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US 11,788,421 B2Granted
Slotted ceramic coatings for improved CMAS resistance and methods of forming the same
AssigneeGeneral Electric Company
InventorsCurtis Alan Johnson, Hrishikesh Keshavan, Shankar Sivaramakrishnan, Byron Andrew Pritchard, Jr., Hongqiang Chen, Bernard Patrick Bewlay
Life of this patent
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Abstract
Methods for preparing slotted ceramic coatings and the resulting components comprising the same are provided. The methods and products include the incorporation of a coating system comprising a ceramic coating with cooling holes disposed throughout the ceramic coating and slots defined in the thermal barrier coating and disposed in relation to the cooling holes. The resulting ceramic coating has improved resistance to CMAS infiltration and improved compliance resulting in an increased life of the coated component.
Claims20
A coated component for a gas turbine engine, the coated component comprising:
- a metal substrate defining an outer surface, the outer surface being a surface of the metal substrate that is facing an engine flowpath, the engine flowpath being a hot gas flow path;
- and
- a ceramic coating disposed along the outer surface of the metal substrate and exposed to the engine flowpath, the ceramic coating having a thickness, wherein the ceramic coating comprises yttria stabilized zirconia,
- wherein the ceramic coating comprises one or more cooling holes disposed in the ceramic coating and a plurality of slots disposed in the ceramic coating forming segments of ceramic coating material, each slot of the plurality of slots having a length, a width, and a depth,
- wherein each slot of the plurality of slots is arranged such that a direction defined by its depth is perpendicular to a surface of the ceramic coating,
- wherein the slots are disposed relative to the one or more cooling holes such that the slots do not pass through any of the one or more cooling holes, the slots extending through 80 percent or more of the thickness of the ceramic coating, and
- wherein each segment of ceramic coating material overlies and defines a segment of the metal substrate, each segment of the metal substrate being substantially planar.
4 more elements
A method of forming a coated component comprising:
- forming a ceramic coating along an outer surface of a metal substrate, the outer surface being a surface of the metal substrate that is facing an engine flowpath, the engine flowpath being a hot gas flow path;
- wherein the ceramic coating has a thickness and is exposed to the engine flowpath, the ceramic coating comprising one or more cooling holes disposed in the ceramic coating, and wherein the ceramic coating comprises yttria stabilized zirconia;
- and
- forming a plurality of slots along the ceramic coating relative to the one or more cooling holes such that each of the plurality of slots do not pass through any of the one or more cooling holes, the plurality of slots form segments of ceramic coating material, each of the plurality of slots extend through 80 percent or more of the thickness of the ceramic coating, and each of the plurality of slots are arranged such that a direction defined by its depth is perpendicular to a surface of the ceramic coating,
- wherein forming the plurality of slots to form segments of ceramic coating material includes forming the segments of ceramic coating material such that each segment of ceramic coating material overlies and defines a segment of the metal substrate, each segment of the metal substrate being substantially planar.
2 more elements
A coated component for a gas turbine engine, the coated component comprising:
- a metal substrate defining an outer surface, the outer surface being a surface of the metal substrate that is facing an engine flowpath, the engine flowpath being a hot gas flow path;
- and
- a ceramic coating disposed along the outer surface of the metal substrate and exposed to the engine flowpath, the ceramic coating having a thickness,
- wherein the ceramic coating comprises one or more cooling holes disposed in the ceramic coating and a plurality of slots disposed in the ceramic coating forming segments of ceramic coating material, each slot of the plurality of slots having a length, a width, and a depth, wherein the ceramic coating surrounding each slot is a continuous coating,
- wherein each slot of the plurality of slots is arranged such that a direction defined by its depth is perpendicular to a surface of the ceramic coating,
- wherein the slots are disposed relative to the one or more cooling holes such that the slots do not pass through any of the one or more cooling holes, the slots extending through 80 percent or more of the thickness of the ceramic coating, and
- wherein each segment of ceramic coating material overlies and defines a segment of the metal substrate, each segment of the metal substrate being substantially planar.
4 more elements
Dependencies are inferred from the claim text.