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 coating and method for overcoating a TBC on a component used in a high-temperature environment, such as the combustor section of an industrial gas turbine. The coating defines the outermost surface of the component and is formed of at least two layers having different compositions. An inner layer of the coating contains alumina in a first silica-containing matrix material that is free of zinc titanate. An outer layer of the coating contains alumina, a glass material, and zinc titanate in a second silica-containing matrix material. The outer layer of the coating has a surface roughness of not greater than three micrometers Ra and forms the outermost surface of the component. The coating reduces the component temperature by reducing the convective and radiant heat transfer thereto.

Abstract: Electrostatic deposition of high performance powdered materials onto gas turbine surfaces. The process also includes post-deposition thermal staging of the deposited powder to provide a durable coating that will satisfy the demands of turbine engine operation. The process envisions application of organic-based powdered materials, glass/ceramic powdered materials and metal-based powdered materials and combinations thereof using electrostatic techniques to components exposed to low temperature operations, such as may be found in the front section of a gas turbine engine or to the exterior portions of an aircraft engine, and metal-containing glass ceramics, glass-ceramic materials, or materials that can be transformed into glass ceramic materials, when applied to components exposed to high temperature operations, such as may be found in the turbine and exhaust sections of a gas turbine engine or the flaps of an aircraft.

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: A method for applying a plasma prayed coating using liquid injection is disclosed. The method includes providing a mixture of a liquid and solid particles. The solid particles are constituents of a thermal barrier coating. The mixture is injected into a plasma jet of a plasma spray device and the plasma jet is directed toward a substrate to deposit a gradient film formed from the constituents onto the substrate.

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 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: A bond coat composition is provided for applying to the surface of a ceramic composite component between the composite substrate and the thermal barrier coat. The composition includes an alumina powder, a silica-yielding liquid, glass frits, and sufficient solvent to permit mixing of the components and forming a bond coat.

Abstract: A high emissivity (Hi-E) coating for use on the exhaust baffles of HIRSS systems. HIRSS systems were developed to reduce the infrared (IR) signature of helicopter engines. Increasing operating temperatures of helicopter engines have made the HIRSS systems less effective. An infrared coating applied over selected portions of the HIRSS reduces the IR of the system. The Hi-E coating comprises, in weight percent, 30-80% refractory oxide pigment, 5-20% binder, 1-15% potassium oxide, optionally up to about 15% glass-forming material and the balance refractory oxide powder. When applied to provide a surface finish of 1100Ra microinches or coarser, the coated HIRSS has a significantly reduced hemispherical reflectance in the IR frequency range.

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 coating and method for overcoating a TBC on a component used in a high-temperature environment, such as the combustor section of an industrial gas turbine. The coating defines the outermost surface of the component and is formed of at least two layers having different compositions. An inner layer of the coating contains alumina in a first silica-containing matrix material that is free of zinc titanate. An outer layer of the coating contains alumina, a glass material, and zinc titanate in a second silica-containing matrix material. The outer layer of the coating has a surface roughness of not greater than three micrometers Ra and forms the outermost surface of the component. The coating reduces the component temperature by reducing the convective and radiant heat transfer thereto.

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: In accordance with one embodiment of the invention, there is provided a method of coating a gas turbine engine component using a powder coating process. The method comprises providing a gas turbine engine component; and applying a powder coating to the gas turbine engine component using the powder coating process. The powder coating is applied in a dry form without an organic solvent. The method further comprises heating the applied powder coating to melt and fuse particles of the powder coating to the gas turbine engine component and cure the powder coating.

Abstract: Non-spherical particles including a major dimension, for example flakes of material, are positioned with the major dimension oriented generally along an article surface in respect to which the particle is disposed. The particles, disposed in a fluid medium, the viscosity of which can be increased to secure the particles in position, are positioned using a force from flow of the fluid medium on the particles.

Abstract: A method for producing a coating for applying to parts used in combustive gas atmospheres includes applying a layer of a material having a high index of radiative reflectance to a surface, and then applying a layer of a material having a low index of radiative reflectance over the high reflectance layer. After sufficient alternate layers of material have been applied to meet a predetermined spectral reflectance profile, the combined layers are exposed to a heating cycle to release the combined layers from the surface. The combined layers are then collected, pulverized and mixed with the appropriate solvent for application to the desired component.

Abstract: Non-spherical particles including a major dimension, for example flakes of material, are positioned with the major dimension oriented generally along an article surface in respect to which the particle is disposed. The particles, disposed in a fluid medium, the viscosity of which can be increased to secure the particles in position, are positioned using a force of gravity on the particles.

Abstract: A ceramic matrix composite system includes multiple stacked layers of ceramic fiber cloth impregnated with resin matrix material. The resin matrix material in each of the fiber cloth layers substantially remains with the same layer during subsequent processing. Ceramic-containing material inner layers are applied between each of the fiber cloth layers enhancing the cross ply strength of the composite system.

Abstract: A method for applying a coating system that is applied to a surface of a component for preventing or at least substantially preventing interdiffusion between the component surface and a protective thermal layer applied to the component surface when the thermal layer is exposed to elevated temperatures. The method includes applying a carrier layer containing aluminum to the component surface. Next, the layer is heated to a first predetermined temperature for a first predetermined period of time in the substantial absence of oxygen to bond the aluminum with the component surface, the heat dissolving the carrier portion of the aluminum layer. The remaining portion of the aluminum layer is then heated to a second predetermined temperature for a second predetermined period of time to form an oxidized aluminum layer. Finally, at least one protective thermal layer is applied over the oxidized aluminum layer.

Abstract: Apparatus and methods for cleaning and 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 apparatus is a handheld tool that includes an applicator and a fluid dispensing unit. The method involves use of the apparatus to clean and repair a damaged coating such as a thermal barrier coating on a coated article. After cleaning the surface area of the component exposed by the localized spallation using a first apparatus, a second apparatus is used to apply and distribute a liquid mixture such as a primer or a coating repair composition the damaged area of the coating. The cleaning and repair methods can be performed while the component remains installed, e.g., in a gas turbine engine.

Abstract: Coating systems suitable for protecting components exposed to high-temperature environments, such as the hot gas flow path through a gas turbine engine. A multilayer thermal barrier coating (TBC) system characterized by a low coefficient of thermal conductivity and having a heat-absorbing topcoat comprised of the thermal decomposition product of at least one metallic element and at least one ceramic precursor binder component.