TURBINE ENGINES, ENGINE STRUCTURES, AND METHODS OF FORMING ENGINE STRUCTURES WITH IMPROVED INTERLAYER BONDING

• US 20180252119A1
• Filed: 03/01/2017
• Published: 09/06/2018
• Est. Priority Date: 03/01/2017
• Status: Abandoned Application

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Whalen, Terence, Oboodi, Reza, Piascik, James, Olson, Don Martin, Kruk, Natalie
• Application Number:
  US15/446,867
• Publication Number:
  US 20180252119A1
• Time in Patent Office: Days
• CPC Class Codes: C23C 24/082 without intermediate formation of a liquid in the layer
• CPC Class Codes: C23C 28/04 only coatings of inorganic non-metallic material
• CPC Class Codes: C23C 28/042 including a refractory ceramic layer, e.g. refractory metal oxides, ZrO2, rare earth oxides
• CPC Class Codes: C23C 4/02 Pretreatment of the material to be coated, e.g. for coating on selected surface areas
• CPC Class Codes: C23C 4/11 Oxides
• CPC Class Codes: C23C 4/134 Plasma spraying
• CPC Class Codes: F01D 25/005 Selecting particular materials
• CPC Class Codes: F01D 5/284 Selection of ceramic materials
• CPC Class Codes: F01D 5/288 Protective coatings for blades
• CPC Class Codes: F05D 2220/32 in gas turbines
• CPC Class Codes: F05D 2230/10 by removing material
• CPC Class Codes: F05D 2230/22 by sintering
• CPC Class Codes: F05D 2230/42 by hot isostatic pressing
• CPC Class Codes: F05D 2230/90 Coating; Surface treatment manufacture with deposition of material F05D2230/30
• CPC Class Codes: F05D 2300/2102 Glass
• CPC Class Codes: F05D 2300/222 Silicon
• CPC Class Codes: F05D 2300/2283 of silicon
• CPC Class Codes: Y02T 50/60 Efficient propulsion technologies, e.g. for aircraft

Abstract

Engine structures and methods of forming the engine structures are provided herein. In an embodiment, an engine structure includes a silicon-based ceramic-containing substrate having an in-tolerance surface and one or more barrier layers disposed on the in-tolerance surface of the ceramic-containing substrate. The ceramic-containing substrate includes a bulk zone and a gradient zone. The bulk zone includes a first bulk material. The gradient zone includes the first bulk material and a second material that is different from the first bulk material. The gradient zone has a gradient of increasing concentration of the second material from the bulk zone to the in-tolerance surface of the ceramic-containing substrate.

Claims

1. An engine structure comprising:

a silicon-based ceramic-containing substrate having an in-tolerance surface, wherein the ceramic-containing substrate comprises;

a bulk zone including a first bulk material; and

a gradient zone including the first bulk material and a second material different from the first bulk material, wherein the gradient zone has a gradient of increasing concentration of the second material from the bulk zone to the in-tolerance surface of the ceramic-containing substrate; and

one or more barrier layers disposed on the in-tolerance surface of the ceramic-containing substrate.

2. The engine structure of claim 1, wherein the ceramic-containing substrate comprises fused particles with atoms in the fused particles diffused across boundaries of the particles.

3. The engine structure of claim 2, wherein in-tolerance surface of the ceramic-containing substrate is a machined surface.

4. The engine structure of claim 3, wherein the machined surface of the ceramic-containing substrate comprises the fused particles.

5. The engine structure of claim 2, wherein the ceramic-containing substrate further comprises a glass encapsulation formed prior to high temperature isostatic processing, and wherein the in-tolerance surface is a surface of the glass encapsulation.

6. The engine structure of claim 1, wherein the first bulk material comprises silicon nitride.

7. The engine structure of claim 1, wherein the second material is an environmental barrier coat material.

8. The engine structure of claim 7, wherein the second material is an oxide comprising at least one of a rare earth element or silicon.

9. The engine structure of claim 8, wherein the second material is chosen from Yb₂O₃, Y₂O₃, SiO₂, Y₂Si₂O₇, and/or Yb₂SiO₇.

10. The engine structure of claim 7, wherein the second material is present within fused particles of the substrate.

11. The engine structure of claim 1, wherein the one or more barrier layers comprises an environmental barrier coat layer disposed directly on the ceramic-containing substrate.

12. The engine structure of claim 11, wherein the one or more barrier layers further comprises a thermal barrier coat layer disposed over the environmental barrier coat layer.

13. The engine structure of claim 1, wherein the gradient zone is disposed from the in-tolerance surface of the substrate to at least 1 mm into the substrate from the in-tolerance surface of the substrate.

14. The engine structure of claim 1, wherein the engine structure is free from a bond layer between the substrate and a barrier layer disposed directly thereon.

15. A turbine engine including the engine structure of claim 1.

16. An engine structure comprising:

a silicon-based ceramic-containing substrate, wherein the ceramic-containing substrate comprises;

a bulk zone including a first bulk material; and

a gradient zone including the first bulk material and a second material different from the first bulk material, wherein the gradient zone has a gradient of increasing concentration of the second material from the bulk zone to the in-tolerance surface of the ceramic-containing substrate; and

one or more barrier layers disposed on the surface of the ceramic-containing substrate;

wherein the engine structure is free from a bond layer between the ceramic-containing substrate and a barrier layer disposed directly thereon.

17. A method of forming an engine structure, wherein the method comprises:

sintering silicon-based ceramic particles to form an intermediate structure comprising fused particles with atoms in the fused particles diffused across boundaries of the particles;

machining the intermediate structure to form a silicon-based ceramic-containing substrate having a machined surface, wherein the silicon-based ceramic-containing substrate comprises;

a bulk zone including a first bulk material; and

a gradient zone including the first bulk material and a second material different from the first bulk material, wherein the gradient zone has a gradient of increasing concentration of the second material from the bulk zone to the in-tolerance surface of the ceramic-containing substrate; and

forming one or more barrier layers on the machined surface of the substrate.

18. The method of claim 17, wherein sintering further comprises forming a glass encapsulation over the silicon-based ceramic particles and high temperature isostatic processing after forming the glass encapsulation to form the intermediate structure.

19. The method of claim 18, wherein machining the intermediate structure comprises machining the glass encapsulation, and wherein the machined surface is a surface of the glass encapsulation.

20. The method of claim 17, wherein machining the intermediate structure comprises machining the fused particles of the intermediate structure.