Abstract: Methods for forming a coated component, along with the resulting coated components, are provided. The method may include forming a silicon-based bond coating on a surface of a substrate and forming a barrier coating on the silicon-based bond coating. The silicon-based bond coating comprises columnar grains of crystalline silicon. Chemical vapor depositing (CVD) may be used to form the silicon-based bond coating through CVD of a silicon-containing precursor at a deposition temperature and deposition pressure that causes crystallization of the silicon material during the deposition of the silicon-based bond coating. The silicon-containing precursor may be silane, monochlorosilane, dichlorosilane, and/or trichlorosilane.

Abstract: A coated component, along with methods of its formation and use, is provided. The coated component includes a substrate having a surface; a silicon-based bond coating on the surface of the substrate; and a barrier coating on the silicon-based bond coating. The silicon-based bond coating comprises amorphous silicon phase having grains of crystalline silicon (e.g., having an average size of about 0.03 ?m to about 3 ?m) distributed therein. The amorphous silicon phase may be formed of pure silicon metal, or may be formed from silicon metal with boron, oxygen, and/or nitrogen dispersed therein.

Abstract: Methods for forming a coated component, along with the resulting coated components, are provided. The method may include forming a silicon-based bond coating on a surface of a substrate and forming a barrier coating on the silicon-based bond coating. The silicon-based bond coating comprises columnar grains of crystalline silicon. Chemical vapor depositing (CVD) may be used to form the silicon-based bond coating through CVD of a silicon-containing precursor at a deposition temperature and deposition pressure that causes crystallization of the silicon material during the deposition of the silicon-based bond coating. The silicon-containing precursor may be silane, monochlorosilane, dichlorosilane, and/or trichlorosilane.

Abstract: Articles coated via a plasma spray process, and methods for making such articles, are presented. For example, one embodiment is an article comprising a substrate comprising a top surface and a channel disposed in the substrate. The channel is defined by an internal channel surface disposed beneath the top surface and having a terminal end at an orifice at the top surface. A coating is disposed on the top surface and on at least a portion of the internal channel surface. A coating thickness at any point on the internal channel surface is less than a nominal coating thickness on the top surface, and the coating comprises a plurality of at least partially melted and solidified particles.

Abstract: Articles coated via a plasma spray process, and methods for making such articles, are presented. For example, one embodiment is an article comprising a substrate comprising a top surface and a channel disposed in the substrate. The channel is defined by an internal channel surface disposed beneath the top surface and having a terminal end at an orifice at the top surface. A coating is disposed on the top surface and on at least a portion of the internal channel surface. A coating thickness at any point on the internal channel surface is less than a nominal coating thickness on the top surface, and the coating comprises a plurality of at least partially melted and solidified particles.

Abstract: Articles coated via a plasma spray process, and methods for making such articles, are presented. For example, one embodiment is an article comprising a substrate comprising a top surface and a channel disposed in the substrate. The channel is defined by an internal channel surface disposed beneath the top surface and having a terminal end at an orifice at the top surface. A coating is disposed on the top surface and on at least a portion of the internal channel surface. A coating thickness at any point on the internal channel surface is less than a nominal coating thickness on the top surface, and the coating comprises a plurality of at least partially melted and solidified particles.

Abstract: An apparatus for providing a vacuum coating to a workpiece, including: a coating chamber containing a coating material, with the coating chamber being operable at an elevated temperature and a sub-atmospheric pressure; an electron beam gun projecting an electron beam into the coating chamber and onto the coating material, where the electron beam gun is operable to melt the coating material and to evaporate molten coating material; and, a mechanism for supporting manipulating the workpiece in the coating chamber. The supporting mechanism further includes: a coupling device for retaining the workpiece; a joint connected to the coupling device enabling movement of the workpiece in all directions; an intermediate member connecting the coupling device and the joint; and, a device connected to the intermediate member for moving the workpiece in a designated vertical plane.

