Abstract: An electron beam physical vapor deposition (EBPVD) apparatus and a method for using the apparatus to produce a coating material (e.g., a ceramic thermal barrier coating) on an article. The EBPVD apparatus generally includes a coating chamber that is operable at elevated temperatures and subatmospheric pressures. An electron beam gun projects an electron beam into the coating chamber and onto a coating material within the chamber, causing the coating material to melt and evaporate. An article is supported within the coating chamber so that vapors of the coating material deposit on the article. The operation of the EBPVD apparatus is enhanced by the inclusion of a crucible that supports the coating material and is configured to be efficiently cooled so as to reduce the rate at which the process temperature increases within the coating chamber.

Abstract: An article having a substrate is protected by a thermal barrier coating system. An interfacial layer contacts the upper surface of the substrate. The interfacial layer may comprise a bond coat only, or a bond coat and an overlay coat. The interfacial layer has on its upper surface a preselected, controllable pattern of three-dimensional features, such as grooves in a parallel array or in two angularly offset arrays. The features are formed by an ablation process using an ultraviolet laser such as an excimer laser. A ceramic thermal barrier coating is deposited over the pattern of features on the upper surface of the interfacial layer.

Abstract: A coated superalloy component includes a substrate article formed of a superalloy and an adherent coating over the substrate. The coating is a nickel-base superalloy containing 0.3 volume percent or more of a dispersed oxide of yttrium, hafnium and/or a rare earth, and, preferably, grain boundary strengthening elements such as carbon, zirconium, and boron. The oxide dispersoids improve the performance of the coating in service, reducing the incidence failures due to thermal fatigue, oxidation, and corrosion damage. The dispersoid-containing coating may be formed by directly depositing the oxide-containing coating, or by depositing a metallic coating under conditions which permit the formation of such dispersoids during the deposition process.