Protective coating with high adhesion and articles made therewith

Abstract

Coatings and articles suitable for use in high temperature environments, for example, are presented. One embodiment is a coating that comprises a plurality of elongate material growth domains defined between domain boundaries. The domains have an intra-domain density of at least about 75% of theoretical density, have a substantially equiaxed grain morphology, and comprise a plurality of at least partially melted and solidified particles. Another embodiment is a coating that comprises a matrix comprising a substantially equiaxed grain morphology and a plurality of vertically oriented cracks disposed in the matrix. Further embodiments include articles comprising one or more of the coatings described above.

1 . An article for use at elevated temperatures, comprising:
 a substrate; and   a coating disposed on the substrate,   wherein the coating comprises a matrix comprising a substantially equiaxed grain morphology, and a plurality of vertically oriented cracks disposed in the matrix.   
     
     
         2 . The article of  claim 1 , wherein the coating has a density of at least about 90%. 
     
     
         3 . The article of  claim 1 , wherein the cracks are present at a level of greater than about 250 cracks per linear inch. 
     
     
         4 . The article of  claim 1 , wherein the coating comprises a ceramic material. 
     
     
         5 . The article of  claim 1 , wherein the coating comprises an oxide. 
     
     
         6 . The article of  claim 1 , wherein the coating comprises a material selected from the group consisting of stabilized zirconia, zirconates, and stabilized oxides. 
     
     
         7 . The article of  claim 1 , further comprising a bondcoat disposed between the substrate and the coating. 
     
     
         8 . The article of  claim 7 , wherein the bondcoat has a surface roughness of less than about 150 microinches R a . 
     
     
         9 . The article of  claim 7 , wherein the adhesion strength is greater than about 28 megapascals. 
     
     
         10 . The article of  claim 1 , wherein the coating has a density of at least about 95%. 
     
     
         11 . The article of  claim 1 , wherein the article comprises a component of a gas turbine assembly.