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US 12,760,401 B2Granted
Components having coating systems comprising highly porous layers and methods for forming the coating systems
AssigneeHoneywell Aerospace US LLC
InventorsMehrad Mehr, Bahram Jadidian
Life of this patent
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Abstract
Components for a gas turbine engine and method for producing the components are provided. The components may include a substrate and a thermal barrier coating (TBC) having at least a first layer secured to a surface of the substrate. The first layer is formed of a ceramic material with a first microstructure that includes a plurality of interconnected unit cells having struts that have a relative density of greater than 98 percent and a closed cell porosity of 10 percent or greater. The TBC is secured to the substrate subsequent to formation of the TBC.
Claims19
A method, comprising:
- locating a first mixture within a mold cavity defined by inner surfaces of a mold, the first mixture including a ceramic material and a first polymeric foaming composition;
- locating a second mixture in the mold cavity, the second mixture including the ceramic material and a second polymeric foaming composition;
- retaining the first mixture and the second mixture within the mold cavity for a period of time sufficient to allow the first mixture and the second mixture to simultaneously foam and cure and thereby produce a foam body having a shape defined by the mold cavity;
- performing a one or more heat treatments to remove non-ceramic materials from the foam body and sinter the ceramic material to produce a ceramic body, wherein the ceramic body includes a first layer having a first microstructure resulting from foaming of the first mixture and a second layer having a second microstructure resulting from foaming of the second mixture;
- performing a machining process to modify a size and/or a shape of the ceramic body;
- and
- securing the ceramic body to a substrate of a component to define at least a portion of a thermal barrier coating (TBC) on the substrate, wherein the component is configured to be installed in a gas turbine engine.
4 more elements
A method, comprising:
- locating a first mixture within a mold cavity defined by inner surfaces of a mold, the first mixture including a ceramic material comprising a rare earth disilicate and a first polymeric foaming composition comprising a polyurethane foaming composition;
- retaining the first mixture within the mold cavity for a period of time sufficient to allow the first mixture to foam and cure and thereby produce a foam body having a shape defined by the mold cavity;
- performing one or more heat treatments to remove non-ceramic materials from the foam body and sinter the ceramic material to produce a ceramic body, wherein a microstructure of the ceramic body is based on the first polymeric foaming composition;
- performing a machining process to modify a size and/or a shape of the ceramic body to have a shape conformal to a surface of a substrate;
- and
- securing the ceramic body to the surface of the substrate of a component to define at least a portion of a thermal barrier coating (TBC) on the substrate, wherein the component is configured to be installed in a gas turbine engine, wherein securing the ceramic body to the substrate includes bonding the ceramic body to the surface with bonding or adhesive material.
3 more elements
A method, comprising:
- locating a first mixture within a mold cavity defined by inner surfaces of a mold, the first mixture including a ceramic material and a first polymeric foaming composition;
- retaining the first mixture within the mold cavity for a period of time sufficient to allow the first mixture to foam and cure and thereby produce a foam body having a shape defined by the mold cavity;
- performing one or more heat treatments to remove non-ceramic materials from the foam body and sinter the ceramic material to produce a ceramic body, wherein a microstructure of the ceramic body is based on the first polymeric foaming composition;
- performing a machining process to modify a size and/or a shape of the ceramic body;
- and
- securing the ceramic body to a substrate of a component to define at least a portion of a thermal barrier coating (TBC) on the substrate, wherein the component is configured to be installed in a gas turbine engine, wherein the TBC has a porosity gradient through a thickness thereof that increases in porosity with decreasing distance from the substrate,
- wherein the foam body includes a dense outer layer formed by either:
- contact with the inner surfaces of the mold during foaming and curing of the first mixture, wherein securing the ceramic body to the substrate includes orienting the ceramic body such that the dense outer layer defines an outermost surface of the TBC relative to the substrate, or
- application of a sealing composition to the ceramic body;
- wherein the dense outer layer has a density of 95% or greater and a thickness of 5 to 30 micrometers, wherein securing the ceramic body to the substrate includes orienting the ceramic body such that the dense outer layer defines an outermost surface of the TBC relative to the substrate.
7 more elements
Dependencies are inferred from the claim text.