U.S. patent application number 15/955161 was filed with the patent office on 2019-10-17 for reactive phase spray formulation coatings.
The applicant listed for this patent is General Electric Company. Invention is credited to Bernard Patrick Bewlay, Mehmet Dede, Hrishikesh Keshavan, Ambarish Kulkarni, Byron Pritchard, Margeaux Wallace.
Application Number | 20190316246 15/955161 |
Document ID | / |
Family ID | 66175321 |
Filed Date | 2019-10-17 |
United States Patent
Application |
20190316246 |
Kind Code |
A1 |
Keshavan; Hrishikesh ; et
al. |
October 17, 2019 |
REACTIVE PHASE SPRAY FORMULATION COATINGS
Abstract
A reactive phase spray formulation coating is configured to be
disposed on the thermal barrier coating of an article. The reactive
phase spray formulation coating comprises a base material and a
binder material. The base material has a compliance that is higher
than a compliance of the binder material, the binder material has a
cohesive strength that is greater than a cohesive strength of the
base material, the binder material has an adhesive strength that is
greater than an adhesive strength of the base material, and the
binder material has a surface area of at least ten square-meters
per gram that is greater than a surface area of the base material.
The binder material is configured to improve a cohesive strength
level, an adhesive strength level, and a compliance of the
formulation coating of the thermal barrier coating relative to the
formulation coating not including the binder material.
Inventors: |
Keshavan; Hrishikesh;
(Niskayuna, NY) ; Pritchard; Byron; (Cincinnati,
OH) ; Wallace; Margeaux; (Niskayuna, NY) ;
Kulkarni; Ambarish; (Niskayuna, NY) ; Dede;
Mehmet; (Cincinnati, OH) ; Bewlay; Bernard
Patrick; (Niskayuna, NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
General Electric Company |
Schenectady |
NY |
US |
|
|
Family ID: |
66175321 |
Appl. No.: |
15/955161 |
Filed: |
April 17, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C23C 4/10 20130101; C23C
4/11 20160101; C23C 14/06 20130101; C23C 4/134 20160101; C23C 14/28
20130101; C23C 28/042 20130101 |
International
Class: |
C23C 14/06 20060101
C23C014/06; C23C 14/28 20060101 C23C014/28; C23C 4/10 20060101
C23C004/10; C23C 4/134 20060101 C23C004/134 |
Claims
1. A reactive phase spray formulation coating configured to be
deposited on a thermal bather coating of an article, the reactive
phase spray formulation coating comprising: a base material having
a compliance that is higher than a compliance of a binder material;
and the binder material having a cohesive strength that is greater
than a cohesive strength of the base material, wherein the binder
material has an adhesive strength that is greater than an adhesive
strength of the base material, wherein the binder material has a
surface area of at least ten square meters per gram that is greater
than a surface area of the base material, and wherein the binder
material is configured to improve a cohesive strength level, an
adhesive strength level, and a compliance of the reactive phase
spray formulation coating of the thermal barrier coating relative
to the reactive phase spray formulation coating not including the
binder material.
2. The reactive phase spray formulation coating of claim 1, wherein
the reactive phase spray formulation coating is configured to react
with dust deposits on the thermal barrier coating.
3. The reactive phase spray formulation coating of claim 1, wherein
the reactive phase spray formulation coating is configured to
reduce an amount of spalling of the thermal barrier coating
relative to the reactive phase spray formulation coating not being
disposed on the thermal barrier coating.
4. The reactive phase spray formulation coating of claim 1, wherein
the reactive phase spray formulation coating is configured to be
deposited on the thermal barrier coating in a non-thermal
process.
5. The reactive phase spray formulation coating of claim 1, wherein
the binder material has a particle size that is less than one
micron, and wherein the base material has a particle size between
one micron and ten microns.
6. The reactive phase spray formulation coating of claim 1, wherein
the base material has a chemical configuration that is common to a
chemical configuration of the binder material.
7. The reactive phase spray formulation coating of claim 1, wherein
the article is a surface of a turbine assembly.
8. The reactive phase spray formulation coating of claim 1, wherein
the reactive phase spray formulation coating has a ratio comprising
of at least seven parts of the base material to at least three
parts of the binder material.
9. The reactive phase spray formulation coating of claim 1, wherein
the reactive phase spray formulation coating has a ratio comprising
of at least nineteen parts of the base material to at least one
part of the binder material.
10. The reactive phase spray formulation coating of claim 1,
wherein the base material includes one or more parts of zirconium,
oxygen, or yttrium.
11. The reactive phase spray formulation coating of claim 1,
wherein the binder material includes one or more parts of
zirconium, oxygen, or yttrium.
12. The reactive phase spray formulation coating of claim 1,
wherein the reactive phase spray formulation coating deposited on
the thermal barrier coating has a thickness of at least ten
microns.
13. A method comprising: combining a base material with a binder
material to create a reactive phase spray formulation coating, the
reactive phase spray formulation coating configured to be deposited
on a thermal barrier coating of an article, wherein the base
material has a compliance that is higher than a compliance of the
binder material, wherein the binder material has a cohesive
strength that is greater than a cohesive strength of the base
material, wherein the binder material has an adhesive strength that
is greater than an adhesive strength of the base material, wherein
the binder material has a surface area of at least ten square
meters per gram that is greater than a surface area of the base
material; and depositing the reactive phase spray formulation
coating on the thermal barrier coating of the article, wherein the
binder material is configured to improve a cohesive strength level,
an adhesive strength level, and a compliance of the reactive phase
spray formulation coating of the thermal barrier coating relative
to the reactive phase spray formulation coating not including the
binder material.
