Silicate resistant thermal barrier coating with alternating layers

1. A thermal barrier coating system for use on a turbine engine component which reduces sand related distress, said coating system comprising a plurality of first layers of a stabilized material selected from the group consisting of zirconia, hafnia, and titania and a plurality of second layers containing at least one of oxyapatite and garnet, said first layers and said second layers being alternating, and an outermost layer of said thermal barrier coating comprising a second layer.

2. The thermal barrier coating of claim 1 , wherein said first layer comprises a material selected from the group consisting of zirconia, hafnia, and titania stabilized with a rare earth material comprises at least one oxide selected from the group consisting of lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, homium, erbium, thulium, ytterbium, lutetium, scandium, indium and mixtures thereof.

3. The thermal barrier coating of claim 2 , wherein said rare earth material is present in an amount from 5.0 to 99 wt %.

4. The thermal barrier coating of claim 2 , wherein said rare earth material is present in an amount from 30 to 70 wt %.

5. The thermal barrier coating of claim 1 , wherein said first layer comprises a material selected from the group consisting of zirconia, hafnia, and titania stabilized with yttria.

6. The thermal barrier coating of claim 5 , wherein said yttria is present in an amount from 1.0 to 25 wt %.

7. The thermal barrier coating of claim 5 , wherein said yttria is present in an amount from 5.0 to 9.0 wt %.

8. The thermal barrier coating of claim 1 , wherein each said second layer contains garnet having the formula A 3 B 3 X 3 O 12 where A comprises at least one of the metals selected from the group consisting of Ca +2 , Gd +3 , In +3 , Mg +2 , Na + , K + , Fe +2 , La +2 , Ce +2 , Pr +2 , Nd +2 , Pm +2 , Sm +2 , Eu +2 , Gd +2 , Tb +2 , Dy +2 , Ho +2 , Er +2 , Tm +2 , Yb +2 , Lu +2 , Sc +2 , Y +2 , Ti +2 , Zr +2 , Hf +2 , V +2 , Ta +2 , Cr +2 , W +2 , Mn +2 , Tc +2 , Re +2 , Fe +2 , Os +2 , Co +2 , Ir +2 , Ni +2 , Zn +2 , and Cd +2 ; where B comprises at least one of the metals selected from the group consisting of Zr +4 , Hf +4 , Gd +3 , Al +3 , Fe +3 , La +2 , Ce +2 , Pr +2 , Nd +2 , Pm +2 , Sm +2 , Eu +2 , Gd +2 , Tb +2 , Dy +2 , Ho +2 , Er +2 , Tm +2 , Yb +2 , Lu +2 , In +3 , Sc +2 , Y +2 , Cr +3 , Sc +3 , Y +3 , V +3 , Nb +3 , Cr +3 , Mo +3 , W +3 , Mn +3 , Fe +3 , Ru +3 , Co +3 , Rh +3 , Ir +3 , Ni +3 , and Au +3 ; where X comprises at least one of the metals selected from the group consisting of Si +4 , Ti +4 , Al +4 , Fe +3 , Cr +3 , Sc +3 , Y +3 , V +3 , Nb +3 , Cr +3 , Mo +3 , W +3 , Mn +3 , Fe +3 , Ru +3 , Co +3 , Rh +3 , Ir +3 , Ni +3 , and Au +3 ; and where O is oxygen.

9. The thermal barrier coating of claim 1 , wherein each said second layer consists solely of garnet.

10. The thermal barrier coating of claim 1 , wherein each said first layer has a thickness in the range of from 0.5 to 50 mils.

11. The thermal barrier coating of claim 1 , wherein each said first layer has a thickness in the range of from 0.5 to 5.0 mils.

12. The thermal barrier coating of claim 1 , wherein each said second layer has a thickness in the range of from 0.5 to 50 mils.

13. The thermal barrier coating of claim 1 , wherein each said second layer has a thickness in the range of from 0.5 to 5.0 mils.

14. The thermal barrier coating of claim 1 , wherein said thermal barrier coating has a thickness in the range of from 0.5 to 40 mils.

15. A thermal barrier coating system for use on a turbine engine component which reduces sand related distress, said coating system comprising at least one first layer of a stabilized material selected from the group consisting of zirconia, hafnia, and titania and at least one second layer consisting solely of oxyapatite.

16. The thermal barrier coating of claim 15 , comprising a plurality of first layers and a plurality of second layers wherein said first layers and said second layers are alternating.

17. The thermal barrier coating of claim 16 , wherein an outermost layer of said thermal barrier coating comprises a second layer.

