Thermal barrier coating application method and heat-resistant member

Abstract

To improve work efficiency when forming thermal barrier coating.SOLUTION: A construction method of thermal barrier coating in at least one embodiment, includes steps of: forming a bond coat layer by high-speed flame spraying, by a flame spray gun arranged in a spray booth on a heat-prof alloy base material of an object arranged in the spray booth; and forming a top coat layer by spraying suspension containing ceramic powder by high-speed flame spraying, by the flame spray gun arranged in the spray booth on the bond coat layer of the object arranged in the spray booth.SELECTED DRAWING: Figure 4A

Description

[Technical field]

[0001] The present disclosure relates to a method for applying a thermal barrier coating and a heat-resistant component. [Background technology]

[0002] It is known that thermal barrier coatings (TBCs) are provided on heat-resistant components exposed to high-temperature combustion gases, such as combustor panels and turbine blades in aircraft engines, turbine blades and segmented rings in industrial gas turbines, etc. Such thermal barrier coatings include a bond coat layer formed on a heat-resistant alloy substrate, and a top coat layer as a thermal barrier layer formed on the bond coat layer (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2011-117012 A Summary of the Invention [Problem to be solved by the invention]

[0004] For example, a bond coat layer is desired to have a strong adhesive strength with a heat-resistant alloy substrate, and therefore there is a need to form the bond coat layer by high-velocity flame spraying, which can obtain a relatively strong adhesive strength by colliding the raw material powder of the bond coat layer with the heat-resistant alloy substrate at supersonic speed. Furthermore, since the properties and materials required for the top coat layer are different from those required for the bond coat layer, there is a need to form the ceramic layer using a thermal spraying method different from the thermal spraying method used to form the bond coat layer. In this way, when the bond coat layer and the top coat layer are formed by different thermal spraying methods, it is difficult to perform thermal spraying in the same thermal spraying booth due to differences in the equipment configuration and the required peripheral equipment and utilities, such as the gases used, etc. This requires the effort of moving the object to be sprayed to a different thermal spraying booth and the setup work, such as setting the object after moving it, before the start of thermal spraying.

[0005] In view of the above circumstances, at least one embodiment of the present disclosure aims to improve work efficiency when forming a thermal barrier coating. [Means for solving the problem]

[0006] (1) A method for applying a thermal barrier coating according to at least one embodiment of the present disclosure includes: forming a bond coat layer by high velocity oxygen flame spraying on a heat resistant alloy substrate of an object disposed in a thermal spray booth using a thermal spray gun disposed in the thermal spray booth; forming a top coat layer on the bond coat layer of the object placed in the thermal spray booth by spraying a suspension containing a ceramic powder by high velocity flame spraying using a thermal spray gun placed in the thermal spray booth; Equipped with.

[0007] (2) A high-temperature component according to at least one embodiment of the present disclosure has the bond coat layer and the top coat layer formed by the thermal barrier coating application method according to the method (1) above. Effect of the Invention

[0008] According to at least one embodiment of the present disclosure, the work efficiency when forming a thermal barrier coating can be improved. [Brief description of the drawings]

