US20150125681A1 - High Temperature Imaging Media for Digital Image Correlation - Google Patents
High Temperature Imaging Media for Digital Image Correlation Download PDFInfo
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- US20150125681A1 US20150125681A1 US14/460,975 US201414460975A US2015125681A1 US 20150125681 A1 US20150125681 A1 US 20150125681A1 US 201414460975 A US201414460975 A US 201414460975A US 2015125681 A1 US2015125681 A1 US 2015125681A1
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
- C23C4/08—Metallic material containing only metal elements
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
- C23C28/34—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/02—Processes for applying liquids or other fluent materials performed by spraying
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/36—Successively applying liquids or other fluent materials, e.g. without intermediate treatment
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/14—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to metal, e.g. car bodies
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
- C23C28/32—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
- C23C28/32—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer
- C23C28/321—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer with at least one metal alloy layer
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
- C23C28/32—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer
- C23C28/322—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer only coatings of metal elements only
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
- C23C28/34—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates
- C23C28/345—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
- C23C28/34—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates
- C23C28/345—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer
- C23C28/3455—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one oxide layer with a refractory ceramic layer, e.g. refractory metal oxide, ZrO2, rare earth oxides or a thermal barrier system comprising at least one refractory oxide layer
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C8/00—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
- G01L5/00—Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes
- G01L5/0047—Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes measuring forces due to residual stresses
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N25/00—Investigating or analyzing materials by the use of thermal means
- G01N25/005—Investigating or analyzing materials by the use of thermal means by investigating specific heat
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N3/00—Investigating strength properties of solid materials by application of mechanical stress
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
- Y10T428/2495—Thickness [relative or absolute]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
- Y10T428/2495—Thickness [relative or absolute]
- Y10T428/24967—Absolute thicknesses specified
- Y10T428/24975—No layer or component greater than 5 mils thick
Definitions
- the present disclosure generally relates to thermal barrier coatings, and particularly to thermal barrier coatings for use in non-contact characterization of high temperature materials.
- Thermal barrier coatings are applied to a variety of materials typically exposed to high temperatures or high temperature gradients. Thermal barrier coatings are typically applied to the surfaces of metallic substrates to insulate and protect the general integrity of the underlying substrate from prolonged thermal loads. The unique characteristics of thermal barrier coatings allow for expanded use in non-contact strain measurements.
- thermal barrier coatings are comprised of two or more layers, such as a bond coat, a thermally grown oxide and a top layer.
- the bond coat is typically formed of a metallic material or metal alloy which provides an adhering interface between the top coat and the substrate.
- Existing non-contact strain measurements are limited to relatively low temperatures ( ⁇ 1000° F.), and strain levels less than ⁇ 10%. These limits are associated with the materials, such as ceramic paint, used to provide optical contrast.
- Ceramic paints are limited both in temperature capability and strain compatibility. They are susceptible to spalling and flaking at high strain levels. Degradation of this type will preclude successful use of a non-contact strain measurement technique such as digital image correlation.
- the present disclosure is directed at addressing one or more of the deficiencies set forth above.
- a thermal barrier coating includes a bond layer having a first thickness, and a top layer having a second thickness that is approximately two-thirds of the first thickness.
- one or more of the bond layer and the top layer may be configured to maintain substantial adherence with a metallic substrate at temperatures of at least approximately 1400° F. and under strain levels of at least approximately 30%.
- a thermal barrier coating includes a metallic bond coat having a thickness of approximately 0.003 inches, and a second layer ceramic top coat having a thickness of approximately 0.002 inches.
- a method of applying a thermal barrier coating onto a metallic substrate includes applying a first layer of a partially metallic material of a first thickness to a surface of the metallic substrate; and applying a second layer of a partially ceramic material of a second thickness to the first layer.
- the second layer is applied such that the second thickness is approximately two-thirds of the first thickness.
- FIG. 1 is an enlarged, cross-sectional view of one exemplary thermal barrier coating constructed in accordance with the teachings of the present disclosure
- FIG. 2 is a perspective view of a sample substrate having a thermal barrier coating applied thereon;
- FIG. 3 is a perspective view of the sample substrate of FIG. 2 with a thermal barrier coating thereon at 1400° F. after 10% strain;
- FIG. 4 is a perspective view of the sample substrate of FIG. 2 with a thermal barrier coating thereon at 1400° F. after 20% strain;
- FIG. 5 is a perspective view of the sample substrate of FIG. 2 with a thermal barrier coating thereon at 1400° F. after 30% strain.
