| abstract |
A method of forming a ceramic layer on a metal substrate. A substrate ( 40 ) is formed ( 54 ) from a powder ( 24 ) of the metal, and may optionally be partially sintered ( 56 ). A layer ( 43 ) of powdered ceramic is formed ( 58 ) on or applied against the substrate ( 45 ). The ceramic powder may include a proportion of nano-sized particles effective to reduce the ceramic sintering temperature and to increase the sintering shrinkage of the ceramic layer to more closely match that of the metal substrate. The substrate and layer are then co-sintered ( 21, 60 ) at a temperature and for a duration that densifies and bonds them, producing a metal/ceramic layered material system with low interface stress that is durable to temperature variations in a gas turbine. Spark plasma sintering ( 32, 34, 36 ) may be used to sinter and/or co-sinter substrate and layer materials that normally cannot be sintered. |