Abstract: A process for applying a coating to a component used in an engine is provided. The process includes the steps of providing a component with at least one surface to be coated, and depositing at least one layer of powder coating material onto the at least one surface using a non-oxidizing carrier gas so that the powder coating material plastically deforms without melting and bonds to the at least one surface upon impact with the at least one surface. The process of the present invention has particular utility in applying bond coats to airfoil portions of turbine blades or vanes and to applying bond coats to combustion chamber liners.

Abstract: A process for restoring a worn edge of a component used in an engine is provided. The process comprises providing a component with a worn edge, and depositing at least one layer of powder metal material onto the worn edge using a non-oxidizing carrier gas so that the powder metal material plastically deforms without melting and bonds to the worn edge upon impact with the worn edge.

Abstract: A method for repairing components comprises the steps of providing a component having a defect to be repaired and depositing an aluminum containing repair material over an affected area on a surface of the component so that the repair material plastically deforms and bonds to the affected area upon impact with the affected area and thereby covers the affected area.

Abstract: A process for depositing a powder metal onto a substrate is performed by providing a substrate, depositing at least one layer of powder metal onto a surface of the substrate using a non-oxidizing carrier gas so that the powder metal plastically deforms without melting and bonds to a surface upon impact with the surface, and subjecting the at least one powder metal deposited layer to a treatment to improve density and/or raise a temperature of the at least one powder metal deposited layer. In a preferred embodiment of the present invention, the treatment to improve density and/or raise a temperature of the at least one powder metal deposited layer is a laser treatment.

Abstract: A method for repairing components formed from a superalloy material comprises the steps of providing a component formed from a superalloy material having a defect to be repaired and depositing a repair material onto a surface of the component using a non-oxidizing carrier gas so that the repair material plastically deforms and bonds to the surface upon impact with the surface and thereby covers the defect.