
of barium-magnesium alumino-silicate and a dispersed phase of
SiO.sub.2.
9. The article as recited in claim 1, wherein the silicon
oxycarbide-based layer further includes a continuous matrix phase
of SiO.sub.2 or barium-magnesium alumino-silicate, the silicon
oxycarbide-based layer including, by volume, 5-65% of the
continuous matrix phase, and 1-30% of a dispersed phase of the
other of the SiO.sub.2 or barium-magnesium alumino-silicate, with a
remainder of silicon oxycarbide.
10. The article as recited in claim 1, wherein the
calcium-magnesium alumino-silicate-based layer partially penetrates
into the silicon oxycarbide-based layer such that at least a
central core of the silicon oxycarbide-based layer is free of
calcium-magnesium alumino-silicate-based material.
11. The article as recited in claim 1, wherein the silicon
oxycarbide-based layer has a composition SiO.sub.xM.sub.zC.sub.y,
where M is at least one metal, x<2, y>0 and z<1 and x and
z are non-zero.
12. The article as recited in claim 1, wherein the silicon
oxycarbide-based layer is thicker than the calcium-magnesium
alumino-silicate-based layer.
13. The article as recited in claim 1, wherein the
calcium-magnesium alumino-silicate-based layer has an average
thickness of 1 micrometer to 3 millimeters.
14. The article as recited in claim 1, wherein the silicon
oxycarbide-based layer includes discrete regions of silicon
oxycarbide-based material, the discrete regions having an average
maximum dimension of 1-75 micrometers.
15. The article as recited in claim 1, the calcium-magnesium
alumino-silicate-based layer sealing the silicon oxycarbide-based
layer from oxygen diffusion and steam recession into the silicon
oxycarbide-based layer.
16. A composite comprising: a silicon oxycarbide-based material
having Si, O, and C in a covalently bonded network, the silicon
oxycarbide-based material having a surface; and a calcium-magnesium
alumino-silicate-based material interfaced with the surface of the
silicon oxycarbide-based material.
17. The composite as recited in claim 16, wherein the silicon
oxycarbide-based material further includes a dispersed phase of
barium-magnesium alumino-silicate.
18. The composite as recited in claim 17, wherein the silicon
oxycarbide-based material includes, by volume, 1-30% of the
dispersed phase of barium-magnesium alumino-silicate.
19. The composite as recited in claim 16, wherein the silicon
oxycarbide-based material further includes a continuous matrix
phase of SiO.sub.2 or barium-magnesium alumino-silicate, and a
dispersed phase of the other of barium-magnesium alumino-silicate
or SiO.sub.2.
20. The composite as recited in claim 16, wherein the silicon
oxycarbide-based material has a composition
SiO.sub.xM.sub.zC.sub.y, where M is at least one metal, x<2,
y>0 and z<1 and x and z are non-zero.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional
Application No. 61/927,079, filed Jan. 14, 2014.
BACKGROUND
[0003] This disclosure relates to composite articles, such as those
used in gas turbine engines.
[0004] Components, such as gas turbine engine components, may be
subjected to high temperatures, corrosive and oxidative conditions,
and elevated stress levels. In order to improve the thermal and/or
oxidative stability, the component may include a protective ceramic
barrier coating.
SUMMARY
[0005] An article according to an example of the present disclosure
includes a silicon oxycarbide-based layer having Si, O, and C in a
covalently bonded network, the silicon oxycarbide-based layer
having first and second opposed surfaces, and a calcium-magnesium
alumino-silicate-based layer interfaced with the first surface of
the silicon oxycarbide-based layer.
[0006] In a further embodiment of any of the foregoing embodiments,
the silicon oxycarbide-based layer further includes SiO.sub.2.
[0007] In a further embodiment of any of the foregoing embodiments,
the silicon oxycarbide-based layer includes, by volume, 5-65% of
the SiO.sub.2 with a remainder of silicon oxycarbide.
[0008] In a further embodiment of any of the foregoing embodiments,
the SiO.sub.2 is a continuous matrix phase with regions of the
silicon oxycarbide dispersed there through.
