Patent ID: 7172820

Claim:
A bond coat for adhering a thermal barrier coating to an underlying metal substrate, the bond coat having an upper portion and which comprises: (1) a bond coating material selected from the group consisting of aluminide diffusion coating materials, and combinations of aluminide diffusion coating materials and overlay alloy coating materials other than a beta-phase NiAl intermetallic overlay coating material, wherein the aluminide diffusion coating material is selected from the group consisting of platinum aluminides and simple aluminides, and wherein overlay alloy coating material is selected from the group consisting of MCrAlX, wherein M is iron, cobalt, nickel, or alloys thereof, and wherein X is hafnium, zirconium, yttrium, tantalum, platinum, palladium, rhenium, silicon or a combination thereof; and (2) a dispersion within at least the upper portion of the bond coat of particles having a particle size of about 2 microns or less and comprising a substantially insoluble bond coat strengthening compound, the amount of dispersed particles within the at least upper portion of the bond coat being sufficient to impart increased strengthening to the bond coat and provide a volume percent of dispersed particles from about 0.5 to about 2.