- the thermal bather coating 20 may include a plurality of layers configured to bond against one another as well as with a given surface of the metallic substrate 22 in a manner which substantially withstands relatively high temperatures, for example, approximately 1400F or greater, and relatively high strain levels, for example, strain levels of approximately 30% or greater. More particularly, the thermal barrier coating 20 may be structured to substantially maintain the integrity thereof and thereby enable non-contact characterization of the metallic substrate 22 , such as by digital image correlation, or the like, under both high temperature and high strain conditions.
- the thermal barrier coating 20 may include a first coat or layer 24 that is configured to adhere or bond with a surface of a metallic substrate 22 .
- the first layer 24 may be applied in the form of a bond coat or layer 24 as is commonly used in the art.
- the bond layer 24 may be generally metallic, or at least partially composed of a metallic substance or material, such as in the form of a metal alloy, or the like.
- the bond layer 24 may be composed of any material commonly used in the art that is suited to adhere to the metallic substrate 22 and provide a sufficient interface between the metallic substrate 22 and any one or more additional layers of the thermal barrier coating 20 .
- the bond layer 24 may be applied onto the surface of the metallic substrate 22 in the form of a spray or any other means conventionally used in the art.
- the thermal barrier coating 20 of FIG. 1 may additionally include a second layer 26 that is configured to adhere or bond with the first or bond layer 24 .
- the second layer 26 may be applied, for example, via spray, or the like, onto the bond layer 24 in the form of a top coat or layer 26 as is commonly used in the art, and composed of a generally ceramic material.
- the top layer 26 may include any one or more of yttria-stabilized zirconia (YSZ), alumina compounds, or any other material capable of sufficiently adhering with the bond layer 24 .
- the thermal barrier coating 20 may additionally include a third layer or a thermally grown oxide layer 28 that is generally disposed between the first layer 24 and the second layer 26 .
- the thermally grown oxide layer 28 may be composed of a slow-growing oxide that is formed through oxidation of the bond layer 24 , which may further serve to generally protect the bond layer 24 .
- the bond layer 24 and the top layer 26 of the thermal barrier coating 20 of FIG. 1 may be provided with different thicknesses to exhibit different properties under high temperatures and high strain levels.
- the bond layer 24 may be provided with a thickness of t 1
- the top layer 26 may be provided with a thickness of t 2 .
- the bond layer 24 and the top layer 26 may be configured such that the second thickness t 2 is approximately two-thirds of the first thickness t 1 .
- the bond layer 24 may have a thickness of approximately 0.003 inches and the top layer 26 may have a thickness of approximately 0.002 inches.
- Such thicknesses of the bond layer 24 and the top layer 26 have been found to exhibit desirable results under high temperatures (approximately 1400° F. to approximately 1600° F. or greater) and high levels of strain (approximately 30% to approximately 40% or greater).
- FIGS. 2-5 one exemplary thermal barrier coating 20 is applied to a sample metallic substrate 22 and tested under high temperature and high strain conditions.
- the thermal barrier coating 20 applied may include a bond layer 24 having a thickness of approximately 0.003 inches and two passes of a top layer 26 having an overall thickness of approximately 0.002 inches.
- FIG. 2 illustrates the substrate 22 as coated with the thermal barrier coating 20 as described and prior to being subjected to any high temperatures or high strain conditions.
- FIG. 3 illustrates the thermal barrier coating 20 at 1400° F. after 10% strain
- FIG. 4 illustrates the thermal barrier coating 20 at 1400° F. after 20% strain
- FIG. 5 illustrates the thermal barrier coating 20 at 1400° F. after 30% strain. As more clearly shown in FIG.
- the integrity of the thermal barrier coating 20 may be substantially intact while exhibiting surface cracks under high temperatures and high levels of strain.
- the network of surface cracks are desirable as they are indicative of coating behavior with the ability to assess or map relatively high levels of strain on the sample substrate 22 using non-contact characterization means, such as digital image correlation, or the like, that was otherwise not possible under such high temperatures due to flaking, spalling, or other modes of degradation.
