Rolls-royce Corporation

Rolls-royce North American Technologies Inc.

Purdue Research Foundation

Rolls-royce High Temperature Composites Inc.

Stephanie Gong

Li Li

Ann Bolcavage

Taylor K Blair

Ngunjoh Lawrence Ndamka

Matthew R Gold

Sunny Chang

Sungbo Shim

Scott Nelson

Sean E Landwehr

Michael Cybulsky

Jeffrey Paul Youngblood

Robert Alexander Sean Golden

Rodney W Trice

John Grubbs

Kenneth A Green

Robert Golden

Taylor Keffer Blair

An example article includes a substrate and a barrier coating on the substrate. The barrier coating includes a matrix including a rare-earth disilicate extending from an inner interface facing the substrate to an outer surface opposite the inner interface. The barrier coating includes a graded volumetric distribution of rare-earth oxide rich (REO-rich) phase regions in the matrix along a direction from the inner interface to the outer surface. The graded volumetric distribution defines a first volumetric density of the REO-rich phase regions at a first region of the matrix adjacent the outer surface. The graded volumetric distribution defines a second volumetric density of the REO-rich phase regions at a second region of the matrix adjacent the inner surface. The second volumetric density is different from the first volumetric density. An example technique includes forming the barrier coating on the substrate of a component.

CMAS-resistant barrier coatings

A method may include controlling, by a computing device, an energy source to form a melt pool at a build surface; and controlling, by the computing device, a material delivery device to direct a powder at the melt pool to form the seal fin comprising a metal matrix composite on the build surface, wherein the metal matrix composite comprises a matrix material and a reinforcement phase.

Metal matrix composite seal using directed energy deposition

An article may include a substrate including a ceramic matrix composite (CMC); a composite coating layer including a first coating material that includes a rare-earth disilicate and a second coating material that includes at least one of a rare-earth monosilicate, a CMAS-resistant material, or a high-temperature dislocating material, where the second coating material forms a substantially continuous phase in the composite coating layer.

Composite coating layer for ceramic matrix composite substrate

An article that includes a substrate; a first layer including yttria and zirconia or hafnia, where the first layer has a columnar microstructure and includes predominately the zirconia or hafnia; a second layer on the first layer, the second layer including zirconia or hafnia, ytterbia, samaria, and at least one of lutetia, scandia, ceria, neodymia, europia, and gadolinia, where the second layer includes predominately zirconia or hafnia, and where the second layer has a columnar microstructure; and a third layer on the second layer, the third layer including zirconia or hafnia, ytterbia, samaria, and a rare earth oxide including at least one of lutetia, scandia, ceria, neodymia, europia, and gadolinia, where the third layer has a dense microstructure and has a lower porosity than the second layer.

Thermal barrier coatings for components in high-temperature mechanical systems

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.

Barrier layer and surface preparation thereof

In one example, a method for forming a coating system including a bond coat and an environmental barrier coating on a ceramic or CMC substrate, e.g., with an abradable coating on the environmental barrier coating. The method may include depositing a bond coat on a ceramic or ceramic matrix composite (CMC) substrate to form an as-deposited bond coat; heat treating the as-deposited bond coat following the deposition of the as-deposited bond coat on the substrate to form a heat treated bond coat; depositing an environment barrier coating (EBC) layer on the heat treated bond coat to form as deposited EBC layer; and heat treating the as-deposited EBC layer to form a heat treated EBC layer.

Post deposition heat treatment of bond coat and additional layers on ceramic or CMC substrate

An article for use in a high-temperature environment that includes a substrate including a superalloy material, a ceramic, or a ceramic matrix composite, and an abradable coating on the substrate, the abradable coating including a rare earth silicate and a dislocator phase, the dislocator phase forms one or more distinct phase regions in the abradable coating and comprises at least one of hafnium diboride (HfB), zirconium diboride (ZrB), tantalum nitride (TaN or TaN), tantalum carbide (TaC), titanium diboride (TiB), zirconium carbide (ZrC), hafnium carbide (HfC), tantalum diboride (TaB), hafnium nitride (HfN), or niobium carbide (NbC).

Low porosity abradable coating

A method that includes introducing a suspension comprising a coating material and a carrier into a heated plume of a thermal spray device. The coating material may include silicon or a silicon alloy. The method further includes directing the coating material using the heated plume toward a substrate that includes a ceramic or a ceramic matrix composite and depositing the coating material to form a bond coat directly on the substrate such that the bond coat defines a porosity of less than about 3 percent by volume.

High density bond coat for ceramic or ceramic matrix composites

An article includes a substrate, a bond coat on the substrate, and a multilayer environmental barrier coating (EBC) on the bond coat. The multilayer EBC includes a first EBC layer defining a first thickness and a second EBC layer defining a second thickness. The first EBC layer includes a first rare earth disilicate and a first concentration of a sintering aid that includes alumina. The second EBC layer includes a second rare earth disilicate and a second concentration of the sintering aid that includes alumina, less than the first concentration of the sintering aid.

Multilayer environmental barrier coating

In some examples, an article may include a substrate and a coating on the substrate. The substrate may include a superalloy, a ceramic, or a ceramic matrix composite. The coating may include a layer comprising a matrix material and a plurality of nanoparticles. The matrix material may include at least one of silica, zirconia, alumina, titania, or chromia, and the plurality of nanoparticles may include nanoparticles including at least one of yttria, zirconia, alumina, or chromia. In some examples, an average diameter of the nanoparticles is less than about 400 nm.

Coating system including oxide nanoparticles in oxide matrix

An article may include a substrate including a ceramic or a CMC; a bond layer on the substrate; and a diffusion barrier layer between the substrate and the bond layer. The diffusion barrier layer may include at least one of molybdenum metal, tantalum metal, tungsten metal, or niobium metal. In some examples, the article may include a stabilizing layer that includes at least one of a silicide of molybdenum (MoSi), tantalum (TaSi), tungsten (WSi), or niobium (NbSi), between the diffusion barrier layer and the bond layer.

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Indianapolis, IN, United States of America

Stephanie Gong