High Temperature Imaging Media for Digital Image Correlation
A thermal barrier coating is provided. The thermal barrier coating is configured to remain adherent to the substrate under high strains, thus allowing the use of non-contacting strain measurement systems, such as digital image correlation. The thermal barrier coating may include a first layer of a partially metallic material configured to adhere to a metallic substrate, and a second layer of a partially ceramic material configured to adhere to the first layer. A successful configuration has a top layer thickness that is approximately two-thirds of the first layer thickness.
This is a non-provisional US patent application claiming priority under U.S.C §119(e) to U.S. Provisional Ser. No. 61/900,752 filed on Nov. 6, 2013
FIELD OF THE DISCLOSUREThe present disclosure generally relates to thermal barrier coatings, and particularly to thermal barrier coatings for use in non-contact characterization of high temperature materials.
BACKGROUND OF THE DISCLOSUREThermal barrier coatings are applied to a variety of materials typically exposed to high temperatures or high temperature gradients. Thermal barrier coatings are typically applied to the surfaces of metallic substrates to insulate and protect the general integrity of the underlying substrate from prolonged thermal loads. The unique characteristics of thermal barrier coatings allow for expanded use in non-contact strain measurements.
Conventional thermal barrier coatings are comprised of two or more layers, such as a bond coat, a thermally grown oxide and a top layer. The bond coat is typically formed of a metallic material or metal alloy which provides an adhering interface between the top coat and the substrate. Existing non-contact strain measurements are limited to relatively low temperatures (<1000° F.), and strain levels less than ˜10%. These limits are associated with the materials, such as ceramic paint, used to provide optical contrast.
Ceramic paints are limited both in temperature capability and strain compatibility. They are susceptible to spalling and flaking at high strain levels. Degradation of this type will preclude successful use of a non-contact strain measurement technique such as digital image correlation. The present disclosure is directed at addressing one or more of the deficiencies set forth above.
SUMMARY OF THE DISCLOSUREIn accordance with one aspect of the disclosure, a thermal barrier coating is provided. The thermal barrier coating includes a bond layer having a first thickness, and a top layer having a second thickness that is approximately two-thirds of the first thickness.
In a refinement, one or more of the bond layer and the top layer may be configured to maintain substantial adherence with a metallic substrate at temperatures of at least approximately 1400° F. and under strain levels of at least approximately 30%.
In accordance with another aspect of the disclosure, a thermal barrier coating is provided. The thermal barrier coating includes a metallic bond coat having a thickness of approximately 0.003 inches, and a second layer ceramic top coat having a thickness of approximately 0.002 inches.
In accordance with yet another aspect of the disclosure, a method of applying a thermal barrier coating onto a metallic substrate is provided. The method includes applying a first layer of a partially metallic material of a first thickness to a surface of the metallic substrate; and applying a second layer of a partially ceramic material of a second thickness to the first layer. The second layer is applied such that the second thickness is approximately two-thirds of the first thickness.
These and other aspects of this disclosure will become more readily apparent upon reading the following detailed description when taken in conjunction with the accompanying drawings.
While the present disclosure is susceptible to various modifications and alternative constructions, certain illustrative embodiments thereof have been shown in the drawings and will be described below in detail. It should be understood, however, that there is no intention to be limited to the specific forms disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions, and equivalents falling with the spirit and scope of the present disclosure.
DETAILED DESCRIPTIONReferring to
As shown in
The thermal barrier coating 20 of
Still referring to
Furthermore, the bond layer 24 and the top layer 26 of the thermal barrier coating 20 of
Turning now to
The foregoing disclosure is exemplary rather than defined by the limitations within. Various non-limiting embodiments are disclosed herein, however, one of ordinary skill in the art would recognize that various modifications and variations in light of the above teachings will fall within the scope of the appended claims. It is therefore to be understood that within the scope of the appended claims, the present disclosure may be practiced other than as specifically described. For that reason, the appended claims should be studied to determine true scope and content.
Claims
1. A thermal barrier coating, comprising:
- a bond layer having a first thickness; and
- a top layer having a second thickness that is approximately two-thirds of the first thickness.
2. The thermal barrier coating of claim 1, wherein one or more of the bond layer and the top layer is configured to maintain substantial adherence with a metallic substrate at temperatures of at least approximately 1400° F. and under strain levels of at least approximately 30%.
3. The thermal barrier coating of claim 1, wherein the top layer is at least partially formed of a ceramic material.
4. The thermal barrier coating of claim 1, further comprising a thermally grown oxide layer that is disposed between the bond layer and the top layer.
5. A thermal barrier coating, comprising:
- a first layer of a partially metallic material configured to adhere to a metallic substrate, the first layer having a thickness of approximately 0.003 inches; and
- a second layer of a partially ceramic material configured to adhere to the first layer, the second layer having a thickness of approximately 0.002 inches.
6. The thermal barrier coating of claim 5, wherein one or more of the first layer and the second layer is configured to maintain adherence with the metallic substrate at temperatures of at least approximately 1400° F. and under strain levels of approximately 30% strain.
7. The thermal barrier coating of claim 5, wherein one or more interfaces between the first layer and the second layer is configured to enable non-contact characterization of a sample substrate under high temperature and high strain conditions.
8. The thermal barrier coating of claim 5, wherein the first layer is a bond layer configured to adhere to the metallic substrate, and the second layer is a top layer configured to adhere to the first layer.
9. The thermal barrier coating of claim 5, further comprising a third layer formed of an at least partially oxide material, the third layer being disposed between the first layer and the second layer.
10. The thermal barrier coating of claim 5, wherein each of the first layer and the second layer is applied by one or more spray coats.
11. A method of applying a thermal barrier coating onto a metallic substrate, the method comprising:
- applying a first layer of a partially metallic material of a first thickness to a surface of the metallic substrate; and
- applying a second layer of a partially ceramic material of a second thickness to the first layer, the second layer being applied such that the second thickness is approximately two-thirds of the first thickness.
12. The method of claim 11, wherein one or more of the first layer and the second layer is configured to maintain adherence with the surface of the metallic substrate in temperatures of at least approximately 1400° F. and under strain levels of approximately 30% strain.
13. The method of claim 11, wherein the first layer is a bond layer and is bonded to the surface of the metallic substrate, and the second layer is a top layer and is bonded to the first layer.
14. The method of claim 11, wherein each of the first layer and the second layer is applied by one or more spray coats.
Type: Application
Filed: Aug 15, 2014
Publication Date: May 7, 2015
Inventors: Michael L. Hribernik (Jupiter, FL), Fred K. Haake (Palm Beach Gardens, FL)
Application Number: 14/460,975
International Classification: C23C 28/00 (20060101); B05D 1/36 (20060101); B05D 7/14 (20060101); B05D 1/02 (20060101);