High temperature erosion resistant, abradable thermal barrier composite coating
AssigneeSiemens Westinghouse Power Corporation
InventorsGary B. Merrill, Jay A. Morrison
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Abstract
A composite thermal barrier coating system includes a honeycomb metallic structure filled with high thermal expansion ceramic hollow spheres in a phosphate bonded matrix. The composite thermal barrier coating system may be manufactured to thicknesses in excess of current thermal barrier coating systems, thereby imparting greater thermal protection. Superior erosion resistance and abrasion properties are also achieved. The composite thermal barrier coating is useful on combustion turbine components such as ring seal segments, vane segment shrouds, transitions and combustors.
Claims43
An abradable composite thermal barrier coating comprising:
- a metal substrate;
- a metal support structure comprising open cells secured to the substrate;
- and
- a ceramic filler material at least partially inside the cells of the metal support structure comprising hollow ceramic particles having an average size of greater than 0.2 mm in a ceramic matrix.
A method of making an abradable composite thermal barrier coating comprising:
- securing a metal support structure having open cells to a metal substrate;
- at least partially filling the cells of the metal support structure with a flowable ceramic filler material comprising hollow ceramic particles having an average size of greater than 0.2 mm and a binder material;
- and
- heating the flowable ceramic filler material to form a ceramic matrix connecting the hollow ceramic particles.
Dependencies are inferred from the claim text.