WO1996031687A1 - Procede et composite pour proteger un revetement servant d'isolant thermique au moyen d'une couche d'isolation impermeable - Google Patents
Procede et composite pour proteger un revetement servant d'isolant thermique au moyen d'une couche d'isolation impermeable Download PDFInfo
- Publication number
- WO1996031687A1 WO1996031687A1 PCT/US1996/003685 US9603685W WO9631687A1 WO 1996031687 A1 WO1996031687 A1 WO 1996031687A1 US 9603685 W US9603685 W US 9603685W WO 9631687 A1 WO9631687 A1 WO 9631687A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- oxide
- barrier coating
- group
- coating
- mixtures
- Prior art date
Links
- 239000012720 thermal barrier coating Substances 0.000 title claims abstract description 98
- 238000000576 coating method Methods 0.000 title claims abstract description 85
- 239000011248 coating agent Substances 0.000 title claims abstract description 72
- 230000004888 barrier function Effects 0.000 title claims abstract description 69
- 238000000034 method Methods 0.000 title claims abstract description 21
- 239000002131 composite material Substances 0.000 title claims abstract description 15
- 239000000203 mixture Substances 0.000 claims abstract description 86
- 239000000356 contaminant Substances 0.000 claims abstract description 55
- 230000007613 environmental effect Effects 0.000 claims abstract description 23
- 229910052751 metal Inorganic materials 0.000 claims description 31
- 239000002184 metal Substances 0.000 claims description 31
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 claims description 22
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 claims description 20
- DJOYTAUERRJRAT-UHFFFAOYSA-N 2-(n-methyl-4-nitroanilino)acetonitrile Chemical compound N#CCN(C)C1=CC=C([N+]([O-])=O)C=C1 DJOYTAUERRJRAT-UHFFFAOYSA-N 0.000 claims description 15
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 15
- 206010010144 Completed suicide Diseases 0.000 claims description 14
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 13
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims description 13
- 229910052710 silicon Inorganic materials 0.000 claims description 13
- 239000010703 silicon Substances 0.000 claims description 13
- GSWGDDYIUCWADU-UHFFFAOYSA-N aluminum magnesium oxygen(2-) Chemical compound [O--].[Mg++].[Al+3] GSWGDDYIUCWADU-UHFFFAOYSA-N 0.000 claims description 12
- 229910052814 silicon oxide Inorganic materials 0.000 claims description 12
- 229910052709 silver Inorganic materials 0.000 claims description 12
- 239000004332 silver Substances 0.000 claims description 12
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 11
- 229910052763 palladium Inorganic materials 0.000 claims description 11
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 10
- 150000004767 nitrides Chemical class 0.000 claims description 10
- BPUBBGLMJRNUCC-UHFFFAOYSA-N oxygen(2-);tantalum(5+) Chemical compound [O-2].[O-2].[O-2].[O-2].[O-2].[Ta+5].[Ta+5] BPUBBGLMJRNUCC-UHFFFAOYSA-N 0.000 claims description 10
- 229910052697 platinum Inorganic materials 0.000 claims description 10
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 10
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 10
- 229910001936 tantalum oxide Inorganic materials 0.000 claims description 10
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 claims description 9
- 229910044991 metal oxide Inorganic materials 0.000 claims description 9
- 150000004706 metal oxides Chemical class 0.000 claims description 9
- 229910000510 noble metal Inorganic materials 0.000 claims description 9
- 229910002076 stabilized zirconia Inorganic materials 0.000 claims description 9
- 239000007788 liquid Substances 0.000 claims description 8
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 7
- 239000000758 substrate Substances 0.000 claims description 7
- 229910045601 alloy Inorganic materials 0.000 claims description 6
- 239000000956 alloy Substances 0.000 claims description 6
- 230000015556 catabolic process Effects 0.000 claims description 6
- 238000006731 degradation reaction Methods 0.000 claims description 6
- 229910052742 iron Inorganic materials 0.000 claims description 6
- 229910001233 yttria-stabilized zirconia Inorganic materials 0.000 claims description 6
- 229910052582 BN Inorganic materials 0.000 claims description 5
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 claims description 5
