Abstract: A method for reducing thermal conductivity in thermal barrier coatings broadly includes the steps of depositing a mixture containing a ceramic matrix and a metallic dispersant capable of forming a metal oxide upon a substrate to form one or more layers; and heating the layers at a temperature and for a time sufficient to oxidize the metallic dispersant and form one or more layers of a thermal barrier coating.

Abstract: A spallation resistant metallic article comprising a metallic substrate, at least one ceramic thermal barrier coating comprising a zirconia base and at least one other element selected from the group consisting of La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Sc, In, Y, Mo and C, rare earth oxides, scandium, and indium, and a ceramic bond coat located on at least a portion of the substrate and between the metallic substrate and the at least one ceramic thermal barrier coating wherein the ceramic bond coat is composed of yttria stabilized zirconia (YSZ).

Abstract: A ceramic material having particular utility as a thermal insulating or thermal barrier coating on metallic substrates is provided. The ceramic material broadly comprises at least one oxide and the balance comprising a first oxide selected from the group consisting of zirconia, ceria, and hafnia. The at least one oxide has a formula A2O3 where A is selected from the group consisting of La, Pr, Nd, Sm, Eu, Tb, In, Sc, Y, Dy, Ho, Er, Tm, Yb, Lu, and mixtures thereof. The present invention also broadly relates to an article having a metal substrate and a thermal barrier coating as discussed above.

Abstract: A turbine component has a substrate formed from a ceramic material selected from the group consisting of a monolithic ceramic material and a composite ceramic material and a thermal barrier coating bonded to the substrate. In one embodiment, the ceramic material forming the substrate is selected from the group of silicon nitride and self-reinforced silicon nitride. In another embodiment, the ceramic material forming the substrate is selected from the group consisting of a silicon carbide-silicon carbide material and a carbon-carbon material. At least one bond coat layer may be interposed between the substrate and the thermal barrier coating.

Abstract: A turbine component has a substrate formed from a ceramic material selected from the group consisting of a monolithic ceramic material and a composite ceramic material and a thermal barrier coating bonded to the substrate. In one embodiment, the ceramic material forming the substrate is selected from the group of silicon nitride and self-reinforced silicon nitride. In another embodiment, the ceramic material forming the substrate is selected from the group consisting of a silicon carbide-silicon carbide material and a carbon-carbon material. At least one bond coat layer may be interposed between the substrate and the thermal barrier coating.

Abstract: A ceramic material having particular utility as a thermal insulating or thermal barrier coating on metallic substrates is provided. The ceramic material broadly comprises at least one oxide and the balance comprising a first oxide selected from the group consisting of zirconia, ceria, and hafnia. The at least one oxide has a formula A2O3 where A is selected from the group consisting of La, Pr, Nd, Sm, Eu, Th, In, Sc, Y, Dy, Ho, Er, Tm, Yb, Lu, and mixtures thereof. The present invention also broadly relates to an article having a metal substrate and a thermal barrier coating as discussed above.

Abstract: A ceramic material having particular utility as a thermal insulating or thermal barrier coating on metallic substrates is provided. The ceramic material broadly comprises at least one oxide and the balance comprising a first oxide selected from the group consisting of zirconia, ceria, and hafnia. The at least one oxide has a formula A2O3 where A is selected from the group consisting of La, Pr, Nd, Sm, Eu, Tb, In, Sc, Y, Dy, Ho, Er, Tm, Yb, Lu, and mixtures thereof. The present invention also broadly relates to an article having a metal substrate and a thermal barrier coating as discussed above.

Abstract: A ceramic material having particular utility as a thermal insulating or thermal barrier coating on metallic substrates is provided. The ceramic material broadly comprises at least one lanthanide sesquioxide and the balance comprising a first oxide selected from the group consisting of zirconia, ceria, and hafnia. The lanthanide sesquioxide has a formula A2O3 where A is selected from the group consisting of La, Pr, Nd, Sm, Eu, Tb, In, Sc, Y, Dy, Ho, Er, Tm, Yb, Lu, and mixtures thereof. The present invention also broadly relates to an article having a metal substrate and a thermal barrier coating as discussed above.

Abstract: A superalloy article is disclosed having a thermal barrier coating. The article comprises a superalloy substrate, an adherent alumina layer on the substrate, and a ceramic, thermally insulating layer on the alumina layer. The ceramic layer has an overall thickness and comprises a relatively strain tolerant, columnar grain ceramic on the alumina layer and relatively more thermally insulating ceramic on the columnar grain ceramic. The alumina layer may be formed using an alumina forming layer such as an overlay or aluminide bond coat, or the superalloy may comprise a material that is capable of forming an alumina layer. The ceramic layers may be formed of a stabilized zirconia or other suitable material, and may have the same or different compositions.

Abstract: A thermal barrier coating system for a superalloy substrate is disclosed. The superalloy is preferably of the type that is capable of forming an adherent alumina layer. A bond coat is applied to a local area of the substrate, so that a portion of the substrate remains exposed. The localized area is defined to be the area(s) at which a TBC typically fails first, e.g., the leading and trailing edges of an airfoil, or other area. An alumina layer is formed on the remaining portion of the substrate, and also on the bond coat. A ceramic layer is then applied on the alumina layer. Even if the ceramic material is removed, the localized bond coat remains, and reduces the rate at which the underlying substrate oxidizes. A coated article is also disclosed, as is a system that utilizes a conventional superalloy and aluminide coating with the localized bond coat.

