Spaced Ceramic Column Coatings for Thermal Stress Relief
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Solution Overview
Problem
Existing thermal barrier coatings for components exposed to high temperatures, such as those in aircraft engines and stationary gas turbines, suffer from irregular columnar structures that lead to uneven distribution and contact, resulting in poor thermal stress management and reduced durability.
Innovation Solution
A thermal insulation layer with ceramic columns that are spaced apart and perpendicular to the substrate, allowing for controlled expansion and minimizing contact points, combined with a method of laser-welded powder deposition to create uniform and non-porous columns with optional cavities for enhanced insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If plasma spraying is used to produce columnar thermal insulation structures, then thermal insulation capability is improved, but the columns become irregular in orientation and distribution, reducing manufacturing precision
Solution Approach 1:
The patent replaces the mechanical plasma spraying process with a laser-based energy field approach. Laser beams are used to melt and deposit ceramic powder, forming controlled columnar structures through optical energy rather than mechanical plasma jet impact. This substitution enables precise control of column formation while maintaining thermal insulation effectiveness.
Solution Approach 2:
The patent changes the energy deposition parameters by using laser power, beam focus, and scanning speed to control the melting and solidification of ceramic material. By adjusting these parameters, uniform columnar structures with controlled spacing and orientation are achieved, eliminating the irregularities inherent in plasma spraying while preserving thermal insulation properties.
2Area of stationary object
If columns are densely packed to provide complete coverage, then area coverage is improved, but thermal stress management deteriorates due to increased contact points
Solution Approach 1:
The patent applies local quality by creating columns with varying properties: the columns are spaced to have minimal contact points at their bases where they attach to the substrate, reducing stress concentration. The columns maintain sufficient spacing while still providing complete surface coverage, allowing local stress relief without compromising overall area protection.
Solution Approach 2:
The patent utilizes a columnar structure with inherent void spaces between columns, creating a porous-like architecture that provides thermal insulation pathways while managing thermal stresses. The controlled spacing between columns creates air gaps that reduce heat transfer and allow for stress accommodation during thermal cycling.
3Temperature
If conventional vapor deposition is used to create columnar structures, then thermal insulation is achieved, but the columns become porous and irregular, reducing reliability
Solution Approach 1:
The patent replaces conventional vapor deposition processes with laser-assisted direct deposition. The laser beam provides localized melting and rapid solidification of ceramic powder, creating dense, uniform columnar structures without the porosity and irregularity characteristic of vapor deposition methods. This direct energy-to-material transformation ensures reliable, consistent column formation.
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 solution provides improved thermal insulation and durability, protecting components from temperatures up to 1800°C with reduced thermal stress and increased lifespan by allowing controlled expansion and minimizing crack formation.
Implementation Method 1
A ceramic column of the thermal barrier layer is produced from a powder which is welded by a laser
Implementation Method 2
Components of turbine blades in aircraft engines and components of stationary gas turbines can be exposed to temperatures exceeding 1000°C or even 2000°C. Such components are protected from heat by thermal barrier coatings
Data Source
Figure 1
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AI summary
The invention relates to a system comprising a substrate (1) and a ceramic heat-insulating layer which is formed of columns (4, 13) and applied onto the substrate (1), characterized in that the columns (4, 13) at the substrate (1) are spatially separated from each other or at least hardly ever touch. The invention relates to a method for producing the system by laser welding. The invention allows the production of long-lasting, heat-resistant components which can be used for example in turbines or in metal-supported fuel cells.