Rolls-royce Corporation

Rolls-royce North American Technologies Inc.

Rolls-royce High Temperature Composites Inc.

Robert Alexander Sean Golden

Li Li

Adam Lee Chamberlain

Sungbo Shim

Matthew T Kush

Gregory John Kenneth Harrington

Jun Shi

Scott Nelson

Matthew R Gold

Taylor K Blair

Stephanie Gong

In some examples, a method including depositing a plurality of particles on a ceramic or ceramic matrix composite (CMC) substrate to form a barrier coating on the ceramic or CMC substrate, the plurality of particles including a silica-rich rare earth (RE) disilicate material and a second material, wherein the silica-rich RE disilicate material includes excess silica compared to a stoichiometric RE disilicate material, wherein the barrier coating includes a first domain including the silica-rich RE disilicate material and a second phase, the second phase being disposed at grain boundaries, splat boundaries, or both of the barrier coating.

Silica-rich barrier coatings

An article may include a substrate, such as a silicon-containing ceramic matrix composite, an environmental barrier coating (EBC) layer on the substrate, and a CMAS-resistant EBC layer on the EBC layer. The EBC layer may include at least one rare-earth disilicate (REDS). The CMAS-resistant EBC layer may include at least one rare-earth monosilicate (REMS) configured to react with CMAS to form crystalline reaction products. The CMAS-resistant EBC layer may include a plurality of vertical cracks extending from a surface of the CMAS-resistant EBC layer at least partially into the CMAS-resistant EBC layer. Additionally, or alternatively, the EBC layer may include a plurality of vertical cracks extending from a surface of the EBC layer into at least a portion of the EBC layer.

CMAS-resistant environmental barrier coating system

An article may include a substrate and a coating system on the substrate. The coating system may include a thermal barrier coating (TBC) layer and a CMAS resistant layer on the TBC layer. The CMAS layer includes a rare-earth (RE) monosilicate composition including a plurality of RE metal cations, wherein RE monosilicate composition is configured to react with CMAS to form a reaction product including a RE apatite phase with a REO·SiOcomposition, wherein the RE of the REO·SiOcomposition includes at least one of the plurality of RE metal cations of the RE monosilicate.

CMAS resistant thermal barrier coating system

An article may include a substrate and a coating system on the substrate. The coating system may include an environmental barrier coating (EBC) layer and a CMAS resistant layer on the EBC layer (e.g., as the top coat of the system). The CMAS layer includes a rare-earth (RE) monosilicate composition including a plurality of RE metal cations, wherein RE monosilicate composition is configured to react with CMAS to form a reaction product including a RE apatite phase with a REO·SiOcomposition, wherein the RE of the REO·SiOcomposition includes at least one of the plurality of RE metal cations of the RE monosilicate.

CMAS resistant environmental barrier coating system

The disclosure describes braze tape coatings and technique to form articles with differing physical properties in different layers or regions of the article. An example method includes forming a braze tape defining at least one layer that includes a first segment and a second segment. A portion of the second segment in the plane is adjacent to a portion of the first segment in a plane of the layer. The method also includes positioning the braze tape on a surface of a substrate, the plane of the layer of the braze tape being parallel to the surface of the substrate. The method also includes heating the braze tape to melt a constituent of at least one of the first coating material and the second coating material to form a densified coating on the surface of the substrate.

Tape casting coating for ceramic matrix composite

The disclosure describes articles having coating systems configured to inhibit or prevent crystallization of TGO at the operating temperature of the article. An article includes a substrate defining a surface; a bond coat on the surface of the substrate; a coating layer that includes a boron dopant configured to inhibit crystallization of amorphous silicon dioxide thermally grown oxide on the bond coat at an operating temperature of the article. By inhibiting or preventing TGO crystallization, the described coating systems may increase a useable life of the component.

EBC layer containing boron

In one example, a method for forming an environmental barrier coating (EBC) and/or abradable coating on a substrate. The method may include depositing a coating on a ceramic or ceramic matrix composite (CMC) substrate to form an as-deposited coating, wherein the coating includes at least one of an environmental barrier coating (EBC) and an abradable coating. The method further comprises heat treating the as-deposited coating at or above a first temperature for a first period of time following the deposition of the as-deposited coating on the substrate, wherein heat treating the as-deposited coating includes heating the as-deposited coating to or above the first temperature at a controlled rate. The heat treatment may be configured to at least one of decrease the open pores and/or microcracks of the heat-treated coating compared to the as-deposited coating or control a grain size of the heat-treated coating.

Post deposition heat treatment of coating on ceramic or ceramic matrix composite substrate

In some examples, the disclosure describes an article and a method of making the same that includes a substrate defining an outer surface, a barrier layer on the outer surface of the substrate, the barrier layer defining a textured surface having a plurality of cells, each cell having a geometry and a depth, and an overlying layer formed on the textured surface of the barrier layer. The barrier layer may be configured to reduce migration of material from the substrate to the overlaying layer to reduce or prevent formation of cristobalite phase thermally grown oxide.

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Noblesville, IN, United States of America

Robert Alexander Sean Golden