Multi-layered Ceramic Coating for Heat Shield Thermal Radiation Management
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Solution Overview
Problem
Gas turbine engine combustors face challenges in effectively protecting against high temperatures due to the limitations of existing heat shields, which fail to adequately manage thermal radiation and reflection.
Innovation Solution
A heat shield panel with a substrate and a multi-layered ceramic coating, comprising alternating layers of stabilized zirconia and hafnia, supported by a bond coat, is used to protect the combustor from high temperatures. The multi-layered coating is fabricated using thermal spraying techniques, with layers thinner than 25 micrometers and a total thickness of 0.1-0.6 millimeters, facilitating thermal radiation scattering and reflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If existing heat shields are used, then thermal protection is provided, but thermal radiation and reflection are not adequately managed
Solution Approach 1:
The patent applies composite materials by creating a multi-layered coating system consisting of alternating layers of different ceramic materials (such as stabilized zirconia and stabilized hafnia) with different optical and thermal properties. This composite structure enables both thermal radiation scattering and reflection to occur simultaneously at different interfaces, effectively managing thermal radiation while protecting the substrate, thereby resolving the contradiction between heat shield effectiveness and thermal radiation management.
Solution Approach 2:
The patent applies segmentation by dividing the heat shield coating into multiple thin layers (each less than 25 micrometers thick) rather than using a single thick coating. This segmented multi-layer structure creates numerous interfaces that scatter and reflect thermal radiation, improving thermal protection effectiveness while maintaining adequate heat shield performance.
2Object-affected harmful factors
If multi-layered coating with thin layers is used, then thermal radiation scattering is enhanced, but manufacturing complexity increases
Solution Approach 1:
The patent applies parameter changes by carefully controlling the thickness parameter of each layer (keeping individual layers below 25 micrometers) and the total coating thickness (0.1-0.6 millimeters). These specific parameter ranges optimize thermal radiation scattering while ensuring the complex multi-layer structure can be manufactured using conventional thermal spraying techniques, thus balancing enhanced scattering with manageable manufacturing complexity.
3Object-affected harmful factors
If alternating layers of different ceramic materials are used, then thermal reflection is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies parameter changes by establishing specific thickness parameters for each layer (individual layers less than 25 micrometers, total thickness 0.1-0.6 millimeters) that optimize thermal reflection while remaining compatible with thermal spraying manufacturing processes. These parameter specifications balance the need for precise alternating layer structures with the practical constraints of manufacturing precision.
Solution Approach 2:
The patent applies local quality by using different ceramic materials (such as stabilized zirconia and stabilized hafnia) with distinct optical and thermal properties in alternating layers. Each material is selected for its specific contribution to thermal reflection and scattering, creating locally optimized zones within the coating structure that collectively enhance overall thermal protection while maintaining manufacturability.
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 enhanced thermal protection by scattering and reflecting thermal radiation, preventing damage to the underlying substrate and improving the durability and efficiency of the heat shield panel in high-temperature environments.
Implementation Method 1
facilitating thermal radiation scattering and reflection
Implementation Method 2
facilitating thermal radiation scattering and reflection
Implementation Method 3
The multi-layered coating is fabricated using thermal spraying techniques
Data Source
AI summary
An article such as a heat shield panel includes a substrate and a multi-layered coating supported on the substrate. The multi-layered coating can include alternating layers of different ceramic material compositions having individual thicknesses of less than 25 micrometers.