Infiltration and Reactive Coatings for Thermal Barrier Spallation

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Solution Overview

Problem

Thermal barrier coatings in turbine engines degrade due to spallation caused by dust and CMAS deposits, which infiltrate and compromise the coating's integrity.

Innovation Solution

A coating system comprising an infiltration coating that penetrates and decomposes within the thermal barrier coating to reduce porosity, combined with a reactive phase spray formulation coating that reacts with dust deposits on the surface.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If thermal barrier coating is applied to protect turbine engine surfaces, then protection against thermal damage is improved, but the coating becomes vulnerable to spallation from dust and CMAS infiltration

Engineering Contradiction:

Improveprotection against thermal damageVSAvoidspallation from dust and CMAS infiltration

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The reactive phase spray formulation coating reacts with dust deposits to convert harmful dust infiltration into a beneficial protective reaction layer. The infiltration coating reacts with CMAS deposits to convert harmful CMAS infiltration into a beneficial sealed structure, transforming the harmful infiltration process into a protective mechanism

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The system uses composite coating structure combining infiltration coating and reactive phase spray formulation coating. The infiltration coating penetrates and seals pores, while the reactive phase spray formulation coating reacts with dust deposits, creating a multi-functional composite protection system that addresses both thermal protection and spallation resistance

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If infiltration coating is applied to reduce porosity, then resistance to dust infiltration is improved, but the coating requires decomposition within pores which adds process complexity

Engineering Contradiction:

Improveresistance to dust infiltrationVSAvoidprocess complexity from decomposition requirement

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The infiltration coating undergoes parameter change through decomposition within the pores, transforming from a precursor state to a final protective state. This parameter change enables the coating to fill and seal pores effectively, converting the complexity of decomposition into the benefit of pore sealing and reduced porosity

Inventive Principle:

Principle #35Parameter changes

3Object-affected harmful factors

If reactive phase spray formulation coating is applied to react with dust deposits, then spallation resistance is improved, but the coating requires specific material properties that complicate formulation

Engineering Contradiction:

Improvespallation resistanceVSAvoidformulation complexity from material property requirements

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The reactive phase spray formulation coating has different material properties at different locations and functions. The base material provides compliance for thermal cycling, while the binder material provides cohesive and adhesive strength. This local differentiation of material properties enables the coating to simultaneously achieve spallation resistance and accommodate thermal expansion differences

Inventive Principle:

Principle #3Local quality

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 system significantly reduces spallation of the thermal barrier coating, thereby extending its lifespan and reducing repair and replacement costs, without the need for thermal treatment.

Implementation Method 1

The infiltration coating infiltrates at least some pores of the thermal barrier coating

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 2

The infiltration coating decomposes within at least some pores of the thermal barrier coating to coat a portion of the at least some pores

Methodology Applied

Scientific EffectThermal decomposition: Decomposition (biological)

Implementation Method 3

The reactive phase spray formulation coating reacts with dust deposits on the thermal barrier coating

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Data Source

PatentUS12215428B2Coating systems including infiltration coatings and reactive phase spray formulation coatings

Publication Date: 2025.02.04 GENERAL ELECTRIC CO

AI summary

A coating system configured to be applied to a thermal barrier coating of an article includes an infiltration coating configured to be applied to the thermal barrier coating. The infiltration coating infiltrates at least some pores of the thermal barrier coating. The infiltration coating decomposes within at least some pores of the thermal barrier coating to coat a portion of the at least some pores of the thermal barrier coating. The infiltration coating reduces a porosity of the thermal barrier coating. The coating system also includes a reactive phase spray formulation coat configured to be applied to the thermal barrier coating. The reactive phase spray formulation coating reacts with dust deposits on the thermal barrier coating.