# US 2008/0166574 A1 · Insulating material capable of withstanding cyclically varying high temperatures

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- Number: US 2008/0166574 A1
- Document ID: US20080166574A1
- Status: Published application
- Kind: A1
- Application number: 11/897,260
- Filed: 2007-08-28
- Published: 2008-07-10
- Earliest claimed: 2006-08-29
- Assignees: FNE Forschungsinstitut fuer Nichteisen-Metalle Freiberg GmbH
- Inventors: Heino Pachschwoell; Joachim Klose; Christiane Rothe; Stefan Jonas; Thomas Stolte
- Web page: https://patentgrep.com/patent/US20080166574A1

## CPC

- C04B 35/488: Composites
- C23C 4/02: Pretreatment of the material to be coated, e.g. for coating on selected surface areas
- C23C 4/11: Oxides
- C23C 28/3215: {at least one MCrAlX layer}
- C23C 28/345: {with at least one oxide layer}
- C23C 28/3455: {with a refractory ceramic layer, e.g. refractory metal oxide, ZrO2, rare earth oxides or a thermal barrier system comprising at least one refractory oxide layer}
- C04B 2235/3215: Barium oxides or oxide-forming salts thereof
- C04B 2235/3225: Yttrium oxide or oxide-forming salts thereof
- C04B 2235/3248: Zirconates or hafnates, e.g. zircon
- C04B 2235/80: Phases present in the sintered or melt-cast ceramic products other than the main phase
- Y10T 428/31678: Of metal
- 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
- C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A heat insulation material based on ceramic material includes a top layer containing BaZrO3 and Y2O3 doped ZrO2 A heat insulation material preferably consists of at least one adhesion promotion layer, at least one intermediate layer arranged thereon and a top layer arranged thereon, with the adhesion promotion layer consisting of MeCrAlY, where Me is nickel and/or cobalt, the intermediate layer consists of Y2O3 doped ZrO2 and the top layer consists of 15 to 25% by weight BaZrO3 and 75 to 85% by weight Y2O3 doped ZrO2. A method of coating a substrate with a heat insulation material includes the step of applying an aforesaid top layer to an optionally coated substrate by a thermal spray method or an electron beam method, in particular an EB-PVD method.

## Claims

### Claim at position 1

1-20. (canceled)

### Claim at position 2

21: A heat insulation material on the basis of ceramic material comprising a top layer (4) containing BaZrO3 and Y2O3 doped ZrO2.

### Claim at position 3 (depends on 21)

22: A heat insulation material in accordance with claim 21, wherein the top layer (4) consists of BaZrO3 and Y2O3 doped ZrO2.

### Claim at position 4 (depends on 21)

23: A heat insulation material in accordance with claim 21, wherein the top layer (4) contains or consists of 10 to 50% by weight BaZrO3 and 50 to 90% by weight Y2O3 doped ZrO2.

### Claim at position 5 (depends on 21)

24: A heat insulation material in accordance with claim 21, wherein the top layer (4) consists of 20% by weight BaZrO3 and 80% by weight Y2O3 doped ZrO2.

### Claim 25 (depends on 21)

A heat insulation material in accordance with claim 21, wherein the top layer (4) contains or consists of 15 to 25% by weight BaZrO3 and 75 to 85% by weight Y2O3 doped ZrO2.

### Claim at position 7 (depends on 21)

26: A heat insulation material in accordance with claim 21, wherein the top layer (4) consists of 20% by weight BaZrO3 and 80% by weight Y2O3 doped ZrO2.

### Claim at position 8 (depends on 21)

27: A heat insulation material in accordance with claim 21, including at least one adhesion promotion layer (2) and, optionally, at least one intermediate layer (3) arranged between the adhesion promotion layer (2) and the top layer (4).

### Claim at position 9 (depends on 27)

28: A heat insulation material in accordance with claim 27, wherein the at least one adhesion promotion layer (2) contains MeCrAlY, where Me is nickel and/or cobalt.

