(19)
(11)EP 2 309 024 A3

(12)EUROPEAN PATENT APPLICATION

(88)Date of publication A3:
01.05.2013 Bulletin 2013/18

(43)Date of publication A2:
13.04.2011 Bulletin 2011/15

(21)Application number: 10186959.2

(22)Date of filing:  08.10.2010
(51)International Patent Classification (IPC): 
C23C 18/12(2006.01)
F01D 5/28(2006.01)
(84)Designated Contracting States:
AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR
Designated Extension States:
BA ME

(30)Priority: 12.10.2009 US 577416

(71)Applicant: General Electric Company
Schenectady, NY 12345 (US)

(72)Inventors:
  • McEvoy, Kevin Paul
    Niskayuna, NY 12309 (US)
  • Ruud, James Anthony
    Niskayuna, NY 12309 (US)
  • Szala, Lawrence Edward
    Niskayuna, NY 12309 (US)
  • Manoharan, Mohan
    560066, Bangalore (IN)
  • Willson, Patrick Daniel
    Niskayuna, NY 12309 (US)

(74)Representative: Szary, Anne Catherine et al
GE International Inc. Global Patent Operation - Europe 15 John Adam Street
London WC2N 6LU
London WC2N 6LU (GB)

  


(54)Process of forming a coating system, coating system formed thereby, and components coated therewith


(57) A process by which a ceramic coating (14) is entirely formed from a colloidal-based process to have a thickness that would ordinarily be prone to cracks and spallation involves forming a precursor primer layer on a surface region (12,16,18), and then forming at least a precursor coating layer on the precursor primer layer that is thicker than the precursor primer layer. The precursor primer layer contains particles and a precursor of a first ceramic material. The precursor coating layer contains particles and a precursor of a second ceramic material having the same predominant constituent as the first ceramic material. The precursor primer layer and precursor coating layer are then heated to form a ceramic film (20) and a ceramic coating layer (14), respectively, which consist essentially of the particles and matrices of, respectively, the first and second ceramic materials.







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