Abstract: A method for forming a vertically cracked thermal barrier coating is disclosed including positioning an article relative to a heat source. The article includes a thermal barrier coating disposed on a first surface of a substrate, and the substrate includes a second surface distal across the substrate from the first surface. Heat is applied locally to at least one discrete portion of the second surface of the substrate. At least one vertical crack in the thermal barrier coating is formed disposed over the at least one discrete portion. An article is disclosed including a substrate and a vertically-cracked thermal barrier coating disposed on the substrate. The vertically cracked thermal barrier coating includes at least one vertical crack in the thermal barrier coating and at least one of a low density of less than 85% of a theoretical density for the thermal barrier coating and a selective crack distribution.

Abstract: Manufactured articles, and methods of manufacturing enhanced surface smoothed components and articles. More particularly, surface smoothed components and articles, such as combustor components of turbine engines, having surface treatment conferring reduced roughness for enhanced performance and reduced wear related reduction in part life.

Abstract: A process of welding a weld turbulator on an article includes forming a weld pool on a surface of the article using an arc welder, directing at least one beam of at least one beam welder to at least one fusion edge of the weld pool, and translating the arc welder and the beam welder in a weld direction to shape the weld pool into the weld turbulator extending in the weld direction and having the fusion edge. A turbulator welding system includes an arc welder arranged and disposed to provide an electric arc on a surface of an article to form a weld pool and at least one beam welder arranged and disposed to provide at least one beam to at least one fusion edge of the weld pool. A component includes an article having a surface and a weld turbulator on the surface of the article.

Abstract: A method of modifying an article includes welding a plurality of weld rows of weld beads on a surface of the article such that a gap is formed between each pair of neighboring weld rows. The method optionally includes welding a plurality of fill rows of fill beads on the surface of the article such that each fill row of the plurality of fill rows fills at least a portion of one of the gaps. The weld rows and the fill rows increase a thickness of the article at the surface, provide an uneven contour of the article, and operate as turbulators on the surface of the article. A component includes an article having a surface and a plurality of weld rows of weld beads on the surface of the article arranged such that a gap is formed between each pair of neighboring weld rows.

Abstract: Components are disclosed which include a first component section and a second component section joined to form a hollow structure defining a plenum having an interior surface, wherein the component sections each include mating ridges joined together along the length of the plenum, and a corrosion-resistant cladding layer including a corrosion-resistant material overlaying the interior surface of the plenum. In one embodiment, the component is a gas turbine combustor fuel manifold. A method of forming the components includes applying corrosion-resistant segments including a corrosion-resistant material to each of the surfaces of the component sections, and joining the component sections to form the component, wherein joining the component sections includes fusing the corrosion-resistant segments into the corrosion-resistant cladding layer, and joining the mating ridges of the component sections.

Abstract: A process for forming a diffusion coating on a substrate is disclosed, including preparing a slurry including a donor metal powder, an activator powder, and a binder, and applying the slurry to the substrate. The slurry is dried on the substrate, forming a slurry layer on the substrate. A covering composition is applied over the slurry layer, and the covering composition is dried, forming at least one covering layer enclosing the slurry layer against the substrate. The slurry layer and the at least one covering layer are heated to form the diffusion coating on the substrate, the diffusion coating including an additive layer and an interdiffusion zone disposed between the substrate and the additive layer.

Abstract: In some embodiments, a method of welding includes welding at least one fill bead to fill at least one gap on a substrate with arc scanning by an arc welder. The gap is defined by at least one weld bead on the substrate. The weld beads are non-overlapping. A welded article includes a substrate including a crack-prone superalloy and at least one weld bead and at least one fill bead welded on the substrate. The fill bead, the weld bead, and a heat-affected zone of the substrate are micro-crack-free and macro-crack-free. In some embodiments, a method of welding includes welding weld beads on a substrate and welding fill beads on the substrate with an arc welder while arc scanning. The fill beads fill the gaps between neighboring pairs of weld beads. The fill beads are welded in a non-sequential order.

Abstract: Manufactured articles, and methods of manufacturing enhanced surface smoothed components and articles. More particularly, surface smoothed components and articles, such as combustor components of turbine engines, having surface treatment conferring reduced roughness for enhanced performance and reduced wear related reduction in part life.

Abstract: Manufactured articles, and methods of manufacturing enhanced wear protected components and articles. More particularly, wear protected components and articles, such as combustor components of turbine engines, and even more particularly enhanced wear protected micromixer tubes and assemblies thereof with one or more micromixer plates, the micromixer tubes having wear protection for enhanced performance and reduced wear related failure. Methods including surface treatment to enhance wear, including vacuum braze application of coatings to enhance surface hardness for wear benefits.

Abstract: A braze gel includes a braze powder, a braze binder, and a viscosity reducer. The braze gel has a gel viscosity sufficiently low to permit dip coating of a component with the braze gel to apply a braze coating of the braze gel to the component. A brazing process includes applying the braze gel to a portion of a component. The brazing process also includes drying the braze gel to form a braze coating on the component to form a braze-coated component. A brazing article includes a component and a braze coating over a portion of the component. The component may have structural features having a spacing of less than about 5 mm and a depth of at least about 1 mm, which may be honeycomb cells. The component may be a turbine component.

