US 12,378,657 B2
Reactive phase spray formulation coatings
Hrishikesh Keshavan, Niskayuna, NY (US); Byron Pritchard, Cincinnati, OH (US); Margeaux Wallace, Niskayuna, NY (US); Ambarish Kulkarni, Niskayuna, NY (US); Mehmet Dede, Cincinnati, OH (US); and Bernard Patrick Bewlay, Niskayuna, NY (US)
Assigned to General Electric Company, Evendale, OH (US)
Filed by General Electric Company, Schenectady, NY (US)
Filed on Jan. 13, 2022, as Appl. No. 17/574,923.
Application 17/574,923 is a division of application No. 15/955,161, filed on Apr. 17, 2018, abandoned.
Prior Publication US 2022/0136095 A1, May 5, 2022
Int. Cl. C23C 14/06 (2006.01); C23C 4/10 (2016.01); C23C 4/134 (2016.01); C23C 14/28 (2006.01)
CPC C23C 14/06 (2013.01) [C23C 4/10 (2013.01); C23C 4/134 (2016.01); C23C 14/28 (2013.01)] 20 Claims
OG exemplary drawing
 
11. A coating system comprising:
a thermal barrier coating disposed on a surface of an article, the thermal barrier coating configured to reduce an amount of degradation of the article relative to the article not having the thermal barrier coating disposed on the surface; and
a reactive phase spray formulation coating on the thermal barrier coating of the article to define an external surface of the coating system, the reactive phase spray formulation coating comprising between 5 wt % and 45 wt % of a binder material and a balance of a base material, wherein the reactive phase spray formulation coating has an in-plane modulus of elasticity that is less than 60 GPa, wherein the binder material has a particle size that is less than one micron, the binder material consisting of a zirconium oxide, a gadolinium oxide, of an yttrium oxide, or a combination thereof, and wherein the base material has a particle size between one micron and ten microns, the base material consisting of a zirconium oxide, a gadolinium oxide, an yttrium oxide, or a combination thereof,
wherein the base material has a modulus of elasticity that is less than a modulus of elasticity of the binder material,
wherein the binder material has a cohesive strength that is greater than a cohesive strength of the base material,
wherein the binder material has an adhesive strength that is greater than an adhesive strength of the base material,
wherein the binder material has a surface area of at least ten square-meters per gram that is greater than a surface area of the base material.