Combustion engine components with dynamic thermal insulation coating and method of making and using such a coating

1. A component for exposure to a combustion chamber of an internal combustion engine and/or exhaust gas generated by the internal combustion engine, comprising:

a body portion formed of metal;

a thermal barrier coating applied to said body portion;

said thermal barrier coating including a bond layer formed of metal disposed on said body portion, a mixed layer disposed on said bond layer, and a top layer disposed on said mixed layer;

said mixed layer is formed of a mixture of ceramic and metal;

said ceramic of said mixed layer is formed of at least one of ceria, ceria stabilized zirconia, yttria, yttria stabilized zirconia, calcia stabilized zirconia, magnesia stabilized zirconia, and zirconia stabilized by another oxide; and

said top layer is formed of metal and fills pores of said ceramic of said mixed layer.

2. The component of claim 1 , wherein said top layer has a surface roughness Ra of not greater than 3 microns.

3. The component of claim 1 , wherein said thermal barrier coating has a thickness of not greater than 700 microns.

4. The component of claim 1 , wherein said bond layer has a thickness of 20 to 50 microns, said mixed layer has a thickness of 20 to 50 microns, and said top layer has a thickness of 50 to 100 microns.

5. The component of claim 1 , wherein said mixed layer has a gradient structure, the gradient structure including an increasing concentration of said ceramic material moving from said bond layer to said top layer.

6. The component of claim 1 , wherein said bond layer is formed of NiCrAlY, said metal of said mixed layer is NiCrAlY, said ceramic of said mixed layer is ceria stabilized zirconia, and said top layer is NiCrAlY.

7. The component of claim 1 , wherein said component is a cylinder liner, cylinder head, fuel injector, valve seat, valve face, valve back, seal ring, exhaust port surface, top land of piston, or firedeck.

8. The component of claim 1 , wherein said bond layer is formed of at least one of chromium, nickel, cobalt, chromium alloy, nickel alloy, cobalt alloy, nickel based superalloy, and cobalt based superalloy;

said metal of said mixed layer is formed of at least one of chromium, nickel, cobalt, chromium alloy, nickel alloy, cobalt alloy, nickel based superalloy, and cobalt based superalloy; and

said top layer includes at least one of chromium, nickel, cobalt, chromium alloy, nickel alloy, cobalt alloy, nickel based superalloy, and cobalt based superalloy.

9. A method of manufacturing a component for exposure to a combustion chamber of an internal combustion engine and/or exhaust gas generated by the internal combustion engine, comprising the steps of:

applying a thermal barrier coating to a body portion formed of metal;

the step of applying the thermal barrier coating including applying a bond layer formed of metal to the body portion, and applying a mixed layer formed of a mixture of ceramic and metal to the bond layer, the ceramic of the mixed layer being formed of at least one of ceria, ceria stabilized zirconia, yttria, yttria stabilized zirconia, calcia stabilized zirconia, magnesia stabilized zirconia, and zirconia stabilized by another oxide; and

the step of applying the thermal barrier layer including applying a top layer formed of metal to the mixed layer, the top layer filling pores of the ceramic of the mixed layer.

10. The method of claim 9 , wherein the step of applying the thermal barrier coating to the body portion includes plasma spraying, flame spraying, high velocity oxy-fuel (HVOF), and/or wire arc spraying.

11. The method of claim 9 including abrading the mixed layer until the outermost surface of the mixed layer has a surface roughness Ra of not greater than 3 microns.

12. The method of claim 9 , wherein the step of applying the mixed layer includes increasing a concentration of the ceramic relative to the metal from the bond layer to an outermost surface of the mixed layer.