Ceramic coating for components

Abstract

A component comprising a substrate and a ceramic coating disposed on the substrate, the ceramic coating comprising a surface defining a vertical axis, wherein the ceramic coating comprises a plurality of non-crossing curved grooves defined from the surface, the plurality of non-crossing curved grooves comprising a first curved groove and a second curved groove adjacent to the first curved groove, the first curved groove defining a plurality of first peaks and a plurality of first valleys, the second curved groove defining a plurality of second peaks and a plurality of second valleys, each of the plurality of first valleys of the first curved groove being aligned with an adjacent one of the plurality of second peaks of the second curved groove.

Description

Technical Field

[0001] This disclosure relates to ceramic coatings (e.g., thermal barrier coatings and environmental barrier coatings) for components of turbomachinery (such as gas turbine engines). Background Technology

[0002] The demand for higher turbine efficiency has driven the design of modern gas turbine engines. Ceramic matrix composites (“CMCs”) are attractive materials for turbine applications because they offer high-temperature load-bearing capacity and are lightweight. CMCs and metal components are typically protected in turbine engine environments with environmental barrier coatings (“EBCs”) and / or thermal barrier coatings (“TBCs”) to prevent oxidation and degradation in the presence of high-temperature gas flow. Summary of the Invention

[0003] A first aspect of the present invention relates to a component comprising:

[0004] A substrate; and a ceramic coating disposed on the substrate, the ceramic coating comprising a surface, wherein the ceramic coating includes a plurality of non-intersecting curved grooves defined from the surface, the plurality of non-intersecting curved grooves including a first curved groove and a second curved groove adjacent to the first curved groove, the first curved groove defining a plurality of first peaks and a plurality of first valleys, the second curved groove defining a plurality of second peaks and a plurality of second valleys, at least one of the plurality of first valleys of the first curved groove being aligned with an adjacent one of the plurality of second peaks of the second curved groove.

[0005] A second aspect of the invention relates to a method of forming a ceramic coating for a component, the method comprising: disposing the ceramic coating on a substrate of the component; removing a first bending groove from a surface of the ceramic coating, the first bending groove defining a first bending shape, the first bending shape defining a propagation direction and an amplitude direction; and removing a second bending groove from a surface of the ceramic coating such that the second bending groove is spaced apart from the first bending groove in a non-intersecting manner, the second bending groove defining a second bending shape, wherein the second bending groove is offset from the first bending groove along the propagation direction.

[0006] A third aspect of the invention relates to a ceramic coating for a component, the ceramic coating comprising: a surface defining a vertical axis and a horizontal axis, and a plurality of non-intersecting curved grooves defined in the surface, the plurality of non-intersecting curved grooves including a first curved groove and a second curved groove adjacent to the first curved groove, the first curved groove defining a plurality of first peaks and a plurality of first valleys, the second curved groove defining a plurality of second peaks and a plurality of second valleys, each of the plurality of first valleys of the first curved groove being aligned along the vertical axis with an adjacent one of the plurality of second peaks of the second curved groove. Attached Figure Description

[0007] The complete and feasible disclosure of this disclosure (including its best mode) for those skilled in the art is set forth in the description with reference to the accompanying drawings, in which:

[0008] Figure 1 This is a schematic cross-sectional view of an exemplary component.

[0009] Figure 2 This is a top view schematic diagram of the ceramic coating of an exemplary component.

[0010] Figure 3 This is a top view schematic diagram of the ceramic coating of another exemplary component, which has a sinusoidal groove.

[0011] Figure 4 This is a top view of the ceramic coating of another exemplary component, which has serrated grooves.

[0012] Figure 5 This is a top view of the ceramic coating of another exemplary component, which has non-intersecting square grooves.

[0013] Figures 6A-6D This is a top view schematic diagram of the ceramic coating of other exemplary components, which have non-intersecting horizontal and vertical grooves.

[0014] Figure 7A It is a schematic diagram of a non-planar surface and its projection onto a plane.

[0015] Figure 7B yes Figure 7A A schematic diagram of the groove on a plane. Detailed Implementation

[0016] Reference will now be made in detail to the present embodiments of this disclosure, one or more examples of which are illustrated in the accompanying drawings. The specific embodiments use numerals and letter reference numerals to denote features in the drawings. The same or similar reference numerals are used in the drawings and specific embodiments to denote the same or similar parts of this disclosure.

[0017] The word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any implementation described herein as "exemplary" is not necessarily to be construed as being more preferred or advantageous than other implementations. Furthermore, unless otherwise specifically stated, all embodiments described herein should be considered exemplary.

[0018] Unless the context clearly indicates otherwise, the singular forms “a,” “an,” and “the / that” include plural references.

[0019] In a context such as “at least one of A, B and C”, the term “at least one” means only A, only B, only C, or any combination of A, B and C.

[0020] The phrases “from X to Y” and “between X and Y” refer to the range of values ​​including the endpoints (i.e., the range of values ​​including both X and Y).

[0021] As used herein, the terms “first,” “second,” and “third,” and other ordinal numbers are used to distinguish one component from another and are not intended to indicate the location or importance of the individual components.

[0022] The term "curved" refers to a portion that has multiple curves and / or turns, that is, a portion that changes curvature and / or slope in a curved or straight manner.

[0023] In this context, a "grid" is a grid of horizontal and vertical lines that forms a square or rectangle. The term "grid-like" refers to a pattern that substantially approximates a grid without forming a precise square or rectangle.

