# US 8,784,944 B2 · Plasma-spray powder manufacture technique

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- Number: US 8,784,944 B2
- Document ID: US8784944B2
- Status: Granted
- Kind: B2
- Application number: 11/605,647
- Filed: 2006-11-29
- Published: 2010-02-04
- Granted: 2014-07-22
- Earliest claimed: 2006-11-29
- Assignees: United Technologies Corporation
- Applicants: Kevin W. Schlichting; Paul H. Zajchowski
- Inventors: Kevin W. Schlichting; Paul H. Zajchowski
- Web page: https://patentgrep.com/patent/US8784944B2

## CPC

- C04B 35/488: Composites
- C04B 35/46: based on titanium oxides or titanates (containing also zirconium or hafnium oxides, zirconates or hafnates C04B35/49)
- C04B 35/49: containing also titanium oxides or titanates
- C04B 35/62665: {Flame, plasma or melting treatment}
- C04B 35/653: Processes involving a melting step
- C23C 4/02: Pretreatment of the material to be coated, e.g. for coating on selected surface areas
- C23C 4/08: containing only metal elements (C23C4/073 takes precedence)
- C23C 4/11: Oxides
- C23C 4/12: characterised by the method of spraying
- C23C 4/134: Plasma spraying
- C23C 28/321: {with at least one metal alloy layer}
- C23C 28/3215: {at least one MCrAlX layer}
- C23C 28/3455: {with a refractory ceramic layer, e.g. refractory metal oxide, ZrO2, rare earth oxides or a thermal barrier system comprising at least one refractory oxide layer}
- C04B 2235/3224: Rare earth oxide or oxide forming salts thereof, e.g. scandium oxide
- C04B 2235/3232: Titanium oxides or titanates, e.g. rutile or anatase
- C04B 2235/3234: Titanates, not containing zirconia
- C04B 2235/3244: Zirconium oxides, zirconates, hafnium oxides, hafnates, or oxide-forming salts thereof
- C04B 2235/3246: Stabilised zirconias, e.g. YSZ or cerium stabilised zirconia
- C04B 2235/3248: Zirconates or hafnates, e.g. zircon
- C04B 2235/3255: Niobates or tantalates, e.g. silver niobate
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04)

## Abstract

A ceramic thermal barrier coating having improved erosion resistance includes a metallic layer and a ceramic layer positioned on the metallic layer. The ceramic layer includes a first powder, a second powder, and a third powder. The first powder and the second powder are alloyed together prior to being mixed with the third powder.

## Claims

### Claim 1

A method of applying an erosion resistant coating onto a component, the method comprising:
applying a bond coat to the surface of a component;
melting titanium oxide ceramic powder and zirconium oxide ceramic powder at a temperature higher than the melting points of both ceramic powders to form a first homogeneous ceramic alloy melt consisting of between about 40 mol % and about 95 mol % titanium oxide and the balance zirconium oxide;
cooling the first homogeneous alloy melt to form a first homogeneous solid ceramic alloy;
creating a first homogeneous ceramic alloy powder from the first solid homogeneous ceramic alloy;
mixing the first homogeneous ceramic alloy powder with a second ceramic powder to form a final ceramic powder mixture; and
plasma spraying the final ceramic powder mixture onto the bond coat.

### Claim 2 (depends on 1)

The method of claim 1 wherein the second ceramic powder is selected from a group consisting of a zirconate, a hafnate, a titanate, and mixtures thereof which have been doped with between about 5 weight percent and about 100 weight percent of at least one oxide.

### Claim 3 (depends on 2)

The method of claim 2, wherein the at least one oxide comprises an oxide of scandium, indium, yttrium, lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, and lutetium.

### Claim 4 (depends on 1)

The method of claim 1, wherein the second ceramic powder comprises gadolinia stabilized zirconium oxide powder.

### Claim 5 (depends on 1)

The method of claim 1, wherein the bond coat comprises a MCrAlY bond coat wherein M is at least one of nickel, cobalt, and iron.

### Claim 6 (depends on 1)

The method of claim 1, wherein the bond coat comprises an aluminide or platinum aluminide bond coat.

### Claim 7 (depends on 1)

The method of claim 1, wherein the titanium oxide and zirconium oxide ceramic powders are processed through at least two melting and powder creation operations to form the first homogeneous ceramic alloy powder prior to being mixed with the second ceramic powder to form the final ceramic powder mixture.

### Claim 8 (depends on 1)

The method of claim 1, wherein the final ceramic powder mixture comprises between about 2 weight % and about 50 weight % first homogenous ceramic alloy powder and the balance the second ceramic powder.

### Claim 9 (depends on 1)

The method of claim 1, wherein the bond coat is applied by low pressure plasma spray, high velocity oxygen fuel (HVOF) spray, cathodic arc deposition, diffusion, air plasma spray or plating.