Low thermal conductivity and high toughness TBC composition

Abstract

A composition is provided comprising a rare-earth-doped zirconium oxide having a tetragonal structure and having the following formula: Y a Ln b Ta x Nb z Zr 1‑a‑b‑x‑z O 2‑δ In the formula, Ln is a rare earth element or a mixture of rare earth elements; 0≤a≤0.06; 0.06≤b≤0.12; 0≤x≤0.1; 0≤z≤0.1; 0.08≤(x+z)≤0.1; 0.16≤(a+b+x+z)≤0.22; and 0.01≤δ≤0.05. A method for forming a coating using this composition and a coated component are also provided.

Description

Technical Field

[0001] This invention generally relates to compositions suitable for use in coating systems on components exposed to high-temperature environments (e.g., through the hot gas flow path of a gas turbine engine). More specifically, this invention relates to compositions suitable for use in thermal barrier coating (TBC) systems. Background Technology

[0002] The use of thermal barrier coatings (TBCs) on components of gas turbine engines, such as combustors, high-pressure turbine (HPT) blades, and vanes, is increasing. Typically, the thermal insulation of TBCs allows such components to withstand higher operating temperatures, increasing component durability and improving engine reliability. For TBCs to remain effective throughout the planned lifespan of the components they protect, they are expected to have low thermal conductivity throughout the component's lifespan, including high-temperature excursion. Additionally, high toughness is desired in TBCs to reduce damage from erosion and impact to rotating components of the HPT, combustor components, and static turbine components (e.g., turbine nozzles). Low thermal conductivity TBCs can improve efficiency by reducing heat loss and potentially allowing for higher temperature operation.

[0003] Currently, the TBC material 8YSZ is known for its high toughness and high thermal conductivity. Low thermal conductivity compositions, such as 55YSZ, lack high toughness. Therefore, further improvements to TBC technology are desired, especially when TBC is used for thermal insulation of components designed for more demanding engine specifications. Summary of the Invention

[0004] In one aspect, the present invention provides a composition comprising: a rare-earth-doped zirconium oxide having a tetragonal structure and having the following formula: Y a Ln b Ta x Nb z Zr 1-a-b-x-z O 2-δ In the formula, Ln is a rare earth element or a mixture of rare earth elements; 0≤a≤0.06; 0.06≤b≤0.12; 0≤x≤0.1; 0≤z≤0.1; 0.08≤(x+z)≤0.1; 0.16≤(a+b+x+z)≤0.22; and 0.01≤δ≤0.05.

[0005] In another aspect, the present invention provides a coating component comprising: a substrate having a surface; and a thermal barrier coating on the surface; wherein the thermal barrier coating comprises a layer containing the above-described composition.

[0006] In another aspect, the present invention provides a method for forming a coated component, the method comprising: applying a layer to the surface of a substrate, wherein the layer comprises the above-described composition.

[0007] In another aspect, the present invention provides a coated component comprising: a substrate having a surface; an adhesive coating on the surface of the substrate; and a thermal barrier coating on the adhesive coating; wherein the thermal barrier coating comprises a layer of rare-earth-doped zirconium oxide having a tetragonal structure, the layer having a thermal conductivity of 1.5 W / mk to 1.8 W / mk at 1000 °C as measured by laser scintillation according to ASTM E1461-13. Attached Figure Description

[0008] The complete and practiceable disclosure (including its best mode) of the invention for those skilled in the art is set forth in the specification with reference to the accompanying drawings, wherein:

[0009] Figure 1 This is a cross-sectional schematic diagram of an exemplary coated component; and

[0010] Figure 2 This is a schematic cross-sectional view of an exemplary gas turbine engine according to various embodiments of the subject matter of the present invention.

[0011] The repeated use of reference numerals in the specification and drawings is intended to indicate the same or similar features or elements in the invention. Detailed Implementation

[0012] definition

[0013] As used herein, the term "exemplary" means "serving as an example, illustration, or description." Any implementation described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other implementations. Furthermore, unless otherwise specifically indicated, all implementations described herein should be considered exemplary.

[0014] The term "gas turbine engine" refers to an engine that has a turbine as its power source, either entirely or partially. Exemplary gas turbine engines include turbofan engines, turboprop engines, turbojet engines, turboshaft engines, and hybrid versions of more than one of these engines. The term "turbine" or "turbomachinery" refers to a machine that includes more than one compressor, a heating section (e.g., a combustion section), and more than one turbine that together produce torque output.

