Process of fabricating thermal barrier coatings

Patent metadata

Field	Value
Publication number	US-9347126-B2
Application number	US-201313801478-A
Country	US
Kind code	B2
Filing date	Mar 13, 2013
Priority date	Jan 20, 2012
Publication date	May 24, 2016
Grant date	May 24, 2016

Abstract

A process of fabricating a thermal barrier coating is disclosed. The process includes cold spraying a substrate with a feedstock to form a thermal barrier coating and concurrently oxidizing one or more of the substrate, the feedstock, and the thermal barrier coating. The cold spraying is in a region having an oxygen concentration of at least 10%. In another embodiment, the process includes heating a feedstock with a laser and cold spraying a substrate with the feedstock to form a thermal barrier coating. At least a portion of the feedstock is retained in the thermal barrier coating. In another embodiment, the process of fabricating a thermal barrier coating includes heating a substrate with a laser and cold spraying the substrate with a feedstock to form a thermal barrier coating.

First claim

What is claimed is:

1. A process of fabricating a thermal barrier coating, the process comprising:
cold spraying a substrate with a feedstock to form a thermal barrier coating on the substrate; and
concurrently oxidizing one or more of the substrate, the feedstock, and the thermal barrier coating;
wherein the cold spraying is in a region above the substrate having an oxygen concentration of at least 10%.

2. The process of claim 1 , wherein the oxygen concentration is provided by a process gas.

3. The process of claim 2 , wherein the process gas is air.

4. The process of claim 1 , wherein the oxygen concentration is provided by an inlet gas.

5. The process of claim 1 , wherein the oxygen concentration is above about 50%.

6. The process of claim 1 , wherein the oxygen concentration is above about 70%.

7. The process of claim 1 , wherein an oxide concentration is increased by an increase in the oxygen concentration.

8. The process of claim 1 , further comprising oxidizing at least a portion of the thermal barrier coating.

9. The process of claim 8 , wherein the oxidizing at least a portion of the thermal barrier coating includes baking in an oxygen containing atmosphere.

10. The process of claim 8 , wherein the oxidizing at least a portion of the thermal barrier coating includes chemical treatment.

11. The process of claim 1 , wherein the feedstock comprises mica.

12. The process of claim 11 , wherein a decomposition of the mica forms porosity in the thermal barrier coating.

13. The process of claim 1 , wherein the thermal barrier coating has graded porosity.

14. The process of claim 1 , wherein the feedstock further comprises a homogenous mixture of ceramic particles and a binder.

15. The process of claim 14 , wherein the ceramic particles comprise a material selected from the group consisting of 68.9 wt % Yb 2 O 3 , balance ZrO 2 ; high Y 55 wt %, balance ZrO 2 ; and combinations thereof.

16. The process of claim 14 , wherein the ceramic particles comprise a material selected from the group consisting of 30.5 wt % Yb 2 O 3 , balance ZrO 2 ; 24.8 wt % La 2 O 3 , balance ZrO 2 ; and combinations thereof.

17. The process of claim 1 , further comprising heating the feedstock prior to the cold spraying.

18. The process of claim 1 , further comprising heating the substrate prior to the cold spraying.

19. The process of claim 1 , further comprising heating the feedstock with a laser.

20. The process of claim 1 , further comprising heating the substrate with a laser.

Assignees

• Gen Electric

Inventors

• Pabla Surinder Singh
• Margolies Joshua Lee
• Calla Eklavya
• Parakala Padmaja

Classifications

• C23C24/04 Primary

  Impact or kinetic deposition of particles · CPC title

• C23C4/12 Primary

  characterised by the method of spraying · CPC title