US2013189531A1PendingUtilityA1

Multilayer cmas-resistant barrier coatings

41
Individually held — no corporate assignee on recordPriority: Mar 29, 2010Filed: Mar 29, 2011Published: Jul 25, 2013
Est. expiryMar 29, 2030(~3.7 yrs left)· nominal 20-yr term from priority
Inventors:Kang N. Lee
C04B 41/52C04B 41/009C04B 41/89C09D 5/18C09D 1/00C23C 28/042F01D 5/288
41
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Claims

Abstract

An article comprising a substrate, a calcia-magnesia-alumina-silicate-resistant (CMAS-resistant) layer or a plurality thereof, including a rare earth oxide and alumina formed over the substrate, and a barrier coating layer formed on the CMAS-resistant layer. The barrier coating layer or a plurality thereof, comprising a thermal barrier coating composition or an environmental barrier coating composition.

Claims

exact text as granted — not AI-modified
1 . An article comprising:
 a substrate;   a first calcia-magnesia-alumina-silicate-resistant (CMAS-resistant) layer comprising a rare earth oxide and alumina, wherein the CMAS-resistant layer is formed over the substrate;   a barrier coating layer comprising a thermal barrier coating composition or an environmental barrier coating composition, wherein the barrier coating layer is formed on the CMAS-resistant layer; and   a second CMAS-resistant layer formed on the barrier coating layer.   
     
     
         2 . The article of  claim 1 , wherein at least one of the first CMAS-resistant layer or the second CMAS-resistant layer further comprises silica. 
     
     
         3 . The article of  claim 1 , wherein at least one of the first CMAS-resistant layer or the second CMAS-resistant layer further comprises at least one of Ta 2 O 5 , TiO 2 , HfSiO 4 , an alkali oxide, or an alkali earth oxide. 
     
     
         4 - 8 . (canceled) 
     
     
         9 . The article of  claim 1 , wherein the barrier coating layer comprises the thermal barrier coating composition, and wherein the thermal barrier coating composition comprises ytterbia; samaria; at least one of zirconia or hafnia; and at least one of lutetia, scandia, ceria, gadolinia, neodymia, or europia. 
     
     
         10 . (canceled) 
     
     
         11 . The article of  claim 9 , wherein the thermal barrier coating composition is essentially free of yttria. 
     
     
         12 . The article of  claim 1 , wherein the barrier coating layer comprises an environmental barrier coating composition, and wherein the environmental barrier coating comprises at least one of a rare earth monosilicate, a rare earth disilicate, barium aluminum silicate, barium strontium aluminum silicate, or strontium aluminum silicate. 
     
     
         13 . The article of  claim 1 , wherein the barrier coating layer comprises a first barrier coating layer, wherein the article further comprises a second barrier coating layer formed over the substrate, wherein the second barrier coating layer comprises a thermal barrier coating composition or an environmental barrier coating composition, and wherein the first CMAS-resistant layer is formed on the second barrier coating layer. 
     
     
         14 . The article of  claim 13 , wherein the second barrier coating layer comprises the thermal barrier coating composition, and wherein the thermal barrier coating composition comprises ytterbia; samaria; at least one of zirconia or hafnia; and at least one of lutetia, scandia, ceria, gadolinia, neodymia, or europia. 
     
     
         15 - 16 . (canceled) 
     
     
         17 . The article of  claim 1 , wherein the second CMAS-resistant layer comprises up to about 99 mol. % of at least one rare earth oxide and up to about 90 mol. % alumina, with a total of 100 mol. %. 
     
     
         18 . The article of  claim 17 , wherein the second CMAS-resistant layer further up to about 90 mol. % silica. 
     
     
         19 . The article of  claim 18 , wherein the second CMAS-resistant layer further comprises up to about 50 mol. % of at least one of Ta 2 O 5 , TiO 2 , HfSiO 4 , an alkali oxide, or an alkali earth oxide. 
     
     
         20 - 22 . (canceled) 
     
     
         23 . An article comprising:
 a plurality of barrier coating layers, wherein each barrier coating layer comprises at least one of a thermal barrier coating composition or an environmental barrier coating composition, and wherein the composition of each barrier coating layer is independently selected; and   a plurality of calcia-magnesia-alumina-silicate-resistant (CMAS-resistant) layers comprising a rare earth oxide and alumina, wherein respective ones of the plurality of barrier coating layers alternate with respective ones of the plurality of CMAS-resistant layers.   
     
     
         24 . The article of  claim 23 , wherein at least one of the plurality of CMAS-resistant layers further comprises silica. 
     
     
         25 . The article of  claim 24 , wherein the at least one of the plurality of CMAS-resistant layers further comprises at least one of Ta 2 O 5 , TiO 2 , HfSiO 4 , an alkali oxide, or an alkali earth oxide. 
     
     
         26 - 29 . (canceled) 
     
     
         30 . The article of  claim 23 , wherein at least one of the plurality of barrier coating layers comprises the thermal barrier coating composition, and wherein the thermal barrier coating composition comprises ytterbia; samaria; at least one of zirconia or hafnia; and at least one of lutetia, scandia, ceria, gadolinia, neodymia, or europia. 
     
     
         31 . (canceled) 
     
     
         32 . The article of  claim 30 , wherein the thermal barrier coating composition is essentially free of yttria. 
     
     
         33 . The article of  claim 23 , wherein at least one of the plurality of barrier coating layers comprises the environmental barrier coating composition, and wherein the environmental barrier coating composition comprises at least one of a rare earth monosilicate, a rare earth disilicate, barium aluminum silicate, barium strontium aluminum silicate, and strontium aluminum silicate. 
     
     
         34 - 35 . (canceled) 
     
     
         36 . A method comprising:
 forming, over a substrate, a first calcia-magnesia-alumina-silicate-resistant (CMAS-resistant) layer comprising a rare earth oxide and alumina; and   forming, on the CMAS-resistant layer, a barrier coating layer comprising a thermal barrier coating composition or an environmental barrier coating composition   forming, on the barrier coating layer, a second CMAS-resistant layer.   
     
     
         37 . The method of  claim 36 , wherein forming, on the first CMAS-resistant layer, the barrier coating layer comprises, forming, on the first CMAS-resistant layer, a first barrier coating layer, wherein the method further comprises forming, over the substrate, a second barrier coating layer comprising a thermal barrier coating composition or an environmental barrier coating composition, and wherein forming, over the substrate, the first CMAS-resistant layer comprising the rare earth oxide and alumina comprises forming, on the second barrier coating layer, the first CMAS-resistant layer comprising the rare earth oxide and alumina. 
     
     
         38 . (canceled) 
     
     
         39 . The method of  claim 36 , further comprising:
 forming, on the substrate, a bond coat, wherein forming, over the substrate, the first CMAS-resistant layer comprises forming, over the bond coat, the first CMAS-resistant layer.   
     
     
         40 . (canceled)

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