U.S. patent application number 16/584820 was filed with the patent office on 2020-02-06 for yttrium aluminum garnet based thermal barrier coatings.
This patent application is currently assigned to The University of Connecticut. The applicant listed for this patent is The University of Connecticut. Invention is credited to Maurice Gell, Chen Jiang, Eric H. Jordan, Rishi Kumar.
Application Number | 20200039888 16/584820 |
Document ID | / |
Family ID | 56850158 |
Filed Date | 2020-02-06 |
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United States Patent
Application |
20200039888 |
Kind Code |
A1 |
Jordan; Eric H. ; et
al. |
February 6, 2020 |
YTTRIUM ALUMINUM GARNET BASED THERMAL BARRIER COATINGS
Abstract
A multi-layer coating that allows arrest of contaminant
infiltration includes at least one layer that is not very reactive
to an infiltrating reactive species, and at least one highly
reactive ceramic layer (HRC layer) containing materials that react
to slow or arrest contaminant infiltration.
Inventors: |
Jordan; Eric H.; (Storrs,
CT) ; Gell; Maurice; (Somerset, NJ) ; Kumar;
Rishi; (Ashford, CT) ; Jiang; Chen;
(Willimantic, CT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The University of Connecticut |
Farmington |
CT |
US |
|
|
Assignee: |
The University of
Connecticut
Farmington
CT
|
Family ID: |
56850158 |
Appl. No.: |
16/584820 |
Filed: |
September 26, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
15040871 |
Feb 10, 2016 |
10472286 |
|
|
16584820 |
|
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|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C04B 2235/79 20130101;
C01P 2002/72 20130101; C04B 2237/343 20130101; C04B 35/505
20130101; C01F 17/34 20200101; C04B 2237/34 20130101; C04B
2235/3225 20130101; C04B 2235/3222 20130101; B32B 18/00 20130101;
C01P 2006/37 20130101; C04B 2237/348 20130101 |
International
Class: |
C04B 35/505 20060101
C04B035/505; C01F 17/00 20060101 C01F017/00; B32B 18/00 20060101
B32B018/00 |
Goverment Interests
STATEMENT OF FEDERALLY SPONSORED RESEARCH
[0001] This invention was made with Government support under
DE-SC0007544 awarded by the Department of Energy. The Government
has certain rights to this invention.
Claims
1. A multi-layer coating that allows arrest of contaminant
infiltration comprising: at least one layer that is not very
reactive to an infiltrating reactive species, and at least one
highly reactive ceramic layer (HRC layer) containing materials that
react to slow or arrest contaminant infiltration.
2. The multi-layer coating of claim 1, wherein the HRC layer
comprises one or more oxides of Y and/or one or more oxides of any
lanthanide (La, Ce, Pr, Nd, Pm, SM, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb,
Lu).
3. The multi-layer coating of claim 1, comprising one or more inert
layers or phases and one or more reactive layers or phases.
4. The multi-layer coating of claim 1, wherein the coating
comprises at least two layers of yttrium aluminum garnet (YAG) and
a layer comprising Y.sub.2O.sub.3 between at least two layers of
YAG.
5. The multi-layer coating of claim 1, wherein the coating
comprises at least two layers of YAG, and a layer of
Gd.sub.2Zr.sub.2O.sub.7 between at least two layers of YAG; and
another layer of YAG between at least two layers of YAG and also
between the layers comprising Y.sub.2O.sub.3 and Gd.sub.2Zr.sub.2
O.sub.7.
6. The multi-layer coating of claim 1, wherein the coating
comprises a first layer that includes Y.sub.2O.sub.3 and
Gd.sub.2Zr.sub.2O.sub.7 between layers of YAG and a second layer of
Y.sub.2O.sub.3+Gd.sub.2Zr.sub.2 O.sub.7 between layers of YAG.
7. The multi-layer coating of claim 1 comprising more than one
inert layer and more than one reactive layer.
8. The multi-layer coating of claim 1, wherein the coating is made
by the solution precursor plasma spray process.
9. The multi-layer coating of claim 1, wherein the coating is used
as a thermal barrier coating.
10. The multi-layer coating of claim 1, wherein the coating is
applied on at least one gas turbine hot section component.
11. A method of fabricating a multi-layer coating that allows
arrest of contaminant infiltration comprising: depositing at least
one layer that comprises materials that is not very reactive to an
infiltrating reactive species, and depositing at least one highly
reactive ceramic layer (HRC layer) containing at least one material
that react to slow or arrest contaminant infiltration.
12. The method of claim 11, wherein the HRC layer comprises one or
more oxides of Y and/or one or more oxides of any lanthanide (La,
Ce, Pr, Nd, Pm, SM, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu).
13. The method of claim 11, wherein one or more inert layers or
phases and one or more reactive layers or phases are deposited.
14. The method claim 11 wherein the method includes depositing at
least two layers of YAG, depositing a layer comprising
Y.sub.2O.sub.3 between at least two layers of YAG; a layer of
Gd.sub.2Zr.sub.2 O.sub.7 between at least two layers of YAG; and
depositing another layer of YAG between at least two layers of YAG
and also between the layers comprising Y.sub.2O.sub.3 and
Gd.sub.2Zr.sub.2O.sub.7.
