Thermal barrier coating protected by alumina and method for preparing same

Abstract

A thermal barrier coating for an underlying metal substrate of articles that operate at, or are exposed to, high temperatures, as well as being exposed to environmental contaminant compositions. This coating comprises an optional inner layer nearest to the underlying metal substrate comprising a non-alumina ceramic thermal barrier coating material in an amount up to 100%, and an outer layer having an exposed surface and comprising at least about 50% of a non-alumina ceramic thermal barrier coating material and alumina in an amount up to about 50% and sufficient to protect the thermal barrier coating at least partially against environmental contaminants that become deposited on the exposed surface. This coating can be used to provide a thermally protected article having a metal substrate and optionally a bond coat layer adjacent to and overlaying the metal substrate. The thermal barrier coating can be prepared by optionally forming the inner layer of the non-alumina ceramic thermal barrier coating material, and then codepositing the alumina and non-alumina ceramic thermal barrier coating material to form the outer layer.

1 - 19 . (canceled)  
   
   
       20 . A method for preparing a thermal barrier coating for an underlying metal substrate, the method comprising the steps of: 
 1. forming over the underlying metal substrate an inner layer comprising a non-alumina ceramic thermal barrier coating material in an amount up to 100% by weight; and    2. codepositing on the inner layer a non-alumina ceramic thermal barrier coating material and alumina so as to form an outer layer of different composition from the inner layer and having an exposed surface, the outer layer comprising from about 80 to about 90% by weight of the non-alumina ceramic thermal barrier coating material and from about 10 to about 20% by weight alumina and in an amount sufficient to protect the thermal barrier coating at least partially against environmental contaminants that become deposited on the exposed surface.    
   
   
       21 . The method of  claim 20  wherein a bond coat layer is adjacent to and overlies the metal substrate and wherein the inner layer is formed on the bond coat layer.  
   
   
       22 - 23 . (canceled)  
   
   
       24 . The method of  claim 21  wherein the inner layer is formed in step (1) by plasma spraying the non alumina ceramic thermal barrier coating material on the bond coat layer.  
   
   
       25 . The method of  claim 24  wherein step (2) is carried out by combining the zirconia non-alumina ceramic thermal barrier coating material and the alumina to form a substantially homogeneous mixture and then plasma spraying the mixture on the inner layer.  
   
   
       26 . The method of  claim 44  wherein step (2) is carried out by separately plasma spraying the non-alumina ceramic thermal barrier coating material and the alumina on the inner layer in a manner such that the non-alumina ceramic thermal barrier coating material and the alumina blend together to form a substantially homogeneous mixture.  
   
   
       27 . The method of  claim 21  wherein step (1) comprises depositing a zirconia on the bond coat layer to form the inner layer.  
   
   
       28 . The method of  claim 27  wherein step (2) comprises codepositing from about 80 to about 90% by weight of a zirconia and from about 10 to about 20% by weight alumina on the inner layer to form the outer layer.  
   
   
       29 . The method of  claim 28  wherein step (2) comprises the steps of: (a) codepositing the zirconia and the alumina on the inner layer to form a lower layer; and (b) depositing alumina on the lower layer to form an upper surface layer.  
   
   
       30 - 37 . (canceled)  
   
   
       38 . The method of  claim 50  wherein a bond coat layer is adjacent to and overlies the metal substrate and wherein the outer layer formed during step (2) comprises 100% by weight of the thermal barrier coating and is deposited on the bond coat layer.  
   
   
       39 - 40 . (canceled)  
   
   
       41 . The method of  claim 38  wherein step (2) is carried out by separately plasma spraying each of the non-alumina ceramic thermal barrier coating material and the alumina on the bond coat layer.  
   
   
       42 . The method of  claim 41  wherein step (2) comprises plasma spraying from about 80 to about 90% by weight of a zirconia and from about 10 to about 20% by weight alumina on the bond coat layer to form the outer layer.  
   
   
       43 . The method of  claim 41  wherein step (2) comprises the steps of: (a) separately plasma spraying each of the zirconia and the alumina on the bond coat layer to form a lower layer; and (b) plasma spraying alumina on the lower layer to form an upper surface layer.  
   
   
       44 . A method for preparing a thermal barrier coating for an underlying metal substrate, the method comprising the steps of: 
 1. forming over the underlying metal substrate an inner layer comprising a non-alumina ceramic thermal barrier coating material in an amount up to 100% by weight; and    2. codepositing on the inner layer a non-alumina ceramic thermal barrier coating material and alumina so as to form an outer layer of different composition than the inner layer and having an exposed surface, the outer layer comprising at least about 50% by weight non-alumina ceramic thermal barrier coating material and up to about 50% by weight alumina and in an amount sufficient to protect the thermal barrier coating at least partially against environmental contaminants that become deposited on the exposed surface, wherein the non-alumina ceramic thermal barrier coating material and the alumina are separately deposited on the inner layer in a manner such that the non-alumina ceramic thermal barrier coating material and the alumina combine together to form a substantially homogeneous mixture.    
   
   
       45 . The method of  claim 44  wherein a bond coat layer is adjacent to and overlies the metal substrate and wherein the inner layer is formed on the bond coat layer  
   
   
       46 . The method of  claim 45  wherein the inner layer is formed in step (1) by plasma spraying the non alumina ceramic thermal barrier coating material on the bond coat layer.  
   
   
       47 . The method of  claim 45  wherein step (1) comprises depositing a zirconia on the bond coat layer to form the inner layer.  
   
   
       48 . The method of  claim 47  wherein step (2) comprises codepositing from about 80 to about 90% by weight of a zirconia and from about 10 to about 20% by weight alumina on the inner layer to form the outer layer.  
   
   
       49 . The method of  claim 48  wherein step (2) comprises the steps of: (a) codepositing the zirconia and the alumina on the inner layer to form a lower layer; and (b) depositing alumina on the lower layer to form an upper surface layer.  
   
   
       50 . A method for preparing a thermal barrier coating for an underlying metal substrate of an article, wherein when the article is an airfoil, the thermal barrier coating overlaying portions of the metal substrate other than solely the tip of the airfoil, the method comprising the steps of: 
 1. optionally forming over the underlying metal substrate an inner layer comprising a non-alumina ceramic thermal barrier coating material in an amount up to 100% by weight; and    2. codepositing on the inner layer, or over the underlying metal substrate in the absence of the inner layer, a non-alumina ceramic thermal barrier coating material and alumina so as to form an outer layer of different composition than the inner layer and having an exposed surface, the outer layer comprising at least about 50% by weight non-alumina ceramic thermal barrier coating material and up to about 50% by weight alumina and in an amount sufficient to protect the thermal barrier coating at least partially against environmental contaminants that become deposited on the exposed surface, wherein the non-alumina ceramic thermal barrier coating material and the alumina are separately deposited over the substrate in a manner such that the non-alumina ceramic thermal barrier coating material and the alumina combine together to form a substantially homogeneous mixture.    
   
   
       51 . The method of  claim 28  wherein the inner layer comprises from about 95 to 100% by weight zirconia.  
   
   
       52 . The method of  claim 48  wherein the inner layer comprises from about 95 to 100% by weight zirconia.