[0009] In a further embodiment of any of the foregoing embodiments,
the silicon oxycarbide-based layer further includes a dispersed
phase of barium-magnesium alumino-silicate.
[0010] In a further embodiment of any of the foregoing embodiments,
the silicon oxycarbide-based layer includes, by volume, 1-30% of
the dispersed phase of barium-magnesium alumino-silicate.
[0011] In a further embodiment of any of the foregoing embodiments,
the silicon oxycarbide-based layer further includes a continuous
matrix phase of SiO.sub.2 and a dispersed phase of barium-magnesium
alumino-silicate.
[0012] In a further embodiment of any of the foregoing embodiments,
the silicon oxycarbide-based layer further includes a continuous
matrix phase of barium-magnesium alumino-silicate and a dispersed
phase of SiO.sub.2.
[0013] In a further embodiment of any of the foregoing embodiments,
the silicon oxycarbide-based layer further includes a continuous
matrix phase of SiO.sub.2 or barium-magnesium alumino-silicate, the
silicon oxycarbide-based layer including, by volume, 5-65% of the
continuous matrix phase, and 1-30% of a dispersed phase of the
other of the SiO.sub.2 or barium-magnesium alumino-silicate, with a
remainder of silicon oxycarbide.
[0014] In a further embodiment of any of the foregoing embodiments,
the calcium-magnesium alumino-silicate-based layer partially
penetrates into the silicon oxycarbide-based layer such that at
least a central core of the silicon oxycarbide-based layer is free
of calcium-magnesium alumino-silicate-based material.
[0015] In a further embodiment of any of the foregoing embodiments,
the silicon oxycarbide-based layer has a composition
SiO.sub.xM.sub.zC.sub.y, where M is at least one metal, x<2,
y>0 and z<1 and x and z are non-zero.
[0016] In a further embodiment of any of the foregoing embodiments,
the silicon oxycarbide-based layer is thicker than the
calcium-magnesium alumino-silicate-based layer.
[0017] In a further embodiment of any of the foregoing embodiments,
the calcium-magnesium alumino-silicate-based layer has an average
thickness of 1 micrometer to 3 millimeters.
[0018] In a further embodiment of any of the foregoing embodiments,
the silicon oxycarbide-based layer includes discrete regions of
silicon oxycarbide-based material, the discrete regions having an
average maximum dimension of 1-75 micrometers.
[0019] In a further embodiment of any of the foregoing embodiments,
the calcium-magnesium alumino-silicate-based layer sealing the
silicon oxycarbide-based layer from oxygen diffusion and steam
recession into the silicon oxycarbide-based layer.
[0020] A composite according to an example of the present
disclosure includes a silicon oxycarbide-based material having Si,
O, and C in a covalently bonded network, the silicon
oxycarbide-based material having a surface, and a calcium-magnesium
alumino-silicate-based material interfaced with the surface of the
silicon oxycarbide-based material.
[0021] In a further embodiment of any of the foregoing embodiments,
the silicon oxycarbide-based material further includes a dispersed
phase of barium-magnesium alumino-silicate.
[0022] In a further embodiment of any of the foregoing embodiments,
the silicon oxycarbide-based material includes, by volume, 1-30% of
the dispersed phase of barium-magnesium alumino-silicate.
[0023] In a further embodiment of any of the foregoing embodiments,
the silicon oxycarbide-based material further includes a continuous
matrix phase of SiO.sub.2 or barium-magnesium alumino-silicate, and
a dispersed phase of the other of barium-magnesium alumino-silicate
or SiO.sub.2.
[0024] In a further embodiment of any of the foregoing embodiments,
the silicon oxycarbide-based material has a composition
SiO.sub.xM.sub.zC.sub.y, where M is at least one metal, x<2,
y>0 and z<1 and x and z are non-zero.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The various features and advantages of the present
disclosure will become apparent to those skilled in the art from
the following detailed description. The drawings that accompany the
detailed description can be briefly described as follows.