[0009] [Figure 1] 1 is a schematic diagram of a cross-section of a high-temperature component having a thermal barrier coating applied by a thermal barrier coating application method according to some embodiments. [Diagram 2] FIG. 1 is a diagram illustrating the external appearance of a combustor panel for an aircraft engine as an example of a heat-resistant member. [Diagram 3] 1 is a flow chart illustrating steps in a method for applying a thermal barrier coating according to some embodiments. [Figure 4A] FIG. 1 is a diagram for explaining an outline of an apparatus for a thermal barrier coating application method according to one embodiment. [Figure 4B] FIG. 4 is a diagram for explaining an outline of an apparatus for a method of applying a thermal barrier coating according to another embodiment. [Figure 4C] FIG. 13 is a diagram for explaining an outline of an apparatus for a thermal barrier coating application method according to still another embodiment. [Figure 5A] FIG. 2 is a schematic diagram for explaining the structure of an internal supply type thermal spray gun. [Figure 5B] FIG. 2 is a schematic diagram for explaining the structure of an external supply type thermal spray gun. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Hereinafter, some embodiments of the present disclosure will be described with reference to the accompanying drawings. However, the dimensions, materials, shapes, relative arrangements, etc. of components described as the embodiments or shown in the drawings are merely illustrative examples and are not intended to limit the scope of the present disclosure. For example, expressions expressing relative or absolute configuration, such as "in a certain direction," "along a certain direction," "parallel," "orthogonal," "center," "concentric," or "coaxial," not only strictly express such a configuration, but also express a state in which there is a relative displacement with a tolerance or an angle or distance to the extent that the same function is obtained. For example, expressions indicating that things are in an equal state, such as "identical," "equal," and "homogeneous," not only indicate a state of strict equality, but also indicate a state in which there is a tolerance or a difference to the extent that the same function is obtained. For example, expressions describing shapes such as a rectangular shape or a cylindrical shape do not only refer to rectangular shapes, cylindrical shapes, etc. in the strict geometric sense, but also refer to shapes that include uneven portions, chamfered portions, etc., to the extent that the same effect is obtained. On the other hand, the expressions "comprise," "include," "have," "includes," or "have" of one element are not exclusive expressions excluding the presence of other elements.

[0011] (About Thermal Barrier Coating 3) FIG. 1 is a schematic diagram of a cross-section of a high-temperature component 1 having a thermal barrier coating 3 applied by a method for applying a thermal barrier coating according to some embodiments. FIG. 2 is a diagram illustrating the appearance of a combustor panel 1A for an aircraft engine as an example of the heat-resistant member 1. As shown in FIG. A thermal barrier coating (TBC) 3 for insulating the heat-resistant member 1 from heat is formed on a heat-resistant member 1 such as a combustor panel 1A or turbine blade for an aircraft engine, or a turbine blade or a segmented ring for an industrial gas turbine. In some embodiments, a metal bonding layer (bond coat layer) 7 and a top coat layer 9 as a thermal barrier layer are formed in this order on a heat-resistant alloy substrate (base material) 5 of a heat-resistant component 1. That is, in some embodiments, a thermal barrier coating 3 includes the bond coat layer 7 and the top coat layer 9.

[0012] The bond coat layer 7 according to some embodiments is made of an MCrAlY alloy (M represents a metal element such as Ni, Co, or Fe, or a combination of two or more of these elements).

[0013] The topcoat layer 9 according to some embodiments may be made of a ZrO2-based material, such as YSZ (yttria-stabilized zirconia), which is ZrO2 partially or fully stabilized with Y2O3. Also, the topcoat layer 9 according to some embodiments may be made of DySZ (dysprosia-stabilized zirconia), ErSZ (erbia-stabilized zirconia), Gd2Zr2O7, or Gd2Hf2O7. This results in a thermal barrier coating 3 with excellent thermal barrier properties.

[0014] In the top coat layer 9 according to some embodiments, vertical cracks Cv extending in the thickness direction of the top coat layer 9 are dispersed in the planar direction, i.e., the left-right direction and the depth direction of the paper in Fig. 1. In addition, in the top coat layer 9 according to some embodiments, horizontal cracks Ch extending in the planar direction are dispersed. In some embodiments of the thermal barrier coating 3, the structure of the top coat layer 9 having multiple vertical cracks Cv can mitigate the generation of thermal stress due to the difference in linear expansion coefficient with the heat-resistant alloy substrate 5, thereby providing excellent thermal cycle durability.

[0015] (flowchart) 3 is a flow chart showing the steps of a method for applying a thermal barrier coating according to some embodiments. The method for applying a thermal barrier coating according to some embodiments includes a step S10 of forming a bond coat layer 7 and a step S20 of forming a top coat layer 9.

