Thermal barrier coated article and a method of manufacturing a thermal barrier coated article

Abstract

A method of manufacturing a thermal barrier coated article including the steps of: a) forming an article having a first surface and a second surface, the article having a plurality of projections extending from the first surface in a direction away from the first surface and away from the second surface, each projection having a first end adjacent the first surface and a second end remote from the first surface, b) depositing a thermal barrier coating on the first surface of the article around each of the projections and on the second ends of the projections, c) removing the thermal barrier coating from the second ends of the projections, and d) forming at least one passage through each projection extending from the second surface of the article through the article and through the respective projection to the second end of the respective projection.

1 . A thermal barrier coated article, the article having a first surface and a second surface, the article having at least one projection extending from the first surface in a direction away from the first surface and away from the second surface, the projection having a first end adjacent the first surface and a second end remote from the first surface, the second end of the at least one projection having a surface, the article having at least one passage extending from the second surface of the article through the article and through the at least one projection to the surface at the second end of the at least one projection, the at least one passage being an effusion cooling aperture and the article having a thermal barrier coating on the first surface around the at least one projection. 
     
     
         2 . A thermal barrier coated article as claimed in  claim 1  wherein the article having a plurality of projections extending from the first surface in a direction away from the first surface and away from the second surface, each projection having a first end adjacent the first surface and a second end remote from the first surface, the second end of each projection having a surface, the article having a plurality of passages extending from the second surface of the article, each passage extending from the second surface of the article through the article and through a respective one of the projections to the surface at the second end of the respective projection and the article having a thermal barrier coating on the first surface around each of the projections. 
     
     
         3 . A thermal barrier coated article as claimed in  claim 1  wherein the second end of the at least one projection is arranged at a first distance from the first surface of the article and the thermal barrier coating has a first thickness and the first distance is at least equal to the first thickness. 
     
     
         4 . A thermal barrier coated article as claimed in  claim 1  wherein the thermal barrier coating comprising a metallic bond coating on the first surface of the article and a ceramic thermal barrier coating on the metallic bond coating. 
     
     
         5 . A thermal barrier coated article as claimed in  claim 4  wherein the metallic bond coating is selected from the group consisting of a MCrAlY coating and an aluminide coating, where M is one or more of Ni, Co and Fe. 
     
     
         6 . A thermal barrier coated article as claimed in  claim 4  wherein the ceramic thermal barrier coating is selected from the group consisting of stabilised zirconia and yttria stabilised zirconia. 
     
     
         7 . A thermal barrier coated article as claimed in  claim 1  wherein the article is selected from the group consisting of a combustor tile, a turbine blade and a turbine vane. 
     
     
         8 . A method of manufacturing a thermal barrier coated article comprising the steps of:
 a) forming an article having a first surface and a second surface, the article having at least one projection extending from the first surface in a direction away from the first surface and away from the second surface, the at least one projection having a first end adjacent the first surface and a second end remote from the first surface, the second end of the at least one projection having a surface,   b) depositing a thermal barrier coating on the first surface of the article around the at least one projection and on the surface at the second end of the at least one projection,   c) removing the thermal barrier coating from the second end of the at least one projection, and   d) forming at least one passage through the at least one projection extending from the second surface of the article through the article and through the at least one projection to the surface at the second end of the at least one projection, the at least one passage being an effusion cooling aperture.   
     
     
         9 . A method as claimed in  claim 8  wherein in step a) comprises forming an article having a plurality of projections extending from the first surface in a direction away from the first surface and away from the second surface, each projection having a first end adjacent the first surface and a second end remote from the first surface, the second end of each projection having a surface, step b) comprises depositing the thermal barrier coating on the first surface of the article around each of the projections and on the surface at the second end of each of the projections, step c) comprises removing the thermal barrier coating from the second end of each of the projections and step d) comprises forming a passage through each projection extending from the second surface of the article through the article and through the respective projection to the surface at the second end of the respective projection. 
     
     
         10 . A method as claimed in  claim 8  wherein the second end of the at least one projection is arranged at a first distance from the first surface of the article and the thermal barrier coating has a first thickness and the first distance is at least equal to the first thickness. 
     
     
         11 . A method as claimed in  claim 8  wherein step b) comprises depositing a metallic bond coating on the first surface of the article and depositing a ceramic thermal barrier coating on the metallic bond coating, 
     
     
         12 . A method as claimed in  claim 11  wherein the metallic bond coating is selected from the group consisting of a MCrAlY coating and an aluminide coating, where M is one or more of Ni, Co and Fe. 
     
     
         13 . A method as claimed in  claim 11  wherein the ceramic thermal barrier coating is selected from the group consisting of stabilised zirconia and yttria stabilised zirconia 
     
     
         14 . A method as claimed in  claim 8  wherein the article is selected from the group consisting of a combustor tile, a turbine blade and a turbine vane. 
     
     
         15 . A method as claimed in  claim 8  wherein step a) comprises forming the article and the at least one projection from a method selected from the group consisting of casting and direct laser deposition. 
     
     
         16 . A method as claimed in  claim 8  wherein step c) comprises machining. 
     
     
         17 . A method as claimed in  claim 8  wherein step d) comprises electro-discharge machining. 
     
     
         18 . A method as claimed in  11  wherein step b) comprises depositing the metallic bond coating by a method selected from the group consisting of plasma spraying, thermal spraying and HVOF. 
     
     
         19 . A method as claimed in  claim 11  wherein step b) comprises depositing the ceramic thermal barrier coating by a method selected from the group consisting of plasma spraying, thermal spraying and HVOF. 
     
     
         20 . A method as claimed in  claim 10  wherein step d) comprises removing at least a portion of the projection such that the first distance is less than the first thickness.