Rolls-royce Corporation

Chromalloy United Kingdom Limited

Daniel Kim White

David S Rickerby

Stanley R Bell

A superalloy turbine blade (10) has a MCRALY bond coating (22) and a thermal barrier coating (24). The thermal barrier coating (24) comprises a plurality of alternate layers (25, 27) which have different structure to produce a plurality of interfaces (26) substantially parallel to the metallic substrate (20)/ bond coating (22) interface. These interfaces (26) provide paths of increased resistance to heat transfer to reduce thermal conductivity of thermal barrier coating (24). The structure in the alternate layers (25, 27) of the thermal barrier coating (24) is columnar (28), or segmented, to ensure that the strain tolerance of the thermal barrier coating (24) is not impaired. The columnar grains (28) in the layers (25, 27) extend substantially perpendicular to the metallic substrate (20)/ bond coating (22) interface. This enables thermal barrier coating (24) of reduced thickness and weight to be used. The bond coat may have an oxide or oxide/metal interface which improves the adhesion of the thermal barrier coating.

Coated Article

A coated article includes a superalloy substrate, an intermediate bond coat and a thermal barrier coating. The bond coat may include a platinum aluminide layer underlying a thin oxide layer. The thin oxide layer may include alumina. The coated article has high strength and durability at high temperatures over extended periods of time and thus is especially useful in the form of, e.g., a turbine blade or turbine vane.

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Garnerville, NY, United States of America

Daniel Kim White