Thermal barrier coating system having no bond coat
First Claim
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1. A method for preparing a coated article, comprising the steps of:
- furnishing an aluminum-bearing nickel base superalloy article substrate;
thereafterdesulfurizing the article substrate; and
applying by a physical vapor deposition process a ceramic thermal barrier coating overlying the substrate, there being no bond coat applied to the substrate prior to the application of the thermal barrier coating.
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Abstract
A coated article is prepared by melting and casting an article substrate formed of a nickel-base superalloy. The article substrate is heated in a hydrogen-containing atmosphere at a temperature of at least 2000° F. for a period sufficient to desulfurize the substrate to a sulfur content of less than about 1 part per million. Optionally, an aluminum-oxide environmental coating is provided overlying the substrate. A ceramic thermal barrier coating is applied overlying the substrate. Significantly, there being no bond coat applied to the substrate prior to the application of the thermal barrier coating.
117 Citations
24 Claims
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1. A method for preparing a coated article, comprising the steps of:
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furnishing an aluminum-bearing nickel base superalloy article substrate;
thereafterdesulfurizing the article substrate; and applying by a physical vapor deposition process a ceramic thermal barrier coating overlying the substrate, there being no bond coat applied to the substrate prior to the application of the thermal barrier coating. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A method for preparing a coated article, comprising the steps of:
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furnishing an article substrate formed of a nickel-base superalloy;
thereafterheating the article substrate in a gaseous reactive agent for a period sufficient to desulfurize the substrate; and applying a ceramic thermal barrier coating by a physical vapor deposition process overlying the substrate, there being no bond coat applied to the substrate prior to the application of the thermal barrier coating. - View Dependent Claims (11, 12, 13, 14, 15, 16, 17, 18, 19)
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20. A method for preparing a coated article, comprising the steps of:
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furnishing an article substrate formed of a nickel-base superalloy, the superalloy having a sulfur content of less than about 1 part per million by weight; and applying, using a low sulfur application method, a ceramic thermal barrier coating overlying the substrate, there being no bond coat applied to the substrate prior to the application of the thermal barrier coating. - View Dependent Claims (21, 22, 23, 24)
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Specification