Coating processes – Spray coating utilizing flame or plasma heat – Metal or metal alloy coating
Patent
1997-09-23
1998-10-06
Bareford, Katherine A.
Coating processes
Spray coating utilizing flame or plasma heat
Metal or metal alloy coating
427454, 427455, C23C 406, C23C 412
Patent
active
058173722
ABSTRACT:
A method of depositing a bond coat (16) of a thermal barrier coating (TBC) system (14) for components designed for use in a hostile thermal environment, such as turbine, combustor and augmentor components (10) of a gas turbine engine. The method yields a bond coat (16) having an adequate surface roughness for adhering a plasma-sprayed ceramic layer (18) while also producing a bond coat (16) that is dense with low porosity, thereby yielding a thermal barrier coating system (14) that is highly resistant to spallation. The method generally entails forming the bond coat (16) by depositing two metal powders on the substrate (12) using either a vacuum plasma spraying (VPS) or high velocity oxy-fuel (HVOF) technique. The particle size distributions of the two powders are chosen to yield a bimodal (dual-peak) particle size distribution that will produce a VPS and HVOF bond coat (16) characterized by a macro-surface roughness of at least about 350 microinches Ra attributable to particles of the coarser powder. The particles of the finer powder fill the interstices between particles of the coarser powder to achieve a density of at least about 95% of theoretical density, and contribute to a micro-surface roughness that, in combination with the macro-surface roughness provided by the coarser particles, enhances adhesion of the ceramic layer (18).
REFERENCES:
patent: 5236745 (1993-08-01), Gupta et al.
patent: 5277936 (1994-01-01), Olson et al.
patent: 5362523 (1994-11-01), Gorynin et al.
Bareford Katherine A.
General Electric Co.
Hartman Domenica N. S.
Lampe, Jr. Robert C.
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