Abstract: An article includes a substrate and a multi-layered ceramic barrier coating on a substrate. The coating includes, from the substrate outward, a first layer of a low-dopant ceramic material and a second layer high-dopant ceramic material. The first layer has a columnar microstructure and the second layer has a branched columnar microstructure.

Abstract: A method includes forming a multi-layered ceramic barrier coating under a chamber pressure of greater than 1 Pascals. In the method, low- and high-dopant ceramic materials are evaporated using input evaporating energies that fall, respectively, above and below a threshold for depositing the materials in a columnar microstructure (low-dopant) and in a branched columnar microstructure (high-dopant).

Abstract: The thermal barrier coating system comprises a matrix of a first chemistry with multiple embedded second phases of a second chemistry. The matrix comprises a stabilized zirconia. The second regions comprise at least 40 mole percent of oxides having the formula Ln2O3, where Ln is selected from the lanthanides La through Lu, Y, Sc, In, Ca, and Mg with the balance zirconia (ZrO2), hafnia (HfO2), titania (TiO2), or mixtures thereof. The second phases have a characteristic thickness (T6) of less than 2.0 micrometers (?m). The spacing between second phases has a characteristic thickness (T5) of less than 8.0 micrometers (?m).

Abstract: A coated component with a coating applied by Electron Beam Physical Vapor Deposition (EB-PVD) includes at least one Non Line of Sight (NLOS) area and at least one Line of Sight (LOS) area, a coating on the workpiece defines a ratio greater than about 10% NLOS/LOS.

Abstract: A method for use in a physical vapor deposition coating process includes depositing a ceramic coating material from a plume onto at least one substrate to form a ceramic coating thereon, and during the deposition, rotating the at least one substrate at rotational speed selected with respect to deposition rate of the ceramic coating material onto the at least one substrate.

Abstract: A method for use in a coating process includes pre-heating a substrate in the presence of a coating material and shielding the substrate during the pre-heating from premature deposition of the coating material by establishing a gas screen between the substrate and the coating material. An apparatus for use in a coating process includes a chamber, a crucible that is configured to hold a coating material in the chamber, an energy source operable to heat the interior of the chamber, a coating envelope situated with respect to the crucible, and at least one gas manifold located near the coating envelope. The at least one gas manifold is configured to provide a gas screen between the coating envelope and the crucible. A second manifold provides gas during a later coating deposition to compress a vapor plume of the coating material and focus the plume on the substrate to increase deposition rate.

Abstract: The thermal barrier coating system comprises a matrix of a first chemistry with multiple embedded second phases of a second chemistry. The matrix comprises a stabilized zirconia. The second regions comprise at least 40 mole percent of oxides having the formula Ln2O3, where Ln is selected from the lanthanides La through Lu, Y, Sc, In, Ca, and Mg with the balance zirconia (ZrO2), hafnia (HfO2), titania (TiO2), or mixtures thereof. The second phases have a characteristic thickness (T6) of less than 2.0 micrometers (?m). The spacing between second phases has a characteristic thickness (T5) of less than 8.0 micrometers (?m).

Abstract: A coating-substrate combination includes: a Ni-based superalloy substrate comprising, by weight percent: 2.0-5.1 Cr; 0.9-3.3 Mo; 3.9-9.8 W; 2.2-6.8 Ta; 5.4-6.5 Al; 1.8-12.8 Co; 2.8-5.8 Re; 2.8-7.2 Ru; and a coating comprising, exclusive of Pt group elements, by weight percent: Ni as a largest content 5.8-9.3 Al; 4.4-25 Cr; 3.0-13.5 Co; up to 6.0 Ta, if any; up to 6.2 W, if any; up to 2.4 Mo, if any; 0.3-0.6 Hf; 0.1-0.4 Si; up to 0.6 Y, if any; up to 0.4 Zr, if any; up to 1.0 Re, if any.

