Thermal-Sprayed Bonding of a Ceramic Structure to a Substrate

Patent metadata

Field	Value
Publication number	US-2016123160-A1
Application number	US-201514923574-A
Country	US
Kind code	A1
Filing date	Oct 27, 2015
Priority date	Oct 30, 2014
Publication date	May 5, 2016
Grant date	—

Abstract

A thermal barrier system includes a protective coating on a substrate, and a ceramic feature layer attached to the protective coating via an adhesive spray coat.

First claim

What is claimed:

1 . A thermal barrier system, comprising:
a protective coating on a substrate; and a ceramic feature layer attached to said protective coating via an adhesive spray coat.

2 . The thermal barrier system as recited in claim 1 , wherein said protective coating is an environmental coating.

3 . The thermal barrier system as recited in claim 1 , wherein said protective coating is a bond coat.

4 . The thermal barrier system as recited in claim 1 , wherein said adhesive spray coat at least partially overfills said ceramic feature layer

5 . The thermal barrier system as recited in claim 1 , wherein said adhesive spray coat at least partially fills said ceramic feature layer.

6 . The thermal barrier system as recited in claim 1 , wherein said ceramic feature layer forms a lattice structure.

7 . The thermal barrier system as recited in claim 1 , wherein said ceramic feature layer includes an extended area which facilitates a mechanical interlock between said ceramic feature layer and said protective coating via said adhesive spray coat.

8 . The thermal barrier system as recited in claim 7 , wherein said extended area is flared.

9 . The thermal barrier system as recited in claim 8 , wherein said extended area includes an angle of about 5-15 degrees with respect to a side wall of said ceramic feature layer.

10 . A thermal barrier system, comprising:
a protective coating on a metallic substrate, the protective coating includes a ceramic material; and a ceramic feature layer mechanically interlocked to said protective coating via an adhesive spray coat.

11 . The thermal barrier system as recited in claim 10 , wherein said ceramic feature layer forms a lattice structure.

12 . The thermal barrier system as recited in claim 11 , wherein said adhesive spray coat is about 0.003 to 0.030 inch thick.

13 . The thermal barrier system as recited in claim 11 , wherein said adhesive spray coat at least partially fills said ceramic feature layer.

14 . The thermal barrier system as recited in claim 11 , wherein said ceramic feature layer forms a honeycomb pattern.

15 . A method of applying a thermal barrier system to a component, comprising:
applying a protective coating to a substrate; and mechanically interlocking a ceramic feature layer with the protective coating via an adhesive spray coat thermally sprayed onto the ceramic feature layer and the protective coating.

16 . The method as recited in claim 15 , wherein the ceramic feature layer is mechanically attached to the protective coating prior to thermally spraying the adhesive spray coat.

17 . The method as recited in claim 15 , wherein the ceramic feature layer is temporarily tacked to the protective coating prior to thermally spraying the adhesive spray coat.

18 . The method as recited in claim 15 , further comprising preforming the ceramic feature layer.

19 . The method as recited in claim 15 , further comprising additively manufacturing the ceramic feature layer.

20 . The method as recited in claim 15 , further comprising at least partially filling the ceramic feature layer with the adhesive spray coat.

Assignees

• United Technologies Corp

Inventors

• Strock Christopher W
• Lutjen Paul M

Classifications

• F01D11/12

  using a rubstrip, e.g. erodible. deformable or resiliently-biased part · CPC title

• F05D2300/22

  Non-oxide ceramics · CPC title

• F05D2250/283

  honeycomb · CPC title

• F05D2230/312

  by plasma spraying · CPC title

• F01D11/127

  with a deformable or crushable structure, e.g. honeycomb · CPC title