Abstract: Methods are provided that include depositing a nickel-base superalloy powder including gamma nickel solid solution and gamma prime (Ni3Al) solid solution phases onto a seed crystal having a predetermined primary orientation, fully melting the powder and a portion of the seed crystal at a superliquidus temperature to form an initial layer having the predetermined primary orientation, heat treating the layer at subsolvus temperatures to precipitate gamma prime solid solution phase particles, depositing additional powder over the layer, melting the deposited powder and a portion of the initial layer at a superliquidus temperature to form a successive layer having the predetermined primary orientation, heat treating the layer at a subsolvus temperature to precipitate gamma prime solid solution phase particles, and repeating depositing additional powder, melting the additional powder and the portion of the successive layer at the superliquidus temperature, and heat treating the successive layer at a subsolvus temp

Abstract: Methods are provided that include depositing a nickel-base superalloy powder including gamma nickel solid solution and gamma prime (Ni3Al) solid solution phases onto a seed crystal having a predetermined primary orientation, fully melting the powder and a portion of the seed crystal at a superliquidus temperature to form an initial layer having the predetermined primary orientation, heat treating the layer at subsolvus temperatures to precipitate gamma prime solid solution phase particles, depositing additional powder over the layer, melting the deposited powder and a portion of the initial layer at a superliquidus temperature to form a successive layer having the predetermined primary orientation, heat treating the layer at a subsolvus temperature to precipitate gamma prime solid solution phase particles, and repeating depositing additional powder, melting the additional powder and the portion of the successive layer at the superliquidus temperature, and heat treating the successive layer at a subsolvus temp

Abstract: Methods are provided that include depositing a nickel-base superalloy powder including gamma nickel solid solution and gamma prime (Ni3Al) solid solution phases onto a seed crystal having a predetermined primary orientation, fully melting the powder and a portion of the seed crystal at a superliquidus temperature to form an initial layer having the predetermined primary orientation, heat treating the layer at subsolvus temperatures to precipitate gamma prime solid solution phase particles, depositing additional powder over the layer, melting the deposited powder and a portion of the initial layer at a superliquidus temperature to form a successive layer having the predetermined primary orientation, heat treating the layer at a subsolvus temperature to precipitate gamma prime solid solution phase particles, and repeating depositing additional powder, melting the additional powder and the portion of the successive layer at the superliquidus temperature, and heat treating the successive layer at a subsolvus temp

Abstract: A turbine engine component includes an electron beam-physical vapor deposition thermal barrier coating covering at least a portion of a substrate. The thermal barrier coating includes an inner layer having a columnar-grained microstructure with inter-columnar gap porosity. The inner layer includes a stabilized ceramic material. The thermal barrier coating also includes a substantially non-porous outer layer, covering the inner layer and including the stabilized ceramic material. The outer layer is deposited with continuous line-of-sight exposure to the vapor source under oxygen deficient conditions. The outer layer may further comprise a dopant oxide that is more readily reducible than the stabilized ceramic material. During deposition, the outer layer may also have an oxygen deficient stoichiometry with respect to the inner layer. Oxygen stoichiometry in the outer layer may be restored by exposure of the coated component to an oxidizing environment.

Abstract: Chemical vapor deposition systems and methods of coating a substrate are provided. The method includes evacuating a processing chamber to a threshold pressure. The substrate and the processing chamber are heated to a first processing temperature. A first pellet having a vaporization temperature that is below the first processing temperature is dispensed into the processing chamber and exposed to the first processing temperature within the processing chamber to vaporize the first pellet into a first processing vapor to produce a pressure change from the threshold pressure to a first pressure to cause the first processing vapor to flow through the processing chamber and onto the substrate. The substrate is exposed to the first processing vapor for a predetermined time.

Abstract: Engine components that include a compacted powder material comprising a nickel-based superalloy having less than five parts per million sulfur, by weight and methods of forming the components are provided. In an embodiment, by way of example only, a method includes flowing a gas into a can with a metal powder therein, the gas comprising hydrogen, the can configured to be used for a consolidation process, and the superalloy comprising sulfur. Gas is flowed into and then removed from the can. A sulfur content of the removed gas is determined during the process. The can and the metal powder therein are subjected to the consolidation process, if a determination is made that the sulfur content of the metal powder is below a threshold value, the threshold value being a value below about 1 part per million by weight.

Abstract: A turbine engine component includes an electron beam-physical vapor deposition thermal barrier coating covering at least a portion of a substrate. The thermal barrier coating includes an inner layer having a columnar-grained microstructure with inter-columnar gap porosity. The inner layer includes a stabilized ceramic material. The thermal barrier coating also includes a substantially non-porous outer layer, covering the inner layer and including the stabilized ceramic material. The outer layer is deposited with continuous line-of-sight exposure to the vapor source under oxygen deficient conditions. The outer layer may further comprise a dopant oxide that is more readily reducible than the stabilized ceramic material. During deposition, the outer layer may also have an oxygen deficient stoichiometry with respect to the inner layer. Oxygen stoichiometry in the outer layer may be restored by exposure of the coated component to an oxidizing environment.

Abstract: A diffuser particle separator may be integrated into a gas turbine engine to remove corrosive dust and salt particles from the engine's core air flow. The air flow may pass over a series of particle accumulator entrance orifices, trapping particles in a particle accumulator while allowing the air flow to continue unimpeded. Since dust deposits may become molten at high temperatures, removal of dust from the core and secondary airflow may be critical for long-life superalloy and ceramic components, particularly those with small diameter air-cooling holes and thermal barrier coatings.

