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US 2026/0103993 A1Published application
Abradable coating
AssigneeRtx Corporation
InventorsAlex SCHNEIDER, Peter WILKINS, Winston SMIDDY, Paul Lutjen
Life of this patent
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Abstract
An abradable coating/thermal barrier coating suitable for use with jet engine CMC components is described which comprises a material selected from hafnon, mixtures of hafnon and zircon, and rare earth disilicates (RE2Si2O7), wherein RE is Sc, Y, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, or Lu. The coating has a porosity gradient wherein the porosity decreases in a radial direction. The porosity gradient provides a progressively increasing wear resistance to slow the rate of rub interaction. The porosity gradient also reduces the thermal gradient through the coating thereby reducing the formation of thermal stresses within the coating and any underlying CMC component.
Claims20
A coated substrate comprising:
- a substrate made from a superalloy or a ceramic matrix composite (CMC) material having a radially outward surface and a radially inward surface;
- a coating system applied to the radially inward surface of the substrate, said coating system includes a coating having an abradable coating region or thermal barrier coating region made of material selected from hafnon, mixtures of hafnon and zircon, and rare earth disilicates (RE2Si2O7), wherein RE is Sc, Y, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, or Lu;
- wherein the coating has a first surface proximate with respect to the radially inward surface and a second surface distal with respect to the radially inward surface, and the abradable coating region or thermal barrier coating region has a porosity wherein the porosity decreases from the first surface to the second surface in a linear or stepwise manner such that a first region of the abradable coating region encompassing the first surface has a porosity of at least 60% of the total volume of the first region and a second region of the coating encompassing the second surface has a porosity of not more than 10% of the total volume of the second region,
- wherein the coating is directly applied to the radially inward surface or is directly applied to a bond coat which is directly applied to the radially inward surface.
1 more element
A method of preparing a jet engine component comprising:
- providing a superalloy or a ceramic matrix composite (CMC) substrate having a radially outward surface and a radially inward surface;
- and
- applying a coating system to a surface of the superalloy or CMC substrate, said coating system including a coating having an abradable coating region or thermal barrier coating region made of material selected from hafnon, mixtures of hafnon and zircon, and rare earth disilicates (RE2Si2O7), wherein RE is Sc, Y, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, or Lu;
- wherein the coating has a first surface proximate with respect to the radially inward surface and a second surface distal with respect to the radially inward surface, and the abradable coating region or thermal barrier coating region has a porosity wherein the porosity decreases from the first surface to the second surface in a linear or stepwise manner such that a first region of the abradable coating region encompassing the first surface has a porosity of at least 60% of the total volume of the first region and a second region of the coating encompassing the second surface has a porosity of not more than 10% of the total volume of the second region.
1 more element
A gas turbine engine comprising:
- a fan section, a compressor section, a combustion section, and a turbine section, said turbine section including at least one rotor and one or more turbine blade(s) extending radially outwardly from said at least one rotor;
- a blade outer air seal assembly positioned between the one or more turbine blade(s) and an outer casing to the engine;
- said blade outer air seal is formed of a plurality blade outer air seal segments, wherein each blade outer air seal segment comprises:
- a substrate made from a superalloy material or ceramic matrix composite (CMC) material having a radially outward surface and a radially inward surface;
- a coating system applied to the radially inward surface of the substrate, said coating system includes a coating having an abradable coating region or thermal barrier coating region made of material selected from hafnon, mixtures of hafnon and zircon, and rare earth disilicates (RE2Si2O7), wherein RE is Sc, Y, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, or Lu;
- wherein the coating has a first surface proximate with respect to the radially inward surface and a second surface distal with respect to the radially inward surface, and the abradable coating region or thermal barrier coating region has a porosity wherein the porosity decreases from the first surface to the second surface in a linear or stepwise manner such that a first region of the abradable coating region encompassing the first surface has a porosity of at least 60% of the total volume of the first region and a second region of the coating encompassing the second surface has a porosity of not more than 10% of the total volume of the second region.
3 more elements
Dependencies are inferred from the claim text.