- KJTLSVCANCCWHF-UHFFFAOYSA-N Ruthenium Chemical compound [Ru] KJTLSVCANCCWHF-UHFFFAOYSA-N 0.000 claims description 5
- 229910052581 Si3N4 Inorganic materials 0.000 claims description 5
- 229910002084 calcia-stabilized zirconia Inorganic materials 0.000 claims description 5
- -1 calcium- magnesium-aluminum-silicon oxide Chemical group 0.000 claims description 5
- 238000000151 deposition Methods 0.000 claims description 5
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 claims description 5
- 229910052737 gold Inorganic materials 0.000 claims description 5
- 239000010931 gold Substances 0.000 claims description 5
- 229910000449 hafnium oxide Inorganic materials 0.000 claims description 5
- WIHZLLGSGQNAGK-UHFFFAOYSA-N hafnium(4+);oxygen(2-) Chemical compound [O-2].[O-2].[Hf+4] WIHZLLGSGQNAGK-UHFFFAOYSA-N 0.000 claims description 5
- 229910052741 iridium Inorganic materials 0.000 claims description 5
- GKOZUEZYRPOHIO-UHFFFAOYSA-N iridium atom Chemical compound [Ir] GKOZUEZYRPOHIO-UHFFFAOYSA-N 0.000 claims description 5
- 229910002085 magnesia-stabilized zirconia Inorganic materials 0.000 claims description 5
- 239000000395 magnesium oxide Substances 0.000 claims description 5
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 5
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims description 5
- NFFIWVVINABMKP-UHFFFAOYSA-N methylidynetantalum Chemical compound [Ta]#C NFFIWVVINABMKP-UHFFFAOYSA-N 0.000 claims description 5
- 229910052759 nickel Inorganic materials 0.000 claims description 5
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 claims description 5
- 229910052703 rhodium Inorganic materials 0.000 claims description 5
- 239000010948 rhodium Substances 0.000 claims description 5
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 claims description 5
- 229910052707 ruthenium Inorganic materials 0.000 claims description 5
- HYXGAEYDKFCVMU-UHFFFAOYSA-N scandium oxide Chemical compound O=[Sc]O[Sc]=O HYXGAEYDKFCVMU-UHFFFAOYSA-N 0.000 claims description 5
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 claims description 5
- 229910003468 tantalcarbide Inorganic materials 0.000 claims description 5
- 229910052715 tantalum Inorganic materials 0.000 claims description 5
- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum atom Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 claims description 5
- MZLGASXMSKOWSE-UHFFFAOYSA-N tantalum nitride Chemical compound [Ta]#N MZLGASXMSKOWSE-UHFFFAOYSA-N 0.000 claims description 5
- MTPVUVINMAGMJL-UHFFFAOYSA-N trimethyl(1,1,2,2,2-pentafluoroethyl)silane Chemical compound C[Si](C)(C)C(F)(F)C(F)(F)F MTPVUVINMAGMJL-UHFFFAOYSA-N 0.000 claims description 5
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 claims description 5
- ZVWKZXLXHLZXLS-UHFFFAOYSA-N zirconium nitride Chemical compound [Zr]#N ZVWKZXLXHLZXLS-UHFFFAOYSA-N 0.000 claims description 5
- 229910001928 zirconium oxide Inorganic materials 0.000 claims description 5
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 4
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 claims description 4
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 4
- ODINCKMPIJJUCX-UHFFFAOYSA-N calcium oxide Inorganic materials [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 claims description 4
- 229910052804 chromium Inorganic materials 0.000 claims description 4
- 239000011651 chromium Substances 0.000 claims description 4
- 229910052719 titanium Inorganic materials 0.000 claims description 4
- 239000010936 titanium Substances 0.000 claims description 4
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 claims description 3
- 239000000292 calcium oxide Substances 0.000 claims description 3
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 claims description 2
- 229910052750 molybdenum Inorganic materials 0.000 claims description 2
- 239000011733 molybdenum Substances 0.000 claims description 2
- 229910021332 silicide Inorganic materials 0.000 claims 9
- FVBUAEGBCNSCDD-UHFFFAOYSA-N silicide(4-) Chemical compound [Si-4] FVBUAEGBCNSCDD-UHFFFAOYSA-N 0.000 claims 9
- WEAMLHXSIBDPGN-UHFFFAOYSA-N (4-hydroxy-3-methylphenyl) thiocyanate Chemical compound CC1=CC(SC#N)=CC=C1O WEAMLHXSIBDPGN-UHFFFAOYSA-N 0.000 claims 4
- WQJQOUPTWCFRMM-UHFFFAOYSA-N tungsten disilicide Chemical compound [Si]#[W]#[Si] WQJQOUPTWCFRMM-UHFFFAOYSA-N 0.000 claims 4
- 229910021342 tungsten silicide Inorganic materials 0.000 claims 4
