US 12,227,464 B2
CMAS-resistant environmental barrier coating system
Li Li, Carmel, IN (US); Matthew T. Kush, Martinsville, IN (US); Robert Alexander Sean Golden, Noblesville, IN (US); and Jun Shi, 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 May 18, 2021, as Appl. No. 17/302,996.
Prior Publication US 2022/0371967 A1, Nov. 24, 2022
Int. Cl. C04B 41/89 (2006.01); C04B 35/16 (2006.01); C04B 35/80 (2006.01); C04B 41/00 (2006.01); C04B 41/50 (2006.01); C04B 41/52 (2006.01); C04B 41/87 (2006.01); F01D 5/28 (2006.01); C04B 103/61 (2006.01); C04B 111/00 (2006.01); C04B 111/20 (2006.01)
CPC C04B 41/526 (2013.01) [C04B 35/16 (2013.01); C04B 35/80 (2013.01); C04B 41/009 (2013.01); C04B 41/5024 (2013.01); C04B 41/87 (2013.01); C04B 41/89 (2013.01); F01D 5/288 (2013.01); C04B 2103/61 (2013.01); C04B 2111/00431 (2013.01); C04B 2111/20 (2013.01); C04B 2111/2038 (2013.01); C04B 2235/3427 (2013.01); C04B 2235/3826 (2013.01); C04B 2235/5244 (2013.01)] 20 Claims
OG exemplary drawing
 
1. An article comprising:
a substrate;
an environmental barrier coating (EBC) layer on the substrate, wherein the EBC layer comprises at least one rare-earth disilicate (REDS), and wherein the EBC layer defines a first surface opposite the substrate; and
a CMAS-resistant EBC layer on the first surface of the EBC layer, wherein the CMAS-resistant EBC layer comprises at least one rare-earth monosilicate (REMS) configured to react with CMAS to form at least one crystalline reaction product, and wherein the CMAS-resistant EBC layer defines a second surface,
wherein the EBC layer comprises a plurality of vertical cracks extending from the first surface into the EBC layer, and the CMAS-resistant EBC does not include vertical cracks extending into a surface of the CMAS-resistant EBC,
wherein a porosity of the CMAS-resistant EBC layer is less than or equal to about 40 volume percent,
wherein the CMAS-resistant EBC layer further comprises at least one rare-earth disilicate (REDS), and wherein a content of the REMS is equal to or greater than about 20 weight percent, and
wherein the CMAS-resistant EBC layer and the EBC layer are discrete layers such that an interface is formed at the first surface of the EBC layer between a composition of the CMAS-resistant EBC layer and a composition of the EBC layer.
 
12. An article comprising:
a substrate;
a first environmental barrier coating (EBC) layer on the substrate, wherein the first EBC layer comprises a rare-earth disilicate (REDS);
a second EBC layer on the substrate, wherein the second EBC layer comprises the REDS, and wherein the second EBC layer defines a surface and a plurality of vertical cracks extending from the surface into the second EBC layer; and
a CMAS-resistant EBC layer on the surface of the second EBC layer, wherein the CMAS-resistant EBC layer comprises at least one rare-earth monosilicate (REMS) configured to react with CMAS to form at least one crystalline reaction product, wherein a porosity of the CMAS-resistant EBC layer is less than about 15 volume percent, wherein the CMAS-resistant EBC does not include vertical cracks extending into a surface of the CMAS-resistant EBC,
wherein the first EBC layer and the second EBC layer each include the REMS, and
wherein the first EBC layer has a lower REMS/REDS composition ratio than a REMS/REDS composition ratio of the second EBC layer.
 
17. An article comprising:
a substrate;
a first environmental barrier coating (EBC) layer on the substrate, wherein the first EBC layer comprises a rare-earth disilicate (REDS);
a second EBC layer on the substrate, wherein the second EBC layer comprises at least one of a rare-earth monosilicate (REMS) or REDS, and wherein the second EBC layer defines a surface and a plurality of vertical cracks extending from the surface into the second EBC layer; and
a CMAS-resistant EBC layer on the surface of the second EBC layer, wherein the CMAS-resistant EBC layer comprises at least one of a REMS or REDS, wherein the CMAS-resistant EBC does not include vertical cracks extending into a surface of the CMAS-resistant EBC.