Thermal protection method using barrier coating with strain tolerance groove
Patent Information
- Application Number
- JP2024112590
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2023-08-15
- Filing Date
- 2024-07-12
- Publication Date
- 2025-03-26
Smart Images
Figure 2025041524000001_ABST
Abstract
Description
[Technical field]
[0001] FIELD OF THE DISCLOSURE This disclosure relates broadly to thermal protective coatings for use on turbine engine components, and more specifically to a method for depositing material into strain-resistant grooves in thermal barrier coatings applied to turbine engine components. [Background technology]
[0002] Turbine engines, such as gas turbine engines and / or steam turbine engines, are commonly used in industry and power generation. Known turbine engines are subjected to high temperatures for extended periods of time, which can lead to deformation of turbine engine components over time. To protect the components from heat, at least some known turbine engine components include a thermal barrier coating. Typically, the thermal barrier coating for a turbine engine component includes a metallic bond coat layer that extends directly over a metal substrate of the component, as well as one or more thermal barrier layers.
[0003] At least some known thermal barrier coatings are formed with strain tolerance grooves extending over the turbine engine component to improve the strain tolerance of the coating. However, the presence of such grooves can reduce the thickness of the thermal barrier coating at the location of each groove formed in the turbine engine component. This can make the metallic bond coat layer more susceptible to oxidation and degradation in or near the strain tolerance grooves when exposed to high operating temperatures at these locations. Therefore, there is a need for a method of depositing additional material in the strain tolerance grooves of a thermal barrier coating to help improve the overall thermal protection of the turbine engine component. Summary of the Invention
[0004] In one aspect, a method of forming a component is provided. The method includes applying a thermal barrier coating to the component to reduce heat transfer to the component, the thermal barrier coating including one or more thermal barrier layers and a metallic bond coat layer, the one or more thermal barrier layers extending over the metallic bond coat layer, and the metallic bond coat layer in contact with an exterior surface of the component. The method also includes forming a plurality of grooves in the one or more thermal barrier layers of the thermal barrier coating to increase strain tolerance of the thermal barrier coating, each of the plurality of grooves extending to a depth within the one or more thermal barrier layers. The method further includes depositing material in the plurality of grooves to increase an amount of thermal protection of the metallic bond coat layer in areas of the thermal barrier coating where the plurality of grooves are formed.
[0005] In another aspect, a method for manufacturing a turbine engine component is provided. The method includes applying a thermal barrier coating to the component to reduce heat transfer to the component, the thermal barrier coating including one or more thermal barrier layers and a metallic bond coat layer, the one or more thermal barrier layers extending over the metallic bond coat layer, and the metallic bond coat layer contacting an exterior surface of the component. The method also includes forming a plurality of grooves in the one or more thermal barrier layers of the applied thermal barrier coating to increase strain tolerance of the thermal barrier coating, each of the plurality of grooves extending along a line perpendicular to the metallic bond coat layer to a bottom of the groove at a depth within the one or more thermal barrier layers. The method further includes depositing material within the plurality of grooves to increase an amount of thermal protection of the metallic bond coat layer proximate an extension of each of the plurality of grooves. [Brief description of the drawings]
[0006] [Figure 1] 1 is a schematic diagram of an exemplary turbine engine component including a thermal barrier coating; [Diagram 2] 1 is a schematic diagram of an exemplary turbine engine component including a thermal barrier coating having a plurality of strain-tolerant grooves formed in a first layer of the thermal barrier coating; [Diagram 3]1 is a schematic diagram of an exemplary turbine engine component including a thermal barrier coating having a plurality of strain-tolerant grooves formed in a first layer and a second layer of the thermal barrier coating; [Figure 4] 1 is a schematic diagram of an exemplary turbine engine component including a thermal barrier coating having a plurality of strain-tolerant grooves formed in first and second layers of the thermal barrier coating that are in contact with a metallic bond coat layer of the thermal barrier coating; [Diagram 5] 3 is a schematic diagram of the turbine engine component of FIG. 2 including material deposited within a plurality of strain-tolerant grooves; [Figure 6] 4 is a schematic diagram of the turbine engine component of FIG. 3 including material deposited within a plurality of strain-tolerant grooves; [Figure 7] 5 is a schematic diagram of the turbine engine component of FIG. 4 including material deposited within a plurality of strain-tolerant grooves; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0007] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The embodiments described herein relate to methods used to deposit material into strain-tolerant grooves in thermal barrier coatings to help improve thermal protection of turbine engine components.