15. The method of claim 11, wherein the method includes depositing
a first layer of Y.sub.2O.sub.3+Gd.sub.2Zr.sub.2O.sub.7 between
layers of YAG and depositing a second layer of
Y.sub.2O.sub.3+Gd.sub.2Zr.sub.2O.sub.7 between layers of YAG.
16. The method of claim 11, wherein the method includes depositing
more than one inert layer and more than one reactive layer.
17. The method of claim 11, wherein at least one layer is deposited
using plasma spray processes.
18. The method of claim 11, wherein at least one layer is deposited
using the solution plasma spray process.
19. The method of claim 11, wherein the coating fabricated is a
thermal barrier coating.
20. The method of claim 11, wherein the coating fabricated is
deposited on a gas turbine hot section component.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0002] This application is a continuation application of U.S.
patent application Ser. No. 15/040,871, filed Feb. 10, 2016, which
claims the benefit of U.S. Provisional Patent Application Ser. No.
62/114,264 filed on Feb. 10, 2015, and entitled "Improved Yttrium
Aluminum Garnet Based Thermal Barrier Coating." Each of these
applications is incorporated by reference herein in its
entirety.
FIELD OF INVENTION
[0003] The disclosure contained herein is in the general field of
compositions, equipment and methods related to thermal barrier
coatings and more specifically of yttrium aluminum garnet (YAG)
thermal barrier coatings.
BACKGROUND
[0004] Thermal barrier coatings (TBCs) are used to protect hot
section components of equipment such as aircraft engines, marine
propulsion systems, and industrial gas turbines, from the extreme
temperatures of the associated gas. Advanced thermal barrier
coatings are needed to satisfy more demanding durability
requirements, such as those of industrial gas turbines operating at
turbine inlet temperatures of 2650.degree. F. (1454.degree. C.) and
beyond.
[0005] Yttrium aluminum garnet (YAG) has desirable properties for a
thermal barrier coating as previously disclosed, for example, in
International Publication Number WO 2013/163058, published on Oct.
31, 2013, which also discloses methods of making such coatings. In
some embodiments such coatings can be made to have significantly
reduced thermal conductivity by doping with other elements.
SUMMARY
[0006] Embodiments of a multi-layer coating that allows arrest of
contaminant infiltration includes at least one layer that is not
very reactive to an infiltrating reactive species, and at least one
highly reactive ceramic layer (HRC layer) containing materials that
react to slow or arrest contaminant infiltration. Other embodiments
of a multi-layer coating that allows arrest of contaminant
infiltration are described.
[0007] In some embodiments, the HRC layer includes one or more
oxides of Y and/or one or more oxides of any lanthanide (La, Ce,
Pr, Nd, Pm, SM, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu).
[0008] In some embodiments, the multi-layer coating further
includes one or more inert layers or phases and one or more
reactive layers or phases
[0009] In some embodiments, the multi-layer coating further
includes at least two layers of yttrium aluminum garnet (YAG) and a
layer comprising Y.sub.2O.sub.3 between at least two layers of
YAG.
[0010] In some embodiments, the multi-layer coating further
includes at least two layers of YAG, and a layer of
Gd.sub.2Zr.sub.2O.sub.7 between at least two layers of YAG; and
another layer of YAG between at least two layers of YAG and also
between the layers comprising Y.sub.2O.sub.3 and Gd.sub.2Zr.sub.2
O.sub.7.
[0011] In some embodiments, the multi-layer coating further
includes a first layer that includes Y.sub.2O.sub.3 and
Gd.sub.2Zr.sub.2O.sub.7 between layers of YAG and a second layer of
Y.sub.2O.sub.3+Gd.sub.2Zr.sub.2 O.sub.7 between layers of YAG.
[0012] In some embodiments, the multi-layer coating further
includes more than one inert layer and more than one reactive
layer.
[0013] In some embodiments, the multi-layer coating is made by the
solution precursor plasma spray process.
[0014] In some embodiments, the multi-layer coating is used as a
thermal barrier coating.
[0015] In some embodiments, the multi-layer coating is applied on
at least one gas turbine hot section component.
[0016] Embodiments of a method of fabricating a multi-layer coating
that allows arrest of contaminant infiltration are described. In
one embodiment, the method includes depositing at least one layer
that comprises materials that is not very reactive to an
infiltrating reactive species. The method further includes
depositing at least one highly reactive ceramic layer (HRC layer)
containing at least one material that react to slow or arrest
contaminant infiltration. Other embodiments of a method of
fabricating a multi-layer coating that allows arrest of contaminant
infiltration are described.
[0017] In some embodiments, the HRC layer comprises one or more
oxides of Y and/or one or more oxides of any lanthanide (La, Ce,
Pr, Nd, Pm, SM, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu).
[0018] In some embodiments, one or more inert layers or phases and
one or more reactive layers or phases are deposited.
[0019] In some embodiments, the method further includes depositing
at least two layers of YAG, depositing a layer comprising
Y.sub.2O.sub.3 between at least two layers of YAG; a layer of
Gd.sub.2Zr.sub.2 O.sub.7 between at least two layers of YAG; and
depositing another layer of YAG between at least two layers of YAG
and also between the layers comprising Y.sub.2O.sub.3 and
Gd.sub.2Zr.sub.2O.sub.7.