Abstract
Description
- This is a non-provisional US patent application claiming priority under U.S.C §119(e) to U.S. Provisional Ser. No. 61/900,752 filed on Nov. 6, 2013
- The present disclosure generally relates to thermal barrier coatings, and particularly to thermal barrier coatings for use in non-contact characterization of high temperature materials.
- Thermal barrier coatings are applied to a variety of materials typically exposed to high temperatures or high temperature gradients. Thermal barrier coatings are typically applied to the surfaces of metallic substrates to insulate and protect the general integrity of the underlying substrate from prolonged thermal loads. The unique characteristics of thermal barrier coatings allow for expanded use in non-contact strain measurements.
- Conventional thermal barrier coatings are comprised of two or more layers, such as a bond coat, a thermally grown oxide and a top layer. The bond coat is typically formed of a metallic material or metal alloy which provides an adhering interface between the top coat and the substrate. Existing non-contact strain measurements are limited to relatively low temperatures (<1000° F.), and strain levels less than ˜10%. These limits are associated with the materials, such as ceramic paint, used to provide optical contrast.
- Ceramic paints are limited both in temperature capability and strain compatibility. They are susceptible to spalling and flaking at high strain levels. Degradation of this type will preclude successful use of a non-contact strain measurement technique such as digital image correlation. The present disclosure is directed at addressing one or more of the deficiencies set forth above.
- In accordance with one aspect of the disclosure, a thermal barrier coating is provided. The thermal barrier coating includes a bond layer having a first thickness, and a top layer having a second thickness that is approximately two-thirds of the first thickness.
- In a refinement, one or more of the bond layer and the top layer may be configured to maintain substantial adherence with a metallic substrate at temperatures of at least approximately 1400° F. and under strain levels of at least approximately 30%.
- In accordance with another aspect of the disclosure, a thermal barrier coating is provided. The thermal barrier coating includes a metallic bond coat having a thickness of approximately 0.003 inches, and a second layer ceramic top coat having a thickness of approximately 0.002 inches.
- In accordance with yet another aspect of the disclosure, a method of applying a thermal barrier coating onto a metallic substrate is provided. The method includes applying a first layer of a partially metallic material of a first thickness to a surface of the metallic substrate; and applying a second layer of a partially ceramic material of a second thickness to the first layer. The second layer is applied such that the second thickness is approximately two-thirds of the first thickness.
- These and other aspects of this disclosure will become more readily apparent upon reading the following detailed description when taken in conjunction with the accompanying drawings.
-
FIG. 1 is an enlarged, cross-sectional view of one exemplary thermal barrier coating constructed in accordance with the teachings of the present disclosure; -
FIG. 2 is a perspective view of a sample substrate having a thermal barrier coating applied thereon; -
FIG. 3 is a perspective view of the sample substrate ofFIG. 2 with a thermal barrier coating thereon at 1400° F. after 10% strain; -
FIG. 4 is a perspective view of the sample substrate ofFIG. 2 with a thermal barrier coating thereon at 1400° F. after 20% strain; and -
FIG. 5 is a perspective view of the sample substrate ofFIG. 2 with a thermal barrier coating thereon at 1400° F. after 30% strain. - While the present disclosure is susceptible to various modifications and alternative constructions, certain illustrative embodiments thereof have been shown in the drawings and will be described below in detail. It should be understood, however, that there is no intention to be limited to the specific forms disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions, and equivalents falling with the spirit and scope of the present disclosure.