[0008] The methods described herein provide for thermal protection of turbine engine components, and advantages of the methods described herein include at least (i) improved thermal protection of the turbine engine component by a thermal barrier coating that protects the component from thermal damage, (ii) improved strain tolerance of the thermal barrier coating of the turbine engine component by grooves in the thermal barrier coating, and (iii) improved thermal protection of the turbine engine component by deposition of material in the strain-tolerant grooves of the thermal barrier coating to reduce oxidation and degradation of a metallic bond coat layer of the thermal barrier coating adjacent the strain-tolerant grooves.
[0009] When introducing elements of various embodiments disclosed herein, the singular articles "a," "an," and "they" mean that there are one or more of the elements. The terms "comprising," "including," and "having" are inclusive and mean that there may be additional elements other than the listed elements.
[0010] Unless otherwise stated, approximation expressions such as "approximately," "substantially," and "about" used herein indicate that the modified term is not absolute or exact, but merely approximate as would be obvious to one of ordinary skill in the art. Thus, values modified with terms such as "approximately," "substantially," and "about" are not limited to their exact numerical values. In at least some cases, approximation expressions correspond to the accuracy of the instrument that measures the value. Furthermore, unless otherwise stated, terms such as "first," "second," and "second" are merely appended in this application and do not impose numerical, positional, or hierarchical requirements on what they are appended to. Furthermore, for example, "second" does not require or exclude the presence of, for example, "first" or less or "third" or more.
[0011] FIG. 1 is a schematic diagram of an exemplary turbine engine component 100. The component 100 may be any of a variety of components used in various turbine engine applications, such as, for example, components utilized in high temperature applications. In some embodiments, the component 100 is a turbine blade, a compressor blade, a vane, a nozzle, a shroud, a rotor, a transition piece, and / or a rotor casing. In other embodiments, the component 100 may be other components of a turbine engine. In the exemplary embodiment, the component 100 includes a metal base material 102 and a thermal barrier coating 104. The thermal barrier coating 104 may facilitate improved thermal protection of the metal base material 102 from high temperature exposure during use.
[0012] In the exemplary embodiment, the thermal barrier coating 104 includes a metallic bond coat layer 106 in contact with the metal base material 102. The thermal barrier coating 104 also includes a number of thermal barrier layers 108. For example, in the illustrated embodiment, the thermal barrier coating 104 includes a first thermal barrier layer 108a and a second thermal barrier layer 108b. In some embodiments, the thermal barrier coating 104 may include more than two or less than two thermal barrier layers 108.
[0013] In general, the thermal barrier coating 104 may include any material known in the art that is conducive to the thermal protection methods described herein. For example, the first thermal barrier layer 108 and / or the second thermal barrier layer 108b may include one or more materials having one or more material properties that are conducive to thermally protecting the metallic bond coat layer 106 of the thermal barrier coating 104 from the high operating temperatures of the component 100. In an exemplary embodiment, the one or more materials included in the first thermal barrier layer 108 and / or the second thermal barrier layer 108b have material properties of a certain chemical composition.
[0014] In general, the chemical composition of one or more materials included in the first thermal barrier layer 108 and / or the second thermal barrier layer 108b can include chemical composition characteristics conducive to the thermal protection methods described herein. For example, the size, shape, and properties of one or more materials included in the first thermal barrier layer 108 and / or the second thermal barrier layer 108b can be adjusted by adjusting the geometry (e.g., element geometry and / or composition geometry), length, and / or ratio (e.g., molar ratio, weight ratio, and / or volume ratio). In some embodiments, the chemical composition may be varied in the thermal barrier layers 108. For example, the chemical composition of the first thermal barrier layer 108 may be different from the chemical composition of the second thermal barrier layer 108b. In other embodiments, the chemical composition may be substantially the same in all the thermal barrier layers 108. For example, the chemical composition of the first thermal barrier layer 108 may be substantially the same as the chemical composition of the second thermal barrier layer 108b.
