Novel Architectures For Ultra Low Thermal Conductivity Thermal Barrier Coatings With Improved Erosion And Impact Properties
A technology of thermal conductivity and thermal barrier, applied in the field of thermal barrier coatings and thermal barrier coating systems, can solve problems such as high thermal conductivity
Inactive Publication Date: 2014-07-16
GENERAL ELECTRIC CO
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Problems solved by technology
Most YSZ thermal barrier coatings are considered to be somewhat "porous" in nature (porosity typically 5-20%), which reduces thermal conductivity but tends to make the coating less mechanically stable and less resistant in harsh environments. erosion
[0008] Unfortunately, some known methods for improving the mechanical strength of ceramic coatings result in higher thermal conductivity
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[0051] As noted above, the novel thermal barrier coatings of the present invention result in a unique combination of improved physical properties, ie, increased corrosion resistance coupled with significantly lower thermal conductivity ("k"). From a practical and commercial standpoint, lower erosion and reduced thermal conductivity of critical hot gas components allow gas turbine engines to operate at higher firing temperatures for much longer periods of time, resulting in significantly higher overall operation efficiency. For example, it has been found that the combined cycle operating efficiency of gas turbine engines can be improved by at least the point of 0.1% using the new ultra-low-k thermal conductivity ceramic coatings described below. The cooling benefit of designing the TBC with lower thermal conductivity also increases the overall combined cycle efficiency (including buckets, nozzles, etc.) by at least 0.1%. Thus, a 30% drop in thermal k translates to an efficienc...
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Abstract
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 ), yttrium 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.
Description
[0001] The present invention relates to thermal barrier coatings applied to metal parts, including gas turbine blades and other metal parts in direct contact with high temperature exhaust gases, that are exposed to high operating temperatures, such as the harsh thermal environment inside a gas turbine engine. Specifically, the present invention relates to a new thermal barrier coating ("TBC") system comprising an insulating ceramic layer with ultra-low thermal conductivity and improved Resistance to erosion, spalling or degradation due to lifetime. [0002] In an exemplary embodiment, the novel ceramic layer comprises a zirconium-based lattice structure stabilized by a compound comprising one or more oxides of ytterbium, yttrium oxide, hafnium, lanthanum, tantalum, and / or zirconium. The present invention also includes a novel method of applying thermal barrier coatings to metal substrates using the suspension plasma spray technique, wherein said coatings exhibit significantly im...
Claims
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IPC IPC(8): C23C4/12C23C4/10B32B15/04B32B9/04
CPCF01D5/288C23C4/02F01D5/28C23C4/11C23C4/134Y10T428/12549Y10T428/12618F01D5/284F05D2300/2118
Inventor K.阿南德J.A.鲁德S.S.帕布拉J.L.马戈利斯P.帕拉卡拉L.S.罗森斯维希
Owner GENERAL ELECTRIC CO