- 229910021355 zirconium silicide Inorganic materials 0.000 claims 4
- YXTPWUNVHCYOSP-UHFFFAOYSA-N bis($l^{2}-silanylidene)molybdenum Chemical compound [Si]=[Mo]=[Si] YXTPWUNVHCYOSP-UHFFFAOYSA-N 0.000 claims 3
- 229910021357 chromium silicide Inorganic materials 0.000 claims 3
- 229910021344 molybdenum silicide Inorganic materials 0.000 claims 3
- 229910021341 titanium silicide Inorganic materials 0.000 claims 3
- 229910000531 Co alloy Inorganic materials 0.000 claims 2
- 238000004519 manufacturing process Methods 0.000 claims 1
- 229910000480 nickel oxide Inorganic materials 0.000 claims 1
- GNRSAWUEBMWBQH-UHFFFAOYSA-N oxonickel Chemical compound [Ni]=O GNRSAWUEBMWBQH-UHFFFAOYSA-N 0.000 claims 1
- RUDFQVOCFDJEEF-UHFFFAOYSA-N yttrium(III) oxide Inorganic materials [O-2].[O-2].[O-2].[Y+3].[Y+3] RUDFQVOCFDJEEF-UHFFFAOYSA-N 0.000 claims 1
- 230000002939 deleterious effect Effects 0.000 abstract 1
- 238000001764 infiltration Methods 0.000 description 12
- 230000008595 infiltration Effects 0.000 description 11
- 239000003570 air Substances 0.000 description 9
- 239000000126 substance Substances 0.000 description 6
- 230000008018 melting Effects 0.000 description 5
- 238000002844 melting Methods 0.000 description 5
- SWELZOZIOHGSPA-UHFFFAOYSA-N palladium silver Chemical compound [Pd].[Ag] SWELZOZIOHGSPA-UHFFFAOYSA-N 0.000 description 5
- 239000011253 protective coating Substances 0.000 description 5
- 239000007921 spray Substances 0.000 description 5
- 238000006243 chemical reaction Methods 0.000 description 4
- 238000012360 testing method Methods 0.000 description 4
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 3
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 3
- 229910052782 aluminium Inorganic materials 0.000 description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 3
- 238000004458 analytical method Methods 0.000 description 3
- 229910052791 calcium Inorganic materials 0.000 description 3
- 239000011575 calcium Substances 0.000 description 3
- 238000005229 chemical vapour deposition Methods 0.000 description 3
- 238000001816 cooling Methods 0.000 description 3
- 230000032798 delamination Effects 0.000 description 3
- 239000011777 magnesium Substances 0.000 description 3
- 229910052749 magnesium Inorganic materials 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 238000005088 metallography Methods 0.000 description 3
- 230000003647 oxidation Effects 0.000 description 3
- 238000007254 oxidation reaction Methods 0.000 description 3
- 230000000717 retained effect Effects 0.000 description 3
- 239000000919 ceramic Substances 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 238000005336 cracking Methods 0.000 description 2
- 230000001351 cycling effect Effects 0.000 description 2
- 239000000446 fuel Substances 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 239000012535 impurity Substances 0.000 description 2
- 239000010410 layer Substances 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 229910052596 spinel Inorganic materials 0.000 description 2
- 239000011029 spinel Substances 0.000 description 2
- 238000004544 sputter deposition Methods 0.000 description 2
- 229910001316 Ag alloy Inorganic materials 0.000 description 1
- 229910019142 PO4 Inorganic materials 0.000 description 1
- 241000968352 Scandia <hydrozoan> Species 0.000 description 1
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 1
- 229910052783 alkali metal Inorganic materials 0.000 description 1
- 150000001340 alkali metals Chemical class 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 239000002956 ash Substances 0.000 description 1
- 229910052788 barium Inorganic materials 0.000 description 1
- DSAJWYNOEDNPEQ-UHFFFAOYSA-N barium atom Chemical compound [Ba] DSAJWYNOEDNPEQ-UHFFFAOYSA-N 0.000 description 1
- 238000000339 bright-field microscopy Methods 0.000 description 1
- 150000004649 carbonic acid derivatives Chemical class 0.000 description 1
- 239000004568 cement Substances 0.000 description 1
- 238000005524 ceramic coating Methods 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 239000008199 coating composition Substances 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 238000001446 dark-field microscopy Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000000280 densification Methods 0.000 description 1
- 230000008021 deposition Effects 0.000 description 1
