Abstract: A method for creating a three-dimensional (3D) mark in a protective coating including at least one of a TBC and a bond coating over a metal part, is provided. The method may include positioning a mask over the protective coating, the mask including an opening pattern therein; and performing an abrasive waterjet process on the protective coating using the mask. The abrasive waterjet erodes a first portion of the protective coating exposed through the first opening pattern to create the 3D mark. The mask is removed, leaving the 3D mark in the protective coating. The 3D mark only partially penetrates through the protective coating. A metal part may include a metal body, a protective coating over the metal body, and the 3D mark in the protective coating, is also provided. The 3D mark in the protective coating may include an opening having a width of between 30 and 300 micrometers.

Abstract: A system for analyzing layer thickness of a multilayer component is provided. The system includes: an opening forming device configured to create an opening having a predefined geometry partially into the multilayer component at a selected location on a surface of the multilayer component, where the multilayer component includes a plurality of material layers including a substrate and a bond coat and the opening exposes each of the plurality of material layers, and an imaging device configured to create an image of the exposed plurality of material layers in the opening. The system is configured to calculate at least a thickness of the bond coat of the exposed plurality of material layers from the image and based on the predefined geometry of the opening. The system may also include a repairing device configured to repair the opening, allowing the multilayer component to be used for an intended purpose.

Abstract: An automated system is provided. The system includes: a manipulator coupled to: an opening forming device configured to create an opening having a predefined geometry partially into a multilayer component at a selected location on a surface of the multilayer component, where the multilayer component includes a plurality of material layers including at least a substrate and a bond coat, and where the opening exposes each of the plurality of material layers; and an imaging device configured to create an image of the exposed plurality of material layers in the opening; and a processor configured to calculate at least a thickness of the bond coat of the exposed plurality of material layers from the image and based on the predefined geometry of the opening. Methods of using the system to analyze layer thickness of a multilayer component and repair a multilayer component are also provided.

Abstract: A method of analyzing layer thickness of a multilayer component is provided. The method includes: creating an opening having a predefined geometry partially into the multilayer component at a selected location on a surface of the multilayer component. The multilayer component includes a plurality of material layers including a substrate and a bond coat. The opening exposes each of the plurality of material layers including the substrate. Contrast of the exposed plurality of material layers can be increased. An image is created of the exposed layers in the opening using a digital microscope, and thickness of a bond coat, thickness of a depletion layer\ and/or thickness of an oxide layer is calculated from the image and based on the predefined geometry of the opening. Repairing the opening, allows the multilayer component to be used for an intended purpose after testing, e.g., re-installed and reused in a gas turbine.

Abstract: A method for creating a three-dimensional (3D) mark in a protective coating including at least one of a TBC and a bond coating over a metal part, is provided. The method may include positioning a mask over the protective coating, the mask including an opening pattern therein; and performing an abrasive waterjet process on the protective coating using the mask. The abrasive waterjet erodes a first portion of the protective coating exposed through the first opening pattern to create the 3D mark. The mask is removed, leaving the 3D mark in the protective coating. The 3D mark only partially penetrates through the protective coating. A metal part may include a metal body, a protective coating over the metal body, and the 3D mark in the protective coating, is also provided. The 3D mark in the protective coating may include an opening having a width of between 30 and 300 micrometers.

Abstract: A method of analyzing layer thickness of a multilayer component is provided. The method includes: creating an opening having a predefined geometry partially into the multilayer component at a selected location on a surface of the multilayer component. The multilayer component includes a plurality of material layers including a substrate and a bond coat. The opening exposes each of the plurality of material layers including the substrate. Contrast of the exposed plurality of material layers can be increased. An image is created of the exposed layers in the opening using a digital microscope, and thickness of a bond coat, thickness of a depletion layer\ and/or thickness of an oxide layer is calculated from the image and based on the predefined geometry of the opening. Repairing the opening, allows the multilayer component to be used for an intended purpose after testing, e.g., re-installed and reused in a gas turbine.

Abstract: A method for generating coatings is disclosed. The method involves applying a flame spray technique. A metallic powder material is provided to the flame, and the process parameters of the flame spray process are chosen such as to achieve a metallic coating layer with a distinct surface roughness. In a subsequent process phase, a non-metallic material may be disposed on the rough metallic layer by flame spraying. The non-metallic layer effectively interlocks with the roughness of the metallic layer. The method may be carried out with hand-held equipment.

