Abstract: A method for forming a protective coating on a substrate comprising, applying a bond coating to the substrate, the bond coating having a first surface roughness, ionizing an inert gas which flows into the surface of the bond coating so as to impart a second surface roughness to the bond coating greater than the first surface roughness, wherein the inert gas is ionized and caused to flow into the surface of the bond coating by a reverse polarity current supplied to an electrode which removes at least one electron from the inert gas, and applying a top coating to the bond coating. Additionally, a method for preparing a surface to receive and adhere to a coating comprising roughening the surface to create a micro-roughening network on the surface. In addition, a method of improving strain tolerance and cyclic spallation life of a protective coating.

Abstract: A method for forming a protective coating on a substrate comprising, applying a bond coating to the substrate, the bond coating having a first surface roughness, ionizing an inert gas which flows into the surface of the bond coating so as to impart a second surface roughness to the bond coating greater than the first surface roughness, wherein the inert gas is ionized and caused to flow into the surface of the bond coating by a reverse polarity current supplied to an electrode which removes at least one electron from the inert gas, and applying a top coating to the bond coating. Additionally, a method for preparing a surface to receive and adhere to a coating comprising roughening the surface to create a micro-roughening network on the surface. In addition, a method of improving strain tolerance and cyclic spallation life of a protective coating.

Abstract: An article and method of forming the article are disclosed. The method includes positioning a first workpiece, positioning a second workpiece, and applying energy to the first workpiece and the second workpiece to form a weld. The article includes the first and second workpiece. The first workpiece includes a first weld surface, which includes at least one porosity reducing channel. The second workpiece includes a second weld surface positioned to be welded to the first weld surface. The application of energy generates gas that is directed by the at least one porosity reducing channel.

Abstract: A tip cap for use in a turbine bucket. The tip cap may include a shield of an oxidant resistant material and a cap positioned within the shield of a high strength material.

Abstract: A method of welding superalloy components comprising: pre-heat one or more components to be welded to a temperature of at least 1500° F. in a substantially enclosed inert gas atmosphere; supplying multiple fillers to the weld zone, at least two of said fillers having different compositions; and welding the one or more preheated components utilizing a laser beam, while maintaining said pre-heat temperature.

Abstract: A method of welding superalloy components comprising: preheating one or more components to be welded to a target temperature of at least 1500OF in a vacuum chamber; welding the one or more preheated components in a weldment region utilizing an electron beam, while maintaining the target temperature until welding is completed.