[0015] In this invention, when a layer is described as being “on” or “above” another layer or substrate, it should be understood that, unless explicitly stated otherwise, the layers may be in direct contact with each other or have another layer or feature between them. Therefore, these terms merely describe the relative positions of the layers and do not necessarily mean “on top of”, as the relative position of above or below depends on the orientation of the device relative to the observer.

[0016] In this invention, chemical elements are discussed using their common chemical abbreviations, such as those commonly found on the periodic table. For example, hydrogen is represented by its common chemical abbreviation H; helium by its common chemical abbreviation He; and so on.

[0017] As used herein, “Ln” refers to a rare earth element or a mixture of rare earth elements. More specifically, “Ln” refers to the rare earth elements scandium (Sc), yttrium (Y), lanthanum (La), cerium (Ce), praseodymium (Pr), neodymium (Nd), promethium (Pm), samarium (Sm), europium (Eu), gadolinium (Gd), terbium (Tb), dysprosium (Dy), holmium (Ho), erbium (Er), thulium (Tm), ytterbium (Yb), lutetium (Lu), or mixtures thereof.

[0018] As used herein, the term "substantially (materially) free of" should be understood to mean either completely free of the ingredient or containing trace amounts of the ingredient. "Trace amounts" are quantitative levels of chemical components that are virtually undetectable and do not provide any benefit to the functional or aesthetic properties of the subject composition. The term "substantially (materially) free of" also includes completely free of. Detailed Implementation

[0020] Reference will now be made in detail to embodiments of the invention, one or more of which are illustrated in the accompanying drawings. The examples provided are merely illustrative of the invention and not intended to limit it. Indeed, various modifications and variations can be made to the invention without departing from its scope, as will be apparent to those skilled in the art. For example, a feature described or illustrated as part of one embodiment may be used in another embodiment to produce yet another embodiment. Therefore, it is intended that the invention cover such modifications and variations, all of which fall within the scope of the appended claims and their equivalents.

[0021] Generally, compositions based on rare-earth-tantalum / niobium-doped zirconium oxides with a tetragonal structure and coatings formed from these compositions are disclosed. In 95-100% dense pucks, these compositions and coatings can exhibit relatively low thermal conductivity (e.g., 1.5 W / mK to 1.8 W / mK at 1000 °C, measured by laser scintillation according to ASTM E1461-13) and 5 MPa-m 1 / 2Up to 8MPa-m 1 / 2 The indentation fracture toughness is improved. Typically, these compositions can be used to form a TBC layer with lower thermal conductivity and enhanced toughness and / or CMAS protection. Therefore, the resulting TBC will allow for higher part surface temperatures and / or reduced coating thickness at the same surface temperature. Reduced TBC thickness, especially in applications requiring relatively thick TBC (e.g., burners), will result in significant cost reductions and weight benefits. Additionally, the resulting TBC can provide improved protection to the underlying substrate, reducing erosion that might occur throughout the part's lifespan in the absence of a TBC layer.

[0022] The composition typically comprises a rare-earth-doped zirconium oxide having a tetragonal structure. In one embodiment, the composition has the formula shown in Formula 1:

[0023] Formula 1:Y a Ln b Ta x Nb z Zr 1-a-b-x-z O 2-δ

[0024] In the formula,

[0025] Ln is a rare earth element or a mixture of rare earth elements;

[0026] 0 ≤ a ≤ 0.06;

[0027] 0.06≤b≤0.12;

[0028] 0 ≤ x ≤ 0.1;

[0029] 0≤z≤0.1;

[0030] 0.08≤(x+z)≤0.1;

[0031] 0.16≤(a+b+x+z)≤0.22; and

[0032] 0.01≤δ≤0.05.

[0033] In certain embodiments, Ln may include Sm, Gd, Yb, La, Ce, Nd, Eu, Dy, Er, Ho, Lu, or mixtures thereof. In one particular embodiment, Ln is substantially free of Tb and Pr.

[0034] In one embodiment, a is greater than 0, such that Y is present in the composition, for example, where 0.03 ≤ a ≤ 0.06. In an alternative embodiment, a is 0, such that the composition is substantially free of Y. It is not desirable to be bound by any particular theory, but it is believed that too much Y in rare-earth-doped zirconium oxide may lead to the formation of a cubic phase with lower toughness. However, if Y is present, Ta can be included within Ln to stabilize and maintain the tetragonal structure while reducing thermal conductivity. However, it is not desirable to be bound by any particular theory, but it is believed that too much Ta in rare-earth-doped zirconium oxide may also lead to the formation of a cubic phase and lower toughness. Therefore, in one embodiment, particularly when a is 0, Ln may be present toward its upper limit in Equation 1, for example, 0.08 ≤ b ≤ 0.12.

