Segmented abradable ceramic coating

A segmented abradable ceramic coating system having enhanced abradability, the system comprising a duct segment including:

• a metallic substrate;
• a MCrAlY bond coat on the substrate;
• and
• a segmented abradable ceramic coating on the MCrAlY bond coat, said segmented abradable ceramic coating consisting essentially of three ceramic layers which include:
• i) a base coat foundation layer deposited on the bond coat, said base coat foundation layer comprising a ceramic layer of material selected from the group consisting of zirconia stabilized with ceria, zirconia stabilized with magnesia, zirconia stabilized with calcia, zirconia stabilized with yttria and mixtures thereof,
• ii) an interlayer deposited on the base coat foundation layer, and
• iii) an abradable top layer deposited on the interlayer, said abradable top layer comprising zirconia,
• wherein said interlayer is a compositional blend of the base coat foundation layer and the abradable top layer,
• said segmented abradable ceramic coating having at least four vertical microcracks per inch, wherein the three ceramic layers are deposited in one continuous spray process using powder particles which are spherical and hollow for increased abradability.

A segmented abradable ceramic coating having a base coat foundation layer, an interlayer and an abradable top layer, said segmented abradable ceramic coating comprising:

• the base coat foundation layer of a ceramic layer between about 5 mils (0.127 mm) and about 15 mils (0.381 mm) thick, said base coat foundation layer comprising between about 7 weight percent and about 12 weight percent yttria stabilized zirconia;
• the interlayer between about 3 mils (0.076 mm) and about 10 mils (0.254 mm) thick on the base coat foundation layer, said interlayer comprising a compositional blend of the base coat foundation layer and the abradable top layer;
• and
• the abradable top layer between about 15 mils (0.381 mm) and about 55 mils (1.397 mm) thick, said abradable top layer comprising 20 weight percent yttria stabilized zirconia, wherein each layer is deposited during one continuous spray process using particles having a spherical and hollow morphology for increased abradability and wherein said segmented abradable coating comprises at least four vertical microcracks per inch.

A segmented abradable sealing system having enhanced abradability, the system comprising:

• (a) a duct segment including:
• (1) a metallic substrate;
• (2) a MCrAlY bond coat on the metallic substrate;
• and
• (3) a segmented abradable ceramic coating on the bond coat, said segmented abradable ceramic coating comprising three ceramic layers which include:
• i) a base coat foundation layer deposited on the bond coat, said base coat foundation layer consisting essentially of a ceramic layer of material selected from the group consisting of zirconia stabilized with ceria, zirconia stabilized with magnesia, zirconia stabilized with calcia, zirconia stabilized with yttria and mixtures thereof;
• ii) an interlayer deposited on the base coat foundation layer;
• and
• iii) an abradable top layer deposited on the interlayer, said abradable top layer comprising zirconia,
• wherein said interlayer consists essentially of a compositional blend of the base coat foundation layer and the abradable top layer,
• said segmented abradable ceramic coating having a plurality of vertical microcracks and said three ceramic layers formed using powder particles which are spherical and hollow for increased abradability;
• and
• (b) a cooperating interacting turbine component having an abrasive coating on a portion thereof such that said abrasive coating can interact with said segmented abradable coating to provide sealing.

A segmented abradable ceramic coating system having enhanced abradability, the system comprising a duct segment including:

• a metallic substrate;
• a MCrAlY bond coat on the substrate;
• and
• a segmented abradable ceramic coating on the bond coat, said segmented abradable ceramic coating comprising three ceramic layers which include:
• i) a base coat foundation layer deposited on the bond coat, said base coat foundation layer consisting essentially of a ceramic layer of material selected from the group consisting of zirconia stabilized with ceria, zirconia stabilized with magnesia, zirconia stabilized with calcia, zirconia stabilized with yttria and mixtures thereof,
• ii) an interlayer deposited on the base coat foundation layer, and
• iii) an abradable top layer deposited on the interlayer, said abradable top layer comprising zirconia,
• wherein said interlayer consists essentially of a compositional blend of the base coat foundation layer and the abradable top layer,
• said segmented abradable ceramic coating having a plurality of vertical microcracks and wherein said three ceramic layers are formed using powder particles which are spherical and hollow for increased abradability.

A segmented abradable ceramic coating having a base coat foundation layer, an interlayer and an abradable top layer, wherein:

• said base coat foundation layer comprises a ceramic layer between about 5 mils (0.127 mm) and about 15 mils (0.381 mm) thick consisting essentially of zirconia with between about 7 weight percent and about 12 weight percent yttria stabilized zirconia;
• said interlayer is between about 3 mils (0.076 mm) and about 10 mils (0.254 mm) thick on the base coat foundation layer and consists essentially of a compositional blend of the base coat foundation layer and the abradable top layer;
• and
• said abradable top layer is between about 15 mils (0.381 mm) and about 55 mils (1.397 mm) thick and comprises 20 weight percent yttria stabilized zirconia.