Abstract: A process for forming an aluminide coating system on a substrate. The process includes preparing a slurry including, by weight, about 35 to about 65% of an aluminum donor powder, the aluminum donor material comprising at least 35% aluminum, about 1 to about 25% of a binder, and balance essentially carrier. The slurry is applied to the substrate. The substrate is a nickel or cobalt based superalloy being essentially free of aluminum. The slurry is heated to form an aluminide diffusion coating including an additive aluminide layer and an interdiffusion zone disposed between the substrate and the additive aluminide layer.

Abstract: A method for reconditioning a hot gas path part of a gas turbine to flexibly adapt an operation regime of said gas turbine for subsequent operation intervals. The method includes providing a hot gas path part to be reconditioned; removing a predetermined area of the hot gas path part, resulting in a cutout at the hot gas path part; and manufacturing a coupon for insertion into the cutout to replace the removed area of the hot gas path part. The method further includes inserting the coupon into the cutout; and joining the hot gas path part with the coupon. The coupon is manufactured by a selective laser melting method resulting in a fine grain sized material with significantly improved low cycle fatigue lifetime. The hot gas path part is coated, at least in an area including the inserted coupon, with a metallic overlay with improved thermo-mechanical fatigue and oxidation lifetime.

Abstract: The invention relates to a coating system for a component of a turbomachine, which includes at least two different base powders. Each of the at least two different base powders has an individual predetermined distribution within the coating system. Further, each of the at least two different base powders is responsible for a specific property of the coating system.

Abstract: A method for reconditioning a hot gas path part of a gas turbine in order to flexibly adapt an operation regime of said gas turbine for subsequent operation intervals is disclosed. The method includes providing a hot gas path part to be reconditioned; removing a predetermined area of said hot gas path part, resulting in a cutout at said hot gas path part; and manufacturing a coupon for being inserted into said cutout to replace said removed area of said hot gas path part. The method further includes inserting said coupon into said cutout; and joining said hot gas path part with said inserted coupon. The coupon is manufactured by a selective laser melting (SLM) method resulting in a fine grain sized material with significantly improved low cycle fatigue (LCF) lifetime. The hot gas path part is coated, at least in an area comprising said inserted coupon, with a metallic overlay with improved thermo-mechanical fatigue (TMF) and oxidation lifetime.

Abstract: The invention proposes a method for applying a high-temperature stable coating layer on the surface of a component, which includes: providing a component with a surface to be coated; providing a powder material containing at least a fraction of sub-micron powder particles; and applying said powder material to the surface of the component by means of a spraying technique to build up a coating layer, whereby said sub-micron powder particles are each at least partially surrounded by an oxide shell and establish with their oxide shells an at least partially interconnected sub-micron oxide network within said coating layer.

Abstract: The invention relates to a method for separating a metal part from a ceramic part, which are joined at a connecting face within a modular hybrid component, especially of a gas turbine. The method includes said component being subjected to a reducing atmosphere in a gaseous process at elevated temperatures to dissolve the connection between said metal part and said ceramic part, especially by dissolving the ceramic part itself.

Abstract: The invention relates to a method for processing a modular hybrid component having a first part made of a first material and a second part made of a second material, which is different from the first material with regard to its electromagnetic and/or thermal properties. The method including exposing the modular hybrid component to an alternating electromagnetic field, whereby both parts are heated up differently, and that a brazing or soldering joint or field sensitive mineral cement between the first part and the second part is affected by the heating action.

Abstract: The invention relates to a coating system for a component of a turbomachine, which includes at least two different base powders. Each of the at least two different base powders has an individual predetermined distribution within the coating system. Further, each of the at least two different base powders is responsible for a specific property of the coating system.

Abstract: A component for use in an engine in which the component is subjected to at least one of a high temperature, a corrosive atmosphere, an oxidizing atmosphere, a high mechanical load, a cyclic thermal load and transient conditions such that the component is prone to crack formation and propagation. At least one base material includes a self healing system in a form of an added active phase, the self healing system including at least one of a melting point depressant and a substance having a softening or a melting point below or within a range of an operating temperature of the component.