Abstract: The invention provides an improved near net-shape VPS formed multilayered combustion system component having an inner surface consisting of a smooth protective thermal barrier coating, and an outer layer of superalloy capable of withstanding temperatures in excess of 700° C. The invention also includes the method of forming such components by first vacuum plasma spraying a suitable mold with a ceramic top coat, followed by a bond coat and followed by a thick structural layer of superalloy. The mold is then separated from the multilayered structure which results in the desired near net-shape component. Combustor liners and transition ducts of gas turbine engines can be advantageously formed in this manner.

Abstract: The invention provides an improved near net-shape VPS formed multilayered combustion system component having an inner surface consisting of a smooth protective thermal barrier coating, and an outer layer of superalloy capable of withstanding temperatures in excess of 700.degree. C. The invention also includes the method of forming such components by first vacuum plasma spraying a suitable mold with a ceramic top coat, followed by a bond coat and followed by a thick structural layer of superalloy. The mold is then separated from the multilayered structure which results in the desired near net-shape component. Combustor liners and transition ducts of gas turbine engines can be advantageously formed in this manner.

Abstract: The invention provides an improved thermal barrier coating system for a hot section component. The thermal barrier coating has a metallic bond coat and a ceramic top coat made of two constituents. The top coat is formed so that there is provided a graded interface between the monolithic layers of the two top coat constituents. This allows an increase in overall thickness of the thermal barrier coating which provides a higher thermal insulation for the component being protected.