Thermal barrier coatings and processes
AssigneeOerlikon Metco (US) Inc.
InventorsDianying Chen, Christopher G. Dambra, Mitchell R. Dorfman
Life of this patent
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Abstract
Articles coated with a porous, segmented thermal barrier coating. The coating described has a density less than about 88% of the theoretical density. Multi-layer articles and methods of applying the thermal barrier coatings to an article are also described.
Claims2
An article coated with a porous, segmented strain tolerant yttria stabilized zirconia (YSZ) thermal barrier coating applied by plasma spraying a spray dried YSZ spherical powder material having a bimodal distribution of 75 weight percent plasma densified material with a particle size range of 11 μm to 75 μm and 25 weight percent spray dried material with a particle size range of 75 μm to 180 μm, wherein the YSZ thermal barrier coating comprises:
- a density ranging between 4.2 g/cc and 4.9 g/cc;
- portions formed from fully melted splats;
- portions formed from partially melted and un-melted particles;
- and
- between 5 and 60 vertical macrocracks per linear inch.
An article coated with a porous, segmented strain tolerant thermal barrier coating applied by plasma spraying a spray dried powder material having a bimodal distribution of 75 weight percent plasma densified material with a particle size range of 11 μm to 75 μm and 25 weight percent spray dried material with a particle size range of 75 μm to 180 μm, wherein the coating comprises:
- a density ranging from 3.0 g/cc to 5.5 g/cc;
- portions formed from fully melted splats;
- portions formed from partially melted and un-melted particles;
- and
- between 5 and 60 vertical macrocracks per linear inch,
- wherein the coating comprises zirconium oxide stabilized with one or more of yttria and ytterbia.
Dependencies are inferred from the claim text.