Thermal barrier coating for a superalloy article and a method of application thereof

A multilayer thermal barrier coating for a superalloy substrate, comprising a bond coating on the superalloy substrate, an oxide layer on the bond coating and a ceramic thermal barrier coating on the oxide layer,

• the bond coating comprising a first coating on the superalloy substrate and a second aluminum containing alloy coating on the first coating,
• the first coating including at least one metal compound distributed evenly throughout the whole of the first coating, the at least one metal compound being selected such that at least one harmful element diffusing from the superalloy substrate into the first coating reacts with the metal compound to release the metal into the first coating and to form a compound with the harmful element.

A multi-layer thermal barrier coating for a superalloy substrate, comprising a bond coating on the superalloy substrate, an oxide layer on the bond coating and a ceramic thermal barrier coating on the oxide layer,

• the bond coating comprising a first coating on the superalloy substrate and a second aluminum containing alloy coating on the first coating, a platinum-group metal enriched aluminum containing alloy layer on the aluminum containing alloy coating, a coating of at least one aluminide of the platinum-group metals on the platinum-group metal enriched aluminum containing alloy layer,
• the first coating including at least one metal compound distributed evenly throughout the whole of the first coating, the at least one metal compound being selected such that at least one metal compound being selected such that at least one harmful element diffusing from the superalloy substrate into the first coating reacts with the metal compound to release the metal into the first coating and to form a compound with the harmful element.

A multi-layer thermal barrier coating for a superalloy substrate, comprising a bond coating on the superalloy substrate, an oxide layer on the bond coating and a ceramic thermal barrier coating on the oxide layer,

• the bond coating comprising an inner region adjacent the superalloy substrate and an outer region adjacent the oxide layer, the bond coating comprising aluminum at least in the outer region of the bond coating, the bond coating comprising at least one metal compound at least in the inner region of the bond coating, the at least one metal compound being selected from the group consisting of a carbide, an oxide, a nitride and a boride, and the metal compound reacts with at least one harmful element diffusing from the superalloy substrate into the aluminum containing alloy bond coating to release the metal into the bond coating and to form a compound with the harmful element.

A multi-layer thermal barrier coating for a superalloy substrate, comprising a bond coating on the superalloy substrate, an oxide layer on the bond coating and a ceramic thermal barrier coating on the oxide layer,

• the bond coating comprising an inner region adjacent the superalloy substrate and an outer region adjacent the oxide layer, the bond coating comprising aluminum at least in the outer region of the bond coating, the bond coating comprising at least one metal compound at least in the inner region of the bond coating, the at least one metal compound being selected from the group consisting of chromium carbide, manganese carbide, molybdenum carbide, aluminum carbide, nickel carbide and tungsten carbide, and the at least one metal compound is selected such that at least one harmful element diffusing from the superalloy substrate into the aluminum containing alloy bond coating reacts with the metal compound to release the metal into the bond coating and to form a compound with the harmful element.

A multi-layer thermal barrier coating for a superalloy substrate, comprising a bond coating on the superalloy substrate, an oxide layer on the bond coating and a ceramic thermal barrier coating on the oxide layer,

• the bond coating comprising a first coating on the superalloy substrate and a second aluminum containing alloy coating on the first coating, a platinum-group metal enriched aluminum containing alloy layer on the aluminum containing alloy coating, a coating of at least one aluminide of the platinum-group metals on the platinum-group metal enriched aluminum containing alloy layer,
• the first coating including at least one metal compound distributed evenly throughout the whole of the first coating, the at least one metal compound being selected from the group consisting of chromium carbide, manganese carbide, molybdenum carbide, aluminum carbide, nickel carbide and tungsten carbide, and the at least one metal compound being selected such that at least one metal compound being selected such that at least one harmful element diffusing from the superalloy substrate into the first coating reacts with the metal compound to release the metal into the first coating and to form a compound with the harmful element.