Thermal barrier coating system and method therefor

Fluid reaction surfaces (i.e. – impellers) – Specific blade structure – Coating – specific composition or characteristic

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415200R, 416241B, 428141, 428156, 428472, 428701, 428702, 428615, 428623, 428632, 428650, 428552, 428669, 428680, 428652, 428668, 427348, 427402, 4274191, 4274192, B32B 1504

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059758520

ABSTRACT:
A thermal barrier coating and a method for forming the coating on an article designed for use in a hostile thermal environment, such as turbine, combustor and augmentor components of a gas turbine engine. The method is particularly directed to increasing the spallation resistance of a thermal barrier coating system that includes a thermal insulating ceramic layer. The coating system of this invention generally includes a nickel aluminide alloy on which an aluminum oxide layer is formed, over which a ceramic layer is deposited so as to overlie and contact the aluminum oxide layer. The coating system does not include a bond coat, such as a diffusion aluminide or MCrAlY coating known in the prior art. The nickel aluminide alloy may be a binary NiAl alloy consisting essentially of nickel and aluminum in stoichiometric amounts, or may contain one or more oxygen-active elements. The NiAl alloy may be provided as a monolithic layer on a superalloy, or may be the base material for the article on which the thermal barrier coating is formed.

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