Coated component for reducing carbon deposits in gas turbine engines

Abstract

A coated component for reducing carbon deposition in a gas turbine engine. The coated component includes a metal substrate at least partially defining a flow channel for the hydrocarbon fluid, and a nanophase separated catalytic coating deposited on the metal substrate to be exposed to the flow channel for reducing carbon deposition from the hydrocarbon fluid. The nanophase separated catalytic coating comprises a substantially pure transition metal phase, a substantially pure noble metal phase, and a substantially pure transition metal oxide phase.

Description

Technical Field

[0001] This disclosure relates to coated components for reducing carbon deposits, such as coated components for reducing carbon deposits in aircraft gas turbine engines. Background Technology

[0002] Gas turbine engines include surfaces that come into contact with hydrocarbon fluids, such as fuel and lubricating oil. When exposed to hydrocarbon fluids at high temperatures, carbonaceous deposits (also known as carbon deposits) can form on these surfaces, causing carbon to adhere to and accumulate as deposits on surfaces in contact with fuel or oil. Summary of the Invention

[0003] One aspect of the present invention provides a coating component for reducing carbon deposits in a gas turbine engine, the coating component comprising: a metal substrate that at least partially defines a flow channel for a hydrocarbon fluid; and a nanophase-separated catalytic coating deposited on the metal substrate to expose the flow channel for reducing carbon deposits from the hydrocarbon fluid, the nanophase-separated catalytic coating comprising substantially pure transition metal phase, substantially pure noble metal phase, and substantially pure transition metal oxide phase.

[0004] Another aspect of the present invention provides a method for manufacturing the above-mentioned coated component, the method comprising: co-depositing a transition metal and a noble metal on a metal substrate to produce a coating substrate, wherein the transition metal and the noble metal are substantially immiscible; and oxidizing a portion of the transition metal to produce the coated component. Attached Figure Description

[0005] The features and advantages of this disclosure will become apparent in the following description of various exemplary embodiments, as shown in the accompanying drawings, wherein the same reference numerals generally denote the same, functionally similar and / or structurally similar elements.

[0006] Figure 1 A schematic diagram of an aircraft having a gas turbine engine according to an embodiment of the present disclosure.

[0007] Figure 2 For along Figure 1 The line 2-2 in the middle is cut off Figure 2 The image shows a cross-sectional view of an aircraft gas turbine engine.

[0008] Figure 3 According to one embodiment of this disclosure Figure 2 The image shows a cross-sectional view of the combustor of a gas turbine engine. Figure 3 To display Figure 2 Detail view of part 3 in the image.

[0009] Figure 4 for Figure 3 Cross-sectional view of the mixer assembly of the burner. Figure 4 To display Figure 3 Detailed view of part 4 in the image.

[0010] Figure 5 According to another embodiment of this disclosure Figure 2 The image shows a cross-sectional view of the combustor of a gas turbine engine.

[0011] Figure 6 for Figure 5 A cross-sectional view of the mixer assembly of the burner shown. Figure 6 To display Figure 5 Detailed view of part 6 in the image.

[0012] Figure 7 A cross-sectional view of a nanophase-separated catalytic coating applied to a flow channel for hydrocarbon fluids.

[0013] Figure 8A A schematic cross-sectional view of a coated substrate according to one embodiment of the present disclosure is shown.

[0014] Figure 8B Showing Figure 8A A detailed view of part 8B of the coating substrate shown.

[0015] Figure 9A A schematic cross-sectional view of a coated component according to one embodiment of the present disclosure is shown.

[0016] Figure 9B Showing Figure 9A A detailed view of part 9B of the coated component shown.

[0017] Figure 9C This is a schematic cross-sectional view of a coated component according to one embodiment of the present disclosure.

[0018] Figure 10 A flowchart illustrating a method for manufacturing a coated component according to one embodiment of the present disclosure. Detailed Implementation

[0019] The features, advantages, and embodiments of this disclosure will be illustrated or apparent from consideration of the following detailed description, the accompanying drawings, and the claims. Furthermore, the following detailed description is exemplary and intended to provide further explanation, not to limit the scope claimed by this disclosure.

[0020] Several implementation methods are discussed in detail below. While specific implementation methods are discussed, this is for illustrative purposes only. Those skilled in the art will recognize that other components and configurations can be used without departing from this disclosure.

[0021] The terms "front" and "rear" refer to relative positions within a gas turbine engine or vehicle, and to the normal operating posture of the gas turbine engine or vehicle. For example, for a gas turbine engine, "front" refers to the position closer to the engine inlet, and "rear" refers to the position closer to the engine nozzle or exhaust port.

[0022] The terms "upstream" and "downstream" refer to the relative directions of fluid flow within a fluid channel. For example, "upstream" refers to the direction from which the fluid flow originates, and "downstream" refers to the direction in which the fluid flow is directed. The term "fluid" can refer to either a gas or a liquid. The term "fluid connectivity" refers to the ability of fluids to establish a connection between specific areas.

[0023] Unless otherwise specified herein, the terms “connection,” “fixation,” “attachment,” “linkage,” etc., refer to both direct connection, fixation, attachment, or linking, and indirect connection, fixation, attachment, or linking through one or more intermediate components or features.

[0024] The term "transition metals" refers to elements in groups 3 (IIIb) to 12 (IIb) of the periodic table and combinations thereof, excluding precious metals.

[0025] The term "precious metals" refers to the elements rhenium, ruthenium, rhodium, palladium, silver, osmium, iridium, platinum, and gold.

[0026] As used herein, a material is “nanophase-separated” if it has at least two phases, each of which is contained in multiple regions of the material, and the average diameter of the multiple regions of each phase is from one nanometer to one micrometer. In some embodiments, the multiple regions are grains.

[0027] As used herein, a "substantially pure transition metal phase" comprises at least one transition metal element and has at least 95% by weight of the transition metal element based on the total weight of the substantially pure transition metal phase. In some embodiments, the substantially pure transition metal phase comprises at least one transition metal element and has at least 99% by weight of the transition metal element based on the total weight of the substantially pure transition metal phase. In some embodiments, the substantially pure transition metal phase comprises at least one transition metal element and has at least 99.9% by weight of the transition metal element in the substantially pure transition metal phase.

[0028] As used herein, a "substantially pure transition metal oxide phase" comprises at least one transition metal oxide compound and has at least 95% by weight of the transition metal oxide compound based on the total weight of the substantially pure transition metal oxide phase. In some embodiments, the substantially pure transition metal oxide phase comprises at least one transition metal oxide compound and has at least 99% by weight of the transition metal oxide compound based on the total weight of the substantially pure transition metal oxide phase. In some embodiments, the substantially pure transition metal oxide phase comprises at least one transition metal oxide compound and has at least 99.9% by weight of the transition metal oxide compound in the substantially pure transition metal oxide phase.

[0029] As used herein, a "substantially pure noble metal phase" comprises at least one noble metal element and has at least 95% by weight of the noble metal element based on the total weight of the substantially pure noble metal phase. In some embodiments, the substantially pure noble metal phase comprises at least one noble metal element and has at least 99% by weight of the noble metal element based on the total weight of the substantially pure noble metal phase. In some embodiments, the substantially pure noble metal phase comprises at least one noble metal element and has at least 99.9% by weight of the noble metal element in the substantially pure noble metal phase.

[0030] As used herein, if an equilibrium mixture (e.g., an alloy or solid solution) of the first phase or first compound and the second phase or second compound cannot be formed at a temperature of 273.15 Kelvin and an absolute pressure of exactly 101.325 kPa, and wherein the first compound accounts for 5% to 95% by weight of the total weight of the equilibrium mixture, then the first phase or first compound and the second phase or second compound are “substantially immiscible”.

[0031] As used herein, an alloy is considered "element-based" when an element is present in the alloy at the maximum weight percentage of all elements in the alloy, based on the total weight of the alloy. For example, in an iron-based alloy, the weight percentage of iron is higher than that of any other single element present in the alloy.

[0032] As used herein, the average grain size of a material can be determined, for example, by X-ray diffraction (XRD) or scanning electron microscopy.

[0033] Unless the context clearly indicates otherwise, the singular forms “a,” “an,” and “the” include plural references.

[0034] In this specification and throughout the claims, scope limitations may be combined and / or interchanged. Unless the context or language otherwise indicates, such scope is defined and includes all subscopes contained herein. For example, all scopes disclosed herein include endpoints, and endpoints may be independently combined with each other.

[0035] As mentioned above, carbon deposits can occur on the surfaces of gas turbine engines that are exposed to hydrocarbon fluids, such as fuel and lubricating oil, at high temperatures. Fuel nozzles and swirlers (collectively referred to as the mixer assembly) used in the combustor of a gas turbine engine have such surfaces.

