Thermal Barrier Coating Grooves for Bond Coat Protection

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Solution Overview

Problem

Turbine engine components face increased oxidation and degradation of the metallic bond coat layer due to strain tolerance grooves in thermal barrier coatings, which reduce the coating thickness and expose these areas to higher temperatures.

Innovation Solution

Depositing a material within the strain tolerance grooves of the thermal barrier coating to enhance thermal protection and reduce oxidation and degradation of the metallic bond coat layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If strain tolerance grooves are formed in the thermal barrier coating, then strain tolerance of the coating is improved, but thermal barrier coating thickness at groove locations is decreased

Engineering Contradiction:

Improvestrain tolerance of the coatingVSAvoidthermal protection reliability

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The patent applies local quality by depositing additional thermal barrier coating material specifically within the groove regions where thickness is reduced. This creates a non-uniform coating structure where areas with grooves receive supplemental material to restore thermal protection, while other areas maintain the original coating design. The selective reinforcement at groove locations resolves the contradiction by locally compensating for the thickness reduction caused by groove formation.

Inventive Principle:

Principle #3Local quality

2Stability of the object's composition

If strain tolerance grooves are formed in the thermal barrier coating, then strain tolerance of the coating is improved, but oxidation and degradation of the metallic bond coat layer is more likely to occur

Engineering Contradiction:

Improvestrain tolerance of the coatingVSAvoidoxidation and degradation of metallic bond coat layer

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The patent implements preliminary anti-action by proactively depositing additional thermal barrier coating material into the groove regions before the component is exposed to high-temperature service conditions. This preventive measure ensures that the metallic bond coat layer is protected from oxidation and degradation at groove locations before harmful effects can occur during operation. The supplemental coating acts as a pre-established protective barrier against the anticipated thermal and oxidative environment.

Inventive Principle:

Principle #9Preliminary anti-action

3Reliability

If additional material is deposited into the grooves, then thermal protection of the metallic bond coat layer is improved, but device complexity increases

Engineering Contradiction:

Improvethermal protection of metallic bond coat layerVSAvoidcoating structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by incorporating the deposition of additional material into the groove regions as an integral step within the coating application process itself. Rather than treating groove repair as a separate post-processing operation, the method performs the supplemental deposition concurrently with or immediately following the initial thermal barrier coating application. This integration reduces overall process complexity and eliminates the need for separate repair operations.

Inventive Principle:

Principle #10Preliminary action

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

Improves thermal protection and strain tolerance of turbine engine components by reducing oxidation and degradation at the grooves, thereby extending the component's useful life.

Implementation Method 1

applying a thermal barrier coating to the component to facilitate decreasing heat transfer to the component, wherein the thermal barrier coating includes at least one thermal insulating layer

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

depositing a material within the plurality of grooves to facilitate increasing an amount of thermal protection of the metallic bond coat layer

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS12523163B2Thermal protection methods using barrier coatings with strain tolerance grooves

Publication Date: 2026.01.13 GE INFRASTRUCTURE TECH LLC

AI summary

A method of forming a component. The method includes applying a thermal barrier coating to the component to facilitate decreasing heat transfer to the component, wherein the thermal barrier coating includes at least one thermal insulating layer and a metallic bond coat layer in contact with an outer surface of the component. The method also includes forming a plurality of grooves in the at least one thermal insulating layer of the thermal barrier coating to facilitate increasing a strain tolerance of the thermal barrier coating, wherein each of the plurality of grooves extends a depth into the at least one thermal insulating layer. The method further includes depositing a material within the plurality of grooves to facilitate increasing an amount of thermal protection of the metallic bond coat layer within those areas of the thermal barrier coating in which the plurality of grooves are formed.