US 12,215,428 B2
Coating systems including infiltration coatings and reactive phase spray formulation coatings
Hrishikesh Keshavan, Watervliet, NY (US); Bernard Patrick Bewlay, Niskayuna, NY (US); Jose Sanchez, Niskayuna, NY (US); Margeaux Wallace, Niskayuna, NY (US); Byron Pritchard, Cincinnati, OH (US); and Ambarish Kulkarni, Glenville, NY (US)
Assigned to General Electric Company, Evendale, OH (US)
Filed by General Electric Company, Schenectady, NY (US)
Filed on Feb. 26, 2024, as Appl. No. 18/586,711.
Application 18/586,711 is a division of application No. 17/329,326, filed on May 25, 2021, granted, now 11,946,146.
Application 17/329,326 is a division of application No. 16/208,605, filed on Dec. 4, 2018, granted, now 11,028,486, issued on Jun. 8, 2021.
Prior Publication US 2024/0247378 A1, Jul. 25, 2024
Int. Cl. C23C 28/04 (2006.01); C23C 18/12 (2006.01); F01D 5/28 (2006.01)
CPC C23C 28/042 (2013.01) [C23C 18/1216 (2013.01); C23C 18/1295 (2013.01); F01D 5/288 (2013.01); F05B 2220/30 (2013.01); F05B 2280/6011 (2013.01); F05D 2230/90 (2013.01)] 13 Claims
OG exemplary drawing
 
1. A method of coating an article having a thermal barrier coating thereon, the method comprising:
applying a liquid solution to the thermal barrier coating, wherein the liquid solution includes a nitrate of one or more of aluminum, gadolinium, yttrium, or strontium, wherein the liquid solution penetrates into at least some open pores of the thermal barrier coating and decomposes therein to form solid oxide particles that fill a portion of the at least some open pores to form an infiltration coating within the thermal barrier coating that reduces a porosity of the thermal barrier coating; and
applying a reactive phase spray formulation coating on the thermal barrier coating to form a reactive surface coating for reacting with dust deposits on the thermal barrier coating during use of the article, wherein the reactive phase spray formulation includes a base ceramic material and a ceramic binder material, wherein the base ceramic material has a particle size between 1 and 10 μm, wherein the ceramic binder material has a particle size that is less than 1 μm, wherein the base ceramic material and ceramic binder material each comprises an earth oxide.