US 11,851,770 B2
Thermal barrier coatings for components in high-temperature mechanical systems
Matthew R. Gold, Carmel, IN (US); Michael Cybulsky, Indianapolis, IN (US); Stephanie Gong, Indianapolis, IN (US); and Li Li, Carmel, IN (US)
Assigned to Rolls-Royce Corporation, Indianapolis, IN (US); and Rolls-Royce North American Technologies, Inc., Indianapolis, IN (US)
Filed by Rolls-Royce Corporation, Indianapolis, IN (US); and Rolls-Royce North American Technologies, Inc., Indianapolis, IN (US)
Filed on Aug. 25, 2020, as Appl. No. 17/002,203.
Application 17/002,203 is a division of application No. 16/034,801, filed on Jul. 13, 2018, abandoned.
Claims priority of provisional application 62/533,422, filed on Jul. 17, 2017.
Prior Publication US 2020/0385871 A1, Dec. 10, 2020
Int. Cl. C23C 28/04 (2006.01); C23C 4/11 (2016.01); C23C 4/134 (2016.01); F01D 5/28 (2006.01); C23C 28/00 (2006.01); C04B 41/87 (2006.01); C04B 41/50 (2006.01); C04B 41/00 (2006.01); C23C 4/073 (2016.01); B32B 18/00 (2006.01); C23C 24/08 (2006.01); C04B 111/00 (2006.01); B32B 15/16 (2006.01)
CPC C23C 28/042 (2013.01) [B32B 18/00 (2013.01); C04B 41/009 (2013.01); C04B 41/5042 (2013.01); C04B 41/87 (2013.01); C23C 4/073 (2016.01); C23C 4/11 (2016.01); C23C 4/134 (2016.01); C23C 24/08 (2013.01); C23C 28/3215 (2013.01); C23C 28/345 (2013.01); C23C 28/3455 (2013.01); F01D 5/288 (2013.01); B32B 15/16 (2013.01); C04B 2111/0025 (2013.01); C04B 2111/00577 (2013.01); C04B 2235/3224 (2013.01); C04B 2235/5436 (2013.01); C04B 2235/5445 (2013.01); C04B 2235/76 (2013.01); C04B 2237/343 (2013.01); C04B 2237/348 (2013.01); C04B 2237/586 (2013.01); C04B 2237/588 (2013.01); C04B 2237/704 (2013.01); F05D 2230/312 (2013.01); F05D 2230/90 (2013.01); F05D 2300/15 (2013.01); F05D 2300/2112 (2013.01); F05D 2300/2118 (2013.01)] 16 Claims
 
1. A method comprising:
depositing a first plurality of particles on a substrate to form a first layer, wherein the first plurality of particles comprises a first base oxide comprising zirconia or hafnia and a first rare earth oxide comprising yttria, wherein the first layer comprises a columnar microstructure;
depositing a second plurality of particles directly on the first layer using a suspension plasma spray technique to form a second layer, wherein the second plurality of particles comprises a second base oxide comprising zirconia or hafnia, a second rare earth oxide comprising ytterbia, a third rare earth oxide comprising samaria, and a fourth rare earth oxide comprising at least one of lutetia, scandia, ceria, neodymia, europia, and gadolinia, wherein the second layer comprises a columnar microstructure, wherein a coefficient of thermal expansion (CTE) of the second layer is higher than the CTE of the first layer; and
depositing a third plurality of particles using a suspension plasma spray technique to form a third layer on the second layer, wherein the third plurality of particles comprises a third base oxide comprising zirconia or hafnia, the second rare earth oxide, the third rare earth oxide, and a fifth rare earth oxide comprising at least one of lutetia, scandia, ceria, neodymia, europia, and gadolinia, wherein the third layer has a dense microstructure, and wherein a porosity of the third layer is lower than a porosity of the second layer.