Abstract: Metal components with a protective coating containing silicon and a process for forming such protective coatings. The protective coating is formed by applying a silicon-containing fluid composition to the metal component as a silicon-containing layer and then heating the silicon-containing layer to a temperature exceeding 400° F.

Abstract: A turbine engine component (10) with a non-aluminide protective coating (14) containing silicon and chromium and a process for forming such non-aluminide protective coatings (14). The non-aluminide protective coating (14) is formed by applying a silicon-containing fluid composition to the turbine engine component (10) as a silicon-containing layer (20) and heating the silicon-containing layer (20) to a temperature effective to form the non-aluminide protective coating (14).

Abstract: A chemical vapor deposition (CVD) system and method for applying an aluminide coating constituted by two or more extrinsic metal components on a jet engine component. The aluminide coating is capable of forming a protective complex oxide upon subsequent heating in an oxidizing environment. At least one of the extrinsic metals in the aluminide coating is provided as a first vapor phase reactant from a receptacle coupled by a closed communication path with the reaction chamber of the CVD system and free of a carrier gas. The aluminide coating is formed by the chemical combination of the first vapor phase reactant with a second vapor phase reactant either created in situ in the reaction chamber or supplied by a carrier gas to the reaction chamber from a precursor source.

Abstract: Methods and systems for forming modified metal coatings on a gas turbine engine component (20). The gas turbine engine component (20) is placed inside a container (50) having a known volume, along with a source material (32) containing a secondary element. The container (50), gas turbine engine component (20), and the source material (32) inside the container are placed into an oxygen-depleted space (18) inside a reaction chamber (12). At least one temperature for the source material (32) is determined based upon the known volume of the container (50) and an amount of the source material (32). While in the oxygen-depleted space (18), the source material (32) is heated to the at least one temperature sufficient to release a vapor phase reactant (35) containing the secondary element.

Abstract: Metal components with a protective coating containing silicon and a process for forming such protective coatings. The protective coating is formed by applying a silicon-containing fluid composition to the metal component as a silicon-containing layer and then heating the silicon-containing layer to a temperature exceeding 400° F.

Abstract: A metal component (10) with a protective coating (16) containing silicon and a process for forming such protective coatings (14). The protective coating (16) is formed by applying a silicon-containing fluid composition to the metal component (10) as a silicon-containing layer (12) and heating the silicon-containing layer (12) to a temperature exceeding 400° F.

Abstract: A gas turbine engine component with an aluminide coating on at least a portion of an airflow surface that includes a roughening agent effective to provide a desired surface roughness and a deposition process for forming such aluminide coatings. A layer including a binder and the roughening agent may be applied to the superalloy substrate of the component and the aluminide coating formed on the airflow surface portion by exposing the component and layer to an appropriate deposition environment. Suitable roughening agents include metal and ceramic particles that are dispersed on the airflow surface portion before exposure to the deposition environment. The particles, which are substantially intact after the aluminide coating is formed, are dispersed in an effective number to supply the desired surface roughness.

Abstract: A gas turbine engine component (10) with an aluminide coating (42) on at least a portion of an airflow surface (18) that includes a roughening agent (44) effective to provide a desired surface roughness and a deposition process for forming such aluminide coatings (42). A layer (40) including a binder (38) and the roughening agent (44) maybe applied to the superalloy substrate (46) of the component (10) and the aluminide coating (42) formed on the airflow surface portion by exposing the component (10) and layer (40) to an appropriate deposition environment. Suitable roughening agents include metal and ceramic particles (44) that are dispersed on the airflow surface portion before exposure to the deposition environment. The particles (44), which are substantially intact after the aluminide coating (42) is formed, are dispersed in an effective number to supply the desired surface roughness.

Abstract: Methods and systems for forming modified metal coatings on a gas turbine engine component (20). The gas turbine engine component (20) is placed inside a container (50) having a known volume, along with a source material (32) containing a secondary element. The container (50), gas turbine engine component (20), and the source material (32) inside the container are placed into an oxygen-depleted space (18) inside a reaction chamber (12). At least one temperature for the source material (32) is determined based upon the known volume of the container (50) and an amount of the source material (32). While in the oxygen-depleted space (18), the source material (32) is heated to the at least one temperature sufficient to release a vapor phase reactant (35) containing the secondary element.

Abstract: A turbine engine component (10) with a protective aluminide coating (14) that include additions of silicon and a dopant, such as yttrium and/or hafnium, in an amount effective to reduce sulfidation and a deposition process for forming such aluminide coatings (14). A silicon-containing layer (30) may be applied to the superalloy substrate (12) of the component (10) and the aluminide coating (14) formed by exposing component (10) and layer (30) to a vapor phase reactant containing the dopant. The aluminide coating (14), which contains dopant from the layer (30), may operate as a standalone environmental coating or as a bond coating for an optional ceramic thermal barrier layer (24). An optional zirconia layer (26) maybe provided between the aluminide coating (14) and the ceramic thermal barrier layer (24).