[0035] In one particular implementation, (a+b) is 0.12. Alternatively or additionally, (x+z) is 0.1. When (a+b) is 0.12 and (x+z) is 0.1, then (a+b+x+z) is 0.22.

[0036] Typically, δ refers to the oxygen vacancy formed within rare-earth-doped zirconium oxide, with the valence state of the composition balanced based on a specific Y / Ln / Ta / Nb / Zr composition present in the compound. In a particular embodiment, 0.01 ≤ δ ≤ 0.03.

[0037] When z is 0, the composition can be represented by the formula shown in Formula 2:

[0038] Formula 2: Y a Ln b Ta x Zr 1-a-b-x O 2-δ

[0039] In the formula,

[0040] Ln is a rare earth element or a mixture of rare earth elements;

[0041] 0 ≤ a ≤ 0.06;

[0042] 0.06≤b≤0.12;

[0043] 0.08≤x≤0.1;

[0044] 0.16≤(a+b+x)≤0.22; and

[0045] 0.01≤δ≤0.05.

[0046] Particularly suitable compositions of rare-earth-tantalum / niobium-doped zirconium oxides with a tetragonal structure may include, but are not limited to:

[0047] Y 0.06 Sm 0.06 Yes 0.1 Zr 0.78 About 1.99 ;

[0048] Y 0.06 Sm 0.06 Nb 0.1 Zr 0.78 About 1.99 ;

[0049] Y 0.03 Sm 0.09 Yes 0.1 Zr 0.78 About 1.99 ;

[0050] Y 0.03 Sm 0.09 Nb 0.1 Zr 0.78 About 1.99 ;

[0051] Y 0.03 Sm 0.06 Yb 0.03 Yes 0.1 Zr 0.78 About 1.99 ;

[0052] Y 0.03 Sm 0.06 Yb 0.03 Nb 0.1 Zr 0.78 About 1.99 ;

[0053] Y 0.06 Gd 0.06 Yes 0.1 Zr 0.78 About 1.99 ;

[0054] Y 0.06 Gd 0.06 Nb 0.1 Zr 0.78 About 1.99 ;

[0055] Sm 0.12 Yes 0.1 Zr 0.78 About 1.99 ;

[0056] Sm 0.12 Nb 0.1 Zr 0.78 About 1.99 ;

[0057] Sm 0.08 Yb 0.04 Ta 0.1 Zr 0.78 O 1.99 ;

[0058] Sm 0.12 Nb 0.1 Zr 0.78 O 1.99 ;or

[0059] A mixture of them.

[0060] As described above, rare-earth-tantalum / niobium-doped zirconium oxide compositions with a tetragonal structure are particularly suitable for use as thermal barrier coating layers on components.

[0061] For example, refer to Figure 1 An exemplary coated component 100 is shown, which is formed from a substrate 102 having a surface 103 and a coating system 106 thereon. Typically, the coating system 106 includes an adhesive coating 104 on the surface 103 of the substrate 102 and a TBC 108 on the adhesive coating 104. In the illustrated embodiment, the adhesive coating 104 is directly on the surface 103 without any layers in between. Adhesive coating materials widely used in TBC systems may include, but are not limited to: antioxidant overlay coatings, such as MCrAlX (where M is iron, cobalt and / or nickel, and X is yttrium or other rare earth elements); and antioxidant diffusion coatings, such as diffused aluminides containing aluminum intermetallic compounds.

[0062] The substrate 102 can be any suitable material, such as a metal for high-temperature resistance, such as steel or a superalloy (e.g., a nickel-based superalloy, a cobalt-based superalloy, or an iron-based superalloy, such as Rene N5, N500, N4, N2, IN718, Hastelloy X, or Haynes 188) or other suitable materials. The coating system 106 can be disposed along more than one portion of the substrate 102, or substantially over the entire exterior of the substrate 102. In certain embodiments, the coating system 106 can have a total thickness of 50 μm (i.e., micrometers or μm) to 2500 μm (e.g., 100 μm to 700 μm).

