公开(公告)号：US06180260B2

公开(公告)日：2001-01-30

申请号：US09324551

申请日：1999-06-03

申请人： Dennis Michael Gray ,  Wayne Charles Hasz ,  Timothy Francis Bethel ,  Curtis Alan Johnson ,  Marcus Preston Borom

发明人： Dennis Michael Gray ,  Wayne Charles Hasz ,  Timothy Francis Bethel ,  Curtis Alan Johnson ,  Marcus Preston Borom

IPC分类号： B32B1500

CPC分类号： C23C4/02 ,  C23C4/18 ,  Y02T50/67 ,  Y10T428/12493 ,  Y10T428/12549 ,  Y10T428/12611

摘要： A method for providing a substantially-smooth protective coating on a metal-based substrate is disclosed. It comprises the steps of: (a) applying a thermal barrier coating over the substrate by plasma-spraying; (b) plasma-heating the applied coating according to a time- and temperature schedule sufficient to re-melt the surface region of the coating, allowing it to flow and smoothen; and then (c) cooling the surface region to a temperature below its melting point. The thermal barrier coating is often zirconia-based, e.g., yttria-stabilized zirconia. After being cooled, the surface is much smoother than when originally applied, thereby allowing the coating to be used in a higher-temperature environment.

摘要翻译： 公开了一种在金属基底上提供基本平滑的保护涂层的方法。 其包括以下步骤：（a）通过等离子体喷涂在衬底上施加热障涂层;（b）根据足以重新熔化涂层表面区域的时间和温度程序等级加热涂覆的涂层 ，让它流畅平滑; 然后（c）将表面区域冷却到低于其熔点的温度。热障涂层通常是基于氧化锆的，例如氧化钇稳定的氧化锆。 冷却后，表面比最初施加的表面更光滑，从而允许涂层在较高温度的环境中使用。

公开(公告)号：US6103315A

公开(公告)日：2000-08-15

申请号：US58938

申请日：1998-04-13

申请人： Dennis Michael Gray ,  Wayne Charles Hasz ,  Timothy Francis Bethel ,  Curtis Alan Johnson ,  Marcus Preston Borom

发明人： Dennis Michael Gray ,  Wayne Charles Hasz ,  Timothy Francis Bethel ,  Curtis Alan Johnson ,  Marcus Preston Borom

IPC分类号： C23C4/02 ,  C23C4/18

CPC分类号： C23C4/02 ,  C23C4/18 ,  Y02T50/67 ,  Y10T428/12493 ,  Y10T428/12549 ,  Y10T428/12611

摘要： A method for providing a substantially-smooth protective coating on a metal-based substrate is disclosed. A thermal barrier coating is first applied over the substrate by plasma-spraying. The coating is then plasma-heated according to a time- and temperature schedule sufficient to re-melt its surface region, allowing the coating material to flow and smoothen. The surface region is then allowed to cool to a temperature below its melting point. After being cooled, the surface is much smoother than when originally applied, which allows the coating to be used in a higher-temperature environment. The coating is often zirconia-based, e.g., yttria-stabilized zirconia.

摘要翻译： 公开了一种在金属基底上提供基本平滑的保护涂层的方法。 首先通过等离子体喷涂在衬底上施加热障涂层。 然后根据足以使其表面区域再熔化的时间和温度进行等离子体加热，使涂层材料流动和平滑。 然后将表面区域冷却至低于其熔点的温度。 冷却后，表面比最初施加的表面更光滑，这使涂层能够在较高温度的环境中使用。 涂层通常是基于氧化锆的，例如氧化钇稳定的氧化锆。

公开(公告)号：US6022594A

公开(公告)日：2000-02-08

申请号：US32511

申请日：1998-02-27

申请人： Marcus Preston Borom ,  Lawrence Edward Szala ,  Curtis Alan Johnson ,  Yuk-Chiu Lau ,  Dennis Michael Gray

发明人： Marcus Preston Borom ,  Lawrence Edward Szala ,  Curtis Alan Johnson ,  Yuk-Chiu Lau ,  Dennis Michael Gray

IPC分类号： C23C4/10

CPC分类号： C23C4/11 ,  Y02T50/67

摘要： A method for improving the quality of a zirconia-based coating deposited on a metal-based substrate is disclosed. The method comprises the step of plasma-spraying zirconia powder of substantially uniform particle size onto the substrate. The disclosure further relates to an improved powder source material for use in a plasma. The source material is zirconia powder having a uniform particle size, and optionally, a uniform particle density. The use of such a material results in improved thermal barrier coatings for various substrates, such as those found in a turbine engine.

