US4485151A
Expired / Lapsed
US
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Thermal barrier coating system
Assignee: United States, REPRESENTED BY SECRETARY OF NASA
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Filing: 1983-08-16
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Granted: 1984-11-27
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Expires: 2003-08-16
Abstract
Abstract This invention relates to a high temperature oxidation resistant thermal barrier coating system for a nickel-, cobalt-, or iron-base alloy substrate. An inner metal bond coating contacts the substrate, and a thermal barrier coating covers the bond coating. NiCrAlR, FeCrAlR, and CoCrAlR alloys have been satisfactory as bond coating compositions where R=Y or Yb. These alloys contain, by weight, 24.9-36.7% chromium, 5.4-18.5% aluminum, and 0.05 to 1.55% yttrium or 0.05 to 0.53% ytterbium. The coatings containing ytterbium are preferred over those containing yttrium. An outer thermal barrier coating of partially stabilized zirconium oxide (zirconia) which is between 6% and 8%, by weight, of yttrium oxide (yttria) covers the bond coating. Partial stabilization provides a material with superior durability. Partially stabilized zirconia consists of mixtures of cubic, tetragonal, and monoclinic phases.
Inventors
- 👤 Stephan Stecura
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-31 02:36
CPC Classifications
C; C23; C23C; C23C28/00; C23C4/00; C23C4/02; Y; Y02; Y02T; Y02T50/00; Y02T50/60; Y10; Y10T; Y10T428/00; Y10T428/12; Y10T428/12493; Y10T428/12535; Y10T428/12611; Y10T428/12618; Y10T428/12771; Y10T428/12778; Y10T428/12861; Y10T428/12931; Y10T428/12937; Y10T428/12944; Y10T428/12951; Y10T428/12958; Y10T428/12965; Y10T428/12972
Claims Analysis
Total Claims: 10
Claim 1
Independent Claim
99 words
A coated article of manufacture having a duplex thermal barrier coating system comprising a substrate of a material selected from the group consisting of nickel-base, cobalt-base, and iron-base alloys, a bond coating consisting essentially of an alloy of about 24.9 w/o to about 36.7 w/o chromium, about 5.5 w/o to about 18.5 w/o aluminum, and about 0.05 w/o to about 0.53 w/o ytterbium with a metal selected from the group consisting essentially of nickel, cobalt, and iron, and a thermal barrier coating consisting essentially of zirconia partially stabilized with about 6% by weight to about 8% by weight yttria.
Claim 2
Dependent Claim
99 words
A coated article of manufacture having a duplex thermal barrier coating system comprising a substrate of a material selected from the group consisting of nickel-base, cobalt-base, and iron-base alloys, a bond coating consisting essentially of an alloy of about 24.9 w/o to about 36.7 w/o chromium, about 5.5 w/o to about 18.5 w/o aluminum, and about 0.05 w/o to about 0.53 w/o ytterbium with a metal selected from the group consisting essentially of nickel, cobalt, and iron, and a thermal barrier coating consisting essentially of zirconia partially stabilized with about 6% by weight to about 8% by weight yttria.
Claim 3
Dependent Claim
24 words
A coated article of manufacture as claimed in claim 1 wherein the bond coating has a thickness between about 0.003 inch and 0.022 inch.
Claim 4
Dependent Claim
54 words
A coated article of manufacture as claimed in claim 2 wherein the substrate is a nickel base alloy, and the bond coating is an alloy comprising about 25.4 w/o to about 35.7 w/o chromium, about 5.6 w/o to about 6.4 w/o aluminum, about 0.34 w/o to about 0.53 w/o ytterbium, and the remainder nickel.
Claim 5
Dependent Claim
35 words
A coated article of manufacture as claimed in claim 2 wherein the substrate is an iron base, alloy and the bond coating contains about 0.09 w/o to about 0.14 w/o ytterbium, and the remainder iron.
Claim 6
Dependent Claim
98 words
A coated article of manufacture having a duplex thermal barrier coating system comprising a substrate of a material selected from the group consisting of nickel-base, cobalt-base, and iron-base alloys, a bond coating consisting essentially of an alloy of about 24.9 w/o to 36.7 w/o chromium, about 5.6 w/o to about 18.5 w/o aluminum, and about 0.05 w/o to about 0.53 w/o ytterbium with a metal selected from the group consisting essentially of nickel, cobalt, and iron, and a thermal barrier coating consisting essentially of zirconia partially stabilized with about 6% by weight to about 8% by weight yttria.
Claim 7
Dependent Claim
98 words
A coated article of manufacture having a duplex thermal barrier coating system comprising a substrate of a material selected from the group consisting of nickel-base, cobalt-base, and iron-base alloys, a bond coating consisting essentially of an alloy of about 24.9 w/o to 36.7 w/o chromium, about 5.6 w/o to about 18.5 w/o aluminum, and about 0.05 w/o to about 0.53 w/o ytterbium with a metal selected from the group consisting essentially of nickel, cobalt, and iron, and a thermal barrier coating consisting essentially of zirconia partially stabilized with about 6% by weight to about 8% by weight yttria.
Claim 8
Dependent Claim
54 words
A coated article of manufacture as claimed in claim 5 wherein the substrate is a nickel base alloy, and the bond coating is an alloy comprising about 25.4 w/o to about 35.6 w/o chromium, about 5.9 w/o to about 6.2 w/o aluminum, about 0.34 w/o to about 0.53 w/o ytterbium, and the remainder nickel.
Claim 9
Dependent Claim
31 words
A coated article of manufacture as claimed in claim 5 wherein the substrate is an iron base alloy, and the bond coating contains about 0.09 w/o to about 0.14 w/o ytterbium.
Claim 10
Dependent Claim
31 words
A coated article of manufacture as claimed in claim 5 wherein the substrate is a cobalt base alloy, and the bond coating contains about 0.05 w/o to about 0.15 w/o ytterbium.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1987-11-27 | 1988-05-28 | 1988-11-27 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1991-11-27 | 1992-05-28 | 1992-11-27 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1995-11-27 | 1996-05-28 | 1996-11-27 | $7700.00 | Window Closed / Lapsed |