14. The method of claim 13, wherein the reactive phase spray
formulation coating is configured to react with dust deposits on
the thermal barrier coating.
15. The method of claim 13, wherein the reactive phase spray
formulation coating is configured to reduce an amount of spalling
of the thermal barrier coating relative to the reactive phase spray
formulation coating not being disposed on the thermal barrier
coating.
16. The method of claim 13, further comprising depositing the
reactive phase spray formulation coating on the thermal barrier
coating in a non-thermal process.
17. The method of claim 13, wherein the binder material has a
particle size that is less than one micron, and wherein the base
material has a particle size between one micron and ten
microns.
18. The method of claim 13, wherein the base material has a
chemical configuration that is common to a chemical configuration
of the binder material.
19. The method of claim 13, wherein the article is a surface of a
turbine assembly.
20. The method of claim 13, wherein the reactive phase spray
formulation coating has a ratio comprising of at least seven parts
of the base material to at least three parts of the binder
material.
21. The method of claim 13, wherein the reactive phase spray
formulation coating has a ratio comprising of at least nineteen
parts of the base material to at least one part of the binder
material.
22. The method of claim 13, wherein the base material includes one
or more parts of zirconium, oxygen, or yttrium.
23. The method of claim 13, wherein the binder material includes
one or more parts of zirconium, oxygen, or yttrium.
24. The method of claim 13, wherein the reactive phase spray
formulation coating deposited on the thermal barrier coating has a
thickness of at least ten microns.
25. A system comprising: a thermal barrier coating disposed on a
surface of an article, the thermal barrier coating configured to
reduce an amount of degradation of the article relative to the
article not having the thermal barrier coating disposed on the
surface; and a reactive phase spray formulation coating configured
to be deposited on the thermal barrier coating of the article, the
reactive phase spray formulation coating comprising a base material
and a binder material, wherein the base material has a compliance
that is higher than a compliance of the binder material, wherein
the binder material has a cohesive strength that is greater than a
cohesive strength of the base material, wherein the binder material
has an adhesive strength that is greater than an adhesive strength
of the base material, wherein the binder material has a surface
area of at least ten square-meters per gram that is greater than a
surface area of the base material, and wherein the binder material
is configured to improve a cohesive strength level, an adhesive
strength level, and a compliance of the reactive phase spray
formulation coating of the thermal barrier coating relative to the
reactive phase spray formulation coating not including the binder
material.
Description
FIELD
[0001] The subject matter described herein relates to reactive
coatings.
BACKGROUND
[0002] Coatings are extensively used in turbine engines, such as
aircraft engines and industrial gas turbines, in order to protect
various surfaces of the turbine engine when the turbine engine is
operating. One example of a coating is a thermal barrier coating.
Coatings may often degrade during service of the turbine engine by
spallation, damage, or the like. Spallation may also be caused by
the build up of dust and calcia-magnesium-silica (CMAS) deposits on
the thermal barrier coating that may infiltrate and compromise the
thermal barrier coating.
BRIEF DESCRIPTION
[0003] In one embodiment, a reactive phase spray formulation
coating is configured to be disposed on the thermal barrier coating
of an article. The reactive phase spray formulation coating
comprises a base material and a binder material. The base material
has a compliance that is higher than a compliance of the binder
material, the binder material has a cohesive strength that is
greater than a cohesive strength of the base material, the binder
material has an adhesive strength that is greater than an adhesive
strength of the base material, and the binder material has a
surface area of at least ten square-meters per gram that is greater
than a surface area of the base material. The binder material is
configured to improve a cohesive strength level, an adhesive
strength level, and a compliance of the reactive phase spray
formulation coating of the thermal barrier coating relative to the
reactive phase spray formulation coating not including the binder
material.
[0004] In one embodiment, a method comprises combining a base
material with a binder material to create a reactive phase spray
formulation coating. The reactive phase spray formulation coating
is configured to be disposed on a thermal barrier coating of an
article. The base material has a compliance that is higher than a
compliance of the binder material, the binder material has a
cohesive strength that is greater than a cohesive strength of the
base material, the binder material has an adhesive strength that is
greater than an adhesive strength of the base material, and the
binder material has a surface area of at least ten square-meters
per gram that is greater than a surface area of the base material.
The method also comprises depositing the reactive phase spray
formulation coating on the thermal barrier coating of the article.
The binder material is configured to improve a cohesive strength
level, an adhesive strength level, and a compliance of the reactive
phase spray formulation coating of the thermal barrier coating
relative to the reactive phase spray formulation coating not
including the binder material.
[0005] In one embodiment, a system comprises a thermal barrier
coating disposed on a surface of an article. The thermal barrier
coating is configured to reduce an amount of degradation of the
article relative to the article not having the thermal barrier
coating disposed on the surface. The system also comprises a
reactive phase spray formulation coating configured to be disposed
on the thermal barrier coating of the article. The reactive phase
spray formulation coating comprises a base material and a binder
material. The base material has a compliance that is higher than a
compliance of the binder material, the binder material has a
cohesive strength that is greater than a cohesive strength of the
base material, the binder material has an adhesive strength that is
greater than an adhesive strength of the base material, and the
binder material has a surface area of at least ten square-meters
per gram that is greater than a surface area of the base material.
