Protective coatings for metal-based substrates, and related processes
AssigneeGeneral Electric Company
InventorsMarcus Preston Borom, Dennis Michael Gray, Yuk-Chiu Lau, Surinder Singh Pabla
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Abstract
An article is described, which includes a metal-based substrate, such as a superalloy; a dense, primary bond layer; and a spongy secondary bond layer. A thermal barrier coating is applied over the secondary bond layer. The spongy layer has a microstructure which includes an open network of interconnected pores. A process is also described. It includes the step of applying a spongy, metallic bond layer over the substrate, followed by the application of a thermal barrier coating. A dense, primary bond layer may optionally be applied before the application of the spongy layer.
Claims8
A method for providing a protective coating on a metal-based substrate, comprising the following steps:
- (a) applying a dense, primary bond layer over the substrate,
- (b) applying a spongy bond layer over the primary bond layer, wherein the spongy bond layer has a microstructure which comprises an open network of interconnected pores;
- and then
- (c) applying a thermal barrier coating over the spongy bond layer.
A method for providing a thermal barrier coating on a superalloy substrate, comprising the following steps:
- (a) applying a dense, primary bond layer over the substrate, comprising an alloy of the formula MCrAlY, where M is selected from the group consisting of Fe, Ni, Co, and mixtures of any of the foregoing;
- (b) applying a spongy bond layer over the dense, primary bond layer by air plasma-spraying, wherein the spongy bond layer has a microstructure which comprises an open network of interconnected pores, and further comprises an alloy of the formula MCrAlY, where M is selected from the group consisting of Fe, Ni, Co, and mixtures of any of the foregoing;
- and then
- (c) applying a zirconia-based thermal barrier coating over the spongy bond layer.
Dependencies are inferred from the claim text.