[0036] Carbon deposits can accumulate in fuel flow channels at locations such as nozzles, fuel orifices, cyclones, or other locations where fuel flow blockage or disruption of fuel flow is likely to occur, affecting the hydrodynamics or aerodynamics of fuel flow. Some of these hydrocarbon flow channels (e.g., these fuel flow channels) may be susceptible to soak-back heating, leading to soak-back coking. Soak-back heating occurs immediately after shutdown. During shutdown, the flow of hydrocarbon fluids (e.g., fuel) within the fuel flow channels and on the inner surfaces defining these channels may stagnate (or at least be significantly reduced). Furthermore, various cooling fluids (e.g., cooling air) cease flowing to cool the gas turbine engine. Meanwhile, combustor components (e.g., fuel nozzles or surrounding areas) remain hot. Consequently, the temperature of the hydrocarbon fluids (e.g., fuel) and the temperature of the walls defining the hydrocarbon flow channels rise above the carbon deposit formation temperature. At this temperature, the inner surfaces exposed to the hydrocarbon fluid and made of the metals described herein may readily accumulate substantial amounts of carbon deposits. In such cases, carbon deposits can accumulate over time to a considerable thickness, restricting or even blocking the flow of hydrocarbon fluids through the hydrocarbon flow channels.

[0037] Nanophase-separated catalytic coatings can be applied to mitigate this re-leaching coking. These coatings, capable of catalyzing coke degradation reactions (e.g., coke oxidation), can reduce or eliminate coke deposits. For example, coke oxidation can convert solid coke deposits into gaseous reaction products because it can involve the reaction of carbon with diatomic oxygen to form reaction products such as carbon monoxide and carbon dioxide. Without nanophase-separated catalytic coatings capable of catalyzing coke degradation reactions, coke deposits may accumulate on surfaces, degrading system and component performance. For example, as described below, nanophase-separated catalytic coatings can reduce coking at low temperatures (e.g., from 300°F to 500°F) and, as detailed below, can help reduce coking on fuel nozzles and valves.

[0038] This paper discloses a nanophase-separated catalytic coating that can be applied to various surfaces and components to reduce carbon buildup. The nanophase-separated catalytic coating comprises substantially pure transition metal phases, substantially pure noble metal phases, and substantially pure transition metal oxide phases, thereby endowing the nanophase-separated catalytic coating with catalytic activity.

[0039] Unwilling to be bound by theory, the inventors believe that the transition metal oxide phase can provide oxygen vacancy defects to achieve better surface oxygen availability (both in terms of concentration and mobility). The noble metal phase can provide faster pathways for electrons, contributing to rapid charge transfer kinetics. The transition metal phase can be dispersed within the noble metal phase to increase the number of phase boundaries between the noble metal phase and the transition metal phase during oxidation, which can help enhance reaction kinetics. The transition metal phase can also help replenish the transition metal oxide phase with transition metal oxides on the outer surface of the coating in the event of transition metal oxide loss. Together, the noble metal and transition metal phases can contribute to good adhesion to the metal substrate and enhance the overall durability of the coating.

[0040] When nanophase-separated catalytic coatings are applied to a metal substrate (e.g., a surface or part of a component), the grain size of substantially pure transition metal phases, substantially pure noble metal phases, and substantially pure transition metal oxide phases can be customized to improve, for example, the catalytic activity of the nanophase-separated catalytic coating. Reducing the grain size can increase the reactivity of the nanophase-separated catalytic coating by, for example, increasing the available catalytic surface area for contact with and catalytic degradation of carbon deposits.

[0041] The nanophase-separated catalytic coating is a metallic coating. Due to the metallic strength of the nanophase-separated catalytic coating, the metallurgical bond between the nanophase-separated catalytic coating and the metal substrate, and the favorable matching of the coefficients of thermal expansion between the nanophase-separated catalytic coating and the metal substrate, the phase-separated catalytic coating can exhibit improved durability. After using the nanophase-separated catalytic coating, its catalytic activity can be regenerated by oxidizing the nanophase-separated catalytic coating to regenerate a substantially pure transition metal oxide phase. For example, in the case of loss of transition metal oxides, the substantially pure transition metal oxide phase can be replenished with transition metal oxides by oxidizing the transition metal elements in the substantially pure transition metal phase. Some non-limiting examples of suitable surfaces and components include aircraft components and gas turbine engine components (including lubrication system components and fuel system components).

[0042] Fuel system components may include fuel circuit components, fuel nozzles (e.g., fuel flow channels and fuel injection orifices), mixer assembly components (e.g., venturi surfaces on fuel nozzles, fuel nozzle tips, or combinations thereof), and parts and combinations thereof. Gas turbines may be gas turbines for aircraft, land turbines (e.g., turbines for power plants), or marine gas turbine engines for ships. Some of these components will be described in more detail below.

[0043] Figure 1 An aircraft 20 capable of various implementations is shown. The aircraft 20 includes a fuselage 22, wings 24 attached to the fuselage 22, and a tail 26. The aircraft 20 also includes a propulsion system that generates the thrust required to propel the aircraft 20 during flight, taxiing, and other operations. Figure 1 The propulsion system of the aircraft 20 shown includes a pair of engines 100. In this embodiment, each engine 100 is attached to one of the wings 24 in an underwing configuration via a pylon 28. Although Figure 1 The engine 100 is shown attached to the wing 24 in an underwing configuration, but in other embodiments, the engine 100 may have an alternative configuration and be coupled to other parts of the aircraft 20. For example, the engine 100 may additionally or alternatively include more than one aspect coupled to other parts of the aircraft 20, such as the tail 26 and the fuselage 22.

[0044] The following will be for reference Figure 2 To describe further, Figure 1 The engine 100 shown is a gas turbine engine, and each gas turbine engine is capable of selectively generating propulsive thrust for the aircraft 20. The magnitude of the propulsive thrust can be at least partially based on the thrust generated by the fuel system 150 (see fuel system 150). Figure 3 The amount of fuel supplied to engine 100 (e.g., a gas turbine engine) is controlled by the amount of fuel supplied. In the embodiments described herein, the aviation turbine fuel is a combustible hydrocarbon liquid fuel, such as kerosene-type fuel having the required number of carbon atoms, synthetic aviation fuel, biofuel, biodiesel, ethanol, bioethanol, etc., and the fuel is stored in fuel tank 151 of fuel system 150. Figure 2 As shown, at least a portion of the fuel tank 151 is located within each wing 24, and a portion of the fuel tank 151 is located within the fuselage 22 between the wings 24. However, the fuel tank 151 may be located in other suitable locations within the fuselage 22 or the wings 24. The fuel tank 151 may also be entirely located within the fuselage 22 or the wings 24. The fuel tank 151 may also be a separate container rather than a single unit, for example, two containers each located within a respective wing 24.

[0045] although Figure 1The aircraft 20 shown is an airplane, but the embodiments described herein can also be applied to other aircraft 20, including, for example, helicopters and unmanned aerial vehicles (UAVs). The aircraft described herein are fixed-wing or rotary-wing aircraft that generate lift through aerodynamic forces acting on, for example, a fixed wing (e.g., wing 24) or a rotor (e.g., the rotor of a helicopter), and are heavier-than-air aircraft, rather than lighter-than-air aircraft (e.g., airships). Furthermore, although not described herein, in other embodiments, the gas turbine engine can be any other suitable type of gas turbine engine, such as an industrial gas turbine engine integrated into a power generation system, a marine gas turbine engine, etc.

[0046] Figure 2 for Figure 1 A schematic cross-sectional view of one of the engines 100 used in the propulsion system of the aircraft 20 shown. Figure 2 The cross-sectional view is along Figure 1 It was cut from line 2-2 in the middle. For Figure 2 In the embodiment shown, engine 100 is a high bypass ratio engine. Engine 100 has an axial direction A (extending parallel to the longitudinal centerline axis 101, such as...) Figure 2 (as shown), radial (R) and circumferential ( ). Circumferential ( Figure 2 (Not shown in the image) Extends in a direction of rotation about axis A. Engine 100 includes a fan section 102 and a turbine engine 104 disposed downstream of the fan section 102.

[0047] Figure 2 The illustrated turbine engine 104 includes a compressor section 103, a combustion section 114, and a turbine section 115 in series flow. The turbine engine 104 is substantially enclosed within a casing 106, which is generally tubular and defines a core inlet 108. In the illustrated embodiment, the core inlet 108 is annular. Figure 2As schematically shown, compressor section 103 includes a turbocharger or low-pressure (LP) compressor 110, downstream of which is a high-pressure (HP) compressor 112. Combustion section 114 is located downstream of compressor section 103. Turbine section 115 is located downstream of combustion section 114 and includes a high-pressure (HP) turbine 116, downstream of which is a low-pressure (LP) turbine 118. Turbine engine 104 also includes an exhaust nozzle section 120, a high-pressure (HP) shaft 122 or spool, and a low-pressure (LP) shaft 124, all located downstream of turbine section 115. HP shaft 122 drivably connects HP turbine 116 to HP compressor 112. HP turbine 116 and HP compressor 112 rotate synchronously via HP shaft 122. LP shaft 124 drivably connects LP turbine 118 to LP compressor 110. LP turbine 118 and LP compressor 110 rotate synchronously via LP shaft 124. The compressor section 103, combustion section 114, turbine section 115 and injection exhaust nozzle section 120 together define the core air flow passage 121 through which the core air 139 flows.

