Spray shadowing for stress relief and mechanical locking in thick protective coatings

Inactive Publication Date: 2005-03-24
RGT UNIV OF CALIFORNIA +1
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0009] In accordance with the purposes of the present invention, as embodied and broadly described herein, the present invention includes an article with a surface that includes undercut grooves depending beneath the surface to a bottom portion, where the grooves have an upper width on the surface and a lower width on the bottom portion

Problems solved by technology

Historical protective coatings were detrimentally affected by differential dilation, i.e., a difference in expansion/contraction of two (or more) objects, so that dimensions that aligned at one time do not align at another time.
Induced stresses can cause the loss of bonding between the coating and the underlying mat

Method used

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  • Spray shadowing for stress relief and mechanical locking in thick protective coatings
  • Spray shadowing for stress relief and mechanical locking in thick protective coatings
  • Spray shadowing for stress relief and mechanical locking in thick protective coatings

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Embodiment Construction

[0016] This present invention is a method, and corresponding article, that allows the buildup of thick, protective coatings by mechanically locking the coating to the underlying material, and avoids the debonding and spallation problems that normally limit the coating thickness that can be applied. Debonding is defined as a separation between the substrate and coating. Spallation is defined as removal of part of or all of the coating from the substrate, as a result of external thermal and physical forces. Furthermore, the present invention includes a beneficial feature, the formation of weak paths, which relieve stresses and strains experienced by a protective coating without experiencing full or partial debonding.

[0017] The existing technology for preparing substrates is to grit blast, chemically etch, laser roughen, or arc roughen the substrate prior to depositing a coating. These micro-roughening techniques are on the scale of 1 to 50 microns in feature dimension (height). Where...

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Abstract

An article with a surface that includes undercut grooves depending beneath the surface to a bottom portion, where the grooves have an upper width on the surface and a lower width on the bottom portion connected by side walls, and where at least one of said side walls connects the upper width to the lower width to form an undercut angle with the surface of less than 90°. The article is covered with a coating that contains weak paths for stress relief. The coating fills the undercut grooves and ranges above the surface with a thickness from about 0.1 to 50 mm.

Description

STATEMENT REGARDING FEDERAL RIGHTS [0001] This invention was made with government support under Contract No. W-7405-ENG-36 awarded by the U.S. Department of Energy. The government has certain rights in the invention.FIELD OF THE INVENTION [0002] The present invention relates generally to protective coating systems, and, more particularly to the stress relief and mechanical locking of a thick thermal sprayed coating. BACKGROUND OF THE INVENTION [0003] Protective coatings are generally used to protect the underlying material, the substrate, from damage due to direct exposure to outside environments. Historical protective coatings were detrimentally affected by differential dilation, i.e., a difference in expansion / contraction of two (or more) objects, so that dimensions that aligned at one time do not align at another time. This can be the result of mechanical loads, temperature gradients, or different coefficients of thermal expansion. Any or all of these causes might apply for coati...

Claims

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Application Information

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IPC IPC(8): C23C4/02C23C14/02
CPCC23C4/02Y10T428/2457Y10T428/24612C23C14/028
Inventor HOLLIS, KENDALLBARTRAM, BRIAN
Owner RGT UNIV OF CALIFORNIA
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