Yb2O3-Stabilized ZrO2 Thermal Spray Particles for Turbine Coatings

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Solution Overview

Problem

Existing thermal barrier coatings formed using ceramic thermal spray particles have high thermal conductivity and inadequate thermal cycle durability, which limits their efficiency in industrial gas turbines.

Innovation Solution

Ceramic thermal spray particles containing ZrO2 and Yb2O3 with a standard deviation of Yb2O3 content between 2 mass % and 7.0 mass % are used to form a thermal barrier coating layer, which includes a metal bonding layer and a ceramic layer formed by thermal spraying.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If ceramic thermal spray particles are manufactured using conventional spray drying methods, then the coating can be formed, but the thermal conductivity is too high and thermal cycle durability is insufficient

Engineering Contradiction:

Improvethermal cycle durabilityVSAvoidthermal conductivity

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The invention changes the chemical composition parameters of the ceramic particles by incorporating Yb2O3 as a stabilizer in addition to conventional additives. This compositional parameter change results in particles that form a coating with improved thermal cycle durability and reduced thermal conductivity, directly resolving the technical contradiction

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses composite ceramic particles containing multiple oxides (ZrO2, Yb2O3, and other stabilizers) rather than single-component ceramics. This composite material approach creates a coating that simultaneously achieves low thermal conductivity and high thermal cycle durability through synergistic effects of the different oxide components

Inventive Principle:

Principle #40Composite materials

2Reliability

If the standard deviation of Yb2O3 content is controlled within 2-7.0 mass %, then both low thermal conductivity and high thermal cycle durability are achieved

Engineering Contradiction:

Improvethermal cycle durabilityVSAvoidYb2O3 content uniformity

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The invention optimizes the Yb2O3 content parameter within a specific range (2-7.0 mass %) and controls its standard deviation to achieve the desired balance between thermal cycle durability and thermal conductivity. This parameter optimization resolves the contradiction by identifying the precise compositional window that satisfies both requirements

Inventive Principle:

Principle #35Parameter changes

3Power

If industrial gas turbine efficiency and temperature are increased, then power output improves, but the thermal barrier coating requirements become more stringent

Engineering Contradiction:

Improvegas turbine power outputVSAvoidcoating thermal cycle durability

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

The invention modifies the ceramic particle composition parameters to create a coating that can withstand the higher temperatures and more stringent conditions required for increased gas turbine efficiency. The optimized Yb2O3 content and standard deviation range enable the coating to maintain reliability under enhanced operating conditions

Inventive Principle:

Principle #35Parameter changes

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 resulting thermal barrier coating exhibits low thermal conductivity and excellent thermal cycle durability, effectively addressing the limitations of previous coatings.

Implementation Method 1

a ceramic layer forming step of thermally spraying ceramic thermal spray particles onto the metal bonding layer to form a ceramic layer

Methodology Applied

Scientific EffectThermal spraying: Plasma Spray

Data Source

PatentUS20250146117A1Ceramic thermal spray particles and method for forming thermal barrier coating layer

Publication Date: 2025.05.08 MITSUBISHI HEAVY IND LTD

AI summary

Ceramic thermal spray particles according to the present invention contain ZrO2 and Yb2O3, wherein the standard deviation of the content of the Yb2O3 is 2-7.0 mass %.