[0063] TBC 108 may be formed from a plurality of separate layers 114. In one embodiment, at least one of the layers 114 of TBC 108 is a layer comprising a composition of rare-earth-tantalum / niobium-doped zirconium oxide (e.g., having the formula of Formula 1) having a tetragonal structure. For example, at least one of the layers 114 of TBC 108 may comprise at least 80 wt% of a composition of rare-earth-tantalum / niobium-doped zirconium oxide (e.g., having the formula of Formula 1) having a tetragonal structure. In one embodiment, at least one of the layers 114 of TBC 108 may comprise 90 wt% to 100 wt% of a composition of rare-earth-tantalum / niobium-doped zirconium oxide (e.g., having the formula of Formula 1) having a tetragonal structure. In a particular embodiment, at least one of the layers 114 of TBC 108 is substantially composed of a composition of rare-earth-tantalum / niobium-doped zirconium oxide (e.g., having the formula of Formula 1) having a tetragonal structure.

[0064] In a particular embodiment, each layer of the TBC 108 in layers 114 may have a layer thickness of 25 μm to 100 μm (e.g., 25 μm to 50 μm).

[0065] One or more of the individual layers 114 can be formed of a stable ceramic capable of withstanding relatively high temperature gradients, allowing the coated metal component to operate at gas temperatures above the metal's melting point. For example, the stable ceramic material can be one or more of the following: yttrium-stabilized zirconium oxide (YSZ) and other rare-earth-stabilized zirconium oxide compositions, mullite (3Al₂O₃-2SiO₂), alumina, cerium dioxide (CeO₂), rare-earth lanthanum zirconate, rare-earth oxides (e.g., La₂O₃, Nb₂O₅, Pr₂O₃, CeO₂), and metal-glass composites and combinations thereof (e.g., alumina and YSZ, or cerium dioxide and YSZ). In addition to high-temperature stability, YSZ also possesses a good combination of high toughness and chemical inertness, and its coefficient of thermal expansion is suitably matched to that of the coated metal component.

[0066] Individual layers 114 can be formed by any suitable process. For example, more than one individual layer 114 can be formed by air-plasma spraying (APS), suspension plasma spraying (SPS), solution precursor plasma spraying (SPPS), electron beam physical vapor deposition (EBPVD), high-velocity oxygen fuel spraying (HVOF), electrostatic spraying assisted vapor deposition (ESAVD), and direct vapor deposition.

[0067] In one embodiment, TBC 108 may include a YSZ-based (e.g., 8YSZ) layer closest to the substrate 102 (e.g., directly on the adhesive coating 104). Thus, yttrium-stabilized zirconium oxide can form a barrier coating between the substrate and the layer (which comprises a composition of rare-earth-tantalum / niobium-doped zirconium oxides (e.g., having the formula of Formula 1) with a tetragonal structure).

[0068] The coated component 100 is particularly suitable for use as components located in high-temperature environments, such as those in gas turbine engines, including combustor components, turbine blades, shrouds, nozzles, heat shields, and impellers. Specifically, the coated component 100 can be a component located within the hot gas flow path of the gas turbine, such that the coating system 106 forms a thermal barrier for the substrate 102 beneath it, protecting the component 100 within the gas turbine when exposed to the hot gas flow path.

[0069] Figure 2 This is a schematic cross-sectional view of a gas turbine engine according to an exemplary embodiment of the present invention. More specifically, for Figure 2 In this implementation, the gas turbine engine is a high-bypass turbofan engine 10, referred to herein as "turbofan engine 10". Figure 2 As shown, the turbofan engine 10 defines an axial direction A (extending parallel to the longitudinal axis 12 for reference) and a radial direction R. Typically, the turbofan engine 10 includes a fan section 14 and a core turbine engine 16 disposed downstream of the fan section 14. Although described below with reference to the turbofan engine 10, the invention is generally applicable to turbomachinery, including turbojet engines, turboprop engines, and turboshaft gas turbine engines, including industrial and marine gas turbine engines and auxiliary power units. It is also applicable to other high-temperature applications where water vapor is present in the gas phase (e.g., those caused by the combustion of hydrocarbon fuels).

[0070] The exemplary core turbine engine 16 shown generally includes a substantially tubular housing 18 defining an annular inlet 20. The housing 18 surrounds, in a series flow relationship: a compressor section (including a boost or low-pressure (LP) compressor 22 and a high-pressure (HP) compressor 24); a combustion section 26; a turbine section (including a high-pressure (HP) turbine 28 and a low-pressure (LP) turbine 30); and an exhaust nozzle section 32. A high-pressure (HP) shaft or spool 34 drives the HP turbine 28 to the HP compressor 24. A low-pressure (LP) shaft or spool 36 drives the LP turbine 30 to the LP compressor 22.

