Systems for applying a thermal barrier coating to a superalloy substrate

Abstract

Systems for applying a thermal barrier coating to a superalloy substrate including at least one target for supplying a material for making the thermal barrier coating; at least one laser operably directed toward the target for liberating atomic particles from the target; and a plasma torch for generating a plasma for accelerating and depositing the atomic particles onto the superalloy substrate as the thermal barrier coating where the superalloy substrate is a nickel based superalloy or a cobalt based superalloy.

Description

TECHNICAL FIELD[0001]Embodiments described herein generally relate to systems for applying a thermal barrier coating to a superalloy substrate. More particularly, embodiments herein generally relate to systems for carrying out laser assisted plasma coating at atmospheric pressure for applying a thermal barrier coating to a superalloy substrate.BACKGROUND OF THE INVENTION[0002]Increasingly stringent demands are being imposed on the efficacy of gas turbine engines employed in the aerospace and power generation industries. This demand is driven by the requirement to reduce the consumption of fossil fuels, and in turn, operating costs. One way to improve turbine efficiency is to increase the operating temperature in the turbine section of the engine. However, with increased operating temperatures comes an increased demand on materials used in the turbine section. Not only must these materials be able to withstand the higher operating temperatures (from about 800° C. to about 1500° C.), ...

AI Technical Summary

Benefits of technology

"The patent text describes systems for applying a thermal barrier coating to a superalloy substrate using a laser and a plasma torch. The systems can use different targets and lasers to release atomic particles from the targets and deposit them onto the substrate to create the coating. The technical effect of the patent is to provide a method for applying a thermal barrier coating to a variety of superalloys, which can improve their performance in high-temperature applications."

Problems solved by technology

This demand is driven by the requirement to reduce the consumption of fossil fuels, and in turn, operating costs.

, but they must also endure increased mechanical stresses, corrosion, erosion, and other severe operating conditions, while continuing to fulfill lifetime requirements expected by the industry. T

Conventional practices often utilize plasma spray or electron beam physical vapor deposition (EBPVD) to apply the high temperature TBCs, both of which can be problematic.

Such plasma sprayed coatings can be susceptible to plugging up the cooling holes of turbine components to which they are applied.

While EBPVD can produce more desirable coatings, it is an expensive process because it is carried out under a high vacuum and has higher equipment costs.

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