Thermal barrier coating systems and methods of making and using the same
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Solution Overview
Problem
Conventional thermal barrier coatings for gas turbines face challenges in achieving high strain tolerance and adhesion while requiring expensive processes like PVD and needing extensive surface preparation, especially when applied to smooth bondcoats.
Innovation Solution
The development of thermal barrier coatings with non-vertical growth domains and a microstructure comprising partially melted and solidified particles, deposited using plasma spray techniques at specific angles, which enhances adhesion and strain tolerance without the need for rough bondcoats and reduces surface preparation requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If PVD processes are used to deposit thermal barrier coatings, then strain tolerance and adhesion are improved, but equipment cost and complexity increase significantly
Solution Approach 1:
The patent uses conventional plasma spray equipment instead of expensive PVD vacuum chambers, applying a disposable-like approach where standard equipment is utilized to achieve PVD-quality coatings without the high capital investment in specialized equipment
Solution Approach 2:
The invention changes the deposition parameters by controlling spray angle (45-75 degrees from substrate normal) and using specific feedstock particle sizes (1-10 micrometers) to create the characteristic non-vertical columnar grain structure that provides strain tolerance normally associated with PVD coatings
2Device complexity
If conventional thermal spray processes are used to apply thermal barrier coatings, then equipment cost is reduced, but strain tolerance and adhesion deteriorate
Solution Approach 1:
The patent modifies conventional thermal spray parameters by controlling spray angle (45-75 degrees), feedstock particle size (1-10 micrometers), and plasma power to achieve columnar grain structures with strain tolerance comparable to PVD coatings
Solution Approach 2:
The invention introduces a new dimensional control parameter (spray angle relative to substrate normal) to achieve microstructural features (non-vertical columnar grains) that provide strain tolerance, moving beyond traditional vertical spray deposition
3Ease of manufacture
If plasma spray processes are used with smooth bondcoats, then surface preparation complexity is reduced, but adhesion of thermal barrier coating deteriorates
Solution Approach 1:
The patent changes the deposition parameters by using controlled spray angles (45-75 degrees) and optimized plasma parameters to achieve adequate adhesion on smooth bondcoat surfaces without requiring grit blasting or rough surface preparation
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
These coatings exhibit high adhesion strength and improved thermal cycle performance, comparable to PVD methods, while being more cost-effective and scalable, with minimal delamination and increased durability at high temperatures.
Implementation Method 1
The coating is deposited by a plasma spray process
Implementation Method 2
One or more growth domains of the plurality of growth domains comprise a plurality of at least partially melted and solidified particles
Data Source
AI summary
A coating comprising a first surface and a second surface is provided. The coating includes a plurality of growth domains. An orientation of at least one growth domain of the plurality of growth domains is non-vertical with respect to the first surface of the coating. One or more growth domains of the plurality of growth domains comprise a plurality of at least partially melted and solidified particles.