[0071] In the illustrated embodiment, fan section 14 includes a variable-pitch fan 38 having a plurality of fan blades 40 spaced apart from disk 42. As shown, the fan blades 40 extend outward from disk 42 generally along a radial direction R. Since the fan blades 40 are operatively connected to suitable actuating members 44 (configured to collectively and uniformly change the pitch of the fan blades 40), each fan blade 40 can rotate relative to disk 42 about a pitch axis P. The fan blades 40, disk 42, and actuating members 44 rotate together about a longitudinal axis 12 via an LP spool 36 (passing through an optional power gearbox 46). The power gearbox 46 includes a plurality of gears for progressively reducing the rotational speed of the LP spool 36 to a more efficient fan speed.

[0072] Still referencing Figure 2 In an exemplary embodiment, disk 42 is covered by a rotatable forward nacelle 48 having an aerodynamic profile to facilitate airflow through a plurality of fan blades 40. Additionally, the exemplary fan section 14 includes an annular fan housing or external nacelle 50 that circumferentially surrounds at least a portion of the fan 38 and / or the core turbine engine 16. It should be understood that the nacelle 50 may be configured to be supported relative to the core turbine engine 16 by a plurality of circumferentially spaced outlet guide vanes 52. Furthermore, a downstream section 54 of the nacelle 50 may extend beyond an external portion of the core turbine engine 16 to define a bypass airflow passage 56 therebetween.

[0073] During operation of the turbofan engine 10, a volume of air 58 enters the turbofan engine 10 through the nacelle 50 and / or the associated inlet 60 of the fan section 14. As the volume of air 58 passes through the fan blades 40, a first portion 62 of the air 58 is directed or guided, as indicated by arrows, into the bypass airflow passage 56, and a second portion 64 of the air 58 is directed or guided, as indicated by arrows, into the LP compressor 22. The ratio between the first portion 62 and the second portion 64 of the air is commonly referred to as the bypass ratio. Then, as the second portion 64 of the air is guided through the high-pressure (HP) compressor 24 and into the combustion section 26, the pressure of the second portion 64 of the air increases, where it mixes with fuel and burns to provide combustion gases 66.

[0074] Combustion gas 66 is guided through HP turbine 28, where a portion of the thermal and / or kinetic energy from the combustion gas 66 is extracted via a sequential stage of HP turbine stator blades 68 (connected to housing 18) and HP turbine rotor blades 70 (connected to HP shaft or spool 34), causing the HP shaft or spool 34 to rotate, thereby supporting the operation of HP compressor 24. Combustion gas 66 is then guided through LP turbine 30, where a second portion of the thermal and kinetic energy is extracted from the combustion gas 66 via a sequential stage of LP turbine stator blades 72 (connected to housing 18) and LP turbine rotor blades 74 (connected to LP shaft or spool 36), causing the LP shaft or spool 36 to rotate, thereby supporting the operation of LP compressor 22 and / or fan 38.

[0075] Subsequently, the combustion gases 66 are directed through the injection exhaust nozzle section 32 of the core turbine engine 16 to provide propulsive thrust. Simultaneously, before the first portion of air 62 is exhausted from the fan nozzle exhaust section 76 of the turbofan engine 10, the pressure of the first portion of air 62 increases significantly as it is directed through the bypass airflow passage 56, also providing propulsive thrust. The HP turbine 28, LP turbine 30, and injection exhaust nozzle section 32 at least partially define a hot gas path 78 for directing the combustion gases 66 through the core turbine engine 16.

[0076] Other aspects of the invention are provided by the subject matter of the following clauses:

[0077] 1. A composition comprising a rare-earth-doped zirconium oxide having a tetragonal structure and having the following formula: Y a Ln b Ta x Nb z Zr 1-a-b-x-z O 2-δ In the formula, Ln is a rare earth element or a mixture of rare earth elements; 0≤a≤0.06; 0.06≤b≤0.12; 0≤x≤0.1; 0≤z≤0.1; 0.08≤(x+z)≤0.1; 0.16≤(a+b+x+z)≤0.22; and 0.01≤δ≤0.05.

[0078] 2. The composition according to any one of the preceding clauses, wherein 0.03 ≤ a ≤ 0.06.

[0079] 3. The composition according to any one of the preceding clauses, wherein a is 0; and 0.08 ≤ b ≤ 0.12.

[0080] 4. The composition according to any one of the preceding clauses, wherein (a+b) is 0.12.

[0081] 5. The composition according to any one of the preceding clauses, wherein (x+z) is 0.1.