- 238000004455 differential thermal analysis Methods 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 238000004090 dissolution Methods 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000002003 electrode paste Substances 0.000 description 1
- 238000004453 electron probe microanalysis Methods 0.000 description 1
- 230000003628 erosive effect Effects 0.000 description 1
- 239000000374 eutectic mixture Substances 0.000 description 1
- 238000004299 exfoliation Methods 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 239000010408 film Substances 0.000 description 1
- 239000010881 fly ash Substances 0.000 description 1
- 230000000977 initiatory effect Effects 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 150000001247 metal acetylides Chemical class 0.000 description 1
- 238000002488 metal-organic chemical vapour deposition Methods 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- HJGMWXTVGKLUAQ-UHFFFAOYSA-N oxygen(2-);scandium(3+) Chemical compound [O-2].[O-2].[O-2].[Sc+3].[Sc+3] HJGMWXTVGKLUAQ-UHFFFAOYSA-N 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 235000021317 phosphate Nutrition 0.000 description 1
- 150000003013 phosphoric acid derivatives Chemical class 0.000 description 1
- 238000005240 physical vapour deposition Methods 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 230000001902 propagating effect Effects 0.000 description 1
- 239000011241 protective layer Substances 0.000 description 1
- 230000002829 reductive effect Effects 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 238000007650 screen-printing Methods 0.000 description 1
- 229910052566 spinel group Inorganic materials 0.000 description 1
- 238000009718 spray deposition Methods 0.000 description 1
- 229910000601 superalloy Inorganic materials 0.000 description 1
- 230000008961 swelling Effects 0.000 description 1
- 238000005382 thermal cycling Methods 0.000 description 1
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
- 239000010937 tungsten Substances 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/04—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material
- C23C28/042—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material including a refractory ceramic layer, e.g. refractory metal oxides, ZrO2, rare earth oxides
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/04—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material
- C23C28/044—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material coatings specially adapted for cutting tools or wear applications
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T50/00—Aeronautics or air transport
- Y02T50/60—Efficient propulsion technologies, e.g. for aircraft
Definitions
- This invention relates to a method and composite for protecting thermal barrier coatings at operating temperatures from degradation caused by environmental contaminants. More specifically, the invention relates to the method and composite using an impermeable coating on a thermal barrier coating, where the impermeable coating reduces infiltration of liquid contaminant compositions into the thermal barrier coatings.
- Thermal barrier coatings are deposited onto gas turbine and other heat engine parts to reduce heat flow and to limit the operating temperature of metal parts. These coatings generally are a ceramic material, such as chemically stabilized zirconia. Yttria-stabilized zirconia, scandia-stabilized zirconia, calcia-stabilized zirconia, and magnesia- stabilized zirconia are contemplated as thermal barrier coatings.
- the thermal barrier coating of choice is a yttria-stabilized zirconia ceramic coating.
- a typical thermal barrier coating comprises about 8 weight percent yttria-92 weight percent zirconia.
- thermal barrier coating depends on the application, but generally ranges between about 5-60 mils thick for high temperature engine parts.
- Metal parts provided with thermal barrier coatings can be made from nickel, cobalt, and iron based superalloys. The process is especially suited for parts and hardware used in turbines . Examples of turbine parts would be turbine blades, buckets, nozzles, combustion liners, and the like.
- Thermal barrier coatings are a key element in current and future gas turbine engine designs expected to operate at high temperatures which produce high thermal barrier coating surface temperatures.
