Thermal barrier coating applied with cold spray technique
AssigneeSiemens Westinghouse Power Corporation
InventorsRamesh Subramanian, Gregg P. Wagner, Brij B. Seth
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Abstract
A process (20) for applying a thermal barrier coating (51) to a turbine component (50) including the step (34) of depositing a bond coating layer (56) by, directing solid particles using a cold spray process. The layer of bond coating material may have different depths (80,82) in different areas of the component (50), and it may have different compositions (60,62) across its depth. The precise control afforded by the cold spray material deposition step allows the surface of the bond coating material layer to be formed with a predetermined surface roughness or with a plurality of micro-ridges (86) in order to optimize its bond to the overlying ceramic insulating layer (52).
Claims18
A method of applying a thermal barrier coating comprising the steps of:
- providing a substrate material;
- directing solid particles of bond coating material toward a surface of the substrate material at a velocity sufficiently high to cause the particles to deform and to adhere to the surface to form a layer of bond coating material;
- applying a layer of ceramic insulating material over the layer of bond coating material.
A method of fabricating a component for a gas turbine engine, the method comprising the steps of:
- forming a substrate comprising a superalloy material into a predetermined shape appropriate for use in a gas turbine engine;
- and
- directing solid particles of an MCrAlY material toward a surface of the substrate at a velocity sufficiently high to cause at least a first portion of the particles to deform and to adhere to the surface to form an overlay layer of MCrAlY material.
A method of fabricating a component for a gas turbine engine, the method comprising the steps of:
- forming a substrate into a predetermined shape useful in a gas turbine;
- defining a first surface area of the substrate and a second surface area of the substrate as a function of the environment to which the predetermined shape will be exposed during the operation of the gas turbine;
- directing, solid particles of a bond coating material toward a surface of the substrate at a velocity sufficiently high to cause the particles to deform and to adhere to the surface to form a layer of bond coating material having a first thickness over the first surface area and a second thickness over the second surface area.
A method of fabricating a component for a gas turbine engine, the method comprising the steps of:
- forming a substrate into a predetermined shape appropriate for use in a gas turbine engine;
- depositing a plurality of layers of an overlay coating on a surface of the substrate by directing solid particles of a coating material toward the surface at a velocity sufficiently high to cause the particles to deform and to adhere to the surface;
- and
- changing the composition of the particles between a first composition for a first of the plurality of layers to a second composition for a second of the plurality of layers.
A method of forming a part for a turbine, the method comprising the steps of:
- providing a substrate;
- applying a layer of a bond coat material to a surface of the substrate by directing solid particles of MCrAlY material toward the surface of the substrate at a velocity sufficiently high to cause the particles to deform and to adhere to the surface of the substrate;
- applying a layer of platinum to only a selected portion of the layer of bond coat material by directing solid particles of platinum toward a surface of the layer of bond coat material at a velocity sufficiently high to cause the particles to deform and to adhere to the surface of the layer of bond coat material;
- subjecting the layer of platinum to a diffusion heat treatment process;
- and
- applying a layer of a ceramic insulating material over at least the selected portion of the layer of bond coat material.
Dependencies are inferred from the claim text.