[0020] In some embodiments, the method further includes depositing
a first layer of Y.sub.2O.sub.3+Gd.sub.2Zr.sub.2O.sub.7 between
layers of YAG and depositing a second layer of
Y.sub.2O.sub.3+Gd.sub.2Zr.sub.2O.sub.7 between layers of YAG.
[0021] In some embodiments, the method further includes depositing
more than one inert layer and more than one reactive layer.
[0022] In some embodiments, at least one layer is deposited using
plasma spray processes.
[0023] In some embodiments, at least one layer is deposited using
the solution plasma spray process.
[0024] In some embodiments, the multi-layer coating fabricated is a
thermal barrier coating.
[0025] In some embodiments, the multi-layer coating fabricated is
deposited on a gas turbine hot section component.
[0026] Other aspects and advantages of embodiments of the present
invention will become apparent from the following detailed
description, taken in conjunction with the accompanying drawings
illustrated by way of example of the principles of the
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 depicts one embodiment of a diagram of a phase
stability and inert behavior of YAG in the presence of CMAS.
[0028] FIG. 2 depicts one embodiment of infiltration of YSZ with
pure yttria materials.
[0029] FIG. 3 depicts one embodiment of infiltration of YSZ with
yttria via precursors.
[0030] FIG. 4 depicts one embodiment of diagram of YAG with small
excess of yttrium showing primarily YAM as the second phase.
[0031] FIG. 5 depicts embodiments of arrangements of layers greater
than two components.
[0032] FIG. 6 depicts an embodiment of APS Al.sub.2O.sub.3-40 wt %
ZrO.sub.2 Using Al.sub.2O.sub.3-ZrO.sub.2 powder.
[0033] It will be appreciated that the drawings are illustrative
and not limiting of the scope of the invention which is defined by
the appended claims. The embodiments shown accomplish various
aspects and objects of the invention. It is appreciated that it is
not possible to clearly show each element and aspect of the
invention in a single figure, and as such, multiple figures are
presented to separately illustrate the various details of the
invention in greater clarity. Similarly, not every embodiment need
accomplish all advantages of the present invention.
[0034] While the disclosure is susceptible to various modifications
and alternative forms, specific embodiments have been shown by way
of example in the drawings and will be described in detail herein.
However, it should be understood that the disclosure is not
intended to be limited to the particular forms disclosed. Rather,
the intention is to cover all modifications, equivalents and
alternatives falling within the spirit and scope of the invention
as defined by the appended claims.
[0035] Throughout the description, similar reference numbers may be
used to identify similar elements.
DETAILED DESCRIPTION
[0036] In the following description, specific details of various
embodiments are provided. However, some embodiments may be
practiced with less than all of these specific details. In other
instances, certain methods, procedures, components, structures,
and/or functions are described in no more detail than to enable the
various embodiments of the invention, for the sake of brevity and
clarity.
[0037] It will be readily understood that the components of the
embodiments as generally described herein and illustrated in the
appended figures could be arranged and designed in a wide variety
of different configurations. Thus, the following more detailed
description of various embodiments, and embodiments as represented
in the figures, is not intended to limit the scope of the present
disclosure, but is merely representative of various embodiments.
While the various aspects of the embodiments are presented in
drawings, the drawings are not necessarily drawn to scale unless
specifically indicated.
[0038] The present invention may be embodied in other specific
forms without departing from its spirit or essential
characteristics. The described embodiments are to be considered in
all respects only as illustrative and not restrictive. The scope of
the invention is, therefore, indicated by the appended claims
rather than by this detailed description. All changes which come
within the meaning and range of equivalency of the claims are to be
embraced within their scope.
[0039] Reference throughout this specification to features,
advantages, or similar language does not imply that all of the
features and advantages that may be realized with the present
invention should be or are in any single embodiment of the
invention. Rather, language referring to the features and
advantages is understood to mean that a specific feature,
advantage, or characteristic described in connection with an
embodiment is included in at least one embodiment of the present
invention. Thus, discussions of the features and advantages, and
similar language, throughout this specification may, but do not
necessarily, refer to the same embodiment.
[0040] Furthermore, the described features, advantages, and
characteristics of the invention may be combined in any suitable
manner in one or more embodiments. One skilled in the relevant art
will recognize, in light of the description herein, that the
invention can be practiced without one or more of the specific
features or advantages of a particular embodiment. In other
instances, additional features and advantages may be recognized in
certain embodiments that may not be present in all embodiments of
the invention.
[0041] Reference throughout this specification to "one embodiment",
"an embodiment", "some embodiments", or similar language means that
a particular feature, structure, or characteristic described in
connection with the indicated embodiment is included in at least
one embodiment of the present invention. Thus, the phrases "in one
embodiment", "in an embodiment", "in some embodiments", and similar
language throughout this specification may, but do not necessarily,
all refer to the same embodiment.
[0042] While many embodiments are described herein, at least some
of the described embodiments facilitate the enhancement of the
durability of ceramic coatings.
[0043] FIG. 1 depicts one embodiment of a diagram of a phase
stability and inert behavior of YAG in the presence of CMAS.
