Abstract:
A method of manufacturing a substrate ( 16 ) with a ceramic thermal barrier coating ( 28, 32 ). The interface between layers of the coating contains an engineered surface roughness ( 12, 24 ) to enhance the mechanical integrity of the bond there between. The surface roughness is formed in a surface of a mold ( 10,20 ) and is infused by a subsequently cast layer of material ( 16, 28 ). The substrate may be partially sintered ( 76 ) prior to application of the coating layer(s) and the coated substrate and coating layer(s) may be co-sintered to form a fully coherent strain-free interlayer.

Description:
[0001]    This application is a continuation-in-part of co-pending application Ser. No. 13/221,077 filed 30 Aug. 2011 (attorney docket 2010P13124US) which is incorporated by reference herein in its entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This invention relates generally to ceramic coated metal components and to methods for applying such coatings. 
       BACKGROUND OF THE INVENTION 
       [0003]    It is known to use ceramic thermal barrier coatings to protect metallic parts that are exposed to hot combustion gas in a gas turbine engine. United States Patent Application Publication US 2009/0110954 A1 describes known thermal barrier coating systems which typically include a bond coat material deposited between the ceramic thermal barrier coating and the underlying metal substrate. It is also known that improved adherence of the thermal barrier coating can be achieved by providing a roughened surface on the bond coat material, such as by controlling the process parameters used to deposit the bond coat material. One such technique is described in United States Patent Application Publication US 2010/0092662 A1. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0004]    The invention is explained in the following description in view of the drawings that show: 
           [0005]      FIGS. 1 through 5  illustrate steps in a method in accordance with an embodiment of the invention. 
           [0006]      FIG. 6  is a cross sectional view of a gas turbine component in accordance with an embodiment of the invention. 
           [0007]      FIG. 7  illustrates the steps in a method in accordance with an embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0008]    The present inventors have recognized a need for further improvements in techniques for enhancing the adhesion of a ceramic thermal barrier coating. For example, while it is known to affect the surface roughness of a bond coat material by controlling the spray parameters by which the material is deposited, the present inventors have found that such spray process controls may be inadequate for some advanced gas turbine engine applications due to variability in the structure of the mechanical interface between layers in the thermal barrier coating system over multiple applications of a process. 
         [0009]      FIGS. 1-6  illustrate the steps of a method in accordance with one embodiment of the present invention. In  FIG. 1 , a mold  10  (substrate mold) is formed to have a first designed surface roughness  12  on an interior surface  14 . The surface roughness  12  is not a randomly derived topography, such as might be achieved through a sand blasting or spraying process, but rather is an engineered surface that is specifically designed to have desired surface feature geometries and sizes. Such designed surface topographies may be formed by a tomo-lithographic process, as described in U.S. Pat. No. 7,141,812, or by any other known process. This substrate mold is used to cast a green body  16  as shown in  FIG. 2 , thereby replicating the designed surface roughness  12  onto an exterior surface  18  of the green body  16 . The green body  16  may be cast from a ceramic or metal powder slurry, for example, and may be in the shape of a substrate of a component for a gas turbine engine. 
         [0010]    Another mold  20  (bond layer mold) is formed to have another designed surface roughness  22  on an interior surface  24  as illustrated in  FIG. 3 . Here, again, the surface roughness  22  is not a randomly derived topography, but rather is an engineered surface that is specifically designed to have desired surface feature geometries and sizes. The green body  16  is removed from the mold  10  and is positioned within mold  20  with a small controlled space  26  separating the green body surface  18  from the second mold surface  24 . The space  26  represents a desired thickness of a bond coat material to be joined to the green body  16 . 
         [0011]    A bond coat material  28  is then cast in slurry form into the space  26  and allowed to solidify as illustrated in  FIG. 4 . The slurry cooperates with the surface roughness  12  on the outer surface  18  of the green body  16  to form a desired mechanical interconnection between the green body  16  and the bond coat material  28 . Furthermore, the surface roughness  22  on the interior surface  24  of the mold  20  is transferred into the bond coat material  28 , such that when the green body  16  with coating  28  is removed from the mold  20 , its outer surface  30  is available for receiving a thermal barrier coating material  32  to form a thermally insulated component  34  as shown in  FIG. 5 . The thermal barrier coating material  32  may be applied by a known spray process or it may be cast by using yet another mold  36  (coating mold). 
         [0012]    Advantageously, a thermally insulated component according to an embodiment of this invention has a first desired mechanical interconnection between a substrate and a bond coating that is defined by a first designed surface roughness formed on the substrate, and a second desired mechanical interconnection between the bond coating and an overlying ceramic thermal barrier coating that is defined by a second designed surface roughness formed on the bond coat material. The first and second mechanical interconnections may have different physical parameters as may be desired by the designer. For example, the dimensions of the roughness features may be designed to be different between the two mechanical interconnections in response to differences in the physical parameters of the two different slurries used to cast the green body  16  and the bond coat material  28 . Furthermore, the physical parameters of the first and/or second mechanical interconnections, and the thickness of the bond coat material may vary from one region of the component to another. For example, a leading edge of an airfoil component may be subjected to more severe impact damage than the remainder of the airfoil during operation of a gas turbine engine. That airfoil manufactured in accordance with the present invention may have a thicker layer of the bond coat material in the leading edge area and/or it may have a mechanical interconnection in the leading edge area that provides more surface area contact between the two material layers (i.e. a more aggressive surface roughness pattern). 
