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1. Field of the Invention
This invention relates generally to gas turbines, and more particularly to a thermal barrier coating for use on turbine airfoils.
2. Description of the Prior Art
A gas turbine engine typically includes a compressor section, a combustor section, and a turbine section. Air entering the compressor section is compressed and delivered into the combustion section where it is mixed with fuel and ignited to generate a high-speed exhaust gas flow. The high-speed gas flow expands through the turbine section to drive the compressor and the engine.
The turbine section includes a plurality of stages of stator vanes and rotor blades. The vanes and blades typically include an airfoil that extends radially outwardly from a platform. The airfoil may include a tip that includes a tip region, a first shoulder region, and a second shoulder region. The tip region includes a fillet and an included angle.
As the gas turbine engine operates, the tips of the airfoils may be exposed to extremely high temperatures. The tip region of the airfoil is susceptible to extreme temperatures due to its close proximity to the combustor and its direct exposure to high temperature gas flow. Thus, the tip region may experience excessive thermal growth and oxidation. This results in high wear and potential failure of the airfoil.
A thermal barrier coating (TBC) is typically applied to the airfoil in the tip region to reduce the temperature of the tip region. The TBC is applied to the airfoil as an outermost layer, and it forms a bond with the airfoil and does not use mechanical fasteners. Thus, the TBC is exposed to the most severe heat environments.
One type of TBC includes multiple layers including an inner bond coat layer, a middle thermal-insulating ceramic layer, and an outer bond coat layer. The TBC typically includes two bond coat layers. The bond coat layers include diffusion bonding, high-velocity air thermal spraying, plasma spray, or electron beam spraying. The TBC may also include a low-velocity thermal spray. One or more bond coat layers and a thermal-insulating ceramic layer