摘要翻译： 公开了一种提高沉积在金属基底上的氧化锆基涂层的质量的方法。 该方法包括将基本上均匀粒径的氧化锆粉末等离子体喷涂到基底上的步骤。 本公开还涉及用于等离子体的改进的粉末源材料。 源材料是具有均匀粒度的氧化锆粉末，并且任选地具有均匀的颗粒密度。 使用这种材料导致用于各种基底（例如在涡轮发动机中发现的那些）的改进的热障涂层。

公开(公告)号：US5897921A

公开(公告)日：1999-04-27

申请号：US788010

申请日：1997-01-24

申请人： Marcus Preston Borom ,  Dennis Michael Gray ,  Curtis Alan Johnson

发明人： Marcus Preston Borom ,  Dennis Michael Gray ,  Curtis Alan Johnson

IPC分类号： C23C4/02 ,  C23C4/12 ,  C23C4/10

CPC分类号： C23C4/12 ,  C23C4/02 ,  Y02T50/67

摘要： A method and apparatus form a thermal barrier coating on a metal component. A molten thermal barrier coating powder is sprayed on the component in sweeping strokes. A plurality of overlapping solidified coating ribbons are deposited on the component and include a sequentially deposited surface ribbon forming sublayer ribbons therebelow. The surface ribbon is preheated at a spray site so that the sprayed molten powder remelts the surface ribbon at the spray site for sequentially welding the sequentially deposited surface ribbons to the sublayer ribbons.

公开(公告)号：US06180184B2

公开(公告)日：2001-01-30

申请号：US08957213

申请日：1997-10-24

申请人： Dennis Michael Gray ,  Yuk-Chiu Lau ,  Curtis Alan Johnson ,  Marcus Preston Borom ,  Warren Arthur Nelson

发明人： Dennis Michael Gray ,  Yuk-Chiu Lau ,  Curtis Alan Johnson ,  Marcus Preston Borom ,  Warren Arthur Nelson

IPC分类号： C23C410

CPC分类号： C23C4/12 ,  C23C4/02 ,  C23C4/134 ,  Y10T428/12535 ,  Y10T428/12611 ,  Y10T428/12618 ,  Y10T428/12806 ,  Y10T428/12931 ,  Y10T428/12944 ,  Y10T428/24314

摘要： An article having a spallation resistant TBC comprises a metal substrate, such as a high temperature superalloy, and a TBC, such as a coating of yttria stabilized zirconia. The TBC comprises a plurality of plasma-sprayed layers. The TBC has a coherent, continuous columnar grain microstructure, wherein at least one layer has a plurality of continuous columnar grains which have been extended by directional solidification into an adjacent layer. In a preferred embodiment, the coherent, continuous columnar microstructure comprises substantially all of the volume of TBC. A coherent, continuous columnar grain microstructure is also taught wherein at least some of the plurality of coherent, continuous columnar grains which comprise a TBC extend through essentially the entire thickness of the coating. A columnar crack pattern of cracks extending generally normal to the surface of the metal substrate is also developed within TBCs of the present invention in conjunction with the coherent, continuous columnar grain microstructures described.