         [0013]      FIG. 6  is an illustration of one such thermally insulated component  40  in accordance with an embodiment of the invention. The component  40  includes a substrate  42  protected by a thermal barrier coating  44  which varies from one region of the component to another. The thermal barrier coating  44  includes a layer of bond coat material  46  and a top layer of ceramic insulating material  48 . In a first region  50  of the component  40 , such as a suction side of an airfoil or a straight region of a combustor transition piece, the mechanical interconnection  52  between the substrate  42  and the bond coat material  46  may be created by a roughness of the substrate surface approximating a sine wave shape with a relatively long period; whereas in a second region  54  of the component  40 , such as an airfoil leading edge or a curved region of a combustor transition piece, the mechanical interconnection  56  between the substrate  42  and the bond coat material  46  may be created by a roughness of the substrate surface approximating a sine wave shape with a relatively shorter period. The relatively shorter sine wave shape provides a more aggressive interconnection with more contact area per unit area of surface. Furthermore, the mechanical interconnection  58  between the bond coat material  46  and the ceramic insulating material  48  in the first region  50  may be created by a roughness of the bond coat surface characterized by saw tooth shapes  64 ; whereas the mechanical interconnection  62  between the bond coat material  46  and the ceramic insulating material  48  in the second region  54  may be created by a roughness of the bond coat surface including protruding undercut shapes  60 . The protruding undercut shapes  60  provide a more aggressive interconnection than do the saw tooth shapes  64 . Furthermore, the average thickness of the bond coat material  46  may be greater in region  54  than in region  50 . Such features may be produced with precision in repeated applications by the molding and casting techniques described above and illustrated in  FIGS. 1-5 . Thus, the present invention provides degrees of flexibility and precision of control in the design of thermal barrier coating systems that are not available with prior art techniques. 
         [0014]    A primary purpose for utilizing a bond coat layer in prior art ceramic thermal barrier systems is to provide a desired degree of roughness in the surface forming the metal-to-ceramic interface, since the cast metallic substrate surface would not provide a desired degree of mechanical interface with the ceramic insulating layer if the bond coat layer were not present. Furthermore, traditional MCrAlY bond coat materials also provide a supply of aluminum for the formation of a protective alumina layer when the component is exposed to high temperatures. In one embodiment of the present invention, the green body  16  of  FIG. 2  is cast using an alumina-forming substrate material with a desired engineered surface roughness  12  appropriate for the direct application of the ceramic thermal barrier coating material  32  without any intervening bond coat layer. The surface roughness  12  in such embodiments may correspond to or improve upon the surface roughness that is achieved with the traditional thermally sprayed bond coat material. Thus, in some embodiments, the present invention provides a desired degree of roughness at the surface of the substrate effective to ensure an adequate metal-to-ceramic interface without the need for a bond coat layer. 
         [0015]    The present invention is advantageously implemented with a process wherein the metal and ceramic materials are selected and processed to be cooperatively matched for both sintering shrinkage and thermal expansion performance. One such process  70  is illustrated in  FIG. 7  which includes the steps of:  72 —selecting CTE-compatible metal and ceramic materials;  74 —forming a substrate from a powder of the metal material;  76 —partially sintering the substrate;  78 —forming a layer on the substrate from a powder of the ceramic material containing a quantity of nano-particles effective to suppress a sintering temperature of the material; and  79 —co-sintering the substrate and the layer of ceramic material to final density. The step  76  of partially sintering the substrate may ensure that the shrinkage of the substrate and the layer during the co-sintering step are approximately the same, and the step  78  of including a quantity of nano-particles may ensure that the sintering temperatures of the substrate and the layer are approximately the same to enable the co-sintering step  79 . 
         [0016]    One will appreciate that to achieve a desired mechanical interface between the layers, the step  76  of forming the substrate may be accomplished in accordance with the molding process described above with respect to  FIGS. 1 and 2 , and the step  78  of forming a layer on the substrate may be accomplished in accordance with the molding process described above with respect to  FIGS. 3 and 4 . The result is a layered material system having a fully coherent strain-free interlayer consisting of interspersed elements of both constituents along an interface defined by an engineered surface roughness topography. The resulting co-processed system is dense and dimensionally stable and may be used in advanced modular inserts for aggressive, impact resistant, high temperature gas turbine applications. In various embodiments, the methods disclosed herein permit the co-processing of a low expansion alloyed refractory metal system based on chromium, molybdenum, niobium, tantalum, tungsten and/or iron with a sinter-active ceramic powder thermal barrier overlay composition employing a bi-modal particle size distribution of alumina, stabilized zirconia and/or yttrium aluminum garnet powders. 
         [0017]    The processes and materials described herein allow a much thicker ceramic layer on a metal substrate than was previously possible without the use of a flexible intermediate layer and/or engineered slots in the ceramic layer for strain relief. Whereas prior monolithic ceramic layers in this temperature range were limited to about 0.3 mm thick, the present invention can produce durable monolithic ceramic layers over 1.0 mm thick, including over 2.0 mm thick, for example up to 3.0 mm thick in some embodiments, on superalloy substrates for use over a wide operating temperature range such as 0-1000° C. or 0-1500° C. in some embodiments. Herein, “monolithic” means a layer without a flexible intermediate layer or engineered slots for strain relief. 
         [0018]    While various embodiments of the present invention have been shown and described herein, it will be obvious that such embodiments are provided by way of example only. Numerous variations, changes and substitutions may be made without departing from the invention herein. Accordingly, it is intended that the invention be limited only by the spirit and scope of the appended claims.