Thermal spray coating of porous nanostructured ceramic feedstock
OwnerRogerio S. Lima, Basil R. Marple +1inventors
InventorsRogerio S. Lima, Basil R. Marple, Christian Moreau
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Abstract
By engineering thermal spray parameters, such as temperature and velocity, and engineering feedstock powder size and morphology, ceramic coatings may be produced having desired mechanical and thermal properties. The ceramic thermal spray coating may have a microstructure having about 10-80% by cross-sectional area of a particulate phase based on surface area of the coating, and the particulate phase is uniformly distributed throughout the coating. The particulate phase is an unmelted portion of the thermal sprayed feedstock, which is highly porous and may be produced by agglomerating nanoparticles of the ceramic. Such coatings can be applied as TBCs or as abradable coatings.
Claims21
A method for producing a coating on a substrate, the method comprising:
- obtaining a ceramic powder of high porosity particles;
- collecting from the ceramic powder particles within a selected size distribution;
- and
- thermal spraying the collected particles while controlling parameters of the thermal spray to impart temperatures and velocities on the collected particles, wherein the selected size distribution, and imparted temperatures and velocities ensure that a core of the collected particles are not melted,
- whereby a coating is produced having a uniform distribution of porous nanostructured inclusions.
A ceramic coating with a microstructure having about 10-80% by cross-sectional area of porous nanostructured microzones distributed uniformly throughout.
A thermal barrier coating comprising a ceramic material with a microstructure having about 10-80% by cross-sectional area of porous nanostructured inclusions distributed uniformly throughout.
An abradable ceramic coating comprising a ceramic material, the coating having a microstructure comprising about 10-50% by area, based on surface area of a cross-section of the coating, of a particulate phase comprising agglomerated ceramic nanoparticles of the ceramic material.
Dependencies are inferred from the claim text.