Reactive phase spray formulation coatings

Abstract

A reactive phase spray formulation coating is configured to be disposed on the thermal barrier coating of an article. The reactive phase spray formulation coating comprises a base material and a binder material. The base material has a compliance that is higher than a compliance of the binder material, the binder material has a cohesive strength that is greater than a cohesive strength of the base material, the binder material has an adhesive strength that is greater than an adhesive strength of the base material, and the binder material has a surface area of at least ten square-meters per gram that is greater than a surface area of the base material. The binder material is configured to improve a cohesive strength level, an adhesive strength level, and a compliance of the formulation coating of the thermal barrier coating relative to the formulation coating not including the binder material.

What is claimed is: 
     
         1 . A reactive phase spray formulation coating configured to be deposited on a thermal bather coating of an article, the reactive phase spray formulation coating comprising:
 a base material having a compliance that is higher than a compliance of a binder material; and   the binder material having a cohesive strength that is greater than a cohesive strength of the base material,
 wherein the binder material has an adhesive strength that is greater than an adhesive strength of the base material, 
 wherein the binder material has a surface area of at least ten square meters per gram that is greater than a surface area of the base material, and 
 wherein the binder material is configured to improve a cohesive strength level, an adhesive strength level, and a compliance of the reactive phase spray formulation coating of the thermal barrier coating relative to the reactive phase spray formulation coating not including the binder material. 
   
     
     
         2 . The reactive phase spray formulation coating of  claim 1 , wherein the reactive phase spray formulation coating is configured to react with dust deposits on the thermal barrier coating. 
     
     
         3 . The reactive phase spray formulation coating of  claim 1 , wherein the reactive phase spray formulation coating is configured to reduce an amount of spalling of the thermal barrier coating relative to the reactive phase spray formulation coating not being disposed on the thermal barrier coating. 
     
     
         4 . The reactive phase spray formulation coating of  claim 1 , wherein the reactive phase spray formulation coating is configured to be deposited on the thermal barrier coating in a non-thermal process. 
     
     
         5 . The reactive phase spray formulation coating of  claim 1 , wherein the binder material has a particle size that is less than one micron, and wherein the base material has a particle size between one micron and ten microns. 
     
     
         6 . The reactive phase spray formulation coating of  claim 1 , wherein the base material has a chemical configuration that is common to a chemical configuration of the binder material. 
     
     
         7 . The reactive phase spray formulation coating of  claim 1 , wherein the article is a surface of a turbine assembly. 
     
     
         8 . The reactive phase spray formulation coating of  claim 1 , wherein the reactive phase spray formulation coating has a ratio comprising of at least seven parts of the base material to at least three parts of the binder material. 
     
     
         9 . The reactive phase spray formulation coating of  claim 1 , wherein the reactive phase spray formulation coating has a ratio comprising of at least nineteen parts of the base material to at least one part of the binder material. 
     
     
         10 . The reactive phase spray formulation coating of  claim 1 , wherein the base material includes one or more parts of zirconium, oxygen, or yttrium. 
     
     
         11 . The reactive phase spray formulation coating of  claim 1 , wherein the binder material includes one or more parts of zirconium, oxygen, or yttrium. 
     
     
         12 . The reactive phase spray formulation coating of  claim 1 , wherein the reactive phase spray formulation coating deposited on the thermal barrier coating has a thickness of at least ten microns. 
     
     
         13 . A method comprising:
 combining a base material with a binder material to create a reactive phase spray formulation coating, the reactive phase spray formulation coating configured to be deposited on a thermal barrier coating of an article, wherein the base material has a compliance that is higher than a compliance of the binder material, wherein the binder material has a cohesive strength that is greater than a cohesive strength of the base material, wherein the binder material has an adhesive strength that is greater than an adhesive strength of the base material, wherein the binder material has a surface area of at least ten square meters per gram that is greater than a surface area of the base material; and   depositing the reactive phase spray formulation coating on the thermal barrier coating of the article, wherein the binder material is configured to improve a cohesive strength level, an adhesive strength level, and a compliance of the reactive phase spray formulation coating of the thermal barrier coating relative to the reactive phase spray formulation coating not including the binder material.   
     
     
         14 . The method of  claim 13 , wherein the reactive phase spray formulation coating is configured to react with dust deposits on the thermal barrier coating. 
     
     
         15 . The method of  claim 13 , wherein the reactive phase spray formulation coating is configured to reduce an amount of spalling of the thermal barrier coating relative to the reactive phase spray formulation coating not being disposed on the thermal barrier coating. 
     
     
         16 . The method of  claim 13 , further comprising depositing the reactive phase spray formulation coating on the thermal barrier coating in a non-thermal process. 
     
     
         17 . The method of  claim 13 , wherein the binder material has a particle size that is less than one micron, and wherein the base material has a particle size between one micron and ten microns. 
     
     
         18 . The method of  claim 13 , wherein the base material has a chemical configuration that is common to a chemical configuration of the binder material. 
     
     
         19 . The method of  claim 13 , wherein the article is a surface of a turbine assembly. 
     
     
         20 . The method of  claim 13 , wherein the reactive phase spray formulation coating has a ratio comprising of at least seven parts of the base material to at least three parts of the binder material. 
     
     
         21 . The method of  claim 13 , wherein the reactive phase spray formulation coating has a ratio comprising of at least nineteen parts of the base material to at least one part of the binder material. 
     
     
         22 . The method of  claim 13 , wherein the base material includes one or more parts of zirconium, oxygen, or yttrium. 
     
     
         23 . The method of  claim 13 , wherein the binder material includes one or more parts of zirconium, oxygen, or yttrium. 
     
     
         24 . The method of  claim 13 , wherein the reactive phase spray formulation coating deposited on the thermal barrier coating has a thickness of at least ten microns. 
     
     
         25 . A system comprising:
 a thermal barrier coating disposed on a surface of an article, the thermal barrier coating configured to reduce an amount of degradation of the article relative to the article not having the thermal barrier coating disposed on the surface; and   a reactive phase spray formulation coating configured to be deposited on the thermal barrier coating of the article, the reactive phase spray formulation coating comprising a base material and a binder material,
 wherein the base material has a compliance that is higher than a compliance of the binder material, 
 wherein the binder material has a cohesive strength that is greater than a cohesive strength of the base material, 
 wherein the binder material has an adhesive strength that is greater than an adhesive strength of the base material, 
 wherein the binder material has a surface area of at least ten square-meters per gram that is greater than a surface area of the base material, and 
 wherein the binder material is configured to improve a cohesive strength level, an adhesive strength level, and a compliance of the reactive phase spray formulation coating of the thermal barrier coating relative to the reactive phase spray formulation coating not including the binder material.