[0044] FIG. 2 depicts one embodiment of infiltration of YSZ with
pure yttria materials.
[0045] FIG. 3 depicts one embodiment of infiltration of YSZ with
yttria via precursors.
[0046] FIG. 4 depicts one embodiment of diagram of YAG with small
excess of yttrium showing primarily YAM as the second phase.
[0047] FIG. 5 depicts embodiments of arrangements of layers greater
than two components.
[0048] FIG. 6 depicts an embodiment of APS Al.sub.2O.sub.3-40 wt %
ZrO.sub.2 Using Al.sub.2O.sub.3-ZrO.sub.2 powder.
[0049] Thermal barrier coatings (TBCs) are widely used to protect
hot section components of equipment such as aircraft engines,
marine propulsion systems, and industrial gas turbines, from the
extreme temperatures of the associated gas. Advanced thermal
barrier coatings are needed to satisfy more demanding durability
requirements, such as those of industrial gas turbines operating at
turbine inlet temperatures of 2650.degree. F. (1454.degree. C.) and
beyond.
[0050] Yttrium aluminum garnet (YAG) has desirable properties for a
thermal barrier coating as previously disclosed, for example, in
International Publication Number WO 2013/163058, published on Oct.
31, 2013, which also discloses methods of making such coatings. In
some embodiments such coatings can be made to have significantly
reduced thermal conductivity by doping with other elements.
[0051] Disclosed herein are methods of enhancing the durability of
ceramic coatings. Embodiments of this invention also include
methods of fabricating ceramic coatings. Embodiments of this
invention further include equipment that has at least one or more
components that may experience temperatures in excess of
700.degree. C. that utilize these improved coatings and/or coatings
processed using the methods described herein. Embodiments of this
invention further include operation and use of equipment that has
at least one or more components that utilize these improved
coatings and/or coatings processed using the methods described
here.
[0052] As used herein, the term "coating" describes a coating that
may be used in any of the types of equipment described above. The
embodiments describing the methods, use and equipment listed above
also include any embodiment of the coating, alone or in
combination, included in the rest of this document. A thermal
barrier coating may be treated as a type of thermal barrier
coating, and where the word "coating" is used in the rest of this
document, it can, but does not necessarily, refer to a thermal
barrier coating. Further, the word "coating" may refer to a coating
produced by any technique, including without limitation, thermal
spray (including plasma spray), physical vapor deposition (PVD)
including electron beam physical vapor deposition (EB-PVD),
chemical vapor deposition (CVD), solution based techniques such as
sol-gel techniques, sputtering, any method conventionally referred
to as "thin film deposition" and electrochemical deposition
techniques. Further the word "coating" may refer to a coating of
any thickness, and in particular to a coating of thickness between
1 micrometer and 10 millimeters. The word "coating" anywhere in
this document may also refer specifically to a thermal barrier
coating.
[0053] The word "equipment", unless otherwise explicitly specified,
used anywhere in this document may refer to, without limitation,
equipment that has at least one or more components that may
experience temperatures in excess of 700.degree. C., including
gas-fired engines and turbines, coil-fired engines and turbines,
biomass-fired engines and turbines, boilers, chemical reactors, hot
gas/liquid pipelines, fuel cells (including solid oxide fuel cell
and molten carbonate fuel cell systems), and gas
production/extraction/purification/concentration systems. Further,
the word "equipment" includes any equipment that may at any time
during assembly or operation have a function that requires at least
one component, which may be a metal component, to experience a
temperature less than 25.degree. C. below the temperature of the
operating environment, or the temperature that the fluid (gas or
liquid) in the operating component of that component may experience
at the same time, or a time within a short duration prior (to
account for the time taken for heat transfer). Also, the word
"equipment" in this document may refer to any equipment that may at
any time during assembly or operation be exposed a reactive solid
species that is carried by a fluid. This reactive solid species may
comprise, without limitation, particles or "ash". The reactive
species may comprise, without limitation, particles that are
introduced into the fluid from the environment around the equipment
(e.g. dust particles in the air), or formed during the operation of
the equipment (e.g. fly ash particles formed during combustion of
coal, biomass etc.).
[0054] Yttrium aluminum garnet (YAG) has desirable properties for a
thermal barrier coating as previously disclosed and the inventors
have disclosed methods of making such coatings. (See Maurice Gell
et al. METHOD OF FORMING THERMAL BARRIER COATING, THERMAL BARRIER
COATING FORMED THEREBY, AND ARTICLE COMPRISING SAME, International
Publication Number WO 2013/163058, published on Oct. 31, 2013. [53
pages], hereinafter "Gell", the contents of which are hereby
incorporated by reference herein.) In one embodiment of this
invention describes a method of enhancing the durability of thermal
barrier coatings that may be used in engines, turbines or other
equipment that has at least one or more components that may
experience temperatures in excess of 700.degree. C. Embodiments of
this invention also include methods of fabricating thermal barrier
coatings, to be used in engines, turbines or other equipment that
has at least one or more components that may experience
temperatures in excess of 700.degree. C., that have greater
durability and/or reliability compared with today's state of the
art thermal barrier coatings. All modern gas turbines have thermal
barrier coatings (TBCs). Thermal barrier coatings are typically
ceramic coatings that have thermal conductivity. The improvement in
firing temperatures these allow along with the durability
improvement are so compelling that all modern gas turbines use such
coatings.
