Honeywell International Inc.

David Jorgensen

Vladimir K Tolpygo

Wil Baker

Bradley Lutz

A method for forming a porous barrier coating on a substrate without substantial chemical segregation includes the steps of providing or obtaining a barrier coating material in powdered form and spraying the barrier coating material onto the substrate using air plasma spraying. The air plasma spraying is performed using an average homologous surface temperature of the depositing particles in a range of about 1.25 to about 1.5 and a particle velocity in a range of about 300 m/s to about 500 m/s. The depositing particles are fully molten.

Methods for manufacturing porous barrier coatings using air plasma spray techniques

Thermal barrier coatings, which may be used in gas turbine engines, comprise or consist of a tantala-niobia-zirconia mixture that is stabilized with two or more stabilizers. An exemplary thermal barrier coating comprises or consists of, by mole percent: about 2% to about 30% YO; about 8% to about 30% YbOor GdOor combination thereof; about 6% to about 30% TaO; about 0.1% to about 10% NbO; about 0% to about 10% HfO; and a balance of ZrO.

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Phoenix, AZ, United States of America

David Jorgensen