Tile-Based Coating Systems for Ceramic Gas Turbine Components
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The complexity of manufacturing ceramic components and building coating systems on their surfaces, particularly for high-temperature applications in the aircraft industry, leads to inefficiencies and opportunities for complications in existing coating application methods.
Innovation Solution
A method involving the use of prefabricated tiles secured to the surface of ceramic components, forming a coating system that includes environmental barrier coatings (EBC) and/or thermal barrier coatings (TBC), with the tiles being joined using a bonding compound and processed through drying, debinding, and sintering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple rounds of process steps such as doctor blading, spraying, and firing are used to apply coating systems, then the coating system can be formed on the ceramic component, but the manufacturing complexity and number of opportunities for complications increase
Solution Approach 1:
The coating system is segmented into discrete tiles that can be individually manufactured and then assembled onto the ceramic component. Each tile is a separate unit that can be produced independently, then joined together to form the complete coating system, reducing the complexity of applying multiple coating layers in sequence
Solution Approach 2:
The tiles are pre-formed and pre-prepared before being applied to the ceramic component. The coating material is prepared in advance as discrete tile units, allowing for quality control and preparation to be completed before the actual application process, thereby reducing on-site manufacturing complexity
2Reliability
If traditional coating application methods are used, then coating systems can be applied to ceramic components, but the number of process steps and potential for complications increases
Solution Approach 1:
The coating system is divided into separate tile units that can be manufactured independently and then assembled on the component. This segmentation allows each tile to be optimized for its specific function (environmental barrier or thermal barrier) while simplifying the overall manufacturing process compared to applying multiple coating layers sequentially
Solution Approach 2:
The coating system uses composite tile structures that combine different materials (such as silicon nitride, SiC/SiC composites, and rare earth silicates) in a modular fashion. This allows the coating to provide both environmental barrier and thermal barrier functions while maintaining ease of manufacture through modular assembly
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 reduces the complexity of coating system application, enhances the integrity and durability of the coatings in high-temperature environments, and improves the survivability of silicon-based ceramic components.
Implementation Method 1
joining the set of tiles to a surface of the component by securing the tiles at interfaces between the set of tiles and the surface and between each of the set of tiles
Implementation Method 2
processed through drying, debinding, and sintering
Data Source
AI summary
Components of gas turbine engines, aircraft comprising the components, and methods of producing the components are provided. The component includes a surface, and a set of tiles secured to the surface at interfaces between the set of tiles and the surface and between each of the set of tiles. The set of tiles conform to the surface and in combination define a coating system on the surface that includes an environmental barrier coating and/or a thermal barrier coating.