Methods for applying a hybrid thermal barrier coating

• US 7,422,771 B2
• Filed: 09/01/2005
• Issued: 09/09/2008
• Est. Priority Date: 09/01/2005
• Status: Active Grant

• Current Assignee: Rtx Corporation
• Original Assignee: United Technologies Corporation (Rtx Corporation)
• Inventors: Pietraszkiewicz, Edward F., Schlichting, Kevin W., Litton, David A., Terry, Heather A.
• Primary Examiner(s): CHEN, BRET P
• Application Number:
  US11/219,157
• Publication Number:
  US 20070048534A1
• Time in Patent Office: 1,104 Days
• Field of Search: 427/282, 427/287, 427/596, 427/255.32, 427/255.7
• US Class Current: 427/255.7
• CPC Class Codes: C23C 14/042 using masks
• 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 28/322 only coatings of metal elements only
• 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: F01D 5/288 Protective coatings for blades
• CPC Class Codes: F05D 2230/312 by plasma spraying
• CPC Class Codes: F05D 2230/313 by physical vapour deposition
• CPC Class Codes: F05D 2230/314 by chemical vapour deposition
• CPC Class Codes: Y02T 50/60 Efficient propulsion technologies, e.g. for aircraft

Abstract

A method for applying a hybrid thermal barrier coating, comprising masking at least a portion of a first surface of a component with a first maskant; applying a first coating material to at least a portion of a second surface of said component; removing said first maskant; optionally masking at least a portion of said second surface of said component with a second maskant; applying a second coating material to at least a portion of said first surface of said component; and removing said second maskant.

Claims

1. A method for applying a hybrid thermal barrier coating, comprising:

applying a metallic sheet having one or more protrusions to at least a portion of a first surface of a component; and

inserting said one or more protrusion into one or more apertures along an edge on said first surface;

applying a first coating material having a first thermal conductivity value to at least a portion of a second surface of said component;

removing said metallic sheet; and

applying a second coating material having a second thermal conductivity value to at least a portion of said first surface of said component,

wherein said first thermal conductivity value is greater or less than said second thermal conductivity value.

2. The method of claim 1, wherein applying said first coating material and said second coating material comprises using a physical vapor deposition process.

3. The method of claim 2, wherein applying said first coating material and said second coating material comprises using an electron beam physical vapor deposition process.

4. The method of claim 1, wherein said second coating material comprises a thermal barrier coating having a thermal conductivity value of about 1 btu in/hr ft² °

F. (0.145 W/mK) to 10 btu in/hr ft² °

F. (1.45 W/mK).

5. The method of claim 1, wherein said first coating material comprises a thermal barrier coating having a thermal conductivity value of about 5 btu in/hr ft² °

F. (0.72 W/mK) to 17 btu in/hr ft² °

F. (2.45 W/mK).

6. The method of claim 1, wherein said first thermal conductivity value is greater than a second thermal conductivity value.

7. The method of claim 1, wherein said second thermal conductivity value is greater than a first thermal conductivity value.

8. The method of claim 1, wherein said second coating material overlaps at least a portion of said first coating material.

9. The method of claim 1, further comprising applying a bond coat to said second surface of said component prior to applying said first coating material.

10. The method of claim 1, further comprising applying a bond coat to said first surface of said component prior to applying said second coating material.

11. The method of claim 1, wherein said component is a vane or a blade, said first surface is a pressure side and said second surface comprises a suction side and a platform.

12. The method of claim 1, further comprising optionally masking at least a portion of said second surface of said component with a second maskant prior to applying said second coating material;

and removing said optional second maskant after applying said second coating material.

13. The method of claim 12, wherein optionally masking at least said portion of said second surface comprises applying a mask having a shape substantially conforming to a negative of said second surface of said component and permitting exposure of said first surface.

14. The method of claim 13, wherein said mask comprises any one of the following materials:

aluminum sheet, aluminum tape, nickel alloy sheet and combinations thereof.

15. The method of claim 1, wherein said component comprises any one of the following materials:

nickel based superalloy, cobalt based superalloy, ferrous based superalloy, titanium alloy, copper alloy and combinations thereof.

16. The method of claim 1, wherein said metallic sheet comprises any one of the following materials:

aluminum sheet, aluminum tape, aluminum foil, nickel alloy sheet and combinations thereof.

17. The method of claim 1, wherein said second coating material tapers together with at least a portion of said first coating material.

18. The method of claim 1, wherein said second thermal barrier coating material overlaps at least a portion of said first thermal barrier coating material.

19. The method of claim 1, further comprising forming a coating transition zone comprising said first coating material and said second coating material on at least a portion of said first surface or at least a portion of said second surface or both of said component.