Abstract: A thermal coating includes a substrate, a first coating layer, and a second coating layer. The substrate is selected from the group consisting of superalloys and ceramic matrix composites. The first coating layer comprises an alumina powder, a silica binder, and at least one additive selected from either a first group or a second group. The second coating layer comprises at least one of zinc titanate or cerium oxide. A method for applying a thermal coating system includes spraying a bond coat mixture onto a substrate using a liquid electrostatic sprayer. The bond coat mixture comprises an alumina powder, a silica binder, and at least one additive selected from either a first group or a second group. The method further includes applying a top coat mixture onto the bond coat mixture, wherein the top coat mixture comprises at least one of zinc titanate or cerium oxide.

Abstract: A thermal coating includes a substrate, a first coating layer, and a second coating layer. The substrate is selected from the group consisting of superalloys and ceramic matrix composites. The first coating layer comprises an alumina powder, a silica binder, and at least one additive selected from either a first group or a second group. The second coating layer comprises at least one of zinc titanate or cerium oxide. A method for applying a thermal coating system includes spraying a bond coat mixture onto a substrate using a liquid electrostatic sprayer. The bond coat mixture comprises an alumina powder, a silica binder, and at least one additive selected from either a first group or a second group. The method further includes applying a top coat mixture onto the bond coat mixture, wherein the top coat mixture comprises at least one of zinc titanate or cerium oxide.

Abstract: A method of fabricating a component for a gas turbine engine is provided. The method includes applying a bond coat to at least a portion of the component, applying a dense vertically cracked (DVC) thermal barrier coating to at least a portion of the bond coat using a spray mechanism positioned a first distance from the component, and overlying at least a portion of the DVC thermal barrier coating with a soft coat thermal barrier coating using a spray mechanism that is positioned a second distance away from the component, wherein the second distance is greater than the first distance to facilitate adherence of the soft coating thermal barrier coating to the DVC thermal barrier coating.

Abstract: A coated article suitable for use at elevated temperature includes a metal substrate and a coating on the substrate. The coating includes a corrosion resistant particulate component having an average coefficient of thermal expansion (CTE) greater than alumina at 1200° F. (649° C.) dispersed in a binder matrix. An aspect ratio of at least a portion of the corrosion resistant particulate component is greater than about 2:1. The binder matrix includes a silicon-containing material and/or a phosphate-containing material.

Abstract: Method comprising providing a coating precursor composition including a corrosion resistant particulate component having an average coefficient of thermal expansion (CTE) greater than alumina at 1200° F. (649° C.) dispersed in a binder matrix, wherein an aspect ratio of at least a portion of the corrosion resistant particulate component is greater than about 2:1, and wherein the binder matrix includes at least one member of the group consisting of a silicon-containing material and a phosphate-containing material; providing the coating precursor composition on at least a portion of a metal substrate, and; curing the coating precursor composition to provide a corrosion-resistant coating on at least the portion of the metal substrate.

Abstract: A thermal coating includes a substrate, a first coating layer, and a second coating layer. The substrate is selected from the group consisting of superalloys and ceramic matrix composites. The first coating layer comprises an alumina powder, a silica binder, and at least one additive selected from either a first group or a second group. The second coating layer comprises at least one of zinc titanate or cerium oxide. A method for applying a thermal coating system includes spraying a bond coat mixture onto a substrate using a liquid electrostatic sprayer. The bond coat mixture comprises an alumina powder, a silica binder, and at least one additive selected from either a first group or a second group. The method further includes applying a top coat mixture onto the bond coat mixture, wherein the top coat mixture comprises at least one of zinc titanate or cerium oxide.

Abstract: A coating composition and repair method suitable for repairing thermal barrier coatings (TBCs), and particularly TBCs based on alumina-silica compositions. The method includes preparing a coating composition containing solid ceramic particles, hollow ceramic particles, and a silica precursor binder, applying the coating composition on a surface area of a component exposed by an opening, for example, spallation of the TBC, and then reacting the binder to yield a repair coating that covers the surface area of the component. The resulting repair coating contains the solid ceramic particles and the hollow ceramic particles in a silica matrix formed by thermally decomposing the binder.

Abstract: A method of fabricating a component for a gas turbine engine is provided. The method includes applying a bond coat to at least a portion of the component, applying a dense vertically cracked (DVC) thermal barrier coating to at least a portion of the bond coat using a spray mechanism positioned a first distance from the component, and overlying at least a portion of the DVC thermal barrier coating with a soft coat thermal barrier coating using a spray mechanism that is positioned a second distance away from the component, wherein the second distance is greater than the first distance to facilitate adherence of the soft coating thermal barrier coating to the DVC thermal barrier coating.

Abstract: A chemical composition and method for repairing a thermal barrier coating on a component designed for use in a hostile thermal environment, such as turbine, combustor and augmentor components of a gas turbine engine. The method repairs a thermal barrier coating on a component that has suffered localized damage to the thermal barrier coating. After cleaning the surface area of the component exposed by the localized spallation, a paste-like mixture of a ceramic composition comprising ceramic powders and nano-sized ceramic materials in a binder, further including an accelerant, is applied to the surface area of the component, and is optionally smoothed using mechanical means. The composition is then allowed to dry and cure to form a dried coating having polymeric characteristics. Upon subsequent heating, the dried coating reacts to produce a glassy ceramic repair coating.

Abstract: An optical coating is applied to an article surface of an article by providing a deposition substrate other than the article surface, wherein the deposition substrate is made of a removable material. The optical coating is thereafter deposited onto the deposition substrate. The optical coating is thereafter transferred to the article surface using a transfer support, which may be the deposition substrate or may be a different piece. The method includes thereafter affixing the optical coating to the article surface, and thereafter removing the transfer support.

