Thermal-sprayed bonding of a ceramic structure to a substrate

• US 10,458,256 B2
• Filed: 10/27/2015
• Issued: 10/29/2019
• Est. Priority Date: 10/30/2014
• Status: Active Grant

• Current Assignee: Rtx Corporation
• Original Assignee: United Technologies Corporation (Raytheon Technologies Corporation d/b/a RTX)
• Inventors: Strock, Christopher W, Lutjen, Paul M
• Primary Examiner(s): Langman, Jonathan C
• Application Number:
  US14/923,574
• Publication Number:
  US 20160123160A1
• Time in Patent Office: 1,463 Days
• CPC Class Codes: B32B 2250/02 2 layers
• CPC Class Codes: B32B 2255/00 Coating on the layer surface
• CPC Class Codes: B32B 2255/06 on metal layer
• CPC Class Codes: B32B 2255/20 Inorganic coating
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 2603/00 Vanes, blades, propellers, rotors with blades
• CPC Class Codes: B32B 3/12 characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
• CPC Class Codes: B32B 37/12 characterised by using adhesives
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B32B 9/005 comprising one layer of ceramic material, e.g. porcelain, ceramic tile layered products with at least two ceramic layers composed mainly of ceramic B32B18/00
• CPC Class Codes: B32B 9/041 of metal
• CPC Class Codes: C23C 4/12 characterised by the method of spraying
• CPC Class Codes: F01D 11/08 for sealing space between rotor blade tips and stator specially-shaped blade tips therefor F01D5/20
• CPC Class Codes: F01D 11/12 using a rubstrip, e.g. erodible. deformable or resiliently-biased part
• CPC Class Codes: F01D 11/127 with a deformable or crushable structure, e.g. honeycomb
• CPC Class Codes: F01D 25/08 Cooling of machines or engines in general F01P; Heating; Heat-insulation of blade-carrying members, of blades F01D5/00
• CPC Class Codes: F01D 5/288 Protective coatings for blades
• CPC Class Codes: F01D 9/041 using blades F01D5/148 takes precedence
• CPC Class Codes: F05D 2220/32 in gas turbines
• CPC Class Codes: F05D 2230/312 by plasma spraying
• CPC Class Codes: F05D 2230/80 : Repairing, retrofitting or upgrading methods
• CPC Class Codes: F05D 2240/12 : Fluid guiding means, e.g. vanes
• CPC Class Codes: F05D 2240/30 : Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor
• CPC Class Codes: F05D 2240/55 : Seals
• CPC Class Codes: F05D 2250/283 : honeycomb
• CPC Class Codes: F05D 2260/231 : Preventing heat transfer
• CPC Class Codes: F05D 2300/20 : Oxide or non-oxide ceramics
• CPC Class Codes: F05D 2300/22 : Non-oxide ceramics
• CPC Class Codes: F05D 2300/5023 : Thermal capacity
• CPC Class Codes: F05D 2300/611 : Coating

Abstract

A thermal barrier system includes a protective coating on a substrate, and a ceramic feature layer attached to the protective coating via an adhesive spray coat.

Claims

1. A thermal barrier system, comprising:

a protective coating on a substrate; and

a ceramic feature layer attached to said protective coating via an adhesive spray coat, said ceramic feature layer comprises a flared extended area to facilitate a mechanical interlock between said ceramic feature layer and said protective coating via said adhesive spray coat that partially fills said ceramic feature layer such that said ceramic feature layer at least partially extends from said adhesive spray coat.

2. The thermal barrier system as recited in claim 1, wherein said protective coating is an environmental coating.

3. The thermal barrier system as recited in claim 1, wherein said protective coating is a bond coat.

4. The thermal barrier system as recited in claim 1, wherein said adhesive spray coat at least partially fills said ceramic feature layer.

5. The thermal barrier system as recited in claim 1, wherein said ceramic feature layer forms a lattice structure.

6. The thermal barrier system as recited in claim 5, wherein said lattice structure forms a pattern with a multiple of openings, said adhesive spray coat at least partially fills said openings.

7. The thermal barrier system as recited in claim 5, wherein said lattice structure forms a honeycomb pattern, said adhesive spray coat at least partially fills said honeycomb pattern.

8. The thermal barrier system as recited in claim 1, wherein said flared extended area includes an angle of about 5-15 degrees with respect to a side wall of said ceramic feature layer.

9. A thermal barrier system, comprising:

a protective coating on a metallic substrate, the protective coating includes a ceramic material; and

a ceramic feature layer mechanically interlocked to said protective coating via an adhesive spray coat, said ceramic feature layer comprises a flared extended area to facilitate the mechanical interlock between said ceramic feature layer and said protective coating via said adhesive spray coat that partially fills said ceramic feature layer such that said ceramic feature layer at least partially extends from said adhesive spray coat.

10. The thermal barrier system as recited in claim 9, wherein said ceramic feature layer forms a lattice structure.

11. The thermal barrier system as recited in claim 10, wherein said adhesive spray coat is about 0.003 to 0.030 inch thick.

12. The thermal barrier system as recited in claim 10, wherein said adhesive spray coat at least partially fills said ceramic feature layer.

13. The thermal barrier system as recited in claim 10, wherein said ceramic feature layer forms a honeycomb pattern.