[0048] Figure 2 The fan segment 102 shown includes a fan 126 (e.g., a variable pitch fan) having a plurality of fan blades 128 spaced apart and coupled to the disk 130. Figure 2 As shown, fan blades 128 extend outward from disk 130 generally radially R. In the case of a variable-pitch fan, multiple fan blades 128 can rotate relative to disk 130 about pitch axis P because fan blades 128 are operatively coupled to actuating member 131, which is configured to change the pitch of fan blades 128 together. Fan blades 128, disk 130, and actuating member 131 can rotate together via fan shaft 133 about longitudinal central axis 101, fan shaft 133 being powered by LP shaft 124 via a power gearbox (also referred to as gearbox assembly 135). Thus, fan 126 is drivenly coupled to and powered by turbine engine 104, engine 100 being an indirect-drive engine. Gearbox assembly 135 can be a reduction gearbox assembly for regulating the speed of fan shaft 133 as power is transmitted from LP shaft 124 to fan shaft 133, thereby regulating the speed of fan 126 relative to LP shaft 124.

[0049] Still referencing Figure 2In an exemplary embodiment, disk 130 is covered by fan hub 132, which has an aerodynamic profile to facilitate airflow through a plurality of fan blades 128. Furthermore, fan section 102 includes an annular fan housing or nacelle 134 circumferentially surrounding at least a portion of fan 126 and turbine engine 104. Nacelle 134 is supported relative to turbine engine 104 by a plurality of outlet guide vanes 136 circumferentially spaced around nacelle 134 and turbine engine 104. Additionally, a downstream section 138 of nacelle 134 extends over an outer portion of turbine engine 104 and, together with housing 106, defines a bypass airflow passage 140 between them.

[0050] During operation of engine 100, a certain amount of air enters the turbine engine (e.g., engine 100) through engine inlet 129 or fan section 102 of engine nacelle 134. As the air passes through fan blades 128, a first portion of the air (also referred to as bypass air 137) is directed into bypass airflow passage 140, while a second portion of the air (also referred to as core air 139) is directed into the upstream section of core airflow passage 121 through core inlet 108 of LP compressor 110. The ratio between bypass air 137 and core air 139 is commonly referred to as the bypass ratio. The pressure of core air 139 is then increased in compressor section 103, more specifically, in LP compressor 110, to produce compressed air 141. Compressed air 141 is directed through HP compressor 112, where it is further compressed, and enters combustion section 114, where it is mixed with fuel and ignited to produce combustion gases 143.

[0051] Combustion gas 143 is directed into and expanded by the HP turbine 116, where a portion of the thermal or kinetic energy is extracted through the HP turbine stator and rotor blades of a higher stage connected to the HP shaft 122. This causes the HP shaft 122 to rotate, thereby supporting the operation of the HP compressor 112 (self-sustaining cycle). In this way, the combustion gas 143 performs work on the HP turbine 116. The combustion gas 143 is then directed into and expanded by the LP turbine 118. Here, a second portion of the thermal or kinetic energy is extracted from the combustion gas 143 through the LP turbine stator and rotor blades of a higher stage connected to the LP shaft 124. This causes the LP shaft 124 to rotate, thereby supporting the operation of the LP compressor 110 (self-sustaining cycle) and the rotation of the fan 126 via the gearbox assembly 135. In this way, the combustion gas 143 performs work on the LP turbine 118.

[0052] Combustion gas 143 is then directed through the injection exhaust nozzle section 120 of the turbine engine 104 to provide propulsive thrust. Simultaneously, bypass air 137 is directed through bypass airflow passage 140 and then discharged from the fan nozzle exhaust section of the engine 100, also providing propulsive thrust. The HP turbine 116, LP turbine 118, and injection exhaust nozzle section 120 at least partially define hot gas passages for directing combustion gas 143 through the turbine engine 104.

[0053] Engine 100 can operate in conjunction with fuel system 150 and receive fuel flow from fuel system 150. Fuel system 150 includes fuel delivery assembly 153 that supplies fuel flow from fuel tank 151 to engine 100, and more specifically, to a plurality of fuel injectors 200 that inject fuel into combustor 300 of combustion section 114 (see [link to fuel delivery assembly]). Figure 4 (to be discussed further below) in combustion chamber 302.

[0054] As discussed in more detail below, the components of the fuel system 150 (more specifically, the fuel tank 151) are examples of fuel sources that supply fuel to the fuel injector 200. The fuel delivery assembly 153 includes tubes, pipes, conduits, etc., to fluidly connect the various components of the fuel system 150 to the engine 100. The fuel tank 151 is configured to store hydrocarbon fuel, and hydrocarbon fuel is supplied from the fuel tank 151 to the fuel delivery assembly 153. The fuel delivery assembly 153 is configured to transport hydrocarbon fuel between the fuel tank 151 and the engine 100, thereby providing a flow path (fluid passage) for hydrocarbon fuel from the fuel tank 151 to the engine 100.

[0055] Fuel system 150 includes at least one fuel pump fluidly connected to fuel delivery assembly 153 to direct fuel flow through fuel delivery assembly 153 to engine 100. One such pump is a main fuel pump 155. The main fuel pump 155 is a high-pressure pump and is the primary source of pressure increase in the fuel delivery assembly 153 between fuel tank 151 and engine 100. The main fuel pump 155 may be configured to increase the pressure in fuel delivery assembly 153 to a level greater than that of combustor 300 in combustion section 114 (see [link to documentation]). Figure 4 The pressure inside combustion chamber 302 (to be discussed further below).

[0056] Fuel system 150 also includes a fuel metering unit 157 in fluid communication with fuel delivery assembly 153. Any suitable fuel metering unit 157 can be used, such as a metering valve. The fuel metering unit 157 is located downstream of main fuel pump 155 and upstream of fuel manifold 159, which is configured to distribute fuel to fuel injectors 200. Fuel system 150 is configured to supply fuel to fuel metering unit 157, and fuel metering unit 157 is configured to receive fuel from fuel tank 151. Fuel metering unit 157 is also configured to supply fuel flow to engine 100 in a desired manner. More specifically, fuel metering unit 157 is configured to meter fuel and supply a desired amount of fuel to fuel manifold 159 of engine 100 at, for example, a desired flow rate. Fuel manifold 159 is in fluid communication with fuel injectors 200 and distributes (supplyes) the received fuel to a plurality of fuel injectors 200, wherein fuel is injected into combustion chamber 302 and burned. Adjusting the fuel metering unit 157 changes the amount of fuel supplied to the combustion chamber 302, thereby changing the magnitude of the propulsive thrust generated by the engine 100 to propel the aircraft 20.

[0057] Engine 100 also includes various auxiliary systems to assist in the operation of engine 100 and / or the aircraft including engine 100. For example, engine 100 may include a main lubrication system 162, a compressor cooling air (CCA) system 164, an active thermal gap control (ATCC) system 166, and a generator lubrication system 168, each system in... Figure 2 The diagram is schematically shown. The main lubrication system 162 is configured to provide lubricant to various bearings and gear meshing in the compressor section, turbine section, HP shaft 122, and LP shaft 124. The lubricant provided by the main lubrication system 162 can increase the service life of such components and can remove a certain amount of heat from such components by using more than one heat exchanger. The compressor cooling air (CCA) system 164 supplies air from one or both of the HP compressor 112 or LP compressor 110 to one or both of the HP turbine 116 or LP turbine 118. The active thermal gap control (ATCC) system 166 is used to minimize the gap between the turbine blade tip and the casing wall when the casing temperature changes during flight operations. The generator lubrication system 168 provides lubrication to the electric generator (not shown) and provides cooling / de-heating to the electric generator. The electric generator can provide power to, for example, the starter motor of engine 100 and / or various other electronic components of engine 100 and / or the aircraft including engine 100. The lubrication system for engine 100 (e.g., main lubrication system 162 and generator lubrication system 168) can be lubricated using hydrocarbon fluids (e.g., oil), wherein the oil circulates through the inner surface of oil removal lines.

[0058] The engine 100 described herein is provided by way of example only. In other embodiments, any other suitable engine may be used with aspects of this disclosure. For example, in other embodiments, the engine may be any other suitable gas turbine engine, such as a turboshaft engine, a turboprop engine, a turbojet engine, a ductless single-fan engine, etc. In this way, in other embodiments, the gas turbine engine may have other suitable configurations, such as a direct-drive configuration, a fixed-pitch fan, or other suitable number or arrangement of shafts, compressors, turbines, fans, etc. Furthermore, although Figure 2 A specific engine 100 is shown, but the nanophase-separated catalytic coating disclosed herein can be used more broadly and / or used in conjunction with other engine implementations. For example, in alternative implementations, aspects of this disclosure can be incorporated into any other type of engine (e.g., a reciprocating engine) or otherwise used with any other type of engine (e.g., a reciprocating engine). Furthermore, in other exemplary implementations, the exemplary engine 100 may include any other suitable auxiliary systems or be operatively connected to any other suitable auxiliary system. Additionally or alternatively, the exemplary engine 100 may not include one or more of the auxiliary systems 162, 164, 166, and 168 as described above, or may be operatively connected to one or more of the auxiliary systems 162, 164, 166, and 168 as described above.

