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US 2015/0147524 A1Published application
Modified thermal barrier composite coatings
OwnerChristopher A. Petorakinventor
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Abstract
A novel coating system is provided that allows for a single coating structure to exhibit properties previously considered mutually exclusive. A unique approach for tailoring specific properties of a coating structure as a function of location within the coating is provided with a specially designed undercoat having a columnar macrostructure and a second coating layer that is selected to be compatible with and complement the undercoat. The resultant composite coating system can maintain thermocomechanical compliance while improving various bulk and/or free surface properties of the composite coating system.
Claims21
A thermal barrier modified composite coating, comprising:
- a first coating layer bonded to a surface of a substrate, said first coating layer comprising macro columnar features characterized by a predetermined distribution of peaks and valleys at their corresponding free surfaces to create improved mechanical bonding between the first layer and a second layer;
- said columnar features derived from a precursor liquid suspension of nano-sized and/or submicron-sized splats to form a thermomechanical compliant interface at the substrate surface, said splats being randomly oriented to produce an isotropic crystallographic orientation for the first coating;
- said splats comprising non-equiaxed columnar grains that grow opposite to a direction of heat flow upon cooling to produce an anisotropic crystallographic grain orientation;
- and wherein said second coating layer is bonded to the corresponding free surfaces of the first coating layer, said second coating layer at the bulk and/or free surface having at least one improved coating property in comparison to the first coating layer.
1 more element
A thermal barrier modified composite coating, comprising:
- a first coating layer bonded to a surface of a smooth substrate, said first coating layer having a size less than about 10 μm;
- said first coating layer comprising macro columnar features characterized by a predetermined distribution of peaks and valleys at their corresponding free surfaces to create improved mechanical bonding between the first layer and a second layer;
- said columnar features derived from a precursor liquid suspension of nano-sized and/or submicron-sized splats to form a thermomechanical compliant interface at the substrate surface, said splats being randomly oriented to produce an isotropic crystallographic orientation for the first coating;
- said splats comprising non-equiaxed columnar grains that grow opposite to a direction of heat flow upon cooling to produce an anisotropic crystallographic grain orientation;
- and
- said second layer comprising a densified coating layer bonded to the corresponding free surfaces of the first coating layer, said densified coating having a lower porosity than that of the first coating layer, said densified coating having an improved mechanical erosion barrier in comparison to the first coating layer.
3 more elements
A thermal barrier modified composite coating, comprising:
- a first coating layer bonded to a surface of a smooth substrate, said first coating layer having a size less than about 10 μm;
- said first coating layer comprising macro columnar features characterized by a predetermined distribution of peaks and valleys at their corresponding free surfaces to create improved mechanical bonding between the first layer and a second layer;
- said columnar features derived from a precursor liquid suspension of nano-sized and/or submicron-sized splats to form a thermomechanical compliant interface at the substrate surface, said splats being randomly oriented to produce an isotropic crystallographic orientation for the first coating;
- said splats comprising non-equiaxed columnar grains that grow opposite to a direction of heat flow upon cooling to produce an anisotropic crystallographic grain orientation;
- and
- said second layer comprising a densified coating layer bonded to the corresponding free surfaces of the first coating layer, said densified coating having a lower porosity than that of the first coating layer, said densified coating derived from a dry powder applied by atmospheric spraying, said coating comprising partially molten and fully molten particles having an improved mechanical erosion barrier in comparison to the first coating layer.
3 more elements
Dependencies are inferred from the claim text.