Patent ID: 7879457
Filing Date: 2011-02-01
Classification: C22C,C23C,Y10T

Abstract:
1. A coating for a metal or non-metal substrate comprising: (i) a thermal sprayed bondcoat layer applied to said substrate comprising an alloy of MCrAlM′ wherein M is an element selected from nickel, cobalt, iron and mixtures thereof, and M′ is an element selected from yttrium, zirconium, hafnium, ytterbium and mixtures thereof, and wherein M comprises from about 35 to about 80 weight percent of said alloy, Cr comprises from about 15 to about 45 weight percent of said alloy, Al comprises from about 5 to about 30 weight percent of said alloy, and M′ comprises from about 0.01 to about 1.0 weight percent of said alloy, said alloy thermally sprayed from a powder having a mean particle size of 50 percentile point in distribution of from about 5 microns to about 100 microns, said bondcoat having a surface roughness of at least 200 micro-inches, said bondcoat having a thermal expansion of about 6.5 millimeters per meter or less between a temperature of from about 25° C. to about 525° C., and said bondcoat having a thickness of from about 4 to about 480 mils, and (ii) a thermal sprayed ceramic layer applied to said bondcoat layer, said ceramic layer having a thickness of from about 0.001 to about 0.1 inches; wherein said coating has a helium leak rate of less than 6×10