Thermal barrier coatings
Coated components, along with methods of their formation, are provided. The coated component may include a substrate having a surface and a thermal barrier coating on the surface of the substrate. The thermal barrier coating includes a plurality of elongated surface-connected voids therein, and wherein the thermal barrier coating comprises a plurality of nonspherical particles within a thermal barrier material.
1 . A coated component, comprising:
a substrate having a surface; and
a thermal barrier coating on at least a portion of the surface of the substrate, wherein the thermal barrier coating includes a plurality of elongated surface-connected voids therein, and wherein the thermal barrier coating comprises a plurality of nonspherical particles dispersed within a thermal barrier material, and wherein the thermal barrier coating comprises 50 vol. % to 99 vol % of the thermal barrier material and 1 vol. % to 50 vol % of the plurality of nonspherical particles.
2 . The coated component of claim 1 , wherein the thermal barrier coating further includes a plurality of surface-connected microporosity cracks that are connected to the surface or to at least one of the plurality of elongated surface-connected voids.
3 . The coated component of claim 1 , wherein the thermal barrier coating is a thermally sprayed barrier coating.
4 . The coated component of claim 1 , wherein the thermal barrier material comprises 75 vol. % to 95 vol % of the thermal barrier coating.
5 . The coated component of claim 4 , wherein the plurality of nonspherical particles comprises 5 vol. % to 25 vol % of the thermal barrier coating.
6 . The coated component of claim 1 , wherein the plurality of nonspherical particles comprises a CMAS resistant material, wherein CMAS refers to a material containing calcium, magnesium, aluminum, silicon or a combination thereof.
7 . The coated component of claim 6 , wherein the CMAS resistant material comprises rare earth containing oxides.
8 . The coated component of claim 1 , wherein the plurality of nonspherical particles comprises a fluorescing compound.
9 . The coated component of claim 8 , wherein the fluorescing compound comprises oxides doped with materials including Ce, Nd, Pr, Eu, Sm, Tb, Dy, Er, Ti, Mn, and or Bi.
10 . The coated component of claim 1 , wherein at least 50% of the plurality of nonspherical particles have an aspect ratio that is greater than 5.
11 . The coated component of claim 1 , wherein at least 50% of the plurality of nonspherical particles have an aspect ratio that is 10 to 10,000.
12 . The coated component of claim 1 , wherein at least 90% of the plurality of nonspherical particles have an aspect ratio that is greater than 5.
13 . The coated component of claim 1 , wherein at least 90% of the plurality of nonspherical particles have an aspect ratio that is 10 to 10,000.
14 . The coated component of claim 1 , wherein the thermal barrier material comprises a stabilized zirconia.
15 . The coated component of claim 1 , wherein the thermal barrier material has a thermal conductivity that is less than 1.8 W/mK at 1000° C.
16 . The coated component of claim 1 , further comprising:
a bond coat on the surface of the substrate, the bond coat positioned between the surface of the substrate and the thermal barrier coating.
17 . The coated component of claim 1 , wherein the thermal barrier coating has a thickness of 25 μm to 2000 μm.
18 . The coated component of claim 1 , wherein the plurality of nonspherical particles further comprise a coating thereon.
19 . The coated component of claim 18 , wherein the coating on the plurality of nonspherical particles comprises a monazite phosphate coating, a boron nitride coating, or an inert environmental barrier material coating.
20 . The coated component of claim 18 , wherein the coating on the plurality of nonspherical particles includes a fluorescent indicator.