# US 12,006,269 B2 · Multilayer protective coating systems for gas turbine engine applications and methods for fabricating the same

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- Number: US 12,006,269 B2
- Document ID: US12006269B2
- Status: Granted
- Kind: B2
- Application number: 17/445,889
- Filed: 2021-08-25
- Published: 2023-03-02
- Granted: 2024-06-11
- Earliest claimed: 2021-08-25
- Assignees: Honeywell International Inc.
- Applicants: Honeywell International Inc.
- Inventors: John Downs; Bahram Jadidian
- Web page: https://patentgrep.com/patent/US12006269B2

## CPC

- C04B 41/522: {Multiple coatings, for one of the coatings of which at least one alternative is described}
- C04B 35/80: Fibres, filaments, whiskers, platelets, or the like
- C04B 41/0072: {Heat treatment}
- 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 41/87: Ceramics
- C04B 41/89: for obtaining at least two superposed coatings having different compositions
- C23C 28/04: only coatings of inorganic non-metallic material
- F01D 5/005: {Repairing methods or devices}
- F01D 5/282: {Selecting composite materials, e.g. blades with reinforcing filaments}
- F01D 5/284: {Selection of ceramic materials}
- F01D 5/288: {Protective coatings for blades}
- F01D 9/02: Nozzles; Nozzle boxes; Stator blades; Guide conduits {, e.g. individual nozzles (nozzle boxes F01D9/047)}
- F01D 11/08: for sealing space between rotor blade tips and stator (specially-shaped blade tips therefor F01D5/20)
- F01D 25/007: {Preventing corrosion}
- C04B 2235/3826: Silicon carbides
- C04B 2235/3873: Silicon nitrides, e.g. silicon carbonitride, silicon oxynitride
- C04B 2235/5244: Silicon carbide
- F05D 2230/90: Coating; Surface treatment
- F05D 2240/11: Shroud seal segments
- F05D 2250/294: grooved
- F05D 2300/15: Rare earth metals, i.e. Sc, Y, lanthanides
- F05D 2300/20: Oxide or non-oxide ceramics
- F05D 2300/211: Silica
- F05D 2300/2261: of silicon
- F05D 2300/2283: of silicon
- F05D 2300/50212: dissimilar
- F05D 2300/6033: Ceramic matrix composites [CMC]
- Y02T 50/60: Efficient propulsion technologies, e.g. for aircraft
- 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)
- F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D)
- 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

A multilayer protective coating system includes a turbine engine component substrate formed of a ceramic matrix composite material, an environmental barrier coating layer including a rare earth disilicate material deposited directly on the substrate, and a plurality of pairs of alternating layers of the rare earth disilicate material and a rare earth monosilicate material deposited and sintered directly on the environmental barrier coating layer. Each layer of the plurality of pairs of alternating layers is relative less thick as compared with the environmental barrier coating layer.

## Claims

### Claim 1

A multilayer protective coating system comprising:
a turbine engine component substrate formed of a ceramic material or a ceramic matrix composite material;
an environmental barrier coating layer comprising a rare earth disilicate material deposited directly on the substrate; and
a plurality of pairs of alternating layers of the rare earth disilicate material and a rare earth monosilicate material deposited and sintered directly on the environmental barrier coating layer,
wherein each layer of the plurality of pairs of alternating layers is relative less thick as compared with the environmental barrier coating layer;
wherein a single layer of the rare earth disilicate material defines an outermost surface of an entirety of the plurality of pairs of alternating layers.

### Claim 2 (depends on 1)

The multilayer protective coating system of claim 1, wherein the ceramic material is a silicon nitride (Si3N4) material or the ceramic matrix composite material is a silicon carbide—silicon carbide (SiC—SiC) material.

### Claim 3 (depends on 1)

The multilayer protective coating system of claim 1, wherein the environmental barrier coating layer has a thickness of about 1.5 mils to about 15 mils.

### Claim 4 (depends on 3)

The multilayer protective coating system of claim 3, wherein the environmental barrier coating layer has a thickness of about 1.5 mils to about 3 mils.

### Claim 5 (depends on 1)

The multilayer protective coating system of claim 1, wherein the rare earth disilicate material comprises a rare earth element that is selected from the group consisting of: Scandium (Sc), Yttrium (Y), Lanthanum (La), Cerium (Ce), Praseodymium (Pr), Neodymium (Nd), Promethium (Pm), Samarium (Sm), Europium (Eu), Gadolinium (Gd), Terbium (Tb), Dysprosium (Dy), Holmium (Ho), Erbium (Er), Thulium (Tm), Ytterbium (Yb), and Lutetium (Lu).