[0015] FIG 2 is a schematic diagram of an exemplary turbine engine component 200. The component 200 shown in FIG 2 is similar to the component 100 (FIG 1) with the differences described below, and therefore FIG 2 uses the same reference numbers as FIG 1 to identify the same components. The high temperatures of the environment in which the component 200 is used can distort the structure of the thermal barrier coating 104. As such, as known in the art, the thermal barrier coating 104 may include vertical microcracks to increase the strain tolerance of the thermal barrier coating 104. In an exemplary embodiment, the thermal barrier coating 104 includes a plurality of grooves 202 to improve the strain tolerance of the thermal barrier coating 104.
[0016] In the exemplary embodiment, the grooves 202 extend inwardly from the top surface 112 of the thermal barrier coating 104 toward the base metal 102 of the component 200, with the depth 114 of each groove 202 extending to a bottom 116 of the groove 202 defined in the second thermal barrier layer 108b of the thermal barrier coating 104. Although seven grooves 202 are illustrated in Figures 2-7, the thermal barrier coating 104 may include more than seven or less than seven grooves 202, and the number of grooves 202 shown in the figures is not intended to be limiting. Additionally, while the grooves 202 are illustrated as each having approximately the same depth 114, in alternative embodiments, one or more grooves 202 may be formed with a different depth 114 than one or more other grooves 202. Additionally, although the grooves 202 are shown as being substantially equally spaced on the component 200 and substantially parallel to one another, in alternative embodiments, the grooves 202 may be spaced apart in any orientation and / or aligned with one another in any direction, provided that the grooves 202 can aid in improving the distortion resistance of the thermal barrier coating 104.
[0017] In an exemplary embodiment, the grooves 202 are shaped with a blunt or rounded bottom 116 to reduce cracking of the thermal barrier coating 104. For example, the bottom 116 of each groove 202 may be formed with a radius or may be semi-elliptical. In other embodiments, the grooves 202 may have other shapes, such as a generally triangular shape, that may contribute to improving the strain tolerance of the thermal barrier coating 104 without increasing the likelihood of crack formation in the grooves 202.
[0018] FIG. 3 is a schematic diagram of an exemplary turbine engine component 300. The component 300 shown in FIG. 3 is similar to the component 100 (FIG. 1) and the component 200 (FIG. 2) with the differences described below, and therefore FIG. 3 uses the same reference numbers as FIG. 1 and FIG. 2 to identify the same components. The thermal barrier coating 104 includes a plurality of grooves 202 for improving the strain tolerance of the thermal barrier coating 104. More specifically, in the exemplary embodiment, each groove 202 extends inwardly from the top surface 112 of the thermal barrier coating 104 toward the metal base material 102 of the component 300, and the depth 114 of each groove 202 is defined by a groove bottom 116 in the second thermal barrier layer 108b of the thermal barrier coating 104. Thus, the depth 114 of each groove 202 shown in FIG. 3 is deeper than the depth 114 of each groove 202 shown in FIG. 2.
[0019] FIG. 4 is a schematic diagram of an exemplary turbine engine component 400. The component 400 shown in FIG. 4 is similar to the component 100 (FIG. 1), the component 200 (FIG. 2), and the component 300 (FIG. 3), with the differences described below, and therefore FIG. 4 uses the same reference numbers as FIGS. 1-3 to identify like components. The thermal barrier coating 104 includes a plurality of grooves 202 for improving the strain tolerance of the thermal barrier coating 104. More specifically, in the exemplary embodiment, each groove 202 extends inwardly from the top surface 112 of the thermal barrier coating 104 toward the metal base material 102 of the component 300, and the depth 114 of each groove 202 is defined by a groove bottom 116 at the junction 117 between the first thermal barrier layer 108 and the metallic bond coat layer 106. Thus, the depth 114 of each groove 202 shown in FIG. 4 is deeper than the depth 114 of each groove 202 shown in FIGS. 2 and 3.
[0020] In an exemplary embodiment, the thickness 118 of the thermal barrier coating 104 is defined by the combined thickness of all of the individual thermal barrier layers 108 (e.g., the first thermal barrier layer 108a and the second thermal barrier layer 108b) as measured from the top surface 112 of the thermal barrier coating 104 to the junction 117 defined between the first thermal barrier layer 108 and the metallic bond coat layer 106. For example, in the embodiment illustrated in Figures 2-4, the thickness 118 of the thermal barrier coating is defined as the combined thickness of the first thermal barrier layer 108a and the second thermal barrier layer 108b.
