Bond Coating and Thermal Barrier Compositions, Processes for Applying Both, and Their Coated Articles

Abstract

A coated article includes an article having at least one surface and composed of a molybdenum based refractory metal alloy base substrate, a niobium based refractory metal alloy base substrate or a silicon base substrate. A bond coat layer is disposed upon the surface. The bond coat layer includes a molybdenum disilicide base compound and at least one of the following: silicon nitride, silicon carbide or tantalum oxide. A process for coating the article includes the steps of applying upon the article's surface the aforementioned bond coat layer. A functionally graded material layer is applied upon the bond coat layer. The functionally graded material layer comprising molybdenum disilicide, mullite and at least one of the following: silicon nitride, silicon carbide or tantalum oxide. A thermal barrier coating layer is then applied upon the functionally graded material layer.

1 . A process for coating an article, comprising:
 applying upon at least one surface of a molybdenum based refractory metal alloy base or niobium based refractory metal alloy base substrate a bond coat material layer comprising a molybdenum disilicide base compound and at least one of the following: silicon nitride, silicon carbide or tantalum oxide.   
   
   
       2 . The process of  claim 1 , wherein the application step comprises an application process selected from the group consisting of plasma spraying processes, sol gel processes and slurry processes. 
   
   
       3 . The process of  claim 1 , further comprising forming a layer of thermally grown oxide upon said bond coat material layer. 
   
   
       4 . The process of  claim 3 , further comprising applying a thermal barrier composition layer upon said thermally grown oxide layer. 
   
   
       5 . The process of  claim 1 , further comprising applying a thermal barrier composition layer upon said bond coat material layer. 
   
   
       6 . The process of  claim 5 , further comprising drying said substrate. 
   
   
       7 . The process of  claim 1 , further comprising applying upon said bond coat material layer a functionally graded material layer comprising molybdenum disilicide, mullite and at least one of the following: silicon nitride, silicon carbide or tantalum oxide. 
   
   
       8 . The process of  claim 1 , wherein the application step further comprises applying said bond coat material layer comprising a molybdenum disilicide base compound and at least one of the following: silicon nitride, silicon carbide or tantalum oxide. 
   
   
       9 . The process of  claim 1 , wherein the application step further comprises applying said bond coat material layer upon said at least one surface of one of the following:
 molybdenum based refractory metal alloy base substrate, niobium based refractory metal alloy base substrate or silicon base substrate.   
   
   
       10 - 22 . (canceled)