Coating system including oxide nanoparticles in oxide matrix

Abstract

In some examples, an article may include a substrate and a coating on the substrate. The substrate may include a superalloy, a ceramic, or a ceramic matrix composite. The coating may include a layer comprising a matrix material and a plurality of nanoparticles. The matrix material may include at least one of silica, zirconia, alumina, titania, or chromia, and the plurality of nanoparticles may include nanoparticles including at least one of yttria, zirconia, alumina, or chromia. In some examples, an average diameter of the nanoparticles is less than about 400 nm.

1 . A system comprising:
 a first component comprising an alloy substrate comprising an alloy substrate coated with a coating, wherein the coating comprises a layer comprising an oxide matrix and a plurality of oxide nanoparticles, and wherein:
 the oxide matrix comprises at least one of silica, zirconia, alumina, titania, or chromia; 
 the plurality of oxide nanoparticles comprises at least one of yttria, zirconia, alumina, or chromia; 
 a chemical composition of the plurality of oxide nanoparticles is different from the chemical composition of the oxide matrix such that the plurality of oxide nanoparticles form a second, distinct phase in the oxide matrix; 
 an average diameter of the plurality of oxide nanoparticles is less than 400 nm; and 
 the layer is formed from a mixture that comprises a precursor of the oxide matrix and between about 0.7 volume percent and about 13 volume percent of the plurality of oxide nanoparticles, wherein the volume percent of the plurality of oxide nanoparticles is based on the volume of oxide nanoparticles divided by a total volume of the plurality of oxide nanoparticles plus the precursor of the oxide matrix; and 
   a second component comprising a ceramic or a CMC substrate, wherein at least a portion of the second component is in contact with at least a portion of the coating.   
     
     
         2 . The system of  claim 1 , wherein the mixture from which the layer is formed comprises between about 5 volume percent and about 7.5 volume percent of the nanoparticles. 
     
     
         3 . The system of  claim 1 , wherein the matrix material comprises silica and zirconia. 
     
     
         4 . The system of  claim 1 , wherein the nanoparticles comprise zirconia stabilized with at least one of yttria, alumina, or chromia. 
     
     
         5 . The system of  claim 1 , wherein the nanoparticles comprise yttria-stabilized zirconia. 
     
     
         6 . The system of  claim 1 , wherein the coating comprises a plurality of layers, each layer of the plurality comprises the matrix material and the plurality of nanoparticles. 
     
     
         7 . The system of  claim 6 , wherein the coating comprises between 1 and 20 layers. 
     
     
         8 . The system of  claim 1 , wherein the coating defines a thickness of between about 0.1 micrometers and about 25 micrometers. 
     
     
         9 . The system of  claim 1 , wherein the first component comprises a gas turbine engine disk and the second component comprises a gas turbine engine blade. 
     
     
         10 . The system of  claim 1 , wherein the second component comprises a gas turbine engine blade track. 
     
     
         11 . A system comprising:
 a first component comprising an alloy substrate; and   a second component comprising a ceramic or a CMC substrate coated with a coating, wherein the coating comprises a layer comprising an oxide matrix and a plurality of oxide nanoparticles, and wherein:
 the oxide matrix comprises at least one of silica, zirconia, alumina, titania, or chromia; 
 the plurality of oxide nanoparticles comprises at least one of yttria, zirconia, alumina, or chromia; 
 a chemical composition of the plurality of oxide nanoparticles is different from the chemical composition of the oxide matrix such that the plurality of oxide nanoparticles forms a second, distinct phase in the oxide matrix; 
 an average diameter of the plurality of oxide nanoparticles is less than 400 nm; 
 the layer is formed from a mixture comprising a precursor of the oxide matrix and between about 0.7 volume percent and about 13 volume percent of the plurality of oxide nanoparticles, wherein the volume percent of the plurality of oxide nanoparticles is based on the volume of oxide nanoparticles divided by a total volume of the plurality of oxide nanoparticles plus a precursor of the oxide matrix; and 
 at least a portion of the first component is in contact with at least a portion of the coating on the second component. 
   
     
     
         12 . The system of  claim 11 , wherein the mixture from which the layer is formed comprises between about 5 volume percent and about 7.5 volume percent of the nanoparticles. 
     
     
         13 . The system of  claim 11 , wherein the matrix material comprises silica and zirconia. 
     
     
         14 . The system of  claim 1 , wherein the nanoparticles comprise zirconia stabilized with at least one of yttria, alumina, or chromia. 
     
     
         15 . The system of  claim 1 , wherein the nanoparticles comprise yttria-stabilized zirconia. 
     
     
         16 . The system of  claim 1 , wherein the coating comprises a plurality of layers, each layer of the plurality comprises the matrix material and the plurality of nanoparticles. 
     
     
         17 . The system of  claim 16 , wherein the coating comprises between 1 and 20 layers. 
     
     
         18 . The system of  claim 1 , wherein the coating defines a thickness of between about 0.1 micrometers and about 25 micrometers. 
     
     
         19 . The system of  claim 1 , wherein the first component comprises a gas turbine engine disk and the second component comprises a gas turbine engine blade. 
     
     
         20 . The system of  claim 1 , wherein the second component comprises a gas turbine engine blade track.