Method for increasing the cyclic spallation life of a thermal ba

Coating processes – Spray coating utilizing flame or plasma heat – Metal oxide containing coating

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427250, 427252, 427405, 4274192, 427456, 428609, 428621, 428633, 428680, 428937, B05D 102

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052367452

ABSTRACT:
An article is coated with a thermal barrier coating system to increase its thermal cyclic spallation life. A single layer bond coating is applied to the surface of the article to a surface roughness in the range of 200 to 600 microinches RA by low pressure plasma spraying of coarse MCrAlY alloy particles into the surface. A metal selected from aluminum and its alloys is applied to the bond coating by aluminiding and is diffused into the bond coating to provide an aluminum-rich bond coating metal outer surface, while substantially retaining the surface roughness of about 2300 to 600 microinches RA. A metal oxide thermal barrier coating layer is then applied onto the aluminum-rich bond coating outer surface.

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