Abstract:
The invention is directed to high purity zirconia-based and/or hafnia-based materials and coatings for high temperature cycling applications. Thermal barrier coatings made from the invention high purity material was found to have significantly improved sintering resistance relative to coatings made from current materials of lower purity. The invention materials are high purity zirconia and/or hafnia partially or fully stabilized by one or any combinations of the following stabilizers: yttria, ytterbia, scandia, lanthanide oxide and actinide oxide. Limits for impurity oxide, oxides other than the intended ingredients, that lead to significantly improved sintering resistance were discovered. High purity coating structures suitable for high temperature cycling applications and for application onto a substrate were provided. In one structure, the coating comprises a ceramic matrix, porosity and micro cracks. In another structure, the coating comprises a ceramic matrix, porosity, macro cracks and micro cracks. In another structure, the coating comprises ceramic columns and gaps between the columns. In another structure, the coating comprises ceramic columns, gaps between the columns and nodules distributing randomly in the gaps and columns.
Abstract:
A thermal spray process comprises injecting precursor solution droplets into the hot zone of the thermal spray flame. Also described are materials resulting from the process.
Abstract:
The invention is directed to a material and method for obtaining a ceramic abradable system for high temperature applications. High purity partially stabilized zirconia and/or hafnia base material has higher sintering resistance compared to conventional 6-9 weight percent yttria stabilized zirconia systems. The benefits of these systems are higher service lifetime and low thermal conductivity to achieve high operating temperatures. System includes a superalloy substrate, oxidation resistant bond coat and a thick ceramic abradable top coat. Total coating thickness is about 0.5-5 mm. In some applications an intermediate layer of high purity partially stabilized zirconia or a partially stabilized YSZ/MCrAlY cermet is applied over the oxidation resistant bond coat. In other applications an abradable system is applied on top of a grid. Additional benefits should be reduced blade wear at high operating conditions.
Abstract:
The invention is directed to high purity zirconia-based and/or hafnia-based materials and coatings for high temperature cycling applications. Thermal barrier coatings made from the invention high purity material was found to have significantly improved sintering resistance relative to coatings made from current materials of lower purity. The invention materials are high purity zirconia and/or hafnia partially or fully stabilized by one or any combinations of the following stabilizers: yttria, ytterbia, scandia, lanthanide oxide and actinide oxide. Limits for impurity oxide, oxides other than the intended ingredients, that lead to significantly improved sintering resistance were discovered. High purity coating structures suitable for high temperature cycling applications and for application onto a substrate were provided. In one structure, the coating comprises a ceramic matrix, porosity and micro cracks. In another structure, the coating comprises a ceramic matrix, porosity, macro cracks and micro cracks. In another structure, the coating comprises ceramic columns and gaps between the columns. In another structure, the coating comprises ceramic columns, gaps between the columns and nodules distributing randomly in the gaps and columns.
Abstract:
A metal oxide powder includes a powder feed material structured and arranged to form molten droplets when melted in a plasma stream. The molten droplets are structured and arranged to form frozen spherical droplets under free-fall conditions such that said molten droplets have ample time for complete in-flight solidification before reaching a collection chamber.
Abstract:
A metal oxide powder includes a powder feed material structured and arranged to form molten droplets when melted in a plasma stream. The molten droplets are structured and arranged to form frozen spherical droplets under free-fall conditions such that said molten droplets have ample time for complete in-flight solidification before reaching a collection chamber.
Abstract:
The present invention provides a high-purity fused and crushed stabilized zirconia powder. The powder—with or without further processing, such as plasma spheroidization—is used in thermal spray applications of thermal barrier coatings (TBCs) and high-temperature abradables. The resulting coatings have a significantly improved high temperature sintering resistance, which will enhance the durability and thermal insulation effect of the coating.
Abstract:
A thermal spray process comprises injecting precursor solution droplets into the hot zone of the thermal spray flame. Also described are materials resulting from the process.
Abstract:
The invention is directed to a material and method for obtaining a ceramic abradable system for high temperature applications. High purity partially stabilized zirconia and/or hafnia base material has higher sintering resistance compared to conventional 6-9 weight percent yttria stabilized zirconia systems. The benefits of these systems are higher service lifetime and low thermal conductivity to achieve high operating temperatures. System includes a superalloy substrate, oxidation resistant bond coat and a thick ceramic abradable top coat. Total coating thickness is about 0.5-5 mm. In some applications an intermediate layer of high purity partially stabilized zirconia or a partially stabilized YSZ/MCrAlY cermet is applied over the oxidation resistant bond coat. In other applications an abradable system is applied on top of a grid. Additional benefits should be reduced blade wear at high operating conditions.
Abstract:
The invention is directed to a material and method for obtaining a ceramic abradable system for high temperature applications. High purity partially stabilized zirconia and/or hafnia base material has higher sintering resistance compared to conventional 6-9 weight percent yttria stabilized zirconia systems. The benefits of these systems are higher service lifetime and low thermal conductivity to achieve high operating temperatures. System includes a superalloy substrate, oxidation resistant bond coat and a thick ceramic abradable top coat. Total coating thickness is about 0.5-5 mm. In some applications an intermediate layer of high purity partially stabilized zirconia or a partially stabilized YSZ/MCrAlY cermet is applied over the oxidation resistant bond coat. In other applications an abradable system is applied on top of a grid. Additional benefits should be reduced blade wear at high operating conditions.