Abstract: The use of a physical mixture of partially stabilized and fully stabilized zirconium oxide powder for producing a thermal barrier coating results in good thermal barrier properties and good mechanical properties is provided.

Abstract: A turbine abradable component includes a support surface and a thermally sprayed ceramic/metallic abradable substrate coupled to the support surface for orientation proximal a rotating turbine blade tip circumferential swept path. An elongated pixelated major planform pattern (PMPP) of a plurality of discontinuous micro surface features (MSF) project from the substrate surface. The PMPP repeats radially along the swept path in the blade tip rotational direction, for selectively directing airflow between the blade tip and the substrate surface. Each MSF is defined by a pair of first opposed lateral walls defining a width, length and height that occupy a volume envelope of 1-12 cubic millimeters. The PMPP arrays of MSFs provide airflow control of hot gasses in the gap between the abradable surface and the blade tip with smaller potential rubbing surface area than solid projecting ribs with similar planform profiles.

Abstract: Metallic components, including superalloy components such as turbine vanes and blades, are joined or repaired by electric resistance with a high electrical resistivity brazing alloy composition. In some embodiments the brazing alloy comprises filler metal selected from the group consisting of nickel, iron, and cobalt base alloy and elements selected from the group consisting of phosphorous (P), boron (B), silicon (Si), germanium (Ge), sulfur (S), selenium (Se), carbon (C), tellurium (Te) and manganese (Mn). In performing the method of the present invention a high electrical resistivity brazing alloy composition is introduced within a substrate defect or interposed between two substrates that are to be joined. An electric current is passed through the brazing alloy until the alloy melts and bonds to the adjoining substrate. High resistivity of the brazing alloy concentrates heat generated by the current flow in the brazing alloy rather than in the substrate.

Abstract: Turbine and compressor casing abradable component embodiments for turbine engines, with composite grooves and vertically projecting asymmetric non-parallel walls or trapezoidal cross section ridges that reduce, redirect and/or block blade tip airflow leakage downstream into the grooves rather than from turbine blade airfoil high to low pressure sides. In some embodiments at least one angularly oriented first groove formed in the ridge plateau is adapted for angular orientation upstream a turbine blade rotation direction to resist blade tip airflow leakage and the ridges are separated by second grooves that are skewed relative to the respective ridge plateaus and the substrate that are also adapted for orientation upstream the turbine blade rotation direction to resist blade tip airflow leakage.

Abstract: Turbine and compressor casing abradable component embodiments for turbine engines, with composite grooves and vertically projecting alternating rows of first and second height ridges in planform patterns, to reduce, redirect and/or block blade tip airflow leakage downstream into the grooves rather than from turbine blade airfoil high to low pressure sides. The first ridges have a first ridge height greater than that of the second ridges. These ridge or rib embodiments have first lower and second upper wear zones. The lower zone, at and below the second ridge height, optimizes engine airflow characteristics, while the upper zone, between tips of the second and first ridges, is optimized to minimize blade tip gap and wear by being more easily abradable than the lower zone.

Abstract: Turbine and compressor casing abradable component embodiments for turbine engines, with composite grooves and vertically projecting asymmetric non-parallel walls or trapezoidal cross section ridges that reduce, redirect and/or block blade tip airflow leakage downstream into the grooves rather than from turbine blade airfoil high to low pressure sides. In some embodiments at least one angularly oriented first groove formed in the ridge plateau is adapted for angular orientation upstream a turbine blade rotation direction to resist blade tip airflow leakage and the ridges are separated by second grooves that are skewed relative to the respective ridge plateaus and the substrate that are also adapted for orientation upstream the turbine blade rotation direction to resist blade tip airflow leakage.

Abstract: Turbine and compressor casing abradable component embodiments for turbine engines, with composite grooves and vertically projecting alternating rows of first and second height ridges in planform patterns, to reduce, redirect and/or block blade tip airflow leakage downstream into the grooves rather than from turbine blade airfoil high to low pressure sides. The first ridges have a first ridge height greater than that of the second ridges. These ridge or rib embodiments have first lower and second upper wear zones. The lower zone, at and below the second ridge height, optimizes engine airflow characteristics, while the upper zone, between tips of the second and first ridges, is optimized to minimize blade tip gap and wear by being more easily abradable than the lower zone.

