Multilayered erosion resistant coating for gas turbines

An erosion-resistant coating system for use on an engine component having an outer surface that is configured to be exposed to a first plurality of particles impinging against the outer surface at an angle within a first angle range and a second plurality of particles impinging against the outer surface at an angle in a second angle range that is different than the first angle range, the system comprising:

• a bond layer overlying the engine component outer surface, the bond layer comprising a material comprising a first crystallographic structure;
• a first erosion-resistant layer overlying the bond layer and comprising a first material that is more resistant to erosion by particles impinging the component outer surface at an angle within the first angle range than by particles impinging within the second angle range, at least a portion of the first material having the first crystallographic structure;
• an interlayer overlying the first erosion-resistant layer, the interlayer comprising a material comprising a second crystallographic structure;
• and
• a second erosion-resistant layer overlying the interlayer and comprising a second material that is more resistant to erosion by particles impinging the component outer surface at an angle within the second angle range than by particles impinging within the first angle range, at least a portion of the second material having the second crystallographic structure.

A method of coating an engine component having an outer surface, the coating configured to be exposed to a first plurality of particles impinging against the outer surface at an angle within a first angle range and a second plurality of particles impinging against the outer surface at an angle in a second angle range that is different than the first angle range, the method comprising the steps of:

• forming a bond layer overlying the engine component outer surface, the bond layer comprising an amorphous material;
• depositing a first material over the bond layer to form a first erosion-resistant layer comprising a first material that is more resistant to erosion by particles impinging the component outer surface at an angle within the first angle range than by particles impinging within the second angle range;
• forming an interlayer overlying the first erosion-resistant layer, the interlayer comprising the amorphous material;
• and
• depositing a second material over the interlayer to form a second erosion-resistant layer that is more resistant to erosion by particles impinging the component outer surface at an angle within the second angle range than by particles impinging within the first angle range.

A method of coating an engine component having an outer surface that is configured to be exposed to a first plurality of particles impinging against the outer surface at an angle within a first angle range and a second plurality of particles impinging against the outer surface at an angle within a second angle range that is different than the first angle range, the method comprising the steps of:

• forming a bond layer overlying the engine component outer surface, the bond layer comprising a material comprising a first crystallographic structure;
• depositing a first material overlying the bond layer to form a first erosion-resistant layer that is more resistant to erosion by particles impinging the component outer surface at an angle within the first angle range than by particles impinging within the second angle range, at least a portion of the first material having the first crystallographic structure;
• forming an interlayer overlying the first erosion-resistant layer, the interlayer comprising a material comprising a second crystallographic structure;
• and
• depositing a second material overlying the interlayer to form a second erosion-resistant layer that is more resistant to erosion by particles impinging the component outer surface at an angle within the second angle range than by particles impinging within the first angle range, at least a portion of the second material having the second crystallographic structure.