General Electric Company

University of California

Julin Wan

Glen Harold Kirby

Don Mark Lipkin

Krishan Lal Luthra

Patrick Roland Lucien Malenfant

Amiya K Mukherjee

Reza Sarrafi-Nour

Mohan Manoharan

Peter Joel Meschter

Larry Steven Rosenzweig

Anant Achyut Setlur

Joshua D Kuntz

Curtis Alan Johnson

Andrea Jeannine Peters

Sairam Sundaram

Guodong Zhan

Matthew J Gasch

Sergio Lemaitre

Milivoj Konstantin Brun

Sergio Paulo Martins Loureiro

Joshua Lee Margolies

Seth Thomas Taylor

Hongbo Cao

Andrey Meshkov

Nicholas Edward Antolino

Azar Alizadeh

Nathaniel Patrick Brown

Sergiy Zalyubovsky

Guruvenket Srinivasan

Taryn Elizabeth Hewitt

Sivakumar Ramasamy

Eric James Crane Olson

Krishnan Lal Luthra

Don M Lipkin

Reza Saraffi-Nour

Coated components and their methods of formation are provided. The coated component includes: a ceramic matrix composite substrate comprising silicon carbide and having a surface; a bond coat on the surface of the substrate; and an environmental barrier coating on the bond coat. The bond coat includes a plurality of discrete particles dispersed within a matrix phase that includes mullite. The plurality of discrete particles includes an oxygen getter and a transition metal oxide.

Bond coat including metal oxides and oxygen getters

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

An article for high temperature service is presented herein. One embodiment is an article including a substrate having a silicon-bearing ceramic matrix composite; and a layer disposed over the substrate, wherein the layer includes silicon and a dopant, the dopant including aluminum. In another embodiment, the article includes a ceramic matrix composite substrate, wherein the composite includes a silicon-bearing ceramic and a dopant, the dopant including aluminum; a bond coat disposed over the substrate, where the bond coat includes elemental silicon, a silicon alloy, a silicide, or combinations including any of the aforementioned; and a coating disposed over the bond coat, the coating including a silicate (such as an aluminosilicate or rare earth silicate), yttria-stabilized zirconia, or a combination including any of the aforementioned.

Article for high temperature service

Methods are provided for repairing a defect on a silicon-containing substrate. The method may include applying a powder mixture into the defect of an existing coating on a surface of the silicon-containing substrate, wherein the powder mixture comprises silicon and germanium at a Ge mole fraction of 0.01 to 0.3; and heat treating the powder mixture within the defect at a sintering temperature that is 1150° C. to 1400° C. to form a repaired bondcoat within the defect. Repaired components are also provided that include a repaired bondcoat formed within the defect on the silicon-containing substrate, wherein the repaired bondcoat comprises a silicon-germanium phase comprising a Ge mole fraction of germanium of 0.01 to 0.3 and a Si mole fraction of silicon of 0.7 to 0.99.

Repair of a silicon-based bondcoat

Methods for preparing an environmental barrier coating and the resulting coating are provided. The methods and products include the incorporation of a continuous ceramic inner layer and a segmented ceramic outer layer on a CMC component. The segmented ceramic outer layer may be formed by thermal spray techniques. The coating is more stable at higher temperatures and provides for a longer lifetime of the coated component.

Segmented environmental barrier coating systems and methods of forming the same

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

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 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

A coated component, along with methods of its formation and use, is provided. The coated component includes a ceramic matrix composite (CMC) substrate comprising silicon carbide and having a mullite bondcoat on its surface. The mullite bondcoat includes an oxygen getter phase contained within a mullite phase. For example, the mullite bondcoat may include 60% to 98% by volume of the mullite phase. An environmental barrier coating is on the mullite bondcoat.

EBC with mullite bondcoat that includes an oxygen getter phase

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 methods of making and using the same, is provided. The coated component includes a ceramic matrix composite (CMC) substrate comprising silicon carbide and having a surface; a mullite/NOSC bondcoat on the surface of the substrate; and an environmental barrier coating on the mullite/NOSC bondcoat. The mullite/NOSC bondcoat comprises a non-oxide silicon ceramic (NOSC) phase contained within a mullite phase, with the mullite/NOSC bondcoat comprising 60% to 95% by volume of the mullite phase, such as 65% to 93% by volume of the mullite phase.

EBC with mullite bondcoat having a non-oxide silicon ceramic

High-temperature machine components, more particularly, articles capable of operating in high-temperature environments, including for example turbines of gas engines, may be formed of a high temperature ceramic matrix composite that includes a ceramic substrate including silicon; an environmental harrier coating system including a silicon containing bond coat; and a diffusion barrier layer of a carbide or a nitride between the substrate of the article and the silicon bond coat of the environmental barrier coating system. The diffusion harrier layer selectively prevents or reduces the diffusion of boron and impurities from the substrate to the bond coat of the environmental barrier coating system.

High temperature tolerant ceramic matrix composites and environmental barrier coatings

A ceramic component is provided that includes a silicon-based layer comprising a silicon-containing material (e.g., a 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 of the boron-doped refractory compound). A coated component is also provided that includes a CMC component defining a surface; a bond coating directly on the surface of the CMC component, with the bond coating comprises a silicon-containing material and a boron-doped refractory compound (e.g., about 0.1% to about 25% of the boron-doped refractory compound); a thermally grown oxide layer on the bond coating; and an environmental barrier coating on the thermally grown oxide layer.

Growing community of inventors

Rexford, NY, United States of America

Julin Wan