Adhesion Promoter Layer for Bonding a High-Temperature Protective Layer to a Substrate, and Method for Producing the Same

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

This patent describes a two-layer adhesion promoter (bond coat) designed for attaching high-temperature protective coatings—such as thermal barrier or environmental barrier coatings—to components exposed to extreme heat, like turbine blades. The first layer is a conventional adhesion material (e.g., MCrAlY alloy), serving as a reservoir for oxide formation, while the second, thinner layer is made from a similar material with finely distributed stable oxide particles (oxide-dispersion-strengthened, ODS). This dual-layer system improves the bond between the substrate and protective coating, and results in increased coating and component lifespan under thermal cycling and harsh environments.

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

• Thermal barrier coating systems for gas turbine blades in aerospace and power generation.
• Extending the service life of metallic or ceramic engine components exposed to high temperatures and aggressive environments.
• Protective coatings for parts in industrial furnaces and heat exchangers.
• Environmental barrier coatings on ceramic fiber composite components (e.g. C/SiC or SiC/SiC used in space or aviation).
• High-performance corrosion/oxidation protection layers for offshore or marine equipment.
• Advanced wear-resistant and oxidation-resistant surfaces in automotive or process industries.

BenefitsContent extracted from patent full text and abstract with AI.

• Significantly increases the durability and service life of high-temperature protection coatings, delaying failure mechanisms such as spallation.
• Improves bonding strength between the substrate and the protective layer, reducing delamination and cracking during thermal cycling.
• Reduces oxidation, corrosion, and erosion of the underlying components, protecting critical infrastructure under extreme conditions.
• Cost-effective: only the thinner outer layer uses the more expensive ODS alloy, keeping production costs manageable while retaining performance gains.
• Applicable to both metallic and ceramic substrates, making the technology versatile for a wide range of materials and industries.
• Allows for established industrial deposition methods (thermal spray, plasma spray, etc.), facilitating easy integration into existing manufacturing lines.

Technical Classifications (CPCs)

Inventors & Applicants

Patent Abstract

The invention relates to an adhesion promoter layer for joining a high-temperature protection layer to a substrate, which adhesion promoter layer is characterized in that the adhesion promoter layer comprises a first layer of an adhesion promoter material for applying to the substrate and a second layer, which is arranged on the first layer and has introduced stable oxide dispersions and is provided for the connection of a high-temperature protection layer. The material of the first layer can preferably also be used as an adhesion promoter material for the second layer, in which second layer stable oxide dispersions were additionally introduced at a fraction of 0.01 to 50 wt%. In summary, the invention provides an improved adhesion promoter layer in the case of which a first adhesion promoter layer is produced from a first material, this adhesion promoter material is enhanced and improved by introducing oxide dispersions, and this improved material is applied to the previously deposited first adhesion promoter layer as a thin second layer.