The binder material is configured to improve a cohesive strength
level, an adhesive strength level, and a compliance of the reactive
phase spray formulation coating of the thermal barrier coating
relative to the reactive phase spray formulation coating not
including the binder material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The present inventive subject matter will be better
understood from reading the following description of non-limiting
embodiments, with reference to the attached drawings, wherein
below:
[0007] FIG. 1 illustrates a cross-sectional view of a reactive
phase spray formulation coating in accordance with one
embodiment;
[0008] FIG. 2 illustrates a magnified view of the reactive phase
spray formulation coating of FIG. 1 in accordance with one
embodiment;
[0009] FIG. 3 illustrates a known reaction of a thermal barrier
coating applied to an article;
[0010] FIG. 4 illustrates a reaction of a thermal barrier coating
and a reactive phase spray formulation coating applied to an
article in accordance with one embodiment;
[0011] FIG. 5 illustrates a cyclical process flow of applying a
reactive phase spray formulation coating to an article in
accordance with one embodiment;
[0012] FIG. 6 illustrates post thermal shock inspection images of a
thermal barrier coating and a base material applied to an article
in accordance with one embodiment;
[0013] FIG. 7A illustrates post thermal shock inspection images a
thermal barrier coating and a reactive phase spray formulation
coating applied to an article in accordance with one embodiment;
and
[0014] FIG. 7B illustrates post thermal shock inspection images of
a thermal barrier coating and a reactive phase spray formulation
coating applied to an article in accordance with one
embodiment.
DETAILED DESCRIPTION
[0015] One or more embodiments of the inventive subject matter
described herein teaches towards improvements to the life of
thermal barrier coatings. Specifically, the embodiments teach the
use of reactive phase formulation coatings on the thermal barrier
coatings. The reactive phase formulation coating consists of a
combination of large ceramic particles (e.g., particles that have a
size from 1-10 microns) together with very fine ceramic particles
(e.g., particles that have a size less than 1 micron). The very
fine ceramic particles function as a binder for the large ceramic
particles. The combination of the large and fine ceramic particles
can be adjusted to provide preferred combinations of the following
properties: adhesive strength, cohesive strength, and
compliance.
[0016] One or more embodiments of the inventive subject matter
described herein relate to reactive phase spray formulation
coatings that effectively improve the life of a thermal barrier
coating. Dust deposits and/or calcia-magnesium-silica (CMAS)
deposits form layers on the thermal barrier coatings during
operation of a system, such as a turbine engine. The dust deposits
infiltrate the thermal barrier coating and degrade and/or damage
the thermal barrier coating during service of the turbine engine.
To address one or more of these problems, one embodiment of the
subject matter described herein includes a reactive phase spray
formulation coating including a base material (e.g., the large
ceramic particles) and a binder material (e.g., the fine ceramic
particles). The base material has a base compliance that is higher
than a binder compliance of the binder material. The binder
material has a cohesive strength that is greater than a cohesive
strength of the base material. The binder material also has an
adhesive strength that is greater than an adhesive strength of the
base material. The particles of the binder material also have a
surface area of at least ten (10) square-meters per gram (m2/g)
that is greater than a surface area of the particles of the base
material. The formulation or combination of the base material and
the binder material is deposited or sprayed onto the thermal
barrier coating of an article (e.g., a surface of a turbine engine)
in order to form the reactive phase spray formulation coating on
the thermal barrier coating of the article.
[0017] The binder material improves a cohesive strength level of
the reactive phase spray formulation coating, improves an adhesive
strength level of the reactive phase spray formulation coating, and
improves a compliance of the reactive phase spray formulation
coating of the thermal barrier coating relative to the reactive
phase spray formulation coating not including the binder material.
At least one technical effect of the subject matter described
herein includes improving the life of the thermal barrier coating
without removal of the turbine engine from a wing of an aircraft,
or in a land-based gas turbine installation, relative to the
reactive phase spray formulation coating not including the binder
material. Another technical effect of the subject matter described
herein includes improving the reduction of component damage,
improving the reduction of repair and/or replacement costs, or
improving the time between outages of the turbine engine, relative
to the reactive phase spray formulation coating not including a
binder material. Another technical effect of the subject matter
described herein includes improving an adhesive strength level of
the reactive phase spray formulation coating to the thermal barrier
coating without any thermal treatment or thermal processes.
[0018] FIG. 1 illustrates a cross-sectional view of a reactive
phase spray formulation coating 100 in accordance with one
embodiment. FIG. 2 illustrates a magnified view of the reactive
phase spray formulation coating 100 of FIG. 1 in accordance with
one embodiment. The reactive phase spray formulation coating 100 is
applied to a thermal barrier coating 14 of an article (not shown).
In one embodiment, the article may be a surface of a turbine
engine, and the thermal barrier coating 14 may be a ceramic thermal
barrier coating, a ceramic coating, or the like, that is applied to
one or more surfaces of the turbine engine. The coating 100 may be
applied on the thermal barrier coating of a new part (e.g., a new
component of a turbine engine), the coating 100 may be applied on
the thermal barrier coating of a repaired part (e.g., an existing
and/or used component of the turbine engine), may be applied on the
repaired part in the field or at a maintenance location, or the
like. In one or more embodiments, the thermal barrier coating 14
may be applied by a physical vapor deposition (PVD) method, or the
like. Additionally or alternatively, the thermal barrier coating 14
may be deposited onto the article by one or more processes, such
as, but not limited to, air plasma sprays (APS), electron
beam-physical vapor deposition (EBPVD), directed vapor deposition
(DVD), suspension plasma spray (SPS), or the like.
[0019] In the illustrated embodiment of FIG. 1, a layer of dust
deposits 16 are disposed between the thermal barrier coating 14 and
the reactive phase spray formulation coating 100. For example,
responsive to the turbine engine operating during a test cycle,
operating cycle, service cycle, or the like, dust deposits may
collect, form, or the like, on one or more surfaces of the turbine
engine on the thermal barrier coating 14. Optionally, a layer of
dust deposits 16 may not collect or may not have formed on the
thermal barrier coating 14. Additionally or alternatively, a layer
of calcia-magnesia-alumina-silica (CMAS) deposits may also collect,
form, or the like, on the one or more surfaces of the turbine
engine on the thermal barrier coating 14.