[0055] Other embodiments disclosed herein may include engines,
turbines or other equipment that has at least one or more
components that may experience temperatures in excess of
700.degree. C. that utilize these improved coatings and/or coatings
processed using the methods described herein. Embodiments of this
invention further include operation and use of engines, turbines or
other equipment that has at least one or more components that may
experience temperatures in excess of 700.degree. C. that utilize
these improved coatings and/or coatings processed using the methods
described here. In the rest of this document, the term "thermal
barrier coating" describes a coating that may be used in any of the
types of equipment described above. The embodiments describing the
methods, use and equipment listed above also include any embodiment
of the thermal barrier coating, alone or in combination, included
in the rest of this document.
[0056] In, some embodiments of this invention, the thermal barrier
coating may comprise a doped yttrium aluminum garnet (YAG) based
material. In some embodiments of this invention, the thermal
barrier coating may comprise a rare earth oxide doped YAG based
material. Some embodiments of this invention may possess higher
maximum use temperature and/or better erosion resistance. Some
embodiments of this invention may include a thermal barrier coating
with lower thermal conductivity that one with similar thickness and
porosity and manufactured with an undoped YAG or with
yttria-stabilized zirconia. Some embodiments of this invention may
include a rare earth element doped YAG material, where dopant may
be one or more oxides of one or more of the elements represented by
the chemical symbols La, Ce, Pr, Nd. Pm, Sm, Eu, Gd, TB, Dy, Ho,
Er. Tm, Yb, Lu, and Y, Sr and Sc. Some embodiments of this
invention may include a rare earth element doped YAG material,
where dopant may be one or more oxides of one or more of the
elements represented by the chemical family commonly referred to as
the Lanthanides. The choice of any particular dopant or combination
of dopants, in no way limits the scope of this invention.
[0057] It should specifically be noted that coatings disclosed
herein may or may not contain other materials, including other
ceramic or oxide materials in addition to the YAG based materials
and the inclusion or non-inclusion of such other materials in no
way limits the scope of this invention. These other materials may
be added deliberately to change or tailor specific properties of
the coating and/or be included, intentionally or unintentionally,
as byproducts of the coating process. In particular, the
composition of the coating may contain excess Y than specified for
the line compound YAG. In particular, such coatings may contain one
or both of yttrium aluminum monoclinic (YAM) or yttrium aluminum
pervoskite (YAP).
[0058] A continuing problem in the field of operation of equipment
at higher temperatures, especially under combustion conditions, is
the degradation of the performance of a thermal barrier coating due
to the reaction with or degradation caused by reactive species. For
example, this reactive species may be components of the "fly
ash"--particles in the combustion gas environment--that are
deposited on the surface of the coating during operation. One
component in the fly ash that may also arise from any number of
sources which is particularly problematic is calcium magnesium
alumino-silicate (CMAS). CMAS and similar deposits may arise from
many sources including volcanic ash, wend blow sand a dust,
particles from industrial activities such a mining and
manufacturing. Embodiments of the invention apply to the mitigation
of this mineral or oxide deposition problem regardless of the
origin. YAG itself may be a good choice as a CMAS resistant
coating. An important feature of YAG that has been demonstrated by
the contributors to this disclosure and which is consistent with
optical basicity theory [A. Krause, B. Senturk, H. Garces, G.
Dwivendi, A. Ortiz, S. Sampath and N. Padture, "2Zr)2.Y2O3 Thermal
Barrier Coatings Resistant to Degradation by Molten CMAS: Part I,
Optical Basicity Considerations and Processing," J. Am Ceram. Soc ,
97 {12} 3943-3949 (2014), and A. Krause et al. "2Zr)2.Y2O3 Thermal
Barrier Coatings Resistant to Degradation by Molten CMAS: Part II,
Interactions with Sand and Fly Ash," J. Am Ceram. Soc , 97 {12}
3950-3957 (2014), hereinafter "Krause", the contents of which are
hereby incorporated by reference herein] is that YAG is nearly
inert in the presence of CMAS (FIG. 1). The primary vulnerability
to CMAS for a YAG based coating is infiltration via cracks and
pores.
[0059] The current standard method of coping with CMAS for other
types of coatings is to have materials that react with CMAS
creating new phases in the CMAS or other similar contaminant that
cause it to solidify into this new phase that arrests the flow and
attack of the contaminants including CMAS. In so reacting, the
coating will be eventually be depleted of reacting elements and
will ultimately fail. This reaction is across a broad front at all
locations. Because of materials transport, the reactive element
will be eventually depleted by this reaction occurring on a large
surface area. The most widely studied and commercially implemented
version of this approach is based on gadolinium zirconate coatings
[C G Levi, J. Hutchinson, M H Vidal-Setif and C A Johnson,
Environmental degradation of thermal-barrier Coatings by molten
deposits, "MRS Bulletin, Vol. 37, pp. 932-941, (2013), hereinafter
"Levi", the contents of which are hereby incorporated by reference
herein]. For all such coatings there is full planer surface
reaction with the CMAS consuming some of the underlying coating to
arrest the CMAS infiltration.
