Gap-filling sealing layer of thermal barrier coating

Abstract

A multi-layer thermal barrier coating is provided that includes an insulating layer having an outer surface defining a plurality of crevices therein and a sealing layer bonded to the outer surface of the insulating layer. The sealing layer is substantially non-permeable and is configured to seal against the insulating layer. The sealing layer fills in at least a portion of the crevices. A method of forming a thermal barrier coating is also provided, which includes a step of providing a plurality of hollow round microstructures bonded together, each having a diameter in the range of 10 to 100 microns to create an insulating layer. The method further includes depositing a plurality of metal particles onto the insulating layer and heating the plurality of metal particles to form a substantially non-permeable sealing layer over the insulating layer.

Dependencies are inferred from the claim text.