Turbine abrasive blade tips with improved resistance to oxidation
An abrasive coating for a substrate of a component in a gas path exposed to a maximum temperature of 1750 degree Fahrenheit, comprising a plurality of grit particles adapted to be placed on a top surface of the substrate; a matrix material bonded to the top surface; the matrix material partially surrounds the grit particles, wherein the grit particles extend above the matrix material relative to the top surface; a film of oxidant resistant coating applied over the plurality of grit particles and the matrix material and a thermal barrier coating material applied over said film of oxidant resistant coating.
1. An abrasive coating for a substrate of a component in a gas path exposed to a maximum temperature of 1750 degrees Fahrenheit, comprising:
a plurality of grit particles adapted to be placed on a top surface of said substrate;
a matrix material bonded to said top surface; said matrix material partially surrounds said grit particles, wherein said grit particles extend above said matrix material relative to said top surface;
a film of oxidant resistant coating applied over said plurality of grit particles and said matrix material, said film of oxidant resistant coating consisting of a mixture of aluminum and zirconium oxide; and
a thermal barrier coating material applied over said film of oxidant resistant coating.
2. The abrasive coating for a substrate of a component in a gas path exposed to a maximum temperature of 1750 degrees Fahrenheit according to claim 1 , wherein said grit particles comprise a hard ceramic phase.
3. The abrasive coating for a substrate of a component in a gas path exposed to a maximum temperature of 1750 degrees Fahrenheit according to claim 1 , wherein said matrix material comprises a matrix formed from at least one of Ni, Co and MCrAlY, wherein M is Ni or Co, pure Ni and a cobalt chrome carbide material.
4. The abrasive coating for a substrate of a component in a gas path exposed to a maximum temperature of 1750 degrees Fahrenheit according to claim 1 , wherein said thermal barrier coating comprises an abradable material.
5. The abrasive coating for a substrate of a component in a gas path exposed to a maximum temperature of 1750 degrees Fahrenheit according to claim 1 , further comprising:
an adhesion layer coupled to said top surface, wherein said adhesion layer is configured to adhere said grit particles to said top surface.
6. A turbine engine component configured for a gas path of at most 1750 degrees Fahrenheit comprising:
an airfoil having a tip;
a composite abrasive coating bonded to said tip;
said composite abrasive coating comprising an adhesion layer bonded to said tip;
a layer of grit particles bonded to said adhesion layer;
a matrix material coupled to said adhesion layer and connected to said grit particles;
a film of oxidant resistant coating consisting of a mixture of aluminum and zirconium oxide applied over said plurality of grit particles and said matrix material; and
a thermal barrier coating material applied over said film of oxidant resistant coating.
7. The turbine engine component configured for a gas path of at most 1750 degrees Fahrenheit according to claim 6 , wherein said airfoil is a portion of said component configured for a gas path of at most 1750 degrees Fahrenheit.
8. The turbine engine component configured for a gas path of at most 1750 degrees Fahrenheit according to claim 6 , wherein said film of oxidant resistant coating has a thickness from 0.0002 inch-0.002 inch.
9. The turbine engine component configured for a gas path of at most 1750 degrees Fahrenheit according to claim 6 , wherein said thermal barrier coating thickness is about 10% to 20% of the diameter of the grit particles.
10. The turbine engine component configured for a gas path of at most 1750 degrees Fahrenheit according to claim 6 , wherein said component is in a high pressure turbine.
11. A process for coating a turbine engine airfoil with an abrasive, said process comprising:
applying an adhesion layer onto a tip of said airfoil, wherein said airfoil is configured to operate in a gas path having a maximum temperature of 1750 degrees Fahrenheit;
adhering a plurality of grit particles to said adhesion layer, wherein spaces are formed between said grit particles;
applying a matrix material to said adhesion layer and connecting to said grit particles;
applying a film of oxidant resistant coating consisting of a mixture of aluminum and zirconium oxide over said plurality of grit particles and said matrix material; and
applying a thermal barrier coating material over said film of oxidant resistant coating.
12. The process of claim 11 , wherein said film of oxidant resistant coating has a thickness from 0.0002 inch-0.002 inch.
13. The process of claim 11 , wherein said thermal barrier coating thickness is about 10% to 20% of the diameter of the grit particles.
14. The process of claim 13 , wherein said turbine engine airfoil is part of a component in a high pressure turbine.