18. A thermal barrier coating system for use on a turbine engine component which reduces sand related distress, said coating system comprising at least one first layer of a stabilized material selected from the group consisting of zirconia, hafnia, and titania and at least one second layer containing at least one of oxyapatite and garnet, wherein each said second layer contains an oxyapatite having the formula A 4 B 6 X 6 O 26 where A comprises at least one of the metals selected from the group consisting of is Ca +2 , Mg +2 , Fe +2 , Na + , K + , Gd +3 , Zr +4 , Hf +4 , Y +2 , Sc +2 , Sc +3 , In +3 , La +2 , Ce +2 , Pr +2 , Nd +2 , Pm +2 , Sm +2 , Eu +2 , Gd +2 , Tb +2 , Dy +2 , Ho +2 , Er +2 , Tm +2 , Yb +2 , Lu +2 , Sc +2 , Y +2 , Ti +2 , Zr +2 , Hf +2 , V +2 , Ta +2 , Cr +2 , W +2 , Mn +2 , Tc +2 , Re +2 , Fe +2 , Os +2 , Co +2 , Ir +2 , Ni +2 , Zn +2 , and Cd +2 ; where B comprises at least one of the metals selected from the group consisting of Gd +3 , Y +2 , Sc +2 , In +3 , Zr +4 , Hf +4 , Cr +3 , Sc +3 , Y +3 , V +3 , Nb +3 , Cr +3 , Mo +3 , W +3 , Mn +3 , Fe +3 , Ru +3 , Co +3 , Rh +3 , Ir +3 , Ni +3 , and Au +3 ; where X comprises at least one of the metals selected from the group consisting of Si +4 , Ti +4 , Al +4 , Cr +3 , Sc +3 , Y +3 , V +3 , Nb +3 , Cr +3 , Mo +3 , W +3 , Mn +3 , Fe +3 , Ru +3 , Co +3 , Rh +3 , Ir +3 , Ni +3 , and Au +3 ; and where O is oxygen.

19. A thermal barrier coating system for use on a turbine engine component which reduces sand related distress, said coating system comprising at least one first layer of a stabilized material selected from the group consisting of zirconia, hafnia, and titania and at least one second layer containing at least one of oxyapatite and garnet, wherein said second layer consists of from 5.0 to 90 wt % of oxyapatite and the balance being garnet.

20. The thermal barrier coating of claim 19 , wherein each said second layer consists of from 5.0 to 50 wt % of oxyapatite and the balance being garnet.

21. A turbine engine component comprising:

a substrate and a thermal barrier coating deposited onto said substrate; and

said thermal barrier coating comprising a plurality of first layers of a stabilized material selected from the group consisting of zirconia, hafnia, and titania and a plurality of second layers containing at least one of oxyapatite and garnet, said first layers and said second layers being alternating, and an outermost layer of said thermal barrier coating comprising a second layer.

22. The turbine engine component of claim 21 , wherein said first layer comprises a material selected from the group consisting of zirconia, hafnia, and titania stabilized with a rare earth material comprises at least one oxide selected from the group consisting of lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, homium, erbium, thulium, ytterbium, lutetium, scandium, indium and mixtures thereof.

23. The turbine engine component of claim 22 , wherein said rare earth material is present in an amount from 5.0 to 99 wt %.

24. The turbine engine component of claim 22 , wherein said rare earth material is present in an amount from 30 to 70 wt %.

25. The turbine engine component of claim 21 , wherein said first layer comprises a material selected from the group consisting of zirconia, hafnia, and titania stabilized with yttria.

26. The turbine engine component of claim 25 , wherein said yttria is present in an amount from 1.0 to 25 wt %.

27. The turbine engine component of claim 25 , wherein said yttria is present in an amount from 5.0 to 9.0 wt %.

28. The turbine engine component of claim 21 , wherein each said second layer consists solely of garnet.

29. The turbine engine component of claim 21 , wherein each said first layer has a thickness in the range of from 0.5 to 50 mils.

30. The turbine engine component of claim 21 , wherein each said first layer has a thickness in the range of 0.5 to 5.0 mils.

31. The turbine engine component of claim 21 , wherein each said second layer has a thickness in the range of from 0.5 to 50 mils.

32. The turbine engine component of claim 21 , wherein each said second layer has a thickness in the range of from 0.5 to 5.0 mils.

33. The turbine engine component of claim 21 , wherein said thermal barrier coating has a thickness in the range of from 0.5 to 40 mils.

34. The turbine engine component of claim 21 , wherein said substrate is formed from a metallic material selected from the group consisting of a nickel based superalloy, a cobalt based alloy, a molybdenum based alloy, a niobium based alloy, a titanium based alloy, a ceramic based material and a ceramic matrix composite material.

