Abrasive thermal coating
AssigneeUnited Technologies Corporation
InventorsJoseph J. Parkos, Jr., Melvin Freling
Life of this patent
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Abstract
A protective coating for a surface exposed to hot gas flow comprises a thermal layer, a conducting layer and an abrasive layer. The thermal layer comprises stabilized zirconia, and overlies the surface. The conducting layer overlies the thermal layer. The abrasive layer comprises abrasive particles bonded in a metal matrix that is electroplated onto the conducting layer.
Claims25
A protective coating system for a surface exposed to hot gas flow, the protective coating system comprising:
- a thermal layer overlying the surface, the thermal layer comprising stabilized zirconia, wherein the thermal layer is yttria stabilized and has one of a lenticular grain structure or a lamellar grain structure;
- a conducting layer overlying the thermal layer;
- a bond coat overlying the surface and underlying the thermal layer;
- and
- an abrasive layer overlying the conducting layer, the abrasive layer comprising abrasive particles bonded in a metal matrix electroplated onto the thermal layer.
A gas path component comprising:
- a substrate defining a surface exposed to hot gas flow;
- and
- a protective coating on the surface, the protective coating comprising:
- a thermal barrier layer comprising stabilized zirconia overlying the substrate;
- a bond coat between the substrate and the thermal barrier layer;
- a conducting layer overlying the thermal barrier layer;
- and
- an abrasive layer comprising abrasive particles and a metal matrix bonded to the conducting layer;
- wherein the abrasive layer comprises an interface formed of the metal matrix electroplated onto the conducting layer, and the abrasive particles are bonded into the metal matrix by electrodeposition.
A method for protecting a surface exposed to hot gas flow, the method comprising:
- thermal spraying a layer of yttria stabilized zirconia over the surface;
- applying a layer of conducting material over the layer of yttria stabilized zirconia;
- and
- electroplating an abrasive layer onto the layer of conducting material, the abrasive layer comprising a metal matrix and abrasive particles;
- wherein electroplating the abrasive layer comprises electroplating a layer of metal onto the layer of conducting material to form the metal matrix, and bonding individual abrasive boron nitride particles into the metal matrix by electrodeposition.
A protective coating system for an airfoil surface exposed to hot gas flow, the protective coating system comprising:
- a thermal layer overlying the airfoil surface, the thermal layer comprising stabilized zirconia and the airfoil surface comprising an unshrouded tip surface;
- a conducting layer overlying the thermal layer;
- and
- an abrasive layer overlying the conducting layer, the abrasive layer comprising abrasive particles bonded in a metal matrix electroplated onto the thermal layer.
Dependencies are inferred from the claim text.