- the ideal system for a hot high temperature engine part consists of a strain-tolerant thermal barrier ceramic layer deposited onto a bond coat which exhibits good corrosion resistance and closely matched thermal expansion coefficients.
- thermal barrier coated engine parts can be susceptible to various modes of damage, including erosion, oxidation, and attack from environmental contaminants. At temperatures of engine operation adherence of these environmental contaminants on the hot thermal barrier coated surface can lead to damage to the thermal barrier coating. Environmental contaminants form compositions, which are liquid at the surface temperatures of thermal barrier coatings.
- Molten contaminant compositions can dissolve the thermal barrier coating or can infiltrate its pores and openings, initiating and propagating cracks causing delamination and loss of thermal barrier coating material.
- CMAS calcium- magnesium-aluminum-silicon-oxide systems
- thermal barrier coatings caused by the reaction or infiltration of molten contaminant compositions at the operating temperature of the engine. This can be accomplished by covering the thermal barrier coating with an impermeable barrier that prevents liquid contaminant compositions when they form on the hot surfaces of thermal barrier coated parts from reacting or flowing into the thermal barrier coating.
- the present invention satisfies this need by protecting a thermal barrier coating from degradation by environmental contaminant compositions which form on and adhere to a surface of a thermal barrier coated part.
- the method of the invention comprises depositing an impermeable coating on the surface of thermal barrier coating, in an effective amount, so that the impermeable coating inhibits liquid contaminant compositions formed from the environmental contaminants from infiltrating into or reacting with the thermal barrier coating at the operating temperature of said thermal barrier coating.
- the impermeable barrier is a dense, non-cracked, non- porous layer comprising oxides, non-oxides, or metallic coatings in conjunction with thermal barrier coatings.
- the present invention also satisfies this need by providing a composite comprising a thermal barrier coating on a part with a continuous impermeable barrier coating on the outer surface of the thermal barrier coating.
- the invention also includes a protected thermal barrier coated part comprising a part with a thermal barrier coating on said part and a single protective layer of an impermeable barrier coating on an outer surface of said thermal barrier coating.
- the composite thermal barrier coating according to the present invention also comprises a substrate with a thermal barrier coating, an impermeable barrier coating, and when needed a bond coat between the substrate and the thermal barrier coating.
- Environmental contaminants are materials that exist in the environment and are ingested into engines, from air and fuel sources, and impurities and oxidation products of engine components, such as iron oxide.
- operating temperature means the surface temperature of the thermal barrier coating during its operation in a given application, such as a gas turbine engine. Such temperatures are above room temperature, and generally are above 500"C. High temperature operation of thermal barrier coating parts is usually above about lOOO'C. DESCRIPTION OF THE INVENTION It has been discovered that the degradation of thermal barrier coatings by environmental contaminants that form molten contaminant compositions can be prevented by depositing impermeable barrier coatings that are dense and non-cracked on surfaces of thermal barrier coatings. An impermeable barrier coating inhibits the degradation of the thermal barrier coating when in contact with the molten contaminant composition at operating temperatures of the thermal barrier coating.
- thermal barrier coating Infiltration or viscous flow of the contaminant composition into thermal barrier coating cracks, openings, and pores is prevented.
- This invention also protects the thermal barrier coating from dissolution or spallation due to chemical and mechanical attack by the contaminant composition.
- the liquid contaminant composition is unable to penetrate the impermeable coating, and therefore can not attack the thermal barrier coating.
- the barrier coating enhances the life of the thermal barrier coated part and thus, reduces thermal barrier coated part failure.
- Sources of environmental contaminants include, but are not limited to, sand, dirt, volcanic ash, fly ash, cement, runway dust, substrate impurities, fuel and air sources, oxidation products from engine components, and the like.
- the environmental contaminants adhere to the surfaces of thermal barrier coated parts. At the operating temperatures of the thermal barrier coating, the environmental contaminants then form contaminant compositions on surfaces of the thermal barrier coating which may have melting ranges or temperatures at or below the operating temperature.
- the environmental contaminant may include magnesium, calcium, aluminum, silicon, chromium, iron, nickel, barium, titanium, alkali metals, and compounds thereof, to mention a few.