[0016] In some embodiments, step S10 of forming the bond coat layer 7 is a step of forming the bond coat layer 7 on the heat-resistant alloy substrate 5 of the object (heat-resistant component 1) placed in a thermal spray booth 20 described later by high velocity flame spraying using a thermal spray gun 30 described later placed in the thermal spray booth 20. That is, in some embodiments, in step S10 of forming the bond coat layer 7, a powder of an MCrAlY alloy or the like as a thermal spray material is thermally sprayed onto the surface of the heat-resistant alloy substrate 5 by high velocity flame spraying.

[0017] In some embodiments, step S20 of forming the top coat layer 9 is a step of forming the top coat layer 9 by spraying a suspension containing ceramic powder by high-velocity flame spraying using a thermal spray gun 30 arranged in the thermal spray booth 20 onto the bond coat layer 7 of the object (heat-resistant component 1) that is placed in the thermal spray booth 20 where step S10 of forming the bond coat layer 7 is performed. That is, in some embodiments, the thermal spraying performed in step S20 of forming the top coat layer 9 is high-velocity fuel spraying using a suspension (S-HVOF). In some embodiments, in step S20 of forming the top coat layer 9, a suspension in which a ceramic powder as a thermal spray material is dispersed in a solvent is thermally sprayed onto the surface of the bond coat layer 7 by high-velocity fuel spraying. In high-velocity fuel spraying using a suspension, the thermal spray material TM supplied as a suspension is sprayed onto the surface of the object to be thermally sprayed by a combustion flame jet flow CF (see FIGS. 5A and 5B described later).

[0018] The difference between high velocity fuel spraying (HVOF) and high velocity fuel spraying with suspension (S-HVOF) is that the raw material (spraying material) used for spraying is supplied in powder form or in suspension dispersed in a solvent, but both are spraying methods using a high velocity fuel spraying device. Therefore, although there is a difference in the device configuration of the spray gun 30 and the like between high velocity fuel spraying and high velocity fuel spraying with suspension, there is almost no difference in the required peripheral devices and utilities such as the gas used. Therefore, the spray gun 30 for high velocity flame spraying and the spray gun 30 for high velocity flame spraying with suspension can be arranged in the same spray booth 20, and spraying can be performed for each. Therefore, according to the method of applying a thermal barrier coating in some embodiments, it is not necessary to move the heat-resistant component 1 as the target object to another thermal spray booth after the bond coat layer 7 is formed, which eliminates the need to move the heat-resistant component 1 to a different thermal spray booth. This significantly reduces the amount of setup work required, such as setting up the heat-resistant component 1 before the start of thermal spraying by high-velocity flame spraying with a suspension, thereby improving work efficiency when forming the thermal barrier coating 3 and reducing production costs.

[0019] Conventionally, the topcoat layer 9 has often been formed by electron beam physical vapor deposition (EB-PVD) so that the layer contains cracks (vertical cracks Cv) extending in the thickness direction of the topcoat layer 9 to ensure thermal cycle durability. However, the initial cost of an apparatus for performing electron beam physical vapor deposition is more than 10 times more expensive than that of a thermal spraying apparatus or the like. In addition, the running cost for forming a layer by electron beam physical vapor deposition is about 10 times more expensive than that for forming a layer by thermal spraying or the like. Furthermore, the rate at which a layer is formed by electron beam physical vapor deposition is low, about a fraction of the rate at which a layer is formed by thermal spraying or the like. As a result of extensive research, the inventors have found that if a top coat layer is formed by spraying a suspension containing ceramic powder using high-velocity flame spraying, it is possible to ensure performance such as heat insulation properties and thermal cycle durability equivalent to that achieved when a top coat layer is formed on a bond coat layer 7 by electron beam physical vapor deposition. According to the thermal barrier coating application method of some embodiments, the top coat layer can be formed at lower running costs and in a shorter time than when the top coat layer 9 is formed on the bond coat layer 7 by electron beam physical vapor deposition. Furthermore, according to the thermal barrier coating application method of some embodiments, the introduction cost of the equipment for forming the top coat layer 9 can be significantly reduced.

