# US 10,871,078 B2 · Low porosity abradable coating

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- Number: US 10,871,078 B2
- Document ID: US10871078B2
- Status: Granted
- Kind: B2
- Application number: 16/135,036
- Filed: 2018-09-19
- Published: 2019-03-28
- Granted: 2020-12-22
- Earliest claimed: 2017-09-27
- Assignees: ROLLS-ROYCE plc
- Applicants: Rolls-Royce Corporation; Rolls-Royce plc
- Inventors: Ngunjoh Lawrence Ndamka; Li Li; Stephanie Gong; Sunny Chang; Ann Bolcavage; Taylor K. Blair
- Web page: https://patentgrep.com/patent/US10871078B2

## CPC

- F01D 11/122: {with erodable or abradable material (blades having cutting or grinding tips F01D5/20)}
- C04B 41/009: {characterised by the material treated}
- C04B 41/5024: {Silicates (C04B41/5022 takes precedence; silico-fluorides C04B41/5018)}
- C04B 41/52: Multiple coating or impregnating {multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation}
- C04B 41/85: with inorganic materials
- C04B 41/89: for obtaining at least two superposed coatings having different compositions
- C23C 28/042: {including a refractory ceramic layer, e.g. refractory metal oxides, ZrO2, rare earth oxides}
- C23C 28/044: {coatings specially adapted for cutting tools or wear applications}
- F05D 2230/31: Layer deposition
- F05D 2230/90: Coating; Surface treatment
- F05D 2240/55: Seals
- F05D 2300/15: Rare earth metals, i.e. Sc, Y, lanthanides
- F05D 2300/175: Superalloys
- F05D 2300/2112: Aluminium oxides
- F05D 2300/226: Carbides
- F05D 2300/228: Nitrides
- F05D 2300/30: Inorganic materials other than provided for in groups F05D2300/10 - F05D2300/2291
- F05D 2300/611: Coating
- Y02T 50/60: Efficient propulsion technologies, e.g. for aircraft
- F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D)
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- 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 (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04)
- F05D: INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

An article for use in a high-temperature environment that includes a substrate including a superalloy material, a ceramic, or a ceramic matrix composite, and an abradable coating on the substrate, the abradable coating including a rare earth silicate and a dislocator phase, the dislocator phase forms one or more distinct phase regions in the abradable coating and comprises at least one of hafnium diboride (HfB2), zirconium diboride (ZrB2), tantalum nitride (TaN or Ta2N), tantalum carbide (Ta2C), titanium diboride (TiB2), zirconium carbide (ZrC), hafnium carbide (HfC), tantalum diboride (TaB2), hafnium nitride (HfN), or niobium carbide (NbC).

## Claims

### Claim 1

An article for use in a high-temperature environment comprising:
a substrate comprising a superalloy material, a ceramic, or a ceramic matrix composite; and
an abradable coating on the substrate, the abradable coating comprising a rare earth silicate and a dislocator phase, wherein the dislocator phase forms one or more distinct phase regions in the abradable coating and comprises at least one of hafnium diboride (HfB2), zirconium diboride (ZrB2), tantalum nitride (TaN or Ta2N), tantalum carbide (Ta2C), titanium diboride (TiB2), zirconium carbide (ZrC), hafnium carbide (HfC), tantalum diboride (TaB2), hafnium nitride (HfN), or niobium carbide (NbC), and wherein the abradable coating comprises between about 5 percent by weight (wt. %) and about 20 wt. % of the dislocator phase.

### Claim 2 (depends on 1)

The article of claim 1, wherein the dislocator phase reduces the internal mechanical strength of the abradable coating.

### Claim 3 (depends on 2)

The article of claim 2, wherein the abradable coating further comprises at least one additive selected from the group consisting of calcium oxide (CaO), barium oxide (BaO), magnesium oxide (MgO), titanium dioxide (TiO2), alumina (Al2O3), silicon dioxide (SiO2), tantalum pentoxide (Ta2O5), hafnium silicate (HfSiO4), an alkali oxide, and an alkali earth oxide.

### Claim 4 (depends on 1)

The article of claim 1, wherein the dislocator phase has a lower coefficient of friction than the rare earth silicate.

### Claim 5 (depends on 1)

The article of claim 1, wherein the abradable coating defines a porosity of less than 20 percent by volume (vol. %).

### Claim 6 (depends on 1)

The article of claim 1, wherein the rare earth silicate comprises at least one of ytterbium monosilicate or ytterbium disilicate.

### Claim 7 (depends on 1)

The article of claim 1, further comprising:
a bond coat on the substrate; and
an environmental barrier coating (EBC) or a thermal barrier coating (TBC) between the bond coat and the abradable coating.

### Claim 8 (depends on 7)

The article of claim 7, wherein the article comprises the EBC, wherein the EBC comprises:
a base layer on the bond coat, the base layer comprising a first rare earth silicate; and
a barrier coating on the base layer, the barrier coating comprising a first layer and a second layer on the first layer, the first layer comprising barium-strontium-aluminosilicate, the second layer comprising a second rare earth silicate.