[0060] Embodiments of this invention describe a fundamentally
different approach to prevention of degradation of the coating
and/or the metal components that the coating is designed to
protect. In some embodiments of this invention, reactive species
blocking reactions are promoted at least in part in cracks and/or
pores in the coating. In some embodiments of this invention, a
majority, most or all of the reactive blocking is locally in
cracks, pores and/or pore channels. The term "pore channel" in this
disclosure may refer to, without limitation, any space between at
least two parts of the coating that may be introduced during
processing or operation, without limitation on the processing
technique. For instance, a "pore" may refer to a space between at
least two columns in a coating fabricated by an electron beam
physical vapor (EBPVD) deposition technique. Also, for instance, a
"pore" may refer to a crack or microcrack in a coating fabricated
by a plasma spray technique method, including, without limitation,
air plasma spray (APS), solution precursor plasma spray (SPPS)
and/or suspension plasma spray (SPS). Also, for instance, a "pore"
may refer to a crack in a coating fabricated by a thermal spray
method, where the coating has a nominally high density between at
least two of these cracks. Also, for instance, a "pore" may refer
to a crack in a coating that may be referred to by those familiar
to the art as a "dense vertically cracked" coating.
[0061] In some embodiments of the coating, the inert properties of
the YAG are relied upon to provide some, most or all of the CMAS
blocking. In some embodiments of this invention, at least one pore,
pore channel, crack, microcrack will contain at least one reactive
material to arrest the infiltration in that pore, pore channel,
crack, microcrack.
[0062] In some embodiments of this invention, the coating will
contain at least some yttrium oxide added to the YAG. In some
embodiments, the coating may contain yttrium-rich regions. In some
embodiments, the coating may contain yttrium-rich regions, which
when encountered by a reactive species (including CMAS) will be
significantly reactive to the reactive species and arrest
infiltration of the reactive species.
[0063] In some embodiments of this invention, the coating may
comprise a non-stoichiometric YAG composition. In some embodiments
of this invention, the coating may comprise a non-stoichiometric
YAG composition represented by a composition on the yttria-alumina
phase diagram with a yttria/alumina composition near, but not
exactly the same as that of stoichiometric YAG. Some embodiments of
the invention may contain yttrium aluminum monoclinic (YAM) or
Yttrium aluminum perovskite (YAP), also known under the name of
yttrium orthoaluminate. In some embodiments of the invention, YAP
or YAM may react more strongly with a reactive species (including
CMAS) than YAG. In some embodiments of this invention, the coating
may primarily comprise of YAG and YAM.
[0064] Embodiments of coatings disclosed herein may be fabricated
by one of the methods described herein.
[0065] In one method, cracks are infiltrated with reactive CMAS
blocking materials.
[0066] In one step, choose a highly reactive ceramic, hereafter
referred to as "HRC", to be selectively deposited into the cracks,
porous locations and near surface locations of YAG. The reactive
ceramics are to specifically include yttria, and all oxides of the
lanthanides (La, Ce, Pr, Nd, Pm, SM, Eu, Gd, Tb, Dy, Ho, Er, Tm,
Yb, Lu).
[0067] In another step, infiltrate the pores and cracks with these
materials by, without limitation, at least one of the following
several methods listed as a, b, or c below.
[0068] a. Slurry/Suspension Method: Mix the oxide in very fine
particle form with a liquid carrier to form a slurry or suspension,
such that the particles can easily fit into the cracks,
microcracks, pores or pore channels. The sizes of particles used in
this method may range, without limitation, from nanometers to
multiple micron sizes. Liquids carriers that may be used in this
method may comprise, without limitation, water and/or any organic
liquid. Specifically, the organic liquids in this method may
include, without limitation thermo set plastics. Embodiments
utilizing this method have been successfully reduced to practice as
illustrated in FIG. 2 and FIG. 3.
[0069] b. Chemical Precursor Method: Use at least one chemical
precursor that upon exposure to a temperature, at least in excess
of 50.degree. C., will produce at least some of at least one highly
reactive ceramic (HRC). The chemical precursor may include, without
limitation, at least one nitrate, chloride, fluoride, acetate,
propionate, isopropoxide, and/or citrate and any carboxylate. The
precursor may be a liquid. This liquid may include, but not be
limited to, aqueous and non-aqueous solutions of the candidate
elements of at least one lanthanide (La, Ce, Pr, Nd, Pm, SM, Eu,
Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu). In some embodiments, the liquid
may include compositions, which after thermal exposure may produce
at least some YAM or YAP. Embodiments disclosed herein include
coatings, use of coatings and methods of fabrication of coatings
where the infiltration could be done with gas or vapor phase
infiltration.
[0070] c. Methods to infiltrate Precursors The Slurry/Suspensions
and Chemical Precursors listed above are collectively referred to
as "precursors". Methods to infiltrate the precursors into the
cracks, microcracks, pores or pore channels may include, without
limitation, at least one of: (1) direct infiltration by immersion
or spraying, or (2) vacuum assisted infiltration in which the
sample is put under a vacuum and the precursor is spread or poured
on the surface followed by breaking the vacuum to force the
precursor into the cracks, microcracks, pores and/or pore channels;
vacuum may be repeatedly applied and broken. Some embodiments may
include single or multiple infiltrations. In some embodiments that
may include multiple infiltrations, heat treatment between one or
more infiltrations may be included. Heat treatment may be used to
remove suspending agents and/or to pyrolyze the precursors to make
additional infiltration easier.