[0021] In the exemplary embodiment, each of the groove bottoms 116 is defined at an intermediate distance 120 from a junction 117 defined between the first thermal barrier layer 108 and the metallic bond coat layer 106. As shown in FIGS. 2-4, the intermediate thickness 120 is less than the total thickness 118 of the thermal barrier coating 104. Thus, at the bottoms 116 of the grooves 202, the thermal barrier coating 104 provides less thermal protection to the metallic bond coat layer 106 from the high ambient operating temperatures of the component (e.g., component 200, 300, 400). Without the present invention, the increased proximity to the high operating temperatures (e.g., due to less of the thermal barrier coating 104 extending over the metallic bond coat layer 106 at each groove bottom 116) increases the likelihood of oxidation and / or degradation of the metallic bond coat layer 106 at such locations relative to the thermal barrier coating 104.
[0022] 5-7 are schematic illustrations of a turbine engine component (e.g., components 200, 300, 400) including a thermal insulating filler material 502 deposited in at least one of a plurality of grooves 202 in a thermal barrier coating 104. In an exemplary embodiment, the thermal insulating filler material 502 provides improved thermal protection in relative locations in the thermal barrier coating 104 where less of the thermal barrier coating 104 extends over the metallic bond coat layer 106 (e.g., locations such as the bottom 116 of each groove 202).
[0023] In general, the insulating filler material 502 may be any material known in the art that contributes to improving the thermal protection of a component as described herein. For example, the insulating filler material 502 may have one or more material properties that improve the thermal protection of the components (e.g., components 200, 300, 400) and the metal base material 102 of the metallic bond coat layer 106 from the high environmental operating temperatures to which each component is exposed.
[0024] In an exemplary embodiment, the insulating filler material 502 is selected to have inherent material properties of desired chemical composition and porosity. For example, the selected material may be selected to have chemical composition properties conducive to a desired level of thermal protection as described herein. The size, shape and properties of the insulating filler material 502 may be selected and adjusted, for example, by adjusting the geometry (e.g., elemental geometry and / or composition geometry), length and / or ratios (e.g., molar ratios, weight ratios and / or volume ratios).
[0025] Moreover, in general, the insulating filler material 502 may be selected to include porosity conducive to the thermal protection methods described herein. For example, various materials may be selected to include desired particle density, particle size distribution, and / or particle shape characteristics.
[0026] 5A and 5B are schematic diagrams of part 200 in which thermal insulating filler material 502 substantially fills (FIG. 5A) and partially fills (FIG. 5B) each of grooves 202. FIGS. 6A and 6B are schematic diagrams of part 300 in which thermal insulating filler material 502 substantially fills (FIG. 6A) and partially fills (FIG. 6B) each of grooves 202. FIGS. 7A and 7B are schematic diagrams of part 400 in which thermal insulating filler material 502 substantially fills (FIG. 7A) and partially fills (FIG. 7B) each of grooves 202. Grooves 202 may contain any amount of thermal insulating filler material 502, with at least some grooves 202 remaining empty and other grooves 202 being completely filled with thermal insulating filler material 502. Thus, the amount of thermal insulating filler material 502 inserted into grooves 202 is not limited by the amounts shown in FIGS. 5-7.
[0027] Additionally, the amount of insulating filler material inserted into the grooves 202 may not be uniform throughout the part (e.g., part 200, 300, 400). Thus, while a substantially uniform amount of insulating filler material 502 is shown inserted into the grooves 202 in FIGS. 5-7, this is by way of example only and is not intended to limit the amount and / or displacement of insulating filler material 502 inserted into the grooves 202. In general, the amount of insulating filler material 502 placed into each groove 202 may be based on, for example, the type, size, and / or shape of the part (e.g., part 200, 300, 400). In particular, certain parts and / or certain regions of the parts may be more susceptible to high operating temperatures or may be exposed to higher environmental operating temperatures than other regions of the part. Thus, for such parts, the amount of insulating filler material 502 introduced into the grooves 202 may be increased as compared to other types and / or regions of the same part.