[0020] The reactive phase spray formulation coating 100 includes a
base material 103 that is combined with a binder material 105. In
one embodiment, the reactive phase spray formulation coating 100
contains between 1% and 75% of the binder material 105, and the
balance is the base material 103. In a preferred embodiment, the
reactive phase spray formulation coating 100 contains between 3%
and 50% of the binder material 105, and the balance is the base
material 103. In an even more preferred embodiment, the reactive
phase spray formulation coating 100 contains between 5% and 45% of
the binder material 105, and the balance is the base material 103.
Optionally, the reactive phase spray formulation coating 100 may
contain the base material 103 and/or the binder material 105 with
any alternative weight percentage.
[0021] In one or more embodiments, the base material 103 may be
referred to herein as a base ceramic material. The base material
103 may be an earth oxide, such as, but not limited to, yttrium
(Y), gadolinium (Gd), zirconium (Zr), oxygen (O), or the like. The
base material 103 reacts with the CMAS in order to form or generate
a melting point phases that is greater than a melting point phase
of an alternative base material. For example, the reaction between
the base material 103 and the CMAS may change the chemistry or
chemical composition of the CMAS. In one embodiment, the base
material 103 has a particle size of between less than 1 micron and
25 microns. In a preferred embodiment, the base material 103 has a
particle size of between and including 1 micron and 10 microns.
Optionally, the base material 103 may have an alternative particle
size.
[0022] In one or more embodiments, the binder material 105 may also
be referred to herein as a ceramic binder material, a ceramic
powder binder, a ceramic binder, or the like. The binder material
105 has a chemical configuration that is similar to the chemical
configuration of the base material 103. For example, the binder
material 105 may be an earth oxide, such as, but not limited to,
yttrium (Y), gadolinium (Gd), zirconium (Zr), oxygen (O), or the
like. In one embodiment, the binder material 105 has a particle
size that is between a size greater than 5 nanometers and 1 micron.
In a preferred embodiment, the binder material 105 has a particle
size that is greater than 5 nanometers and less than 1 micron.
Optionally, the binder material 105 may have an alternative
particle size. In one or more embodiments, the binder material 105
may have a morphology that is non-spherical, spherical, angular, or
the like. In a preferred embodiment, the particles of the binder
material 105 are not spherical.
[0023] In one embodiment, the binder material 105 has a surface
area that is between 1 square-meters per gram (m2/g) and an
infinite size. In a more preferred embodiment, the binder material
105 has a surface area that is between 5 m2/g and 10 m2/g. In an
even more preferred embodiment, the binder material 105 has a
surface area that at least 10 m2/g or greater (e.g., larger).
Optionally, the binder material 105 may have an alternative surface
area.
[0024] The surface area of the binder material 105 is greater than
a surface area of the base material 103. Additionally, the binder
material 105 has a cohesive strength that is greater than a
cohesive strength of the base material 103. In one or more
embodiments, the cohesive strength of the base material 103 may
also be referred to herein as a base cohesive strength, and the
cohesive strength of the binder material 105 may also be referred
to herein as a binder cohesive strength. The larger surface area
particles of the binder material 105 bond to the other larger
diameter particles of the binder material 105. For example, the
larger surface area of the particles of the binder material 105
improves a cohesive strength level of the reactive phase spray
formulation coating 100 relative to the reactive phase spray
formulation coating 100 not including the binder material 105.
Additionally, the binder material 105 improves a cohesive strength
level of the reactive phase spray formulation coating 100 on the
thermal barrier coating 14 after thermal exposure of the reactive
phase spray formulation coating 100, relative to the reactive phase
spray formulation coating 100 that does not include the binder
material 105.
[0025] The particle size of the binder material 105 is less than
the particle size of the base material 103. Additionally, the
binder material 105 has an adhesive strength that the greater than
an adhesive strength of the base material 103. For example, the
smaller particle size of the binder material 105 improves an
adhesive strength level of the reactive phase spray formulation
coating 100 relative to the reactive phase spray formulation
coating 100 not including the binder material 105. In one or more
embodiments, the adhesive strength of the base material 103 may
also be referred to herein as a base adhesive strength, and the
adhesive strength of the binder material 105 may also be referred
to herein as a binder adhesive strength. The smaller particle size
and the larger surface area of the binder material 105, relative to
the base material 103, improves the adhesion of the reactive phase
spray formulation coating 100 to the thermal barrier coating 14
relative to the reactive phase spray formulation coating 100 not
including the binder material 105. Additionally, the binder
material 105 improves an adhesive strength level of the reactive
phase spray formulation coating 100 on the thermal barrier coating
14 after thermal exposure of the reactive phase spray formulation
coating 100, relative to the reactive phase spray formulation
coating 100 that does not include the binder material 105.
[0026] In one embodiment, the inventors found that the binder
material 105 unexpectedly improves the adhesive strength level of
the reactive phase spray formulation coating 100 to the thermal
barrier coating, and improves the cohesive strength level of the
reactive phase spray formulation coating 100 without a thermal
treatment, thermal process, or the like, relative to the
formulation coating 100 that does not include the binder material
105. For example, the large surface energy component of the large
surface area of the binder particles (e.g., relative to the small
surface area of the base particles) drives a low temperature
sintering and/or bonding of the binder particles to adjacent
surfaces. The low temperature sintering improves the cohesive
strength level of the reactive phase spray formulation coating 100
and improves the adhesive strength level of the reactive phase
spray formulation coating 100 to the thermal barrier coating 14
relative to the reactive phase spray formulation coating 100 that
does not include the binder material 105. In one or more
embodiments, the reactive phase spray formulation coating 100 may
be applied, deposited, or the like, onto the thermal barrier
coating 14 with a cold and/or non-thermal process such as, but not
limited to, a spray process, a slurry process, or the like.