[0071] The above methods can be used in any combination and
repeated as needed to achieve the degree of infiltration
desired.
[0072] In another method, the Y content of YAG is increased to
produce more reactive coating.
[0073] The reaction behavior of CMAS with ceramics can be roughly
predicted by optical basicity OB theory [Krause]. This theory
correctly predicts the low reactivity of YAG and high reactivity
with CMAS of Y and Gd. In addition, it predicts increasing
reactivity as the Y content of YAG is increased in the limit to
produce YAM.
[0074] Experimental results disclosed herein (FIG. 4) show the
solution sprayed YAG can contain YAM as a second phase. The OB
theory [Krause] suggests that this phase will be very reactive and
will stop CMAS infiltration.
[0075] It is demonstrated herein that with small excesses of
yttrium the primary phases formed are YAG and primarily YAM (FIG.
3). YAM is not the phase predicted by the equilibrium phase diagram
for this low level of excess yttrium, rather YAP is the predicted
phase. Disclosed herein is the surprising finding in thermal spray
processing, that YAM is formed more than YAP. This unexpected and
non-obvious result is favorable in that YAM is expected based on
general understandings in the field [For example, Krause] to be
more reactive to a reactive species such as CMAS.
[0076] Some embodiments of this invention include coatings with YAG
based compositions wherein the amount of Y relative to Al in YAG is
increased to increase the amount of YAM and/or also increase the
amount of YAP in the coating. In some embodiments, the coating may
comprise a multiphase coating that may contain more than one of
YAG, YAM and YAP.
[0077] In some embodiments, such as coatings used in equipment, a
reactive species including CMAS, while infiltrating cracks,
microcracks, pores and/or pore channels will contact YAM and/or YAP
and react and be substantially blocked from further
infiltration.
[0078] Some embodiments of this invention include coatings with
compositions that are on the Y.sub.2O.sub.3 rich side of the
Y.sub.2O.sub.3-Al.sub.2O.sub.3 phase diagram relative to
stoichiometric YAG. Further embodiments of this invention include
use or operation of equipment that include such Y.sub.2O.sub.3-rich
YAG-based coatings. Some embodiments of this invention include
methods of manufacturing or making coatings, including thermal
barrier coatings, that have a Y.sub.2O.sub.3-rich YAG-based
composition by a process that, without limitation, may include a
thermal spray (including plasma spray) process, a PVD (including
EBPVD) process, a CVD process, a sputtering process or a solution
based process.
[0079] In another method, a stratified microstructure is created
with inert and reactive layers.
[0080] Disclosed herein is a microstructure that allows arrest of
contaminant infiltration, by way of example, a microstructure
wherein there is at least one (and potentially more) "inert layer"
or "inter layers" (i.e. layers that are not very reactive to an
infiltrating reactive species) and at least one "highly reactive
ceramic" layer (HRC layer) or "reactive layer" (i.e., a layer
comprised of materials that react with a reactive contaminant
species to potentially slow or arrest their infiltration). Such
coatings are referred to as "stratified coatings". The inert layers
may comprise materials not limited to, YAG-based materials.
Reactive layers can include, but are not limited to one or more
oxides of Y and/or any lanthanide (La, Ce, Pr, Nd, Pm, SM, Eu, Gd,
Tb, Dy, Ho, Er, Tm, Yb, Lu). In such a microstructure, an
infiltrating reactive species will encounter reactive layers that
can arrest infiltration in cracks and pores, one or more times.
[0081] An embodiment of a microstructure disclosed herein comprises
a YAG-based material as an inert layer and a material containing
yttrium oxide as a reactive phase. In another embodiment, the YAG
may be used as the inert phase and the reactive phase may contain
or comprise YAP (which is in equilibrium phase stable with YAG
according to the equilibrium phase diagram). In another embodiment,
YAG may be used as the inert phase and the reactive phase may
contain or comprise YAM.
[0082] Disclosed herein are coatings/microstructures where more
than one inert phase is used or more than one reactive phase is
used or both multiple inert and multiple reactive phases are used.
Because of the broad range of possible reactive species, the use of
multiple inert and reactive materials can provide protection from a
wide range of reactive species. No one material is inert or (HRC)
reactive to all possible contaminants or reactive species such as
CMAS.
[0083] An embodiment of multiple material layers is that different
layer pairs would be deposited one pair at a time. For example, one
might have a relatively thin layer of YAG, Y.sub.2O.sub.3
alternating with layers of YAG and gadolium zirconate (FIG. 5A). In
some embodiments, the coating may have many other arrangements
where in the inert layer's composition is changed or where both
layers are changed. The purpose of such an arrangement would be to
achieve a higher concentration of the desired reactive or inert
materials than could be achieved if, for example, two reactive
elements were used during the same spray application.
