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: 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 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: 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: A coating suitable for use as a wear-resistant coating for a gas turbine engine component comprises titanium chrome carbonitride and nickel cobalt.

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 method for repairing a workpiece using microplasma includes the steps of generating a microplasma stream having a width of about 0.5 millimeters to about 5 millimeters; applying the microplasma stream to a workpiece; and coating a portion of the workpiece with the microplasma stream without masking the workpiece. One or more quantities of powdered materials entrained in the microplasma stream may be applied to the workpiece without masking the workpiece after applying the first layer.

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 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: 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 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 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.