General Electric Company

Glen Harold Kirby

Brett Allen Boutwell

Julin Wan

Jessica Licardi Subit

John Frederick Ackerman

James Dale Steibel

Nicholas Edward Antolino

Suresh Subramanian

Suresh Viswanathan

Bangalore Aswatha Nagaraj

Brian Thomas Hazel

Ming Fu

Guruvenket Srinivasan

Jeffery Allen Bross

Justin Michael Nagy

Thomas Grandfield Howell

Brett Alan Boutwell

Anant Achyut Setlur

Venkat Subramaniam Venkataramani

Krishan Lal Luthra

Neelesh Nandkumar Sarawate

Mark Eugene Noe

Jeffrey Allan Pfaendtner

Larry Steven Rosenzweig

Reza Sarrafi-Nour

Michael Ray Tuertscher

Stephen Francis Bancheri

Paul Stephen Manicke

Brian Harvey Pilsner

Edip Sevincer

Evin Nathaniel Barber

Anthony Christopher Marin

Luc Stephane Leblanc

Nathaniel Patrick Brown

Sheena Kum Foster Walker

John Tam Nguyen

Jessica Lee Licardi

Robert Martin Fecke

Sivakumar Ramasamy

Alan David Gerken

Taryn Elizabeth Hewitt

Nathaniel David Goss

Nicholas Eward Antolino

Environmental barrier coatings including a bondcoat layer including silicon and a rare earth silicate-based hermetic layer and rare earth silicate-based non-hermetic layer are provided. The rare earth silicate-based hermetic layer is deposited on the bondcoat via a thermal spray process and has an elastic modulus ranging from 100 GPa to 180 GPa. The at least one rare earth silicate-based non-hermetic layer is deposited on the rare earth silicate-based hermetic layer and has an elastic modulus ranging from 50 GPa to 100 GPa. Coated gas turbine engine components and methods for coating gas turbine engine components are also provided.

Environmental barrier coatings

Methods are provided for forming a coating on a surface of a substrate. The method may include: applying a negative charge to the surface of the substrate; electrophoretically depositing a slurry layer onto the surface of the substrate; and densifying the slurry layer on the surface of the substrate at a sintering temperature to form a sintered layer of the coating. The slurry layer may include a plurality of EBC material particles, a cationic polyelectrolyte, a plurality of polymeric binder particles, and a solvent. The plurality of EBC material particles may comprise barium strontium aluminosilicate (BSAS), mullite, silicon, rare earth compounds, or combinations thereof.

Formation of a barrier coating using electrophoretic deposition of a slurry

Methods of forming sintered coatings are provided, along with the resulting coatings on a substrate. The sintered coating may comprise a rare earth compound and a sintering aid, with the rare earth compound has the formula: ABZDMOwhere A is Al, Ga, In, Sc, Y, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Fe, Cr, Co, Mn, Bi, or a mixture thereof; b is 0 to about 0.5; Z is Hf, Ti, or a mixture thereof; D is Zr, Ce, Ge, Si, or a mixture thereof; d is 0 to about 0.5; and M is Ta, Nb, or a mixture thereof. The coating may be densified at a sintering temperature, such as 1300° C. to 1600° C.

Slurry processing for deposition of rare earth hafnium tantalate based barrier coatings

A coated component, along with methods of its formation and use, is provided. The coated component may include a substrate having a surface with a plurality of cavities defined therein, a bond coating (e.g., including a silicon material) on the surface of the substrate within the cavities, and an environmental barrier coating over the surface of the substrate and encasing the bond coating within the cavities such that the bond coating, when melted, is contained within the cavities. Such a coated component may be, in one embodiment, a turbine component, such as a CMC component for use in a hot gas path of a gas turbine engine.

Liquid bond coatings for barrier coatings

A method for processing a component is provided and includes masking a first portion of the component with a maskant. The maskant includes a slurry having a plurality of particles in a fluid carrier. The plurality of particles comprises at least one of silicon, carbon, one or more rare earth disilicates, monosilicates or oxides, and combinations thereof. The method includes depositing a silicon-based coating on a second portion of the component via a chemical vapor deposition process and removing the maskant and any overlying silicon-based coating from the first portion of the component.

Methods for coating a component

A composition is provided that includes a silicon-containing material (e.g., a silicon metal and/or a silicide) and about 0.001% to about 85% of a Ga-containing compound, an In-containing compound, or a mixture thereof. The silicon-based layer can be a bond coating directly on the surface of the substrate. Alternatively or additionally, the silicon-based layer can be an outer layer defining a surface of the substrate, with an environmental barrier coating on the surface of the substrate. A coated component is also provided, as well as a method for coating a ceramic component. Gas turbine engines are also provided that include such a ceramic component.

