Protective coating systems for gas turbine engine applications and methods for fabricating the same

Abstract

Protective coating systems for gas turbine engine applications and methods for fabricating such protective coating systems are provided. An exemplary method of manufacturing a turbine engine component includes providing a substrate in the form of the turbine engine component and forming a bond coating on and over the substrate. The method further includes forming a thermal barrier coating or an environmental barrier coating on and over the bond coating and forming a magnetoplumbite structure ceramic top coating on an over the thermal barrier coating or the environmental barrier coating.

What is claimed is: 
     
         1 . A method of manufacturing a turbine engine component comprising:
 providing a substrate in the form of the turbine engine component;   forming a bond coating on and over the substrate;   forming a thermal barrier coating or an environmental barrier coating on and over the bond coating; and   forming a magnetoplumbite structure ceramic top coating on and over the thermal barrier coating or the environmental barrier coating.   
     
     
         2 . The method of  claim 1 , wherein the turbine engine component is selected from the group consisting of: a turbine blade, a turbine shroud, a combustor, and a heat shield. 
     
     
         3 . The method of  claim 1 , wherein providing the substrate comprises providing a substrate that is formed of a material selected from the group consisting of: a superalloy, a ceramic, and a ceramic matrix composite. 
     
     
         4 . The method of  claim 1 , wherein forming the bond coating comprises forming a bond coating that comprises a material selected from the group consisting of: an aluminum-based material, a silicon-based material, a nickel-platinum aluminide material, an MCrAlY material, and an MCoCrAlY material. 
     
     
         5 . The method of  claim 1 , wherein forming the thermal barrier coating or the environmental barrier coating comprises forming a thermal barrier coating or an environmental barrier coating that comprises a material selected from the group consisting of: yttria stabilized zirconia and yttria stabilized hafnia. 
     
     
         6 . The method of  claim 1 , wherein forming the ceramic top coating comprises forming a ceramic top coating that comprises a material selected from the group consisting of: MAl 12 O 19 ; MMeAl 12 O 19 ; MAl 11 O 19 ; MMeAl 11 O 19 ; MAl 11 O 18 ; and MMeAl 11 O 18 , where M and Me are cations selected independently from the group consisting of: Mg 2+ , La 3+ , Gd 3+ , Mn 2+ , Si 4+ , Na + , K + , Ca 2+ , Ba 2+ , La 3+ , Mg 2+ , Fe + , Fe 3+ , and Ti 4+ . 
     
     
         7 . The method of  claim 1 , wherein forming the bond coating is performed using a method selected from the group consisting of: over-the-pack aluminizing, electroplating, electron beam physical vapor deposition, chemical vapor deposition, low pressure spraying, and cold spraying. 
     
     
         8 . The method of  claim 1 , wherein forming the thermal barrier coating or the environmental barrier coating is performed using a method selected from the group consisting of: plasma spraying, physical vapor deposition, and electron beam physical vapor deposition. 
     
     
         9 . The method of  claim 1 , wherein forming the ceramic top coating is performed using a method selected from the group consisting of: electron beam physical vapor deposition, air plasma spraying, high velocity oxy-fuel coating spraying, and sol-gel based methods. 
     
     
         10 . The method of  claim 1 , further comprising installing the turbine engine component in a turbine engine. 
     
     
         11 . A turbine engine component comprising:
 a substrate in the form of the turbine engine component;   a bond coating on and over the substrate;   a thermal barrier coating or an environmental barrier coating on and over the bond coating; and   a magnetoplumbite structure ceramic top coating on and over the thermal barrier coating or the environmental barrier coating.   
     
     
         12 . The turbine engine component of  claim 11 , wherein the turbine engine component is selected from the group consisting of: a turbine blade, a turbine shroud, a combustor, and a heat shield. 
     
     
         13 . The turbine engine component of  claim 11 , wherein the substrate comprises a material selected from the group consisting of: a superalloy, a ceramic, and a ceramic matrix composite. 
     
     
         14 . The turbine engine component of  claim 11 , wherein the bond coating comprises a material selected from the group consisting of: an aluminum-based material, a silicon-based material, a nickel-platinum aluminide material, an MCrAlY material, and an MCoCrAlY material. 
     
     
         15 . The turbine engine component of  claim 11 , wherein the thermal barrier coating or the environmental barrier coating comprises a material selected from the group consisting of: yttria stabilized zirconia and yttria stabilized hafnia. 
     
     
         16 . The turbine engine component of  claim 11 , wherein the ceramic top coating comprises a material selected from the group consisting of: MAl 12 O 19 ; MMeAl 12 O 19 ; MAl 11 O 19 ; MMeAl 11 O 19 ; MAl 11 O 18 ; and MMeAl 11 O 18 , where M and Me are cations selected independently from the group consisting of: Mg 2+ , La 3+ , Gd 3+ , Mn 2+ , Si 4+ , Na + , K + , Ca 2+ , Ba 2+ , La 3+ , Mg 2+ , Fe + , Fe 3+ , and Ti 4+ . 
     
     
         17 . A method of operating a turbine engine, the turbine engine comprising a turbine engine component comprising a substrate in the form of the turbine engine component, a bond coating on and over the substrate, a thermal barrier coating or an environmental barrier coating on and over the bond coating, and a magnetoplumbite structure ceramic top coating on an over the thermal barrier coating or the environmental barrier coating, the method comprising:
 exposing the turbine engine to a calcium-alumino-silicate (CMAS) material at a temperature sufficient such that at least a portion of the CMAS material is molten or becomes molten and adheres to the ceramic top coating of the turbine engine component.   
     
     
         18 . The method of  claim 17 , wherein exposing the turbine engine comprises exposing the turbine engine to a temperature above about 2150° F. 
     
     
         19 . The method of  claim 18 , further comprising cooling the turbine engine component below the temperature of about 2150° F. after the CMAS material has adhered to the ceramic top coating of the turbine engine component. 
     
     
         20 . The method of  claim 19 , wherein exposing the turbine engine comprises exposing the turbine engine to combustion gasses during the operation of the gas turbine engine.