摘要翻译： 具有抗剥落TBC的制品包括金属基底，例如高温超合金，以及TBC，例如氧化钇稳定的氧化锆的涂层。 TBC包括多个等离子体喷涂层。 TBC具有连续的连续的柱状晶粒微观结构，其中至少一层具有多个通过定向凝固延伸到相邻层中的连续柱状晶粒。 在一个优选的实施方案中，相干连续的柱状微结构包含基本上所有体积的TBC。 还教导了连续的，连续的柱状晶粒微结构，其中包括TBC的多个连续的连续柱状晶粒中的至少一些基本上延伸穿过涂层的整个厚度。 本发明的TBCs与所描述的连贯的连续的柱状微结构相结合，也开发出大致垂直于金属基底表面的裂纹的柱状裂纹图案。

公开(公告)号：US5989343A

公开(公告)日：1999-11-23

申请号：US208864

申请日：1998-12-10

申请人： Marcus Preston Borom ,  Dennis Michael Gray ,  Curtis Alan Johnson

发明人： Marcus Preston Borom ,  Dennis Michael Gray ,  Curtis Alan Johnson

IPC分类号： C23C4/02 ,  C23C4/12 ,  C23C4/10

CPC分类号： C23C4/12 ,  C23C4/02 ,  Y02T50/67

摘要： A method and apparatus form a thermal barrier coating on a metal component. A molten thermal barrier coating powder is sprayed on the component in sweeping strokes. A plurality of overlapping solidified coating ribbons are deposited on the component and include a sequentially deposited surface ribbon forming sublayer ribbons therebelow. The surface ribbon is preheated at a spray site so that the sprayed molten powder remelts the surface ribbon at the spray site for sequentially welding the sequentially deposited surface ribbons to the sublayer ribbons.

摘要翻译： 一种方法和装置在金属部件上形成热障涂层。 熔融的热障涂层粉末以清扫的冲程喷涂在部件上。 多个重叠的固化涂层带沉积在部件上并且包括顺序沉积的表面带形成下面的下层带。 表面带在喷涂部位被预热，使得喷涂的熔融粉末在喷涂位置重熔表面带，以将顺序地沉积的表面带顺序地焊接到子层带上。

公开(公告)号：US5830586A

公开(公告)日：1998-11-03

申请号：US681558

申请日：1996-07-29

申请人： Dennis Michael Gray ,  Yuk-Chiu Lau ,  Curtis Alan Johnson ,  Marcus Preston Borom ,  Warren Arthur Nelson

发明人： Dennis Michael Gray ,  Yuk-Chiu Lau ,  Curtis Alan Johnson ,  Marcus Preston Borom ,  Warren Arthur Nelson

IPC分类号： C23C4/02 ,  C23C4/12 ,  B32B15/04

CPC分类号： C23C4/12 ,  C23C4/02 ,  C23C4/134 ,  Y10T428/12535 ,  Y10T428/12611 ,  Y10T428/12618 ,  Y10T428/12806 ,  Y10T428/12931 ,  Y10T428/12944 ,  Y10T428/24314

摘要： An article having a spallation resistant TBC comprises a metal substrate, such as a high temperature superalloy, and a TBC, such as a coating of yttria stabilized zirconia. The TBC comprises a plurality of plasma-sprayed layers. The TBC has a coherent, continuous columnar grain microstructure, wherein at least one layer has a plurality of continuous columnar grains which have been extended by directional solidification into an adjacent layer. In a preferred embodiment, the coherent, continuous columnar microstructure comprises substantially all of the volume of TBC. A coherent, continuous columnar grain microstructure is also taught wherein at least some of the plurality of coherent, continuous columnar grains which comprise a TBC extend through essentially the entire thickness of the coating. A columnar crack pattern of cracks extending generally normal to the surface of the metal substrate is also developed within TBCs of the present invention in conjunction with the coherent, continuous columnar grain microstructures described.

摘要翻译： 具有抗剥落TBC的制品包括金属基底，例如高温超合金，以及TBC，例如氧化钇稳定的氧化锆的涂层。 TBC包括多个等离子体喷涂层。 TBC具有连续的连续的柱状晶粒微观结构，其中至少一层具有多个通过定向凝固延伸到相邻层中的连续柱状晶粒。 在一个优选的实施方案中，相干连续的柱状微结构包括基本上全部的TBC体积。 还教导了连续的，连续的柱状晶粒微结构，其中包括TBC的多个连续的连续柱状晶粒中的至少一些基本上延伸穿过涂层的整个厚度。 本发明的TBCs与所描述的连贯的连续的柱状微结构相结合，也开发出大致垂直于金属基底表面的裂纹的柱状裂纹图案。

