Abstract: A process for forming a coating on a substrate, such as a turbine engine component, is provided. The process comprises the steps of: providing a first rare earth oxide stabilized zirconia composition; providing a second composition selected from the group consisting of a yttria stabilized zirconia composition, a ceria stabilized zirconia composition, alumina, a chromia-alumina composition, a gadolinia stabilized zirconia composition, and mixtures thereof; blending the first rare earth oxide stabilized zirconia composition with the second composition to form a blended powder; and depositing the blended powder onto the substrate. Articles having the coating formed from the above process are also described.

Abstract: A process for forming a thermal barrier coating comprises the steps of providing a substrate, providing a gadolinia stabilized zirconia powder, and forming a thermal barrier coating having at least one of a porosity in a range of from 5 to 20% and a dense segmented structure on said substrate by supplying the gadolinia stabilized powder to a spray gun and using an air plasma spray technique.

Abstract: A process for forming a coating on a substrate, such as a turbine engine component, is provided. The process comprises the steps of: providing a first rare earth oxide stabilized zirconia composition; providing a second composition selected from the group consisting of a yttria stabilized zirconia composition, a ceria stabilized zirconia composition, alumina, a chromia-alumina composition, a gadolinia stabilized zirconia composition, and mixtures thereof; blending the first rare earth oxide stabilized zirconia composition with the second composition to form a blended powder; and depositing the blended powder onto the substrate. Articles having the coating formed from the above process are also described.

Abstract: A process for forming a coating on a substrate, such as a turbine engine component, is provided. The process comprises the steps of providing a rare earth oxide stabilized zirconia composition, blending the first rare earth oxide stabilized zirconia composition with at least one additional constituent selected from the group consisting of TiO2, Al2O3, a blend of Al2O3—TiO2, La2Zr2O7, and 20 wt % Yttria Stabilized Zirconia; and depositing the blended powder onto the substrate. Articles having the coating formed from the above process are also described.

Abstract: A method of forming a thermal barrier coating on a turbine component is disclosed. The method comprises first depositing a bond coat on the turbine component. A dispersion strengthened ceramic layer containing boride particles as dispersoids is formed on the bond coat layer by plasma deposition. Ceramic coated boride particles comprise the plasma deposition feedstock in order to disperse the boride particles in the ceramic layer. The dispersion strengthened ceramic layer includes at least one of yttria-stabilized zirconia, rare earth stabilized zirconia, rare earth stabilized hafnia, and rare earth stabilized titanate.

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 substrate, such as a gas turbine compressor blade, 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 inert 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 compressor blade is coated with the powdered material without having to mask the compressor blade.

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.

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: In a process for forming a coating on a substrate, a rare earth oxide stabilized zirconia composition is provided. At least one additional constituent is provided comprising titania stabilized with zirconia. The rare earth oxide stabilized zirconia composition and additional constituent are blended to form a blended material. The blended material is deposited onto the substrate.

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 of forming a thermal barrier coating on a turbine component is disclosed. The method comprises first depositing a bond coat on the turbine component. A dispersion strengthened ceramic layer containing boride particles as dispersoids is formed on the bond coat layer by plasma deposition. Ceramic coated boride particles comprise the plasma deposition feedstock in order to disperse the boride particles in the ceramic layer. The dispersion strengthened ceramic layer includes at least one of yttria-stabilized zirconia, rare earth stabilized zirconia, rare earth stabilized hafnia, and rare earth stabilized titanate.

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: A method for repairing a workpiece includes the steps of providing an unstripped, coated workpiece comprising a surface having a localized damage site; masking the workpiece about the localized damage site; generating a microplasma stream; and applying a first powdered material to the localized damage site using the microplasma stream; and applying a second powdered material to the workpiece surface using the microplasma stream. Another method for repairing a workpiece includes the steps of providing an unstripped, coated workpiece comprising a surface having a localized damage site; generating a microplasma stream; applying without a maskant a powdered metal alloy to the damage site using the microplasma stream; and dimensionally restoring the workpiece.

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 portable, hand-held microplasma spray coating apparatus comprises an anode, a cathode and an arc gas emitter disposed in a housing, and a powder feeding system, a cooling system and a power source connected to the apparatus. The powder feeding system, cooling system and power source are detachably mounted on a mobile platform. The microplasma spray apparatus can be transported to on-site locations in the field to facilitate quick repair work.

Abstract: A metallic coating containing hard carbide particles is described. The coating is applied by an HVOF process using powder particles whose size ranges from about 15 to about 44 microns. The carbide particles are held in a 80% nickel-20% chromium matrix. The coating has a reduced tensile compressive stress relative to similar plasma sprayed coatings and exhibits a high strain to cracking value.

Abstract: A metallic coating containing hard carbide particles is described. The coating is applied by an HVOF process using powder particles whose size ranges from about 15 to about 44 microns. The carbide particles are held in a 80% nickel-20% chromium matrix. The coating has a reduced tensile compressive stress relative to similar plasma sprayed coatings and exhibits a high strain to cracking value.

Abstract: An abrasive coating is prepared by plasma spraying a top coating over a bond coating medium. The resultant structure has an improved resistance to corrosion, and a lower thermal conductivity. The coating provides substantially enhanced engine efficiency and improved durability.

Abstract: A shield 98 and method of shielding an airfoil 44 is disclosed. Various construction details are developed which increase the effectiveness of the shield and its reusability. In one embodiment, the shield has a plurality of interdigitated tabs 112,118 which urge the shield against the airfoil surfaces 94,96.