Abstract: A thermal barrier coating system for a superalloy substrate is disclosed. The superalloy is preferably of the type that is capable of forming an adherent alumina layer. A bond coat is applied to a local area of the substrate, so that a portion of the substrate remains exposed. The localized area is defined to be the area(s) at which a TBC typically fails first, e.g., the leading and trailing edges of an airfoil, or other area. An alumina layer is formed on the remaining portion of the substrate, and also on the bond coat. A ceramic layer is then applied on the alumina layer. Even if the ceramic material is removed, the localized bond coat remains, and reduces the rate at which the underlying substrate oxidizes. A coated article is also disclosed, as is a system that utilizes a conventional superalloy and aluminide coating with the localized bond coat.

Abstract: A thermal barrier coating system for a superalloy substrate is disclosed. The superalloy is preferably of the type that is capable of forming an adherent alumina layer. A bond coat is applied to a local area of the substrate, so that a portion of the substrate remains exposed. The localized area is defined to be the area(s) at which a TBC typically fails first, e.g., the leading and trailing edges of an airfoil, or other area. An alumina layer is formed on the remaining portion of the substrate, and also on the bond coat. A ceramic layer is then applied on the alumina layer. Even if the ceramic material is removed, the localized bond coat remains, and reduces the rate at which the underlying substrate oxidizes. A coated article is also disclosed, as is a system that utilizes a conventional superalloy and aluminide coating with the localized bond coat.

Abstract: A thermal barrier coating system for a superalloy substrate is disclosed. The superalloy is preferably of the type that is capable of forming an adherent alumina layer. A bond coat is applied to a local area of the substrate, so that a portion of the substrate remains exposed. The localized area is defined to be the area(s) at which a TBC typically fails first, e.g., the leading and trailing edges of an airfoil, or other area. An alumina layer is formed on the remaining portion of the substrate, and also on the bond coat. A ceramic layer is then applied on the alumina layer. Even if the ceramic material is removed, the localized bond coat remains, and reduces the rate at which the underlying substrate oxidizes. A coated article is also disclosed, as is a system that utilizes a conventional superalloy and aluminide coating with the localized bond coat.

Abstract: An apparatus for applying ceramic coatings using an electron beam-physical vapor deposition apparatus is described. The apparatus includes means for introducing the anionic constitutent of the ceramic into a coating chamber and means for confining the anionic constituent about the component to be coated during the coating process.

Abstract: An improved thermal barrier coating system is described. A key feature of the invention is the presence of a thin, adherent aluminum oxide scale on the surface of the substrate. An oxide stabilized ceramic coating is present on the surface of the scale. Preferably, the ceramic coating has a columnar grain structure.

Abstract: A method for applying ceramic coatings using electron beam--physical vapor deposition techniques is described. The method includes the step of introducing the anionic constituent of the ceramic into a coating chamber and confining the anionic constituent about the component to be coated during the coating cycle.

Abstract: Concepts relating to the heat treatment of single crystal superalloy articles are disclosed. A first concept is the use of a heat treatment sequence which includes incipient melting of the article being heat treated followed by one or more steps which essentially heal the incipient melting damage. A second concept relates to the treatment of previously heat treated single crystal articles which have incipient melting. Methods are disclosed for healing this damage and for recovering the mechanical properties of such articles. A third concept disclosed is a particular cycle which permits effective heat treatment of a specific single crystal alloy composition.

Abstract: A coated article and method for producing the coated article are described. The article is coated with a system which provides protection against oxidation and corrosion and which significantly reduces the substrate temperature. An MCrAlY layer is applied to the article to be protected and a columnar grain ceramic is applied by vapor deposition to the MCrAlY coated article. An alumina layer which exists between the MCrAlY layer and the columnar ceramic layer provides for the adherence of the columnar layer to the MCrAlY layer. An important feature of the invention is that the interface between the MCrAlY layer and the alumina layer has a low surface roughness and this greatly improves the columnar ceramic layer adherence.

Abstract: A coated article and method for producing the coated article are described. The article is coated with a system which provides protection against oxidation and corrosion and which significantly reduces the substrate temperature. An MCrAlY layer is applied to the article to be protected and a columnar grain ceramic is applied by vapor deposition to the MCrAlY coated article. An alumina layer which exists between the MCrAlY layer and the columnar ceramic layer provides for the adherence of the columnar layer to the MCrAlY layer. An important feature of the invention is that the interface between the MCrAlY layer and the alumina layer has a low surface roughness and this greatly improves the columnar ceramic layer adherence.

Abstract: A coated article and method for producing the coated article are described. The article is provided with a coating system which provides protection against hot corrosion at moderate temperatures (1200-1700.degree. F.). An overlay coating based on a metal selected from the group consisting of iron, nickel or cobalt or mixtures thereof and containing chromium and optionally aluminum, yttrium and/or hafnium is applied to the article to be protected. A silicon rich surface zone is produced at the surface of the overlay coating. Methods including pack cementation and physical vapor deposition are described for producing the coating.