# US 7,744,986 B2 · Multilayered erosion resistant coating for gas turbines

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- Number: US 7,744,986 B2
- Document ID: US7744986B2
- Status: Granted
- Kind: B2
- Application number: 12/275,566
- Filed: 2008-11-21
- Published: 2009-03-19
- Granted: 2010-06-29
- Earliest claimed: 2005-08-16
- Assignees: Honeywell International Inc.
- Inventors: Derek A. Rice; Adrienne Lamm
- Web page: https://patentgrep.com/patent/US7744986B2

## CPC

- F01D 5/288: {Protective coatings for blades}
- C23C 28/021: {including at least one metal alloy layer}
- C23C 28/023: {only coatings of metal elements only}
- C23C 28/028: {Including graded layers in composition or in physical properties, e.g. density, porosity, grain size}
- Y10T 428/12493: Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
- Y10T 428/12632: Four or more distinct components with alternate recurrence of each type component
- Y10T 428/12771: Transition metal-base component
- Y10T 428/12806: Refractory [Group IVB, VB, or VIB] metal-base component
- Y10T 428/12986: Adjacent functionally defined components
- Y10T 428/12993: Surface feature [e.g., rough, mirror]
- Y10T 428/24942: including components having same physical characteristic in differing degree
- Y10T 428/31504: Composite [nonstructural laminate]
- Y10T 428/31678: Of metal
- F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D)
- 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)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A coating system is used on an engine component having an outer surface configured to be exposed to a first plurality of particles impinging against the outer surface at an angle within a first angle range and a second plurality of particles impinging at an angle in a second angle range. The system includes a bond layer overlying the engine component outer surface, a first erosion-resistant layer comprising a first material that is more resistant to erosion by particles impinging the component outer surface at an angle within the first angle range than by particles impinging within the second angle range, an interlayer overlying the first erosion-resistant layer, and a second erosion-resistant layer comprising a second material that is more resistant to erosion by particles impinging the component outer surface at an angle within the second angle range than by particles impinging within the first angle range.

## Claims

### Claim 1

An erosion-resistant coating system for use on an engine component having an outer surface that is configured to be exposed to a first plurality of particles impinging against the outer surface at an angle within a first angle range and a second plurality of particles impinging against the outer surface at an angle in a second angle range that is different than the first angle range, the system comprising:
a bond layer overlying the engine component outer surface, the bond layer comprising a first material having an amorphous structure;
a first erosion-resistant layer overlying the bond layer, the first erosion-resistant layer comprising a first material having a first predetermined crystallographic structure that is not the amorphous structure and that is more resistant to erosion by particles impinging the component outer surface at a first angle within the first angle range than by particles impinging the component outer surface at a second angle within the second angle range;
an interlayer overlying the first erosion-resistant layer, the interlayer comprising a second material having an amorphous structure; and
a second erosion-resistant layer overlying the interlayer, the second erosion-resistant layer comprising a second material having a second predetermined crystallographic structure that is different from the first predetermined crystallographic structure, is not the amorphous structure, and that is more resistant to erosion by particles impinging the component outer surface at a third angle within the second angle range than by particles impinging the component outer surface at a fourth angle within the first angle range.

### Claim 2 (depends on 1)

The coating system of claim 1, wherein the bond layer and the interlayer comprise different amorphous materials.

### Claim 3 (depends on 1)

The coating system of claim 1, wherein the bond layer and the interlayer comprise the same amorphous materials.

### Claim 4 (depends on 1)

The coating system of claim 1, wherein the amorphous material comprises a superalloy.

### Claim 5 (depends on 4)

The coating system of claim 4, wherein the superalloy comprises at least one metal selected from the group consisting of nickel, titanium, chromium, palladium, and platinum.

### Claim 6 (depends on 1)

The coating system of claim 1, wherein the first material comprises at least one element selected from the group consisting of titanium, tungsten, zirconium, lanthium, hafnium, tantalum, rhenium, chromium, and aluminum.

### Claim 7 (depends on 1)

The coating system of claim 1, wherein the first erosion-resistant layer comprises a doped transition metal.

### Claim 8 (depends on 1)

The coating system of claim 1, wherein the first erosion-resistant layer comprises a transition metal doped with a material selected from the group consisting of boron, carbon, nitrogen, and oxygen.

### Claim 9 (depends on 1)

The coating system of claim 1, wherein the first angle range includes angles less than about 45 degrees relative to the component outer surface and the second angle range includes angles greater than about 45 degrees with respect to the component outer surface.