[0020] Additionally, the high-temperature component 1 according to some embodiments has a bond coat layer 7 and a top coat layer 9 formed by the method for applying a thermal barrier coating according to some embodiments. This makes it possible to reduce the manufacturing cost of the heat-resistant member 1.

[0021] FIG. 4A is a diagram for explaining an outline of an apparatus for a method of applying a thermal barrier coating according to one embodiment. FIG. 4B is a diagram for explaining an outline of an apparatus for a method of applying a thermal barrier coating according to another embodiment. FIG. 4C is a diagram for explaining an outline of an apparatus for a method of applying a thermal barrier coating according to still another embodiment. FIG. 5A is a schematic diagram for explaining the structure of an internal supply type thermal spray gun 30I. FIG. 5B is a schematic diagram for explaining the structure of an external supply type thermal spray gun 30E.

[0022] As shown in Figures 4A to 4C, in the method of applying a thermal barrier coating according to some embodiments, a thermal barrier coating 3 is applied using a thermal spray gun 30, a moving device 50 for the thermal spray gun 30, and a dust collection hood 70. In addition to the devices shown in Figures 4A to 4C, the method of applying a thermal barrier coating according to some embodiments also includes, in addition to these devices, a thermal spray control panel, a control device that controls the driving of the moving device 50, a device for supplying the thermal spray material, and the like, although not shown. When applying the thermal barrier coating 3, if it is necessary to fix the heat-resistant component 1, which is the object to which the thermal barrier coating 3 is applied, a fixing jig 91 may be used, and if it is necessary to rotate the heat-resistant component 1 continuously, a rotation drive device (not shown) may be used.

[0023] The moving device 50 according to some embodiments is, for example, an industrial robot, but may also be, for example, a scanning device having a slide axis capable of moving in a plurality of directions, such as an NC device.

[0024] 4A to 4C, in the application method of a thermal barrier coating according to some embodiments, for example, the thermal spray gun 30, the moving device 50, and the dust collection hood 70 are arranged inside one thermal spray booth 20. The thermal spray booth 20 forms a space separated from the surroundings for the purpose of sound insulation and prevention of scattering of dust to the surroundings. For example, the thermal spray booth 20 may be a box-shaped one arranged in a work room, may be a section obtained by separating part of a work room with a wall or the like, or may be a dedicated room provided in a building. The heat-resistant component 1 , which is the object of application of the thermal barrier coating 3 , has the thermal barrier coating 3 , that is, the bond coat layer 7 and the top coat layer 9 , formed in the thermal spray booth 20 .

[0025] As shown in Fig. 4A, in the method for applying a thermal barrier coating according to one embodiment, in step S10 of forming a bond coat layer 7, the bond coat layer 7 may be formed by high velocity flame spraying while moving a first thermal spray gun 30A by a moving device 50. Then, in step S20 of forming a top coat layer 9, S20 In this case, the top coat layer may be formed while moving a second thermal spray gun 30B, which is different from the first thermal spray gun 30A, by the moving device 50 used in step S10 for forming the bond coat layer 7. That is, the method of applying a thermal barrier coating according to one embodiment shown in FIG. 4A includes a step S10 of forming a bond coat layer 7 and a step S2 of forming a top coat layer 9. S20 In this way, the thermal spray gun 30 to be used (the thermal spray gun 30 attached to the moving device 50) is replaced. This completes the process of forming the bond coat layer 7 and the process of forming the top coat layer 9. S20 Both can be performed in the same thermal spray booth 20.

