Self-Healing Thermal Insulation Layers and Methods for the Production Thereof

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This invention describes a method for manufacturing a self-healing thermal insulation (barrier) coating using a carefully controlled plasma spraying process. The process introduces molybdenum disilicide (MoSi2) powder containing aluminum into the ceramic thermal barrier material (such as yttria-stabilized zirconia, YSZ) during spraying. By precisely controlling the injection points and conditions, the MoSi2 particles partially melt and distribute within the coating, enabling cracks that form during service to be automatically sealed through oxidation reactions, significantly increasing the coating's lifespan.

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• Thermal barrier coatings for gas turbines used in power plants and aviation engines
• Protective, insulating layers on high-temperature industrial components (e.g., reactors, furnaces)
• Aerospace components exposed to rapid temperature cycling and oxidative environments
• Automotive engine parts requiring durable heat shielding
• Energy sector equipment (such as turbochargers or heat exchangers) subject to extreme thermal stress

BenefitsContent extracted from patent full text and abstract with AI.

• Significantly longer service life of thermal barrier coatings due to self-healing of cracks
• Reduces risk of catastrophic component failure and downtime by maintaining insulation integrity
• Enables coatings to withstand more severe thermal cycling and higher temperatures
• Potential to lower maintenance costs and extend replacement intervals for high-value components
• Improved reliability and safety in critical high-temperature applications (e.g., turbines, jet engines)

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Inventors & Applicants

Patent Abstract

The invention relates to a method for producing a self-healing heat damping layer using APS. The invention is characterized in that MoSi2 powder containing aluminum is introduced into the heat damping layer. The MoSi2 powder contains an aluminum content of 2 to 12 wt.%. The MoSi2 powder is applied onto the heat damping layer in a mass proportion between 0.5 and 5 wt.% relative to the heat damping layer. In the method, the heat damping layer powder is injected at a first point at a distance from the burner in an axial direction, and the MoSi2 powder is injected at a second point at a farther distance from the burner in the axial direction. An injection distance (I) between 20 and 60 mm is set between the first and the second point. By virtue of the double injection principle and the selection of the injection distance (I) in combination with the spray distance, it is ensured that the heat damping layer material sufficiently melts in the plasma jet; the supplied MoSi2 powder however is only melted on or to the material without destroying the material. Thus, a clear improvement in the service life of the heat damping layer can be achieved in comparison to a heat damping layer which has not been supplied with corresponding MoSi2 powder.