[0024] The term "sine" or "sinusoidal" refers to a curved shape similar to the mathematical sine and cosine functions; that is, a shape that extends vertically above and below a horizontal reference point and repeats periodically in a specified direction. A "sine pattern" can be mathematically defined by either the sine or cosine function.

[0025] The term "serration" refers to a curved shape with alternating ascending and descending straight lines forming corners, similar to the teeth of a saw blade. The corners can be symmetrical, such that the ascending and descending lines have the same slope. Alternatively, the corners can be asymmetrical, such that the ascending and descending lines have different slopes. Furthermore, the corners can have sharp or rounded intersections.

[0026] The term "adjacent / nearby" means "right next to". Two slots are "adjacent" to each other when there are no other similar slots or structures between them.

[0027] A "planar" surface is a surface that is essentially flat and deviates little or no from the mathematical plane. A "non-planar" surface includes multiple regions on the surface that are not flat, such as concave, convex, hyperboloid, wavy, serrated, etc.

[0028] This disclosure generally relates to ceramic coatings for composite metallic materials. The stresses experienced by ceramic coatings can reduce component life, particularly stresses from crack initiation and propagation. The strain tolerance of coatings used in gas turbine engines (such as TBC and EBC) has been improved by utilizing through-thickness porosity and cracks in ceramic coatings manufactured by air plasma spraying (APS) and by utilizing columnar ceramic coatings manufactured by electron beam physical vapor deposition (EBPVD). However, ambient dust, such as dust containing certain combinations of calcium-magnesium-aluminum-silicates (CMAS), is frequently drawn into the hot sections of gas turbine engines. This dust can deposit on components within the engine and melt due to the high ambient temperature. The resulting low-viscosity liquid penetrates into the engineered pores and / or columnar structure of the ceramic coating on the component protecting the substrate. Once the liquid CMAS cools and solidifies, the compliance and strain tolerance of the ceramic coating are significantly reduced. The coating characteristics required for strain tolerance are filled by the solidified CMAS. Furthermore, thermal stress can cause cracks in the coating and / or the coating may delaminate from the substrate.

[0029] When grooves are formed in a ceramic coating, patterns with intersecting grooves can cause the grooves to extend into the adhesive coating or substrate at the intersection. This is because some tools used to remove material from the ceramic coating remove additional material at the intersection. For example, when removing grooves by laser, the laser dwell time at the intersection is longer, resulting in areas with greater groove depth. These areas with less ceramic material may be more prone to additional CMAS penetration, higher thermal strain, and / or lower hermiticity. In particular, when the component is subjected to biaxial stress, the lack of material at the intersection can reduce the overall lifespan of the component.

[0030] By forming grooves with a non-intersecting pattern, ceramic coatings can alleviate biaxial stress without the presence of intersections that could penetrate the adhesive coating or substrate. In particular, non-intersecting curved grooves can approach the strain tolerance of the groove's grid pattern, reducing biaxial stress without compromising the durability of the ceramic coating. Tools such as lasers can be programmed to form non-intersecting patterns in the ceramic coating, such as patterns with sinusoidal or serrated grooves. Furthermore, the non-intersecting pattern can be customized for specific stress patterns, such as when one direction of stress is more favorable than the other. Such a pattern can improve the overall lifespan of the component.

[0031] Referring now to the accompanying drawings, the same numbers in all figures represent the same elements. Figure 1 This is a cross-sectional view of an exemplary component 100. Component 100 includes a substrate 102, an adhesive coating 104, and a ceramic coating 106. The ceramic coating 106 includes a surface 108 and a plurality of grooves 110 defined from the surface 108.

[0032] In particular, Figure 1 In the illustrated embodiment, the ceramic coating 106 is either a thermal barrier coating (TBC) or an environmental barrier coating (EBC). The ceramic coating 106 may comprise a single layer of TBC material or EBC material. However, in other embodiments, multiple layers may be used to form the ceramic coating 106. Grooves may extend through more than one layer of the ceramic coating 106. The total thickness of the ceramic coating 106 may be from about 100 micrometers to about 2500 micrometers, for example, from about 350 micrometers to about 700 micrometers.

[0033] As shown in the figure, multiple grooves 110 are formed throughout the ceramic coating 106. Figure 1 In the illustrated embodiment, the groove 110 extends from surface 108 but not to the adhesive coating 104. Specifically, the respective bottoms 112 of the groove 110 are located above the upper surface 114 of the substrate 102. The “bottom” 112 of the groove 110 is the point on the groove 110 that is furthest from surface 108 in the vertical direction. Without wishing to be bound by any particular theory, it is considered that extending the groove 110 to the adhesive coating 104 or the substrate 102 may, in some cases, reduce component life.

[0034] In a particular embodiment, the groove 110 extends through approximately 10% to approximately 90% of the total thickness of the ceramic coating 106, for example, approximately 30% to approximately 90%, or approximately 50% to approximately 90%. For example, if the total thickness of the ceramic coating 106 is approximately 1300 micrometers (approximately 50 mils), the depth of the groove 110 can be approximately 400 micrometers (approximately 15 mils) to approximately 1200 micrometers (approximately 45 mils). As another example, if the total thickness of the ceramic coating 106 is approximately 600 micrometers (approximately 24 mils), the depth of the groove 110 can be approximately 300 micrometers (approximately 12 mils) to approximately 540 micrometers (approximately 21 mils). As another example, if the total thickness of the ceramic coating 106 is approximately 125 micrometers (approximately 5 mils), the depth of the groove 110 can be approximately 12 micrometers (approximately 0.5 mils) to approximately 110 micrometers (approximately 4.5 mils).