- the environmental contaminants may be oxides, phosphates, carbonates, salts, and mixtures thereof.
- the chemical composition of the contaminant composition corresponds to the composition of the environmental contaminants from which it is formed.
- the contaminant composition corresponds to compositions of calcium-magnesium- aluminum-silicon oxide system or CMAS.
- the environmental contaminant compositions known as CMAS comprise primarily a mixture of magnesium oxide (MgO) , calcium oxide (CaO) , aluminum oxide (A1203), and silicon oxide (Si02) .
- MgO magnesium oxide
- CaO calcium oxide
- Al oxide aluminum oxide
- Si02 silicon oxide
- Other elements, such as nickel, iron, titanium, and chromium may be present in the CMAS in minor amounts when these elements or their compounds are present in the environmental contaminants.
- a minor amount is an amount less than about ten weight percent of the total amount of contaminant composition present.
- the protective coatings of this invention can be described as impermeable or impervious in that they prevent the liquid contaminant composition from contacting the thermal barrier coating so that chemical or physical changes of the thermal barrier coating do not occur due to infiltration or reaction with the contaminant composition.
- the character of the protective coating is dense and non- penetratable. The result is that infiltration of the contaminant composition, e.g., liquid CMAS, into the thermal barrier coating at operating temperatures of engines is eliminated or decreased.
- Such an impermeable or impervious coating is a ceramic or metal outer coating, deposited on the outer surface of the thermal barrier coating.
- the impermeable coating acts as a barrier between the thermal barrier coating and the contaminant eutectic mixture; it is dense and non-porous.
- Impermeable barrier coatings can be various oxides; non-oxides such as carbides, suicides, and nitrides; and metals that form non-porous deposits.
- the metal oxide coating may be selected from the group consisting of silicon oxide, tantalum oxide, scandium oxide, aluminum oxide, hafnium oxide, zirconium oxide, calcium zirconate, and spinels, such as magnesium aluminum oxide, and mixtures thereof.
- the metal carbide coating may be selected from the group consisting of silicon carbide, tantalum carbide, titanium carbide, tungsten carbide, silicon oxycarbide, and mixtures thereof.
- the metal nitride coating may be selected from the group consisting of silicon nitride, zirconium nitride, tantalum nitride, boron nitride, and mixtures thereof.
- the metal suicide may be selected from the group consisting of chromium suicide, molybdenum suicide, tantalum suicide, titanium suicide, tungsten suicide, zirconium suicide, and mixtures thereof.
- Noble metals that are suitable for coatings can include platinum, palladium, silver, gold, ruthenium, rhodium, iridium, and alloys thereof, such as 80 weight percent palladium-20 weight percent silver.
- Impermeable barrier coatings that are especially effective are a palladium-silver alloy, in particular about 80 weight % palladium-20 weight % silver, palladium, platinum, silicon carbide, silicon oxide, tantalum oxide, calcium zirconate, magnesium aluminum oxide, silicon oxycarbide, and mixtures thereof.
- An effective amount of an impermeable barrier coating is an amount needed to inhibit the contaminant composition from penetrating an opening in the thermal barrier coating.
- the thickness of the impermeable barrier coating is determined by such considerations as: the application and design of the thermal barrier coated part, the amount and composition of the contaminant composition that is encountered during service, the operating temperature of the thermal barrier coating, and the locality and geographical limitations where the thermal barrier coated part will be used.
- the surface temperature of the thermal barrier coating during its operation needs to be considered, as well as the type and composition of the environmental contaminants that will be encountered. It is contemplated that the impermeable barrier coating will have a melting temperature above the operating temperature of the thermal barrier coating. For instance, if the surface of the thermal barrier coating is about 1200 ' C during operation, than the impermeable barrier coating needs to have a melting temperature above 1200 ' C.
- the impermeable barrier coating can be deposited on the thermal barrier coating by coating methods known in the art, such as sol-gel, sputtering, air plasma spray, organo- etallic chemical vapor deposition, physical vapor deposition, chemical vapor deposition, and the like.
- coating methods known in the art, such as sol-gel, sputtering, air plasma spray, organo- etallic chemical vapor deposition, physical vapor deposition, chemical vapor deposition, and the like.
