Ceramic Coating CMAS Protection via Phosphor Infiltration
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Solution Overview
Problem
Thermal barrier coatings in turbine components are susceptible to damage from environmental contaminants like CMAS, which can infiltrate the coating, cause cracks, and lead to premature component failure.
Innovation Solution
Infiltrating a material comprising a protective agent and a phosphor into the surface-connected openings of the ceramic coating, where the protective agent reacts with CMAS to prevent infiltration and the phosphor allows for easy inspection of uniformity and concentration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the ceramic coating is left porous to maintain strain tolerance, then the coating can accommodate thermal expansion and contraction, but the coating becomes vulnerable to CMAS infiltration and damage
Solution Approach 1:
The patent utilizes the inherent porous structure of the ceramic coating by infiltrating it with a protective material that forms a solid barrier within the pores. This allows the coating to maintain its porous characteristics for strain tolerance while the infiltrated material prevents CMAS from causing damage.
Solution Approach 2:
The protective material is nested within the porous structure of the ceramic coating, filling the voids and cracks without compromising the overall porous architecture. This nested configuration allows the coating to maintain its strain tolerance while gaining protection against CMAS infiltration.
2Ease of manufacture
If conventional inspection methods are used to detect coating damage, then the inspection process is simple, but the detection precision and ability to identify uniformity of protective material deposition is insufficient
Solution Approach 1:
The patent incorporates a phosphor into the protective material that emits light at a specific wavelength when excited by UV light. This color change property allows for easy visual detection and measurement of the uniformity of protective material deposition across the coating surface, providing both simplicity and precision in inspection.
3Reliability
If the protective material is deposited uniformly into all surface-connected openings, then the protection against CMAS is maximized, but the deposition process becomes complex and difficult to control
Solution Approach 1:
The patent employs preliminary action by using a carrier fluid to deliver the protective material to the surface-connected openings before the material can be damaged by CMAS. The carrier fluid facilitates uniform distribution and deposition of the protective material into the porous structure, simplifying the overall process while ensuring reliable protection.
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 method effectively prevents CMAS-induced damage to thermal barrier coatings by forming a solid barrier or increasing the viscosity of CMAS, while also enabling efficient quality control and targeted maintenance through phosphor-induced fluorescence.
Implementation Method 1
illuminating a surface of the ceramic coating with a stimulant radiation, wherein the ceramic coating comprises a plurality of surface-connected openings and a material disposed in at least some of the openings, the material comprising i. one or more phosphors
Data Source
Figure 1A~1B
Figure 2
Figure 3A~3C
AI summary
Provided herein are methods and compositions which allow for efficient inspection, maintenance and repair of ceramic coatings, e.g. coating on turbine blade. A method comprising: disposing a material in a plurality of surface-connected openings of a ceramic coating, the material comprising: i. one or more phosphors, and ii. one or more protective agents.