[0082] 6. The composition according to any one of the preceding clauses, wherein z is 0, such that the formula is Y. a Ln b Ta x Zr 1-a-b-x O 2-δ In the formula, Ln is a rare earth element or a mixture of rare earth elements; 0≤a≤0.06; 0.06≤b≤0.12; 0.08≤x≤0.1; 0.16≤(a+b+x)≤0.22; and 0.01≤δ≤0.05.

[0083] 7. The composition according to any one of the preceding clauses, wherein Ln comprises Sm, Gd, Yb, La, Ce, Nd, Eu, Dy, Er, Ho, Lu or mixtures thereof.

[0084] 8. The composition according to any one of the preceding clauses, wherein Ln is substantially free of Tb and Pr.

[0085] 9. The composition according to any one of the preceding clauses, wherein the composition has a thermal conductivity of 1.5 W / mk to 1.8 W / mk at 1000°C as measured by laser scintillation according to ASTM E1461-13.

[0086] 10. The composition according to any one of the preceding clauses, wherein the composition is selected from the group consisting of: Y 0.06 Sm 0.06 Ta 0.1 Zr 0.78 O 1.99 ;Y 0.06 Sm 0.06 Nb 0.1 Zr 0.78 O 1.99 ;Y 0.03 Sm 0.09 Ta 0.1 Zr 0.78 O 1.99 ;Y 0.03 Sm 0.09 Nb 0.1 Zr 0.78 O 1.99 ;Y 0.03 Sm 0.06 Yb 0.03 Ta 0.1 Zr 0.78 O 1.99 ;Y 0.03 Sm 0.06 Yb0.03 Nb 0.1 Zr 0.78 O 1.99 ;Y 0.06 Gd 0.06 Ta 0.1 Zr 0.78 O 1.99 ;Y 0.06 Gd 0.06 Nb 0.1 Zr 0.78 O 1.99 ;Sm 0.12 Ta 0.1 Zr 0.78 O 1.99 ;Sm 0.12 Nb 0.1 Zr 0.78 O 1.99 ;Sm 0.08 Yb 0.04 Ta 0.1 Zr 0.78 O 1.99 ;Sm 0.12 Nb 0.1 Zr 0.78 O 1.99 ; and their mixtures.

[0087] 11. A coating component comprising: a substrate having a surface; and a thermal barrier coating on the surface; wherein the thermal barrier coating comprises a layer comprising a composition according to any one of the preceding clauses.

[0088] 12. The coating component according to any one of the preceding clauses, wherein the coating component further comprises: an adhesive coating on the surface of the substrate and located between the surface of the substrate and the thermal barrier coating.

[0089] 13. The coating component according to any one of the preceding clauses, wherein the coating component further comprises: a barrier coating on the adhesive coating and located between the adhesive coating and the thermal barrier coating, the barrier coating comprising yttrium-stabilized zirconium oxide.

[0090] 14. A method of forming a coated component, the method comprising: applying a layer to a surface of a substrate, wherein the layer comprises the composition described in any one of the preceding clauses.

[0091] 15. A coated component comprising: a substrate having a surface; an adhesive coating on the surface of the substrate; and a thermal barrier coating on the adhesive coating; wherein the thermal barrier coating comprises a layer of rare-earth-doped zirconium oxide having a tetragonal structure, the layer having a thermal conductivity of 1.5 W / mk to 1.8 W / mk at 1000 °C as measured by laser scintillation according to ASTM E1461-13.

[0092] 16. The coating component according to any one of the preceding clauses, wherein the coating component further comprises: a barrier coating on the adhesive coating and located between the adhesive coating and the thermal barrier coating, the barrier coating comprising yttrium-stabilized zirconium oxide.

[0093] 17. The coated component according to any one of the preceding clauses, wherein the indentation fracture toughness of the layer is 5 MPa-m. 1 / 2 Up to 8MPa-m 1 / 2 .

[0094] 18. The coated component according to any one of the preceding clauses, wherein the layer is substantially free of rare earth-doped zirconium oxide having a cubic structure.

[0095] 19. The coated component according to any one of the preceding clauses, wherein the rare-earth-doped zirconium oxide having a tetragonal structure has the following formula: Y a Ln b Ta x Nb z Zr 1-a-b-x-z O 2-δ In the formula, Ln is a rare earth element or a mixture of rare earth elements; 0≤a≤0.06; 0.06≤b≤0.12; 0≤x≤0.1; 0≤z≤0.1; 0.08≤(x+z)≤0.1; 0.16≤(a+b+x+z)≤0.22; and 0.01≤δ≤0.05.

