Abstract: A thermal barrier coating system and a method for forming the coating system on a component designed for use in a hostile thermal environment, such as superalloy turbine, combustor and augmentor components of a gas turbine engine. The method is particularly directed to a thermal barrier coating system that includes a thermal insulating ceramic layer and a diffusion aluminide bond coat on which an aluminum oxide scale is grown to protect the underlying surface of the component and to chemically bond the ceramic layer. The bond coat is formed to contain an additive metal of platinum, palladium, rhodium, chromium and/or silicon, and an additive element of yttrium and/or zirconium, with possible additions of hafnium. The bond coat may be formed by codepositing aluminum with the active element, or by depositing the additive metal and active element on the surface of the component, and then aluminizing to form the diffusion aluminide bond coat.

Abstract: A method for producing a thermal barrier coating system on an article that will be subjected to a hostile environment. The thermal barrier coating system is composed of a metallic bond coat and a ceramic thermal barrier coating having a columnar grain structure. The method generally entails forming the bond coat on the surface of a component, and then grit blasting the bond coat with an abrasive media having a particle size of greater than 80 mesh. The component is then supported within a coating chamber containing at least two ingots of the desired ceramic material. An absolute pressure of greater than 0.014 mbar is established within the chamber containing oxygen and an inert gas. Thereafter, the ceramic ingots are vaporized with an electron beam such that the vapor deposits on the surface of the component to form a layer of the ceramic material on the surface.

Abstract: A thermal barrier coating adapted to be formed on an article subjected to a hostile thermal environment while subjected to erosion by particles and debris, as is the case with turbine, combustor and augmentor components of a gas turbine engine. The thermal barrier coating is composed of a metallic bond layer deposited on the surface of the article, a ceramic layer overlaying the bond layer, and an erosion-resistant composition dispersed within or overlaying the ceramic layer. The bond layer serves to tenaciously adhere the thermal insulating ceramic layer to the article, while the erosion-resistant composition renders the ceramic layer more resistant to erosion. The erosion-resistant composition is either alumina (Al.sub.2 O.sub.3) or silicon carbide (SiC), while a preferred ceramic layer is yttria-stabilized zirconia (YSZ) deposited by a physical vapor deposition technique to have a columnar grain structure.

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: Evaporated ceramic coatings are prepared by furnishing an ingot of a ceramic material, treating the ingot to reduce sources of gas within the ingot, and evaporating the ceramic material in the ingot by melting the surface of the ingot with an intense heat source. The evaporated ceramic is deposited upon a substrate as the ceramic coating. The reduced gas content of the ingot decreases the incidence of spitting and eruptions from the molten surface of the ingot, thereby improving the quality of the deposited coating, and facilitating increases in evaporation rates and coatings process production rates.

Abstract: Apparatus and method for simultaneously coating interior and exterior surfaces of articles, such as advanced turbine airfoils, the interior surfaces defined by narrow, complex passageways. The apparatus and method, in addition to providing for simultaneous coating of interior and exterior surfaces, also permits additional control over the coating process by permitting control over the partial pressure of reactive gas introduced into the reaction chamber. The apparatus also permits for subsequent thermal treatment of the coated parts in an inert gas atmosphere with no intermediate cooling step thereby reducing costs while eliminating the potential for damage due to handling by the elimination of at least one handling operation.

Abstract: An article is protected by a thermal barrier coating system. The article includes a substrate having an outer surface and a thermal barrier coating system deposited upon the substrate. The thermal barrier coating system includes a porous region wherein the ceramic is present as a porosity-containing columnar grain structure extending substantially perpendicular to the substrate surface, and an erosion-resistant densified region overlying the porous region. The thermal barrier coating is preferably applied by rotating the substrate past a deposition source to deposit the columnar grains, and then halting or slowing the rotation while continuing the deposition of the erosion-resistant region.

Abstract: Apparatus and method for simultaneously coating interior and exterior surfaces of articles, such as advanced turbine airfoils, the interior surfaces defined by narrow, complex passageways. The apparatus and method, in addition to providing for simultaneous coating of interior and exterior surfaces, also permits additional control over the coating process by permitting control over the partial pressure of reactive gas introduced into the reaction chamber. The apparatus also permits for subsequent thermal treatment of the coated parts in an inert gas atmosphere with no intermediate cooling step thereby reducing costs while eliminating the potential for damage due to handling by the elimination of at least one handling operation.