SiOC Metal Ceramic Coating for Gas Turbine Thermal Stability
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Solution Overview
Problem
Machine components, such as those in gas turbine engines, face challenges with high temperatures, corrosive, and oxidative conditions, requiring improved thermal and oxidative stability that existing coatings fail to adequately provide.
Innovation Solution
A ceramic structure with a composition of SiOxMzCy, where Si is silicon, O is oxygen, M is at least one metal, and C is carbon, applied as a uniform layer on substrates like superalloys or ceramics, which includes 0.5-20 at% metal, selected from various metals, forming a thermally stable glass that gets oxygen and seals microcracks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional coatings are applied to improve thermal and oxidative stability, then some protection is achieved, but the protection is inadequate under high temperature and corrosive conditions
Solution Approach 1:
The patent modifies the chemical composition parameters of the ceramic coating by incorporating specific metal elements (Al, B, Ti, Zr, Hf, V, Cr, Nb, Ta, Mo, W, Re, La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu) at controlled concentrations (0.1-10 wt%) into the Si-O-C matrix. This compositional parameter change enables the coating to form protective glassy oxides at high temperatures that conventional coatings cannot achieve, thereby improving thermal and oxidative stability while resisting corrosive environments.
Solution Approach 2:
The patent creates a composite ceramic material system combining Si-O-C base matrix with multiple metal oxides formed in situ. The composite structure integrates the thermal stability of Si-O-C with the protective properties of metal oxides (such as Al2O3, B2O3, TiO2, ZrO2, etc.), achieving synergistic effects that provide superior protection against high temperatures, oxidation, and corrosion compared to conventional single-phase coatings.
2Stability of the object's composition
If ceramic coatings are applied to protect substrates, then thermal stability is improved, but microcracks may form and propagate under thermal stress
Solution Approach 1:
The patent adjusts the chemical composition parameters to include specific metal elements that form glassy phases upon oxidation. These glassy phases have different thermal expansion coefficients and viscosities that can accommodate thermal stress, reducing the formation and propagation of microcracks while maintaining thermal stability. The controlled addition of metals like B, Al, and Si creates a more crack-resistant glassy matrix.
Solution Approach 2:
The patent utilizes the phase transition of metal-containing glassy materials that occur at high temperatures. Upon oxidation, the metal elements transform into glassy oxides that can undergo viscous flow and phase transitions, allowing the coating to self-heal microcracks through stress relaxation and material redistribution, thereby maintaining structural integrity under thermal cycling conditions.
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 ceramic structure enhances thermal stability, durability, and oxidative resistance by forming a glassy or crystalline oxide that softens to seal microcracks, protecting the substrate from elevated temperatures and corrosive environments.
Implementation Method 1
forming a thermally stable glass that gets oxygen and seals microcracks
Implementation Method 2
forming a glassy or crystalline oxide that softens to seal microcracks
Implementation Method 3
the forming includes pyrolysis of a preceramic polymer material
Data Source
Figure 1A
Figure 1B
Figure 2~3
AI summary
An article which includes a structure of a ceramic material that has a composition SiOxMzCy, where Si is silicon, O is oxygen, M is at least one metal and C is carbon and wherein x < 2, y > 0 and z < 1 and x and z are non-zero.