Abstract: A component with a ceramic coating system wherein the component includes a substrate, especially a nickel- or cobalt-based superalloy, a metallic bond coat, especially based on a NiCoCrAl composition, a ceramic coating system with an lower ceramic coating and an upper ceramic coating. An intermediate coating is located between lower coating and upper coating, providing a rougher surface which has a maximum thickness of 25% of the thickness of the lower coating or of the upper coating. The bonding capacity of a ceramic coating system is improved by adapting the coating parameters such as size of the powder and changing of the parameters of the spraying system.

Abstract: A method to increase the thermal stress capability of a porous TBC and layer system. Due to a post treatment step to a pose TBC coating cracks are produced inside the post TBC advantages manner to increase the thermal stress capability of the ceramic coating by only heating the surface of the ceramic coating.

Abstract: An improved ceramic material for heat insulation with selection of specific stabilizers and adapted proportions, includes zirconium oxide with 0.2 wt. % to 8.0 wt. % of the base stabilizers: yttrium oxide (Y2O3), hafnium oxide (HfO2), cerium oxide (CeO2), calcium oxide (CaO), and/or magnesium oxide (MgO), wherein at least yttrium oxide (Y2O3) is used, and optionally at least one of the additional stabilizers: 0.2 wt. % to 20 wt. % of erbium oxide (Er2O3) and/or ytterbium oxide (Yb2O3).

Abstract: A seal system for gas turbine that includes a stator and a blade with a blade tip facing the stator. The blade has a protective ceramic coating having an inner ceramic layer being made of a partially stabilized zirconia and having at least a partially segmented microstructure in form of vertical cracks. The ceramic coating further includes an outer ceramic layer made of fully stabilized zirconia and having a segmented microstructure. Advantageously, the entire airfoil surface is provided with the protective ceramic coating. With the fully stabilized zirconia coating on the tip of a blade which faces a casing with a ceramic coating, a result is a better sealing system. The stator includes an abradable coating having at least an outer ceramic coating being made of fully stabilized or ytterbium stabilized zirconia.

Abstract: A ceramic material, in particular for use in a layer system, which has high resistance to sintering, high expansion tolerance and low thermal conductivity and is provided by deliberately choosing the additions of oxides to zirconium oxide.

Abstract: A method to increase the thermal stress capability of a porous TBC and layer system. Due to a post treatment step to a pose TBC coating cracks are produced inside the post TBC advantages manner to increase the thermal stress capability of the ceramic coating by only heating the surface of the ceramic coating.

Abstract: The use of a physical mixture of partially stabilized and fully stabilized zirconium oxide powder for producing a thermal barrier coating results in good thermal barrier properties and good mechanical properties is provided.

Abstract: The corrosion and erosion resistance of ceramic heat shield elements is improved by the use of yttrium oxide on aluminum oxide as a layer or substrate material is provided. A heat is disclosed having aluminum oxide in the substrate or as a layer on a substrate, wherein yttrium oxide, particularly only yttrium oxide, is present as the outermost layer, particularly directly on the aluminum oxide.

Abstract: Engineered groove features (EGFs) are formed within thermal barrier coatings (TBCs) of turbine engine components. The EGFs are advantageously aligned with likely stress zones within the TBC or randomly aligned in a convenient two-dimensional or polygonal planform pattern on the TBC surface and into the TBC layer. The EGFs localize thermal stress- or foreign object damage (FOD)-induced crack propagation within the TBC that might otherwise allow excessive TBC spallation and subsequent thermal exposure damage to the turbine component underlying substrate. Propagation of a crack is arrested when it reaches an EGF, so that it does not cross over the groove to otherwise undamaged zones of the TBC layer. In some embodiments, the EGFs are combined with engineered surface features (ESFs) that are formed in the component substrate or within intermediate layers applied between the substrate and the TBC.

Abstract: A dense vertical cracked microstructure in a ceramic layer system made of an underline partially stabilized zirconia layer and an above laying fully stabilized zirconia layer show good erosion resistance and long life time is provided.

Abstract: A turbine abradable component includes a support surface and a thermally sprayed ceramic/metallic abradable substrate coupled to the support surface for orientation proximal a rotating turbine blade tip circumferential swept path. An elongated pixelated major planform pattern (PMPP) of a plurality of discontinuous micro surface features (MSF) project from the substrate surface. The PMPP repeats radially along the swept path in the blade tip rotational direction, for selectively directing airflow between the blade tip and the substrate surface. Each MSF is defined by a pair of first opposed lateral walls defining a width, length and height that occupy a volume envelope of 1-12 cubic millimeters. The PMPP arrays of MSFs provide airflow control of hot gasses in the gap between the abradable surface and the blade tip with smaller potential rubbing surface area than solid projecting ribs with similar planform profiles.

Abstract: Thermal barrier coatings (TBCs) for turbine engine components are applied over engineered surface features (ESFs) that are formed in the component substrate or within intermediate layers applied between the substrate and the TBC. The ESFs help anchor the TBC layer and/or localize cracks that are bounded by one or more of the ESFs. During engine operation the ESFs arrest thermal stress-or foreign object damage (FOD)-induced crack propagation within the TBC that might otherwise allow excessive TBC spallation and subsequent thermal exposure damage to the turbine component underlying substrate. In some embodiments, the ESFs are combined with engineered groove features that are formed in the TBC.

Abstract: Engineered groove features (EGFs) are formed within thermal barrier coatings (TBCs) of turbine engine components. The EGFs are advantageously aligned with likely stress zones within the TBC or randomly aligned in a convenient two-dimensional or polygonal planform pattern on the TBC surface and into the TBC layer. The EGFs localize thermal stress- or foreign object damage (FOD)-induced crack propagation within the TBC that might otherwise allow excessive TBC spallation and subsequent thermal exposure damage to the turbine component underlying substrate. Propagation of a crack is arrested when it reaches an EGF, so that it does not cross over the groove to otherwise undamaged zones of the TBC layer. In some embodiments, the EGFs are combined with engineered surface features (ESFs) that are formed in the component substrate or within intermediate layers applied between the substrate and the TBC.

Abstract: Turbine and compressor casing abradable component embodiments for turbine engines, with composite grooves and vertically projecting rows of ridges in planform patterns, establishing upper and lower wear zones. The lower wear zone reduces, redirects and/or blocks blade tip downstream airflow leakage, while the upper wear zone is optimized to minimize blade tip gap and wear by being more easily abradable than the lower zone. An elongated first ridge in the lower wear zone terminates in a continuous surface plateau. A plurality of second ridges or nibs, separated by grooves, project from the plateau, forming the upper wear zone. Each of the second ridges has a planform cross section smaller than the plateau planform cross section and a height smaller than the first ridge height. Some embodiments of the second ridges have spacing, planform cross sections, heights and separating groove dimensions selected for shearing when contacted by turbine blade tips.