Method for Producing a Coating and Coating

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This invention describes a method for producing high-quality protective coatings on various substrates using an improved atmospheric plasma spraying (APS) process. Key to the invention is the use of a plasma torch nozzle with a diameter between 4 mm and 8 mm and a high process gas flow (at least 40 standard liters per minute), enabling the formation of dense, largely crystalline, and crack-resistant coatings. These enhanced coatings can be made from materials such as rare earth silicates and aluminates, with superior structural and protective properties, particularly for components exposed to high temperatures or harsh environments.

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• Protective coatings for gas turbine components, such as blades and vanes, to resist high temperatures and oxidation.
• Thermal and environmental barrier coatings for aerospace or space industry parts made of silicon, ceramic, or nickel-based alloys.
• Coatings for industrial machinery exposed to corrosive, erosive, or high-temperature environments.
• Surface protection of semiconductor processing equipment or electronic components requiring high-purity, dense films.
• Enhancement of lifetime for automotive engine parts, including turbochargers and exhaust systems, by providing thermal insulation and corrosion resistance.

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• Produces coatings with higher crystallinity and lower porosity, improving resistance to thermal cycling and extending component lifespan.
• Allows deposition of thick, dense, and crack-resistant coatings in a single operation, increasing production efficiency.
• Reduces formation of unwanted amorphous phases and secondary phases, resulting in more stable and reliable protective layers.
• Applicable to a wide range of substrate materials, including advanced ceramics and metal alloys.
• Can be implemented using more cost-efficient atmospheric plasma spraying, reducing overall production costs compared to other advanced coating methods.
• Improved microstructure increases protection against oxidation, corrosion, and water-induced degradation, making it suitable for advanced industrial and aerospace uses.

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Inventors & Applicants

Patent Abstract

The invention relates to a method for producing a coating (12) in which: - a substrate (1) is provided; and - the substrate (1) is provided with a coating (12), in particular by means of atmospheric plasma spraying, with a plasma torch (2) having a torch nozzle (3) being used, by means of which torch a plasma jet (4) is generated from a supplied process gas (10), and with a supplied spraying material (5) being applied to the substrate (1) by means of the plasma jet (4) in order to obtain the coating (12), wherein the torch nozzle (3) is characterised by a nozzle diameter (D) or a minimum nozzle diameter (D) in the range of 4 mm to 8 mm, in particular 5 mm to 8 mm, preferably 5 mm to 7 mm, and wherein the process gas stream is at least 40 slpm. The invention further relates to a component comprising a substrate (1) and a coating (12).