[0035] The width of the groove 110 can be designed to be large enough to maintain the desired low capillary forces and reduce the risk of bridging the groove 110 with molten material, but small enough not to significantly affect the performance of the ceramic coating 106. For example, the groove 110 can be about 10 micrometers to about 200 micrometers wide, such as about 10 micrometers to about 100 micrometers wide, about 15 micrometers to about 90 micrometers wide, or about 20 micrometers to about 80 micrometers wide. For example, the groove 110 can be about 25 micrometers wide to about 75 micrometers wide.

[0036] Furthermore, the groove 110 may have sufficient depth to reduce stress in the ceramic coating 106 without exposing the substrate 102. For example, the depth of the groove 110 may be from about 50 micrometers to about 1000 micrometers, for example, from about 100 micrometers to about 800 micrometers, or from about 200 micrometers to about 700 micrometers. Preferably, the depth of the groove 110 may be determined as a percentage of the thickness of the ceramic coating 106, for example, 10-90% as described above. The aspect ratio (depth / width) of the groove 110 may be from about 2 to about 50, for example, from about 3 to about 10, or from about 5 to about 10. The grooves 110 may be spaced from about 0.25 mm to about 3 mm, for example, from about 0.5 mm to about 2 mm, or from about 0.5 mm to about 1.5 mm. For example, the grooves 110 may be spaced from about 1 mm. Typically, the grooves 110 may be spaced at a distance based on the depth of the groove 110, for example, from about 1 to about 8 times the depth of the groove 110, for example, from about 2 to about 6 times the depth of the groove 110, as described above.

[0037] The groove 110 can take on various geometries. In one embodiment, the groove 110 is a parallel side notch with an aspect ratio (depth / width) greater than 4 (e.g., about 4 to about 10). In another embodiment, the groove 110 can be a V-shaped and / or U-shaped profile. It should be understood that the terms V-shaped and U-shaped describe the general geometry of the groove 110, while allowing for variations in the actual shape that are not perfectly V- or U-shaped. V-shaped and / or U-shaped profiles can reduce the rate at which the groove 110 closes due to CMAS buildup or CMAS reaction products (e.g., apatite) formed on the sides of the groove 110 during operation.

[0038] Multiple grooves 110 may form an array of grooves 110 extending through the ceramic coating 106, as shown in further detail below. Each groove 110 may extend along the length of the surface 108 of the ceramic coating 106 (i.e., the entire length of the surface 108). In some embodiments, the length of each groove 110 is about 1 cm or longer.

[0039] The ceramic coating 106 can be formed by any suitable process. For example, more than one ceramic coating 106 can be formed by air plasma spraying (APS), electron beam physical vapor deposition (EBPVD), high-velocity oxygen fuel (HVOF), electrostatic spray assisted vapor deposition (ESAVD), direct vapor deposition, and ceramic powder deposition via slurry.

[0040] The adhesive coating 104 can be any suitable adhesive coating 104. For example, in some embodiments, a platinum-modified nickel aluminum compound adhesive coating 104 can be formed on the upper surface 114 of the substrate 102, and then a ceramic coating 106 can be applied over the platinum-modified nickel aluminum compound adhesive coating 104. Without being intended to be limited, the adhesive coating 104 can help prevent or reduce oxidation of the substrate 102, thereby also reducing spalling. Other materials widely used in CMC / EBC systems for the adhesive coating 104 include, but are not limited to, silicon, silica, silicates, silicides (e.g., rare earth silicides such as molybdenum silicide or rhenium silicide, or mixtures thereof), mullite, or combinations thereof. That is, the adhesive coating 104 can be silicon-based, especially for CMC-based substrates. As another example, the adhesive coating 104 can be an MCrAlY coating for Ni-based substrates.

[0041] The substrate 102 can be any suitable material, such as a metal, like steel or a high-temperature alloy (e.g., a nickel-based high-temperature alloy, a cobalt-based high-temperature alloy, or an iron-based high-temperature alloy, such as Rene N5, N500, N4, N2, IN718, Hastelloy X, or Haynes 188), a ceramic matrix composite, or other suitable materials for high-temperature resistance. The ceramic coating 106 can be disposed along one or more portions of the substrate 102, or substantially over the entire exterior of the substrate 102.

[0042] Figure 1 The groove 110 is shown to be substantially perpendicular to the surface 108, that is, extending at an angle of substantially 90 degrees to the surface 108. Preferably, the groove 110 may be "tilted" relative to the surface 108, meaning that the groove 110 defines different angles with the surface 108, such as 75 degrees, 60 degrees, 45 degrees, or other angles. Such a tilted groove 110 may be used on a three-dimensional surface 108.

[0043] Reference Figure 2 The image shows a top view of component 100. Component 100 includes a ceramic coating 106, as described above. The ceramic coating 106 includes a surface 108 defining a horizontal axis H and a vertical axis V.

