Gm Global Technolgoy Operations, Inc.

John R Cavanagh

David L Clingman

Berton Schechter

Kenneth R Cross

A method of applying a thermal barrier coat on an exposed side of a porous metal laminate which method includes the steps of spreading on the laminate an air-curable maskant to force maskant into the perforations in the exposed side, removing excess maskant from the exposed side so that maskant plugs remain in the perforations with tops generally coplanar with the exposed side, allowing the maskant to cure, directing sprays of bond coat and top coat incompatible with the maskant at the exposed side of the porous laminate to deposit a thermal barrier coat thereon but not on the maskant plugs, and removing the maskant plugs by thermal and chemical treatment or by chemical treatment alone.

Porous laminate surface coating method

An improved method for coating a porous metal laminated structure having air flow holes on the coated side of the structure including in part, the steps of roughening an exposed surface of the porous laminated material and thereafter spraying a bond layer on the roughened surface at an angle selected to coat it with a thin bond coat layer while depositing only a limited amount of the bond coat material internally of the air flow holes and thereafter spray coating the bond coated surface with a top ceramic coat of heat resistant composition and characterized by requiring a bond coat for adherence to the porous metal laminated material and wherein the top ceramic coat spray angle is inclined opposite to that of the spray angle of deposition of the bond coat material to prevent deposition of the top coat on bond material internally of the air flow holes so as to prevent bonding of the ceramic top coat in the air flow holes thereby to minimize restriction of flow through the air flow hole in the exposed surface of the porous metal laminate.

Method for coating porous metal structure

An abradable ceramic seal coating on at least one of a pair of members having relative rotational movement, the coating being formed of stabilized zirconia which is codeposited with a thermally decomposable organic powder, the codeposited layer being heated to decompose the organic filler and produce a porous coating of from about 20 to about 33% voids.

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Brownsburg, IN, United States of America

John R Cavanagh