Thermal barrier coating, turbine member, and gas turbine
AssigneeMitsubishi Heavy Industries, Ltd.
InventorsShuji Tanigawa, Masahiko Mega, Taiji Torigoe, Yoshifumi Okajima, Daisuke Kudo
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Abstract
A thermal barrier coating includes a highly porous layer and a dense layer. The highly porous layer is formed on a heat-resistant base, is made of ceramic, has pores, has a layer thickness of equal to or larger than 0.3 mm and equal to or smaller than 1.0 mm, and has a pore ratio of equal to or higher than 1 vol % and equal to or lower than 30 vol %. The dense layer is formed on the highly porous layer, is made of ceramic, has a pore ratio of equal to or lower than 0.9 vol % that is equal to or lower than the pore ratio of the highly porous layer, and has a layer thickness of equal to or smaller than 0.05 mm.
Claims16
A thermal barrier coating comprising:
- a highly porous layer formed on a heat-resistant base, the highly porous layer being made of ceramic;
- and having pores, the highly porous layer having a layer thickness of equal to or larger than 0.3 mm and equal to or smaller than 1.0 mm, and having a pore ratio of equal to or higher than 1 vol % and equal to or lower than 30 vol %, the highly porous layer being made of an ytterbia-stabilized zirconia material;
- a dense layer formed on the highly porous layer, the dense layer having a pore ratio of equal to or lower than 0.9 vol % that is lower than the pore ratio of the highly porous layer, and the dense layer having a layer thickness of equal to or smaller than 0.05 mm and being made of an ytterbia-stabilized zirconia material or an yttria-stabilized zirconia material;
- and
- a molten layer formed on the dense layer by melting a portion of the dense layer;
- wherein a thickness of the dense layer remaining under the molten layer is equal to or larger than 0.01 mm, and the molten layer has a thickness of equal to or larger than the thickness of the dense layer and no greater than 0.04 mm.
A method of producing a thermal barrier coating comprising:
- forming a highly porous layer on a heat-resistant base by atmospheric plasma spraying, the highly porous layer being made of ceramic and having pores, the highly porous layer having a layer thickness of equal to or larger than 0.3 mm and equal to or smaller than 1.0 mm, and having a pore ratio of equal to or higher than 1 vol % and equal to or lower than 30 vol %;
- forming a dense layer on the highly porous layer by atmospheric plasma spraying, cold spraying method, or an aerosol deposition method, the dense layer being made of ceramic and having a pore ratio of equal to or lower than 0.9 vol % that is lower than the pore ratio of the highly porous layer, and the dense layer having a layer thickness of equal to or smaller than 0.05 mm;
- melting a portion of the dense layer to form a molten layer on the dense layer;
- wherein a thickness of the dense layer remaining under the molten layer is equal to or larger than 0.01 mm, and the molten layer has a thickness of equal to or larger than the thickness of the dense layer and no greater than 0.04 mm.
Dependencies are inferred from the claim text.