[0044] The ceramic coating 106 of the component includes a plurality of grooves 110 forming a grid. Specifically, the plurality of grooves 110 includes a plurality of vertical grooves 116 (i.e., grooves substantially aligned with the vertical axis V) and a plurality of horizontal grooves 118 (i.e., grooves substantially aligned with the horizontal axis H). In this context, two objects are "aligned" with each other when the gap between them along a specified direction or axis is within a specified threshold. For example, grooves 110 are aligned along the vertical axis V when they deviate from the vertical axis V by no more than 10%, i.e., the gap between grooves 110 and the reference defining the vertical axis V is no more than 10% of the distance between two adjacent parallel grooves 110.

[0045] Vertical groove 116 and horizontal groove 118 intersect at the intersection point 120 of the grid, one of which is in Figure 2 The intersections 120 are marked. Each intersection 120 is formed by a beam 122 of a laser 124, which cuts one of the vertical grooves 116 and one of the horizontal grooves 118. A controller 126 guides the laser 124 to drive the beam 122 through the surface 108 of the ceramic coating 106 in a specific pattern. Because the beam 122 passes through the same location when forming the vertical grooves 116 and the horizontal grooves 118, more material is removed at the intersections 120 compared to other locations on the ceramic coating 106. That is, the depth of the intersection 120 is greater than the depth of either the horizontal groove 118 or the vertical groove 116. This increased depth reaches the bonding coating 104, so that no ceramic material remains at the intersections 120, which can lead to debris and CMAS penetration, lack of sealing, and / or fatigue damage to the component 100. The grid pattern improves the strain tolerance and durability of the ceramic coating 106, especially for components with biaxial stress. Therefore, it is desirable to obtain the benefits of a grid without the risk of penetration and loss of sealing at the intersection 120.

[0046] Now for reference Figure 3 This shows a top view of another component 130. It should be understood that similar components between components 100 and 130 will share similar figures. The ceramic coating 106 of component 130 includes a surface 108 defining a horizontal axis H and a vertical axis V. The ceramic coating 106 includes a plurality of non-intersecting curved grooves 132 defined from the surface 108. That is, the curved grooves 132 do not intersect each other, thus not forming intersections 120, and the curved grooves 132 do not reach the adhesive coating 104. In this form, the plurality of non-intersecting curved grooves 132 define a non-intersecting grid pattern. Each curved groove 132 defines a propagation direction X and an amplitude direction Y, similar to a two-dimensional waveform. Wherein, the propagation direction X is the direction of wave propagation, and the amplitude direction Y is the direction of the wave magnitude (or amplitude). The amplitude direction Y is perpendicular to the propagation direction X. Each curved groove 132 defines an amplitude A, which is the distance from the axis of the propagation direction X to the wave crest, such as one of the first wave crests 138.

[0047] Specifically, the plurality of non-intersecting bends 132 include a first bend 134 and a second bend 136 adjacent to the first bend 134. The first bend 134 defines a bend shape comprising a plurality of waves, each of the plurality of waves including a first crest 138 and a first trough 140. Figure 3In the first curved groove 134, a sinusoidal shape is formed, wherein adjacent first peaks 138 and adjacent first troughs 140 are spaced apart by a specified wavelength λ to form multiple "periods". Each period begins at one of the first peaks 138 and ends at the next first peak 138. In terms of the mathematical sine curve, each period can be divided into a 360-degree sine wave, where each first peak 138 represents a value of 0 degrees and each first trough 140 represents a value of 180 degrees.

[0048] Similar to the first curved groove 134, the second curved groove 136 defines a sinusoidal shape. That is, the second curved groove 136 defines a sinusoidal shape having a plurality of second peaks 142 and a plurality of second troughs 144 arranged in a plurality of periods. The second curved groove 136 is offset from the first curved groove 134 such that the first peaks 138 of the first curved groove 134 are not aligned with the second peaks 142 of the second curved groove 136. Specifically, each of the plurality of first troughs 140 of the first curved groove 134 is aligned with an adjacent one of the plurality of second peaks 142 of the second curved groove 136, as shown by alignment reference B. Here, one of the first troughs 140 is considered to be "aligned" with one of the second peaks 142 when the distance between the first trough 140 and the second peak 142 along the propagation direction X is less than a specified threshold (e.g., 10% of the wavelength λ).

[0049] In terms of sinusoidal shape, each cycle of the first curved groove 134 is offset by a specified degree from each cycle of the second curved groove 136; this offset is the "phase" difference between the first curved groove 134 and the second curved groove 136. Figure 3 In the first curved groove 134 and the second curved groove 136, the phase difference is approximately half the period, or 180 degrees. By offsetting the first and second curved grooves 134 and 136 in this way, the first and second curved grooves 134 and 136 form a non-intersecting grid pattern.

[0050] The plurality of non-intersecting curved slots 132 include a third curved slot 146 adjacent to the second curved slot 136. The third curved slot 146 defines a sinusoidal shape comprising a plurality of third peaks 148 and a plurality of third troughs 150 arranged in a plurality of periods. The third curved slot 146 is offset by 180 degrees relative to the second curved slot 136, such that each of the plurality of second troughs 144 is aligned with an adjacent one of the plurality of third peaks 148. In this configuration, the third curved slot 146 has no phase difference from the first curved slot 134, such that each of the plurality of third peaks 148 is aligned with a corresponding one of the plurality of first peaks 138, and each of the plurality of third troughs 150 is aligned with a corresponding one of the plurality of first troughs 140. It should be understood that the plurality of curved slots 132 are configured such that adjacent curved slots 132 are 180 degrees out of phase with each other, and alternating ones of the curved slots 132 are phase-aligned with each other. This configuration, in which adjacent curved grooves 132 are offset in phase by 180 degrees, defines a non-intersecting grid pattern.

