# US 12,760,184 B2 · Yttria-stabilized zirconia slurry and methods of application thereof

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- Number: US 12,760,184 B2
- Document ID: US12760184B2
- Status: Granted
- Kind: B2
- Application number: 17/841,861
- Filed: 2022-06-16
- Published: 2023-10-05
- Granted: 2026-10-13
- Earliest claimed: 2022-03-30
- Assignees: General Electric Company
- Applicants: General Electric Company
- Inventors: Atanu Saha; Bernard Patrick Bewlay; Neelesh Nandkumar Sarawate
- Web page: https://patentgrep.com/patent/US12760184B2

## CPC

- C09D 1/00: Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances
- C04B 35/488: Composites
- C04B 35/505: based on yttrium oxide
- C04B 35/6316: {Binders based on silicon compounds}
- C04B 2235/3225: Yttrium oxide or oxide-forming salts thereof
- C04B 2235/3246: Stabilised zirconias, e.g. YSZ or cerium stabilised zirconia
- C04B 2235/5436: micrometer sized, i.e. from 1 to 100 micron
- C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D)
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE

## Abstract

Coated components, along with methods of their formation, are provided. The coating may include a component having a surface and a coating over the surface of the component. The coating may include a first plurality of coarse micrograins having an coarse median grain size of greater than 10 μm to 20 μm, a second plurality of medium micrograins having a medium median grain size of 4 μm to 10 μm, a third plurality of fine micrograins having a fine median grain size of 0.001 μm to less than 4 μm. Each of the coarse micrograins, medium micrograins, and fine micrograins may include, independently, a yttria-stabilized zirconia (YSZ) constituent having a chemical formula of (ZrO2)(1-x)(Y2O3)x with x is from greater than 0 to less than 1.

## Claims

### Claim 1

A coated component comprising:
a component having a surface; and
a coating over the surface of the component, wherein the coating comprises a first plurality of coarse micrograins having an coarse median grain size of greater than 10 μm to 20 μm, a second plurality of medium micrograins having a medium median grain size of 4 μm to 10 μm, a third plurality of fine micrograins having a fine median grain size of 0.001 μm to less than 4 μm, wherein each of the coarse micrograins, medium micrograins, and fine micrograins comprise, independently, a yttria-stabilized zirconia (YSZ) constituent having a chemical formula of (ZrO2)(1-x)(Y2O3)x, wherein x is from greater than 0 to less than 1, wherein the coating extends from an internal surface nearest the surface of the component to an external surface opposite thereof, and wherein the coating has a gradient of the fine micrograins therein such that the fine micrograins have a higher concentration at the internal surface than at the external surface.

### Claim 2 (depends on 1)

The coating of claim 1, wherein the third plurality of fine micrograins further comprise a sintering agent.

### Claim 3 (depends on 1)

The coating of claim 1, wherein the surface of the component comprises a metal, and wherein the coating is directly on the surface or over a bond coat over the surface.

### Claim 4 (depends on 1)

The coating of claim 1, wherein the coating further comprises silica.

### Claim 5 (depends on 1)

The coating of claim 1, wherein the coating has a porosity of 10 vol. % to 80 vol. %.

### Claim 6 (depends on 1)

The coating of claim 1, wherein the coating extends from an internal surface nearest the surface of the component to an external surface opposite thereof, and wherein the coating has a gradient of porosity therein such that the coating has a higher porosity at the external surface than at the internal surface.

### Claim 7 (depends on 1)

The coating of claim 1, wherein the first plurality of coarse particles comprises a first yttria-stabilized zirconia (YSZ) constituent having a chemical formula of (ZrO2)(1-x)(Y2O3)x, wherein x is from greater than 0 to less than 1.

### Claim 8 (depends on 1)

The coating of claim 1, wherein the second plurality of medium particles comprises a second yttria-stabilized zirconia (YSZ) constituent having a chemical formula of (ZrO2)(1-x)(Y2O3)x, wherein x is from greater than 0 to less than 1.

### Claim 9 (depends on 1)

The coating of claim 1, wherein the third plurality of fine particles comprises a third yttria-stabilized zirconia (YSZ) constituent having a chemical formula of (ZrO2)(1-x)(Y2O3)x, wherein x is from greater than 0 to less than 1.

### Claim 10

A method for coating a surface of a component using an yttria-stabilized zirconia slurry, the method comprising:
applying the yttria-stabilized zirconia slurry on an exposed portion of the surface of the component, the yttria-stabilized zirconia slurry comprising:
a carrier fluid;
a binder material within the carrier fluid;
a first plurality of coarse particles dispersed within the carrier fluid and having a coarse median particle average size of greater than 10 μm to 20 μm;
a second plurality of medium particles dispersed within the carrier fluid and having a medium median particle size of 4 μm to 10 μm; and
a third plurality of fine particles dispersed within the carrier fluid and having a fine median particle size of 0.001 μm to less than 4 μm,
wherein each of the coarse particles, medium particles, and fine particles comprise, independently, a yttria-stabilized zirconia (YSZ) constituent having a chemical formula of (ZrO2)(1-x)(Y2O3)x, wherein x is from greater than 0 to less than 1, wherein the coating extends from an internal surface nearest the surface of the component to an external surface opposite thereof, and wherein the coating has a gradient of the fine micrograins therein such that the fine micrograins have a higher concentration at the internal surface than at the external surface.

### Claim 11 (depends on 10)

The method of claim 10, wherein the yttria-stabilized zirconia slurry is applied at an application temperature of 5° C. to 100° C.

### Claim 12 (depends on 10)

The method of claim 10, wherein the yttria-stabilized zirconia slurry is applied to a coating thickness of 1 μm to 3,000 μm.

### Claim 13 (depends on 10)

The method of claim 10, wherein the first plurality of coarse particles, the second plurality of medium particles, and the third plurality of fine particles form a multimodal distribution comprising greater than 0 vol. % to 50 vol. % of the coarse particles, from 40 vol. % to 90 vol. % of the medium particles, and from 10 vol. % to 40 vol. % of the fine particles.

### Claim 14 (depends on 13)

The method of claim 13, wherein the multimodal distribution has a coarse-to-medium particle size ratio from 2 to 4, and wherein the multimodal distribution has a medium-to-fine particle size ratio from 5 to 10.

### Claim 15 (depends on 10)

The method of claim 10, wherein the third plurality of fine particles further comprise a sintering agent.

### Claim 16 (depends on 10)

The method of claim 10, further comprising:
prior to applying the yttria-stabilized zirconia slurry on the exposed portion of the surface of the component, applying a mask material over a portion of the surface of the component leaving the exposed portion uncovered; and
after applying the yttria-stabilized zirconia slurry on the exposed portion of the surface of the component, removing the mask material from the portion of the surface.

### Claim 17 (depends on 10)

The method of claim 10, wherein the binder material is solubilized within the carrier fluid.

### Claim 18 (depends on 10)

The method of claim 10, further comprising:
after applying the yttria-stabilized zirconia slurry on the exposed portion of the surface of the component, allowing the carrier fluid to evaporate to form a dried coating on the exposed portion of the component.