### Claim 9 (depends on 8)

The article of claim 8, wherein the second layer further comprises at least one dopant selected from the group consisting of alumina, an alkali oxide, an alkaline earth oxide, and combinations thereof.

### Claim 10 (depends on 7)

The article of claim 7, wherein the article comprises the EBC, wherein the EBC comprises:
a base layer on the bond coat, the base layer comprising a first rare earth silicate; and
a barrier coating on the bond coat, the barrier coating comprising a second rare earth silicate and at least one of TiSi2 or MoSi2.

### Claim 11 (depends on 7)

The article of claim 7, wherein the EBC or the TBC comprises a calcium-magnesium-alumino-silicate (CMAS) resistant layer, wherein the CMAS-resistant layer comprises a rare earth silicate and at least one additive selected from the group consisting of calcium oxide (CaO), barium oxide (BaO), magnesium oxide (MgO), titanium dioxide (TiO2), alumina (Al2O3), silicon dioxide (SiO2), tantalum pentoxide (Ta2O5), hafnium silicate (HfSiO4), an alkali oxide, an alkali earth oxide, and combinations thereof.

### Claim 12

A method comprising:
depositing a bond coat on a substrate, wherein the substrate comprises a superalloy material, a ceramic, or a ceramic matrix composite;
depositing an environmental barrier coating (EBC) or a thermal barrier coating (TBC) on the bond coat;
depositing an abradable coating on the EBC or the TBC wherein the abradable coating comprises a rare earth silicate and a dislocator phase, wherein the dislocator phase forms one or more distinct phase regions in the abradable coating and comprises at least one of hafnium diboride (HfB2), zirconium diboride (ZrB2), tantalum nitride (TaN or Ta2N), tantalum carbide (Ta2C), titanium diboride (TiB2), zirconium carbide (ZrC), hafnium carbide (HfC), tantalum diboride (TaB2), hafnium nitride (HfN), or niobium carbide (NbC) wherein depositing the EBC or the TBC comprises:
depositing a base layer on the bond coat, the base layer comprising a first rare earth silicate; and
depositing a barrier coating on the base layer, wherein depositing the barrier coating on the base layer comprises at least one of:
depositing a first layer comprising barium-strontium-aluminosilicate and a second layer comprising a second rare earth silicate, or
depositing a layer comprising a second rare earth silicate and at least one of TiSi2 or MoSi2.

### Claim 13 (depends on 12)

The method of claim 12, wherein the dislocator phase reduces the internal mechanical strength of the abradable coating.

### Claim 14 (depends on 13)

The method of claim 13, wherein the abradable coating further comprises at least one additive selected from the group consisting of calcium oxide (CaO), barium oxide (BaO), magnesium oxide (MgO), titanium dioxide (TiO2), alumina (Al2O3), silicon dioxide (SiO2), tantalum pentoxide (Ta2O5), hafnium silicate (HfSiO4), an alkali oxide, and an alkali earth oxide.

### Claim 15 (depends on 12)

The method of claim 12, wherein depositing the abradable coating on the EBC or the TBC comprises depositing a mixture of particles using suspension thermal spraying or thermal spraying, wherein the mixture of particles comprises a first plurality of particles comprising the rare earth silicate, and a second plurality of particles comprising the dislocator phase.

### Claim 16 (depends on 15)

The method of claim 15, wherein the mixture of particles further comprises the rare earth silicate and the at least one additive.

### Claim 17 (depends on 12)

The method of claim 12, wherein the abradable coating defines a porosity of less than 20 percent by volume (vol. %).

### Claim 18

An article for use in a high-temperature environment, the article comprising:
a substrate comprising a superalloy material, a ceramic, or a ceramic matrix composite; and
an abradable coating on the substrate, the abradable coating comprising a rare earth silicate and a dislocator phase, wherein the dislocator phase forms one or more distinct phase regions in the abradable coating and comprises at least one of hafnium diboride (HfB2), zirconium diboride (ZrB2), tantalum nitride (TaN or Ta2N), tantalum carbide (Ta2C), titanium diboride (TiB2), zirconium carbide (ZrC), hafnium carbide (HfC), tantalum diboride (TaB2), hafnium nitride (HfN), or niobium carbide (NbC), and wherein the abradable coating defines a porosity of less than 20 percent by volume (vol. %).

### Claim 19 (depends on 18)

The article of claim 18, wherein the abradable coating further comprises at least one additive selected from the group consisting of calcium oxide (CaO), barium oxide (BaO), magnesium oxide (MgO), titanium dioxide (TiO2), alumina (Al2O3), silicon dioxide (SiO2), tantalum pentoxide (Ta2O5), hafnium silicate (HfSiO4), an alkali oxide, and an alkali earth oxide.

### Claim 20 (depends on 1)

The article of claim 1, wherein the rare earth silicate comprises at least one of ytterbium monosilicate or ytterbium disilicate.