Abstract: A method of forming a thermal barrier coating on an article designed for use in a hostile thermal environment, such as turbine, combustor and augmentor components of a gas turbine engine. The method is particularly directed to increasing spallation resistance of thermal barrier coatings composed of an aluminum-containing bond coat formed on the surface of an article, and an insulating ceramic layer overlaying the bond coat. Processing steps include forming the bond coat on the surface of the article, and then treating the surface of the bond coat with laser energy so as to form a diffusion barrier layer of alumina. Thereafter, a ceramic material is deposited on the surface of the diffusion barrier layer so as to form the insulating ceramic layer. A preferred technique for the treating step is to scan the surface of the bond coat with an ultraviolet laser beam characterized by an appropriate beam geometry and fluence to yield the desired diffusion barrier layer.

Abstract: A process is provided for manufacturing and repairing components, and particularly superalloy components such as gas turbine engine components. The invention entails forming precipitates in a surface of the article that has been cold worked as a result of surface machining, cleaning, handling, etc. The precipitates serve to prevent recrystallization and formation of a secondary reaction zone in the cold worked surface of the superalloy when subsequently exposed to temperatures approaching the solution temperature of the superalloy, such that the microstructure and mechanical properties of the superalloy article are preserved.