Coating composition for metal-based substrates, and related proc

Coating processes – With post-treatment of coating or coating material – Heating or drying

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4273762, 427379, 4274193, 4274194, B05D 302, B05D 308, B05D 138

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059853689

ABSTRACT:
An improved thermal barrier coating for metal substrates such as superalloys is disclosed. The coating is a slurry composition, comprising spheres of zirconia, at least some of which are hollow, contained within a porous oxide matrix, such as aluminosilicate. The slurry composition can be applied by slurry casting or similar techniques to the desired surface. Coating methods are also described. In general, they involve the application of successive layers of variations of the slurry composition, with various curing techniques used between layers and after the final coating is applied. Another embodiment of this invention embraces a composite coating, comprising (i) an oxide matrix phase; (ii) zirconia spheres embedded in the oxide matrix; and (iii) a porous phase.

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patent: 4965095 (1990-10-01), Baldi
patent: 5034358 (1991-07-01), MacMillan
patent: 5514482 (1996-05-01), Strangman
1853400 NTIS Accession No.: N95-26133/5/XAB "Thermal Conductivity of Zirconia Thermal Barrier Coatings" (Abstract)-Oak Ridge National Lab., TN. Mar. 95.
1753380 NTIS Accession No.: DE94000746/XAB-"Thin-Wall Hollow Ceramic Spheres from Slurries". Quarterly Project Status report, Jan. 1-31 Mar., 1991.
03846965-EDB 95-090733 "Thermal Conductivity of Zirconia Thermal Barrier Coatings", Dinwiddle, R.B., Beecher, S.C., Nagaraj, B. A., Moore, C.S.-Mar. 1995.
"Ceramic Slurry Coatings for Advanced Heat Engines", by L. Kamo et al., Proceedings of the International Thermal Spray Conf. & Exposition, Orlando, FL, May 28-Jun. 5, 1992, pp. 45-49.
"ORNL Finds Spheres Could Make a Good Insulation", Oak Ridge National Laboratory Review, vol. 23, No. one 1990, pp. 89-92.

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