Praxair S.t. Technology, Inc.

Praxair Technology, Inc.

Rolls-Royce Corporation

Union Carbide Corporation

Union Carbide Coatings Service Technology Corp.

Technology Corporation

Thomas Alan Taylor

Ann Bolcavage

Albert Feuerstein

Neil Hitchman

Danny Lee Appleby

Robert C Tucker, Jr

James Kent Knapp

Don J Lemen

James Munroe

John E Jackson

David F Bettridge

Kenichi Tsushima

Harold H Fukubayashi

This invention relates to high purity yttria or ytterbia stabilized zirconia powders comprising from about 0 to about 0.15 weight percent impurity oxides, from about 0 to about 2 weight percent hafnium oxide (hafnia), from about 6 to about 25 weight percent yttrium oxide (yttria) or from about 10 to about 36 weight percent ytterbium oxide (ytterbia), and the balance zirconium oxide (zirconia). Thermal barrier coatings for protecting a component such as blades, vanes and seal surfaces of gas turbine engines, made from the high purity yttria or ytterbia stabilized zirconia powders, have a density greater than 88% of the theoretical density with a plurality of verticalzA macrocracks homogeneously dispersed throughout the coating to improve its thermal fatigue resistance.

High purity powders

This invention relates to thermally sprayed coatings of a high purity yttria or ytterbia stabilized zirconia powder, said high purity yttria or ytterbia stabilized zirconia powder comprising from about 0 to about 0.15 weight percent impurity oxides, from about 0 to about 2 weight percent hafnium oxide (hafnia), from about 6 to about 25 weight percent yttrium oxide (yttria) or from about 10 to about 36 weight percent ytterbium oxide (ytterbia), and the balance zirconium oxide (zirconia). Thermal barrier coatings for protecting a component such as blades, vanes and seal surfaces of gas turbine engines, made from the high purity yttria or ytterbia stabilized zirconia powders, have a density greater than 88% of the theoretical density with a plurality of vertical macrocracks homogeneously dispersed throughout the coating to improve its thermal fatigue resistance.

High purity zirconia-based thermally sprayed coatings and processes for the preparation thereof

This invention relates to high purity yttria or ytterbia stabilized zirconia powders comprising from about 0 to about 0.15 weight percent impurity oxides, from about 0 to about 2 weight percent hafnium oxide (hafnia), from about 6 to about 25 weight percent yttrium oxide (yttria) or from about 10 to about 36 weight percent ytterbium oxide (ytterbia), and the balance zirconium oxide (zirconia). Thermal barrier coatings for protecting a component such as blades, vanes and seal surfaces of gas turbine engines, made from the high purity yttria or ytterbia stabilized zirconia powders, have a density greater than 88% of the theoretical density with a plurality of vertical macrocracks homogeneously dispersed throughout the coating to improve its thermal fatigue resistance.

High purity zirconia-based thermally sprayed coatings

A thermally sprayed coating, coating system and coated article are disclosed. The disclosed embodiments of the thermally sprayed coating, coating system and coated article use a customized ceramic powder comprising ceramic powder particles having an average particle size of about 25 to about 75 microns. In particular, the ceramic powder particles contain from about 70 to about 95 percent by weight of a zirconia-based component, with the balance being an (alumina+silica)-based component and wherein said ceramic powder particles comprise micronized sub-particles of the zirconia-based component and the (alumina+silica)-based component.

Thermal barrier coatings and articles made therefrom

This invention relates to dense, vertically cracked thermal barrier coatings made from high purity yttria or ytterbia stabilized zirconia powders. The high purity yttria or ytterbia stabilized zirconia powder consisting essentially of less than about 0.01 weight percent silicon dioxide (silica), less than about 0.002 weight percent aluminum oxide (alumina), less than about 0.005 weight percent calcium oxide, less than about 0.005 weight percent ferric oxide, less than about 0 to about 0.002 weight percent magnesium oxide, less than about 0 to about 0.005 weight percent titanium dioxide, from about 1.5 to about 2 weight percent hafnium oxide (hafnia), from about 6 to about 25 weight percent yttrium oxide (yttria), less than 0.1 weight percent other impurity oxides, and the balance zirconium oxide (zirconia) and the balance zirconium oxide (zirconia). The thermal barrier coatings are intended to be used in cyclic thermal environments such as for gas turbine blades, vanes and seal surfaces exposed in the hot section of gas turbine engines.

