Thermally sprayable ceramics

Claim 2

A component comprised of a substrate which has a metallic surface and which is susceptible to abrasion and erosion at high temperatures and a porous, abradable, erosion, shock and temperature resistant, triple oxide coating which has low thermal conductivity tightly bonded to said metallic surface of said substrate, said coating being, at least in part, a reaction product of a fully fused, thermally sprayable cordierite coating precursor which is capable of releasing sufficient exothermic energy when heated to promote adhesion between the coating and the substrate.

Claim 3

A component comprised of a substrate which has a metallic surface and a coating which is capable of absorbing sound and/or other vibrations tightly bonded to said metallic surface of said substrate, said coating being, at least in part, a reaction product of a fully fused, thermally sprayable cordierite coating precursor which is capable of releasing sufficient exothermic energy when heated to promote the adhesion of the coating to the substrate.

Claim 4

A component comprised of a substrate which has a metallic surface and a coating which is capable of absorbing sound and/or other vibrations tightly bonded to said metallic surface of said substrate, said coating being, at least in part, a reaction product of a fully fused, thermally sprayable cordierite coating precursor which is capable of releasing sufficient exothermic energy when heated to promote the adhesion of the coating to the substrate.

Claim 5

A component as defined in claim 1 or in claim 2 wherein said fully fused, thermally sprayable cordierite coating precursor is essentially a single phase composition in the cordierite-mullite family.

Claim 6

A component as defined in claim 1 or in claim 2 wherein said fully fused, thermally sprayable cordierite coating precursor is obtained by melting together a mixture of magnesium oxide, aluminum oxide, and silicon oxide, said precursor having a composition bounded by the phantom line in the drawing.

Claim 7

A component as defined in claim 1 or in claim 2 in which the coating consists essentially of the reaction product of a fully fused, thermally sprayable coating precursor as aforesaid.

Claim 8

A component as defined in claim 1 or in claim 2 wherein the cordierite constituent of said coating precursor has the formula 2MgO5SiO 2 2Al 2 O 3 .

Claim 9

A component comprised of a substrate which is susceptible to abrasion and erosion at high temperatures and a porous, abradable, erosion, shock and temperature resistant, triple oxide coating which has low thermal conductivity tightly bonded to said substrate, said coating being, at least in part, a reaction product of a fused, thermally sprayable cordierite coating precursor which is capable of undergoing an exothermic reaction when heated, said coating also including a rare earth metal or rare earth metal oxide in an amount effective to favorably influence a desirable property of the coating such as adhesion, strength, or corrosion resistance.

Claim 10

A component comprised of a substrate which is susceptible to abrasion and erosion at high temperatures and a porous, abradable, erosion, shock and temperature resistant, triple oxide coating which has low thermal conductivity tightly bonded to said substrate, said coating being, at least in part, a reaction product of a fused, thermally sprayable cordierite coating precursor which is capable of undergoing an exothermic reaction when heated, said coating also including a rare earth metal or rare earth metal oxide in an amount effective to favorably influence a desirable property of the coating such as adhesion, strength, or corrosion resistance.

Claim 11

A component comprised of a substrate and a coating which is capable of absorbing sound and/or other vibrations tightly bonded to said substrate, said coating being, at least in part, a reaction product of a fused, thermally sprayable cordierite coating precursor which is capable of undergoing an exothermic reaction when heated, said coating also including a rare earth metal or rare earth metal oxide in an amount effective to favorably influence a desirable property of the coating such as adhesion, strength or corrosion resistance.

Claim 12

A component comprised of a substrate and a coating which is capable of absorbing sound and/or other vibrations tightly bonded to said substrate, said coating being, at least in part, a reaction product of a fused, thermally sprayable cordierite coating precursor which is capable of undergoing an exothermic reaction when heated, said coating also including a rare earth metal or rare earth metal oxide in an amount effective to favorably influence a desirable property of the coating such as adhesion, strength or corrosion resistance.

Claim 13

A component comprised of a substrate which is susceptible to abrasion and erosion at high temperatures and a porous, abradable, erosion, shock and temperature resistant, triple oxide coating which has low thermal conductivity tightly bonded to said substrate, said coating being, at least in part, a reaction product of a fused, thermally sprayable cordierite coating precursor which is capable of undergoing an exothermic reaction when heated, said coating also including the combination of a rare earth metal or rare earth metal oxide and a refractory oxide.

Claim 14

A component comprised of a substrate which is susceptible to abrasion and erosion at high temperatures and a porous, abradable, erosion, shock and temperature resistant, triple oxide coating which has low thermal conductivity tightly bonded to said substrate, said coating being, at least in part, a reaction product of a fused, thermally sprayable cordierite coating precursor which is capable of undergoing an exothermic reaction when heated, said coating also including the combination of a rare earth metal or rare earth metal oxide and a refractory oxide.

