Vitreous Glass Monocoating for Ceramic Matrix Composite Turbine Substrates
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Solution Overview
Problem
Turbine engine components face durability challenges due to exposure to high temperatures and corrosive/oxidative conditions, where existing multi-layer coating systems are complex and require metallic bond coats, which may not adequately protect against moisture and degradation.
Innovation Solution
A monocoating system using vitreous glass is applied directly to a ceramic matrix composite substrate with a continuous ceramic matrix phase and fiber phase, providing a seal and thermal barrier without the need for traditional metallic bond coats, and including an interface coating of boron to enhance interfacial bonding and protect against moisture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multi-layer coating system with metallic bond coats is used, then thermal and erosion barrier protection is provided, but the coating system becomes complex and may not adequately protect against moisture and degradation
Solution Approach 1:
The patent extracts and eliminates the metallic bond coat layer from the traditional multi-layer coating system, retaining only the ceramic barrier coating layer. This simplification removes the source of moisture intrusion while maintaining thermal and erosion protection, directly resolving the contradiction between protection effectiveness and system complexity
Solution Approach 2:
The patent employs a composite coating system consisting of a ceramic barrier coating layer combined with a moisture barrier layer. This composite structure provides comprehensive protection against thermal, erosive, and moisture-related degradation without requiring complex multi-layer metallic bond coats, achieving both reliability and simplicity
2Reliability
If a traditional multi-layer coating system is used, then thermal barrier protection is provided, but the coating requires metallic bond coats that may not adequately protect against moisture
Solution Approach 1:
The patent removes the metallic bond coat layer entirely, eliminating the manufacturing complexity associated with applying and bonding metallic layers. The simplified single-layer ceramic coating with integrated moisture barrier properties is easier to apply and manufacture while providing equivalent or superior moisture protection
Solution Approach 2:
The patent changes the material parameters of the coating system by transitioning from metallic bond coats to a ceramic-based monocoating with specific compositional parameters (ceramic matrix, fiber reinforcement, moisture barrier additives). This parameter change enables moisture protection without the manufacturing complexities of metallic bonding processes
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 vitreous glass monocoating effectively seals and protects the substrate from high-temperature environments, preventing moisture intrusion and degradation, thus enhancing the durability and longevity of turbine engine components.
Implementation Method 1
A monocoating is disposed directly on the heat-exposure surface. The monocoating includes vitreous glass, to seal the ceramic matrix composite from the surrounding environment.
Implementation Method 2
The barrier coating system is a multi-layer coating that includes one or more ceramic layers, such as stabilized zirconia... The ceramic layers serve as a thermal and erosion barrier
Implementation Method 3
The ceramic matrix composite includes a continuous ceramic matrix phase, a fiber phase within the matrix phase and an interface coating comprising boron between the matrix phase and the fiber phase
Implementation Method 4
Turbine engine components typically operate under severe environmental conditions. For example, the environment includes exposure to high temperatures and corrosive/oxidative and erosive conditions from combustion gases.
Data Source
Figure 1
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AI summary
An article (70) includes a ceramic matrix composite substrate (74) with a heat-exposure surface (76) and a monocoating (72) disposed directly on the heat-exposure surface (76). The monocoating (72) includes vitreous glass to seal the ceramic matrix composite from the surrounding environment.