[0028] In an exemplary embodiment, the amount (e.g., depth) of the insulating fill material 502 deposited in the groove 202 may also depend on the application process used to deposit the insulating fill material 502. For example, in some embodiments, the insulating fill material 502 may be deposited in the groove 202 as a slurry or sprayed onto the component (e.g., component 200, 300, 400). In one embodiment, the insulating fill material 502 may be a yttria-based material applied in the form of a slurry. In some embodiments, the insulating fill material 502 may be an oxide-based mixture or slurry, such as, but not limited to, a zirconia-based mixture or slurry. In other embodiments, the insulating fill material 502 may be a zirconia-based mixture or slurry and may further contain silicon, aluminum, and / or rare earths.
[0029] The amount of insulating filler material 502 in groove 202 may also be controlled by the type and / or amount of application of insulating filler material 502. For example, multiple passes of spray application may be used to increase the amount of insulating filler material 502 (e.g., to increase the depth of insulating filler material 502 deposited in groove 202). In some embodiments, the part (e.g., part 200, 300, 400) may be subjected to a heat treatment after insulating filler material 502 is deposited in groove 202. In other embodiments, a reactive sintering process may occur during application of insulating filler material 502 to part (e.g., part 200, 300, 400).
[0030] The amount of insulating filler material 502 in grooves 202 may also be controlled by the type of mixture of insulating filler material 502. For example, the mixture of insulating filler material 502 may be altered based on the particle size of the mixture to improve filling of grooves 202 with insulating filler material 502. To improve the depth of thermal protection (e.g., both oxidative protection and thermal protection) provided by the thickness of the coating in grooves 202, the particle size of the mixture may be increased or decreased to improve filling along the length of grooves 202.
[0031] An exemplary method has been described herein for depositing a thermal insulating filler material into strain-resistant grooves in a thermal barrier coating to improve thermal protection of a turbine engine component. The exemplary systems and methods described herein provide several advantages over conventional designs and processes, including improved thermal protection of the turbine engine component, improved strain resistance of the thermal barrier coating on the turbine engine component, and increased service life of the turbine engine component due to reduced effects of long term exposure to high operating temperatures, including reduced oxidation and degradation of the turbine component at the locations of the strain-resistant grooves formed in the thermal barrier coating.
[0032] The above description is merely illustrative, and it will be apparent to those skilled in the art that various modifications may be made to the embodiments without departing from the technical scope of the present invention. Modifications falling within the technical scope of the present invention will be apparent to those skilled in the art in light of the contents of this disclosure, and such modifications fall within the technical scope of the claims. The systems and methods described herein are not limited to the specific embodiments described herein, and parts of the various systems may be used independently and separately from other systems and methods described herein.
[0033] Although specific features of various embodiments of the invention may be shown in some drawings and not in others, this is for convenience only. References to "one embodiment" in this specification should not be interpreted as excluding the existence of additional embodiments that have the recited features. In accordance with the principles of the present disclosure, features shown in one drawing may be referenced and / or claimed in combination with features shown in other drawings.