[0059] Figure 3 The combustion section 114 according to an embodiment of the present disclosure is shown. Figure 2 ) burner 300. Figure 3 To display Figure 2 Detailed view of section 3. The burner 300 is an annular burner, comprising a combustion chamber 302 defined between an inner liner 304 and an outer liner 306. Each of the inner liner 304 and the outer liner 306 is annular about the longitudinal central axis 101 of the engine 100. Figure 2 The burner 300 also includes a burner housing 308, which is also annular about the longitudinal central axis 101 of the engine 100. The burner housing 308 extends circumferentially around an inner liner 304 and an outer liner 306, which are located radially inside the burner housing 308. The burner 300 also includes a dome 310 mounted at the front end of each of the inner liner 304 and the outer liner 306. The dome 310 defines the upstream end (or front end) of the combustion chamber 302.

[0060] Multiple mixer components 210 ( Figure 3 (Only one is shown in the image) spaced apart around the dome 310. Multiple mixer assemblies 210 surround the engine 100 (...). Figure 2 The longitudinal central axis 101 of the ) is spaced circumferentially. Figure 3In the illustrated embodiment, each mixer assembly 210 is a dual-ring premixed cyclone separator (TAPS), comprising a main mixer 212 and a pilot mixer 211. Throughout the engine's operating cycle, the pilot mixer 211 is supplied with fuel by fuel injectors 200. Fuel flows along a pilot fuel passage 215 and exits from one or more pilot fuel injection orifices 217 into the combustion chamber 302. Only under power-increased conditions during the engine operating cycle (e.g., takeoff and climb) is the main mixer 212 supplied with fuel by fuel injectors 200. Fuel flows along a main fuel passage 213 and exits from one or more main fuel injection orifices 219 into the combustion chamber 302. The TAPS mixer assembly 210 is provided as an example only; the nanophase-separated catalytic coating described herein can be applied to other mixer assembly designs and other combustor designs.

[0061] As described above, the compressor section (including HP compressor 112) Figure 2 Air is pressurized, and combustor 300 receives an annular flow of this pressurized air from the discharge outlet (compressor discharge outlet 216) of HP compressor 112. This air may be referred to as compressor discharge pressure air. A portion of the compressor discharge air flows into mixer assembly 210. Fuel is injected into the air in mixer assembly 210 to mix with the air and form a fuel-air mixture. The fuel-air mixture is supplied from mixer assembly 210 to combustion chamber 302 for combustion. Ignition of the fuel-air mixture is accomplished by igniter 312, and the resulting combustion gases flow axially and into an annular first-stage turbine nozzle 314. The first-stage turbine nozzle 314 is defined by an annular flow channel comprising a plurality of radially extending, circularly spaced nozzle blades 316 that rotate the gas, causing the gas to flow at an angle and impinge on HP turbine 116. Figure 2 The first turbine blades (not shown) of the first turbine (not shown).

[0062] The fuel injector 200 is fixed to the burner housing 308 via a nozzle base. In this embodiment, the nozzle base is a flange 202 integrally formed with the rod 204 of the fuel injector 200. The flange 202 is fixed to and sealed to the burner housing 308. The rod 204 includes a flow channel through which hydrocarbon fuel flows and extends radially inward from the flange 202. The fuel injector 200 also includes a fuel nozzle tip 220, which is part of a mixer assembly 210 through which fuel is injected into the combustion chamber 302.

[0063] Figure 4 Showing Figure 3 The mixer assembly 210 of the burner 300 shown. Figure 4 To display Figure 3 Detailed view of detail 4 in the image, and, due to Figure 3 It is a cross-sectional view, therefore Figure 4 Also a cross-sectional view of the mixer assembly 210. Fuel nozzle tip 220 ( Figure 3 This includes a fuel nozzle body 222 and a rear heat shield 224 attached to the fuel nozzle body 222. The fuel nozzle body 222 can be mounted, for example, to an inlet cowl. The inlet cowl and rod 204 ( Figure 3 The fuel nozzle body 222 may be connected to or integrated with rod 204. The fuel nozzle body 222 may include a pilot mixer 211. The pilot mixer 211 and pilot fuel injection orifice 217 may be located at the center of an annular pilot inlet 246. The fuel nozzle body 222 may also include a main fuel passage 213 and a main fuel injection orifice 219, which may be collectively referred to as the main fuel nozzle. The main fuel nozzle (including the main fuel passage 213 and the main fuel injection orifice 219) surrounds the pilot inlet 246, which is located between the main fuel nozzle and the pilot fuel injection orifice 217. In this embodiment, the fuel nozzle tip 220 (see...) Figure 3 The axis extending through the center of the pilot fuel injection orifice 217 is circular. In the following discussion, various features of the fuel nozzle tip 220 can be discussed relative to this axis. The main fuel passage 213, pilot fuel passage 215, pilot fuel injection orifice 217, and main fuel injection orifice 219 can each be formed in a portion of the fuel nozzle body 222. Each of the main fuel passage 213 and pilot fuel passage 215 can be defined by one or more walls formed in the fuel nozzle body 222.

[0064] As described above, fuel is supplied to the main fuel injection orifice 219 via the rod 204. The main fuel injection orifice 219 injects fuel radially outward through a circular array of main fuel injection orifices 219 formed on the outer surface of the fuel nozzle body 222. Fuel is also supplied to the pilot fuel injection orifice 217 via the rod 204. The pilot mixer 211 is supported by an annular pilot housing 270. After the gas turbine engine is shut down, the fuel in the fuel circuit components may be heated (e.g., from 300 to 500 degrees Fahrenheit) due to heat transfer from the hot zone near the combustion chamber. As described above, this heat transfer can lead to re-lamination of carbon deposits when residual fuel in the fuel circuit components forms carbon deposits. Carbon deposits formed on such materials may strongly bond with these metal components (e.g., fuel nozzle tip 220, main fuel channel 213, pilot fuel channel 215, pilot fuel injection orifice 217, main fuel injection orifice 219, or combinations thereof), resulting in the formation of a thick carbon deposit layer, such as carbon deposits with large particles, polymeric carbon deposits, and / or self-oxidizing carbon deposits. A nanophase-separated catalytic coating 288 can be applied to various components of the TAPS mixer assembly 210, such as the pilot fuel channel 215, pilot fuel injection orifice 217, main fuel channel 213, main fuel injection orifice 219, or combinations thereof. More specifically, the nanophase-separated catalytic coating 288 can be applied to the walls defining the pilot fuel channel 215, main fuel channel 213, or both.

[0065] The pilot mixer 211 is supported by an annular pilot housing 270. The pilot housing 270 includes a tapered wall section 272 that surrounds a tapered pilot mixing chamber 274, which is in flow communication with and downstream of the pilot mixer 211. The pilot mixing chamber 274 is also in flow communication with and downstream of a pilot fuel injection orifice 217. The pilot mixing chamber 274 serves as a passage for the fuel injector 200, and more specifically, as a passage for the fuel nozzle tip 220. Since the fuel nozzle tip 220 is also part of the mixer assembly 210, the pilot mixing chamber 274 is also a passage for the mixer assembly 210.

[0066] Therefore, the tapered wall section 272 of the pilot housing 270 serves as a channel wall, including a channel wall surface 276 facing the pilot mixing chamber 274 (channel). In this embodiment, the tapered wall section 272 is part of a second venturi tube 280 formed by the pilot housing 270. The second venturi tube 280 includes a constriction section 282, a diffuser section 284, and a throat 286 between the constriction section 282 and the diffuser section 284. The diffuser section 284 is provided by the tapered wall section 272, which extends downstream from the throat 286 and continues to extend along with the exposed surface 228 of the rear heat shield 224. The exposed surface 228 in this embodiment forms the tapered wall section of the rear heat shield 224, which is coplanar with the channel wall surface 276 of the tapered wall section 272. The diffuser section 284 has an upstream end (throat 286 in this embodiment) and a downstream end (outlet 278 of the pilot mixing chamber 274 in this embodiment). Figure 4 As shown, the cross-sectional area of ​​the second venturi tube 280 at the outlet 278 (downstream end) is greater than the cross-sectional area of ​​the second venturi 280 at the throat 286 (upstream end).

[0067] Air flows through pilot mixer 211, through constriction section 282, to throat 286. This air mixes with the fuel-air mixture from the outlet and moves through throat 286 to diffuser section 284 and rear heat shield 224. As the fuel-air mixture flows through pilot mixing chamber 274, through outlet 278 of pilot mixing chamber 274, and into combustion chamber 302, pilot mixing chamber 274 (more specifically, the passage wall surface 276 of conical wall section 272) is exposed to hydrocarbon fuel. Due to its proximity to combustion chamber 302 and the main combustion zone, the fuel, conical wall section 272, and rear heat shield 224 are exposed to high temperatures. For example, conical wall section 272 and rear heat shield 224 may be at temperatures of 300°C to 600°C and 600°C to 1400°C, respectively.