[0051] The first and second curved grooves 134, 136 are configured close to each other without intersecting. Specifically, each of the plurality of first troughs 140 is spaced apart from its adjacent counterpart of the plurality of second peaks 142 by a distance d ranging from 50 to 1000 micrometers (e.g., 50 to 150 micrometers). Typically, as described above, the width of a curved groove 132 is between 25 and 75 micrometers, and the distance d between the first trough 140 and the second peak 142 can be at least twice the groove width. Furthermore, the wavelengths λ of the first and second curved grooves 134, 136 are in the range of 0.5 to 20 times the depth of the first and second curved grooves 134, 136. The ratio of amplitude A to wavelength λ can be 1:64 to 4:1, such as 1:32 to 2:1, such as 1:16 to 1:1, such as 1:8 to 1:2, such as 1:4. It should be understood that the wavelength λ and / or amplitude A can vary in the propagation direction X, especially when the surface 108 is non-planar.

[0052] The curved groove 132 can be formed in the ceramic coating 106 using a laser 124. It should be understood that the curved groove 132 can be formed by other material removal methods, such as electron beam milling, ultrasonic milling, embossing, etching, or combinations thereof. More specifically, the controller 126 actuates the laser 124 to emit a beam 122 to remove the first curved groove 134 from the surface 108 of the ceramic coating 106. The controller 126 instructs the laser 124 to move the beam 122 along a bending pattern to form the curved shape of the first curved groove 134. The bending pattern can be a first sinusoidal path with a specified phase. That is, the controller 126 may include a memory storing a mathematical model of the first sinusoidal path as a sine curve with a specific amplitude, wavelength, and phase, and 124 moves the beam 122 according to the modeled sine curve.

[0053] Controller 126 actuates laser 124 to emit beam 122 to remove a second curved groove 136 from the surface 108 of ceramic coating 106. Laser 124 moves beam 122 along a second sinusoidal path with a different phase from the first sinusoidal path, such that the second curved groove 136 is spaced apart from the first curved groove 134 in a non-intersecting manner. Furthermore, the second sinusoidal path positions the second curved groove 136 horizontally offset from the first curved groove 134. It should be understood that the second curved groove 136 defines the same curved shape as the first curved groove 134, but is horizontally offset. That is, the second sinusoidal path is mathematically modeled as having the same amplitude and wavelength as the sinusoidal path, but with a phase difference of 180 degrees. Controller 126 then actuates laser 124 to remove multiple curved grooves 132 from the surface 108 of ceramic coating 106, forming a non-intersecting pattern, such as a non-intersecting grid. Specifically, the laser can form a grid-like pattern by alternating (for consecutive grooves) the curved grooves 132 between the first and second sinusoidal paths. Although shown Figure 3 The curved grooves 132 have the same amplitude and wavelength (as curved grooves 132 to each other), but it should be understood that some curved grooves 132 may differ in amplitude, wavelength and / or spacing along a sinusoidal path.

[0054] As described above, the first bending groove 134 is spaced apart above the upper surface 114 of the substrate 102, and the second bending groove 136 is spaced apart above the upper surface 114 of the substrate 102. That is, the controller 126 actuates the laser 124 to remove the first bending groove 134 by removing material to a depth above the upper surface 114 of the substrate. Figure 1 As shown. Since the curved grooves 132 do not intersect, the laser 124 does not produce any intersection points 120, wherein the beam 122 can remove material from the adhesive coating 104 or the substrate 102.

[0055] refer to Figure 4 This shows a top view of another component 200. Component 200 includes a ceramic coating 106 having a surface 108. Component 200 includes a plurality of curved grooves 202, each curved groove 202 having a serrated shape. Figure 3 Similar to component 130, component 200 includes a first curved groove 204 and a second curved groove 206, the second curved groove 206 being horizontally offset relative to the first curved groove 204. That is, the first curved groove 204 has a plurality of first peaks 208 and a plurality of first valleys 210, and the second curved groove 206 has a plurality of second peaks 212 and a plurality of second valleys 214. The first valleys 210 are aligned with the second peaks 212 to form a non-intersecting pattern, such as a non-intersecting grid.

[0056] To form multiple curved grooves 202, the controller 126 actuates the laser 124 to emit a beam 122 along a first sawtooth path having a first phase, thereby forming the first curved groove 202. Figure 3 The first sawtooth path has a specific amplitude, wavelength, and phase, and is identical to the first sawtooth path. Then, controller 126 actuates laser 124 to emit a beam 122 along a second sawtooth path with the same amplitude and wavelength as the first sawtooth path, but the second sawtooth path has a second phase that differs from the first phase by approximately 180 degrees. Controller 126 can actuate laser 124 to form a plurality of curved grooves, each successive curved groove 202 alternating between the first and second sawtooth paths to form a grid pattern.