Abstract: Articles coated via a plasma spray process, and methods for making such articles, are presented. For example, one embodiment is an article comprising a substrate comprising a top surface and a channel disposed in the substrate. The channel is defined by an internal channel surface disposed beneath the top surface and having a terminal end at an orifice at the top surface. A coating is disposed on the top surface and on at least a portion of the internal channel surface. A coating thickness at any point on the internal channel surface is less than a nominal coating thickness on the top surface, and the coating comprises a plurality of at least partially melted and solidified particles.

Abstract: An apparatus for providing a vacuum coating to a workpiece, including: a coating chamber containing a coating material, with the coating chamber being operable at an elevated temperature and a sub-atmospheric pressure; an electron beam gun projecting an electron beam into the coating chamber and onto the coating material, where the electron beam gun is operable to melt the coating material and to evaporate molten coating material; and, a mechanism for supporting manipulating the workpiece in the coating chamber. The supporting mechanism further includes: a coupling device for retaining the workpiece; a joint connected to the coupling device enabling movement of the workpiece in all directions; an intermediate member connecting the coupling device and the joint; and, a device connected to the intermediate member for moving the workpiece in a designated vertical plane.

Abstract: A method for applying an aluminide coating on a gas turbine engine blade having an external surface and an internal cooling cavity having an internal surface that is connected to the external surface by cooling holes. The method is conducted in a vapor coating container having a hollow interior coating chamber, and includes the steps of loading the coating chamber with the blade to be coated; providing an aluminide coating gas in the loaded coating chamber; maintaining the loaded coating chamber comprising the aluminide coating gas at a specified temperature and time to deposit an aluminide coating on the external surface of the blade; and then flowing an inert carrier gas into the loaded coating chamber comprising the aluminide coating gas at a specified gas flow rate and time to move the aluminide coating gas through the cooling holes and internal cooling cavity and deposit an aluminide coating on the internal surface of the blade.

Abstract: A method for applying an aluminide coating on a gas turbine engine blade having an external surface and an internal cooling cavity having an internal surface that is connected to the external surface by cooling holes. The method is conducted in a vapor coating container having a hollow interior coating chamber, and includes the steps of loading the coating chamber with the blade to be coated; providing an aluminide coating gas in the loaded coating chamber; flowing an inert carrier gas into the loaded coating chamber comprising the aluminide coating gas at a specified gas flow rate and time to move the aluminide coating gas through the cooling holes and internal cooling cavity and deposit an aluminide coating on the internal surface of the blade; and then flowing an inert carrier gas into the loaded coating chamber comprising the aluminide coating gas at a specified higher temperature and time to deposit an aluminide coating on the external surface of the blade.

Abstract: A method for applying an aluminide coating on a gas turbine engine blade having an external surface and an internal cooling cavity having an internal surface that is connected to the external surface by cooling holes. The method is conducted in a vapor coating container having a hollow interior coating chamber, and includes the steps of loading the coating chamber with the blade to be coated; providing an aluminide coating gas in the loaded coating chamber; flowing an inert carrier gas into the loaded coating chamber comprising the aluminide coating gas at a specified gas flow rate and time to move the aluminide coating gas through the cooling holes and internal cooling cavity and deposit an aluminide coating on the internal surface of the blade; and then flowing an inert carrier gas into the loaded coating chamber comprising the aluminide coating gas at a specified higher temperature and time to deposit an aluminide coating on the external surface of the blade.

Abstract: A method for applying an aluminide coating on a gas turbine engine blade having an external surface and an internal cooling cavity having an internal surface that is connected to the external surface by cooling holes. The method is conducted in a vapor coating container having a hollow interior coating chamber, and includes the steps of loading the coating chamber with the blade to be coated; providing an aluminide coating gas in the loaded coating chamber; maintaining the loaded coating chamber comprising the aluminide coating gas at a specified temperature and time to deposit an aluminide coating on the external surface of the blade; and then flowing an inert carrier gas into the loaded coating chamber comprising the aluminide coating gas at a specified gas flow rate and time to move the aluminide coating gas through the cooling holes and internal cooling cavity and deposit an aluminide coating on the internal surface of the blade.