Abstract: A plasma spray system including a turntable subsystem operable to position a multiple of work pieces on a respective multiple of workpiece mounts; a plasma spray subsystem operable to plasma spray the multiple of work pieces on said turntable subsystem; and an overspray wash subsystem operable to wash the multiple of work pieces on said turntable subsystem subsequent to plasma spray of the multiple of work pieces.

Abstract: An article such as a heat shield panel includes a substrate and a multi-layered coating supported on the substrate. The multi-layered coating can include alternating layers of different ceramic material compositions having individual thicknesses of less than 25 micrometers.

Abstract: A plasma spray system including a turntable subsystem operable to position a multiple of work pieces on a respective multiple of workpiece mounts; a plasma spray subsystem operable to plasma spray the multiple of work pieces on said turntable subsystem; and an overspray wash subsystem operable to wash the multiple of work pieces on said turntable subsystem subsequent to plasma spray of the multiple of work pieces.

Abstract: A plasma spray system including a turntable subsystem operable to position a multiple of work pieces on a respective multiple of workpiece mounts; a plasma spray subsystem operable to plasma spray the multiple of work pieces on said turntable subsystem; and an overspray wash subsystem operable to wash the multiple of work pieces on said turntable subsystem subsequent to plasma spray of the multiple of work pieces.

Abstract: An article such as a heat shield panel includes a substrate and a multi-layered coating supported on the substrate. The multi-layered coating can include alternating layers of different ceramic material compositions having individual thicknesses of less than 25 micrometers.

Abstract: An abrasive coating on a rotor shaft interacts with cantilevered vanes to form an abradable air seal in a turbine engine. The abrasive coating includes a metal bond coat, and an abrasive layer containing a plurality of abrasive CBN grit particles in a ceramic matrix.

Abstract: A plasma spray system including a turntable subsystem operable to position a multiple of work pieces on a respective multiple of workpiece mounts; a plasma spray subsystem operable to plasma spray the multiple of work pieces on said turntable subsystem; and an overspray wash subsystem operable to wash the multiple of work pieces on said turntable subsystem subsequent to plasma spray of the multiple of work pieces.

Abstract: An abrasive coating on a rotor shaft interacts with cantilevered vanes to form an abradable air seal in a turbine engine. The abrasive coating includes a metal bond coat, and an abrasive layer containing a plurality of abrasive grit particles in a ceramic matrix. The grit particles may be selected from cubic boron nitride (CBN), zirconia, alumina, silicon carbide, diamond and mixtures thereof.

Abstract: A ceramic thermal barrier coating having improved erosion resistance includes a metallic layer and a ceramic layer positioned on the metallic layer. The ceramic layer includes a first powder, a second powder, and a third powder. The first powder and the second powder are alloyed together prior to being mixed with the third powder.

Abstract: A method of applying a wear-resistant coating comprises mixing about 75% to about 85% by weight chromium carbide and about 15% to about 25% by weight nickel chromium to form a chromium carbide-nickel chromium mixture, and simultaneously heating the chromium carbide-nickel chromium mixture to about 1371 degrees Celsius to about 2204 degrees Celsius and applying the chromium carbide-nickel chromium mixture at a velocity in a range of about 305 meters feet per second to about 915 meters per second by high velocity oxygen fuel (HVOF) spraying.

Abstract: A wear-resistant component of a carbon seal includes a surface and a coating applied onto the surface. The coating is a chromium carbide-nickel chromium composition constituting between about 75% and about 85% by weight chromium carbide and between about 15% and about 25% by weight nickel chromium. The chromium carbide-nickel chromium composition is applied onto the surface by high velocity oxy-fuel spraying (HVOF).

Abstract: A microplasma spray coating apparatus includes a microplasma apparatus with an anode, cathode, and an arc generator for generating an electric arc between the anode and cathode. An arc gas emitter injects inert gas through the electric arc. The electric arc is operable for ionizing the gas to create a plasma gas stream. A powder injector nozzle extends through the anode and injects powdered material into the plasma stream for transfer to the workpiece.

Abstract: A method and apparatus for microplasma spray coating a portion of a turbine vane without masking any portions thereof. The apparatus includes a microplasma gun with an anode, cathode, and an arc generator for generating an electric arc between the anode and cathode. An arc gas emitter injects gas through the electric arc. The electric arc is operable for ionizing the gas to create a plasma gas stream. A powder injector injects powdered material into a plasma stream. A localized area of the turbine vane is coated with the powdered material without having to mask the turbine vane.

Abstract: A method and apparatus for repairing a thermal barrier coating on components in gas turbine engines and the like. The apparatus includes a microplasma spray gun having an anode, cathode, and an arc generator for generating an electric arc between the anode and cathode. The apparatus includes a nozzle for emitting arc gas into the electric arc. The electric arc is operable for ionizing the gas to create a plasma gas stream. A powder injector injects powdered thermal barrier coating material into the plasma gas stream. Defective areas of the thermal barrier coating can be patched on the component without masking the component.

Abstract: A method for coating a part includes applying a ceramic mask to a first surface portion of the part. A coating is applied to a second surface portion of the part and at least partially contacting the mask. The mask is destructively removed.

Abstract: An abrasive coating on a rotor shaft interacts with cantilevered vanes to form an abradable air seal in a turbine engine. The abrasive coating includes a metal bond coat, and an abrasive layer containing a plurality of abrasive grit particles in a ceramic matrix. The grit particles may be selected from cubic boron nitride (CBN), zirconia, alumina, silicon carbide, diamond and mixtures thereof.

Abstract: A process for forming a dense abrading thermally insulating coating on a rotor shaft in a gas turbine engine is described. The process comprises fixturing the rotor shaft to allow it to rotate about its axis and plasma spraying the coating on the rotor shaft. The coating comprises a zirconia based ceramic top coat layer on a metallic bond coat.

Abstract: A compressor rotor seal includes a bare radial inward end of a rotor vane in proximity to a rotor surface coated with an abrasive material.

Abstract: An abrasive coating on a rotor shaft interacts with cantilevered vanes to form an abradable air seal in a turbine engine. The abrasive coating includes a metal bond coat, and an abrasive layer containing a plurality of abrasive CBN grit particles in a ceramic matrix.

Abstract: Microspray apparatus and methods involve injecting powdered material into a plasma gas stream. The material comprises first and second component powders. The second powder is a majority by the weight of the powdered material. The first powder acts as a melting point depressant. The first and second powders may have similar compositions but with the first powder including a greater quantity of a melting point depressant element.