[0027] The base material 103 has a chemical configuration that is
similar to the chemical configuration of the binder material 105.
For example, the base material 103 and the binder material 105 may
both have a chemical configuration that includes a Zirconia-yttria
formulation. In one embodiment, the base material 103 may have a
Zirconia--55% yttria formulation (55YSZ), and the binder material
105 may have a Zirconia--8% yttria formulation (8YSZ), a
Zirconia--20% yttria formulation (20YSZ), or any alternative
Zirconia-yttria formulation. Optionally, the base material 103 and
the binder material 105 may have an alternative chemical
formulation comprising one or more of an alpha aluminum oxide
formulation, silicone-dioxide, CMAS, strontium aluminum garnet
(SAG), gallium alumina perovskite (GAP), gadolinia zirconia (GdZr),
or the like.
[0028] In one embodiment, the reactive phase spray formulation
coating 100 may include the base material 103 that has a chemical
configuration of about 70 grams of 55YSZ with a median particle
size less that is than 10 microns and a surface area between 1 m2/g
and 2 m2/g. The base material 103 may be combined with the binder
material 105 having a chemical configuration of about 30 grams of
8YSZ with a median particle size that is less than 1 micron and a
surface area that is greater than 15 m2/g. The reactive phase spray
formulation coating 100 has a ratio having at least seven parts of
the base material 103 to at least three parts of the binder
material 105. For example, the reactive phase spray formulation
coating 100 may contain about 45% of the binder material 105, with
the balance being the base material 103. The reactive phase spray
formulation coating 100 that is deposited onto the thermal barrier
coating 14 may have a thickness of about 5 microns, about 10
microns, about 12 microns, about 15 microns, or the like.
Optionally, the reactive phase spray formulation coating 100 may
include a different amount of the base material 103 and/or the
binder material 105, the base material 103 and/or the binder
material 105 may have an alternative particle size, surface area,
chemical configuration, or any alternative combination therein.
[0029] In one embodiment, the reactive phase spray formulation
coating 100 may include the base material 103 that has a chemical
configuration of about 95 grams of 55YSZ with a median particle
size less that is than 10 microns and a surface area between 1 m2/g
and 2 m2/g. The base material 103 may be combined with the binder
material 105 having a chemical configuration of about 5 grams of
8YSZ with a median particle size that is less than 1 micron and a
surface area that is greater than 15 m2/g. The reactive phase spray
formulation coating 100 has a ratio having at least nineteen parts
of the base material 103 to at least one part of the binder
material 105. For example, the reactive phase spray formulation
coating 100 may contain about 5% of the binder material 105, with
the balance being the base material 103. The reactive phase spray
formulation coating 100 that is deposited onto the thermal barrier
coating 14 may have a thickness of about 5 microns, about 10
microns, about 12 microns, about 15 microns, or the like.
Optionally, the reactive phase spray formulation coating 100 may
include a different amount of the base material 103 and/or the
binder material 105, the base material 103 and/or the binder
material 105 may have an alternative particle size, surface area,
chemical configuration, or any alternative combination therein.
[0030] In one embodiment, the reactive phase spray formulation
coating 100 may include the base material 103 that has a chemical
configuration of 100 grams of pseudo-boehmite that is calcined in
air to form aluminum oxide (Al.sub.2O.sub.3) with a surface area
that is about 50 m2/g. The base material 103 may be combined with
the binder material 105 that has a chemical configuration of about
100 grams of Al.sub.2O.sub.3 with a median particle size that is
less than 1 micron. The reactive phase spray formulation coating
100 that is deposited onto the thermal barrier coating 14 may have
a thickness of about 5 microns, about 10 microns, about 12 microns,
about 15 microns, or the like.
[0031] The base material 103 has a compliance that is higher than a
compliance of the binder material 105. For example, the base
material 103 has a modulus of elasticity and a stiffness that is
less than a modulus of elasticity and a stiffness of the binder
material 105. In one or more embodiments, the compliance of the
base material 103 may also be referred to herein as a base
compliance, and the compliance of the binder material 105 may also
be referred to herein as a binder compliance. The reactive phase
spray formulation coating 100 remains substantially compliant
responsive to deposition of the formulation coating 100 onto the
thermal barrier coating 14, thermal exposure responsive to
operation of the turbine engine, and a reaction with the dust
deposits 16 deposited on the thermal barrier coating 14. In one or
more embodiments, the reactive phase spray formulation coating 100
has an in-plane modulus of elasticity less than 100 gigapascal
(GPa). In a preferred embodiment, the reactive phase spray
formulation coating 100 has an in-plane modulus of elasticity less
than 80 GPa. In an even more preferred embodiment, the reactive
phase spray formulation coating 100 has an in-plane modulus of
elasticity less than 60 GPa. For example, a reactive phase spray
formulation coating 100 with an in-plane modulus of elasticity that
is greater than 60 GPa may cause spallation of the reactive phase
spray formulation coating 100 responsive to a reaction with the
dust deposits 16 during thermal cycling of the turbine engine.
[0032] The reactive phase spray formulation coating 100, that is
created or formed by the reaction of the larger particle size of
the base material (e.g., greater than 1 micron) with the binder
material 105 in the formulation coating 100, and the dust deposits
16 that are incident on the thermal barrier coating 14, need to be
compliant such that upon thermal cycling of the turbine engine, the
cyclic strains do not generate spallation of the formulation
coating 100. Responsive to thermal exposure of the spray
formulation coating 100 by operation of the turbine engine, the
larger base material 103 particles are affected less than the
smaller binder material 105 particles that experience morphological
changes, coarsening, or the like, during the thermal cycling. The
compliance of the base material 103 substantially maintains the
in-plane modulus of elasticity of the reactive phase spray
formulation coating 100 at less than 60 GPa.