- the choice of the coating method in part depends on where and how the thermal barrier coated part will be used and the desired thickness for such use. In selecting a method of deposition, a practitioner should look at the criticality of the thickness requirement for the coating. Both thick and thin coatings should be dense and as pore-free as possible.
- Thicknesses of the impermeable barrier coating can vary from about 0.2 micrometers to about 250 micrometers. The preferred thickness is about 2- 125 micrometers. The thickness of the impermeable coating is also in part, determined by the operating temperature of the thermal barrier coating and the amount and composition of the contaminant. If thick impermeable barrier coatings are required, i.e., about 125 micrometers or more, a compositionally graded deposit can be used to keep internal stresses minimized in order that delamination of the impermeable coating does not occur. For purposes of illustrating the use of a specific impermeable barrier coating, as well as imparting an understanding of the present invention, the reaction of CMAS composition with the impermeable coating on a thermal barrier coating is described at operating temperatures of about 1200 C or higher.
- the chemical composition of the CMAS composition was determined by electron microprobe analysis of infiltrated deposits found on thermal barrier coated engine parts where deposit-induced damage to the thermal barrier coating had been observed. Analysis indicated that 127 micron (5 mils) of CMAS-like deposits (-34 mg/cm ⁇ assuming a density of 2.7 g/c ⁇ r.3) can form on thermal barrier coating surfaces.
- the CMAS deposits evaluated were typically in the compositional range (weight %) : 5-35% CaO, 2- 35% MgO, 5-15% A1 2 0 3 , 5-55% Si0 2 , 0-5% NiO, 5-10% Fe 2°3 ' however the content of the ubiquitous Fe2 ⁇ 3 can be as large as 75 wt%.
- Impermeable barrier coatings on thermal barrier coated components were investigated to prevent the infiltration of environmentally deposited mixtures of oxides of calcium, magnesium, aluminum, and silicon (CMAS) .
- Candidate impermeable barrier coating compositions were deposited on thermal barrier coatings of 8 weight percent yttria-92 weight percent zirconia and assessed for CMAS infiltration resistance using metallography, SEM and electron microprobe chemical analysis. The above testing was conducted under laboratory furnace test conditions (isothermal) . Thermal barrier coated parts with impermeable barrier coatings were found to minimize CMAS infiltration and damage under isothermal conditions.
- Impermeable barrier coatings that were deposited by the sol-gel, air plasma spray, sputtering, and MOCVD methods were: an 80/20 weight percent palladium-silver film, palladium, platinum, silicon carbide, silicon oxide, scandia, silicon oxycarbide, tantalum oxide, calcium zirconate, and magnesium aluminum oxide.
- the effectiveness of protective coatings in preventing CMAS-infiltration-induced thermal barrier coating damage was tested by comparing the infiltration resistance of protected and non-protected thermal barrier coated substrates which were thermally cycled in the presence of surface deposits of CMAS. In these experiments, 8mg/c ⁇ r.2 of ground pre-reacted CMAS was deposited on masked areas of the thermal barrier coated substrates.
- a thermal cycle consisted of heating the samples to 1260 " c in 10 minutes, holding it at 1260 " c for 10 minutes, followed by cooling it to room temperature in 30 minutes. After each cycle the samples were inspected with the unaided eye and at 50x using a stereo microscope. This cycle was repeated several times. After completion of thermal testing, the samples were sectioned, metallographically polished, and inspected using bright field and dark field optical microscopy.
- Example 1 demonstrates the effect of CMAS on a thermal barrier coated part without an impermeable barrier coating.
- Non-protected thermal barrier coating samples tested in the above-mentioned fashion exhibit visible CMAS induced thermal barrier coating swelling and cracking (visible on sample edges under the stereomicroscope) .
- Metallographic preparation and inspection of the non-protected samples shows CMAS induced thermal barrier coating densification, cracking and exfoliation.
- EXAMPLE 2 A thick film (125 micrometers) of 80 weight percent palladium-20 weight percent silver was deposited by thick film screen printing of electrode paste on an 8 weight % yttria-stabilized 92 weight % zirconia coated coupon.
- the palladium-silver coating formed a dense, continuous film without voids after heat treatment.
- the palladium-silver coating partially melted and flowed into the top surface of the thermal barrier coating, providing good adhesion to the substrate.
