Abstract: A method is provided for repairing a surface portion of an article including a metallic environmental resistant coating on a substrate. The coating includes a coating outer portion bonded with the substrate through a diffusion zone that includes at least one feature, for example Al and/or an intermetallic phase, in an amount detrimental to application of a metallic replacement coating and/or repair of the article. The method comprises removing the coating outer portion to expose a surface of the diffusion zone. The substrate and the diffusion zone are heated at a temperature and for a time sufficient to diffuse and/or dissolve at least a portion of the at least one feature in the exposed surface and in a portion of the diffusion zone beneath the exposed surface to a level below the detrimental amount. This provides a replacement surface portion integral with diffusion zone. Then a metallic replacement coating outer portion is applied to the replacement surface portion.

Abstract: A method is provided for refurbishing a service operated metallic coating on a substrate alloy, the coating including at least within a coating outer surface at least one oxide chemically grown from at least one coating element, for example Al, and chemically bonded with the coating outer surface as a result of thermal exposure during service operation. Growth of the oxide has depleted at least a portion of the coating element from the coating. The method comprises removing the oxide from the coating outer surface while substantially retaining the metallic coating, thereby exposing in the coating outer surface at least one surface void that had been occupied by the oxide. The retained metallic coating is mechanically worked, substantially without removal of the retained coating, to close the void, providing a treated metallic coating surface over which a refurbishing coating is applied.

Abstract: A method is provided for repairing a surface portion of an article including a metallic environmental resistant coating on a substrate. The coating includes a coating outer portion bonded with the substrate through a diffusion zone that includes at least one feature, for example Al and/or an intermetallic phase, in an amount detrimental to application of a metallic replacement coating and/or repair of the article. The method comprises removing the coating outer portion to expose a surface of the diffusion zone. The substrate and the diffusion zone are heated at a temperature and for a time sufficient to diffuse and/or dissolve at least a portion of the at least one feature in the exposed surface and in a portion of the diffusion zone beneath the exposed surface to a level below the detrimental amount. This provides a replacement surface portion integral with diffusion zone. Then a metallic replacement coating outer portion is applied to the replacement surface portion.

Abstract: An article includes a substrate and an adhesion layer overlying the substrate. The adhesion layer includes a first phase including particles, and a second phase including braze alloy that bonds the particles to the substrate. The article further includes a ceramic layer overlying the adhesion layer. In one embodiment, the ceramic layer is a thermal barrier coating (TBC), formed of stabilized zirconia (ZrO2).

Abstract: A method is provided for repairing a surface portion of an article including a metallic environmental resistant coating on a substrate. The coating includes a coating outer portion bonded with the substrate through a diffusion zone that includes at least one feature, for example Al and/or an intermetallic phase, in an amount detrimental to application of a metallic replacement coating and/or repair of the article. The method comprises removing the coating outer portion to expose a surface of the diffusion zone. The substrate and the diffusion zone are heated at a temperature and for a time sufficient to diffuse and/or dissolve at least a portion of the at least one feature in the exposed surface and in a portion of the diffusion zone beneath the exposed surface to a level below the detrimental amount. This provides a replacement surface portion integral with diffusion zone. Then a metallic replacement coating outer portion is applied to the replacement surface portion.

Abstract: A method is provided for refurbishing a service operated metallic coating on a substrate alloy, the coating including at least within a coating outer surface at least one oxide chemically grown from at least one coating element, for example Al, and chemically bonded with the coating outer surface as a result of thermal exposure during service operation. Growth of the oxide has depleted at least a portion of the coating element from the coating. The method comprises removing the oxide from the coating outer surface while substantially retaining the metallic coating, thereby exposing in the coating outer surface at least one surface void that had been occupied by the oxide. The retained metallic coating is mechanically worked, substantially without removal of the retained coating, to close the void, providing a treated metallic coating surface over which a refurbishing coating is applied.

Abstract: A method is provided for refurbishing a service operated metallic coating on a substrate alloy, the coating including at least within a coating outer surface at least one oxide chemically grown from at least one coating element, for example Al, and chemically bonded with the coating outer surface as a result of thermal exposure during service operation. Growth of the oxide has depleted at least a portion of the coating element from the coating. The method comprises removing the oxide from the coating outer surface while substantially retaining the metallic coating, thereby exposing in the coating outer surface at least one surface void that had been occupied by the oxide. The retained metallic coating is mechanically worked, substantially without removal of the retained coating, to close the void, providing a treated metallic coating surface over which a refurbishing coating is applied.

Abstract: An article includes a substrate and an adhesion layer overlying the substrate. The adhesion layer includes a first phase including particles, and a second phase including braze alloy that bonds the particles to the substrate. The article further includes a ceramic layer overlying the adhesion layer. In one embodiment, the ceramic layer is a thermal barrier coating (TBC), formed of stabilized zirconia (ZrO2).

Abstract: An article includes a substrate and an adhesion layer overlying the substrate. The adhesion layer includes a first phase including particles, and a second phase including braze alloy that bonds the particles to the substrate. The article further includes a ceramic layer overlying the adhesion layer. In one embodiment, the ceramic layer is a thermal barrier coating (TBC), formed of stabilized zirconia (ZrO2).