[0057] refer to Figure 5 This shows a top view of another component 300. Component 300 includes a plurality of square-shaped grooves 302 formed by the surface 108 of the ceramic coating 106, with each square-shaped groove 302 spaced apart from the others. That is, with... Figure 2 The grid patterns are different, and the grooves 302 do not intersect each other. As shown in region 304, the first corner 306 of the first groove 302A is spaced apart from the second corner 308 of the adjacent second groove 302B. The controller 126 actuates the laser 124 to emit a beam 122 to remove material from the surface 108 of the ceramic coating 106, forming one of the square-shaped grooves 302, stops the operation of the laser 124, and actuates the laser 124 again to remove material from the surface 108 of the ceramic coating 106, forming another square-shaped groove 302. By stopping the operation of the laser 124 between the formation of each consecutive square-shaped groove 302, the grooves 302 are disconnected from each other and do not form intersections. In this way, each square-shaped groove 302 terminates above the adhesive coating 104 of the component 300.

[0058] Now for reference Figures 6A-6D This shows other non-intersecting patterns of slots used for the component. Each pattern is formed by non-intersecting horizontal and vertical slots. Figure 6A Part 320 displays a pattern with vertically aligned non-crossing slots 322. Figure 6B The component 340 displays a pattern with horizontally interlaced non-crossing slots 342. Figure 6C The component 360 displays a grid pattern with non-crossing slots 362 without corners. Figure 6D The component 380 displays a mesh-like woven pattern with non-cross grooves 382.

[0059] refer to Figure 6AThe non-intersecting groove 322 includes a plurality of horizontal grooves 324 and a plurality of vertical grooves 326. The horizontal grooves 324 extend continuously along the surface 108 of the ceramic coating 106. The vertical grooves 326 terminate before reaching the horizontal grooves 324, such that the vertical grooves 326 and the horizontal grooves 324 do not intersect. The vertical grooves 326 are aligned along the vertical axis V. In this form, the controller 126 ( Figure 2 Actuated laser 124 ( Figure 2 ) to emit beam 122 ( Figure 2 A vertical groove 326 is formed along a single vertical position. The operation of the laser 124 stops when the vertical groove 326 is within a specified distance from each of the horizontal grooves 324. Therefore, the laser 124 can form the vertical groove 326 with less vertical movement while still forming a non-intersecting pattern. A channel 328 is defined between two adjacent horizontal grooves 324, and each channel 328 contains the vertical groove 326. The vertical grooves 326 are uniformly spaced apart from each other along the horizontal axis H in each channel 328.

[0060] See Figure 6B The non-crossing groove 342 includes a plurality of horizontal grooves 344 and a plurality of vertical grooves 346. The horizontal grooves 344 extend continuously along the surface 108 of the ceramic coating 106. The vertical grooves 346 are horizontally staggered. That is, a channel 348 is defined between two adjacent horizontal grooves 344, and the vertical grooves 346 within each channel 348 are uniformly spaced apart. The vertical grooves 346 of adjacent channels 348 are horizontally staggered, while the vertical grooves 346 of alternating channels 348 are vertically aligned. For example, the vertical grooves 346 in the first channel 348A and the third channel 348C are vertically aligned, and the vertical grooves 346 in the second channel 348B and the fourth channel 348D are vertically aligned, but the vertical grooves 346 of the second channel 348B are horizontally staggered with the vertical grooves 346 of the first channel 348A. By reducing stress concentration in the vertical direction, the staggered vertical grooves 346 provide non-crossing grooves and improve the dissipation of biaxial stress.

[0061] refer to Figure 6C The non-intersecting groove 362 includes a plurality of horizontal grooves 364 and a plurality of vertical grooves 366 formed in a non-intersecting grid pattern on the surface 108 of the ceramic coating 106. More specifically, the horizontal grooves 364 extend along the horizontal axis H and terminate before meeting one of the vertical grooves 366. The vertical grooves 366 extend along the vertical axis V and terminate before meeting one of the horizontal grooves 364. That is, the horizontal grooves 364 and the vertical grooves 366 are connected by laser 124 (…). Figure 2The pattern is formed in a grid-like pattern, but laser 124 stops operating when the horizontal slots 364 and vertical slots 366 intersect. As an example, some horizontal slots 364 extend along a horizontal reference 368, and some vertical slots 366 extend along the vertical axis V toward the horizontal reference 368. The horizontal slots 364 terminate before the point where the vertical slots 366 meet the horizontal reference 368, and begin after the point where the vertical slots 366 meet the horizontal reference 368. In this form, the pattern is essentially a grid, but without intersecting slots.

[0062] See Figure 6D The non-crossing groove 382 includes a plurality of horizontal grooves 384 and a plurality of vertical grooves 386 formed in a non-crossing mesh pattern on the surface 108 of the ceramic coating 106. Figure 6C The horizontal groove 384 extends along the horizontal reference 388, and the vertical groove 386 extends across the horizontal reference 388 but does not intersect with the horizontal groove 384. This weave pattern configuration of the horizontal groove 384 and vertical groove 386 improves biaxial stress dissipation by reducing stress concentration along the vertical axis V.

[0063] Now for reference Figures 7A-7B This shows a schematic diagram of a groove on a non-planar surface 400, such as a three-dimensional curved surface or a corrugated surface. Figure 7A This is a view of the non-planar surface 400 and its projection onto plane P. Figure 7B This is a view of slot 402 on plane P.

[0064] refer to Figure 7A It should be understood that the groove 402 can be formed in a non-flat or non-rectangular surface 400, such as on a torus, annulus, or airfoil shape. In such a form, although the grooves 402 do not intersect, the alignment of portions of the grooves 402 can differ from that on a flat rectangular surface (e.g., on a flat rectangular surface). Figure 2-6D The alignment of the groove 402 on the non-planar surface 400 is determined by the surface of the plane P. To align the groove 402 on the non-planar surface 400, the groove 402 can be projected onto the plane P. The groove 402 defines an inflection point 404, where the curvature of the groove 402 changes sign, i.e., from positive to negative or from negative to positive. The inflection point 404 is projected onto the plane P to determine the alignment of the groove 402, as described below.