[0068] The pilot housing 270 is made of materials suitable for use in these high-temperature environments, including, for example, stainless steel, corrosion-resistant nickel-chromium alloys, and high-strength nickel-based alloys. Therefore, the pilot housing 270 can be formed of a metal alloy selected from iron-based alloys, nickel-based alloys, cobalt-based alloys, and chromium-based alloys. These types of metal alloys can be used as substrates for nanophase-separated catalytic coatings. For example, in some embodiments, the nanophase-separated catalytic coating is deposited on a metal substrate formed of a metal alloy selected from iron-based alloys, nickel-based alloys, cobalt-based alloys, and chromium-based alloys.

[0069] As described above, the pilot mixing chamber 274 is a channel, and in the embodiments described herein, a portion of the channel wall is a coated channel wall coated with a nano-phase-separated catalytic coating 288. The coated channel wall is located downstream of the pilot fuel injection orifice 217. As described above, air flows through the pilot mixing chamber 274 (channel) and is introduced through an air inlet. In these embodiments, the air inlet is located upstream of the coated channel wall. More specifically, air is introduced into the pilot mixing chamber 274 (channel) through a pilot inlet 246.

[0070] The nanophase-separated catalytic coating 288 can be applied to any region as described above. Depending on the region of application, the thickness of the nanophase-separated catalytic coating 288 can be appropriately determined to address issues such as carbon buildup rate and catalyst wear rate. For example, the thickness of the nanophase-separated catalytic coating 288 can range from 0.02 micrometers to 10 micrometers. In some embodiments, a thickness of 0.02 to 3 micrometers can be applied by methods such as chemical bath deposition (CBD), sol-gel or sol-dip coating, chemical vapor deposition (CVD), and / or electrodeposition. This thickness is suitable for narrow-diameter (e.g., 0.3 to 0.8 mm) fuel / oil circuits, such as the main orifice or valve region in an aircraft engine fuel nozzle.

[0071] The thickness of the nanophase-separated catalytic coating 288 can be, for example, less than 200 micrometers, such as less than 100 micrometers, 10 micrometers, less than 5 micrometers, or less than 2 micrometers. In some embodiments, the thickness of the nanophase-separated catalytic coating 288 can be from 1 micrometer to 200 micrometers. In other embodiments, the thickness of the nanophase-separated catalytic coating 288 can be, for example, less than 300 nanometers, such as less than 100 nanometers. In some embodiments, the thickness of the nanophase-separated catalytic coating 288 can be from 20 nanometers to 300 nanometers. In some embodiments, the thickness of the nanophase-separated catalytic coating 288 can be from 300 nanometers to 10 micrometers.

[0072] In the preceding discussion, the burner 300 and mixer assembly 210 were configured to use a dual-ring premixed cyclone separator (TAPS), but the nanophase-separated catalytic coating 288 described herein can be applied to other mixer assembly designs and other burner designs. Figure 5 Another example of burner 400 is shown. Figure 5 This is a cross-sectional view of burner 400, showing a rich burner design. Figure 6 Showing Figure 5 The mixer assembly 410 of the burner 400 shown. Figure 6 To display Figure 5 Detailed view of part 6 in the middle, due to Figure 5 It is a cross-sectional view, therefore Figure 6This is also a cross-sectional view of the mixer assembly 410. The burner 400 and mixer assembly 410 of this embodiment include the same or similar components as the burner 300 and mixer assembly 210 described above. The same reference numerals are used to denote the same or similar components as described above in this embodiment, and detailed descriptions of these components are omitted.

[0073] The burner 400 of this embodiment shows a fuel-rich burner. Multiple mixer assemblies 410 (only one shown) are spaced apart around a dome 310. Fuel flows along a fuel passage 403 and is injected into the mixer assembly 410 through a fuel injection orifice 402. To reduce carbon buildup, the fuel passage 403, fuel injection orifice 402, or both may be coated with a nanophase-separated catalytic coating 288. The fuel injection orifice 402 injects fuel in a generally downstream direction into compressed air flowing through a first cyclone separator (not shown). The fuel is injected into a mixing chamber 404, which mixes the fuel with the compressed air to form a fuel-air mixture. This is in contrast to the pilot mixing chamber 274 described above. Figure 4 Similarly, in this embodiment, the mixing chamber 404 serves as a passage for the fuel injector 200, having a wall section 406 including a passage wall surface 408 facing the mixing chamber 404 (passage). In this embodiment, the wall section 406 is part of a venturi tube 420, which includes a constriction section 422, a diffuser section 424, and a throat 426 between the constriction section 422 and the diffuser section 424. In this embodiment, a nanophase-separated catalytic coating 288 is formed on the surface of the venturi tube 420. The fuel-air mixture exits through the outlet 428 of the mixing chamber 404 and mixes with air flowing through a second cyclone separator (not shown), located upstream of the exposed surface 228 of the rear heat shield 224.

[0074] Figure 7 This is a cross-sectional view of a flow channel 502 for hydrocarbon fluid 504. The flow channel 502 is at least partially defined by a substrate (more specifically, a metal substrate 506). The metal substrate 506 includes a surface 508 facing the flow channel, to which a nanophase-separated catalytic coating 288 is applied. The nanophase-separated catalytic coating 288 may be deposited on the metal substrate 506 to expose the flow channel 502 to reduce carbon buildup from the hydrocarbon fluid. As discussed in more detail below, the nanophase-separated catalytic coating 288 may be exposed within the flow channel 502 to reduce the resulting carbon buildup. Figure 7It can be, for example, one of the fuel channels described above, in which the hydrocarbon fluid is fuel. However, as described above, the nanophase-separated catalytic coating 288 can be applied to any metal substrate that at least partially defines the flow channel of the hydrocarbon fluid, and the flow channel 502 can be any hydrocarbon fluid channel that may undergo coking. For example, the fuel channel can be the fuel nozzle tip 220 ( Figure 3 ), main fuel passage 213 ( Figure 3 ), pilot fuel passage 215 ( Figure 3 ), pilot fuel injection port 217 ( Figure 3 ), main fuel injection port 219 ( Figure 3 ), Fuel injection port 402 ( Figure 6 ), fuel channel 403 ( Figure 6 (or a combination thereof). In other examples, the hydrocarbon fluid may be oil, and the metal substrate 506 at least partially defines the flow path of the oil.

[0075] The foregoing discussion is merely illustrative; the nanophase-separated catalytic coating 288 can be applied to any metal substrate that at least partially defines a flow path for a hydrocarbon fluid. The nanophase-separated catalytic coating 288 can be deposited on a metal substrate to expose the flow path, thereby reducing carbon buildup from the hydrocarbon fluid. In some embodiments, the metal substrate is selected from iron-based alloys, nickel-based alloys, cobalt-based alloys, chromium-based alloys, copper-based alloys, aluminum-based alloys, alloys containing cobalt and chromium, alloys containing platinum and aluminum, alloys containing nickel and aluminum, and alloys containing nickel, chromium, aluminum, and yttrium. In some embodiments, the metal substrate is an aircraft component, such as the aircraft component described above.

[0076] Figure 8A This is a schematic cross-sectional view of a coating substrate 800 according to an embodiment of the present disclosure. The coating substrate 800 includes a nanophase-separated precursor coating 287, which is a precursor to the nanophase-separated catalytic coating 288 as described above. Reference will be made below. Figure 10 A detailed description is provided of the formation of a nanophase-separated catalytic coating 288 from a precursor coating 287.

[0077] A nanophase-separated precursor coating 287 is deposited on a metal substrate 810. The metal substrate 810 can be selected from iron-based alloys, nickel-based alloys, cobalt-based alloys, alloys containing cobalt and chromium, alloys containing platinum and aluminum, alloys containing nickel and aluminum, and alloys containing nickel, chromium, aluminum, and yttrium. For example, the metal substrate 810 can be part of an aircraft component, such as a fluid passage or a fuel nozzle (e.g., fuel nozzle tip 220). Figure 3 ), valve orifice, blade (e.g., blade 316 ( Figure 3 Pilot hole, main hole, valve, cyclone separator, venturi tube (e.g., second venturi tube 280 ( Figure 4) or Venturi tube 420 ( Figure 6 ), heat exchangers and lubrication system components, such as those described above.

[0078] The nanophase-separated precursor coating 287 comprises a substantially pure transition metal phase 820 and a substantially pure noble metal phase 830. As described below, when the transition metal and noble metal are substantially immiscible, co-depositing the transition metal and noble metal on a metal substrate 810 can produce a coating substrate including the nanophase-separated precursor coating 287. In some embodiments, the substantially pure transition metal phase 820, the substantially pure noble metal phase 830, or both are uniformly distributed throughout the nanophase-separated precursor coating 287, for example... Figure 8A As shown.

[0079] The transition metal and noble metal can include any combination of transition metals and noble metals, provided that the transition metal and noble metal are substantially immiscible with each other. For example, in some embodiments, the substantially pure transition metal phase 820 comprises a transition metal selected from cobalt, molybdenum, manganese, titanium, niobium, chromium, nickel and tantalum, and the substantially pure noble metal phase 830 comprises a noble metal selected from silver and platinum.

