Methods and materials for repairing a thermal barrier coating of a gas turbine component

1. A sprayable thermal barrier coating powder mixture for a gas turbine engine comprising:

a dry composition comprising a low surface area ceramic powder having a median particle size greater than 5 microns and less than 50 microns, and a high surface area ceramic powder having a median particle size smaller than 5 microns, wherein the low surface area ceramic powder makes up at least 50% by weight of the dry composition of the sprayable thermal barrier coating powder mixture;

wherein the low surface area ceramic powder has less than 10 meters squared of surface area per gram, and wherein the high surface area ceramic powder has greater than 10 meters squared of surface area per gram and less than 4,000 meters squared of surface area per gram; and

at least one organic binder additive configured to function as a binder only at temperatures up to 500° C. or below;

wherein the low surface area ceramic powder and the high surface area ceramic powder each comprise zirconia.

2. The mixture of claim 1 , further comprising:

a liquid added to the dry composition to form a slurry for spraying the mixture.

3. The mixture of claim 2 , wherein the liquid comprises a low boiling point liquid.

4. The mixture of claim 2 , wherein the mixture defines a solids loading between 30 percent by mass and 80 percent by mass.

5. The mixture of claim 2 , wherein the mixture defines a density between about 0.8 grams per cubic centimeter and 3 grams per cubic centimeter.

6. The mixture of claim 2 , wherein the mixture once cured defines a thermal conductivity between 0.4 Watts/meters-Kelvin and 2 Watts/meters-Kelvin, each at 1000 degrees C.

7. The mixture of claim 1 , wherein the dry composition defines an activation temperature range from 300 degrees Celsius to 1200 degrees Celsius such that the thermal barrier coating powder mixture is configured to be sprayed on in situ and cured by exposure to operating temperatures within the gas turbine engine.

8. The mixture of claim 1 , further comprising at least one additional binder additive, wherein the low surface area ceramic powder, the high surface area ceramic powder, the at least one organic binder additive and the at least one additional binder additive together define an activation temperature range from at least 300 degrees Celsius to 1200 degrees Celsius.

9. The mixture of claim 1 , wherein the high surface area powder defines a curing temperature greater than 1000 degrees Celsius.

10. The mixture of claim 1 , wherein the low surface area ceramic powder and high surface area ceramic powder together make up at least 80% by weight of the dry composition of the sprayable thermal barrier coating powder mixture.

11. A method for repairing a thermal barrier coating of a component of a gas turbine engine in situ comprising:

spraying a thermal barrier coating powder mixture onto the component of the gas turbine engine in situ, the thermal barrier coating powder mixture comprising a low surface area ceramic powder, a low surface area ceramic powder precursor, or both, the thermal barrier coating powder mixture further comprising a high surface area ceramic powder and at least one organic binder additive configured to function as a binder only at temperatures up to 500° C. or below, the thermal barrier coating powder mixture defining an activation temperature range from 300 degrees Celsius to 1200 degrees Celsius; and

operating the gas turbine engine to cure the thermal barrier coating powder mixture on the component.

12. The method of claim 11 , wherein operating the gas turbine engine to cure the thermal barrier coating powder mixture on the component comprises exposing the thermal barrier coating powder mixture on the component to operational temperatures between 1000 degrees Celsius and 1500 degrees Celsius.

13. The method of claim 11 , wherein spraying the thermal barrier coating powder mixture onto the component of the gas turbine engine in situ comprises spraying the thermal barrier coating powder mixture onto the component of the gas turbine engine in situ to a thickness greater than 2 mils and less than 25 mils.

14. The method of claim 11 , wherein spraying the thermal barrier coating powder mixture onto the component of the gas turbine engine in situ comprises spraying the thermal barrier coating powder mixture onto the component of the gas turbine engine in situ using a pressurized gas source.

15. The method of claim 11 , wherein spraying the thermal barrier coating powder mixture onto the component of the gas turbine engine in situ comprises spraying the thermal barrier coating powder mixture onto the component of the gas turbine engine in situ through one or more tubes having a diameter less than or equal to 0.06 inches.

16. The method of claim 11 , wherein the thermal barrier coating powder mixture further comprises a drying agent to form a slurry, and wherein the drying agent comprises ethanol and a low boiling point liquid.

17. The method of claim 11 , wherein the thermal barrier coating powder mixture comprises the low surface area ceramic powder, and wherein the low surface area ceramic powder and the high surface area ceramic powder together make up at least 80% by weight of a dry composition of the sprayable thermal barrier coating powder mixture.

18. A sprayable thermal barrier coating powder mixture for a gas turbine engine comprising:

a dry composition comprising a low surface area ceramic powder, a low surface area ceramic powder precursor, or both and a high surface area ceramic powder, the dry composition defining an activation temperature range from at least 300 degrees Celsius to 1200 degrees Celsius such that the thermal barrier coating powder mixture is configured to be sprayed on in situ and cured by exposure to operating temperatures within the gas turbine engine; and

at least one organic binder additive configured to function as a binder only at temperatures up to 500° C. or below;

wherein the low surface area ceramic powder and the high surface area ceramic powder each comprise zirconia.

19. The mixture of claim 18 , wherein the low surface area ceramic powder, if included, has less than 5 meters squared of surface area per gram, wherein the low surface area ceramic powder precursor, if included, is configured to form a powder having less than 5 meters squared of surface area per gram, and wherein the high surface area ceramic powder has greater than 10 meters squared of surface area per gram and less than 4,000 meters squared of surface area per gram.