Method for applying a heat insulation layer

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This patent describes a method for applying a heat insulation (thermal barrier) layer to metallic substrates, particularly those made of superalloys, by using plasma spray-physical vapor deposition (PS-PVD). The process involves injecting a ceramic powder (typically stabilized zirconia) into a plasma beam in a specially controlled chamber. The powder is partially or completely evaporated in the plasma, allowing the resulting ceramic material to condense on the substrate in a highly controlled, columnar microstructure that is oriented perpendicular to the surface. The process is optimized for both adhesion and thermal strain tolerance, while being more economical than traditional electron beam physical vapor deposition (EB-PVD) methods.

Use CasesContent extracted from patent full text and abstract with AI.

• Thermal barrier coatings for turbine blades in jet engines and stationary gas turbines
• Protective coatings for metallic parts exposed to high temperatures in industrial furnaces or reactors
• Heat-shielding layers in aerospace components exposed to extreme thermal cycling
• Coatings for automotive engine parts subject to high thermal stress
• Insulation coatings in energy generation equipment (such as power plants)

BenefitsContent extracted from patent full text and abstract with AI.

• Enables the production of heat-insulating coatings with high adhesion and better resistance to thermal cycling, reducing delamination and extending component life.
• Creates columnar microstructures in coatings that improve strain tolerance and durability under repeated heating and cooling.
• Offers a more economical and faster alternative to EB-PVD, lowering production costs and increasing throughput.
• Allows precise control over coating thickness and structure, improving performance consistency.
• Can be applied to complex geometries and is compatible with a variety of superalloy substrates commonly used in high-performance and high-temperature environments.

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Patent Abstract

The method comprises producing a plasma beam (5) and introducing a metallic substrate surface into a working chamber (2) with a plasma burner (4), applying a ceramic coating material on the surface of the substrate by plasma spray-physical vapor deposition, where the ceramic coating material is injected as a powder into the plasma beam and partially or completely evaporated, and applying a heat-insulating layer on the surface of the substrate, where a feed rate of the injected powder is adjusted so that the injected powder (greater than 80 wt.%) is evaporated/completely evaporated. The method comprises producing a plasma beam (5) and introducing a metallic substrate surface into a working chamber (2) with a plasma burner (4), applying a ceramic coating material on the surface of the substrate by plasma spray-physical vapor deposition, where the ceramic coating material is injected as a powder into the plasma beam and partially or completely evaporated, and applying a heat-insulating layer on the surface of the substrate, where a feed rate of the injected powder is adjusted so that the injected powder (greater than 80 wt.%) is evaporated or completely evaporated and/or the applied layer is free of slats and nanoscale cluster. The coating material is removed from a vapor phase onto the substrate surface and forms mixed phases on the substrate surface. The feed rate of the injected powder is gradually increased to a factor of 10 and decreased while increasing a part of the injected powder to be evaporated. The coating material is applied in the form of elongated columns, forms an anisotropic microstructure, and is oriented perpendicular to the substrate surface. The substrate surface is formed with an adhesive layer and/or a hot gas corrosion protection layer, a layer of an alloy and a thermal oxide layer. The substrate is made of super alloy. The ceramic coating material contains oxide-ceramic components. The feed rate of the injected Powder is of 0.5-5 g/minute in the working chamber, and is 5-40 g/minute in the applying step. The heat-insulating layer has a thickness of 0.5-5 mu m. An independent claim is included for a substrate or workpiece.