[0080] The nanophase-separated precursor coating 287 can contain various volume fractions of substantially pure transition metal phase 820 and substantially pure noble metal phase 830. Based on the total volume of the nanophase-separated precursor coating 287, it can contain 20 vol% to 80 vol% of substantially pure transition metal phase 820. Based on the total volume of the nanophase-separated precursor coating 287, it can contain 20 vol% to 80 vol% of substantially pure noble metal phase 830. Different volume fractions of substantially pure transition metal phase 820 and substantially pure noble metal phase 830 can be used to influence the catalytic activity of the nanophase-separated precursor coating 287. For example, in some embodiments, when the nanophase-separated precursor coating 287 has a large volume percentage of substantially pure transition metal phase 820, the nanophase-separated precursor coating 287 can have a large coking oxidation reaction rate, and / or when the nanophase-separated precursor coating 287 has a large volume percentage of substantially pure noble metal phase 830, the nanophase-separated precursor coating 287 can have a large coking oxidation selectivity.

[0081] Figure 8B To display Figure 8AA detailed view of part 8B of the coated metal substrate 810 is shown. As described above, the nanophase-separated precursor coating 287 comprises a substantially pure transition metal phase 820 and a substantially pure noble metal phase 830. The average grain size of the substantially pure transition metal phase 820 can be from 10 nm to 500 nm. For example, the average grain size of the substantially pure transition metal phase 820 can be from 10 nm to 30 nm. Similarly, the average grain size of the substantially pure noble metal phase 830 can be from 10 nm to 500 nm. For example, the average grain size of the substantially pure noble metal phase 830 can be from 10 nm to 30 nm. The grain sizes of the substantially pure noble metal phase 830 and the substantially pure noble metal phase 830 can be selected independently to provide enhanced catalytic performance. For example, a smaller grain size can improve catalytic activity by increasing the area of ​​the interfacial boundary between the substantially pure noble metal phase 830 and the substantially pure noble metal phase 830.

[0082] Figure 9A This is a schematic cross-sectional view of a coated component 900 according to an embodiment of the present disclosure. The coated component 900 includes a metal substrate 910 and a nanophase-separated catalytic coating 288 deposited on the metal substrate 910. The nanophase-separated catalytic coating 288 comprises a substantially pure transition metal phase 920, a substantially pure noble metal phase 930, and a substantially pure transition metal oxide phase 940. Figure 9A As shown, the substantially pure transition metal oxide phase 940 is in contact with at least a portion of the substantially pure transition metal phase 920. For example, the substantially pure transition metal oxide phase 940 may be in contact with a surface portion of the substantially pure transition metal phase 920, the substantially pure transition metal oxide phase 940 may be in contact with a portion of the substantially pure transition metal phase 920 (this portion extends beyond the surface portion of the substantially pure transition metal phase 920 into the bulk portion of the substantially pure transition metal phase 920), or both.

[0083] The following discussion will further elaborate on the formation of Figure 9A The coated component 900 shown is... Figure 8A The coating substrate 800 shown is oxidized to form a substantially pure transition metal oxide phase 940. Therefore, the substantially pure transition metal phase 920 contains a transition metal, and the substantially pure transition metal oxide phase 940 contains an oxide of the transition metal. Figure 8AThe illustrated nanophase-separated precursor coating 287 includes, more specifically, a substantially pure transition metal phase 820 and a substantially pure noble metal phase 830 that can undergo chemical and / or morphological changes when the nanophase-separated precursor coating 287 is oxidized to produce a nanophase-separated catalytic coating 288. A substantially pure transition metal oxide phase 940 can be formed in contact with the substantially pure transition metal phase 920. For example, a substantially pure transition metal oxide phase 940, a substantially pure transition metal phase 920, and a substantially pure noble metal phase 930 can be formed to maximize the interfacial area between the substantially pure transition metal oxide phase 940 and the substantially pure noble metal phase 930.

[0084] As described above, the metal substrate 910 can be a metal substrate selected from the following: iron-based alloys, nickel-based alloys, cobalt-based alloys, alloys containing cobalt and chromium, alloys containing platinum and aluminum, alloys containing nickel and aluminum, and alloys containing nickel, chromium, aluminum, and yttrium. For example, the metal substrate 910 can be part of an aircraft component, such as a fluid passage or a fuel nozzle (e.g., the fuel nozzle tip 220). Figure 3 ), valve orifice, blade (e.g., blade 316 ( Figure 3 Pilot hole, main hole, valve, cyclone separator, venturi tube (e.g., second venturi tube 280 ( Figure 4 ) or Venturi tube 420 ( Figure 6 ), heat exchangers and lubrication system components, such as those described above.

[0085] Similarly, as described above, the substantially pure transition metal phase 920 comprises a transition metal, and the substantially pure noble metal phase 930 comprises a noble metal. The transition metal and noble metal can include any combination of transition metals and noble metals, provided that the transition metal and noble metal are substantially immiscible with each other. For example, in some embodiments, the substantially pure transition metal phase 920 comprises a transition metal selected from cobalt, molybdenum, manganese, titanium, niobium, chromium, nickel, and tantalum, and the substantially pure noble metal phase 930 comprises a noble metal selected from silver and platinum. The substantially pure transition metal oxide phase 940 comprises an oxide of the transition metal in the substantially pure transition metal phase 920. Furthermore, the substantially pure transition metal oxide phase 940 may comprise p-block elements selected from lead, tin, bismuth, antimony, and tellurium. In some embodiments, p-block elements are included in the substantially pure transition metal phase 920, the substantially pure noble metal phase 930, or both. In some embodiments, the nanophase-separated catalytic coating 288 has a composition selected from (M1). x (M2) y (M3) z (M4) u (N) v O w (P1) x (P2) y (P3) z(P4) u (N) v O w and (P1) x (P2) y (M1) z (M2) u (N) v O w The composition includes M1, M2, M3, and M4 as transition metals (e.g., Co, Mo, Mn, Ti, Nb, Ta, etc.), P1, P2, P3, P4, and P5 as p-block elements (e.g., Pb, Sn, Bi, Sb, Te, etc.), and N as a noble metal (e.g., Ag, Pt). x, y, z, u, and v are each independently in the range of 0 to 1 (e.g., 0.001 to 1). In the main body of the nanophase-separated catalytic coating 288, w is 0. On the top oxide surface of the nanophase-separated catalytic coating 288, w / (x+y+z+u+v) is in the range of 1 to 2.

[0086] The nanophase-separated catalytic coating 288 may contain various volume fractions of substantially pure transition metal phase 920, substantially pure noble metal phase 930, and substantially pure transition metal oxide phase 940. Based on the total volume of the nanophase-separated catalytic coating 288, it may contain 20 vol% to 80 vol% of substantially pure transition metal phase 920. Based on the total volume of the nanophase-separated catalytic coating 288, it may contain 20 vol% to 80 vol% of substantially pure noble metal phase 930. Based on the total volume of the nanophase-separated catalytic coating 288, it may contain 1 vol% to 10 vol% of substantially pure transition metal oxide phase 940. As described elsewhere herein, the substantially pure transition metal oxide phase 940 may be formed on the surface portion of the nanophase-separated catalytic coating 288.

[0087] To avoid being bound by theory, the activity of the nanophase-separated catalytic coating 288 can be improved by increasing the boundary between phases near the outer surface of the nanophase-separated catalytic coating 288 exposed to carbon deposits. For example, in some embodiments (e.g., where each phase has a similar average grain size), substantially pure transition metal oxide phase 940 and substantially pure noble metal phase 930 may be present in the nanophase-separated catalytic coating 288 in a one-to-one volume ratio to increase the boundary between phases near the outer surface of the nanophase-separated catalytic coating 288. Furthermore, the durability of the nanophase-separated catalytic coating 288 can be enhanced if substantially pure transition metal phase 920 permeates through the nanophase-separated catalytic coating 288, where substantially pure transition metal oxide phase 940 is embedded in an island-like manner. In some embodiments (e.g., where each phase has dissimilar average grain size), the volume percentage of each phase can be adjusted to improve the performance of the nanophase-separated catalytic coating 288 (e.g., by increasing the boundary between phases near the outer surface of the coating exposed to carbon deposits).

[0088] Figure 9B Showing Figure 9A A detailed view of part 9B of the coated component 900 is shown. The average grain size of the substantially pure transition metal phase 920 can be from 10 nm to 500 nm. For example, the average grain size of the substantially pure transition metal phase 920 can be from 10 nm to 30 nm. Similarly, the average grain size of the substantially pure noble metal phase 930 can be from 10 nm to 500 nm. For example, the average grain size of the substantially pure noble metal phase 930 can be from 10 nm to 30 nm. Furthermore, the average grain size of the substantially pure transition metal oxide phase 940 can be from 10 nm to 500 nm. For example, the average grain size of the substantially pure transition metal oxide phase 940 can be from 10 nm to 30 nm. The grain sizes of the substantially pure transition metal phase 920, the substantially pure noble metal phase 930, and the substantially pure transition metal oxide phase 940 can be selected independently to provide enhanced catalytic performance. For example, a smaller grain size can improve catalytic activity by increasing the area of ​​the interfacial boundaries between the substantially pure transition metal phase 920, the substantially pure noble metal phase 930, and the substantially pure transition metal oxide phase 940. This interfacial boundary area can, for example, represent numerous reactive catalytic sites in the nanophase-separated catalytic coating 288. Furthermore, for example, a smaller grain size can improve catalytic activity by increasing the interfacial area between the substantially pure transition metal phase 920, the substantially pure noble metal phase 930, the substantially pure transition metal oxide phase 940 and carbon deposits, thereby enhancing the catalytic activity of the nanophase-separated catalytic coating 288.

