High temperature insulative coating (XTR)

• Main Authors: RICHARD SHANE M, LOGAN GARY D, SAHOO PURUSOTTAM, MAGDA CYRIL S.JR
• Format: Patent
• Language: English
• Published: 19.04.2007
• 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; LAYERED PRODUCTS; LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT ORNON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM; METALLURGY; PERFORMING OPERATIONS; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THESURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; TRANSPORTING

A thermal barrier coating with unique properties suitable for high temperature thermal insulation control on a substrate is provided. The coating is thermally sprayed, consisting of three layers: 1) a MCrAIY bond coat (basecoat), 2) an intermediate crack resistant ceramic coating, and 3) a top coat of yttria stabilized zirconia. The three layer coating is deposited, preferably, using an air plasma spray system with suitable macro cracks in the top coat, with an underlying crack resistant layer, to enable the ceramic top coat to have properties suitable for advanced gas turbine thermal barrier coatings.