Thermal Barrier Coatings with Columnar Voids for Low Conductivity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current thermal barrier coatings for gas turbine engines face challenges in maintaining low thermal conductivity and high toughness, especially when exposed to demanding engine designs, as they often compromise on erosion resistance and cyclic life due to their microstructural characteristics.
Innovation Solution
The development of a thermal barrier coating system that incorporates a columnar microstructure with elongated surface-connected voids and nonspherical particles, along with surface-connected microporosity cracks, to reduce thermal conductivity while enhancing fracture toughness and cyclic life, using materials like yttria-stabilized zirconia and rare-earth containing oxides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thermal barrier coatings are designed with traditional microstructures to maintain low thermal conductivity, then thermal insulation performance is improved, but erosion resistance and cyclic life deteriorate
Solution Approach 1:
The patent applies porous materials by designing a thermal barrier coating with a columnar microstructure containing elongated surface-connected voids. These voids create a porous network that reduces thermal conductivity while the columnar architecture provides crack deflection paths that improve erosion resistance and cyclic life, resolving the contradiction between thermal insulation and reliability
Solution Approach 2:
The patent employs composite materials by combining yttria-stabilized zirconia (YSZ) with rare-earth containing oxides in a specific composition ratio. This composite formulation achieves ultra-low thermal conductivity while the interaction between different ceramic phases enhances toughness and resistance to thermal cycling and erosion, simultaneously improving both thermal insulation and reliability
2Temperature
If thermal barrier coatings incorporate columnar microstructure with elongated voids to reduce thermal conductivity, then thermal insulation is improved, but coating complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the coating into distinct columnar units with elongated voids between them. This segmented columnar microstructure creates thermal barriers at each column interface while maintaining a relatively simple overall coating architecture that can be applied using conventional thermal spray processes, balancing thermal performance with manufacturing simplicity
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 coating achieves ultra-low thermal conductivity (less than 1.8 W/mK at 1000°C) and suitable toughness, improving the durability and efficiency of components in high-temperature environments by effectively managing thermal expansion and crack propagation.
Implementation Method 1
The coating achieves ultra-low thermal conductivity (less than 1.8 W/mK at 1000°C) and suitable toughness, improving the durability and efficiency of components in high-temperature environments by effectively managing thermal expansion and crack propagation
Implementation Method 2
improving the durability and efficiency of components in high-temperature environments by effectively managing thermal expansion and crack propagation
Data Source
Figure 1~2
Figure 3
AI summary
Coated components (100), along with methods of their formation, are provided. The coated component (100) may include a substrate (120) having a surface (115) and a thermal barrier coating (110) on the surface (115) of the substrate (120). The thermal barrier coating (110) includes a plurality of elongated surface connected voids (130) therein, and wherein the thermal barrier coating (110) comprises a plurality of nonspherical particles (112) within a ceramic thermal barrier material (114).