[0026] For example, when using an internal supply type thermal spray gun 30I configured to supply the thermal spray material TM to the inside of the thermal spray gun 30 as shown in FIG. 5A, the thermal spray gun 30 used can be changed between step S10 for forming the bond coat layer 7 and step S2 for forming the top coat layer 9.

[0027] According to the thermal barrier coating application method of one embodiment shown in FIG. 4A, after forming the bond coat layer 7 and before starting to form the top coat layer 9, the thermal spray gun 30 attached to the moving device 50 can be changed from the first thermal spray gun 30A to the second thermal spray gun 30B, without changing the moving device 50, thereby simplifying the setup work from forming the bond coat layer 7 to starting to form the top coat layer 9.

[0028] 4B , in the method for applying a thermal barrier coating according to another embodiment, in step S10 of forming a bond coat layer 7, the bond coat layer 7 may be formed by high velocity flame spraying while moving the thermal spray gun 30 by a moving device 50. Then, in step S20 of forming a top coat layer 9, the top coat layer 9 may be formed while moving the thermal spray gun 30 used in step S10 of forming the bond coat layer 7 by the moving device 50 used in step S10 of forming the bond coat layer 7. That is, in the method of applying a thermal barrier coating according to another embodiment shown in FIG. 4B, step S10 of forming the bond coat layer 7 and step S20 of forming the top coat layer 9 are performed using the same thermal spray gun 30 without changing the thermal spray gun 30 (the thermal spray gun 30 attached to the moving device 50) between step S10 of forming the bond coat layer 7 and step S20 of forming the top coat layer 9.

[0029] 4B , after the bond coat layer 7 is formed and before the formation of the top coat layer 9 is started, the supply unit 35 for supplying the thermal spray material TM of the bond coat layer 7 may be changed to a supply unit 35 for supplying the thermal spray material TM of the top coat layer 9, as described below, without changing the moving device 50 and the thermal spray gun 30. This simplifies the setup work from the formation of the bond coat layer 7 to the start of the formation of the top coat layer 9.

[0030] In addition to the different thermal spray materials used for the bond coat layer 7 and the top coat layer 9, there is also a difference in the form in which the thermal spray material is supplied, whether as a powder or as a suspension. For this reason, in the method for applying a thermal barrier coating according to another embodiment shown in FIG. 4B, it is preferable to use, as the thermal spray gun 30, an external supply type thermal spray gun 30E configured to supply the thermal spray material TM outside the thermal spray gun 30, as shown in FIG. 5B. Then, a supply unit 35 attached to the outside of the external supply type thermal spray gun 30E for supplying the thermal spray material TM to the combustion flame jet flow CF is provided in step S10 for forming the bond coat layer 7 and step S2 for forming the top coat layer 9. S20That is, in the method of applying a thermal barrier coating according to another embodiment shown in Fig. 4B, the supply unit 35 of the thermal spray material TM sprayed by the thermal spray gun 30 may be changed between step S10 of forming the bond coat layer 7 and step S20 of forming the top coat layer 9.

[0031] 4B, when performing step S10 of forming the bond coat layer 7, a first supply unit 35A for supplying the thermal spray material TM of the bond coat layer 7 may be attached to the external supply type thermal spray gun 30E. When performing step S20 of forming the top coat layer 9, a second supply unit 35B for supplying the thermal spray material TM of the top coat layer 9 may be attached to the external supply type thermal spray gun 30E. This allows step S10 of forming the bond coat layer 7 and the step of forming the top coat layer 9 to be carried out in the same thermal spray booth 20. The first supply section 35A and the second supply section 35B are connected to a supply device (not shown) for supplying the thermal spray material TM to the first supply section 35A and the second supply section 35B, respectively.

[0032] According to another embodiment of the thermal barrier coating application method shown in FIG. 4B, after forming the bond coat layer 7 and before starting to form the top coat layer 9, the first supply unit 35A is changed to the second supply unit 35B, and the moving device 50 and the thermal spray gun 30 do not need to be changed, so that the setup work from forming the bond coat layer 7 to starting to form the top coat layer 9 can be simplified.