- the palladium-silver film filled and bridged the thermal barrier coating microcracks.
- EXAMPLE 4 Calcium zirconate was deposited on thermal barrier coated coupons by air plasma spray.
- the air plasma spray calcium zirconate coating was 125 micrometers thick and graded to accommodate an expansion mismatch.
- Eight mg/cm 2 CMAS was deposited on the above impermeable coated samples. Heat cycling took place to 1260 ' C. Metallography showed that the CMAS was retained on top of impermeable barrier.
- EXAMPLE 5 The above air plasma spray deposition of 125 micrometers (graded) of calcium zirconate on thermal barrier coated coupons was performed. An additional 125 micrometers of calcium zirconate was then air plasma sprayed on the previous graded calcium zirconate deposit. Eight mg/cm 2 CMAS was deposited on the above impermeable coated samples. Heat cycling took place to 1260 ' C. Metallography showed that the CMAS was retained on top of impermeable barrier.
- the practice of this invention makes it possible to extend the effective life of gas turbine engine thermal barrier coatings at a specific set of operating parameters including operating temperature and operating environment. It also provides a means to provide for engine designs which impose increased thermal burdens on thermal barrier coatings such as reduced cooling of thermal barrier coated parts or exposure of such parts to higher temperature input, i.e., effective increase of operating temperatures for the engine system. Accordingly, the practice of this invention provides for substantial enhancement of the functions of currently available thermal barrier coatings under more rigorous thermal assault as demands for performance escalate.
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Abstract
L'invention décrit un procédé et un composite destinés à protéger des revêtements servant d'isolant thermique déposés sur des pièces des effets nocifs des polluants provenant de l'environnement à des températures de fonctionnement. Lesdits procédé et composite font intervenir l'utilisation, avec le revêtement servant d'isolant thermique, d'une couche d'isolation imperméable, ladite couche empêchant que les polluants provenant de l'environnement et les compositions polluantes qu'ils forment ne s'infiltrent dans des orifices des revêtements servant d'isolant thermique en cours d'utilisation à des températures de fonctionnement.
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
KR1019960706937A KR970703482A (ko) | 1994-05-16 | 1996-03-18 | 불투과성 차단 코팅층으로 열 차단 코팅층을 보호하는 방법 및 이를 위한 복합체(method and composite for protection of thermal barrier coating with an impe rmeable barrier coating) |
DE19680259T DE19680259T1 (de) | 1995-04-06 | 1996-03-18 | Verfahren und Verbundstoff zum Schutz eines Wärmesperren-Überzuges durch einen undurchlässigen Sperrüberzug |
JP53031296A JP3727948B2 (ja) | 1995-04-06 | 1996-03-18 | 不浸透性バリアコーティングによりサーマルバリアコーティングを保護するための方法および複合材 |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
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US41757895A | 1995-04-06 | 1995-04-06 | |
US41758095A | 1995-04-06 | 1995-04-06 | |
US08/417,578 | 1995-04-06 | ||
US08/417,580 | 1995-04-06 |
Publications (1)
Publication Number | Publication Date |
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WO1996031687A1 true WO1996031687A1 (fr) | 1996-10-10 |
Family
ID=27023778
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US1996/003685 WO1996031687A1 (fr) | 1994-05-16 | 1996-03-18 | Procede et composite pour proteger un revetement servant d'isolant thermique au moyen d'une couche d'isolation impermeable |
Country Status (5)
Country | Link |
---|---|
JP (1) | JP3727948B2 (fr) |
CH (1) | CH690856A5 (fr) |
DE (1) | DE19680259T1 (fr) |
IN (1) | IN187704B (fr) |
WO (1) | WO1996031687A1 (fr) |
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WO2001083851A1 (fr) * | 2000-04-27 | 2001-11-08 | Standard Aero Limited | Revetements a barriere thermique multicouche |
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Also Published As
Publication number | Publication date |
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DE19680259T1 (de) | 1997-06-19 |
IN187704B (fr) | 2002-06-08 |
JP3727948B2 (ja) | 2005-12-21 |
CH690856A5 (de) | 2001-02-15 |
JPH10502133A (ja) | 1998-02-24 |
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