Abstract: Turbine and compressor casing abradable component embodiments for turbine engines, with composite grooves and vertically projecting rows of stepped first ridges in planform patterns, to reduce, redirect and/or block blade tip airflow leakage downstream into the grooves rather than from turbine blade airfoil high to low pressure sides. Each stepped first ridge has a first portion proximal the substrate surface with a pair of first opposed lateral walls terminating in a plateau, and a second portion terminating in a ridge tip. These ridge or rib embodiments have first lower and second upper wear zones. The lower zone, which at and below first portion height, optimizes engine airflow characteristics, while the upper zone, between the plateau and the second portion ridge is optimized to minimize blade tip gap and wear by being more easily abradable than the lower zone.

Abstract: Turbine and compressor casing abradable component embodiments for turbine engines, with composite grooves and vertically projecting rows of ridges in planform patterns, establishing upper and lower wear zones. The lower wear zone reduces, redirects and/or blocks blade tip downstream airflow leakage, while the upper wear zone is optimized to minimize blade tip gap and wear by being more easily abradable than the lower zone. An elongated first ridge in the lower wear zone terminates in a continuous surface plateau. A plurality of second ridges or nibs, separated by grooves, project from the plateau, forming the upper wear zone. Each of the second ridges has a planform cross section smaller than the plateau planform cross section and a height smaller than the first ridge height. Some embodiments of the second ridges have spacing, planform cross sections, heights and separating groove dimensions selected for shearing when contacted by turbine blade tips.

Abstract: A compliant, impact-absorbing layer (27) on a thermal barrier coating (TBC) (26) on a substrate (24). The impact-absorbing layer (27) has an internal structure of planar grains (28) oriented parallel to the substrate so the impact-absorbing layer preferentially fractures horizontally and it blocks vertical cracking. A ceramic armor layer (30) on the impact-absorbing layer has a higher density, and is fractured (32) into fracture plates (33, 34) of a designed size. This provides a thermal barrier with particle impact-resistance that may be applied to gas turbine components where needed.

Abstract: Metallic components, including superalloy components such as turbine vanes and blades, are joined or repaired by electric resistance with a high electrical resistivity brazing alloy composition. In some embodiments the brazing alloy comprises filler metal selected from the group consisting of nickel, iron, and cobalt base alloy and elements selected from the group consisting of phosphorous (P), boron (B), silicon (Si), germanium (Ge), sulfur (S), selenium (Se), carbon (C), tellurium (Te) and manganese (Mn). In performing the method of the present invention a high electrical resistivity brazing alloy composition is introduced within a substrate defect or interposed between two substrates that are to be joined. An electric current is passed through the brazing alloy until the alloy melts and bonds to the adjoining substrate. High resistivity of the brazing alloy concentrates heat generated by the current flow in the brazing alloy rather than in the substrate.

Abstract: A compliant, impact-absorbing layer (27) on a thermal barrier coating (TBC) (26) on a substrate (24). The impact-absorbing layer (27) has an internal structure of planar grains (28) oriented parallel to the substrate so the impact-absorbing layer preferentially fractures horizontally and it blocks vertical cracking. A ceramic armor layer (30) on the impact-absorbing layer has a higher density, and is fractured (32) into fracture plates (33, 34) of a designed size. This provides a thermal barrier with particle impact-resistance that may be applied to gas turbine components where needed.

Abstract: A method of measuring a thickness of a coating on a substrate material. A first pulse of monochromatic light having a predetermined first wavelength is emitted toward the coating and substrate material. A second pulse of monochromatic light having a predetermined second wavelength is emitted toward the coating and substrate material, the second wavelength being different than the first wavelength. A first elapsed time is measured from emission of the first pulse of light to reception of a reflection of the first pulse of light from a surface of the substrate material at an interface with the coating. A second elapsed time is measured from emission of the second pulse of light to reception of a reflection of the second pulse of light from an outer surface of the coating. A thickness of the coating is determined as a function of a difference between the first and second elapsed times.

Abstract: A method of measuring a thickness of a coating on a substrate material. A first pulse of monochromatic light having a predetermined first wavelength is emitted toward the coating and substrate material. A second pulse of monochromatic light having a predetermined second wavelength is emitted toward the coating and substrate material, the second wavelength being different than the first wavelength. A first elapsed time is measured from emission of the first pulse of light to reception of a reflection of the first pulse of light from a surface of the substrate material at an interface with the coating. A second elapsed time is measured from emission of the second pulse of light to reception of a reflection of the second pulse of light from an outer surface of the coating. A thickness of the coating is determined as a function of a difference between the first and second elapsed times.