[0089] To avoid being bound by theory, the activity of nanophase-separated catalytic coatings can be improved by increasing the boundaries between phases near the outer surface of the coating exposed to carbon deposits. For example, in some embodiments (e.g., each phase has a similar average grain size), substantially pure transition metal oxide phase 940 and substantially pure noble metal phase 930 can be present in the nanophase-separated catalytic coating in a one-to-one volume ratio to increase the boundaries between phases near the outer surface of the coating. Furthermore, the durability of the nanophase-separated catalytic coating can be enhanced if substantially pure transition metal phase 920 permeates through the nanophase-separated catalytic coating, wherein substantially pure transition metal oxide phase 940 is embedded in an island-like manner. In some embodiments (e.g., each phase has dissimilar average grain sizes), the volume percentage of each phase can be adjusted to improve the performance of the nanophase-separated catalytic coating (e.g., by increasing the boundaries between phases near the outer surface of the coating exposed to carbon deposits).

[0090] Figure 9C This is a schematic cross-sectional view of a coating component 901 according to an embodiment of the present disclosure. The coating component 901 includes an outer region 942 of a nanophase-separated catalytic coating 288 with a substantially pure transition metal oxide phase 940, and an inner region 944 sandwiched between the outer region 942 and the metal substrate 910 with a substantially pure transition metal phase 920 and a substantially pure noble metal phase 930.

[0091] Figure 10 This is a flowchart illustrating a method 1000 for manufacturing a coated component 900 according to an embodiment of the present disclosure. Method 1000 includes: in step S1010, co-depositing a transition metal and a noble metal onto a metal substrate to produce the coating as described above. Figure 8A and 8B The coating substrate is 800. The transition metal and the noble metal can be substantially immiscible. In some embodiments, the transition metal and the noble metal can be co-deposited by electrodeposition from a solution containing both the transition metal as dissolved ions and the noble metal as dissolved ions.

[0092] Method 1000 includes: oxidizing a portion of the transition metal in step S1020 to produce the above-mentioned reference. Figure 9A and 9B The coating component 900. As described above, the oxidized portion of the transition metal can be the surface portion of the transition metal. In some embodiments, in step S1020, oxidation includes heating the coating substrate 800 in an oxidizing environment (e.g., air). Figure 8A and 8BHeating can be performed at any temperature sufficient to oxidize the transition metal (e.g., 200°C to 500°C). In some embodiments, in step S1020, oxidation is performed sufficient to form a substantially pure transition metal oxide phase 940 as a coating on the surface portion of the substantially pure transition metal phase 920. Figure 9A and 9B This oxidation is sufficient to form a coating on a substantially pure transition metal oxide phase 940 as a portion of a substantially pure transition metal phase 920, which extends beyond the surface portion of the substantially pure transition metal phase 920 into the body portion of the substantially pure transition metal phase 920, or both (e.g., by oxidizing less of the amount of transition metal required to form an overall outer layer of substantially pure transition metal oxide). In some embodiments, in step S1020, the oxidation is sufficient to form a top composite layer comprising a transition metal oxide and a noble metal, the composite layer having numerous surface-connected phase boundaries.

[0093] As described above, compared with catalytic coatings that do not have the above-mentioned nanophase separation morphology, the nanophase-separated catalytic coating 288 can effectively reduce carbon deposition and can provide improved catalytic activity and / or selectivity.

[0094] As mentioned above, nanophase-separated catalytic coatings can effectively reduce carbon buildup and can be applied to various components, such as aircraft components and / or gas turbine engine components.

[0095] The following clauses provide further aspects of this disclosure:

[0096] A coating component for reducing carbon deposits in a gas turbine engine, comprising a metal substrate and a nanophase-separated catalytic coating. The metal substrate at least partially defines a flow path for a hydrocarbon fluid. The nanophase-separated catalytic coating is deposited on the metal substrate to expose the flow path for reducing carbon deposits from the hydrocarbon fluid. The nanophase-separated catalytic coating comprises substantially pure transition metal phases, substantially pure noble metal phases, and substantially pure transition metal oxide phases.

[0097] The coated component according to the foregoing clauses, wherein the average grain size of the essentially pure transition metal phase is 10 nanometers to 500 nanometers.

[0098] The coated component according to any of the foregoing clauses, wherein the average grain size of the essentially pure noble metal phase is 10 nanometers to 500 nanometers.

[0099] The coated component according to any of the foregoing clauses, wherein the average grain size of the substantially pure transition metal oxide phase is 10 nanometers to 500 nanometers.

[0100] The coating component according to any of the foregoing clauses, wherein a substantially pure transition metal phase is uniformly distributed throughout the catalytic coating.

[0101] The coating component according to any of the foregoing clauses, wherein a substantially pure noble metal phase is uniformly distributed throughout the catalytic coating.

[0102] The coating component according to any of the foregoing clauses, wherein a substantially pure transition metal oxide phase is in contact with at least a portion of a substantially pure transition metal phase.

[0103] The coating component according to any of the foregoing clauses, wherein the substantially pure transition metal phase comprises a transition metal, and the substantially pure transition metal oxide phase comprises an oxide of a transition metal.

[0104] The coating component according to any of the foregoing clauses, wherein, based on the total volume of the catalytic coating, the catalytic coating has a substantially pure transition metal phase of 20 vol% to 80 vol%.

[0105] The coating component according to any of the foregoing clauses, wherein, based on the total volume of the catalytic coating, the catalytic coating has a substantially pure transition metal oxide phase of 1 vol% to 10 vol%.

[0106] The coating component according to any of the foregoing clauses, wherein the catalytic coating has a substantially pure noble metal phase of 20 vol% to 80 vol% based on the total volume of the catalytic coating.

[0107] The coated component according to any of the foregoing clauses, wherein the substantially pure transition metal phase contains a transition metal, the substantially pure noble metal phase contains a noble metal, and the noble metal and the transition metal are substantially immiscible.

[0108] The coating component according to any of the foregoing clauses, wherein the substantially pure transition metal phase comprises a transition metal selected from cobalt, molybdenum, manganese, titanium, niobium, chromium, nickel and tantalum, and the substantially pure transition metal oxide phase comprises an oxide of a transition metal.

[0109] The coated component according to any of the foregoing clauses, wherein the substantially pure noble metal phase comprises a noble metal selected from silver and platinum.

[0110] The coated component according to any of the foregoing clauses, wherein the substantially pure transition metal oxide phase comprises a p-block element selected from lead, tin, bismuth, antimony and tellurium.

[0111] The coated component according to any of the foregoing clauses, wherein the coated component is selected from fluid passages, fuel nozzles, valve orifices, blades, pilot orifices, main orifices, valves, cyclones, venturi tubes, heat exchangers, and lubrication system components.

[0112] A fuel nozzle for a gas turbine engine includes a fuel nozzle body and a fuel passage defined by one or more walls formed within the fuel nozzle. The fuel passage is a flow channel through which hydrocarbon fuel flows. A nanophase-separated catalytic coating is deposited on one or more walls formed within the fuel nozzle to expose the fuel passage, thereby reducing the formation of carbon deposits from the fuel. The nanophase-separated catalytic coating comprises substantially pure transition metal phases, substantially pure noble metal phases, and substantially pure transition metal oxide phases.

[0113] The fuel nozzle as described in the foregoing clause further includes a fuel injection orifice fluidly connected to the fuel passage to receive fuel from the fuel passage.

[0114] The fuel nozzle as described in any of the foregoing clauses, wherein the fuel nozzle body is a metal fuel nozzle body.

[0115] The fuel nozzle according to any of the foregoing clauses, wherein the average grain size of the essentially pure transition metal phase is 10 nanometers to 500 nanometers.

[0116] The fuel nozzle according to any of the foregoing clauses, wherein the average grain size of the essentially pure noble metal phase is 10 nanometers to 500 nanometers.

[0117] The fuel nozzle according to any of the foregoing clauses, wherein the average grain size of the essentially pure transition metal oxide phase is 10 nanometers to 500 nanometers.

[0118] The fuel nozzle according to any of the foregoing clauses, wherein a substantially pure transition metal phase is uniformly distributed throughout the catalytic coating.

[0119] The fuel nozzle according to any of the foregoing clauses, wherein a substantially pure noble metal phase is uniformly distributed throughout the catalytic coating.

[0120] The fuel nozzle according to any of the foregoing clauses, wherein a substantially pure transition metal oxide phase is in contact with at least a portion of a substantially pure transition metal phase.