Abstract: A method for treating a component and a treated component are provided. The method includes the steps of machining a tapered slot in the component. The tapered slot is measured to determine dimensions. An insert is formed to have a corresponding geometry to the tapered slot with a braze gap between an outer surface of the insert and an inner surface of the tapered slot. A layer of a braze material is deposited on the outer surface of the insert, where a thickness of the layer corresponds to the braze gap. The layer of the braze material on the outer surface of the insert is sintered to fabricate a diffusion layer. The insert is positioned into the tapered slot. The diffusion layer is brazed to join the insert to the taper slot. The treated component includes a surface having a tapered slot, an insert, and a braze joint.

Abstract: A method for forming a vertically cracked thermal barrier coating is disclosed including positioning an article relative to a heat source. The article includes a thermal barrier coating disposed on a first surface of a substrate, and the substrate includes a second surface distal across the substrate from the first surface. Heat is applied locally to at least one discrete portion of the second surface of the substrate. At least one vertical crack in the thermal barrier coating is formed disposed over the at least one discrete portion. An article is disclosed including a substrate and a vertically-cracked thermal barrier coating disposed on the substrate. The vertically cracked thermal barrier coating includes at least one vertical crack in the thermal barrier coating and at least one of a low density of less than 85% of a theoretical density for the thermal barrier coating and a selective crack distribution.

Abstract: A method of turbulator fabrication is provided and includes additively disposing an elongate flexible member in tension onto a liner body, dispensing braze paste at an elongate flexible member-liner body interface and conducting a brazing process with respect to the braze paste to attach the elongate flexible member to the liner body.

Abstract: A system and method for repairing a metal substrate includes an electrospark device and an electrode removably supported in the electrode holder. The electrospark device applies a coating of a material when placed into contact with the metal substrate. A cooling device to lowers the temperature of shielding gas flow below an ambient temperature. A conduit is arranged to direct a flow of the shielding gas to the interface of the electrode and the substrate to cool the area of the substrate receiving the coating.

Abstract: A braze gel includes a braze powder, a braze binder, and a viscosity reducer. The braze gel has a gel viscosity sufficiently low to permit dip coating of a component with the braze gel to apply a braze coating of the braze gel to the component. A brazing process includes applying the braze gel to a portion of a component. The brazing process also includes drying the braze gel to form a braze coating on the component to form a braze-coated component. A brazing article includes a component and a braze coating over a portion of the component. The component may have structural features having a spacing of less than about 5 mm and a depth of at least about 1 mm, which may be honeycomb cells. The component may be a turbine component.

Abstract: A process for forming a diffusion coating on a substrate is disclosed, including preparing a slurry including a donor metal powder, an activator powder, and a binder, and applying the slurry to the substrate. The slurry is dried on the substrate, forming a slurry layer on the substrate. A covering composition is applied over the slurry layer, and the covering composition is dried, forming at least one covering layer enclosing the slurry layer against the substrate. The slurry layer and the at least one covering layer are heated to form the diffusion coating on the substrate, the diffusion coating including an additive layer and an interdiffusion zone disposed between the substrate and the additive layer.

Abstract: A method of providing an oxidation resistant coating is disclosed. The method includes providing a substrate having a first surface and cooling holes. A portable coating device includes electro-spark deposition (ESD) equipment and an ESD torch connected with the ESD equipment. The ESD torch has an inert gas source and a rotary electrode conductive material. The rotary electrode is positioned within the ESD torch, and is shielded by an inert gas. The rotary electrode applies a compositionally controlled protective coating to the first surface of the substrate. Then the rotary electrode is inserted into the cooling hole and generates an electrospark between rotary ESD electrode and the substrate to form a rounded edge and deposit a coating of electrode material alloy at a cooling hole edge.

Abstract: Casting methods and articles are disclosed wherein a molten first material is introduced into a mold which distributes the first material to form a first region of the article where it is subjected to a first condition suitable for growing a first grain structure, forming the first region of the article. A molten second material, compositionally distinct from the first material, is introduced into the mold to form a second region of the article. A hybridized material is formed by intermixing a first portion of the second material with the second portion of the first material. A second portion of the second material is subjected to a second condition suitable for growing a second grain structure distinct from the first grain structure, forming the second region of the article. The first region and the second region are integrally formed as a single, continuous article with a hybridized region formed between.

Abstract: A coating method is disclosed including disposing a coating composition into a fluidly communicating space defined by an internal surface of an article. The fluidly communicating space includes at least one aperture, which is sealed, forming an enclosed space. The internal surface and the coating composition are heated under autogenous pressure, coating the internal surface with the coating composition. The at least one aperture is unsealed, re-forming the fluidly communicating space. Another coating method is disclosed in which the coating composition is disposed into a reservoir which is connected in fluid communication with the enclosed space prior to heating under autogenous pressure, coating the internal surface with the coating composition. Yet another coating method is disclosed in which the coating composition and the article are disposed in a vessel, which is sealed, forming the enclosed space prior to heating under autogenous pressure, coating the internal surface with the coating composition.

Abstract: A method of providing an oxidation resistant coating is disclosed. The method includes providing a substrate having a first surface and cooling holes. A portable coating device includes electro-spark deposition (ESD) equipment and an ESD torch connected with the ESD equipment. The ESD torch has an inert gas source and a rotary electrode conductive material. The rotary electrode is positioned within the ESD torch, and is shielded by an inert gas. The rotary electrode applies a compositionally controlled protective coating to the first surface of the substrate. Then the rotary electrode is inserted into the cooling hole and generates an electrospark between rotary ESD electrode and the substrate to form a rounded edge and deposit a coating of electrode material alloy at a cooling hole edge.