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The stability of three water-based slurries containing different loads of Al microparticles was measured by laser scattering. The slurries displayed a Newtonian behaviour and the evolution of viscosity over nine days was found to be constant. Ground surfaces of nickel were also wetted similarly irrespective of the Al content in the slurries (30, 40 or 50 wt%) thereby demonstrating that the 1/10 PVA/H2O water based slurries are adequate for spraying. After deposition and annealing of the as-sprayed coatings, a thermal barrier coating system was formed with a top coat of hollow alumina spheres, an intermediate thermally grown oxide and a bottom aluminized bond coat. The coating system is shown to display very low thermal conductivity and remarkable oxidation resistance at high temperatures.

Rheological Behaviour, Synthesis and Performance of Smart Thermal Barrier Coating Systems Based on Hollow Alumina