Environmental Barrier Coating Feedstock for Stable Spray Deposition
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Solution Overview
Problem
Conventional bond coat constituents for gas turbine engine components degrade during spray processes, making it difficult to apply protective coatings efficiently and effectively.
Innovation Solution
A feedstock of coated particles with gettering particles and diffusive particles, protected by a coating that transforms into a bond coat during spray deposition, providing a durable environmental barrier.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional bond coat constituents are used during spray deposition, then the coating application process can be performed, but the constituents degrade during the spray process, reducing coating quality and effectiveness
Solution Approach 1:
The patent applies preliminary action by pre-coating the gettering particles with a protective coating before spray deposition. This pre-protection allows the particles to survive the spray process without degrading, and the coating later transforms into the desired bond coat structure during thermal processing, resolving the contradiction between achieving effective coating and maintaining process stability
Solution Approach 2:
The patent uses an intermediary approach by introducing a transient protective coating on the gettering particles that serves as a mediator during spray deposition. This coating protects the particles during the harmful spray process and then transforms into the functional bond coat, bridging the gap between process requirements and final coating performance
2Ease of manufacture
If the feedstock particles are sprayed directly without protective coating, then the spray process is simpler, but the particle constituents degrade during deposition
Solution Approach 1:
The patent applies preliminary action by pre-coating the gettering particles with a protective coating before spray deposition. This pre-protection allows the particles to survive the spray process without degrading, and the coating later transforms into the desired bond coat structure during thermal processing, resolving the contradiction between achieving effective coating and maintaining process stability
Solution Approach 2:
The patent uses an intermediary approach by introducing a transient protective coating on the gettering particles that serves as a mediator during spray deposition. This coating protects the particles during the harmful spray process and then transforms into the functional bond coat, bridging the gap between process requirements and final coating performance
3Reliability
If a protective coating is applied to gettering particles before spray deposition, then particle stability during spraying is improved, but the feedstock preparation becomes more complex
Solution Approach 1:
The patent applies parameter changes by transforming the protective coating into the functional bond coat through thermal processing. This parameter change (from protective to functional) simplifies the overall system by eliminating the need for separate protective and functional coatings, reducing feedstock complexity while maintaining particle stability during spray
4Ease of manufacture
If conventional coating materials are used, then the coating can be applied, but the coating degrades under high temperature and oxidative conditions
Solution Approach 1:
The patent applies composite materials by creating a multi-layer structure with gettering particles embedded in a matrix material. This composite structure provides both the ease of spray application and the required thermal/oxidative stability, as the matrix protects the particles while the particles provide protective functions
Solution Approach 2:
The patent applies parameter changes by transforming the protective coating into the functional bond coat through thermal processing. This parameter change (from protective to functional) simplifies the overall system by eliminating the need for separate protective and functional coatings, reducing feedstock complexity while maintaining particle stability during spray
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 spray-deposited bond coat effectively protects engine components from high temperatures, corrosive, and oxidative conditions, enhancing thermal and oxidative stability.
Implementation Method 1
the coating includes a material configured to melt during thermal spray deposition of the coating
Implementation Method 2
A method of coating a substrate according to an exemplary embodiment of this disclosure, among other possible things includes directing a feedstock against a substrate such that the feedstock forms a bond coat on the substrate
Implementation Method 3
The coating also includes transforming the precursor diffusive material or precursor matrix material into diffusive particles or matrix, respectively, by heat treatment after the directing step
Data Source
AI summary
A feedstock for spray deposition of a coating includes particles each including a particle core and a coating. The particle core is a gettering particle. The coating includes at least one of diffusive material, precursor diffusive material, matrix material, and precursor matrix material. A method of coating a substrate is also disclosed.