# US 2014/0193760 A1 · Coated article, process of coating an article, and method of using a coated article > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2014/0193760 A1 - Document ID: US20140193760A1 - Status: Published application - Kind: A1 - Application number: 13/737,104 - Filed: 2013-01-09 - Published: 2014-07-10 - Earliest claimed: 2013-01-09 - Assignees: General Electric Company - Applicants: General Electric Company - Inventors: Warren Arthur NELSON; Yuk-Chiu LAU; Tamara Jean RUSSELL; Joshua Lee MARGOLIES - Web page: https://patentgrep.com/patent/US20140193760A1 ## CPC - C23C 4/02: Pretreatment of the material to be coated, e.g. for coating on selected surface areas - C23C 4/11: Oxides - C23C 4/18: After-treatment - Y10T 428/24942: including components having same physical characteristic in differing degree - Y10T 428/249953: Composite having voids in a component [e.g., porous, cellular, etc.] - 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 coated article, a process of coating an article, and a process of using an article are disclosed. The coated article includes a substrate, a porous coating material, and a thermal barrier coating material. The porous coating material includes a porosity between about 1 percent and about 20 percent, by volume. The thermal barrier coating material has a thermal conductivity that is lower than a thermal conductivity of the substrate. The porous coating material differs in one or both of composition and microstructure from the thermal barrier coating material. Additionally or alternatively, the porous coating material resists at least one of sintering, densification, and phase destabilization for a predetermined period at a predetermined temperature. The process of coating an article includes applying a coating to form the coated article. ## Claims ### Claim 1 A coated article, comprising: a substrate; a porous coating material positioned proximal to the substrate in comparison to a thermal barrier coating material; and the thermal barrier coating material positioned distal from the substrate in comparison to the porous coating material; wherein the porous coating material includes a porosity between about 1 percent and about 20 percent, by volume; wherein the thermal barrier coating material has a thermal conductivity that is lower than a thermal conductivity of the substrate; wherein the porous coating material differs from the thermal barrier coating material in one or both of composition and microstructure. ### Claim 2 (depends on 1) The coated article of claim 1, wherein the thermal barrier coating material includes a rare-earth zirconate. ### Claim 3 (depends on 1) The coated article of claim 1, wherein the porous coating material is substantially devoid of rare-earth metals. ### Claim 4 (depends on 1) The coated article of claim 1, wherein the porous coating material is substantially devoid of rare-earth zirconates. ### Claim 5 (depends on 1) The coated article of claim 1, wherein the porous coating material resists at least one of sintering, densification, and phase destabilization for a predetermined exposure period at a predetermined temperature. ### Claim 6 (depends on 1) The coated article of claim 1, wherein the porous coating material includes yttria stabilized zirconia. ### Claim 7 (depends on 1) The coated article of claim 1, wherein the porous coating material includes tantalum oxide stabilized material, MgO, CaO, CeO, or a combination thereof ### Claim 8 (depends on 1) The coated article of claim 1, wherein the porous coating material includes nano-structures. ### Claim 9 (depends on 1) The coated article of claim 1, wherein the thermal barrier coating material includes, by weight, about 68.9 percent Yb2O3, incidental impurities, and a balance ZrO2. ### Claim 10 (depends on 1) The coated article of claim 1, wherein the thermal barrier coating includes a porosity of less than about 5 percent. ### Claim 11 (depends on 1) The coated article of claim 1, further comprising a bond coat material positioned between the porous coating material and the substrate. ### Claim 12 (depends on 11) The coated article of claim 11, wherein the bond coat material includes MCrAlY. ### Claim 13 (depends on 11) The coated article of claim 11, further comprising a dense vertically cracked thermal barrier coating material. ### Claim 14 (depends on 13) The coated article of claim 13, wherein the dense vertically cracked thermal barrier coating material includes yttria stabilized zirconia. ### Claim 15 (depends on 1) The coated article of claim 1, wherein one or both of the thermal barrier coating material and the porous coating material are applied by air plasma spray, high-velocity oxy-fuel spray, electron beam physical vapor deposition, or a combination thereof. ### Claim 16 (depends on 1) The coated article of claim 1, wherein the thermal barrier coating material includes by weight, about 20 percent Y2O3, incidental impurities, and a balance ZrO2. ### Claim 17 (depends on 1) A process of applying the coating of claim 1. ### Claim 18 (depends on 1) A process of using the coating of claim 1, wherein the porous coating material is at least partially subjected to a temperature of about 2200° F. for a period of about 16,000 hours, wherein the porous coating material resists at least one of sintering, densification, and phase destabilization. ### Claim 19 A coated article, comprising: a substrate; a porous coating material positioned proximal to the substrate in comparison to a thermal barrier coating material; and the thermal barrier coating material positioned distal from the substrate in comparison to the porous coating material; wherein the porous coating material includes a porosity between about 1 percent and about 20 percent, by volume; wherein the thermal barrier coating material has a thermal conductivity that is lower than a thermal conductivity of the substrate; wherein the porous coating material differs in composition from the thermal barrier coating material. ### Claim 20 A coated article, comprising: a substrate; a porous coating material positioned proximal to the substrate in comparison to a thermal barrier coating material; and the thermal barrier coating material positioned distal from the substrate in comparison to the porous coating material; wherein the porous coating material resists at least one of sintering, densification, and phase destabilization for a period of about 16,000 hours at a temperature of about 2200° F.