ARCHITECTURES FOR HIGH TEMPERATURE TBCs WITH ULTRA LOW THERMAL CONDUCTIVITY AND ABRADABILITY AND METHOD OF MAKING

摘要

A method for fabricating thermal barrier coatings. The thermal barrier coatings are produced with a fine grain size by reverse co-precipitation of fine powders. The powders are then sprayed by a solution plasma spray that partially melts the fine powders while producing a fine grain size with dense vertical cracking. The coatings comprise at least one of 45%-65% Yb2O3 the balance Zr, Yb/Y/Hf/Ta the balance Zr and 2.3-7.8% La, 1.4-5.1% Y and the balance Zr and are characterized by a thermal conductivity that is about 25-50% lower than that of thermal barrier coatings comprising YSZ. The thermal barrier coatings also are characterized by at least one of excellent erosion resistance, fracture toughness and abrasion resistance.

主权项

1. A method for fabricating thermal barrier coating, comprising
providing a strong basic reaction environment; controlling the hydrolysis-complex process to precipitate thermal barrier particles by reverse co-precipitation, while controlling morphology, size, crystalline phase and chemical composition of the particles; filtering the thermal barrier precipitate particles; washing the particles; then calcining the particles; ball milling the precipitate particles into powder; sorting and screening the particles; then spraying particles of preselected size onto a substrate to form the thermal barrier coating, wherein the thermal barrier coating is characterized by low thermal conductivity, and at least one of erosion resistance in a hot gas flow path and abradability.