NOVEL ARCHITECTURES FOR ULTRA LOW THERMAL CONDUCTIVITY THERMAL BARRIER COATINGS WITH IMPROVED EROSION AND IMPACT PROPERTIES

摘要

A thermal barrier coating system for metal components in a gas turbine engine having an ultra low thermal conductivity and high erosion resistance, comprising an oxidation-resistant bond coat formed from an aluminum rich material such as MCrAlY and a thermal insulating ceramic layer over the bond coat comprising a zirconium or hafnium oxide lattice structure (ZrO2 or HfO2) and an oxide stabilizer compound comprising one or more of the compounds ytterbium oxide (Yb2O3), yttria oxide (Y2O3), hafnium oxide (HfO2), lanthanum Oxide (La2O3), tantalum oxide (Ta2O5) or zirconium oxide (ZrO2). The invention includes a new method of forming the ceramic-based thermal barrier coatings using a liquid-based suspension containing microparticles comprised of at least one of the above compounds ranging in size between about 0.1 and 5 microns. The coatings form a tortuous path of ceramic interfaces that increase the coating toughness while preserving the ultra low thermal conductivity.

主权项

1. A thermal barrier coating system for a metal component of a gas turbine engine having ultra low thermal conductivity and high erosion and spallation resistance, said coating system comprising:
an oxidation-resistant bond coat comprised of an aluminum rich material overlying said metal component; and a thermal insulating ceramic layer having splat interfaces overlying said bond coat, said ceramic layer comprising a zirconium or hafnium oxide lattice structure and one or more oxide stabilizer compounds comprising ytterbium oxide, yttria oxide, hafnium oxide, lanthanum oxide, tantalum oxide or zirconium oxide.