Thermal barrier coating material and method for production thereof, gas turbine member using the thermal barrier coating material, and gas turbine

Abstract

A thermal barrier coating material, containing a metal binding layer laminated on a base material and ceramic layer laminated on the metal binding layer, the ceramic layer comprising partially stabilized ZrO 2 which is partially stabilized by additives of Dy 2 O 3 and Yb 2 O 3 .

1 . A method for producing a thermal barrier coating material comprising: laminating a metal binding layer on a surface of a base material;
 laminating a ceramic layer on a surface of the metal binding layer; and   forming microcracks that extend in a thickness direction in said ceramic layer by irradiating a surface of said ceramic layer with a laser beam and thereby heating the surface of said ceramic layer while cooling a rear surface of said base material.   
   
   
       2 . The method according to  claim 1 , wherein said surface of said ceramic layer is irradiated with said laser beam at a diameter range of 10 to 40 mm. 
   
   
       3 . The method according to  claim 1 , wherein the surface of said ceramic layer is heated to a temperature in a range of 1000 to 1700° C. by irradiation of said laser beam. 
   
   
       4 . The method according to  claim 1 , wherein said ceramic layer comprises partially stabilized ZrO 2  and wherein said irradiation with said laser beam is carried out from 5 to 1000 times with a proviso that neither phase modification nor sintering of partially stabilized ZrO 2  occurs. 
   
   
       5 . The method according to  claim 1 , wherein said ceramic layer has a porosity in a range of 1 to 30%. 
   
   
       6 . The method according to  claim 1 , wherein said ceramic layer has a density in a range of 4 g/mm 3  to 6.5 g/mm 3 . 
   
   
       7 . The method according to  claim 1 , wherein said microcracks are formed so that thermal conductivity is in a range of 0.5 w/m·K to 5 w/m·K. 
   
   
       8 . The method according to  claim 1 , wherein said microcracks are formed so that the number of said microcracks per unit length (1 mm) of a section of said ceramic layer is in a range of 1 to 10. 
   
   
       9 . The method according to  claim 1 , wherein the ceramic layer comprises ZrO 2  which is partially stabilized by additives of Dy 2 O 3  and Yb 2 O 3 . 
   
   
       10 . The method according to  claim 9 , wherein aid Dy 2 O 3  is in a range of 0.01 wt % to 16.00 wt %, said Yb 2 O 3  is in a range of 0.01 wt % to 17.00 wt %, a sum of said Dy 2 O 3  and said Yb 2 O 3  is in a range of 10 wt % to 20 wt %. 
   
   
       11 . The method according to  claim 9 , wherein said ZrO 2  excluding stabilizers is in a range of 80 wt % to 90 wt %. 
   
   
       12 . The method according to  claim 1 , wherein the ceramic layer has a thickness of 0.05 mm to 1.5 mm. 
   
   
       13 . The method according to  claim 1 , wherein the ceramic layer has a thickness of 0.1 mm to 1.5 mm. 
   
   
       14 . The method according to  claim 9 , wherein said surface of said ceramic layer is irradiated with said laser beam at a diameter range of 10 to 40 mm. 
   
   
       15 . The method according to  claim 9 , wherein the surface of said ceramic layer is heated to a temperature in a range of 1000 to 1700° C. by irradiation of said laser beam. 
   
   
       16 . The method according to  claim 9 , wherein said ceramic layer comprises partially stabilized ZrO 2  and wherein said irradiation with said laser beam is carried out from 5 to 1000 times with a proviso that neither phase modification nor sintering of partially stabilized ZrO 2  occurs. 
   
   
       17 . The method according to  claim 9 , wherein said ceramic layer has a porosity in a range of 1 to 30%. 
   
   
       18 . The method according to  claim 9 , wherein said ceramic layer has a density in a range of 4 g/mm 3  to 6.5 g/mm 3 . 
   
   
       19 . A method for producing a thermal barrier coating (TBC) raw material for thermal spraying, comprising mixing a zirconia powder having a specific surface area of at least 10 m 2 /g and a rare earth oxide powder having a specific surface area of at least 10 m 2 /g along with a binder or dispersant so as to form a slurry, then granulating to form particles having a mean particle diameter of 10 to 100 μm, and then heating at 1300 to 1600° C. for 1 to 10 hours. 
   
   
       20 . The method according to  claim 19 , wherein the rare earth oxide powder comprises Dy 2 O 3  and Yb 2 O 3 .