Compositions containing gallium and/or indium and methods of forming the same

Compounds are generally provided, which may be particularly used to form a layer in a coating system. In one embodiment, the compound may have the formula: ABLnHfTiDMO, where: A is Al, Ga, In, Sc, Y, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Fe, Cr, Co, Mn, Bi, or a mixture thereof; x is about 0.01 to about 0.99; b is 0 to about 0.5, with 1-x-b being 0 to about 0.99 such that Ln is present in the compound; Ln is a rare earth or a mixture thereof that is different than A; t is 0 to about 0.99; D is Zr, Ce, Ge, Si, or a mixture thereof; d is 0 to about 0.5; the sum of t and d is less than 1 such that Hf is present in the compound; and M is Ta, Nb, or a mixture thereof.

Compositions for erosion and molten dust resistant environmental barrier coatings

Coated components, along with methods of their formation, are provided. The coated component includes a ceramic substrate having a surface; an intermediate layer on the surface of the ceramic substrate; and an environmental barrier coating on the intermediate layer. The intermediate layer includes a carbon-sink material that inhibits accumulation of free carbon from a carbon-containing species within the intermediate layer, the ceramic substrate, or both.

Ceramic composites with an intermediate layer having a carbon sink material for high temperature applications

A coated component, along with methods of its formation and use, is provided. The coated component may include a substrate having a surface, a first refractory layer on the surface of the substrate, a silicon-based bond coating on the first refractory layer, and an environmental barrier coating on the silicon-based bond coating. The silicon-based bond coating includes a silicon-phase contained within a refractory phase such that, when melted, the silicon-phase is contained within the refractory phase and between the surface of the substrate and an inner surface of the environmental barrier coating.

Bond coatings having a molten silicon-phase contained between refractory layers

A composition is generally provided that includes a silicon-containing material (e.g., silicon metal and/or a silicide) and a boron-doped refractory compound, such as about 0.001% to about 85% by volume of the boron-doped refractory compound (e.g., about 1% to about 60% by volume). In one embodiment, a bond coating on a surface of a ceramic component is generally provided with the bond coating including such a composition, with the silicon-containing material is silicon metal.

Silicon compositions containing boron and methods of forming the same

Methods for forming a coated component, along with the resulting coated components, are provided. The method may include forming a silicon-based bond coating on a surface of a substrate and forming a barrier coating on the silicon-based bond coating. The silicon-based bond coating comprises columnar grains of crystalline silicon. Chemical vapor depositing (CVD) may be used to form the silicon-based bond coating through CVD of a silicon-containing precursor at a deposition temperature and deposition pressure that causes crystallization of the silicon material during the deposition of the silicon-based bond coating. The silicon-containing precursor may be silane, monochlorosilane, dichlorosilane, and/or trichlorosilane.

Silicon bond coat with columnar grains and methods of its formation

A coated substrate is provided that includes an environmental barrier coating on (e.g., directly on) a surface of a substrate (e.g., a ceramic matrix composite). The environmental barrier coating can include a barrier layer having a refractory material phase and a silicon-containing glass phase. The silicon-containing glass phase may be a continuous phase within the barrier layer (e.g., a breathable grain boundary of the barrier layer), or may be a plurality of discontinuous layers dispersed throughout the refractory material phase. The refractory material phase can include a rare earth silicate material having a rare earth component at a first atomic percent, while the silicon-containing glass phase comprises the rare earth component at a second atomic percent that is less than the first atomic percent. Methods are also provided for forming a barrier layer on a substrate.

Dense environmental barrier coating compositions

A coated component, along with method of forming the same, is provided. The coated component may include a substrate having a surface, a silicon-based bond coating on the surface of the substrate, and an EBC on the silicon-based bond coating. The silicon-based bond coating may include a silicon-phase contained within a refractory phase. The silicon-phase, when melted, is contained within the refractory phase and between the surface of the substrate and an inner surface of the environmental barrier coating. Such a coated component may be, in particular embodiments, a turbine component.

Bond coatings having a silicon-phase contained within a refractory phase

Methods for tape deposition of a sacrificial coating on a CMC substrate are provided. The method comprises: applying a matrix material onto a surface of a film; drying the matrix material to remove the solvent; and transferring the dried matrix material from the film to the CMC substrate. The matrix material comprises a mixture of a rare earth silicate powder, a sintering aid, and a solvent.

Methods of deposition of thick environmental barrier coatings on CMC blade tips

A coated substrate is provided that comprises: a substrate; and a barrier coating comprising a compound having the formula: LnABO, where Ln comprises scandium, yttrium, lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, lutetium, or mixtures thereof; A comprises Si, Ti, Ge, Sn, Ce, Hf, Zr, or a combination thereof; and B comprises Mo, W, or a combination thereof. In one embodiment, B comprises Mo. A gas turbine is also provided that comprises the coated substrate described above.

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Liberty Township, OH, United States of America

Glen Harold Kirby