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US 2015/0030871 A1Published application
Functionally graded thermal barrier coating system
OwnerGerald J. Bruck, Ahmed Kamelinventors
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Abstract
A functionally graded thermal barrier coating (30) formed as a plurality of layers (34, 36 . . . 44, 46) of materials deposited by a powder deposition process wherein the composition of the various layers changes across a thickness of the coating. A composition gradient may exist within a single layer (58) due to the buoyancy of ceramic particles (62) within a melt pool (56) of bond coat material (64). The powder deposition process includes powdered flux material (20) which melts to form a protective layer of slag (28) during the deposition process.
Claims20
A method comprising:
- depositing powder comprising particles of a bond coat material and particles of a flux material onto a substrate;
- melting the powder with an energy beam to form a layer of melted bond coat material covered by a layer of slag on the substrate;
- allowing the melted bond coat material to cool and solidify under the layer of slag to form a coating on the substrate;
- and
- removing the layer of slag.
2 more elements
An apparatus comprising:
- a superalloy substrate;
- a thermal barrier coating disposed on the substrate, the thermal barrier coating further comprising:
- a first region relatively more proximate the substrate comprising a bond coat material but no ceramic material;
- and
- a second region relatively more remote from the substrate comprising the bond coat material and a gradient concentration of a ceramic material, wherein the gradient concentration of the ceramic material relative to the bond coat material increases in a thickness direction away from the substrate.
2 more elements
An apparatus comprising:
- a superalloy substrate;
- a coating disposed on the substrate;
- the coating comprising a plurality of layers of material, the layers changing in proportion of superalloy material to bond coat material from a relatively higher concentration of superalloy material in a first layer to a relatively higher concentration of bond coat material in a second layer more remote from the substrate than the first layer.
Dependencies are inferred from the claim text.