[0026] FIG. 1 illustrates a portion of an example article that
includes a silicon oxycarbide-based layer and a calcium-magnesium
alumino-silicate-based layer.
[0027] FIG. 2 illustrates a covalently bonded network of Si, O, and
C atoms.
[0028] FIG. 3 illustrates a portion of another example article that
includes a silicon oxycarbide-based layer and a calcium-magnesium
alumino-silicate-based layer.
[0029] FIG. 4 illustrates a portion of another example article that
includes a silicon oxycarbide-based layer and a calcium-magnesium
alumino-silicate-based layer.
[0030] FIG. 5 illustrates a portion of another example article that
includes a silicon oxycarbide-based layer and a calcium-magnesium
alumino-silicate-based layer.
[0031] FIG. 6 illustrates a micrograph of a silicon
oxycarbide-based layer and a calcium-magnesium
alumino-silicate-based layer.
DETAILED DESCRIPTION
[0032] FIG. 1 schematically illustrates a representative portion of
an example article 20 that includes a composite material 22. The
article 20 can be a gas turbine engine component, such as but not
limited to an airfoil, a combustor liner panel, a blade outer air
seal, or other component that would benefit therefrom. In this
example, the composite material 22 is used as an environmental
barrier coating system to protect an underlying substrate 24 from
environmental conditions, as well as thermal conditions. As will be
appreciated, the composite material 22 of the coating system can be
used as a stand-alone environmental barrier coating, as an
outermost/topcoat with additional underlying layers, or in
combination with other coatings, such as, but not limited to,
ceramic thermal barrier coatings.
[0033] In this example, the composite material 22 of the article 20
includes a silicon oxycarbide-based layer 26 that extends between
first and second opposed surfaces 26a/26b and a calcium-magnesium
alumino-silicate-based layer 28 interfaced with the first surface
26a of the silicon oxycarbide-based layer 26. The calcium-magnesium
alumino-silicate-based layer 28 can be deposited using known
coating deposition techniques, such as but not limited to thermal
spraying. In other examples, at least a portion of the
calcium-magnesium alumino-silicate-based layer 28 can be deposited
in-situ during use of the article 20, with purposeful exposure to
calcium-, magnesium-, aluminum-, and silicon-containing materials
at temperatures that can cause at least partial liquefaction and
wetting to a coating with at least partial adhesion to the
underlying layer.
[0034] As shown in the example in FIG. 2, the silicon
oxycarbide-based layer 26 has Si, O, and C atoms in a covalently
bonded network 30. The network 30 is amorphous and thus does not
have long range crystalline structure. The illustrated network 30
is merely one example in which at least a portion of the silicon
atoms are bonded to both O atoms and C atoms. As can be
appreciated, the bonding of the network 30 will vary depending upon
the atomic ratios of the Si, C, and O. In one example, the silicon
oxycarbide-based layer 26 has a composition
SiO.sub.xM.sub.zC.sub.y, where M is at least one metal, x is less
than two, y is greater than zero, z is less than one, and x and z
are non-zero. The metal can include aluminum, boron, transition
metals, refractory metals, rare earth metals, alkaline earth metals
or combinations thereof.
[0035] While calcium-magnesium alumino-silicate material is
normally expected to debit the durability of ceramic thermal
barrier coatings, the calcium-magnesium alumino-silicate based
layer 28 serves in the composite material 22 to seal the silicon
oxycarbide-based layer 26 with respect to the combustion
environment, including oxygen and steam, thus protecting the
chemical composition of the silicon oxycarbide-based layer 26 and
the underlying substrate 24 from oxidative attack and steam
recession. In this regard, the calcium-magnesium
alumino-silicate-based layer 28 in one example can have average
thickness of 1 micrometer to 3 millimeters, with a preferred range
of 1-254 micrometers, to provide a sealing functionality. In some
examples, the calcium-magnesium alumino-silicate-based layer 28 can
protect the silicon oxycarbide-based layer 26 and underlying
substrate 24 from oxidation and steam attack at temperatures of up
to about 2700.degree. F. (1482.degree. C.), and potentially greater
than 3000.degree. F. (1648.degree. C.). In this case, although
calcium-magnesium alumino-silicate material typically normally
serves to destroy thermal barrier coatings, the composition of the
silicon oxycarbide-based layer 26 is not readily infiltrated by the
calcium-magnesium alumino-silicate material and, at high
temperatures, the material does not substantially penetrate into
the silicon oxycarbide-based layer 26.