### Claim at position 10 (depends on 28)

29: A heat insulation material in accordance with claim 28, wherein the at least one adhesion promotion layer (2) consists of MeCrAlY, where Me is nickel and/or cobalt.

### Claim at position 11 (depends on 27)

30: A heat insulation material in accordance with claim 27, wherein the at least one intermediate layer (3) contains Y2O3 doped ZrO2.

### Claim at position 12 (depends on 30)

31: A heat insulation material in accordance with claim 30, wherein the at least one intermediate layer (3) consists of Y2O3 doped ZrO2.

### Claim at position 13

32: A heat insulation material consisting of at least one adhesion promotion layer (2), at least one intermediate layer (3) arranged thereon and a top layer (4) arranged thereon, with the adhesion promotion layer (2) consisting of MeCrAlY, where Me is nickel and/or cobalt, the intermediate layer (3) consists of Y2O3 doped ZrO2 and the top layer (4) consists of 15 to 25% by weight BaZrO3 and 75 to 85% by weight Y2O3 doped ZrO2.

### Claim at position 14

33: A method of coating a substrate (1) with a heat insulation material including the step of applying a top layer (4) containing or consisting of BaZrO3 and Y2O3 doped ZrO2 to an optionally coated substrate (1) by one of a thermal spray method, an electron beam method, high velocity flame spraying and plasma spraying.

### Claim at position 15

34: A method of coating a substrate (1) with a heat insulation material consisting of at least one adhesion promotion layer (2), at least one intermediate layer (3) arranged thereon and a top layer (4) arranged thereon, with the adhesion promotion layer (2) consisting of MeCrAlY, where Me is nickel and/or cobalt, the intermediate layer (3) consists of Y2O3 doped ZrO2 and the top layer (4) consists of 15 to 25% by weight BaZrO3 and 75 to 85% by weight Y2O3 doped ZrO2, the method including the step of applying the top layer (4) to an optionally coated substrate (1) by a thermal spray method or an electron beam method.

### Claim at position 16 (depends on 33)

35: A method in accordance with claim 33, wherein BaZrO3 in powder form and Y2O3 doped ZrO2 in powder form are mixed with one another before the application of the top layer (4) and this powder mixture is applied to the optionally coated substrate (1) by a thermal spray method or an electron beam method.

### Claim at position 17 (depends on 34)

36: A method in accordance with claim 34, wherein BaZrO3 with a grain size between 1 and 2 μm and/or Y2O3 doped ZrO2 with a grain size between 5 and 25 μm is/are used to manufacture the powder mixture.

### Claim at position 18 (depends on 34)

37: A method in accordance with claim 34, wherein the BaZrO3 is pressed to form a pressed body, using a bonding aid, and is sintered to form a solid ceramic material before the mixing with the Y2O3 doped ZrO2 before the ceramic material obtained in this manner is prepared as a powder with a grain size between 10 and 125 μm by means of a jaw crusher and/or a ball mill.

### Claim at position 19 (depends on 33)

38: A method in accordance with claim 33, wherein the substrate (1) is an Al piston alloy or an Ni-based super alloy.

### Claim at position 20 (depends on 33)

39: A method in accordance with claim 33, wherein the substrate (1) is coated with an adhesion promotion layer (2), and optionally an intermediate layer (3) arranged thereon, before the application of the top layer (4).

### Claim at position 21 (depends on 39)

40: A method in accordance with claim 39, wherein the adhesion promotion layer (2) consists of MeCrAlY, where Me is nickel and/or cobalt.

### Claim at position 22 (depends on 39)

41: A method in accordance with claim 39, wherein the intermediate layer (3) consists of Y2O3 doped ZrO2.

### Claim at position 23 (depends on 39)

42: A method in accordance with claim 39, wherein the adhesion promotion layer (2) and/or the intermediate layer (3) is/are applied to the substrate (1) by a thermal spray method or an electronic beam method, preferably by plasma spraying.