Composite thermal spray powder of oxides and non-oxides

Abstract

Composite thermal spray powders are formed by manufacturing two or more powder feedstock components having different chemical compositions, particle size ranges and morphologies, these different features arising from different powder manufacturing processes. The resulting coatings typically serve as abradable seals, thermal barrier coatings or environmental barrier coatings, have improved temperature resistance, and maintain favorable properties over a longer time span compared to current coating materials. The thermal spray coating may be formed by using the described composite powders consisting of two or more powder components having at least one of different powder fractions in particle size, morphology and/or chemical composition or by co-spraying the described single components with at least different morphologies such as agglomerated, agglomerated-and-sintered, cladded, fused-and-crushed, or hollow oven spherical powder.