Abstract: A workpiece, such as a turbine engine component, comprises a substrate, a thermal barrier coating on the substrate, and a hard erosion barrier deposited over the thermal barrier coating. The erosion barrier preferably has a Vickers hardness in the range of from 1300 to 2750 kg/mm2. The erosion barrier may be formed from aluminum oxide, silicon carbide, silicon nitride, or molybdenum disilicide. The erosion barrier may be formed using either an electrophoretic deposition process or a slurry process.

Abstract: A turbine engine component is provided which has a substrate and a thermal barrier coating applied over the substrate. The thermal barrier coating comprises alternating layers of yttria-stabilized zirconia and a molten silicate resistant material. The molten silicate resistant outer layer may be formed from at least one oxide of a material selected from the group consisting of lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, lutetium, scandium, indium, zirconium, hafnium, and titanium or may be formed from a gadolinia-stabilized zirconia. If desired, a metallic bond coat may be present between the substrate and the thermal barrier coating system. A method for forming the thermal barrier coating system of the present invention is described.

Abstract: A turbine engine component has a substrate and a thermal barrier coating deposited onto the substrate. The thermal barrier coating comprises a ceramic material having a sodium containing compound incorporated therein. The sodium containing compound is present in a concentration so that when molten sand reacts with the coating, sodium silicate is formed as the by product.

Abstract: A turbine engine component is provided which has a substrate, a yttria-stabilized zirconia coating applied over the substrate, and a molten silicate resistant outer layer. The molten silicate resistant outer layer is formed from gadolinia or gadolinia-stabilized zirconia. A method for forming the coating system of the present invention is described.

Abstract: A coated article includes an article having at least one surface and composed of a molybdenum based refractory metal alloy base substrate, a niobium based refractory metal alloy base substrate or a silicon base substrate. A bond coat layer is disposed upon the surface. The bond coat layer includes a molybdenum disilicide base compound and at least one of the following: silicon nitride, silicon carbide or tantalum oxide. A process for coating the article includes the steps of applying upon the article's surface the aforementioned bond coat layer. A functionally graded material layer is applied upon the bond coat layer. The functionally graded material layer comprising molybdenum disilicide, mullite and at least one of the following: silicon nitride, silicon carbide or tantalum oxide. A thermal barrier coating layer is then applied upon the functionally graded material layer.

Abstract: A coating device for use with an electron beam vapor deposition apparatus includes a crucible portion and a nozzle portion. The crucible portion includes a gas inlet port, a heating zone for presenting a source coating material to be heated, and a flow passage exposed to the heating zone and fluidly connected with the inlet port. The nozzle portion of the coating device includes an outlet orifice fluidly connected with the flow passage for jetting a coating stream from the coating device.

Abstract: A coated article includes an article having at least one surface and composed of a molybdenum based refractory metal alloy base substrate, a niobium based refractory metal alloy base substrate or a silicon base substrate. A bond coat layer is disposed upon the surface. The bond coat layer includes a molybdenum disilicide base compound and at least one of the following: silicon nitride, silicon carbide or tantalum oxide. A process for coating the article includes the steps of applying upon the article's surface the aforementioned bond coat layer. A functionally graded material layer is applied upon the bond coat layer. The functionally graded material layer comprising molybdenum disilicide, mullite and at least one of the following: silicon nitride, silicon carbide or tantalum oxide. A thermal barrier coating layer is then applied upon the functionally graded material layer.

Abstract: A method for forming a thermal barrier coating on a combustor panel or a fuel nozzle comprises the steps of: providing a component selected from the group consisting of a combustor panel, a bulkhead heat shield, and a fuel nozzle; optionally depositing a first layer of a metallic alloy onto the component; and depositing a ceramic composition layer using an electron beam physical vapor deposition technique. If the component is formed from a yttrium or other active element doped single crystal superalloy, the first layer may be omitted and the ceramic composition layer may be deposited directly onto a surface of the component.

Abstract: A turbine engine component is provided which has a substrate, a yttria-stabilized zirconia coating applied over the substrate, and a molten silicate resistant outer layer. The molten silicate resistant outer layer is formed from gadolinia or gadolinia-stabilized zirconia. A method for forming the coating system of the present invention is described.

Abstract: A thermal barrier coating system for use on a turbine engine component which reduces sand related distress is provided. The coating system comprises at least one first layer of a stabilized material selected from the group consisting of zirconia, hafnia, and titania and at least one second layer containing at least one of oxyapatite and garnet. Where the coating system comprises multiple first layers and multiple second layers, the layers are formed or deposited in an alternating manner.

