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US 5,652,044 AGranted
Coated article
AssigneeROLLS-ROYCE plc
InventorDavid Rickerby
Life of this patent
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AssigneeROLLS-ROYCE plc
InventorDavid Rickerby
Estimating the term…
A superalloy turbine blade (10) has a MCrA1Y bond coating (22) and a thermal barrier coating (24). The thermal barrier coating (24) comprises a plurality of alternate layers (25, 27) which have different structure to produce a plurality of interfaces (26) substantially parallel to the metallic substrate (20)/bond coating (22) interface. These interfaces (26) provide paths of increased resistance to heat transfer to reduce the thermal conductivity of the thermal barrier coating (24). The structure in the alternate layers (25, 27) of the thermal barrier coating (24) is columnar (28), or segmented, to ensure that the strain tolerance of the thermal barrier coating (24) is not impaired. The columnar grains (28) in the layers (25, 27) extend substantially perpendicular to the metallic substrate (20)/bond coating (22) interface. This enables thermal barrier coatings (24) of reduced thickness and weight to be used. The bond coating may have an oxide or oxide/metal interface which improves the adhesion of the thermal barrier coating.
An article (10) comprising a metallic substrate (20), a bond coating (22) on the metallic substrate (20), a thermal barrier coating (24) on the bond coating (22), the thermal barrier coating (24) comprising a plurality of layers (25, 27), characterised in that each layer (25, 27) has columnar grains (28), the columnar grains (28) in each layer (25, 27) extend substantially perpendicular to an interface between the bond coating (22) and the metallic substrate (20), adjacent layers (25, 27) have different structures to provide at least one interface (26) between adjacent layers (25, 27) which is substantially parallel to the interface between the bond coating (22) and the metallic substrate (20) to increase the resistance to heat transfer through the thermal barrier coating (24).
An article (10) comprising a metallic substrate (20), a bond coating (22) on the metallic substrate (20), a thermal barrier coating (24) on the bond coating (22), the thermal barrier coating (24) having columnar grains (28), the columnar grains (28) extending substantially perpendicular to an interface between the bond coating (22) and the metallic substrate (20), characterised in that each of the columnar grains (28) in the thermal barrier coating (24) comprises a plurality of layers (25, 27), adjacent layers (25, 27) have different structures to provide at least one interface (26) between adjacent layers (25, 27) which is substantially parallel to the interface between the bond coating (22) and the metallic substrate (20) to increase the resistance to heat transfer through the thermal barrier coating (24).
A method of manufacturing an article (10) comprising applying a bond coating (22) to a metallic substrate (20), applying a thermal barrier coating (24) to the bond coating (22) comprising depositing at least one columnar grained layer (27) by vapour deposition and depositing at least one columnar grained layer (25) by plasma assisted vapour deposition to provide an interface (26) between the adjacent layers (25, 27) which is substantially parallel to the interface between the bond coating (22) and the metallic substrate (20) to increase the resistance to heat transfer through the thermal barrier coating (24).
A method of manufacturing an article (10) comprising applying a bond coating (22) to a metallic substrate (20), applying a thermal barrier coating (24) to the bond coating (22) characterised by applying a first voltage to the metallic substrate (20) and depositing at least one columnar grained layer (27) by vapour deposition, substantially instantaneously applying a second different voltage to the metallic substrate (20) and depositing at least one columnar grained layer (25) by vapour deposition to provide an interface (26) between the adjacent layers (25, 27) which is substantially parallel to the interface between the bond coating (22) and the metallic substrate (20) to increase the resistance to heat transfer through the thermal barrier coating (24).
A method of manufacturing an article comprising applying a bond coating to a metallic substrate, applying a thermal barrier coating to the bond coating characterised by depositing at least one columnar grained layer by vapour deposition without any voltage, substantially instantaneously applying a voltage to the metallic substrate and depositing at least one columnar grained layer by vapour deposition to provide an interface between the adjacent layers which is substantially parallel to the interface between the bond coating and the metallic substrate to increase the resistance to heat transfer through the thermal barrier coating.
Dependencies are inferred from the claim text.