Thermal spray deposition of hollow microspheres

Abstract

Methods of forming an insulating coating from thermal spraying are provides. In one variation, the method includes thermally spraying a jetted stream having a maximum temperature of greater than or equal to about 900° C. towards a substrate to form the insulating coating on the substrate. The thermal spraying may be a high-velocity oxygen flame (HVOF) process. The jetted stream comprises a plurality of hollow microspheres, which may comprise a metal, such as nickel or iron. The insulating coating as formed has a thermal conductivity (K) of less than or equal to about 200 mW / m·K at standard temperature and pressure conditions and may have a thermal capacity (cv) of greater than or equal to about 100 kJ / m3·K.

Description

INTRODUCTION[0001]This section provides background information related to the present disclosure which is not necessarily prior art.[0002]The present disclosure pertains to methods for thermally spraying hollow microparticles onto substrates to form insulating thermal barrier coatings.[0003]Insulating and thermal barrier coatings are used in various applications to reduce heat transfer. Such coatings desirably have low heat capacity and low thermal conductivity. In certain aspects, a thermal barrier coating may comprise an insulating material including one or more hollow microspheres. Thus, the insulating or thermal barrier coating can be used in a variety of applications, including by way of non-limiting example, on surfaces of components within an internal combustion engine to reduce heat transfer losses and increase performance and efficiency. New methods of forming robust thermal barrier coatings on a variety of complex components are desirable.SUMMARY[0004]This section provides...

AI Technical Summary

Benefits of technology

The patent text is discussing the use of insulating and thermal barrier coatings to reduce heat transfer in various applications. These coatings should have low heat capacity and low thermal conductivity. The patent also mentions the use of hollow microspheres as an insulating material. These coatings can be used in various components within an internal combustion engine to decrease heat transfer and increase performance and efficiency. The patent highlights the need for new methods to form robust thermal barrier coatings on complex components.

Problems solved by technology

Such coatings desirably have low heat capacity and low thermal conductivity.

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