초록 ▼

A combustion catalyst coating (36) applied to the surface of a ceramic thermal barrier coating (34) which is supported by a metal substrate (32). The microstructure of the thermal barrier coating surface provides the necessary turbulent flow and surface area for interaction of the catalyst and a fue

A combustion catalyst coating (36) applied to the surface of a ceramic thermal barrier coating (34) which is supported by a metal substrate (32). The microstructure of the thermal barrier coating surface provides the necessary turbulent flow and surface area for interaction of the catalyst and a fuel-air mixture in a catalytic combustor of a gas turbine engine. The temperature gradient developed across the thermal barrier coating protects the underlying metal substrate from a high temperature combustion process occurring at the catalyst surface. The thermal barrier coating deposition process may be controlled to form a microstructure having at least one feature suitable to interdict a flow of fuel-air mixture and cause the flow to become more turbulent than if such feature did not exist.

대표청구항 ▼

We claim as our invention: 1. A catalyst element comprising: a substrate having a surface; a thermal barrier coating disposed over the surface of the substrate, the thermal baffler coating having a specific surface area of less than about 18 m2/g and causing an increased amount of catalytic reactio

We claim as our invention: 1. A catalyst element comprising: a substrate having a surface; a thermal barrier coating disposed over the surface of the substrate, the thermal baffler coating having a specific surface area of less than about 18 m2/g and causing an increased amount of catalytic reactions per surface area of the coating per unit flow on the catalytic element; and a combustion catalyst disposed over the thermal barrier coating. 2. The catalyst element of claim 1, further comprising a ceramic wash-coat disposed between the thermal barrier coating and the catalyst. 3. The catalyst element of claim 1, wherein the thermal barrier coating is applied by a plasma spray process. 4. The catalyst element of claim 1, wherein the increased amount of catalytic reactions per surface area is caused by including on a surface of an element selected from the group consisting of: the thermal barrier coating, a bond coating that underlies the thermal barrier coating or the substrate at least one feature suitable to interdict a flow of fuel-air mixture and cause the flow to become more turbulent than if such feature did not exist. 5. The catalyst element of claim 4, wherein the at least one feature comprises a jagged portion. 6. The catalyst element of claim 4, wherein the at least one feature comprises a plurality of features, at least some of the plurality of features selected from the group consisting of peaks, spikes, canyons, bowls, craters, and tunnels. 7. The catalyst element of claim 1, wherein the substrate is a sheet or a tube. 8. The catalyst element of claim 1, wherein the substrate is substantially flat or corrugated. 9. A catalytic combustor comprising: a fuel-air mixing device for producing a fuel-air mixture; a catalytic element disposed downstream of the fuel-air mixing device for receiving the fuel-air mixture, the catalytic element comprising: a substrate; a thermal barrier coating disposed on the substrate, the thermal barrier coating having a specific surface area of less than about 18 m2/g and causing an increased amount of catalytic reactions per surface area of the coating per unit flow on the catalytic element; and a combustion catalyst disposed on the thermal barrier coating for reaching the fuel-air mixture. 10. The catalytic combustor of claim 9, further comprising a ceramic wash-coat disposed between the thermal barrier coating and the catalyst. 11. The catalytic combustor of claim 9, wherein the thermal barrier coating is applied by a plasma spray process. 12. The catalytic combustor of claim 9, wherein the increased amount of catalytic reactions per surface area is caused by including on a surface of an element select from the group consisting of: the thermal barrier coating, a bond coatin that underlies the thermal barrier coating or the substrate at least one feature suitable to interdict a flow of fuel-air mixture and cause the flow to become more turbulent than if such feature did not exist. 13. The catalytic combustor of claim 12, wherein the at least one feature comprises a jagged portion. 14. The catalytic combustor of claim 12, wherein at least one feature comprises a plurality of features, at least one of the plurality of features selected from the group consisting of peaks, spikes, canyons, bowls, canyons, and tunnels. 15. The catalytic combustor of claim 9, wherein the substrate is a sheet or a tube. 16. The catalytic combustor of claim 9, wherein the substrate is substantially flat or corrugated.