[0065] See now Figure 7B The image shows a groove 402 in plane P. As described above, groove 402 defines the propagation direction X and the amplitude direction Y. Inflection points 404 define portions of groove 402, which may correspond to the crests and troughs of a sine curve. In particular, two consecutive inflection points 404 define portions of groove 402 with curvatures of the same sign. Figure 7BIn the first slot 402A, the first part 406 is defined by inflection points 404A and 404B, and the second part 408 of the second slot 402B is defined by inflection points 404C and 404D.

[0066] The first portion 406 defines a length X1 in the propagation direction X, which is the distance in the propagation direction X between inflection points 404A and 404B. The second portion 408 similarly defines a length X2. The first alignment region 410 is the distance along the propagation direction X (including both lengths X1 and X2). That is, the first alignment region 410 is the area where the first portion 406 and the second portion 408 overlap in the propagation direction X. When the first alignment region 410 is a specified percentage of either length X1 or X2, for example, 75-90% of the shorter of lengths X1 and X2, slots 402A and 402B can be considered "aligned". Because the first portion 406 and the second portion 408 curve toward each other, the first alignment region 410 can also be referred to as the "proximal" alignment region 410.

[0067] The first slot 402A defines a third portion 412 between inflection points 404B and 404E, and the second slot 402B defines a fourth portion 414 between inflection points 404D and 404F. The third portion 412 defines a length of X3, and the fourth portion 414 defines a length of X4. The second alignment region 416 is the region where the third portion 412 and the fourth portion 414 overlap in the propagation direction X, i.e., the region including both lengths X3 and X4. Since the third portion 412 and the fourth portion 414 are curved away from each other, the second alignment region 416 can also be referred to as the "far end" alignment region 416. The alignment of slots 402A and 402B can be determined by a specified number of proximal and far end alignment regions 410 and 416 along the entirety of slots 402A and 402B and / or a percentage of the total length of slots 402A and 402B including alignment regions 410 and 416. As an example, slots 402A and 402B can be considered "aligned" when the combined length of aligned regions 410 and 416 is at least 75% of the total length of slots 402A and 402B. This alignment metric can be used to reduce thermal stress in ceramic coatings by projecting slots 402A and 402B from the non-planar surface 400 onto the plane P.

[0068] Other aspects are provided by the subject of the following clauses:

[0069] A component includes a substrate and a ceramic coating disposed on the substrate, the ceramic coating including a surface, wherein the ceramic coating includes a plurality of non-intersecting curved grooves defined from the surface, the plurality of non-intersecting curved grooves including a first curved groove and a second curved groove adjacent to the first curved groove, the first curved groove defining a plurality of first peaks and a plurality of first valleys, the second curved groove defining a plurality of second peaks and a plurality of second valleys, at least one of the plurality of first valleys of the first curved groove being aligned with an adjacent one of the plurality of second peaks of the second curved groove.

[0070] The component according to any one of the foregoing clauses, wherein each of the plurality of first valleys is positioned at a distance of 50-1000 micrometers from an adjacent one of the plurality of second peaks.

[0071] The component according to any one of the foregoing clauses, wherein the first curved groove has a sinusoidal shape.

[0072] The component according to any one of the foregoing clauses, wherein the first bending groove has a serrated shape.

[0073] The component according to any one of the preceding clauses, wherein the plurality of non-crossing bends includes a third bend adjacent to the second bend, the third bend including a plurality of third peaks and a plurality of third valleys, wherein each of the plurality of second valleys is aligned with an adjacent one of the plurality of third peaks.

[0074] The component according to any one of the foregoing clauses, wherein each of the plurality of third peaks is aligned with a corresponding one of the plurality of first peaks, and each of the plurality of third valleys is aligned with a corresponding one of the plurality of first valleys.

[0075] The component according to any one of the foregoing clauses, wherein a plurality of non-crossing bends define a non-crossing pattern.

[0076] The component according to any one of the foregoing clauses, wherein the first bending groove defines a bending shape comprising a plurality of waves, each of the plurality of waves comprising one of a plurality of first peaks and one of a plurality of first valleys.

[0077] The component according to any one of the foregoing clauses, wherein the first bending groove is defined to a depth in the range of 100 micrometers to 1100 micrometers.

[0078] The component according to any one of the foregoing clauses, wherein the first bending groove defines an amplitude and a wavelength, the ratio of the amplitude to the wavelength being in the range of 1:64 to 4:1.

[0079] The component according to any one of the foregoing clauses, wherein the groove extends through about 10% to about 90% of the total thickness of the ceramic coating.

[0080] A method for forming a ceramic coating for a component, the method comprising: disposing the ceramic coating on a substrate of the component; removing a first bending groove from a surface of the ceramic coating, the first bending groove defining a bending shape, the bending shape defining a propagation direction and an amplitude direction; and removing a second bending groove from a surface of the ceramic coating such that the second bending groove is spaced apart from the first bending groove in a non-intersecting manner, the second bending groove defining a second bending shape, wherein the second bending groove is offset from the first bending groove along the propagation direction.