[0033] FIG. 3 illustrates a known reaction of the thermal barrier
coating 14 applied to an article 12. In one or more embodiments,
the article 12 may be a surface of a turbine engine, a surface of
one or more components of the turbine engine such as a turbine
blade or airfoil, or the like. The thermal barrier coating 14 has a
coating thickness 104 that is deposited onto the article 12 and
extends a distance away from the article 12. At 310, a layer of the
dust deposits 16 is disposed on the thermal barrier coating 14. For
example, responsive to the turbine engine operating during a test
cycle, operating cycle, or the like, dust deposits may collect,
form, or the like, on one or more surfaces of the turbine engine on
the barrier coating 14.
[0034] At 320, the dust deposits 16 and/or CMAS deposits infiltrate
the thermal barrier coating 14 during service or operation of the
turbine engine. For example, the thermal barrier coating 14 begins
to degrade and the dust deposits 16 begin to move into and/or
through thermal barrier coating 14. The dust deposits 16 that
infiltrate the thermal barrier coating 14 compromise the stability
of the thermal barrier coating 14. At 314, the thermal barrier
coating 14 begins to spall responsive to the dust deposits 16
and/or CMAS build up and infiltration. The spallation of the
thermal barrier coating 14 exposes the article 12 at the location
of the spallation such that the article 12 may be damaged at the
location of the spallation.
[0035] Alternatively, FIG. 4 illustrates a reaction of the thermal
barrier coating 14 and the reactive phase spray formulation coating
100 applied to the article 12 in accordance with one embodiment. In
the illustrated embodiment at 410, the reactive phase spray
formulation coating 100 is applied to, deposited onto, sprayed
onto, or the like, the layer of the dust deposits 16 that have
formed on the thermal barrier coating 14. Optionally, the reactive
phase spray formulation coating 100 may be applied directly onto
the thermal barrier coating 14. At 412, during or responsive to the
turbine engine operating during a test cycle, operating cycle, or
the like, the reactive phase spray formulation coating 100 reacts
with the dust deposits 16 and/or CMAS deposits. The reaction
between the formulation coating 100 and the CMAS deposits raises
the fusion temperature of the CMAS deposits. As a result of the
reaction between the formulation coating 100 and the dust deposits
16, the formulation coating 100 and the dust deposits 16 flake off
or fall off of the thermal barrier coating 14 and does not
infiltrate the thermal barrier coating 14. The reactive phase spray
formulation coating 100 reacting with the dust deposits 16 reduces
an amount of spalling of the thermal barrier coating 14 relative to
the reactive phase spray formulation coating 100 not being disposed
on the thermal barrier coating 14.
[0036] FIG. 5 illustrates a cyclical process flow of applying the
reactive phase spray formulation coating 100 to the article 12 in
accordance with one embodiment. At 502, the article 12 includes a
layer of the thermal barrier coating 14 applied to the article 12.
A layer of the dust deposits 16 forms on the thermal barrier
coating 14 as the turbine engine operates. At 504, the reactive
phase spray formulation coating 100 is applied, deposited, or the
like, to the thermal barrier coating 14 and the dust deposits 16.
At 506, responsive to operation of the turbine engine, the reactive
phase spray formulation coating 100 reacts with the dust deposits
16. For example, the reactive phase spray formulation coating 100
consumes, infiltrates, or the like, the dust deposits 16. As the
temperature increases due to the operation of the turbine engine,
the reaction between the formulation coating 100 and the dust
deposits 16 forms or creates a layer of reacted dust 503 that flake
off or fall off of the thermal barrier coating 14. The reacted dust
503 that flakes off or falls off of the thermal barrier coating 14
exposes the thermal barrier coating 14. For example, as the turbine
engine continues to operate, a second, different layer of dust
deposits 16 or CMAS deposits may form on the thermal barrier
coating 14.
[0037] At 508, a second, different layer of the reactive phase
spray formulation coating 100 may be applied to the layer of the
dust deposits 16 that have formed on the thermal barrier coating
14. The second layer of the reactive phase spray formulation
coating 100 may be applied to and adhere to the thermal barrier
coating 14 without dissembling the turbine engine, without a
thermal treatment or process, may be spot-sprayed to a specific
location of the thermal barrier coating 14, or the like. For
example, the small surface area of the binder material 105 relative
to the surface area of the base material 103 improves the adhesive
strength level of the reactive phase spray formulation coating 100
to the thermal barrier coating 14 without any thermal treatment or
thermal process. After exposure to plural cyclical process flows
(as illustrated in FIG. 5), the inventors unexpectedly found that
the thermal barrier coating 14, with the reactive phase spray
formulation coating 100 deposited onto the thermal barrier coating
14, had an improved life benefit of at least 50% relative to the
thermal barrier coating 14 without the reactive phase spray
formulation coating 100.
[0038] FIG. 6 illustrates post thermal shock inspection images of
the thermal barrier coating 14 and the base material 103 applied to
the article 12 in accordance with one embodiment. The base material
103 is deposited on to or applied to the thermal barrier coating 14
disposed on the article 12. For example, a substantially 12-micron
thick layer of the base material 103 having a chemical
configuration of 55SYZ is applied to the thermal barrier coating 14
at an ambient temperature. The article 12, thermal barrier coating
14, and base material 103 are subjected to plural thermal shocks
that may be substantially similar to ten take-off thermal shock
cycles of the turbine engine. The images 602 illustrate the post
thermal shock inspection images. As illustrated at 604, thermal
shock driven spallation of the thermal barrier coating 14 has
occurred during the thermal shock heat treatment. For example, the
base material 103 (e.g., that is not combined with the binder
material 105) that is applied to the thermal barrier coating 14
fails to protect the thermal barrier coating 14 from
spallation.
