Abstract: A method for coating a substrate includes spraying a combination of powders. The combination of powders includes: Hf0.5Si0.5O2; Zr0.5Si0.5O2; and, optionally, at least one of HfO2 and ZrO2. A molar ratio of said Hf0.5Si0.5O2 and HfO2 combined to said Zr0.5Si0.5O2 and ZrO2 combined is from 2:1 to 4:1. A molar ratio of said Hf0.5Si0.5O2 to said HfO2 is at least 1:3.

Abstract: A method of fabricating a barrier layer on a substrate includes mixing gettering particles, diffusive particles, and matrix material in a carrier fluid to form a slurry; applying a layer of the slurry to the substrate; adjusting the surface of the layer of the slurry; and sintering the layer of the slurry to form a barrier layer. An article is also disclosed.

Abstract: A method for forming a self-healing ceramic matrix composite (CMC) component includes depositing a first self-healing particulate material in a first region of a CMC preform of the CMC component and depositing a second self-healing particulate material having a different chemical composition than the first self-healing particulate material in a second region of the CMC preform distinct from the first region.

Abstract: An article includes a ceramic-based substrate and a barrier layer on the ceramic-based substrate. The barrier layer includes a matrix phase and a network of gettering particles in the matrix phase. The gettering particles have an average maximum dimension between about 30 and 70 microns. The gettering particles have maximum dimensions that range from about 1 to 100 microns, and a dispersion of barium-magnesium alumino-silicate particles in the matrix phase. A composite material and a method of applying a barrier layer to a substrate are also disclosed.

Abstract: An article includes a ceramic-based substrate and a barrier layer on the ceramic-based substrate. The barrier layer includes a matrix phase and gettering particles in the matrix phase. The gettering particles with an aspect ratio greater than one are aligned such that a maximum dimension of the gettering particles extends along an axis that is generally parallel to the substrate. The barrier layer includes a dispersion of diffusive particles in the matrix phase. A composite material and a method of applying a barrier layer to a substrate are also disclosed.

Abstract: A method for forming a self-healing ceramic matrix composite (CMC) component includes depositing a first self-healing particulate material in a first region of a CMC preform of the CMC component and depositing a second self-healing particulate material having a different chemical composition than the first self-healing particulate material in a second region of the CMC preform distinct from the first region.

Abstract: A gas turbine engine article includes a substrate and an environmental barrier coating (EBC) system disposed on the substrate. The EBC system includes, from the substrate, a dense bond coat layer, a porous bond coat layer, and a topcoat layer in contact with the porous bond coat layer at an interface. The porous bond coat layer includes a matrix, oxygen-scavenging gas-evolution particles dispersed through the matrix, and engineered buffer pores. The oxygen-scavenging gas-evolution particles react with oxygen and generate a gaseous byproduct that diffuses through the interface to escape the EBC system. The engineered buffer pores buffer diffusion of gaseous byproduct to the interface by retaining at least a portion of the gaseous byproduct.

Abstract: An article includes a ceramic-based substrate and a barrier layer on the ceramic-based substrate. The barrier layer includes a matrix of SiO2 and a dispersion of silicon oxycarbide particles in the matrix. The silicon oxycarbide particles have Si, O, and C in a covalently bonded network, and a dispersion of barium-magnesium alumino-silicate particles in the matrix. The barium-magnesium alumino-silicate particles have an average maximum dimension that is between about 10-40% of an average maximum dimension of the silicon oxycarbide particles. A composite material and a method of applying a barrier layer to a substrate are also disclosed.

Abstract: A method and system for coating metallic powder particles is provided. The method includes: disposing an amount of metallic powder particulates within a fluidizing reactor; removing moisture adhered to the powder particles disposed within the reactor using a working gas; coating the powder particles disposed within the reactor using a precursor gas; and purging the precursor gas from the reactor using the working gas.

Abstract: A coating fabrication method includes providing engineered granules and thermally consolidating the engineered granules on a substrate to form a silicate-resistant barrier coating. Each of the engineered granules is an aggregate of at least one refractory matrix region and at least one calcium aluminosilicate additive region (CAS additive region) attached with the at least one refractory matrix region. In the thermal consolidation, the refractory matrix region from the engineered granules form grains of a refractory matrix of the silicate-resistant barrier coating and the CAS additive region from the engineered granules form CAS additives that are dispersed in grain boundaries between the grains.

Abstract: A process of coating a substrate containing silicon with an environmental barrier coating, comprising altering a surface of the substrate and applying an environmental barrier layer to the surface of the substrate.

Abstract: A process for densification of a ceramic matrix composite comprises forming a reinforcing ceramic continuous fiber stack having a central zone bounded by an outer zone adjacent; locating first particles within the central zone; coating the first particles and the ceramic fibers with silicon carbide through chemical vapor infiltration; locating second particles within the outer zone; coating the second particles and the ceramic fibers with silicon carbide through chemical vapor infiltration; forming the stack into a predetermined three dimensional shape; and densifying the stack.

Abstract: A gas turbine engine includes an airfoil having a core that has a first hardness and a surface on the core. The surface includes a plurality of geometric features that have a second, greater hardness. The geometric features define a surface porosity by area percent and a corresponding surface solidity by area percent. The surface includes a ratio of the surface solidity divided by the surface porosity that is 1.8 or greater. The geometric features and the ratio establish the surface to be hydrophobic, and the second, greater hardness and the ratio establish an erosion rate of the surface that is equal to or less than an erosion rate of the core under identical erosion conditions.

Abstract: A method of selecting a corrosion-inhibiting substance includes selecting a corrosion-inhibiting substance to include a non-tungstate anodic corrosion inhibitor with respect to an amount of zinc in an aluminum alloy substrate that is to be coated with the corrosion-inhibiting substance.

Abstract: A powder material includes spherical metal particles and a spaced-apart distribution of ceramic nanoparticles attached to the surfaces of the particles.

Abstract: An electrical device includes an electromagnetic component configured to generate a magnetic flux. The electromagnetic component includes a soft magnetically-conductive material configured to pass magnetic flux therethrough along a flux path. The soft magnetically-conductive material includes at least one grain oriented portion having metal grains that are oriented parallel with respect to the magnetic flux.

Abstract: A method for forming a self-healing ceramic matrix composite (CMC) component includes depositing a first self-healing particulate material in a first region of a CMC preform of the CMC component and depositing a second self-healing particulate material having a different chemical composition than the first self-healing particulate material in a second region of the CMC preform distinct from the first region.

Abstract: A process for densification of a ceramic matrix composite comprises forming a reinforcing ceramic continuous fiber stack having a central zone bounded by an outer zone adjacent; locating first particles within the central zone; coating the first particles and the ceramic fibers with silicon carbide through chemical vapor infiltration; locating second particles within the outer zone; coating the second particles and the ceramic fibers with silicon carbide through chemical vapor infiltration; forming the stack into a predetermined three dimensional shape; and densifying the stack.

Abstract: A method of making an article using an additive manufacturing technique includes depositing a powder. The powder includes particles formed from an article material and having particle surfaces. A coating formed from a sacrificial coating is deposited over the particle surface. The sacrificial material has a composition that is different from the composition of the article material and is separated from the article material during fusing of the article material into a layer of an additively manufactured article.

Abstract: An electrical device includes an electromagnetic component configured to generate a magnetic flux. The electromagnetic component includes a soft magnetically-conductive material configured to pass magnetic flux therethrough along a flux path. The soft magnetically-conductive material includes at least one grain oriented portion having metal grains that are oriented parallel with respect to the magnetic flux.