ABRADABLE CERAMIC COATINGS AND COATING SYSTEMS

• US 20130108421A1
• Filed: 02/09/2011
• Published: 05/02/2013
• Est. Priority Date: 02/09/2010
• Status: Active Grant

• Current Assignee: Rolls-Royce Corporation (Rolls-Royce Holdings Plc)
• Original Assignee: Rolls-Royce Corporation (Rolls-Royce Holdings Plc)
• Inventors: Sinatra, Raymond J., Daugherty, Jesse S., Alexander, Marvin
• Granted Patent: US 9,581,041 B2
• Time in Patent Office: Days
• US Class Current: 415/182.1
• CPC Class Codes: C23C 28/321 with at least one metal alloy layer
• CPC Class Codes: C23C 28/3215 at least one MCrAlX layer
• CPC Class Codes: C23C 28/325 with layers graded in composition or in physical properties
• CPC Class Codes: C23C 28/345 with at least one oxide layer
• CPC Class Codes: C23C 28/3455 with a refractory ceramic layer, e.g. refractory metal oxide, ZrO2, rare earth oxides or a thermal barrier system comprising at least one refractory oxide layer
• CPC Class Codes: C23C 4/073 containing MCrAl or MCrAlY alloys, where M is nickel, cobalt or iron, with or without non-metal elements
• CPC Class Codes: F01D 11/122 with erodable or abradable material blades having cutting or grinding tips F01D5/20
• CPC Class Codes: F01D 25/00 Component parts, details, or accessories, not provided for in, or of interest apart from, other groups

Abstract

The disclosure relates to a high temperature mechanical system, such as a gas turbine engine, including a first coating deposited on a first substrate and a second coating deposited on a second substrate. The first coating includes a first bond layer, a second bond layer, and a first ceramic outer layer, wherein the second bond layer is between the first bond layer and first ceramic outer layer. The second coating includes a third bond layer deposited on the substrate and a second ceramic outer layer deposited on the third bond layer. The second coating is configured to abrade the first coating, e.g., during operation of the high temperature mechanical system.

Claims

1. A system comprising:

a first coating deposited on a first substrate, the first coating comprising a first bond layer, a second bond layer, and a first ceramic outer layer, wherein the second bond layer is between the first bond layer and first ceramic outer layer; and

a second coating deposited on a second substrate, the second coating comprising a third bond layer deposited on the substrate and a second ceramic outer layer deposited on the third bond layer, wherein the second coating is configured to abrade the first coating.

2. The system of claim 1, wherein the first bond layer, the second bond layer and the third bond layer each comprise at least one of an MCrAlY alloy (where M is Ni, Co, or NiCo), a β

-NiAl nickel aluminide alloy, or a γ

-Ni+γ

′

-Ni₃Al nickel aluminide alloy.

3. The system of claim 1, wherein the first substrate comprises one of a turbine shroud or turbine blade track, and the second substrate comprises one of a turbine vane or turbine blade.

4. The system of claim 1, wherein the composition of the first bond layer is substantially the same as the second bond layer.

5. The system of claim 1, wherein the first bond layer defines a first porosity and the second bond layer defines a second porosity that is greater than the first porosity.

6. The system of claim 5, wherein the first porosity is between approximately 5 percent and approximately 20 percent less than the second porosity.

8. The system of claim 1, wherein the second bond layer defines a surface roughness of approximately 350 microinches to approximately 400 microinches.

12. The system of claim 1, wherein a first hardness of the first ceramic outer layer is less than the second hardness of the second ceramic outer layer.

13. The system of claim 12, wherein the first hardness of the first ceramic outer layer is between approximately 35 to approximately 45 Rockwell hardness (Rc).

14. The system of claim 1, wherein the first coating has a first thickness greater than approximately 50 mils.

15. The system of claim 1, wherein the first ceramic outer layer is deposited directly on the second bond layer.

16. The system of claim 1, wherein the first and second substrate each comprise a superalloy.

7. (canceled)

9-11. -11. (canceled)

17. A method comprising:

forming a first coating on a first substrate, the first coating comprising a first bond layer, a second bond layer, and a first ceramic outer layer, wherein the second bond layer is between the first bond layer and first ceramic outer layer; and

forming a second coating on a second substrate, the second coating comprising a third bond layer deposited on the substrate and a second ceramic outer layer deposited on the third bond layer,

wherein the respective coating are configured such that the second coating at least partially abrades the first coating when brought into to contact with one another.

18. The method of claim 17, wherein the first bond layer, the second bond layer and the third bond layer each comprise at least one of an MCrAlY alloy (where M is Ni, Co, or NiCo), a β

-NiAl nickel aluminide alloy, or a γ

-Ni+γ

′

-Ni₃Al nickel aluminide alloy.

19. The method of claim 17, wherein the first substrate comprises one of a turbine shroud or turbine blade track, and the second substrate comprises one of a turbine vane or turbine blade.

20. The method of claim 17, wherein the composition of the first bond layer is substantially the same as the second bond layer.

21. The method of claim 17, wherein the first bond layer defines a first porosity and the second bond layer defines a second porosity that is greater than the first porosity.

22-32. -32. (canceled)

33. A multilayer coating comprising:

a first bond layer having a first porosity on a substrate;

a second bond layer having a second porosity greater than the first porosity on the first bond layer; and

a ceramic outer layer formed on the second bond layer.

34. The multilayer coating of claim 33, wherein the substrate comprises a superalloy substrate.

35. The multilayer coating of claim 33, wherein the first bond layer and the second bond layer each comprise at least one of an MCrAlY alloy (where M is Ni, Co, or NiCo), a β

-NiAl nickel aluminide alloy, or a γ

-Ni+γ

′

-Ni₃Al nickel aluminide alloy.

36-39. -39. (canceled)