Composition and method for a thermal coating system

Abstract

A thermal coating includes a substrate, a first coating layer, and a second coating layer. The substrate is selected from the group consisting of superalloys and ceramic matrix composites. The first coating layer comprises an alumina powder, a silica binder, and at least one additive selected from either a first group or a second group. The second coating layer comprises at least one of zinc titanate or cerium oxide. A method for applying a thermal coating system includes spraying a bond coat mixture onto a substrate using a liquid electrostatic sprayer. The bond coat mixture comprises an alumina powder, a silica binder, and at least one additive selected from either a first group or a second group. The method further includes applying a top coat mixture onto the bond coat mixture, wherein the top coat mixture comprises at least one of zinc titanate or cerium oxide.

1 . A thermal coating system, comprising:
 a. a substrate selected from the group consisting of superalloys and ceramic matrix composites;   b. a first coating layer applied to the substrate, wherein the first coating layer comprises:
 i. an alumina powder; 
 ii. a silica binder; and 
 iii. at least one additive selected from either a first group or a second group, 
 wherein
 1. the first group consists of toluene, xylene, cellosolve acetate, EE acetate, and mineral spirits; and 
 2. the second group consists of methyl ethyl ketone, methyl isobutyl ketone, lacquer thinner, and acetone; and 
 
   c. a second coating layer applied to the first coating layer, wherein the second coating layer comprises at least one of zinc titanate or cerium oxide.   
     
     
         2 . The thermal coating system of  claim 1 , wherein the first coating layer has a thickness of less than 0.004 inches. 
     
     
         3 . The thermal coating system of  claim 1 , wherein the second coating layer has a thickness of between 0.001 inches and 0.010 inches. 
     
     
         4 . The thermal coating system of  claim 1 , wherein the first coating layer is applied directly to the substrate. 
     
     
         5 . The thermal coating system of  claim 1 , further including an undercoat layer applied between the first coating layer and the substrate, wherein the undercoat layer comprises an alumina powder and a silica binder. 
     
     
         6 . The thermal coating system of  claim 5 , wherein the undercoat layer has a thickness of between 0.001 inches and 0.008 inches. 
     
     
         7 - 19 . (canceled) 
     
     
         20 . A thermal coating system, comprising:
 a. a substrate selected from the group consisting of superalloys and ceramic matrix composites;   b. a first coating layer applied to the substrate, wherein the first coating layer comprises an alumina powder, a silica binder, and at least one additive selected from the group of toluene, xylene, cellosolve acetate, EE acetate, and mineral spirits; and   c. a second coating layer applied to the first coating layer, wherein the second coating layer comprises at least one of zinc titanate or cerium oxide.   
     
     
         21 . The thermal coating system of  claim 20 , wherein the first coating layer has a thickness of less than 0.004 inches. 
     
     
         22 . The thermal coating system of  claim 20 , wherein the second coating layer has a thickness of between 0.001 inches and 0.010 inches. 
     
     
         23 . The thermal coating system of  claim 20 , wherein the first coating layer is applied directly to the substrate. 
     
     
         24 . The thermal coating system of  claim 20 , further including an undercoat layer applied between the first coating layer and the substrate, wherein the undercoat layer comprises an alumina powder and a silica binder. 
     
     
         25 . The thermal coating system of  claim 24 , wherein the undercoat layer has a thickness of between 0.001 inches and 0.008 inches. 
     
     
         26 . A thermal coating system, comprising:
 a. a substrate selected from the group consisting of superalloys and ceramic matrix composites;   b. a first coating layer applied to the substrate, wherein the first coating layer comprises an alumina powder, a silica binder, and at least one additive selected from the group of methyl ethyl ketone, methyl isobutyl ketone, lacquer thinner, and acetone; and   c. a second coating layer applied to the first coating layer, wherein the second coating layer comprises at least one of zinc titanate or cerium oxide.   
     
     
         27 . The thermal coating system of  claim 26 , wherein the first coating layer has a thickness of less than 0.004 inches. 
     
     
         28 . The thermal coating system of  claim 26 , wherein the second coating layer has a thickness of between 0.001 inches and 0.010 inches. 
     
     
         29 . The thermal coating system of  claim 26 , wherein the first coating layer is applied directly to the substrate. 
     
     
         30 . The thermal coating system of  claim 26 , further including an undercoat layer applied between the first coating layer and the substrate, wherein the undercoat layer comprises an alumina powder and a silica binder. 
     
     
         31 . The thermal coating system of  claim 30 , wherein the undercoat layer has a thickness of between 0.001 inches and 0.008 inches.