System with Thermal Insulation Layer and Method for Production

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The invention is a system and manufacturing method for creating a ceramic heat-insulating (thermal barrier) layer on a substrate, where the insulating layer is composed of columns made from ceramic materials that are spatially separated, particularly at their base near the substrate. This arrangement is achieved and precisely controlled through laser welding of ceramic powder, enabling highly regular, non-porous, and customizable column structures. The technology allows for durable, heat-resistant coatings suitable for extreme environments, such as those found in turbines or metal-supported fuel cells.

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

• Thermal protection coatings for turbine blades in aircraft jet engines or power generation gas turbines.
• Insulating layers in metal-supported solid oxide fuel cells to enhance longevity and performance.
• Heat protection in components of internal combustion engines, furnaces, and other high-temperature machinery.
• Localized repair of damaged thermal barrier coatings on existing high-value components without replacing the entire part.
• Advanced thermal management in aerospace, automotive, and energy sector parts exposed to fluctuating and high thermal loads.

BenefitsContent extracted from patent full text and abstract with AI.

• Significantly increases the lifespan of components regularly exposed to temperatures above 1000°C by minimizing thermal stress and cracking.
• Allows for precise, repeatable, and customizable control of the insulating column structure, shape, and distribution using laser-based additive manufacturing.
• Enables the manufacturing of highly regular, dense, and non-porous ceramic columns with optional internal cavities for improved thermal insulation.
• Reduces the risk of thermal expansion-induced failures due to the spatial separation of columns at the substrate interface.
• Allows for local repair or modification of thermal barrier coatings, reducing maintenance costs and downtime for critical hardware.
• Facilitates the use of new ceramic materials or combinations thereof, enabling optimization for specific applications.

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Patent Abstract

The invention relates to a system comprising a substrate (1) and a ceramic heat-insulating layer which is formed of columns (4, 13) and applied onto the substrate (1), characterized in that the columns (4, 13) at the substrate (1) are spatially separated from each other or at least hardly ever touch. The invention relates to a method for producing the system by laser welding. The invention allows the production of long-lasting, heat-resistant components which can be used for example in turbines or in metal-supported fuel cells.