[0039] Alternatively, FIG. 7A illustrates post thermal shock
inspection images of the thermal barrier coating 14 and the
reactive phase spray formulation coating 100 applied to the article
12 in accordance with one embodiment. The base material 103 having
a chemical configuration of 55SYZ is combined with the binder
material 105 having a chemical configuration of 10SYZ to form the
reactive phase spray formulation coating 100. A substantially
12-micron thick layer of the formulation coating 100 is applied to
the thermal barrier coating 14 at an ambient temperature. The
article 12, thermal barrier coating 14, and reactive phase spray
formulation coating 100 are subjected to plural thermal shocks that
may be substantially similar to ten take-off thermal shock cycles
of the turbine engine. The images 702 illustrate the post thermal
shock inspection images. As illustrated in the images 702,
substantially no thermal shock driven spallation of the thermal
barrier coating 14 has occurred during the thermal shock heat
treatment. For example, the reactive phase spray formulation
coating 100 including the binder material 105 combined with the
base material 103 reduces an amount of spalling of the thermal
barrier coating 14 relative to the reactive phase spray formulation
coating 100 that does not include the binder material 105, as
illustrated in FIG. 6. The inventors found that an embodiment of
the reactive phase spray formulation coating having the base
material and the binder material with one or more qualities and
characteristics described herein, increased or improved a cohesive
strength level, an adhesive strength level, and a compliance of the
reactive phase spray formulation coating that was unexpected.
[0040] FIG. 7B illustrates post thermal shock inspection images of
the thermal barrier coating 14 and the reactive phase spray
formulation coating 100 applied to the article 12 in accordance
with one embodiment. The base material 103 having a chemical
configuration of 55SYZ is combined with the binder material 105
having a chemical configuration of 10SYZ to form the reactive phase
spray formulation coating 100. A substantially 12-micron thick
layer of the formulation coating 100 is applied to the thermal
barrier coating 14 at a temperature of about 1600.degree. F. The
article 12, thermal barrier coating 14, and reactive phase spray
formulation coating 100 are subjected to plural thermal shocks that
may be substantially similar to ten take-off thermal shock cycles
of the turbine engine. The images 702 illustrate the post thermal
shock inspection images. As illustrated in the images 702, a
minimal amount of spalling of the thermal barrier coating 14 has
occurred during the thermal shock heat treatment relative to the
spalling of the thermal barrier coating 14 of the images 602. For
example, the reactive phase spray formulation coating 100,
including the binder material 105 combined with the base material
103, reduces an amount of spalling of the thermal barrier coating
14 relative to the reactive phase spray formulation coating 100
that does not include the binder material 105. The inventors found
that an embodiment of the reactive phase spray formulation coating
having the base material and the binder material with one or more
qualities and characteristics described herein improves on-wing
life and overall performance of the components or surfaces with
thermal barrier coatings 14 that was unexpected.
[0041] In one or more embodiments, the coating 100 may be applied
on the thermal barrier coating of a new part (e.g., a new component
of a turbine engine), the coating 100 may be applied on the thermal
barrier coating of a repaired part (e.g., an existing and/or used
component of the turbine engine), may be applied on the new and/or
repaired part in the field or at a maintenance location, or the
like. For example, the coating 100 having a first formulation may
be applied to a new part, and the coating 100 having a different,
second formulation may be applied to an existing part in order to
repair or restore the thermal barrier coating of the existing part.
The first formulation may have a chemical composition that is
different than a chemical composition of the second formulation
such that the second formulation is tailored or specifically
configured to restore the thermal barrier coating of the existing
part.
[0042] In one embodiment of the subject matter described herein, a
reactive phase spray formulation coating is configured to be
disposed on the thermal barrier coating of an article. The reactive
phase spray formulation coating comprises a base material and a
binder material. The base material has a compliance that is higher
than a compliance of the binder material, the binder material has a
cohesive strength that is greater than a cohesive strength of the
base material, the binder material has an adhesive strength that is
greater than an adhesive strength of the base material, and the
binder material has a surface area of at least ten square-meters
per gram that is greater than a surface area of the base material.
The binder material is configured to improve a cohesive strength
level, an adhesive strength level, and a compliance of the reactive
phase spray formulation coating of the thermal barrier coating
relative to the reactive phase spray formulation coating not
including the binder material.
[0043] Optionally, the reactive phase spray formulation coating is
configured to react with dust deposits on the thermal bather
coating.
[0044] Optionally, the reactive phase spray formulation coating is
configured to reduce an amount of spalling of the thermal barrier
coating relative to the reactive phase spray formulation coating
not being disposed on the thermal barrier coating.
[0045] Optionally, the reactive phase spray formulation coating is
configured to be deposited on the thermal barrier coating in a
non-thermal process.
[0046] Optionally, the binder material has a particle size that is
less than one micron, and the base material has a particle size
between one micron and ten microns.
[0047] Optionally, the base material has a chemical configuration
that is common to a chemical configuration of the binder
material.
[0048] Optionally, the article is a surface of a turbine
assembly.
[0049] Optionally, reactive phase spray formulation coating has a
ratio comprising of at least seven parts of the base material to at
least three parts of the binder material.
[0050] Optionally, the reactive phase spray formulation coating has
a ratio comprising of at least nineteen parts of the base material
to at least one part of the binder material.
