Methods for manufacturing porous barrier coatings using air plasma spray techniques
AssigneeHoneywell International Inc.
InventorsBradley Lutz, David Jorgensen
Life of this patent
Estimating the term…
Abstract
A method for forming a porous barrier coating on a substrate without substantial chemical segregation includes the steps of providing or obtaining a barrier coating material in powdered form and spraying the barrier coating material onto the substrate using air plasma spraying. The air plasma spraying is performed using an average homologous surface temperature of the depositing particles in a range of about 1.25 to about 1.5 and a particle velocity in a range of about 300 m/s to about 500 m/s. The depositing particles are fully molten.
Claims18
A method for forming a porous barrier coating on a substrate without substantial chemical segregation, the method comprising the steps of:
- providing or obtaining a barrier coating material in powdered form;
- and spraying the barrier coating material onto the substrate using air plasma spraying to form the porous barrier coating,
- wherein the air plasma spraying is performed using an average homologous surface temperature of the depositing particles in a range of about 1.25 to about 1.5 and a particle velocity in a range of about 300 m/s to about 500 m/s,
- wherein the depositing particles are fully molten, and
- wherein the porous barrier coating has a porosity of from about 10 to about 15%.
A method for forming a porous low-k thermal barrier coating on a turbine engine substrate without substantial chemical segregation, the method comprising the steps of:
- providing or obtaining a low-k thermal barrier coating material in powdered form, wherein the low-k thermal barrier coating material comprises a multi-component ceramic oxide with one or more rare-earth metals;
- and
- spraying the low-k thermal barrier coating material onto the turbine engine substrate using air plasma spraying to form the porous low-k thermal barrier coating,
- wherein the air plasma spraying is performed using an average homologous surface temperature of the depositing particles in a range of about 1.25 to about 1.5 and a particle velocity in a range of about 300 m/s to about 500 m/s, and
- wherein the depositing particles are fully molten, and
- wherein the porous low-k thermal barrier coating has a porosity of from about 10 to about 15%.
Dependencies are inferred from the claim text.