METHOD FOR MANUFACTURING CERAMIC THERMAL BARRIER COATINGS HAVING EXCELLENT ADHESION AND THERMAL DURA

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The present invention relates to a method to manufacture a ceramic thermal barrier coating, comprising : a step (a) of preparing a first suspension having a first oxide powder for a thermal barrier coating dispersed therein and a second suspension having a second oxide powder for the thermal barrier coating dispersed therein; a step (b) of using the first suspension to form a first coating layer on a base material through suspension plasma spraying (SPS); a step (c) of using a mixed suspension of the first and second suspensions to form a buffering layer on the first coating layer through SPS; and a step (d) of using the second suspension to form a second coating layer on the buffering layer through SPS. According to the present invention, a double-layered ceramic thermal barrier coating layer is formed through SPS including a suspension feeder connects two kinds of suspensions of yttria-stabilized zirconia (YSZ) and rare-earth zirconate, which include oxide particles or alloyed complex oxide particles milled through high energy milling, respectively, thereby forming the rare-earth zirconate including a pyrochlore or fluorite phase with low thermal conductivity and high phase stability on an upper layer, which is a high temperature portion of the corresponding coating layer, and depositing the YSZ having a thermal expansion coefficient approximating that of a substrate and excellent high temperature mechanical properties on a lower layer, which is a low temperature portion. Accordingly, the present invention provides the double-layered ceramic thermal barrier coating layer usable in a higher temperature than that of an existing YSZ single-layered coating, and having more improved adhesive force and high temperature durability than that of the rare-earth zirconate single-layered coating.COPYRIGHT KIPO 2018