Abstract: The invention provides hard, ductile coatings comprising a ductile bonding layer of zirconium or titanium alloyed with a precious metal and a hard, surface layer comprising at least one compound selected from the group consisting of zirconium nitride, titanium nitride, zirconium carbide and titanium carbide and a precious metal segregated into the grain boundaries. The present invention also provides hard ductile multilayer coatings comprised of alternating ductile metal and hard nitride or carbide layers. The invention also includes methods to manufacture nitride or carbide coatings with ductile precious metal grain boundaries. The coatings provide an erosion resistant coating to surfaces to which they are applied.

Abstract: A turbine engine component includes an electron beam-physical vapor deposition thermal barrier coating covering at least a portion of a substrate. The thermal barrier coating includes an inner layer having a columnar-grained microstructure with inter-columnar gap porosity. The inner layer includes a stabilized ceramic material. The thermal barrier coating also includes a substantially non-porous outer layer, covering the inner layer and including the stabilized ceramic material. The outer layer is deposited with continuous line-of-sight exposure to the vapor source under oxygen deficient conditions. The outer layer may further comprise a dopant oxide that is more readily reducible than the stabilized ceramic material. During deposition, the outer layer may also have an oxygen deficient stoichiometry with respect to the inner layer. Oxygen stoichiometry in the outer layer may be restored by exposure of the coated component to an oxidizing environment.

Abstract: A component for a turbine engine component includes a ceramic substrate having a surface, an environmental barrier layer bonded to the substrate surface, and an impact-resistance layer bonded to the environmental barrier layer, the impact-resistance layer having a melting point higher than about 2700° F., and further having a between about 10 and about 30% porosity. The impact-resistance layer, environmental barrier layer, and interfaces at which the environmental layer is bound to the substrate surface and the impact-resistance layer are more readily shearable than the substrate. A method for protecting a turbine engine component from environmental and particle impact-related damage includes the steps of coating a substrate surface with the environmental barrier layer, and coating the environmental barrier layer with the impact-resistance layer.

Abstract: A turbine blade tip and shroud clearance control coating system comprising a dense abrasive blade tip layer and an abradable shroud layer are provided. The dense abrasive coating may comprise cubic zirconia, hafnia or mixtures thereof and the abradable layer may be a nanolaminate thermal barrier coating that is softer than the dense abrasive layer.

Abstract: A durable protective coating may be formed by applying a thin layer of metastable alumina to a bond coating on a substrate. A thermal barrier coating may then be applied to the metastable alumina and the resulting part may be heat treated to transform the metastable alumina to a mixed alpha alumina having particles of the thermal barrier coating, such as zirconia in the case of an yttria stabilized zirconia thermal barrier coating, dispersed therein. The resulting thermal barrier coating may inhibit microbuckling of the thermally grown oxide scale that grows over time at the thermal barrier coating-bond coating interface.

Abstract: A protective coating for a component comprising a ceramic based substrate, and methods for protecting the component, the protective coating adapted for withstanding repeated thermal cycling. The substrate may comprise silicon nitride or silicon carbide, and the protective coating may comprise at least one tantalate of scandium, yttrium, or a rare earth element. The protective coating may further comprise one or more metal oxides. The coating protects the substrate from combustion gases in the high temperature turbine engine environment. The coating may be multi-layered and exhibits strong bonding to Si-based substrate materials and composites.

Abstract: A method of modifying a turbine nozzle area comprises depositing a thermal barrier coating (TBC) on the nozzle endwalls to provide a minimum nozzle area, evaluating an airflow through the nozzle, and machining the TBC to increase the nozzle area. Adjacent segment area variation may be minimized, improving engine reliability by reducing the aerodynamic excitation to the down stream blade.

Abstract: A method for stabilizing a porous thermal barrier coating plasma sprayed on a substrate comprises the steps of immersing the porous thermal barrier coating in a sol gel comprising a metal oxide or precursor thereof, a solvent, and a surfactant, applying vacuum pressure to the sol gel to infiltrate the porous thermal barrier coating with the sol gel, and drying the sol gel to produce residual metal oxide particles in the porous thermal barrier coating.

Abstract: A layered structure includes a substrate comprising a layer of an oxide/oxide ceramic based composite material, a first oxide layer disposed directly on the substrate and formed from a material that has no greater than about 10% porosity and is substantially impermeable by water vapor, and a second oxide layer disposed directly on the first oxide layer and having a greater porosity than the first oxide layer. Either or both the first and second oxide layers of the coating system may be deposited using a plasma spraying process, a slurry deposition process which is followed by a sintering step, or an EB-PVD process.

Abstract: The present application relates to a method of producing a metal article having an internal passage coated with a ceramic coating. The method comprises: preparing a core for defining the internal passage; applying the ceramic coating on the core; assembling the core with the ceramic coating applied thereon into a mold; casting metal into the mold at a pour temperature lower than the melting temperature of the ceramic coating; and removing the core. The ceramic coating may be applied by plasma spraying or slurry deposition.

Abstract: A method for combined effusion and thick TBC cooling comprises a providing a substrate, depositing a thick TBC onto the substrate and laser drilling an array of effusion holes through the TBC coated substrate. The thick TBC has a columnar crack structure, which gives compliance and spall resistance. The microstructure of the segmentation microcracked TBC reduces cracking and chipping of the TBC during effusion hole laser drilling.

Abstract: Platinum containing coatings for corrosion and oxidation protection of a substrate, and platinum electrodeposition methods for coating a substrate. The coating may comprise platinum and at least one supplementary constituent, and the method may involve co-electrodeposition of platinum and the supplementary constituent from a single electrolyte composition. The supplementary constituent may comprise chromium, an oxidation protective reactive element, or an alloy of chromium with a reactive element. Components protected by such coatings are also disclosed.