Abstract: A method for depositing a platinum-group-containing layer on a substrate includes furnishing the substrate, and preparing a water-base paint containing metallic platinum-group powder, water, and a binder. The method further includes spraying the water-base paint overlying the substrate to form a platinum-group-containing layer, and thereafter heating the platinum-group-containing layer to interdiffuse the platinum-group-containing layer.

Abstract: A method for forming a ceramic layer on the surface of a turbine component. This method comprises the following steps: (a) providing a turbine component having a surface; (b) providing at least one ceramic tape overlaying the component surface; and (c) manually pressing the at least one ceramic tape against the component surface at a temperature of from about 150° to about 700° F. (from about 66° to about 371° C.) so as to cause the at least one ceramic tape to adhere to the component surface.

Abstract: The present invention is a hover infrared suppression system for a gas turbine engine comprising a hover infrared suppression system having an upstream first stage, a second stage downstream of the first stage and a third stage downstream of the second stage, the engine operating at a temperature sufficient to cause the hover infrared suppression system to emit infrared radiation. The present invention further comprises a high reflectivity coating applied over a preselected area of at least one of the stages of the hover infrared suppression system to reduce the infrared radiation emitted from the engine, the high reflectivity coating being fired after application.

Abstract: A composition comprising a liquid mixture having: a corrosion resistant metal particulate component comprising aluminum-containing metal particulates, wherein the aluminum-containing metal particulates have a phosphate and/or silica-containing insulating layer; a glass-forming binder component; and a liquid carrier component. Also disclosed is a method comprising the following steps: (a) providing an article comprising a metal substrate; (b) imparting to the metal substrate an electrical charge; and (c) electrostatically applying a liquid coating composition to the electrically charged metal substrate, wherein the liquid coating composition comprises a liquid mixture having: a corrosion resistant metal particulate component comprising aluminum-containing metal particulates having a phosphate and/or silica-containing insulating layer; glass-forming binder component; and a liquid carrier component.

Abstract: A chemical composition and method for repairing a thermal barrier coating on a component designed for use in a hostile thermal environment, such as turbine, combustor and augmentor components of a gas turbine engine. The method repairs a thermal barrier coating on a component that has suffered localized damage to the thermal barrier coating. After cleaning the surface area of the component exposed by the localized spallation, a paste-like mixture of a ceramic composition comprising ceramic powders and nano-sized ceramic materials in a binder is applied to the surface area of the component, and is optionally smoothed using mechanical means. The composition is then allowed to dry and cure to form a dried coating having polymeric characteristics. Upon subsequent heating, the dried coating reacts to produce a glassy ceramic repair coating.

Abstract: A composition comprising a corrosion resistant metal particulate component comprising aluminum-containing metal particulates, wherein the aluminum-containing metal particulates have a phosphate and/or silica-containing insulating layer; and a glass-forming binder component. Also disclosed is a method comprising the following steps: (a) providing an article comprising a metal substrate; (b) imparting to the metal substrate an electrical charge; and (c) electrostatically depositing a coating composition on the electrically charged metal substrate, wherein the coating composition comprises aluminum-containing metal particulates having a phosphate and/or silica-containing insulating layer; and glass-forming binder component.

Abstract: An icing protection system and method for enhancing heat transfer includes a substrate having an inner wall, an outer wall and a thickness separating the inner wall and the outer wall. A metallic layer deposited on the inner wall of the substrate by an electric arc thermal spray deposition process using at least one metallic wire has a thickness between about 0.203 mm (0.008 inches) and about 0.432 mm (0.017 inches), a surface roughness greater than about 12.7 microns (500 micro-inches) Ra, and a heat transfer augmentation of at least about 1.1. The metallic layer is formed on the inner wall from an M-Cr—Al alloy where M is selected from Fe, Co and Ni. The metallic layer defines a plurality of turbulators that act as micro-fins to enhance heat transfer from a heated gas in flow communication with the metallic layer through the substrate to prevent the formation of ice on the outer wall.

Abstract: A corrosion resistant tape coating for gas turbine engine includes a glassy ceramic matrix wherein the glassy matrix is silica-based, and includes corrosion resistant particles selected from refractory particles and non-refractory MCrAlX particles, and combinations thereof. The corrosion resistant particles are substantially uniformly distributed within the matrix, and provide the coating with corrosion resistance. Importantly the coating of the present invention has a coefficient of thermal expansion (CTE) greater than that of alumina at engine operating temperatures. The CTE of the coating is sufficiently close to the substrate material such that the coating does not spall after frequent engine cycling at temperatures above 1200° F.

Abstract: An optical coating is applied to an article surface of an article by applying a first release system to a deposition substrate, and depositing the optical coating onto the deposition substrate. A second release system and transfer substrate is applied to the second face of the optical coating. The first release system is dissolvable in a first-release-coating solvent that does not dissolve the second release system. The first release system is dissolved in the first-release-coating solvent that does not dissolve the second release system, to separate the optical coating from the deposition substrate. The first face of the optical coating is affixed to the article surface, and the transfer substrate is separated from the optical coating. Any of a variety of affixing techniques may be used.

Abstract: A method for depositing a platinum-group-containing layer on a substrate includes furnishing the substrate, and preparing a water-base paint containing metallic platinum-group powder, water, and a binder. The method further includes spraying the water-base paint overlying the substrate to form a platinum-group-containing layer, and thereafter heating the platinum-group-containing layer to interdiffuse the platinum-group-containing layer.