Patent ID: 6296723
Filing Date: 2001-10-02
Classification: C23C,Y10S,Y10T

Abstract:
A method of near net-shape forming by vacuum plasma spray of a multi-layered combustion system component having at least an inner ceramic top coat, an intermediate metallic bond coat and an outer structural superalloy layer, which comprises:(a) providing a mold within a vacuum plasma spray chamber, which mold has the shape of the inner surface of the desired component and is capable of operating at high temperatures;(b) heating said mold to a surface temperature above 400.degree. C. and vacuum plasma spraying said mold with the ceramic top coat until a desired thickness thereof is achieved;(c) then heating the so produced ceramic top coat to a surface temperature in excess of 700.degree. C. and vacuum plasma spraying thereon a thin layer of the metallic bond coat;(d) thereafter vacuum plasma spraying on the so produced bond coat, maintained at a temperature in excess of 700.degree. C., the structural superalloy layer until a predetermined thickness thereof is achieved; and(e) cooling the so produced structure and removing the mold therefrom, thereby forming the near net-shape multilayered component from inside out in a single overall operation.