# US 12,006,843 B2 · Methods for forming high temperature coating systems and gas turbine engine components including the same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,006,843 B2 - Document ID: US12006843B2 - Status: Granted - Kind: B2 - Application number: 16/657,303 - Filed: 2019-10-18 - Published: 2020-02-13 - Granted: 2024-06-11 - Earliest claimed: 2017-06-28 - Assignees: Honeywell International Inc. - Applicants: Honeywell International Inc. - Inventors: Jason S. Van Sluytman - Web page: https://patentgrep.com/patent/US12006843B2 ## CPC - F01D 5/288: {Protective coatings for blades} - C23C 4/134: Plasma spraying - C23C 16/06: characterised by the deposition of metallic material - C23C 28/042: {including a refractory ceramic layer, e.g. refractory metal oxides, ZrO2, rare earth oxides} - C23C 28/048: {with layers graded in composition or physical properties} - C23C 28/3215: {at least one MCrAlX layer} - 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} - C23C 28/40: {Coatings including alternating layers following a pattern, a periodic or defined repetition} - C23C 30/005: {on hard metal substrates} - F05D 2220/32: in gas turbines - F05D 2230/90: Coating; Surface treatment - F05D 2300/611: Coating - F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D) - 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 ## Abstract Methods for forming high temperature coating systems are provided. In embodiments, the coating formation method includes forming a fracture-resistant Thermal Barrier Coating (TBC) layer over a workpiece surface. The fracture-resistant TBC layer is produced from a first coating precursor material containing an amount of zirconia in mole percent (ZrOmol%1) and an amount of tantala in mole percent (TaOmol%1). A Calcium-Magnesium Aluminosilicate (CMAS) resistant TBC layer is formed over the fracture-resistant TBC layer from a second coating precursor material, which contains an amount of zirconia in mole percent (ZrOmol%2), an amount of tantala in mole percent (TaOmol%2), and an amount of one or more rare earth oxides in mole percent (REOmol%2). The first and second coating precursor materials are formulated such that ZrOmol%1 is greater than ZrOmol%2, TaOmol%1 is less than TaOmol%2, and TaOmol%2 is substantially equivalent to REOmol%2. ## Claims ### Claim 1 A method for producing a high temperature coating system over a component, the method comprising: forming a fracture-resistant Thermal Barrier Coating (TBC) layer over a surface of the component, the fracture-resistant TBC layer formed from a first coating precursor material containing: an amount of zirconia by mole percent (ZrOmol%1); and an amount of tantala by mole percent (TaOmol%1); forming a Calcium-Magnesium Aluminosilicate-resistant (CMAS-resistant) TBC layer over the fracture-resistant TBC layer, the CMAS-resistant TBC layer formed from a second coating precursor material containing: an amount of zirconia by mole percent (ZrOmol%2) between about 0.1% and about 35%; an amount of tantala by mole percent (TaOmol%2) between about 30% and about 40%; and an amount of at least one rare earth oxide by mole percent (REOmol%2) between about 30% and about 40%; wherein ZrOmol%1 is greater than ZrOmol%2, TaOmol%1 is less than TaOmol%2, and TaOmol%2 is substantially equivalent to REOmol%2. ### Claim 2 (depends on 1) The method of claim 1 further comprising selecting the at least one rare earth oxide selected from the group consisting of yttria, ytterbia, gadolinia, and lanthanum oxides, and combinations thereof. ### Claim 3 (depends on 1) The method of claim 1 further comprising formulating the first coating precursor material to contain an amount of at least one rare earth oxide by mole percent (REOmol%1); wherein REOmol%1 is less than REOmol%2. ### Claim 4 (depends on 3) The method of claim 3 further comprising selecting REOmol%2 to be at least twice REOmol%1. ### Claim 5 (depends on 1) The method of claim 1 further comprising formulating the first coating precursor material to be essentially free of the at least one rare earth oxide. ### Claim 6 (depends on 1) The method of claim 1 further comprising selecting ZrOmol%1 to be at least twice ZrOmol%2. ### Claim 7 (depends on 1) The method of claim 1 wherein forming the CMAS-resistant TBC layer comprises: depositing the second coating material directly onto the fracture-resistant TBC layer; and after deposition of the second coating material, heat treating the second coating material to diffuse the at least one rare earth oxide into the fracture-resistant TBC layer and form a rare earth oxide gradient therein. ### Claim 8 (depends on 7) The method of claim 7 further comprising: producing the fracture-resistant TBC layer to include an outer surface to which the CMAS-resistant TBC layer is bonded and an inner surface opposite the outer surface; and formulating the first coating precursor material and heat treating the second coating material such that the rare earth oxide gradient decreases from a maximum value to a minimum value when moving from the outer surface toward the inner surface. ### Claim 9 (depends on 1) The method of claim 1 further comprising: producing a base TBC layer over the surface of the component prior to forming the fracture-resistant TBC layer thereover; and formulating the base TBC layer to contain zirconia in an amount exceeding ZrOmol%1 by mole percent. ### Claim 10 (depends on 1) The method of claim 1 wherein the component comprises a Gas Turbine Engine (GTE) component; and wherein the method further comprises forming the CMAS-resistant TBC layer as an outermost layer of the high temperature coating system such that the CMAS-resistant TBC layer is directly exposed to core gas flow during GTE operation. ### Claim 11 (depends on 1) The method of claim 1 further comprising: selecting the at least one rare earth oxide to comprise gadolinia; and diffusing the at least one rare earth oxide into the fracture-resistant TBC layer such that the fracture-resistant TBC layer contains a gadolinia gradient, which decreases from a maximum gadolinia concentration to a minimum gadolinia concentration when moving from the outer surface toward the inner surface of the fracture-resistant layer, the minimum gadolinia concentration substantially equivalent to 0% by mole percent. ### Claim 12 (depends on 1) The method of claim 1 further comprising selecting the at least one rare earth oxide selected from the group consisting of gadolinia, lanthanum oxides, and combinations thereof. ### Claim 13 (depends on 1) The method of claim 1 wherein the at least one rare earth oxide is a combination of gadolinia and a lanthanum oxide.