[0096] 20. The coated component according to any one of the preceding clauses, wherein the composition is selected from the following: Y 0.06 Sm 0.06 Ta 0.1 Zr 0.78 O 1.99 ;Y 0.06 Sm 0.06 Nb 0.1 Zr 0.78 O 1.99 ;Y 0.03 Sm 0.09 Ta 0.1 Zr 0.78 O 1.99 ;Y 0.03 Sm 0.09Nb 0.1 Zr 0.78 O 1.99 ;Y 0.03 Sm 0.06 Yb 0.03 Ta 0.1 Zr 0.78 O 1.99 ;Y 0.03 Sm 0.06 Yb 0.03 Nb 0.1 Zr 0.78 O 1.99 ;Y 0.06 Gd 0.06 Ta 0.1 Zr 0.78 O 1.99 ;Y 0.06 Gd 0.06 Nb 0.1 Zr 0.78 O 1.99 ;Sm 0.12 Ta 0.1 Zr 0.78 O 1.99 ;Sm 0.12 Nb 0.1 Zr 0.78 O 1.99 ;Sm 0.08 Yb 0.04 Ta 0.1 Zr 0.78 O 1.99 ;Sm 0.12 Nb 0.1 Zr 0.78 O 1.99 ; and their mixtures.

[0097] 21. The coated component according to any one of the preceding clauses, wherein the rare-earth-doped zirconium oxide having a tetragonal structure is selected from the following: Y 0.06 Sm 0.06 Ta 0.1 Zr 0.78 O 1.99 ;Y 0.06 Sm 0.06 Nb 0.1 Zr 0.78 O 1.99 ;Y 0.03 Sm 0.09 Ta 0.1 Zr 0.78 O 1.99 ;Y 0.03 Sm 0.09 Nb 0.1 Zr 0.78 O1.99 ;Y 0.03 Sm 0.06 Yb 0.03 Ta 0.1 Zr 0.78 O 1.99 ;Y 0.03 Sm 0.06 Yb 0.03 Nb 0.1 Zr 0.78 O 1.99 ;Y 0.06 Gd 0.06 Ta 0.1 Zr 0.78 O 1.99 ;Y 0.06 Gd 0.06 Nb 0.1 Zr 0.78 O 1.99 ;Sm 0.12 Ta 0.1 Zr 0.78 O 1.99 ;Sm 0.12 Nb 0.1 Zr 0.78 O 1.99 ;Sm 0.08 Yb 0.04 Ta 0.1 Zr 0.78 O 1.99 ;Sm 0.12 Nb 0.1 Zr 0.78 O 1.99 ; and their mixtures.

[0098] This written description uses exemplary embodiments to disclose the invention (including the best mode) and also enables any person skilled in the art to practice the invention (including making and using any device or system and performing any combination of methods). The patentable scope of the invention is defined by the claims and may include other examples that may occur to a person skilled in the art. Such other examples are intended to fall within the scope of the claims if they include structural elements that are identical to the written language of the claims, or if they include equivalent structural elements that are not substantially different from the written language of the claims.

Claims

1. A composition comprising: Rare earth-doped zirconium oxide with a tetragonal structure and the following formula: Y a Ln b Yes x Nb z Zr 1-a-b-x-z About 2-δ , In the formula, Ln is a rare earth element or a mixture of rare earth elements, wherein Ln contains Sm; 0≤a≤0.06； 0.06≤b≤0.12； 0≤x≤0.1； 0≤z≤0.1； 0.08≤(x+z)≤0.1; 0.16≤(a+b+x+z)≤0.22; and 0.01≤δ≤0.

05.

2. The composition according to claim 1, wherein, 0≤a≤0.03。 3. The composition according to claim 1, wherein, a is 0; and 0.08 ≤ b ≤ 0.

12.

4. The composition according to claim 1, wherein, (a+b) is 0.

12.

5. The composition according to claim 1, wherein, (x+z) is 0.

1.

6. The composition according to claim 1, wherein, When z is 0, the expression becomes: Y a Ln b Yes x Zr 1-a-b-x About 2-δ , In the formula, Ln is a rare earth element or a mixture of rare earth elements; 0≤a≤0.06； 0.06≤b≤0.12； 0.08≤x≤0.1； 0.16≤(a+b+x)≤0.22; as well as 0.01≤δ≤0.

05.

7. The composition according to claim 1, wherein, Ln also contains Gd, Yb, La, Ce, Nd, Eu, Dy, Er, Ho, Lu, or mixtures thereof.