公开(公告)号：US06306517B1

公开(公告)日：2001-10-23

申请号：US09632354

申请日：2000-08-03

申请人： Dennis Michael Gray ,  Yuk-Chiu Lau ,  Curtis Alan Johnson ,  Marcus Preston Borom ,  Warren Arthur Nelson

发明人： Dennis Michael Gray ,  Yuk-Chiu Lau ,  Curtis Alan Johnson ,  Marcus Preston Borom ,  Warren Arthur Nelson

IPC分类号： B32B900

CPC分类号： C23C4/12 ,  C23C4/02 ,  C23C4/134

摘要： An article having a spallation resistant TBC comprises a metal substrate, such as a high temperature superalloy, and a TBC, such as a coating of yttria stabilized zirconia. The TBC comprises a plurality of plasma-sprayed layers. The TBC has a coherent, continuous columnar grain microstructure, wherein at least one layer has a plurality of continuous columnar grains which have been extended by directional solidification into an adjacent layer.

摘要翻译： 具有抗剥落TBC的制品包括金属基底，例如高温超合金，以及TBC，例如氧化钇稳定的氧化锆的涂层。 TBC包括多个等离子体喷涂层。 TBC具有连续的连续的柱状晶粒微观结构，其中至少一层具有多个通过定向凝固延伸到相邻层中的连续柱状晶粒。

公开(公告)号：US06261643B1

公开(公告)日：2001-07-17

申请号：US09258829

申请日：1999-02-26

申请人： Wayne Charles Hasz ,  Marcus Preston Borom ,  Curtis Alan Johnson

发明人： Wayne Charles Hasz ,  Marcus Preston Borom ,  Curtis Alan Johnson

IPC分类号： B05D302

CPC分类号： C23C28/042 ,  C23C4/02 ,  C23C28/044 ,  C23C28/048 ,  F01D5/288 ,  F05D2300/21 ,  Y02T50/67 ,  Y02T50/672

摘要： A composite that protects thermal barrier coatings from the deleterious effects of environmental contaminants at operational temperatures is discovered. The thermal barrier coated parts have least two outer protective coatings that decrease infiltration of molten contaminant eutectic mixtures into openings in the thermal barrier coating.

摘要翻译： 发现了保护热障涂层免受环境污染物在操作温度下的有害影响的复合材料。 热障涂层部分具有至少两个外部保护涂层，其减少了熔融污染物共晶混合物渗透到热障涂层中的开口中。

公开(公告)号：US06274201B1

公开(公告)日：2001-08-14

申请号：US09558258

申请日：2000-04-25

申请人： Marcus Preston Borom ,  Dennis Michael Gray ,  Yuk-Chiu Lau ,  Surinder Singh Pabla

发明人： Marcus Preston Borom ,  Dennis Michael Gray ,  Yuk-Chiu Lau ,  Surinder Singh Pabla

IPC分类号： C23C404

CPC分类号： C23C28/3215 ,  C23C4/02 ,  C23C28/325 ,  C23C28/345 ,  C23C28/3455 ,  Y02T50/67 ,  Y10S428/937 ,  Y10T428/12458 ,  Y10T428/12479 ,  Y10T428/12618 ,  Y10T428/12861 ,  Y10T428/12931

摘要： An article is described, which includes a metal-based substrate, such as a superalloy; a dense, primary bond layer; and a spongy secondary bond layer. A thermal barrier coating is applied over the secondary bond layer. The spongy layer has a microstructure which includes an open network of interconnected pores. A process is also described. It includes the step of applying a spongy, metallic bond layer over the substrate, followed by the application of a thermal barrier coating. A dense, primary bond layer may optionally be applied before the application of the spongy layer.

摘要翻译： 描述了一种制品，其包括金属基底，例如超级合金; 致密的主键层; 和海绵状二次键合层。 在二次接合层上施加热障涂层。 海绵层具有包括互连孔的开放网络的微结构。 还描述了一个过程。 它包括在衬底上施加海绵状金属粘合层，然后施加热障涂层的步骤。 在施加海绵层之前，可以任选地施加致密的主键层。