Claim 15

A component comprised of a substrate and a coating which is capable of absorbing sound and/or other vibrations tightly bonded to said substrate, said coating being, at least in part, a reaction product of a fused, thermally sprayable cordierite coating precursor which is capable of undergoing an exothermic reaction when heated, said coating also including the combination of a rare earth metal or rare earth metal oxide and a refractory oxide.

Claim 16

A component comprised of a substrate and a coating which is capable of absorbing sound and/or other vibrations tightly bonded to said substrate, said coating being, at least in part, a reaction product of a fused, thermally sprayable cordierite coating precursor which is capable of undergoing an exothermic reaction when heated, said coating also including the combination of a rare earth metal or rare earth metal oxide and a refractory oxide.

Claim 17

A component as defined in any one of claims 7-10 wherein the rare earth metal constituent is yttrium or hafnium or an oxide of yttrium or hafnium.

Claim 18

A component comprised of a substrate which is susceptible to abrasion and erosion at high temperatures and a porous, abradable, shock and temperature resistant, triple oxide coating which has low thermal conductivity tightly bonded to said substrate, said coating being, at least in part, a reaction product of a fused, thermally sprayable cordierite coating precursor which is capable of undergoing an exothermic reaction when heated, at least the pores of the cordierite constituent of said coating being filled with a substance which is capable of keeping corrosive material in the ambient environment from penetrating to the coating substrate or a substance which is capable of keeping cracks from developing in the coating or with a lubricant.

Claim 19

A component comprised of a substrate which is susceptible to abrasion and erosion at high temperatures and a porous, abradable, shock and temperature resistant, triple oxide coating which has low thermal conductivity tightly bonded to said substrate, said coating being, at least in part, a reaction product of a fused, thermally sprayable cordierite coating precursor which is capable of undergoing an exothermic reaction when heated, at least the pores of the cordierite constituent of said coating being filled with a substance which is capable of keeping corrosive material in the ambient environment from penetrating to the coating substrate or a substance which is capable of keeping cracks from developing in the coating or with a lubricant.

Claim 20

A component comprised of a substrate and a coating which is capable of absorbing sound and/or other vibrations tightly bonded to said substrate, said coating being, at least in part, a reaction product of a fused, thermally sprayable cordierite coating precursor which is capable of undergoing an exothermaic reaction when heated, at least the pores of the cordierite consittuent of said coating being filled with a substance which is capable of keeping corrosive material in the ambient environment from penetrating to the coating substrate or with a substance which is capable of keeping cracks from developing in the coating or with a lubricant.

Claim 21

A component comprised of a substrate and a coating which is capable of absorbing sound and/or other vibrations tightly bonded to said substrate, said coating being, at least in part, a reaction product of a fused, thermally sprayable cordierite coating precursor which is capable of undergoing an exothermaic reaction when heated, at least the pores of the cordierite consittuent of said coating being filled with a substance which is capable of keeping corrosive material in the ambient environment from penetrating to the coating substrate or with a substance which is capable of keeping cracks from developing in the coating or with a lubricant.

Claim 22

A component comprised of a substrate which is susceptible to abrasion and erosion at high temperatures; a porous, abradable, erosion, shock and temperature resistant, triple oxide coating which has low thermal conductivity tightly bonded to said substrate, said coating being, at least in part, a reaction product of a fused, thermally sprayable cordierite coating precursor which is capable of undergoing an exothermic reaction when heated; and a layer of an erosion resistant refractory oxide overlying and bonded to said substrate, said coating being, at least in part, a reaction product of a fused, thermally sprayable cordierite coating precursor which is capable of undergoing an exothermic reaction when heated; and a layer of an erosion resistant refractory oxide overlying and bonded to said coating.

Claim 23

A component comprised of a substrate which is susceptible to abrasion and erosion at high temperatures; a porous, abradable, erosion, shock and temperature resistant, triple oxide coating which has low thermal conductivity tightly bonded to said substrate, said coating being, at least in part, a reaction product of a fused, thermally sprayable cordierite coating precursor which is capable of undergoing an exothermic reaction when heated; and a layer of an erosion resistant refractory oxide overlying and bonded to said substrate, said coating being, at least in part, a reaction product of a fused, thermally sprayable cordierite coating precursor which is capable of undergoing an exothermic reaction when heated; and a layer of an erosion resistant refractory oxide overlying and bonded to said coating.

Claim 24

A component comprised of a substrate; a coating which is capable of absorbing sound and/or other vibrations tightly bonded to said substrate, said coating being, at least in part, a reaction product of a fused, thermally sprayable cordierite coating precursor which is capable of undergoing an exothermic reaction when heated; and a layer of an erosion resistant refractory oxide overlying and bonded to said coating.

Claim 25

A component comprised of a substrate; a coating which is capable of absorbing sound and/or other vibrations tightly bonded to said substrate, said coating being, at least in part, a reaction product of a fused, thermally sprayable cordierite coating precursor which is capable of undergoing an exothermic reaction when heated; and a layer of an erosion resistant refractory oxide overlying and bonded to said coating.

Claim 26

A component as defined in claim 14 or in claim 15 wherein said refractory oxide is zirconia.