Ceramic material for high temperature service
AssigneeOerlikon Metco (US) Inc.
InventorsJacobus Doesburg, Mitchell Dorfman, Matthew Gold, Liangde Xie
Life of this patent
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Abstract
A high purity yttria or ytterbia stabilized zirconia powder wherein a purity of the zirconia is at least 99.5 weight percent purity and with a maximum amount of specified oxide impurities.
Claims20
A high purity yttria or ytterbia stabilized zirconia powder having a purity of at least 99.5 weight percent purity and a maximum amount of oxide impurities is as follows:
- less than 0.005 weight percent SiO2;
- less than 0.015 weight percent Al2O3;
- less than 0.002 weight percent TiO2;
- and
- less than 0.002 weight percent MgO.
A high purity yttria or ytterbia stabilized hafnia powder having a purity of at least 99.5 weight percent purity and a maximum amount of oxide impurities is as follows:
- less than 0.002 weight percent Na2O;
- less than 0.005 weight percent SiO2;
- less than 0.015 weight percent Al2O3;
- less than 0.002 weight percent TiO2;
- less than 0.04 weight percent Fe2O3;
- less than 0.02 weight percent CaO;
- less than 0.002 weight percent MgO;
- and
- less than 0.001 weight percent Cr2O3.
A high purity yttria stabilized zirconia powder comprising:
- a purity of at least 99.5 weight percent purity, less than about 0.005 weight percent silicon dioxide (silica), less than about 0.015 weight percent aluminum oxide (alumina), less than about 0.02 weight percent calcium oxide, less than about 0.04 weight percent ferric oxide, less than about 0.002 weight percent magnesium oxide, and less than about 0.002 weight percent titanium dioxide.
A method of coating a substrate with a thermal barrier coating (TBC) on a substrate via thermal spray, the method comprising:
- spraying a powder coating material comprising a yttria stabilized material comprising zirconia and hafnia and a purity of at least 99.5 weight percent and total impurities of said powder coating material comprises less than or equal to:
- about 0.005 weight percent silica, about 0.002 weight percent titania, and about 0.002 weight percent magnesia;
- and
- forming a TBC coating by depositing the coating material in the form of a collection of frozen droplets or splats,
- wherein the TBC coating comprises vertical cracks arranged at repeating intervals and extending in a thickness direction of said thermal barrier coating.
A high purity yttria stabilized zirconia and/or hafnia coating material with a purity of at least 99.5 weight percent purity and a maximum amount of oxide impurities is as follows:
- less than 0.005 weight percent SiO2;
- less than 0.015 weight percent Al2O3;
- less than 0.002 weight percent TiO2;
- and
- less than 0.002 weight percent MgO.
Dependencies are inferred from the claim text.