[0034] Further aspects of the present invention are set out in the following embodiment section. [Embodiment 1] 1. A method of forming a component, the method comprising: applying a thermal barrier coating to the component to reduce heat transfer to the component, the thermal barrier coating including one or more thermal barrier layers and a metallic bond coat layer, the one or more thermal barrier layers extending over the metallic bond coat layer, the metallic bond coat layer in contact with an exterior surface of the component; forming a plurality of grooves in the one or more thermal barrier layers of the thermal barrier coating to increase strain tolerance of the thermal barrier coating, each of the plurality of grooves extending to a depth within the one or more thermal barrier layers; and depositing material in the plurality of grooves to increase an amount of thermal protection of the metallic bond coat layer in areas of the thermal barrier coating where the plurality of grooves are formed. [Embodiment 2] The method of embodiment 1, wherein the step of depositing material into the plurality of grooves comprises depositing material in the form of a slurry. [Embodiment 3] The method of embodiment 1 or embodiment 2, wherein the step of depositing material into the plurality of grooves comprises depositing material in the form of a spray. [Embodiment 4] The method of any one of embodiments 1 through 3, wherein the step of applying a thermal barrier coating to the component includes applying a first thermal barrier layer onto the component, and applying a second thermal barrier layer over at least a portion of the first thermal barrier layer. [Embodiment 5] The method of any one of embodiments 1 through 4, wherein the step of forming a plurality of grooves includes forming a plurality of grooves such that at least some of the plurality of grooves extend into the second thermal barrier layer. [Embodiment 6] The method of any one of embodiments 1 through 5, wherein the step of forming the plurality of grooves includes forming the plurality of grooves such that at least some of the plurality of grooves extend through the second thermal insulation layer and at least partially into the first thermal insulation layer. [Embodiment 7] The method of any one of embodiments 1 through 6, wherein the step of forming a plurality of grooves includes forming a plurality of grooves such that at least some of the plurality of grooves extend through the second and first thermal barrier layers and contact the metallic bond coat layer. [Embodiment 8] The method of any one of embodiment paragraphs 1 through 7, wherein the step of depositing material within the plurality of grooves further comprises depositing material within the plurality of grooves to reduce an amount of degradation of the component in an area of the thermal barrier coating that includes the plurality of grooves. [Embodiment Item 9] The method of any one of embodiments 1 to 8, wherein the step of depositing material into the plurality of trenches further comprises depositing material to completely fill each of the plurality of trenches. [Embodiment 10] The method of any one of embodiments 1 through 9, wherein the step of depositing material into the plurality of trenches further comprises depositing the material such that it only partially fills the plurality of trenches. [Embodiment 11] The method of any one of embodiments 1 through 10, wherein the step of depositing a material in the plurality of grooves further comprises depositing a material in the plurality of grooves to reduce an amount of oxidation of the component in an area of the thermal barrier coating that includes the plurality of grooves. [Embodiment 12] The method of any one of embodiments 1 through 11, wherein the step of forming a plurality of grooves includes forming each groove having a bottom surface defined by a radius. [Embodiment 13] 1. A method of manufacturing a turbine engine component, the method comprising: applying a thermal barrier coating to the component to reduce heat transfer to the component, the thermal barrier coating including one or more thermal barrier layers and a metallic bond coat layer, the one or more thermal barrier layers extending over the metallic bond coat layer, the metallic bond coat layer in contact with an exterior surface of the component; forming a plurality of grooves in the one or more thermal barrier layers of the applied thermal barrier coating to increase strain tolerance of the thermal barrier coating, each of the plurality of grooves extending along a line perpendicular to the metallic bond coat layer to a depth within the one or more thermal barrier layers to a bottom of the groove; and depositing material in the plurality of grooves to increase an amount of thermal protection of the metallic bond coat layer proximate an extension of each of the plurality of grooves. [Embodiment 14] 14. The method of embodiment 13, wherein the step of applying a thermal barrier coating to the component includes applying a first thermal barrier layer on the component, and applying a second thermal barrier layer over at least a portion of the first thermal barrier layer. [Embodiment Item 15] The method of embodiment 13 or embodiment 14, wherein the step of forming the plurality of grooves includes forming the plurality of grooves such that at least some of the plurality of grooves extend into the second thermal barrier layer. [Embodiment 16] The method of any one of embodiments 13 through 15, wherein the step of forming the plurality of grooves includes forming the plurality of grooves such that at least some of the plurality of grooves extend through the second thermal insulation layer and at least partially into the first thermal insulation layer. [Embodiment 17] The method of any one of embodiments 13 through 16, wherein the step of forming a plurality of grooves includes forming a plurality of grooves such that at least some of the plurality of grooves extend through the second and first thermal barrier layers and contact the metallic bond coat layer. [Embodiment 18] The method of any one of embodiments 13 to 17, wherein the step of depositing material within the plurality of grooves further comprises depositing material within the plurality of grooves to reduce an amount of degradation of the component adjacent to an extension of each of the plurality of grooves. [Embodiment 19] The method of any one of embodiments 13 to 18, wherein the step of depositing material into the plurality of trenches further comprises depositing material to completely fill each of the plurality of trenches. [Embodiment 20] The method of any one of embodiments 13 to 19, wherein the step of depositing material into the plurality of trenches further comprises depositing the material such that it only fills a portion of the plurality of trenches.
