General Electric Company

Arnold Thomas Henry

Yuk-Chiu Lau

Hongyu Wang

David Joseph Mitchell

Irene T Spitsberg

A method for manufacturing an article for use in a high-temperature environment, and an article for use in such an environment, are presented. The method comprises providing a substrate; selecting a desired vertical crack density for a protective coating to be deposited on the substrate; providing a powder, wherein the powder has a size range selected to provide a coating having the desired vertical crack density; and applying a thermal-sprayed coating to the substrate, the coating having the desired vertical crack density, wherein the powder is used as a raw material for the coating.

Method for manufacturing articles for high temperature use, and articles made therewith

A process of depositing a coating system suitable for use as an environmental barrier coating on various substrate materials, particularly those containing silicon and intended for high temperature applications such as the hostile thermal environment of a gas turbine engine. The process comprises depositing a first coating layer containing mullite, and preferably a second coating layer of an alkaline earth aluminosilicate, such as barium-strontium-aluminosilicate (BSAS), by thermal spraying while maintaining the substrate at a temperature of 800&deg; C. or less, preferably 500&deg; C. or less, by which a substantially crack-free coating system is produced with desirable mechanical integrity.

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Gloversville, NY, United States of America

Arnold Thomas Henry