Thermal barrier coating having improved durability and method of providing the coating
AssigneeUnited Technologies Corporation
InventorsYan Chai, Gary M. Lomasney, Keith Douglas Sheffler
Life of this patent
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Abstract
A method is disclosed for providing a TBC system including grooves or other features between the bond coat/substrate and the ceramic thermally insulating layer. The features are initially provided by selectively removing material to define the features, for example by laser. Any disturbed surface layer, e.g., re-cast material in the case of a laser or plastically worked material in the case of machining, is then chemically removed, leaving the remaining material with a microstructure of a more uniform geometry, and free of disturbed material. The ceramic layer is then applied. TBC systems using the method show improved durability, with lives up to 4× longer than prior TBC systems.
Claims20
A method of providing an article with a thermal barrier coating system having improved durability comprising the steps of:
- providing a substrate having an exposed surface;
- removing portions of substrate material from the exposed surface of the substrate to provide three dimensional features on the substrate;
- chemically treating substantially all of the exposed surface of the substrate;
- and
- applying a layer of thermally insulating ceramic material to the substrate.
A method of providing an article with a thermal barrier coating system having improved durability comprising the steps of:
- providing a substrate;
- applying a bond coat on the substrate;
- removing portions of bond coat material to provide three dimensional features on the bond coat, the step of removing portions resulting in at least some adjacent areas of material which are disturbed;
- chemically treating substantially all of the bond coat to remove any disturbed material;
- and
- applying a layer of thermally insulating ceramic material to the bond coat.
An article with a thermal barrier coating system having improved durability, the article made in accordance with a method comprising the steps of:
- providing a substrate having an exposed surface;
- removing portions of substrate material from the exposed surface of the substrate to provide three dimensional features on the substrate;
- chemically treating substantially all of the exposed surface of the substrate and the features to remove any disturbed material produced during the step of removing;
- and
- applying a layer of thermally insulating ceramic material to the substrate.
An article with a thermal barrier coating system having improved durability, the article made in accordance with a method comprising the steps of:
- providing a substrate;
- applying a bond coat on the substrate;
- removing portions of bond coat material to provide three dimensional features on the bond coat, the step of removing portions resulting in at least some adjacent areas of material which are disturbed;
- chemically treating the bond coat to remove any disturbed material;
- and
- applying a layer of thermally insulating ceramic material to the bond coat.
Dependencies are inferred from the claim text.