# US 12,594,579 B2 · Environmental barrier coating and method of repairing the same

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- Number: US 12,594,579 B2
- Document ID: US12594579B2
- Status: Granted
- Kind: B2
- Application number: 17/832,050
- Filed: 2022-06-03
- Published: 2023-12-07
- Granted: 2026-04-07
- Earliest claimed: 2022-06-03
- Assignees: Rtx Corporation
- Applicants: Raytheon Technologies Corporation
- Inventors: David A. Litton; James T. Beals; Richard Wesley Jackson, III; Xia Tang
- Web page: https://patentgrep.com/patent/US12594579B2

## CPC

- B05D 5/005: {Repairing damaged coatings}
- C04B 41/009: {characterised by the material treated}
- B05D 3/12: by mechanical means
- C04B 35/80: Fibres, filaments, whiskers, platelets, or the like
- C04B 41/4539: {as a emulsion, dispersion or suspension}
- C04B 41/4572: {Partial coating or impregnation of the surface of the substrate}
- 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 41/53: involving the removal of at least part of the materials of the treated article, {e.g. etching, drying of hardened concrete (C04B41/0036 - C04B41/0054 take precedence)}
- C04B 41/89: for obtaining at least two superposed coatings having different compositions
- C04B 41/91: involving the removal of part of the materials of the treated articles, e.g. etching
- F01D 5/005: {Repairing methods or devices}
- C04B 2111/00405: {Materials with a gradually increasing or decreasing concentration of ingredients or property from one layer to another}
- C04B 2111/00982: {as construction elements for space vehicles or aeroplanes}
- C04B 2111/72: Repairing or restoring existing buildings or building materials
- F01D 5/288: {Protective coatings for blades}
- F05D 2230/80: Repairing, retrofitting or upgrading methods
- F05D 2230/90: Coating; Surface treatment
- F05D 2300/6033: Ceramic matrix composites [CMC]
- B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02)
- 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
- 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

## Abstract

A method of repairing a coating on an article according to an exemplary embodiment of this disclosure, among other possible things includes defining a work area surrounding a discontinuity in the coating, the coating including undisturbed bond coat and undisturbed top coat; removing coating material within the work area; applying a slurry containing bond coat constituents in a carrier fluid to the work area; curing the slurry to form a repaired bond coat; applying a slurry containing top coat constituents in a carrier fluid to the work area; and curing the slurry to form a repaired top coat. A method of repairing a coating on an article and an article are also disclosed.

## Claims

### Claim 1

A method of repairing a coating on an article, comprising:
defining a work area surrounding a discontinuity in the coating, the coating including undisturbed bond coat and undisturbed top coat;
removing coating material, including both undisturbed coating and undisturbed bond coat and top coat within the work area;
applying a bond slurry containing bond coat constituents in a carrier fluid to the work area;
curing the bond slurry to form a repaired bond coat;
applying a top slurry containing top coat constituents in a carrier fluid to the work area; and
curing the top slurry to form a repaired top coat.

### Claim 2 (depends on 1)

The method of claim 1, wherein the removing step includes abrading the work area.

### Claim 3 (depends on 1)

The method of claim 1, wherein the repaired bond coat has the same composition as the undisturbed bond coat.

### Claim 4 (depends on 1)

The method of claim 1, wherein the repaired bond coat has a different component than the undisturbed bond coat.

### Claim 5 (depends on 1)

The method of claim 1, wherein the undisturbed bond coat and the repaired bond coat comprise matrix material, gettering particles, and diffusive particles.

### Claim 6 (depends on 5)

The method of claim 5, wherein the repaired bond coat contains a higher concentration of diffusive particles than the undisturbed bond coat.

### Claim 7 (depends on 1)

The method of claim 1, wherein the repaired top coat has a different composition than the undisturbed top coat.

### Claim 8 (depends on 1)

The method of claim 1, further comprising sintering the repaired bond coat and the repaired top coat.

### Claim 9 (depends on 8)

The method of claim 8, wherein the article is a component of a gas turbine engine, and the sintering occurs during operation of the gas turbine engine.

### Claim 10 (depends on 8)

The method of claim 8, wherein the sintering occurs at temperatures of at least about 1260 degrees C. (2300 degrees F.).

### Claim 11 (depends on 1)

The method of claim 1, further comprising masking the article with masking material having an opening corresponding to the work area after the defining step.

### Claim 12 (depends on 11)

The method of claim 11, wherein the masking material includes pre-cut masking material with a pre-cut opening, and further comprising selecting the pre-cut masking material to accommodate the size of the discontinuity.

### Claim 13 (depends on 1)

The method of claim 1, wherein the step of applying the bond slurry containing bond coat constituents, the step of applying the top slurry containing top coat constituents, or both, includes pressing the slurry into the article.

### Claim 14 (depends on 1)

The method of claim 1, further comprising the step of evaluating the coating to determine a thickness of the undisturbed bond coat, the undisturbed top coat, or both prior to the step of applying the slurry containing bond coat constituents.

### Claim 15

A method of repairing a coating on an article, comprising:
defining a work area surrounding a discontinuity in the coating, the coating including undisturbed bond coat and undisturbed top coat, and the discontinuity being in the top coat;
removing top coat material including undisturbed top coat material within the work area to reveal undisturbed bond coat;
applying a top slurry containing top coat constituents in a carrier fluid to the work area over the undisturbed bond coat; and
curing the top slurry to form a repaired top coat.

### Claim 16 (depends on 14)

The method of claim 14, wherein the repaired top coat has a different composition as the undisturbed top coat.

### Claim 17 (depends on 14)

The method of claim 14, further comprising masking the article with masking material having an opening corresponding to the work area after the defining step.

### Claim 18 (depends on 1)

The method of claim 1, further comprising sintering the repaired top coat.

### Claim 19 (depends on 1)

The method of claim 1, further comprising the step of evaluating the coating to determine a thickness of the undisturbed top coat to the step of applying the slurry containing bond coat constituents.