Controlled thermal expansion coat for thermal barrier coatings

Details Controlled thermal expansion coat for thermal barrier coatings Controlled thermal expansion coat for thermal barrier coatings

1997-10-29

1999-01-26

Zimmerman, John J.

Stock material or miscellaneous articles

All metal or with adjacent metals

Microscopic interfacial wave or roughness

428633, 428678, 416241R, 416241B, B32B 1504, F01D 528

Patent

active

058636684

ABSTRACT:
A improved thermal barrier coating and method for producing and applying such is disclosed herein. The thermal barrier coating includes a high temperature substrate, a first bond coat layer applied to the substrate of MCrAlX, and a second bond coat layer of MCrAlX with particles of a particulate dispersed throughout the MCrAlX and the preferred particulate is Al.sub.2 O.sub.3. The particles of the particulate dispersed throughout the second bond coat layer preferably have a diameter of less then the height of the peaks of the second bond coat layer, or a diameter of less than 5 .mu.m. The method of producing the second bond coat layer may either include the steps of mechanical alloying of particles throughout the second bond coat layer, attrition milling the particles of the particulate throughout the second bond coat layer, or using electrophoresis to disperse the particles throughout the second bond coat layer. In the preferred embodiment of the invention, the first bond coat layer is applied to the substrate, and then the second bond coat layer is thermally sprayed onto the first bond coat layer. Further, in a preferred embodiment of the invention, a ceramic insulating layer covers the second bond coat layer.

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