[0036] FIG. 3 illustrates another example article 120 that is
similar to the article 20 of FIG. 1 with the exception that a
calcium-magnesium alumino-silicate based layer 128 penetrates
partially, as represented at P, into the silicon oxycarbide-based
layer 26. At least a central core 26c of the silicon
oxycarbide-based layer 26 is free of calcium-magnesium
alumino-silicate-based material. In this example, the penetration
of the calcium-magnesium alumino-silicate material partially into
the silicon oxycarbide-based layer 26 can occur at elevated
temperatures at which the calcium-magnesium alumino-silicate
material may soften or liquefy and penetrate into macro- or
micro-pores of the silicon oxycarbide-based layer 26. However, due
to the similar chemistry between the calcium-magnesium
alumino-silicate based layer 128 and the silicon oxycarbide-based
layer 26, the driving force for diffusion is relatively low. The
thermomechanical behavior between the calcium-magnesium
alumino-silicate based layer 128 and the silicon oxycarbide-based
layer 26 is also similar because of the similar chemistry, thus
reducing thermal expansion mismatches that could otherwise serve to
initiate and propagate cracks.
[0037] FIG. 4 illustrates another example article 220 that includes
a silicon oxycarbide-based layer 226. In this example, the article
220 is somewhat similar to the article 20 of FIG. 1, with the
exception that the silicon oxycarbide-based layer 226 includes
discrete regions 232 of silicon oxycarbide-based material that is
dispersed within a continuous matrix phase 234. For example, the
continuous matrix phase 234 is silicon dioxide (SiO.sub.2) or
barium-magnesium alumino-silicate. In one example, the silicon
oxycarbide-based layer 226 includes, by volume, 40% of the silicon
dioxide or barium-magnesium alumino-silicate, with a remainder of
silicon oxycarbide, and the discrete regions 232 of silicon
oxycarbide-based material have an average maximum dimension,
represented at D, of 75 micrometers or less, which facilitates
blocking the diffusion of oxygen. In one further example, the
continuous matrix phase 234 is the barium-magnesium
alumino-silicate and there is also a dispersed phase of
SiO.sub.2.
[0038] FIG. 5 illustrates another example article 320 that is
somewhat similar to the article 220 of FIG. 4 with the exception
that a silicon oxycarbide-based layer 326 additionally includes a
dispersed phase of barium-magnesium alumino-silicate 336. In one
example, the silicon oxycarbide-based layer 326 includes, by
volume, 25% of the silicon dioxide, 4% of the dispersed phase of
barium-magnesium alumino-silicate 336 and a remainder of silicon
oxycarbide.
[0039] FIG. 6 shows an example micrograph of the composite
material. In this example, the composite material includes regions
of the silicon oxycarbide 232 dispersed through a continuous or
semi-continuous matrix phase of silicon dioxide 234, with the
calcium-magnesium alumino-silicate-based layer 28 interfaced with
the surface of the silicon oxycarbide-based material.
[0040] Although a combination of features is shown in the
illustrated examples, not all of them need to be combined to
realize the benefits of various embodiments of this disclosure. In
other words, a system designed according to an embodiment of this
disclosure will not necessarily include all of the features shown
in any one of the Figures or all of the portions schematically
shown in the Figures. Moreover, selected features of one example
embodiment may be combined with selected features of other example
embodiments.
[0041] The preceding description is exemplary rather than limiting
in nature. Variations and modifications to the disclosed examples
may become apparent to those skilled in the art that do not
necessarily depart from the essence of this disclosure. The scope
of legal protection given to this disclosure can only be determined
by studying the following claims.
* * * * *