Process of forming a coating system, coating system formed...

C - Chemistry – Metallurgy – 23 – C

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C23C 24/08 (2006.01) C23C 28/04 (2006.01)

Patent

CA 2715958

Coating systems and processes by which a ceramic coating (14) is entirely formed from a colloidal-based process to have a thickness that would ordinarily prone to cracks and spallation. The process 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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