Rolls-Royce has been granted a patent for a method of forming a coating system on ceramic or ceramic matrix composite substrates. The process involves depositing an environmental barrier coating, heat treating it, and then applying and heat treating an abradable coating, with controlled rates to manage porosity. GlobalData’s report on Rolls-Royce gives a 360-degree view of the company including its patenting strategy. Buy the report here.
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Coating system with environmental barrier and abradable coatings
The patent US12071382B2 outlines a method for enhancing the performance of ceramic or ceramic matrix composite (CMC) substrates through a multi-step coating process. The method begins with the deposition of an environmental barrier coating (EBC) on the substrate, followed by a heat treatment that reduces the porosity of the EBC. This is achieved by heating the EBC at a controlled rate, which is specified to be greater than 100 degrees Celsius per minute. After the EBC is treated, an abradable coating is deposited on the heat-treated EBC, which is then subjected to a second heat treatment at a lower controlled rate of less than 15 degrees Celsius per minute. This process ensures that the porosity of the abradable coating is greater than that of the EBC, allowing for improved performance characteristics.
The claims further detail the specific conditions and materials involved in the process. For instance, the heat treatment of the EBC aims to decrease open porosity and microcracks, enhancing the coating's density and hermeticity. The method also allows for the inclusion of fugitive materials in the abradable coating, which can be removed to create open pores. Additionally, both the EBC and the abradable coating may incorporate rare earth monosilicates or disilicates. The patent emphasizes the importance of controlled heating rates to achieve desired porosity levels and structural integrity in the coatings, ultimately contributing to the durability and effectiveness of the ceramic substrates in various applications.
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GlobalData Patent Analytics tracks bibliographic data, legal events data, point in time patent ownerships, and backward and forward citations from global patenting offices. Textual analysis and official patent classifications are used to group patents into key thematic areas and link them to specific companies across the world’s largest industries.