Abstract: The present disclosure relates to methods for coating gas turbine engine components, such as combustor panels. In one embodiment, a method includes forming a first layer to a substrate to form a bond coat, and forming a second layer over the first layer. The second layer may be formed by a material having a thermal conductivity within the range of 4.45 to 30 Kcal/(m hoC). According to one or more embodiments, the first layer may be formed by at least one of a high velocity oxy-fuel (HVOF) source, an electric-arc source and low pressure plasma spraying. According to one or more embodiments, the second layer, and as a result a thermal barrier coating, may be formed by at least one of air plasma spraying, suspension plasma spraying, and electronic beam physical vapor deposition.

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 1.0 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.

Abstract: A system for depositing coating on a workpiece includes a deposition chamber within which is formed a vortex to at least partially surround a workpiece therein.

Abstract: A deposition apparatus (20) comprising: a chamber (22); a process gas source (62) coupled to the chamber; a vacuum pump (52) coupled to the chamber; at least two electron guns (26); one or more power supplies (30) coupled to the electron guns; a plurality of crucibles (32,33,34) positioned or positionable in an operative position within a field of view of at least one said electron gun; and a part holder (170) having at least one operative position for holding parts spaced above the crucibles by a standoff height H. The standoff height H is adjustable in a range including at least 22 inches.

Abstract: A method or control strategy in a coating apparatus for use in a coating process can include controlling differential gas pressures among multiple selected localized zones in a coating chamber with respect to each other. The controlled differential gas pressure of the multiple selected localized zones is used to influence how a coating deposits on at least one component.

Abstract: A thermal barrier coating is applied to a turbine engine component having a substrate. The thermal barrier coating has a first layer which has a strain tolerant columnar microstructure at an interface with the substrate for spallation resistance and a second layer which is porous conduction and radiation thermally resistant at an outer surface of the thermal barrier coating.

Abstract: A deposition apparatus comprises: an infeed chamber; a preheat chamber; a deposition chamber; and optionally at least one of a cooldown chamber and an outlet chamber. At least a first of the preheat chamber and the cooldown chamber contains a buffer system for buffering workpieces respectively passing to or from the deposition chamber.

Abstract: A thermal barrier coating for a turbine engine component contains neodymia, optionally alumina, and zirconia. The thermal barrier coating has resistance to CMAS attack and a low thermal conductivity.

Abstract: A coating system for coating a part (10), such as a turbine blade or vane, has a mask (14) positioned adjacent to a first portion (16) of the part (10) to be coated and a mechanism (30) for moving the mask (14) relative to the part (10). The mechanism (30) may be a gear mechanism or a magnetic mechanism.

Abstract: An article includes a metallic substrate and a tri-layer thermal barrier coating that is deposited on the metallic substrate. The tri-layer thermal barrier coating includes an inner ceramic layer, an outermost ceramic layer relative to the metallic substrate, and an intermediate ceramic layer between the inner ceramic layer and the outermost ceramic layer. The inner ceramic layer and the outermost ceramic layer are composed of respective first and second ceramic materials and the intermediate ceramic layers composed of a third, different ceramic material. The inner ceramic layer has a first thickness, the outermost ceramic layer has a second thickness, and the intermediate ceramic layer has a third thickness that is greater than the first thickness and the second thickness.

Abstract: A process for coating a part comprises the steps of providing a chamber which is electrically connected as an anode, placing the part to be coated in the chamber, providing a cathode formed from a coating material to be deposited and platinum, and applying a current to the anode and the cathode to deposit the coating material and the platinum on the part.

Abstract: A protective coating system includes a nickel-aluminum-zirconium alloy coating having beta phase nickel-aluminum and at least one phase selected from gamma phase nickel and the gamma prime phase nickel-aluminum. The nickel-aluminum-zirconium alloy coating comprises 10 vol % to 60 vol % of the beta phase nickel-aluminum or 25 vol % to 75 vol % of the beta phase nickel-aluminum.