Al-Si Protective Coating Stack for High-Temperature Corrosion

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing coatings for high-temperature components, such as TiN/TiAlN and TiAlN layer systems, exhibit insufficient corrosion resistance and adhesion issues, particularly on materials like Inconel, TiAl-based materials, and SiC-based CMCs, leading to wear due to oxidation and erosion.

Innovation Solution

A layer system comprising silicon, aluminum, oxygen, and nitrogen, applied using a combination of physical vapor deposition (PVD) and plasma-enhanced chemical vapor deposition (PECVD), with a functional layer containing Al—Si—O and/or Al—Si—N, enhancing adhesion and providing corrosion and erosion protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If TiN/TiAlN or TiAlN layer systems are applied to high-temperature components, then erosion resistance is improved, but corrosion resistance deteriorates due to insufficient protection and formation of mechanically unstable oxides

Engineering Contradiction:

Improveerosion resistanceVSAvoidcorrosion resistance

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The coating system is divided into multiple functional layers: a base layer (TiN/TiAlN) providing erosion resistance, an intermediate adhesion layer, and a top corrosion protection layer. This segmentation allows each layer to optimize its specific function without compromising the others.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses composite coating structures combining different materials (TiN, TiAlN, and other corrosion-resistant materials) to achieve both erosion resistance from the base layer and corrosion resistance from the top layer, resolving the contradiction between these two protective functions.

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If conventional PVD coatings are applied to SiC-based CMC materials, then surface protection is provided, but adhesion deteriorates due to coating detachment at high temperatures

Engineering Contradiction:

Improvesurface protectionVSAvoidadhesion

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

An intermediate adhesion layer is introduced between the SiC-based CMC substrate and the protective coating layers. This intermediate layer acts as a mediator that ensures strong bonding between the substrate and the coating, preventing detachment at high temperatures while maintaining surface protection.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention modifies deposition parameters and coating composition to optimize adhesion to SiC-based CMC materials, changing the physical and chemical parameters of the coating system to achieve stable bonding at high temperatures.

Inventive Principle:

Principle #35Parameter changes

3Loss of substance

If protective coatings are applied to prevent corrosion, then material loss is reduced, but coating complexity increases requiring multiple layers and deposition methods

Engineering Contradiction:

Improvematerial loss preventionVSAvoidcoating structure complexity

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

The invention combines PVD and PECVD deposition methods in a integrated coating process, merging the advantages of both techniques (PVD for erosion resistance and PECVD for corrosion protection) into a single multi-layer system that achieves comprehensive protection.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The coating system is designed with multi-functionality where different layers provide different protective functions (erosion resistance, corrosion protection, adhesion) within a single integrated structure, reducing the need for separate coating systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The new layer system improves adhesion and provides effective corrosion and erosion resistance, maintaining mechanical strength and stability at high temperatures, reducing wear and extending the service life of components.

Implementation Method 1

The material of all layers is applied by physical vapour deposition (PVD)

Methodology Applied

Scientific EffectPhysical vapor deposition: Physical Vapour Deposition

Implementation Method 2

applied using a combination of physical vapor deposition (PVD) and plasma-enhanced chemical vapor deposition (PECVD)

Methodology Applied

Scientific EffectPlasma-enhanced chemical vapor deposition: Plasma Enhanced Chemical Vapour Deposition

Data Source

PatentUS12577682B2Al—Si corrosion protection coatings

Publication Date: 2026.03.17 OERLIKON SURFACE SOLUTIONS AG PFAFFIKON

AI summary

The invention relates to a layer system coated on a substrate, the layer system comprising a functional layer and an intermediate layer, the intermediate layer being disposed between the substrate and the functional layer, the functional layer comprising both the elements aluminum and silicon but not necessarily in elemental form, and the functional layer comprising oxygen or nitrogen or both, characterized in that the intermediate layer comprises, measured in at %, percent more silicon and/or percent more aluminum than the functional layer.