Method for bonding thermal barrier coatings to superalloy substr

Details Method for bonding thermal barrier coatings to superalloy substr Method for bonding thermal barrier coatings to superalloy substr

1997-10-21

1999-02-02

Zimmerman, John J.

Stock material or miscellaneous articles

All metal or with adjacent metals

Component of composite having metal continuous phase...

428609, 428668, 428679, 428332, 428633, 427455, 427250, 148527, 148240, B32B 704, B32B 1504, C23C 402, C23C 802

Patent

active

058662715

ABSTRACT:
A method is provided for bonding a ceramic thermal barrier coating to a nickel or cobalt based superalloy substrate for use in high temperature applications such as gas turbine engines. The method comprises roughening the superalloy substrate itself to produce a surface roughness, preferably from 100 to 350 microinches Roughness Average (RA). The roughened surface of the substrate is treated with a diffusion coating, preferably aluminide or platinum-aluminide to provide oxidation and hot corrosion resistance, while substantially preserving the micro-topography of the roughened surface. A ceramic thermal barrier coating is applied directly to the diffusion treated surface, preferably using an air plasma spray. The surface roughness, which is left substantially undisturbed by the diffusion coating treatment, is altered by the air plasma sprayed ceramic to form a series of interlocking microstructures that firmly attach the ceramic thermal barrier coating to the diffusion treated superalloy substrate. The method creates an inexorable bond between the ceramic thermal barrier coating and the substrate without the need for costly Low Pressure Plasma Sprayed MCrAlY bond coats or costly Electron Beam Physical Vapor Deposited ceramic.

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