Abstract: A thermal barrier coating system for use on a turbine engine component which reduces sand related distress is provided. The coating system comprises at least one first layer of a stabilized material selected from the group consisting of zirconia, hafnia, and titania and at least one second layer containing at least one of oxyapatite and garnet. Where the coating system comprises multiple first layers and multiple second layers, the layers are formed or deposited in an alternating manner.

Abstract: A method for use with a coating process includes depositing a ceramic coating on a substrate within a coating chamber. Prior to depositing the ceramic coating, an electron beam source is used to heat a ceramic material. The ceramic material radiates heat to heat a substrate to an oxidation temperature to form an oxide layer on the substrate. A desired evaporation rate of the ceramic material is established during the heating to thereby provide an improved ceramic coating.

Abstract: A method for use in a coating process includes depositing a ceramic coating on a bond coat that is disposed on a substrate. Prior to depositing the ceramic coating, a desired surface roughness Rz is established to control a bonding strength between the bond coat and the ceramic coating.

Abstract: A coated article includes an article having at least one surface and composed of a molybdenum based refractory metal alloy base substrate, a niobium based refractory metal alloy base substrate or a silicon base substrate. A bond coat layer is disposed upon the surface. The bond coat layer includes a molybdenum disilicide base compound and at least one of the following: silicon nitride, silicon carbide or tantalum oxide. A process for coating the article includes the steps of applying upon the article's surface the aforementioned bond coat layer. A functionally graded material layer is applied upon the bond coat layer. The functionally graded material layer comprising molybdenum disilicide, mullite and at least one of the following: silicon nitride, silicon carbide or tantalum oxide. A thermal barrier coating layer is then applied upon the functionally graded material layer.

Abstract: A turbine engine component is provided which has a substrate and a thermal barrier coating applied over the substrate. The thermal barrier coating comprises at least one layer of a first material selected from the group consisting of a zirconate, a hafnate, a titanate, and mixtures thereof, which first material has been mixed with, and contains, from about 25 to 99 wt % of at least one oxide. The at least one oxide comprises at least one oxide of a material selected from the group consisting of lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, lutetium, scandium, indium, and yttrium. If desired, a metallic bond coat may be present between the substrate and the thermal barrier coating system. A method for forming the thermal barrier coating system of the present invention is described.

Abstract: An electron beam vapor deposition apparatus includes a coating chamber having a first chamber section with a first coating zone for depositing a first coating and a second chamber section with a second coating zone for depositing a second coating. At least one electron beam source is associated with the first chamber section and the second chamber section. A first crucible is adjacent to the first coating zone for presenting a first source coating material, and a second crucible is adjacent to the second coating zone for presenting a second source coating material. A transport is operative to move a work piece between the first coating zone of the first chamber section and the second coating zone of the second chamber section.

Abstract: A deposition apparatus includes a coating chamber and a coating zone within the coating chamber for coating work pieces. A heating source heats the coating zone, and a thermal hood within the coating chamber is located adjacent to the coating zone for controlling a temperature of the coating zone.

Abstract: A process of coating an article includes the steps of (1) applying a ceramic compound to at least one surface of an article to form a layer of ceramic compound; (2) applying at least one inert compound upon the ceramic compound layer to form a protective layer, wherein the at least one inert compound is composed of a first inert compound having a cubic crystalline structure of formula (I) A3B2X3O12, or a second inert compound comprising a hexagonal crystalline structure of formula (II) A4B6X6O26, or a mixture of the first inert compound and the second inert compound; (3) optionally drying the coated article; (4) optionally repeating steps (2) and (3); and (5) heat treating the coated article.

Abstract: A turbine engine component is provided which has a substrate and a thermal barrier coating applied over the substrate. The thermal barrier coating comprises at least one layer of a first material selected from the group consisting of a zirconate, a hafnate, a titanate, and mixtures thereof, which first material has been mixed with, and contains, from about 25 to 99 wt % of at least one oxide. The at least one oxide comprises at least one oxide of a material selected from the group consisting of lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, lutetium, scandium, indium, and yttrium. If desired, a metallic bond coat may be present between the substrate and the thermal barrier coating system. A method for forming the thermal barrier coating system of the present invention is described.

Abstract: The present disclosure relates to an improved low-cost metallic coating to be deposited on gas turbine engine components. The metallic coating consists of 1.0 to 18 wt % cobalt, 3.0 to 18 wt % chromium, 5.0 to 15 wt % aluminum, 0.01 to wt % yttrium, 0.01 to 0.6 wt % hafnium, 0.0 to 0.3 wt % silicon, 0.0 to 1.0 wt % zirconium, 0.0 to 10 wt % tantalum, 0.0 to 9.0 wt % tungsten, 0.0 to 10 wt % molybdenum, 0.0 to 43.0 wt % platinum, and the balance nickel.