- Referring to
FIG. 1 , one exemplary embodiment of athermal barrier coating 20 which may be applied to ametallic substrate 22 is provided. As shown, thethermal bather coating 20 may include a plurality of layers configured to bond against one another as well as with a given surface of themetallic substrate 22 in a manner which substantially withstands relatively high temperatures, for example, approximately 1400F or greater, and relatively high strain levels, for example, strain levels of approximately 30% or greater. More particularly, thethermal barrier coating 20 may be structured to substantially maintain the integrity thereof and thereby enable non-contact characterization of themetallic substrate 22, such as by digital image correlation, or the like, under both high temperature and high strain conditions. - As shown in
FIG. 1 , thethermal barrier coating 20 may include a first coat orlayer 24 that is configured to adhere or bond with a surface of ametallic substrate 22. More specifically, thefirst layer 24 may be applied in the form of a bond coat orlayer 24 as is commonly used in the art. Thebond layer 24 may be generally metallic, or at least partially composed of a metallic substance or material, such as in the form of a metal alloy, or the like. Moreover, thebond layer 24 may be composed of any material commonly used in the art that is suited to adhere to themetallic substrate 22 and provide a sufficient interface between themetallic substrate 22 and any one or more additional layers of thethermal barrier coating 20. Furthermore, thebond layer 24 may be applied onto the surface of themetallic substrate 22 in the form of a spray or any other means conventionally used in the art. - The
thermal barrier coating 20 ofFIG. 1 may additionally include asecond layer 26 that is configured to adhere or bond with the first orbond layer 24. Thesecond layer 26 may be applied, for example, via spray, or the like, onto thebond layer 24 in the form of a top coat orlayer 26 as is commonly used in the art, and composed of a generally ceramic material. For example, thetop layer 26 may include any one or more of yttria-stabilized zirconia (YSZ), alumina compounds, or any other material capable of sufficiently adhering with thebond layer 24. - Still referring to
FIG. 1 , thethermal barrier coating 20 may additionally include a third layer or a thermally grownoxide layer 28 that is generally disposed between thefirst layer 24 and thesecond layer 26. In particular, the thermally grownoxide layer 28 may be composed of a slow-growing oxide that is formed through oxidation of thebond layer 24, which may further serve to generally protect thebond layer 24. - Furthermore, the
bond layer 24 and thetop layer 26 of thethermal barrier coating 20 ofFIG. 1 may be provided with different thicknesses to exhibit different properties under high temperatures and high strain levels. As shown inFIG. 1 , for example, thebond layer 24 may be provided with a thickness of t1, while thetop layer 26 may be provided with a thickness of t2. Moreover, thebond layer 24 and thetop layer 26 may be configured such that the second thickness t2 is approximately two-thirds of the first thickness t1. For example, thebond layer 24 may have a thickness of approximately 0.003 inches and thetop layer 26 may have a thickness of approximately 0.002 inches. Such thicknesses of thebond layer 24 and thetop layer 26 have been found to exhibit desirable results under high temperatures (approximately 1400° F. to approximately 1600° F. or greater) and high levels of strain (approximately 30% to approximately 40% or greater). - Turning now to
FIGS. 2-5 , one exemplarythermal barrier coating 20 is applied to a samplemetallic substrate 22 and tested under high temperature and high strain conditions. For example, thethermal barrier coating 20 applied may include abond layer 24 having a thickness of approximately 0.003 inches and two passes of atop layer 26 having an overall thickness of approximately 0.002 inches. As shown,FIG. 2 illustrates thesubstrate 22 as coated with thethermal barrier coating 20 as described and prior to being subjected to any high temperatures or high strain conditions. Furthermore,FIG. 3 illustrates thethermal barrier coating 20 at 1400° F. after 10% strain,FIG. 4 illustrates thethermal barrier coating 20 at 1400° F. after 20% strain, andFIG. 5 illustrates thethermal barrier coating 20 at 1400° F. after 30% strain. As more clearly shown inFIG. 5 , the integrity of thethermal barrier coating 20 may be substantially intact while exhibiting surface cracks under high temperatures and high levels of strain. Moreover, the network of surface cracks are desirable as they are indicative of coating behavior with the ability to assess or map relatively high levels of strain on thesample substrate 22 using non-contact characterization means, such as digital image correlation, or the like, that was otherwise not possible under such high temperatures due to flaking, spalling, or other modes of degradation. - The foregoing disclosure is exemplary rather than defined by the limitations within. Various non-limiting embodiments are disclosed herein, however, one of ordinary skill in the art would recognize that various modifications and variations in light of the above teachings will fall within the scope of the appended claims. It is therefore to be understood that within the scope of the appended claims, the present disclosure may be practiced other than as specifically described. For that reason, the appended claims should be studied to determine true scope and content.
Claims (14)
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US16/793,675 US11905601B2 (en) | 2013-11-06 | 2020-02-18 | High temperature imaging media for digital image correlation |
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CN110044948A (en) * | 2019-04-29 | 2019-07-23 | 北京工业大学 | It is a kind of for measuring the device in situ of thermal barrier coating system surface crack growth rate |
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