# US 2021/0276925 A1 · Post deposition heat treatment of coating on ceramic or ceramic matrix composite substrate

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- Number: US 2021/0276925 A1
- Document ID: US20210276925A1
- Status: Published application
- Kind: A1
- Application number: 16/726,553
- Filed: 2019-12-24
- Published: 2021-09-09
- Earliest claimed: 2019-12-24
- Assignees: ROLLS-ROYCE plc
- Applicants: Rolls-Royce Corporation
- Inventors: Jun Shi; Li Li; Gregory John Kenneth Harrington
- Web page: https://patentgrep.com/patent/US20210276925A1

## CPC

- C04B 41/009: {characterised by the material treated}
- C04B 41/0072: {Heat treatment}
- C04B 41/5024: {Silicates (C04B41/5022 takes precedence; silico-fluorides C04B41/5018)}
- 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 41/89: for obtaining at least two superposed coatings having different compositions
- C23C 4/18: After-treatment
- F01D 5/282: {Selecting composite materials, e.g. blades with reinforcing filaments}
- F01D 5/286: {Particular treatment of blades, e.g. to increase durability or resistance against corrosion or erosion (F01D5/288 takes precedence)}
- F01D 5/288: {Protective coatings for blades}
- F01D 11/122: {with erodable or abradable material (blades having cutting or grinding tips F01D5/20)}
- F05D 2230/31: Layer deposition
- F05D 2230/40: Heat treatment
- F05D 2230/90: Coating; Surface treatment
- F05D 2300/15: Rare earth metals, i.e. Sc, Y, lanthanides
- F05D 2300/514: Porosity
- F05D 2300/6033: Ceramic matrix composites [CMC]
- F05D 2300/611: Coating
- Y02T 50/60: Efficient propulsion technologies, e.g. for aircraft
- 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
- 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)
- 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
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

In one example, a method for forming a coating system including an environmental barrier coating (EBC) and abradable coating on a substrate. The method may include depositing the EBC on a ceramic or ceramic matric composite (CMC) substrate to form an as-deposited EBC; heat treating the as-deposited EBC following the deposition of the as-deposited EBC on the substrate to form a heat treated EBC; and subsequently depositing an abradable coating on the heat treated EBC to form an as-deposited abradable coating. The as-deposited abradable coating may be heat treated to form a heat treated abradable coating.

## Claims

### Claim 1

A method comprising:
depositing an environmental barrier coating (EBC) on a ceramic or ceramic matrix composite (CMC) substrate to form an as-deposited EBC;
heat treating the as-deposited EBC following the deposition of the as-deposited EBC on the substrate to form a heat treated EBC; and
subsequently depositing an abradable coating on the heat treated EBC to form an as-deposited abradable coating.

### Claim 2 (depends on 1)

The method of claim 1, wherein heat treating the as-deposited EBC comprises heat treating of the as-deposited EBC to decrease a porosity of the heat treated EBC as compared to the as-deposited EBC.

### Claim 3 (depends on 1)

The method of claim 1, wherein heat treating the as-deposited EBC comprises heating the as-deposited EBC at a first controlled rate, wherein the controlled rate is selected to decrease at least one of an open porosity or microcracks of the heat-treated EBC compared to the as-deposited EBC.

### Claim 4 (depends on 3)

The method of claim 3, wherein decreasing the at least one of the open porosity or the microcracks of the heat-treated coating compared to the as-deposited coating comprises decreasing a percentage of interconnected pores and crack networks of the heat-treated coating compared to the as-deposited coating.

### Claim 5 (depends on 3)

The method of claim 3, wherein decreasing the at least one of the open porosity or the microcracks of the heat-treated coating compared to the as-deposited coating comprises closing at least a portion of the interconnected pores and microcrack networks of the as-deposited coating.

### Claim 6 (depends on 1)

The method of claim 1, further comprising heat treating the as-deposited abradable coating following deposition of the abradable coating on the EBC to form a heat treated abradable coating.

### Claim 7 (depends on 6)

The method of claim 6, wherein heat treating the as-deposited EBC includes heating the as-deposited EBC at a first controlled rate, wherein heat treating the as-deposited abradable coating includes heating the as-deposited abradable coating at a second controlled rate that is less than the first controlled rate.

### Claim 8 (depends on 7)

The method of claim 7, wherein the first controlled rate is greater than about 100 degrees Celsius per minute.

### Claim 9 (depends on 7)

The method of claim 7, wherein the second controlled rate is less than 15 degrees Celsius per minute.

### Claim 10 (depends on 6)

The method of claim 6, wherein heat treating the as-deposited EBC includes heating the as-deposited EBC to or above a first temperature, and heat treating the as-deposited abradable coating includes heating the as-deposited EBC to or above a second temperature, wherein the first temperature and the second temperature are approximately equal.

### Claim 11 (depends on 1)

The method of claim 1, wherein the heat treated EBC has a porosity of less than about 5%.

### Claim 12 (depends on 1)

The method of claim 1, wherein the as-deposited abradable coating has a porosity of greater than 10%.

### Claim 13 (depends on 6)

The method of claim 6, wherein the heat treated abradable coating has a porosity of greater than 5%.

### Claim 14 (depends on 1)

The method of claim 1, wherein the as-deposited abradable coating includes a fugitive material, the method further comprising removing the fugitive material of the as-deposited abradable coating to create open pores in the abradable coating.

### Claim 15 (depends on 1)

The method of claim 1, wherein the EBC and abradable coating each includes at least one of rare earth (RE) monosilicate or RE disilicate.

### Claim 16 (depends on 1)

The method of claim 1, wherein depositing the EBC on the substrate to form the as-deposited EBC comprises depositing the EBC on the substrate via at least one of thermal spray deposition or slurry deposition.

### Claim 17 (depends on 1)

The method of claim 1, wherein the heat treated EBC is a substantially hermetic EBC.

### Claim 18

A system comprising:
a deposition device;
a furnace; and
a controller device configured to control the deposition device to deposit an environmental barrier coating (EBC) on a ceramic or ceramic matrix composite (CMC) substrate to form an as-deposited EBC, control the furnace to heat treat the as-deposited EBC following the deposition of the as-deposited EBC on the substrate to form a heat treated EBC, and control the deposition device to subsequently deposit an abradable coating on the heat treated EBC to form an as-deposited abradable coating.

### Claim 19 (depends on 18)

The system of claim 18, wherein the heat treatment of the as-deposited EBC is configured to decrease a porosity of the heat treated EBC as compared to the as-deposited EBC.

### Claim 20 (depends on 18)

The system of claim 18, wherein the controller device configured to control the furnace to heat treat the as-deposited abradable coating following deposition of the abradable coating on the EBC to form a heat treated abradable coating.