Thermal barrier coating system for turbine components
First Claim
1. A thermal barrier coating system, comprising:
- a metal substrate;
a first composite ceramic-comprising thermal barrier coat over a first portion of the substrate capable of withstanding temperatures in excess of 1500°
F.;
a second ceramic-comprising thermal barrier coating over at least an edge portion of the substrate adjacent a periphery of the first composite thermal barrier coating and capable of withstand temperature in excess of 1500°
F.; and
wherein the first composite thermal barrier coating is embedded in a recessed portion of the metal substrate.
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Abstract
A composite thermal barrier coating system includes a first composite thermal barrier coating over a portion of a substrate, and a second deposited thermal barrier coating over edge portions of the substrate. The first composite coating is relatively thick and preferably includes friable graded insulation comprising an abradable honeycomb metallic structure filled with high thermal expansion ceramic hollow spheres in a phosphate bonded matrix. The second deposited edge coating is relatively thin and preferably comprises an electron beam physical vapor deposited thermal barrier coating comprising ZrO2 and Y2O3. The friable graded insulation may be manufactured to thicknesses in excess of current thermal barrier coating systems, thereby imparting greater thermal protection. Superior erosion resistance and abrasion properties are also achieved. The composite thermal barrier coating system is useful on combustion turbine components such as ring seal segments, vane segment shrouds, transitions and combustors.
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Citations
16 Claims
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1. A thermal barrier coating system, comprising:
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a metal substrate;
a first composite ceramic-comprising thermal barrier coat over a first portion of the substrate capable of withstanding temperatures in excess of 1500°
F.;
a second ceramic-comprising thermal barrier coating over at least an edge portion of the substrate adjacent a periphery of the first composite thermal barrier coating and capable of withstand temperature in excess of 1500°
F.; and
wherein the first composite thermal barrier coating is embedded in a recessed portion of the metal substrate. - View Dependent Claims (2, 3)
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4. A thermal barrier coating system, comprising:
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a metal substrate;
a first composite ceramic-comprising thermal barrier coating over a first portion of the substrate capable of withstanding temperatures in excess of 1500°
F.;
a second ceramic-comprising thermal barrier coat over at least an edge portion of the substrate adjacent a periphery of the first composite thermal barrier coating, and capable of withstanding temperatures in excess of 1500°
F.;
wherein a peripheral region of the first composite thermal barrier coating has a thickness less than the thickness of the remainder of the first composite thermal barrier coating; and
wherein the peripheral region is tapered at an angle of from about 5 to about 10 degrees measured from a plane defined by the underlying metal substrate.
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5. A method of making a composite thermal barrier coating system, comprising:
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covering a portion of a metal substrate with a first composite ceramic-comprising thermal barrier coating capable of withstanding temperatures in excess of 1500°
F.; and
depositing a second ceramic-comprising thermal barrier coating over at least an edge portion of the substrate adjacent a periphery of the first composite thermal barrier coating and capable of withstanding temperatures in excess of 1500°
F.; and
wherein the first composite thermal barrier coating is embedded in a recess in the metal substrate, and has a thickness greater than a thickness of the second deposited thermal barrier coating.
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6. A thermal barrier coating system, comprising:
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a metal substrate;
a first composite ceramic-comprising thermal barrier coating over a portion of the substrate capable of withstanding temperatures in excess of 1500°
F.;
a second ceramic-comprising thermal barrier coating over a second portion of the substrate and generally adjacent the first portion of the substrate and capable of withstanding temperatures in excess of 1500°
F.; and
wherein the first composite thermal barrier coating comprises a metal support structure including honeycomb having open cells. - View Dependent Claims (7)
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8. A thermal barrier coating system for a combustion turbine engine ring segment, the thermal barrier coating system comprising:
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a first thermal barrier coat disposed over a non-rubbing portion of the ring segment to a first thickness; and
a second thermal barrier coating disposed over an abrasion portion of the ring segment to a second thickness greater than the first thickness, the second thermal barrier coating comprising a metal support structure extending through at least a portion of the second thickness for supporting the second thickness of thermal barrier coating. - View Dependent Claims (9, 10, 11, 12, 13, 14, 15)
a recessed region formed in the ring sent for receiving the second thermal barrier coating; and
the first thermal barrier coating being disposed over a non-recessed portion of the ring segment adjacent the recessed portion.
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13. The thermal barrier coating of claim 12, wherein a depth of the recessed portion is from 10-80% of the second thickness.
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14. The thermal barrier coating of claim 12, wherein a depth of the recessed portion is from 20-50% of the second thickness.
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15. The thermal barrier coating system of claim 8, further comprising a peripheral region of the second thermal barrier coating comprising a tapered thickness.
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16. A thermal barrier coating system comprising:
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a first thermal barrier disposed over a first portion of a substrate, the first thermal barrier comprising a metal support structure bonded to a generally planar portion of the substrate and extending through at least a portion of a thickness of the first thermal barrier for supporting the first thermal barrier from the substrate; and
a second thermal barrier disposed on an edge portion of the substrate adjacent the first portion.
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Specification