Components having coating systems comprising highly porous layers and methods for forming the coating systems
AssigneeHoneywell International Inc.
InventorsMehrad Mehr, Bahram Jadidian
Life of this patent
Estimating the term…
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.
Claims20
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 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 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.
A component for a gas turbine engine, comprising:
- a substrate;
- a thermal barrier coating (TBC) having at least a first layer secured to a surface of the substrate, the first layer 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,
- wherein the TBC is secured to the substrate subsequent to formation of the TBC.
Dependencies are inferred from the claim text.