Method of forming a thermal barrier coating system with engineered surface roughness
AssigneesSiemens Energy, Inc., Mikro Systems, Inc.
InventorsAndrew J. Burns, Gary B. Merrill, John Paulus
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Abstract
A method of manufacturing a substrate (16) with a ceramic thermal barrier coating (28, 32). The interface between layers of the coating contains an engineered surface roughness (12, 24) to enhance the mechanical integrity of the bond there between. The surface roughness is formed in a surface of a mold (10,20) and is infused by a subsequently cast layer of material (16, 28). The substrate may be partially sintered (76) prior to application of the coating layer(s) and the coated substrate and coating layer(s) may be co-sintered to form a fully coherent strain-free interlayer.
Claims12
A thermally insulated component comprising:
- a green body comprising a first powder, the green body defining a first surface that:
- is integral to the green body;
- substantially surrounds the green body;
- and
- defines a first engineered surface roughness characteristic within a first region of the first surface;
- a coating that:
- comprises a second powder;
- coats the first surface;
- defines a second surface;
- and
- defines a second engineered surface roughness characteristic;
- and
- a ceramic insulating material that:
- coats the second surface;
- and
- defines third surface.
A thermally insulated component comprising:
- a green body comprising a first powder comprising a metallic alloy, the green body defining a first surface that is integral to the green body, substantially surrounds the green body and defines a first engineered surface roughness characteristic within a first region of the first surface;
- a coating that comprises a second powder comprising a bond coat material, coats the first surface, defines a second surface and defines a second engineered surface roughness characteristic;
- and
- a ceramic insulating material that coats the second surface and defines third surface.
Dependencies are inferred from the claim text.