35. The turbine engine component according to claim 21 , wherein each said second layer contains an oxyapatite having the formula A 4 B 6 X 6 O 26 where A comprises at least one of the metals selected from the group consisting of is Ca +2 , Mg +2 , Fe +2 , Na + , K + , Gd +3 , Zr +4 , Hf +4 , Y +2 , Sc +2 , Sc +3 , In +3 , La +2 , Ce +2 , Pr +2 , Nd +2 , Pm +2 , Sm +2 , Eu +2 , Gd +2 , Tb +2 , Dy +2 , Ho +2 , Er +2 , Tm +2 , Yb +2 , Lu +2 , Sc +2 , Y +2 , Ti +2 , Zr +2 , Hf +2 , V +2 , Ta +2 , Cr +2 , W +2 , Mn +2 , Tc +2 , Re +2 , Fe +2 , Os +2 , Co +2 , Ir +2 , Ni +2 , Zn +2 , and Cd +2 ; where B comprises at least one of the metals selected from the group consisting of Gd +3 , Y +2 , Sc +2 , In +3 , Zr +4 , Hf +4 , Cr +3 , Sc +3 , Y +3 , V +3 , Nb +3 , Cr +3 , Mo +3 , W +3 , Mn +3 , Fe +3 , Ru +3 , Co +3 , Rh +3 , Ir +3 , Ni +3 , and Au +3 ; where X comprises at least one of the metals selected from the group consisting of Si +4 , Ti +4 , Al +4 , Cr +3 , Sc +3 , Y +3 , V +3 , Nb +3 , Cr +3 , Mo +3 , W +3 , Mn +3 , Fe +3 , Ru +3 , Co +3 , Rh +3 , Ir +3 , Ni +3 , and Au +3 ; and where O is oxygen.

36. The turbine engine component according to claim 21 , wherein each said second layer contains a garnet having the formula A 3 B 2 X 3 O 12 where A comprises at least one of the metals selected from the group consisting of is Ca +2 , Gd +3 , In +3 , Mg +2 , Na + , K + , Fe +2 , La +2 , Ce +2 , Pr +2 , Nd +2 , Pm +2 , Sm +2 , Eu +2 , Gd +2 , Tb +2 , Dy +2 , Ho +2 , Er +2 , Tm +2 , Yb +2 , Lu +2 , Sc +2 , Y +2 , Ti +2 , Zr +2 , Hf +2 , V +2 , Ta +2 , Cr +2 , W +2 , Mn +2 , Tc +2 , Re +2 , Fe +2 , Os +2 , Co +2 , Ir +2 , Ni +2 , Zn +2 , and Cd +2 ; where B comprises at least one of the metals selected from the group consisting of Zr +4 , Hf +4 , Gd +3 , Al +3 , Fe +3 , La +2 , Ce +2 , Pr +2 , Nd +2 , Pm +2 , Sm +2 , Eu +2 , Gd +2 , Tb +2 , Dy +2 , Ho +2 , Er +2 , Tm +2 , Yb +2 , Lu +2 , In +3 , Sc +2 , Y +2 , Cr +3 , Sc +3 , Y +3 , V +3 , Nb +3 , Cr +3 , Mo +3 , W +3 , Mn +3 , Fe +3 , Ru +3 , Co +3 , Rh +3 , Ir +3 , Ni +3 , and Au +3 ; where X comprises at least one of the metals selected from the group consisting of Si +4 , Ti +4 , Al +4 , Fe +3 , Cr +3 , Sc +3 , Y +3 , V +3 , Nb +3 , Cr +3 , Mo +3 , W +3 , Mn +3 , Fe +3 , Ru +3 , Co +3 , Rh +3 , Ir +3 , Ni +3 , and Au +3 ; and where O is oxygen.

37. The turbine engine component according to claim 21 , further comprising a bondcoat.

38. The turbine engine component according to claim 21 , wherein said bondcoat is formed from at least one material selected from the groups consisting of NiCoCrAlY, NiAl, PtAl, MoSi 2 , a MoSi 2 composite containing Si 3 Ny and/or SiC, and Si.

39. A turbine engine component comprising:

a substrate and a thermal barrier coating deposited onto said substrate; and

said thermal barrier coating comprising at least one first layer of a stabilized material selected from the group consisting of zirconia, hafnia, and titania and at least one second layer consisting solely of oxyapatite.

40. The turbine engine component of claim 39 , comprising a plurality of first layers and a plurality of second layers wherein said first layers and said second layers are alternating.

41. The turbine engine component of claim 40 , wherein an outermost layer of said thermal barrier coating comprises a second layer.

42. A turbine engine component comprising:

a substrate and a thermal barrier coating deposited onto said substrate; and

said thermal barrier coating comprising at least one first layer of a stabilized material selected from the group consisting of zirconia, hafnia, and titania and at least one second layer containing oxyapatite and garnet, wherein each said second layer consists of from 5.0 to 90 wt % of oxyapatite and the balance being garnet.

43. The turbine engine component of claim 42 , wherein each said second layer consists of from 5.0 to 50 wt % of oxyapatite and the balance being garnet.