[0121] The fuel nozzle according to any of the foregoing clauses, wherein the substantially pure transition metal phase comprises a transition metal, and the substantially pure transition metal oxide phase comprises an oxide of a transition metal.

[0122] According to any of the preceding clauses, the fuel nozzle has a substantially pure transition metal phase of 20% to 80% by volume, based on the total volume of the catalytic coating.

[0123] According to any of the preceding clauses, the fuel nozzle has a substantially pure transition metal oxide phase of 1 vol% to 10 vol% based on the total volume of the catalytic coating.

[0124] According to any of the preceding clauses, the fuel nozzle has a substantially pure noble metal phase of 20% to 80% by volume, based on the total volume of the catalytic coating.

[0125] According to any of the preceding clauses, the fuel nozzle comprises a substantially pure transition metal phase containing a transition metal, a substantially pure noble metal phase containing a noble metal, and the noble metal and the transition metal are substantially immiscible.

[0126] According to any of the preceding clauses, the fuel nozzle, wherein the substantially pure transition metal phase comprises a transition metal selected from cobalt, molybdenum, manganese, titanium, niobium, chromium, nickel and tantalum, and the substantially pure transition metal oxide phase comprises oxides of transition metals.

[0127] The fuel nozzle according to any of the foregoing clauses, wherein the essentially pure precious metal phase comprises precious metals selected from silver and platinum.

[0128] According to any of the preceding clauses, the fuel nozzle, wherein the essentially pure transition metal oxide phase comprises p-block elements selected from lead, tin, bismuth, antimony and tellurium.

[0129] A combustor for a gas turbine engine, the combustor comprising an inner liner, an outer liner, and a mixer assembly. The outer liner is located opposite the inner liner to define a combustion chamber therebetween. The combustion chamber includes an upstream end. The mixer assembly is located at the upstream end of the combustion chamber and includes a fuel nozzle as described in any of the preceding clauses.

[0130] The fuel nozzle according to the foregoing provisions further includes a fuel injection orifice fluidly connected to the fuel passage to receive fuel from the fuel passage and inject the fuel into the combustion chamber.

[0131] A gas turbine engine for an aircraft, the gas turbine engine comprising a compressor, a combustor as described in the preceding clause, and a turbine. The compressor, combustor, and turbine at least define an airflow passage. The compressor includes a plurality of compressor blades operable to compress air flowing through the airflow passage and form compressed air. The combustor is fluidly connected to the compressor to receive the compressed air and is operable to inject fuel into the compressed air through fuel nozzles and produce a fuel-air mixture. The fuel-air mixture is combusted in a combustion chamber to produce combustion products, and the turbine is fluidly connected to the combustion chamber to receive the combustion products. The turbine includes a plurality of turbine blades that are rotated by the combustion products flowing through the airflow passage.

[0132] According to any of the preceding clauses, the coating component is wherein a substantially pure transition metal oxide phase is in contact with a surface portion of a substantially pure transition metal phase, a substantially pure transition metal oxide phase is in contact with a portion of a substantially pure transition metal phase, the portion of the substantially pure transition metal phase extending beyond the surface portion of the substantially pure transition metal phase into the body portion of the substantially pure transition metal phase, or both.

[0133] The coating component according to any of the foregoing clauses, wherein the metal substrate is selected from iron-based alloys, nickel-based alloys, cobalt-based alloys, alloys containing cobalt and chromium, alloys containing platinum and aluminum, alloys containing nickel and aluminum, and alloys containing nickel, chromium, aluminum and yttrium.

[0134] A method for manufacturing a coated component as described in any of the preceding clauses, the method comprising co-depositing a transition metal and a noble metal on a metal substrate to produce a coating substrate, wherein the transition metal and the noble metal are substantially immiscible, and oxidizing a portion of the transition metal to produce the coated component.

[0135] A method for coating a component, the method comprising co-depositing a transition metal and a noble metal on a metal substrate to produce a coating substrate, and oxidizing a portion of the transition metal to produce a substantially pure transition metal phase, a substantially pure noble metal phase, and a substantially pure transition metal oxide phase.

[0136] According to the method described in any of the foregoing clauses, the transition metal and the noble metal are essentially immiscible.

[0137] According to the method described in any of the preceding clauses, co-deposition is electrodeposition from a solution containing a transition metal as a dissolved ion and a noble metal as a dissolved ion.

[0138] According to the method described in any of the preceding clauses, the oxidized portion of the transition metal is the surface portion of the transition metal.

[0139] The method according to any of the foregoing clauses, wherein oxidation includes heating the coating substrate in an oxidizing environment.

[0140] According to the method described in the foregoing clauses, the oxidizing environment is air.

[0141] The method according to any of the foregoing clauses, wherein oxidation includes heating the coating substrate to a temperature of 200°C to 500°C.

[0142] The method according to any of the foregoing clauses, wherein the average grain size of the essentially pure transition metal phase is 10 nanometers to 500 nanometers.

[0143] The method described according to any of the foregoing clauses, wherein the average grain size of the essentially pure noble metal phase is 10 nanometers to 500 nanometers.

[0144] The method according to any of the foregoing clauses, wherein the average grain size of the essentially pure transition metal oxide phase is 10 nanometers to 500 nanometers.

[0145] According to the method described in any of the preceding clauses, a substantially pure transition metal phase is uniformly distributed throughout the catalytic coating.

[0146] According to the method described in any of the preceding clauses, the essentially pure noble metal phase is uniformly distributed throughout the catalytic coating.

[0147] The method according to any of the foregoing clauses, wherein a substantially pure transition metal oxide phase is in contact with at least a portion of a substantially pure transition metal phase.

[0148] The method according to any of the foregoing clauses, wherein the substantially pure transition metal phase comprises a transition metal, and the substantially pure transition metal oxide phase comprises an oxide of a transition metal.

[0149] According to the method described in any of the preceding clauses, the catalytic coating has a substantially pure transition metal phase of 20 vol% to 80 vol% based on the total volume of the catalytic coating.

[0150] According to the method described in any of the preceding clauses, the catalytic coating has a substantially pure transition metal oxide phase of 1 vol% to 10 vol% based on the total volume of the catalytic coating.

[0151] According to the method described in any of the preceding clauses, the catalytic coating has a substantially pure noble metal phase of 20 vol% to 80 vol% based on the total volume of the catalytic coating.

[0152] According to the method described in any of the preceding clauses, the substantially pure transition metal phase contains a transition metal, the substantially pure noble metal phase contains a noble metal, and the noble metal and the transition metal are substantially immiscible.

[0153] According to the method described in any of the preceding clauses, the substantially pure transition metal phase comprises a transition metal selected from cobalt, molybdenum, manganese, titanium, niobium, chromium, nickel and tantalum, and the substantially pure transition metal oxide phase comprises an oxide of a transition metal.

[0154] The method described according to any of the foregoing clauses, wherein the essentially pure precious metal phase comprises a precious metal selected from silver and platinum.

[0155] According to the method described in any of the preceding clauses, the essentially pure transition metal oxide phase comprises a p-block element selected from lead, tin, bismuth, antimony, and tellurium.

[0156] While the foregoing description relates to some exemplary embodiments of this disclosure, other variations and modifications will be apparent to those skilled in the art and can be made without departing from this disclosure. Furthermore, even if not explicitly stated above, features associated with one embodiment of this disclosure may be used in combination with other embodiments.

Claims

1. A coating component for reducing carbon deposits in a gas turbine engine, the coating component comprising: A metal substrate that at least partially defines a flow path for a hydrocarbon fluid; as well as A nanophase-separated catalytic coating, deposited on a metal substrate to expose flow channels, is used to reduce carbon buildup from hydrocarbon fluids. The nanophase-separated catalytic coating comprises substantially pure transition metal phases, substantially pure noble metal phases, and substantially pure transition metal oxide phases.

2. The coated component according to claim 1, wherein, The average grain size of the essentially pure transition metal phase is 10 nanometers to 500 nanometers.

3. The coated component according to claim 1, wherein, The average grain size of the essentially pure noble metal phase is 10 nanometers to 500 nanometers.

4. The coated component according to claim 1, wherein, The average grain size of the essentially pure transition metal oxide phase is 10 nanometers to 500 nanometers.

5. The coated component according to claim 1, wherein, The essentially pure transition metal phase is uniformly distributed throughout the catalytic coating.

6. The coated component according to claim 1, wherein, The essentially pure noble metal phase is uniformly distributed throughout the catalytic coating.

7. The coated component according to claim 1, wherein, The substantially pure transition metal oxide phase is in contact with at least a portion of the substantially pure transition metal phase.

8. The coated component according to claim 1, wherein, The substantially pure transition metal phase comprises a transition metal, and the substantially pure transition metal oxide phase comprises an oxide of a transition metal.

9. The coated component according to claim 1, wherein, Based on the total volume of the catalytic coating, the catalytic coating has 20% to 80% of substantially pure transition metal phase.

10. A method for manufacturing the coated component of claim 1, the method comprising: A coating substrate is formed by co-depositing a transition metal and a noble metal on a metal substrate, wherein the transition metal and the noble metal are substantially immiscible; and A portion of the transition metal is oxidized to produce coated parts.

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