[0081] The method according to any one of the foregoing clauses, wherein the bending shape comprises a plurality of waves, each wave comprising a crest and a trough, wherein each trough of the plurality of waves of the first bending groove is aligned with a corresponding crest of the plurality of waves of the second bending groove.

[0082] According to any one of the preceding clauses, removing the first curved groove further includes: moving the laser along a first sinusoidal path having a first phase, and removing the second curved groove further includes: moving the laser along a second sinusoidal path having a second phase, the second phase being 180 degrees out of phase with the first phase.

[0083] The method according to any one of the foregoing clauses, wherein the first sine path and the second sine path each have the same wavelength.

[0084] According to any one of the preceding clauses, the method of removing the first curved groove further includes: moving the laser along a first sawtooth path having a first phase, and actuating the laser to remove the second curved groove further includes: moving the laser along a second sawtooth path having a second phase, the second phase being 180 degrees out of phase with the first phase.

[0085] The method according to any one of the foregoing clauses, wherein the bending shape is a shape different from the second bending shape.

[0086] The method according to any one of the foregoing clauses, wherein the bending shape and the second bending shape are the same shape.

[0087] The method according to any one of the foregoing clauses, wherein the method further comprises: removing a plurality of curved grooves from the surface of the ceramic coating to form a non-intersecting pattern.

[0088] A ceramic coating for a component includes a surface defining a vertical axis and a horizontal axis, and a plurality of non-intersecting curved grooves defined in the surface. The plurality of non-intersecting curved grooves include a first curved groove and a second curved groove adjacent to the first curved groove. The first curved groove defines a plurality of first peaks and a plurality of first valleys, and the second curved groove defines a plurality of second peaks and a plurality of second valleys. Each of the plurality of first valleys of the first curved groove is aligned along the vertical axis with an adjacent one of the plurality of second peaks of the second curved groove.

[0089] The ceramic coating according to any one of the foregoing clauses, wherein the plurality of non-crossing curved grooves includes a third curved groove adjacent to the second curved groove, the third curved groove including a plurality of third peaks and a plurality of third valleys, each of the plurality of second valleys being aligned along a vertical axis with an adjacent one of the plurality of third peaks.

[0090] The ceramic coating according to any one of the foregoing clauses, wherein the first curved groove has a sinusoidal shape.

[0091] The ceramic coating according to any one of the foregoing clauses, wherein the first curved groove has a serrated shape.

[0092] This written description uses examples to disclose this disclosure (including the best mode) and also enables any person skilled in the art to practice this disclosure (including making and using any device or system and methods of making any combination). The patentable scope of this disclosure is defined by the claims and may include other examples that would 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 not different from the literal language of the claims, or if they include equivalent structural elements that are not substantially different from the literal language of the claims.

Claims

1. A component comprising: Base; as well as A ceramic coating disposed on the substrate, the ceramic coating comprising a surface The ceramic coating includes a plurality of non-intersecting curved grooves defined from the surface, the plurality of non-intersecting curved grooves including a first curved groove and a second curved groove adjacent to the first curved groove. The first bending groove defines multiple first peaks and multiple first valleys. The second bending groove defines a plurality of second peaks and a plurality of second valleys. At least one of the plurality of first valleys of the first bend groove is aligned with an adjacent one of the plurality of second peaks of the second bend groove.

2. The component according to claim 1, wherein, Each of the multiple first valleys is set at a distance of 50-1000 micrometers from its adjacent second peak.

3. The component according to claim 1, wherein, The first curved groove has a sinusoidal shape.

4. The component according to claim 1, wherein, The first curved groove has a sawtooth shape.

5. The component according to claim 1, wherein, The plurality of non-intersecting bends include a third bend adjacent to the second bend, the third bend including a plurality of third peaks and a plurality of third valleys, wherein each of the plurality of second valleys is aligned with an adjacent one of the plurality of third peaks.

6. The component according to claim 5, wherein, Each of the multiple third peaks is aligned with a corresponding one of the multiple first peaks, and each of the multiple third valleys is aligned with a corresponding one of the multiple first valleys.

7. The component according to claim 1, wherein, Multiple non-intersecting bends define a non-intersecting pattern.

8. The component according to claim 1, wherein, The first curved groove defines a curved shape comprising a plurality of waves, each of the plurality of waves including one of a plurality of first peaks and one of a plurality of first valleys.

9. A method for forming a ceramic coating for a component, the method comprising: The ceramic coating is applied to the substrate of the component; Remove a first bending groove from the surface of the ceramic coating, the first bending groove defining a first bending shape, the first bending shape defining a propagation direction and an amplitude direction; as well as The second bending groove is removed from the surface of the ceramic coating such that it is spaced apart from the first bending groove in a non-intersecting manner, the second bending groove defining a second bending shape. The second bending groove is offset from the first bending groove along the propagation direction.

10. A ceramic coating for a component, the ceramic coating comprising: Surface, the surface defining a vertical axis and a horizontal axis, and A plurality of non-intersecting curved grooves are defined in the surface, the plurality of non-intersecting curved grooves including a first curved groove and a second curved groove adjacent to the first curved groove. The first curved groove defines multiple first peaks and multiple first valleys. The second bending groove defines a plurality of second peaks and a plurality of second valleys. Each of the plurality of first valleys of the first curved groove is aligned along the vertical axis with an adjacent one of the plurality of second peaks of the second curved groove.

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