Dense vertically cracked thermal barrier coatings

This invention relates to articles coated with a thermally sprayed coating of a high purity yttria or ytterbia stabilized zirconia powder, said high purity yttria or ytterbia stabilized zirconia powder comprising from about 0 to about 0.15 weight percent impurity oxides, from about 0 to about 2 weight percent hafnium oxide (hafnia), from about 6 to about 25 weight percent yttrium oxide (yttria) or from about 10 to about 36 weight percent ytterbium oxide (ytterbia), and the balance zirconium oxide (zirconia). The articles include, for example, blades, vanes and seal surfaces of gas turbine engines coated with a thermal barrier coating.

Coated articles

This invention relates to ceramic powders comprising a zirconia-based component, e.g., yttria-stabilized zirconia, and an (alumina+silica)-based component, e.g., mullite. The ceramic powders are useful for forming thermal shock resistant coatings having the same composition, through deposition by thermal spray devices. This invention also relates to thermal barrier coating systems suitable for protecting components exposed to high temperature environments, such as the thermal environment of a gas turbine engine. This invention further relates to forming free-standing solid ceramic articles.

Ceramic powders and thermal barrier coatings made therefrom

This invention relates to low thermal expansion bondcoats for thermal barrier coatings. The bondcoats comprise: (i) an inner layer comprising an inner layer alloy of MCrAlM', and (ii) an outer layer comprising an outer layer alloy of MCrAlM&#x2032;, wherein M is an element selected from nickel, cobalt, iron and mixtures thereof, and M&#x2032; is an element selected from yttrium, zirconium, hafnium, ytterbium and mixtures thereof. The inner layer alloy is thermally sprayed from a powder having a mean particle size of 50 percentile point in distribution of from about 5 microns to about 50 microns. The outer layer alloy is thermally sprayed from a powder having a mean particle size of 50 percentile point in distribution of from about 30 microns to about 100 microns. The bondcoat has a thermal expansion of about 6.5 millimeters per meter or less between a temperature of from about 25&#xb0; C. to about 525&#xb0; C.

Low thermal expansion bondcoats for thermal barrier coatings

This invention provides a unique gas shield or shroud surrounding the effluent of a thermal spray device that effectively can extend the working distance or standoff between the thermal spray device and the surface being coated. This invention provides a method of spraying materials, including ceramic materials and reactive materials, at a long standoff and a method of controlling the temperature of the effluent being deposited using heated gas shield.

Method of shielding effluents in spray devices

A compressor or turbine blade having its tip coated with a zirconium-based oxide having a plurality of macrocracks extending at least 100 microns through the coating and the process used to produce such a coating.

Zirconia-based tipped blades having macrocracked structure and process

A thermal spray process for producing a MCrAlY-based coating wherein M is selected from the group consisting of iron, cobalt, nickel and mixtures thereof and wherein the oxygen in the fuel-oxidant mixture of the thermal spray process converts a substantial portion of the yttrium component to Y.sub.2 O.sub.3, a minor portion of the aluminum component to Al.sub.2 O.sub.3, and the Y.sub.2 O.sub.3 and Al.sub.2 O.sub.3 are present in an amount of less than 15 volume percent of the coating.

Process for producing an oxide dispersed MCrAlY-based coating

A thermal spray process for producing a MCrAlY-based coating wherein M is selected from the group consisting of iron, cobalt, nickel and mixtures thereof and wherein the carbon in the fuel of the thermal spray process converts between 30 to 80 percent by weight of the chromium component in the coating to chromium carbide.

Process for producing carbide particles dispersed in a MCrAlY-based

Zirconia-based tipped blades having macrocracked structure

A coating composition comprising an alloy having the formula RCrAlR'R' wherein R is nickel, cobalt or the like; R' is yttrium or hafnium and R' is tantalum, rhenium and/or platinum, preferably mixed with an oxide dispersion such as alumina, to provide an improved class of coatings suitable for operating in high temperature oxidizing environments.

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Indianapolis, IN, United States of America

Thomas Alan Taylor