### Claim 6 (depends on 1)

The multilayer protective coating system of claim 1, wherein the rare earth monosilicate material comprises a rare earth element that is, independently from the rare earth disilicate material, selected from the group consisting of: Scandium (Sc), Yttrium (Y), Lanthanum (La), Cerium (Ce), Praseodymium (Pr), Neodymium (Nd), Promethium (Pm), Samarium (Sm), Europium (Eu), Gadolinium (Gd), Terbium (Tb), Dysprosium (Dy), Holmium (Ho), Erbium (Er), Thulium (Tm), Ytterbium (Yb), and Lutetium (Lu).

### Claim 7 (depends on 1)

The multilayer protective coating system of claim 1, wherein the plurality of pairs of alternating layers comprise two or more pairs of alternating layers.

### Claim 8 (depends on 7)

The multilayer protective coating system of claim 7, wherein the plurality of pairs of alternating layers comprise three or more pairs of alternating layers.

### Claim 9 (depends on 1)

The multilayer protective coating system of claim 1, wherein each layer of the plurality of pairs of alternating layers individually has a thickness of about 0.5 mils to about 2 mils.

### Claim 10 (depends on 9)

The multilayer protective coating system of claim 9, wherein each layer of the plurality of pairs of alternating layers individually has a thickness of about 0.5 mils to about 1.5 mils.

### Claim 11

A method of applying a multilayer protective coating to a substrate comprises the steps of:
providing or obtaining a turbine engine component substrate formed of a ceramic material or a ceramic matrix composite material;
depositing an environmental barrier coating layer comprising a rare earth disilicate material directly on the substrate; and
depositing and sintering a plurality of pairs of alternating layers of the rare earth disilicate material and a rare earth monosilicate material directly on the environmental barrier coating layer,
wherein each layer of the plurality of pairs of alternating layers is relative less thick as compared with the environmental barrier coating layer;
wherein a single layer of the rare earth disilicate material defines an outermost surface of an entirety of the plurality of pairs of alternating layers.

### Claim 12 (depends on 11)

The method of claim 11, wherein the ceramic material is a silicon nitride (Si3N4) material or the ceramic matrix composite material is a silicon carbide—silicon carbide (SiC—SiC) material.

### Claim 13 (depends on 11)

The method of claim 11, wherein the environmental barrier coating layer has a thickness of about 1.5 mils to about 15 mils.

### Claim 14 (depends on 13)

The method of claim 13, wherein the environmental barrier coating layer has a thickness of about 1.5 mils to about 3 mils.

### Claim 15 (depends on 11)

The method of claim 11, wherein the rare earth disilicate material comprises a rare earth element that is selected from the group consisting of: Scandium (Sc), Yttrium (Y), Lanthanum (La), Cerium (Ce), Praseodymium (Pr), Neodymium (Nd), Promethium (Pm), Samarium (Sm), Europium (Eu), Gadolinium (Gd), Terbium (Tb), Dysprosium (Dy), Holmium (Ho), Erbium (Er), Thulium (Tm), Ytterbium (Yb), and Lutetium (Lu).

### Claim 16 (depends on 11)

The method of claim 11, wherein the rare earth monosilicate material comprises a rare earth element that is, independently from the rare earth disilicate material, selected from the group consisting of: Scandium (Sc), Yttrium (Y), Lanthanum (La), Cerium (Ce), Praseodymium (Pr), Neodymium (Nd), Promethium (Pm), Samarium (Sm), Europium (Eu), Gadolinium (Gd), Terbium (Tb), Dysprosium (Dy), Holmium (Ho), Erbium (Er), Thulium (Tm), Ytterbium (Yb), and Lutetium (Lu).

### Claim 17 (depends on 11)

The method of claim 11, wherein the plurality of pairs of alternating layers comprise two or more pairs of alternating layers.

### Claim 18 (depends on 17)

The method of claim 17, wherein the plurality of pairs of alternating layers comprise three or more pairs of alternating layers.

### Claim 19 (depends on 11)

The method of claim 11, wherein each layer of the plurality of pairs of alternating layers individually has a thickness of about 0.5 mils to about 2 mils.

### Claim 20 (depends on 19)

The method of claim 19, wherein each layer of the plurality of pairs of alternating layers individually has a thickness of about 0.5 mils to about 1.5 mils.