Ceramic Barrier Coating Gettering Particles Oxidation
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Solution Overview
Problem
Gas turbine engine components face challenges in maintaining thermal and oxidative stability due to high temperatures, corrosive, and oxidative conditions, which existing protective barrier coatings fail to adequately address.
Innovation Solution
A ceramic-based substrate with a barrier layer comprising a matrix phase and a network of gettering particles, including silicon oxycarbide and barium-magnesium alumino-silicate particles, which form a diffusion barrier to protect the substrate from oxygen and moisture, enhancing oxidation resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing protective barrier coatings are used on gas turbine engine components, then the components are protected to some extent, but they fail to adequately address thermal and oxidative stability under high temperature and corrosive conditions
Solution Approach 1:
The patent employs a composite barrier layer comprising a matrix phase (silicon oxide, silicon oxycarbide) combined with dispersed particulate phases (barium magnesium alumino silicate particles, rare earth aluminum silicate particles). This composite structure provides synergistic protection where the matrix phase offers baseline oxidation resistance while the dispersed particles enhance thermal stability and block oxidant diffusion pathways, collectively achieving superior thermal and oxidative stability under high temperature conditions
Solution Approach 2:
The barrier layer acts as an intermediary protective layer between the gas turbine engine component substrate and the harsh oxidizing environment. The specific composition of silicon oxide matrix with barium magnesium alumino silicate and rare earth aluminum silicate particles creates a diffusion barrier that mediates the interaction between oxidants and the substrate, reducing oxidant penetration while maintaining thermal stability
2Reliability
If the barrier layer uses a high concentration of gettering particles to block oxidants, then oxidation resistance improves, but the complexity of the coating composition increases
Solution Approach 1:
The patent optimizes the size parameter of the dispersed particles (barium magnesium alumino silicate and rare earth aluminum silicate) within specific ranges (0.5-10 micrometers average diameter). This parameter control ensures sufficient particle density to block oxidant diffusion pathways while maintaining manageable coating complexity. The controlled particle size distribution allows the coating to achieve effective oxidation resistance without requiring overly complex multi-phase compositions
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 composite barrier layer effectively limits exposure to oxidants, improving the thermal and oxidative stability of gas turbine engine components by diffusing and sealing oxidant species, thereby extending the longevity and effectiveness of the protective coating.
Implementation Method 1
The gettering particles have an average maximum dimension between about 30 and 70 microns. The barrier layer includes a network of gettering particles in the matrix phase.
Implementation Method 2
The barrier layer also includes a dispersion of diffusive particles in the matrix phase.
Data Source
AI summary
An article includes a ceramic-based substrate and a barrier layer on the ceramic-based substrate. The barrier layer includes a matrix phase and a network of gettering particles in the matrix phase. The gettering particles have an average maximum dimension between about 30 and 70 microns. The gettering particles have maximum dimensions that range from about 1 to 100 microns, and a dispersion of barium-magnesium alumino-silicate particles in the matrix phase. A composite material and a method of applying a barrier layer to a substrate are also disclosed.