Method for constructing thermal barrier coating and heat-resistant member

Patent metadata

Field	Value
Publication number	US-2025198007-A1
Application number	US-202318840909-A
Country	US
Kind code	A1
Filing date	Mar 24, 2023
Priority date	Apr 14, 2022
Publication date	Jun 19, 2025
Grant date	—

Abstract

This method for constructing a thermal barrier coating according to at least one embodiment or the present disclosure comprises a step for forming a topcoat layer on a bond coat layer formed on a heat-resistant alloy base material of a target object. In the step for forming a topcoat layer, a topcoat layer is formed by the thermal spraying, using a high-velocity flame thermal spray, of a suspension comprising a ceramic powder while holding the temperature of the topcoat layer at from 300-450° C., to form a topcoat layer in which, with reference to the area of the cross section of the topcoat layer, the percentage or the area or regions in which unmelted ceramic powder is agglomerated is not more than 0.15%.

First claim

1 . A method for forming a thermal barrier coating, comprising:
a step of forming a top coat layer on a bond coat layer formed on a heat-resistant alloy substrate of an object, wherein, in the step of forming the top coat layer, the top coat layer, in which a proportion of an area of a region in which unmelted ceramic powder is agglomerated to an area of a cross section of the top coat layer is equal to or less than 0.15%, is formed by thermally spraying a suspension including the ceramic powder using high velocity oxy-fuel spraying while maintaining a temperature of the top coat layer at 300° C. or higher and 450° C. or lower.

2 . The method for forming a thermal barrier coating according to claim 1 ,
wherein, in the step of forming the top coat layer, the top coat layer, in which the proportion of the area of the region in which the unmelted ceramic powder is agglomerated to the area of the cross section of the top coat layer is equal to or less than 0.02%, is formed by thermally spraying the suspension including the ceramic powder using the high velocity oxy-fuel spraying while maintaining the temperature of the top coat layer at 300° C. or higher and 450° C. or lower.

3 . The method for forming a thermal barrier coating according to claim 1 ,
wherein, in the step of forming the top coat layer, the suspension in which an absolute value of a zeta potential of the ceramic powder is equal to or greater than 40 mV is thermally sprayed by the high velocity oxy-fuel spraying.

4 . The method for forming a thermal barrier coating according to claim 1 ,
wherein, in the step of forming the top coat layer, the suspension in which water or ethanol is used as a dispersion medium and which has a pH of 2 or less or 9 or more is thermally sprayed by the high velocity oxy-fuel spraying.

5 . The method for forming a thermal barrier coating according to claim 1 ,
wherein, in the step of forming the top coat layer, the top coat layer is formed by thermally spraying the suspension including the ceramic powder using the high velocity oxy-fuel spraying while maintaining the temperature at 300° C. or higher and 400° C. or lower.

6 . The method for forming a thermal barrier coating according to claim 1 ,
wherein, in the step of forming the top coat layer, cooling with a cooling medium is performed to control the temperature.

7 . The method for forming a thermal barrier coating according to claim 6 ,
wherein the cooling medium is compressed air that has been compressed by a compressor.

8 . The method for forming a thermal barrier coating according to claim 6 ,
wherein the cooling medium includes dry ice.

9 . The method for forming a thermal barrier coating according to claim 1 ,
wherein the ceramic powder includes any one of yttria-stabilized zirconia, dysprosia-stabilized zirconia, erbia-stabilized zirconia, Gd 2 Zr 2 O 7 , or Gd 2 Hf 2 O 7 .

10 . A heat-resistant member comprising the top coat layer formed by the method for forming a thermal barrier coating according to claim 1 .

Assignees

• Mitsubishi Heavy Ind Aero Engines Ltd

Inventors

• Okajima Yoshifumi
• Torigoe Taiji
• Mizutani Koji
• Kinouchi Arata

Classifications

• C23C4/18

  After-treatment · CPC title

• C23C4/129

  Flame spraying · CPC title

• C23C28/3455 Primary

  with a refractory ceramic layer, e.g. refractory metal oxide, ZrO2, rare earth oxides or a thermal barrier system comprising at least one refractory oxide layer · CPC title

• C23C28/3215

  at least one MCrAlX layer · CPC title

• C23C4/02

  Pretreatment of the material to be coated, e.g. for coating on selected surface areas · CPC title