Patent ID: 7955707
Filing Date: 2011-06-07
Classification: C04B,C23C,F01D,Y02T,Y10T

Abstract:
1. A high-purity coating that is suitable for high temperature cycling applications, said coating formed by the process comprising: providing a ceramic material consisting essentially of about 4 to 20 weight percent of a stabilizer of one or more rare earth oxides, and a balance of at least one of zirconia (ZrO providing a removable placeholder material comprising an inorganic powder material or an organic powder material that can be burned out subsequent to deposition; and spraying said ceramic material and said removable placeholder material onto a metal substrate using a thermal spray process at pressures between 1 Pa and 1 MPa, so as to form a stream of molten and/or semi-molten droplets that build up a coating of frozen lamellar splats subsequent to impact with the substrate, wherein the coating sprayed on the metal substrate includes the ceramic material and the removable placeholder material, and wherein the coating sprayed on the metal substrate further comprises, after removal of the removable placeholder material, a structure including a ceramic matrix, porosity, and micro cracks.