[0033] 4C , in a method for applying a thermal barrier coating according to yet another embodiment, in step S10 of forming a bond coat layer 7, the bond coat layer 7 may be formed by high velocity flame spraying while moving a first thermal spray gun 30A by a first moving device 50A. Then, in step S20 of forming a top coat layer 9, the top coat layer 9 may be formed while moving a second thermal spray gun 30B different from the first thermal spray gun 30A by a second moving device 50B different from the first moving device 50A. In a method for applying a thermal barrier coating according to still another embodiment shown in FIG. 4C, a step S10 for forming a bond coat layer 7 and a step S10 for forming a top coat layer 9 are S20 In this way, the thermal spray gun 30 and the moving device 50 to be used are switched. S20 Both can be performed in the same thermal spray booth 20.

[0034] According to yet another embodiment of the thermal barrier coating application method shown in FIG. 4C, a first moving device 50A and a first thermal spray gun 30A are used as devices for forming the bond coat layer 7, and a second moving device 50B and a second thermal spray gun 30B are used as devices for forming the top coat layer 9. This makes it possible to omit operations such as replacing the thermal spray gun 30 and the supply unit 35 in the setup operations after forming the bond coat layer 7 and before starting to form the top coat layer 9.

[0035] The present disclosure is not limited to the above-described embodiments, and includes modifications to the above-described embodiments and appropriate combinations of these modifications.

[0036] The contents described in each of the above embodiments can be understood, for example, as follows. (1) A method for applying a thermal barrier coating according to at least one embodiment of the present disclosure includes a step (S10) of forming a bond coat layer 7 by high velocity flame spraying on a heat-resistant alloy substrate 5 of an object (heat-resistant member 1) placed in a thermal spray booth 20 using a thermal spray gun 30 placed in the thermal spray booth 20. A method for applying a thermal barrier coating according to at least one embodiment of the present disclosure includes a step (S20) of forming a top coat layer 9 by spraying a suspension containing ceramic powder by high velocity flame spraying on the bond coat layer 7 of the object (heat-resistant member 1) placed in the thermal spray booth 20 using the thermal spray gun 30 placed in the thermal spray booth 20.

[0037] According to the above method (1), there is no need to move the object (heat-resistant member 1) to be sprayed to another thermal spray booth after the bond coat layer 7 is formed, which eliminates the need to move the object (heat-resistant member 1) to be sprayed to a different thermal spray booth. This significantly reduces the amount of setup work required, such as setting up the object (heat-resistant member 1) before starting spraying by high-velocity flame spraying with a suspension, thereby improving work efficiency when forming the thermal barrier coating 3 and reducing production costs. Moreover, according to the above method (1), the top coat layer 9 can be formed at lower running costs and in a shorter time than when the top coat layer 9 is formed on the bond coat layer 7 by electron beam physical vapor deposition. Moreover, according to the above method (1), the introduction cost of equipment for forming the top coat layer 9 can be significantly reduced.

[0038] (2) In some embodiments, in the method of (1) above, in the step (S10) of forming the bond coat layer 7 by high-velocity flame spraying, the bond coat layer 7 may be formed by high-velocity flame spraying while moving the first thermal spray gun 30A by the first moving device 50A. Then, in the step (S20) of forming the top coat layer 9, the top coat layer 9 may be formed while moving a second thermal spray gun 30B different from the first thermal spray gun 30A by a second moving device 50B different from the first moving device 50A.

[0039] According to the above method (2), a first moving device 50A and a first thermal spray gun 30A are used as devices for forming the bond coat layer 7, and a second moving device 50B and a second thermal spray gun 30B are used as devices for forming the top coat layer 9. This makes it possible to omit operations such as replacing the thermal spray gun 30 and replacing the supply unit 35 in the setup operations from the formation of the bond coat layer 7 to the start of the formation of the top coat layer 9.