[0035] While the invention has been described in terms of various specific embodiments, it will be apparent to those skilled in the art that the invention can be practiced with modification within the spirit and scope of the appended claims. [Explanation of symbols]
[0036] 100 parts 200 parts 300 parts 400 parts 102 Metallic Base Material 104 Thermal barrier coating 106 Metallic bond coat layer 108 Heat shield layer 108a First heat shield layer 108b Second heat shield layer 112 Thermal barrier coating top surface 114 Groove Depth 116 Bottom of the Groove ?202 Groove 502 Insulating filling material
Claims
1. 1. A method of forming a part, the method comprising: applying a thermal barrier coating to the component to reduce heat transfer to the component, the thermal barrier coating including one or more thermal barrier layers and a metallic bond coat layer, the one or more thermal barrier layers extending over the metallic bond coat layer, the metallic bond coat layer in contact with an exterior surface of the component; forming a plurality of grooves in one or more thermal barrier layers of the thermal barrier coating to increase the strain tolerance of the thermal barrier coating, each of the plurality of grooves extending to a depth within the one or more thermal barrier layers; depositing material within the plurality of grooves to increase the amount of thermal protection of the metallic bond coat layer in areas where the plurality of grooves are formed in the thermal barrier coating; A method comprising:
2. The method of claim 1 , wherein the step of depositing material into the plurality of grooves comprises depositing the material in the form of a slurry.
3. The method of claim 1 , wherein the step of depositing the material into the plurality of grooves comprises depositing the material in the form of a spray.
4. The method of claim 1 , wherein applying a thermal barrier coating to the component comprises applying a first thermal barrier layer onto the component and applying a second thermal barrier layer over at least a portion of the first thermal barrier layer.
5. The method of claim 4 , wherein the step of forming the plurality of grooves comprises forming the plurality of grooves such that at least some of the plurality of grooves extend into the second thermal barrier layer.
6. The method of claim 4 , wherein forming the plurality of grooves comprises forming the plurality of grooves such that at least some of the plurality of grooves extend through the second thermal barrier layer and at least partially into the first thermal barrier layer.
7. The method of claim 4 , wherein forming the plurality of grooves comprises forming the plurality of grooves such that at least some of the plurality of grooves extend through the second and first thermal barrier layers and contact the metallic bond coat layer.
8. 10. The method of claim 7, wherein depositing a material in the plurality of grooves further comprises depositing a material in the plurality of grooves to reduce an amount of degradation of the component in an area of the thermal barrier coating that includes the plurality of grooves.
9. The method of claim 1 , wherein depositing material into the plurality of trenches further comprises depositing material to completely fill each of the plurality of trenches.
10. The method of claim 1 , wherein depositing material into the plurality of trenches further comprises depositing the material to fill only a portion of the plurality of trenches.
11. 10. The method of claim 1, wherein depositing a material in the plurality of grooves further comprises depositing a material in the plurality of grooves to reduce an amount of oxidation of the component in an area of the thermal barrier coating that includes the plurality of grooves.
12. The method of claim 1 , wherein the step of forming a plurality of grooves includes forming each groove having a bottom surface defined by a radius.
13. 1. A method of manufacturing a turbine engine component, the method comprising: applying a thermal barrier coating to the component to reduce heat transfer to the component, the thermal barrier coating including one or more thermal barrier layers and a metallic bond coat layer, the one or more thermal barrier layers extending over the metallic bond coat layer, the metallic bond coat layer in contact with an exterior surface of the component; forming a plurality of grooves in one or more thermal barrier layers of the applied thermal barrier coating to increase the strain resistance of the thermal barrier coating, each of the plurality of grooves extending a depth within the one or more thermal barrier layers to a bottom of the groove along a line perpendicular to the metallic bond coat layer; depositing a material within the plurality of grooves to increase an amount of thermal protection of the metallic bond coat layer proximate each extension of the plurality of grooves; A method comprising:
14. The method of claim 13 , wherein applying a thermal barrier coating to the component comprises applying a first thermal barrier layer onto the component and applying a second thermal barrier layer over at least a portion of the first thermal barrier layer.
15. The method of claim 14 , wherein forming the plurality of grooves comprises forming the plurality of grooves such that at least some of the plurality of grooves extend into the second thermal barrier layer.