THERMAL BARRIER COATING MATERIAL WITH ENHANCED TOUGHNESS
Disclosed are compositions, devices and methods related to thermal barrier coating materials having enhanced toughness. In some embodiments, a multiphase ceramic can include a first phase formed from a cubic and/or a tetragonally stabilized metal oxide, and a second phase formed from a magnetoplumbite-based aluminate that is chemically compatible with the first phase. Various example applications in which such materials can be utilized are disclosed.
1 . (canceled)
2 . A ceramic material comprising:
about 10 mol. % Nd 2 O 3 — about 90 mol. % Al 2 O 3 — about 0 mol. % ZrO 2 (NdAl 11 O 18 ) on the Al 2 O 3 —Nd 2 O 3 axis to
about 14 mol. % Nd 2 O 3 — about 0 mol. % Al 2 O 3 — about 86 mol. % ZrO 2 on the ZrO 2 —Nd 2 O 3 axis to
about 17 mol. % Nd 2 O 3 — about 0 mol. % Al 2 O 3 — about 83 mol. % ZrO 2 on the ZrO 2 —Nd 2 O 3 axis.
3 . The ceramic material of claim 2 wherein the ceramic material has at least two phases.
4 . The ceramic material of claim 3 wherein the ceramic material has exactly two phases.
5 . The ceramic material of claim 4 wherein the ceramic material includes a magnetoplumbite-based aluminate phase and a zirconium oxide phase.
6 . The ceramic material of claim 4 wherein no substantial chemical reaction takes place between a first phase and a second phase.
7 . The ceramic material of claim 2 wherein the ceramic material is configured as a thermal barrier coating.
8 . The ceramic material of claim 2 wherein the ceramic material retains crack resistance at temperatures of 1250° C. and above.
9 . A thermally insulated component comprising a coating of a multi-phase ceramic material having about 10 mol. % Nd 2 O 3 — about 90 mol. % Al 2 O 3 — about 0 mol. % ZrO 2 (NdAl 11 O 18 ) on the Al 2 O 3 —Nd 2 O 3 axis to about 14 mol. % Nd 2 O 3 — about 0 mol. % Al 2 O 3 — about 86 mol. % ZrO 2 on the ZrO 2 —Nd 2 O 3 axis to about 17 mol. % Nd 2 O 3 — about 0 mol. % Al 2 O 3 — about 83 mol. % ZrO 2 on the ZrO 2 —Nd 2 O 3 axis disposed on the component.
10 . The thermally insulated component of claim 9 wherein the thermally insulated component is a component of a gas-turbine engine.
11 . The thermally insulated component of claim 9 wherein the thermally insulated component is a turbine blade.
12 . The thermally insulated component of claim 9 wherein the multi-phase ceramic material includes a magnetoplumbite-based aluminate phase and a zirconium oxide phase.
13 . The thermally insulated component of claim 9 wherein the multi-phase ceramic material retains crack resistance at temperatures of 1250° C. and above.
14 . The thermally insulated component of claim 9 further including a bond coat between the multi-phase ceramic material and the component.
15 . A method of forming a ceramic thermal barrier coating on a substrate, the method comprising:
preparing a ceramic thermal barrier coating having about 10 mol. % Nd 2 O 3 — about 90 mol. % Al 2 O 3 — about 0 mol. % ZrO 2 (NdAl 11 O 18 ) on the Al 2 O 3 —Nd 2 O 3 axis to about 14 mol. % Nd 2 O 3 — about 0 mol. % Al 2 O 3 — about 86 mol. % ZrO 2 on the ZrO 2 —Nd 2 O 3 axis to about 17 mol. % Nd 2 O 3 — about 0 mol. % Al 2 O 3 — about 83 mol. % ZrO 2 on the ZrO 2 —Nd 2 O 3 axis; and
applying the ceramic thermal barrier coating as a layer on the substrate.
16 . The method of claim 15 further including applying a bond coat to the substrate, wherein the bond coat is between the ceramic thermal barrier coating and the substrate.
17 . The method of claim 15 wherein the ceramic thermal barrier coating includes a magnetoplumbite-based aluminate phase and a zirconium oxide phase.
18 . The method of claim 15 wherein the applying includes vapor deposition.
19 . The method of claim 15 wherein the substrate is an engine exhaust system component.
20 . The method of claim 15 wherein the substrate is a gas turbine engine.
21 . The method of claim 15 wherein the substrate is a superalloy.