PROCESS OF FORMING A COATING SYSTEM, COATING SYSTEM FORMED THEREBY, AND COMPONENTS COATED THEREWITH

• Main Authors: RUUD, JAMES ANTHONY, SZALA, LAWRENCE EDWARD, WILLSON, PATRICK DANIEL, MANOHARAN, MOHAN, MCEVOY, KEVIN PAUL
• Format: Patent
• Language: English; French
• Published: 12.04.2011
• Subjects: CHEMICAL SURFACE TREATMENT; CHEMISTRY; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATIONOR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY IONIMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; COATING MATERIAL WITH METALLIC MATERIAL; COATING METALLIC MATERIAL; DIFFUSION TREATMENT OF METALLIC MATERIAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION INGENERAL; METALLURGY; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THESURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION

Coating systems and processes by which a ceramic coating (14) is entirely formed from a colloidal-based process to have a thickness that would ordinarily prone to cracks and spallation. The process involves forming a precursor primer layer on a surface region (12,16,18), and then forming at least a precursor coating layer on the precursor primer layer that is thicker than the precursor primer layer. The precursor primer layer contains particles and a precursor of a first ceramic material. The precursor coating layer contains particles and a precursor of a second ceramic material having the same predominant constituent as the first ceramic material. The precursor primer layer and precursor coating layer are then heated to form a ceramic film (20) and a ceramic coating layer (14), respectively, which consist essentially of the particles and matrices of, respectively, the first and second ceramic materials.