CMAS-resistant thermal barrier coating for aero-engine parts
AssigneeHoneywell International Inc.
InventorsJason Van Sluytman, Vladimir Tolpygo, Leah Hummel
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Abstract
A method of preparing a coated article is disclosed. The method includes depositing a coating composition on a surface of a substrate to form a calcia-magnesia-alumina-silicate (CMAS)-resistant thermal barrier coating (TBC) thereon and give the coated article. The coating composition comprises from about 3 to about 50 wt. % of one or more rare-earth oxides, from about 45 to about 96.5 wt. % zirconia, and from about 0.5 to about 4 wt. % alumina, each based on the total weight of the coating composition. As deposited, the alumina is distributed substantially homogeneously throughout the CMAS-resistant TBC. A coated part prepared with the method is also disclosed.
Claims11
A method of preparing a coated article, comprising:
- depositing a coating composition on a substrate to form a calcia-magnesia-alumina-silicate (CMAS)-resistant thermal barrier coating (TBC) thereon, the coating composition comprising:
- from about 3 to about 50 wt. % of one or more rare-earth oxides,
- from about 45 to about 96.5 wt. % zirconia, and
- from about 0.5 to about 4 wt. % alumina, each based on the total weight of the coating composition;
- wherein depositing the coating composition comprises forming an as-deposited TBC layer having columnar grains, with the alumina present as a super-saturated solid solution distributed throughout the columnar grains such that the as-deposited TBC layer is substantially free from second-phase precipitates during formation of the columnar grains;
- wherein depositing is carried out via plasma spraying;
- and
- heat treating the as-deposited TBC layer at a temperature sufficient to precipitate the alumina as discrete particles having a maximum particle size of about 1 μm to form the CMAS-resistant TBC with the alumina substantially homogeneously distributed throughout the CMAS-resistant TBC.
Dependencies are inferred from the claim text.