[0084] In additional embodiments disclosed herein, embodiments also
include layers that may include or comprise mixed phases such as in
FIG. 5B. Many variations in addition to those of FIG. 5 are
possible, as FIG. 5 is only meant to illustrate the concept. Not
represented, but also included in the disclosure herein, are
embodiments where there is alternation of the inert phase with for
example YAG as one inert phase and some other composition as
another inert phase. Some embodiments specifically include thermal
spray processes and coatings thereby fabricated where more than two
powder types are used in one spray pass. In some embodiments, the
coatings may comprise three materials phases or mixed phase layers
or combinations thereof, are produced.
[0085] Some embodiments of this invention include use or operation
of equipment that include such stratified coatings. Some
embodiments of this invention include manufacturing or making
stratified coatings, including thermal barrier coatings, that have
a Y.sub.2O.sub.3-rich YAG-based composition by a process that,
without limitation, may include a thermal spray (including plasma
spray) process, a PVD (including EBPVD) process, a CVD process, a
sputtering process or a solution based process.
[0086] A microstructure of this general type having inert and
reactive layers is shown in FIG. 6. We note that FIG. 5 is not an
inert with a reactive phase material but instead illustrates that
layered phase structure may be obtained by spraying mixed powders.
Such structures may be made as follows. Specifically, if mixed
powders are sprayed either as dry powders or in suspensions with
one or more types of powder materials, separation of the phase in
the deposits is generally observed which upon deposition by thermal
spray (plasma spray or combustion torch spray) leads to layering as
the arriving material flattens on impact. This is especially
prominent when suspending two powders in a suspending liquid to
produce a coating using mixed powders in the process commonly known
in the field as suspension plasma spray. This structure can also be
produced spraying mixed dried powders. The methods for producing
desired microstructures comprises thermal spray of mixed powders of
inert and reactive materials either by mixed dry powders or
suspension spray or by hybrid spray in which one material is
suspended and the other is delivered as a solution.
[0087] FIG. 2 depicts infiltration of YSZ with yttria materials via
suspended powders. FIG. 2 further depicts materials stacked on top
of the coating forming a dense layer as shown by the arrows.
[0088] All documents cited herein and the following listed
documents that are attached hereto for submission, all referenced
publications cited therein, and the descriptions and information
contained in these documents are expressly incorporated herein in
their entirety to the same extent as if each document or cited
publication was individually and expressly incorporated herein:
[0089] Maurice Gell et al. METHOD OF FORMING THERMAL BARRIER
COATING, THERMAL BARRIER COATING FORMED THEREBY, AND ARTICLE
COMPRISING SAME, International Publication Number WO 2013/163058,
published on Oct. 31, 2013. [53 pages].
[0090] While the invention has been described with reference to
embodiments, it will be understood by those skilled in the art that
various changes may be made and equivalents may be substituted for
the elements thereof without departing from the scope of the
invention. In addition, many modifications may be made to adapt the
teaching of the invention to particular use, application,
manufacturing conditions, use conditions, composition, medium,
size, and/or materials without departing from the essential scope
and spirit of the invention. Therefore, it is intended that the
invention not be limited to the particular embodiments and best
mode contemplated for carrying out this invention as described
herein.
[0091] All ranges disclosed herein are inclusive of the endpoints,
and the endpoints are independently combinable with each other.
Each range disclosed herein constitutes a disclosure of any point
or sub-range lying within the disclosed range.
[0092] The use of the terms "a" and "an" and "the" and words of a
similar nature in the context of describing the improvements
disclosed herein (especially in the context of the following
claims) are to be construed to cover both the singular and the
plural, unless otherwise indicated herein or clearly contradicted
by context. Further, it should further be noted that the terms
"first," "second," and the like herein do not denote any order,
quantity, or relative importance, but rather are used to
distinguish one element from another. The modifier "about" used in
connection with a quantity is inclusive of the stated value and has
the meaning dictated by the context (e.g., it includes, at a
minimum the degree of error associated with measurement of the
particular quantity).
[0093] All methods described herein can be performed in any
suitable order unless otherwise indicated herein or otherwise
clearly contradicted by context. The use of any and all examples,
or exemplary language (e.g., "such as"), is intended merely to
better illustrate the invention and does not pose a limitation on
the scope of the invention or any embodiments unless otherwise
claimed.
[0094] Chemical compounds are described using standard
nomenclature. Unless defined otherwise, all technical and
scientific terms used herein have the same meaning as is commonly
understood by one of skill in the art to which this invention
belongs.
[0095] In the above description, specific details of various
embodiments are provided. However, some embodiments may be
practiced with less than all of these specific details. In other
instances, certain methods, procedures, components, structures,
and/or functions are described in no more detail than to enable the
various embodiments of the invention, for the sake of brevity and
clarity.
[0096] Although the operations of the method(s) herein are shown
and described in a particular order, the order of the operations of
each method may be altered so that certain operations may be
performed in an inverse order or so that certain operations may be
performed, at least in part, concurrently with other
operations.
[0097] Although specific embodiments of the invention have been
described and illustrated, the invention is not to be limited to
the specific forms or arrangements of parts so described and
illustrated. The scope of the invention is to be defined by the
claims appended hereto and their equivalents.
* * * * *