Method for Internal Coating of Functional Layers with a Tempering Material

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The invention describes a process for internally coating the pores of a porous functional layer (such as thermal barrier coatings) with a hardening or stabilizing material, using vapor-phase deposition techniques. This vapor-phase method, which may include techniques like CVD or ALD, allows the coating material or its chemical precursors to penetrate deeply into the pore network and form a protective barrier on the inner surfaces of the pores. This internal coating significantly reduces the diffusion and reactivity of the base material, leading to improved durability and longevity of the functional layer, especially in high-temperature applications.

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• Enhancing the life of thermal barrier coatings on turbine components such as turbine blades and combustion chamber elements.
• Improving environmental barrier coatings (EBC) for ceramic and fiber-reinforced ceramic components used in gas turbines and other high-temperature machinery.
• Applying protective coatings in high-temperature process equipment to minimize degradation caused by diffusion and reaction with ambient gases.
• Rejuvenating or repairing porous coatings in-situ, extending service intervals without requiring complete removal or replacement.
• Producing advanced coatings for electronics, such as solid oxide fuel cell (SOFC) components and functional electronic elements requiring deep, precise pore coatings.

BenefitsContent extracted from patent full text and abstract with AI.

• Greater penetration depth and uniformity of coating inside pores compared to prior methods, resulting in superior material protection.
• Significantly increased durability and resistance to thermal aging, reducing maintenance frequency and replacement costs.
• Flexibility to use a wide range of hardening (vergütungs) materials tailored to specific applications and environments.
• Minimized reactivity and diffusion between base materials and harsh operational atmospheres, enhancing performance and safety.
• Potential to apply or renew internal coatings without dismantling complex components, enabling more efficient maintenance.
• Enables consistent, high-quality coatings even in sub-micron sized pores, valuable for modern advanced materials.

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Patent Abstract

The invention has involved the development of a process for internally coating the pores of a porous functional layer made of a base material with a through-hardened material, which reduces the diffusion of the base material and/or the reactivity of the base material with its surroundings. According to the invention, the through-hardened material is deposited from the vapour phase on the inner surfaces of the pores. It has been recognized that, owing to the deposition from the vapour phase, the through-hardened material can be introduced into the pore system of the functional layer to a considerably greater depth than was possible according to the present prior art. This is applicable particularly when it is not the through-hardened material itself which is introduced into the pore system, but rather one or two precursors thereof, from which the actual through-hardened material arises only on the inner surfaces of the pores.