[0040] (3) In some embodiments, in the method of (1) above, in the step (S10) of forming the bond coat layer 7 by high velocity flame spraying, the bond coat layer 7 may be formed by high velocity flame spraying while moving the first spray gun 30A by the moving device 50. Then, in the step (S20) of forming the top coat layer 9, the top coat layer 9 may be formed while moving a second spray gun 30B different from the first spray gun 30A by the moving device 50.

[0041] According to the above method (3), after forming the bond coat layer 7, the thermal spray gun 30 attached to the moving device 50 can be changed from the first thermal spray gun 30A to the second thermal spray gun 30B before starting to form the top coat layer 9, and there is no need to change the moving device 50. This simplifies the setup work from forming the bond coat layer 7 to starting to form the top coat layer 9.

[0042] (4) In some embodiments, in the method of (1) above, in the step (S10) of forming the bond coat layer 7 by high velocity flame spraying, the bond coat layer 7 may be formed by high velocity flame spraying while the spray gun 30 is moved by the moving device 50. Then, in the step (S20) of forming the top coat layer 9, the top coat layer 9 may be formed while the spray gun 30 is moved by the moving device 50.

[0043] According to the above method (4), after forming the bond coat layer 7 and before starting to form the top coat layer 9, for example, if the supply unit 35 for supplying the thermal spray material TM of the bond coat layer 7 is changed to the supply unit 35 for supplying the thermal spray material TM of the top coat layer 9, the moving device 50 and the thermal spray gun 30 do not need to be changed, so that the setup work from forming the bond coat layer 7 to starting to form the top coat layer 9 can be simplified.

[0044] (5) In some embodiments, in the method of (4) above, the supply section 35 of the spray material TM sprayed by the spray gun 30 may be different between the step (S10) of forming the bond coat layer 7 by high velocity flame spraying and the step (S20) of forming the top coat layer 9.

[0045] According to the above method (5), after forming the bond coat layer 7, if the supply section (first supply section 35A) for the thermal spray material TM for forming the bond coat layer 7 is changed to the supply section (second supply section 35B) for the thermal spray material TM for forming the top coat layer 9 before starting to form the top coat layer 9, the moving device 50 and the thermal spray gun 30 do not need to be changed, so that the setup work after forming the bond coat layer 7 and before starting to form the top coat layer 9 can be simplified.

[0046] (6) The heat-resistant component 1 according to at least one embodiment of the present disclosure has a bond coat layer 7 and a top coat layer 9 formed by a thermal barrier coating application method according to any one of the methods (1) to (5) above.

[0047] According to the above configuration (6), the manufacturing cost of the heat-resistant member 1 can be reduced. [Explanation of symbols]

[0048] 1 Heat-resistant materials 3. Thermal Barrier Coating (TBC) 5 Heat-resistant alloy base material (base material) 7 Metal bonding layer (bond coat layer) 9 Topcoat Layer 20 Thermal spray booth 30 Thermal spray gun 35 Supply section 50 Mobile Device

Claims

[Claim 1] forming a bond coat layer by high velocity oxygen flame spraying with a first thermal spray gun on a heat resistant alloy substrate of a target disposed in a thermal spray booth; forming a top coat layer on the bond coat layer of the object disposed in the thermal spray booth by spraying a suspension containing a ceramic powder by high velocity flame spraying using a second thermal spray gun different from the first thermal spray gun; Equipped with In the step of forming the bond coat layer by high velocity flame spraying, the bond coat layer is formed by high velocity flame spraying while moving the first spray gun by a first moving device; In the step of forming the topcoat layer by spraying a suspension containing a ceramic powder by high-velocity flame spraying, the topcoat layer is formed while moving the second spray gun by a second moving device different from the first moving device; The first thermal spray gun, the first moving device, the second thermal spray gun, and the second moving device are disposed in the same thermal spray booth. How to apply thermal barrier coating.

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