Rare Earth Silicate EBC Vapor Deposition Composition Control
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Solution Overview
Problem
Existing environmental barrier coatings (EBCs) for high-temperature mechanical systems, such as gas-turbine engines, face challenges in controlling composition and achieving desired properties when deposited using single-source techniques, particularly with materials like yttria-stabilized zirconia, which can result in surface roughness and inadequate erosion resistance.
Innovation Solution
The use of vapor deposition techniques involving multiple target materials, specifically rare earth oxides and silica, where the energy input to each material can be independently controlled to achieve a desired composition, allowing for the formation of rare earth silicate EBCs with improved properties like low volatility and enhanced thermal and mechanical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If single-source vapor deposition is used to deposit environmental barrier coatings, then the deposition process is simple, but the composition control is poor and surface roughness increases
Solution Approach 1:
The single target material is segmented into multiple separate target materials (rare earth oxide target and silica target). Each target can be independently controlled during deposition, allowing precise composition control of the final EBC layer while maintaining process manageability through separate control parameters.
Solution Approach 2:
The patent uses composite target materials consisting of rare earth oxides and silica deposited simultaneously or sequentially. This composite approach allows the EBC to achieve desired composition and properties that cannot be obtained from single-source deposition, improving both composition control and surface quality.
2Reliability
If yttria-stabilized zirconia is used as EBC material, then thermal insulation is provided, but erosion resistance is inadequate
Solution Approach 1:
The patent changes the material composition parameters by using rare earth oxides (such as gadolinium oxide, ytterbium oxide) combined with silica instead of traditional yttria-stabilized zirconia. This parameter change results in EBC materials with lower volatility and enhanced erosion resistance while maintaining thermal insulation properties.
Solution Approach 2:
The EBC is formed as a composite material system combining rare earth oxides and silica. This composite structure provides synergistic effects where the rare earth oxide component offers thermal stability and the silica component provides erosion resistance, collectively improving reliability against environmental degradation.
3Manufacturing precision
If multiple target materials are used with independent energy control, then composition precision is improved, but process complexity increases
Solution Approach 1:
The patent implements dynamic energy control where the electron beam power can be independently adjusted for each target material during deposition. This dynamic control allows real-time optimization of composition by varying energy input to rare earth oxide target versus silica target, achieving precise composition control while adapting to process requirements.
Solution Approach 2:
The deposition process incorporates feedback control mechanisms where deposition rate and composition are monitored and used to adjust electron beam energy distribution to multiple targets. This feedback system maintains precise composition control despite the increased complexity of multi-target energy management.
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
This approach enables the creation of EBCs with controlled composition and microstructure, providing superior thermal insulation, mechanical compliance, and resistance to environmental degradation, thereby extending the operational life of high-temperature components.
Implementation Method 1
applying a first electron beam to vaporize a portion of a first target material comprising a rare earth oxide, wherein the first electron beam delivers a first amount of energy
Implementation Method 2
the portion of the first target material and the portion of the second target material are deposited substantially simultaneously over a substrate to form a layer over the substrate
Data Source
AI summary
A vapor deposition method may include applying a first electron beam to vaporize a portion of a first target material comprising a rare earth oxide, where the first electron beam delivers a first amount of energy. The method also may include applying a second electron beam to vaporize a portion of a second target material comprising silica, where the second electron beam delivers a second amount of energy different from the first amount of energy. In some examples, the second target material is separate from the first target material. Additionally, the portion of the first target material and the portion of the second target material may be deposited substantially simultaneously over a substrate to form a layer over the substrate. A system for practicing vapor deposition methods and articles formed using vapor deposition methods are also described.