Abstract: A method of manufacturing a part with a CMAS-resistant thermal barrier coating (TBC) includes providing a part body having a surface and providing a source of coating material. The coating material includes a thermal protection material and a CMAS-reactive material. The method also includes delivering the coating material from the source toward the surface of the part body to form the CMAS-resistant TBC on the surface. The CMAS-resistant TBC includes both the thermal protection material and the CMAS-reactive material. The CMAS-reactive material is included as a substantially uniform distribution within the thermal protection material.

Abstract: A method for forming a porous barrier coating on a substrate without substantial chemical segregation includes the steps of providing or obtaining a barrier coating material in powdered form and spraying the barrier coating material onto the substrate using air plasma spraying. The air plasma spraying is performed using an average homologous surface temperature of the depositing particles in a range of about 1.25 to about 1.5 and a particle velocity in a range of about 300 m/s to about 500 m/s. The depositing particles are fully molten.

Abstract: A method of providing a bond coat for a thermal barrier coating of a part of a turbomachine includes forming a first metallic bond coat layer on a substrate. The method also includes forming a second bond coat layer on the first metallic bond coat layer. The second bond coat layer has a porosity and a surface roughness that is greater than that of the first metallic bond coat layer. Furthermore, the method includes grit blasting the second bond coat layer to densify the second bond coat layer while substantially maintaining the surface roughness thereof.

Abstract: A method of manufacturing a part with a CMAS-resistant thermal barrier coating (TBC) includes providing a part body having a surface and providing a source of coating material. The coating material includes a thermal protection material and a CMAS-reactive material. The method also includes delivering the coating material from the source toward the surface of the part body to form the CMAS-resistant TBC on the surface. The CMAS-resistant TBC includes both the thermal protection material and the CMAS-reactive material. The CMAS-reactive material is included as a substantially uniform distribution within the thermal protection material.

Abstract: A method of providing a bond coat for a thermal barrier coating of a part of a turbomachine includes forming a first metallic bond coat layer on a substrate. The method also includes forming a second bond coat layer on the first metallic bond coat layer. The second bond coat layer has a porosity and a surface roughness that is greater than that of the first metallic bond coat layer. Furthermore, the method includes grit blasting the second bond coat layer to densify the second bond coat layer while substantially maintaining the surface roughness thereof.

Abstract: A method for forming a porous barrier coating on a substrate without substantial chemical segregation includes the steps of providing or obtaining a barrier coating material in powdered form and spraying the barrier coating material onto the substrate using air plasma spraying. The air plasma spraying is performed using an average homologous surface temperature of the depositing particles in a range of about 1.25 to about 1.5 and a particle velocity in a range of about 300 m/s to about 500 m/s. The depositing particles are fully molten.