Patent Number: 6,165,628

Title: Protective coatings for metal-based substrates and related processes

Abstract: An article is described, which includes a metal-based substrate, such as a superalloy; a dense, primary bond layer; and a spongy secondary bond layer. A thermal barrier coating is applied over the secondary bond layer. The spongy layer has a microstructure which includes an open network of interconnected pores. A process is also described. It includes the step of applying a spongy, metallic bond layer over the substrate, followed by the application of a thermal barrier coating. A dense, primary bond layer may optionally be applied before the application of the spongy layer.

Inventors: Borom; Marcus Preston (Schenectady, NY), Gray; Dennis Michael (Delanson, NY), Lau; Yuk-Chiu (Ballston Lake, NY), Pabla; Surinder Singh (Rexford, NY)

Assignee: General Electric Company

International Classification: C23C 4/02 (20060101); C23C 28/00 (20060101); B32B 015/00 (); B32B 005/18 ()

Expiration Date: 12/26/2017