8. The composition according to claim 1, wherein, Ln contains virtually no Tb or Pr.

9. The composition according to claim 1, wherein, The composition has a thermal conductivity of 1.5 W / mk to 1.8 W / mk at 1000 °C, measured by laser flare method according to ASTM E1461-13.

10. The composition according to claim 1, wherein, The composition is selected from the following: Y 0.06 Sm 0.06 Yes 0.1 Zr 0.78 About 1.99 ; Y 0.06 Sm 0.06 Nb 0.1 Zr 0.78 O 1.99 ; Y 0.03 Sm 0.09 Yes 0.1 Zr 0.78 About 1.99 ; Y 0.03 Sm 0.09 Nb 0.1 Zr 0.78 O 1.99 ; Y 0.03 Sm 0.06 Yb 0.03 Yes 0.1 Zr 0.78 About 1.99 ; Y 0.03 Sm 0.06 Yb 0.03 Nb 0.1 Zr 0.78 O 1.99 ; Sm 0.12 Yes 0.1 Zr 0.78 About 1.99 ; Sm 0.12 Nb 0.1 Zr 0.78 O 1.99 ; Sm 0.08 Yb 0.04 Yes 0.1 Zr 0.78 About 1.99 ; Sm 0.12 Nb 0.1 Zr 0.78 O 1.99 ;as well as A mixture of them.

11. A coating component, the coating component comprising: A substrate with a surface; as well as Thermal barrier coating on the surface; The thermal barrier coating comprises a layer containing the composition of claim 1.

12. The coated component according to claim 11, wherein, The coating component further includes: An adhesive coating on the surface of the substrate and located between the surface of the substrate and the thermal barrier coating.

13. The coated component according to claim 12, wherein, The coating component further includes: A barrier coating is placed on the adhesive coating and located between the adhesive coating and the thermal barrier coating, the barrier coating comprising yttrium-stabilized zirconium oxide.

14. A method of forming a coated component, the method comprising: Apply the layer to the surface of the substrate. The layer comprises the composition of claim 1.

15. A coated component, the coated component comprising: A substrate with a surface; An adhesive coating on the surface of the substrate; as well as Thermal barrier coating on adhesive coating; The thermal barrier coating comprises a layer of rare-earth-doped zirconium oxide having a tetragonal structure, the zirconium oxide containing Sm, and the thermal conductivity of the layer at 1000°C, measured by laser scintillation according to ASTM E1461-13, is between 1.5 W / mk and 1.8 W / mk.

16. The coated component according to claim 15, wherein, The coating component further includes: A barrier coating is placed on the adhesive coating and located between the adhesive coating and the thermal barrier coating, the barrier coating comprising yttrium-stabilized zirconium oxide.

17. The coated component according to claim 15, wherein, The indentation fracture toughness of the layer is 5 MPa-m. 1 / 2 Up to 8MPa-m 1 / 2 .

18. The coated component according to claim 15, wherein, The layer is substantially free of rare-earth-doped zirconium oxide with a cubic structure.

19. The coated component according to claim 15, wherein, The rare-earth-doped zirconium oxide with a tetragonal structure has the following formula: Y a Ln b Yes x Nb z Zr 1-a-b-x-z About 2-δ , In the formula, Ln is a rare earth element or a mixture of rare earth elements; 0≤a≤0.06； 0.06≤b≤0.12； 0≤x≤0.1； 0≤z≤0.1； 0.08≤(x+z)≤0.1; 0.16≤(a+b+x+z)≤0.22; as well as 0.01≤δ≤0.

05.

20. The coated component according to claim 15, wherein, The rare-earth-doped zirconium oxide with a tetragonal structure is selected from the following: Y 0.06 Sm 0.06 Yes 0.1 Zr 0.78 About 1.99 ; Y 0.06 Sm 0.06 Nb 0.1 Zr 0.78 O 1.99 ; Y 0.03 Sm 0.09 Yes 0.1 Zr 0.78 About 1.99 ; Y 0.03 Sm 0.09 Nb 0.1 Zr 0.78 O 1.99 ; Y 0.03 Sm 0.06 Yb 0.03 Yes 0.1 Zr 0.78 About 1.99 ; Y 0.03 Sm 0.06 Yb 0.03 Nb 0.1 Zr 0.78 O 1.99 ; Sm 0.12 Yes 0.1 Zr 0.78 About 1.99 ; Sm 0.12 Nb 0.1 Zr 0.78 O 1.99 ; Sm 0.08 Yb 0.04 Yes 0.1 Zr 0.78 About 1.99 ; Sm 0.12 Nb 0.1 Zr 0.78 O 1.99 ;as well as A mixture of them.

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