Thermal Insulation Layer System and Method for Its Manufacture

Simple SummaryContent extracted from patent full text and abstract with AI.

This patent describes a thermal barrier coating system for protecting components, especially in high-temperature environments such as gas turbines. The system involves applying at least one layer using Atmospheric Plasma Spraying (APS) and at least one further layer using Suspension Plasma Spraying (SPS). The combination and sequence of these layers (such as APS + SPS or APS + SPS + APS) result in unique microstructures, with the SPS layer providing higher porosity and reflectivity. This structure significantly reduces the amount of thermal radiation that reaches the substrate, thereby lowering its temperature and enhancing its longevity.

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

• Thermal protection of turbine blades and parts in gas turbines
• Thermal barrier coatings for aerospace engine components
• Protective coatings for parts exposed to high thermal loads in power plants
• Heat shielding in automotive engine components
• Industrial furnaces and reactors requiring advanced insulation

BenefitsContent extracted from patent full text and abstract with AI.

• Enhanced protection of substrate materials from heat and thermal radiation
• Increased lifespan and reliability of coated components under high thermal stress
• Reduced risk of overheating and component failure
• Optimized balance between mechanical stability (from APS) and superior insulating/reflective properties (from SPS)
• Better control over porosity and optical properties of coatings
• Potential for improved energy efficiency due to reduced thermal losses

Technical Classifications (CPCs)

Inventors & Applicants

Patent Abstract

The invention discloses a method for producing a coating system on a component, in which at least one layer is applied to the component by means of atmospheric plasma spraying (APS) and at least one further layer is deposited by means of suspension plasma spraying (SPS).  The layers are advantageously deposited in particular in the sequence APS + SPS or APS + SPS + APS or else APS + SPS + erosion layer.  These sequences of layers applied in this way regularly have the effect of providing a first, porous layer and a second porous layer arranged thereupon, wherein the porosity of the second layer is greater than that of the first layer, and wherein the reflectivity is greater than that of the first layer.  The increased reflectivity of the layer, in particular in the visible (VIS) and near infrared (NIR) wavelength ranges, advantageously brings about lower thermal loading of the substrate material, since only a smaller proportion of thermal radiation penetrates through the ceramic thermal barrier coating, and consequently also leads to the substrate (component) being heated up to a lesser extent.