[0051] Optionally, the base material includes one or more parts of
zirconium, oxygen, or yttrium.
[0052] Optionally, the binder material includes one or more parts
of zirconium, oxygen, or yttrium.
[0053] Optionally, the reactive phase spray formulation coating
deposited on the thermal barrier coating has a thickness of at
least ten microns.
[0054] In one embodiment of the subject matter described herein, a
method comprises combining a base material with a binder material
to create a reactive phase spray formulation coating. The reactive
phase spray formulation coating is configured to be disposed on a
thermal barrier coating of an article. The base material has a
compliance that is higher than a compliance of the binder material,
the binder material has a cohesive strength that is greater than a
cohesive strength of the base material, the binder material has an
adhesive strength that is greater than an adhesive strength of the
base material, and the binder material has a surface area of at
least ten square-meters per gram that is greater than a surface
area of the base material. The method also comprises depositing the
reactive phase spray formulation coating on the thermal barrier
coating of the article. The binder material is configured to
improve a cohesive strength level, an adhesive strength level, and
a compliance of the reactive phase spray formulation coating of the
thermal barrier coating relative to the reactive phase spray
formulation coating not including the binder material.
[0055] Optionally, the reactive phase spray formulation coating is
configured to react with dust deposits on the thermal barrier
coating.
[0056] Optionally, the reactive phase spray formulation coating is
configured to reduce an amount of spalling of the thermal barrier
coating relative to the reactive phase spray formulation coating
not being disposed on the thermal barrier coating.
[0057] Optionally, the reactive phase spray formulation coating is
configured to be deposited on the thermal barrier coating in a
non-thermal process.
[0058] Optionally, the binder material has a particle size that is
less than one micron, and the base material has a particle size
between one micron and ten microns.
[0059] Optionally, the base material has a chemical configuration
that is common to a chemical configuration of the binder
material.
[0060] Optionally, the article is a surface of a turbine
assembly.
[0061] Optionally, reactive phase spray formulation coating has a
ratio comprising of at least seven parts of the base material to at
least three parts of the binder material.
[0062] Optionally, the reactive phase spray formulation coating has
a ratio comprising of at least nineteen parts of the base material
to at least one part of the binder material.
[0063] Optionally, the base material includes one or more parts of
zirconium, oxygen, or yttrium.
[0064] Optionally, the binder material includes one or more parts
of zirconium, oxygen, or yttrium.
[0065] Optionally, the reactive phase spray formulation coating
deposited on the thermal barrier coating has a thickness of at
least ten microns.
[0066] In one embodiment of the subject matter described herein, a
system comprises a thermal barrier coating disposed on a surface of
an article. The thermal barrier coating is configured to reduce an
amount of degradation of the article relative to the article not
having the thermal barrier coating disposed on the surface. The
system also comprises a reactive phase spray formulation coating
configured to be disposed on the thermal barrier coating of the
article. The reactive phase spray formulation coating comprises a
base material and a binder material. The base material has a
compliance that is higher than a compliance of the binder material,
the binder material has a cohesive strength that is greater than a
cohesive strength of the base material, the binder material has an
adhesive strength that is greater than an adhesive strength of the
base material, and the binder material has a surface area of at
least ten square-meters per gram that is greater than a surface
area of the base material. The binder material is configured to
improve a cohesive strength level, an adhesive strength level, and
a compliance of the reactive phase spray formulation coating of the
thermal barrier coating relative to the reactive phase spray
formulation coating not including the binder material.
[0067] As used herein, an element or step recited in the singular
and proceeded with the word "a" or "an" should be understood as not
excluding plural of said elements or steps, unless such exclusion
is explicitly stated. Furthermore, references to "one embodiment"
of the presently described subject matter are not intended to be
interpreted as excluding the existence of additional embodiments
that also incorporate the recited features. Moreover, unless
explicitly stated to the contrary, embodiments "comprising" or
"having" an element or a plurality of elements having a particular
property may include additional such elements not having that
property.
[0068] It is to be understood that the above description is
intended to be illustrative, and not restrictive. For example, the
above-described embodiments (and/or aspects thereof) may be used in
combination with each other. In addition, many modifications may be
made to adapt a particular situation or material to the teachings
of the subject matter set forth herein without departing from its
scope. While the dimensions and types of materials described herein
are intended to define the parameters of the disclosed subject
matter, they are by no means limiting and are exemplary
embodiments. Many other embodiments will be apparent to those of
skill in the art upon reviewing the above description. The scope of
the subject matter described herein should, therefore, be
determined with reference to the appended claims, along with the
full scope of equivalents to which such claims are entitled. In the
appended claims, the terms "including" and "in which" are used as
the plain-English equivalents of the respective terms "comprising"
and "wherein." Moreover, in the following claims, the terms
"first," "second," and "third," etc. are used merely as labels, and
are not intended to impose numerical requirements on their objects.
Further, the limitations of the following claims are not written in
means-plus-function format and are not intended to be interpreted
based on 35 U.S.C. .sctn. 112(f), unless and until such claim
limitations expressly use the phrase "means for" followed by a
statement of function void of further structure.
[0069] This written description uses examples to disclose several
embodiments of the subject matter set forth herein, including the
best mode, and also to enable a person of ordinary skill in the art
to practice the embodiments of disclosed subject matter, including
making and using the devices or systems and performing the methods.
The patentable scope of the subject matter described herein is
defined by the claims, and may include other examples that occur to
those of ordinary skill in the art. Such other examples are
intended to be within the scope of the claims if they have
structural elements that do not differ from the literal language of
the claims, or if they include equivalent structural elements with
insubstantial differences from the literal languages of the
claims.
* * * * *