Abstract: A plasma spraying system is provided for coating a substrate. The plasma spraying system includes a plasma gun, a nozzle and a mounting system. The plasma gun is adapted to direct plasma towards the substrate. The nozzle is adapted to direct coating medium into the plasma. The mounting system is adapted to rotate the nozzle to change an angle of incidence between the coating medium and the plasma.

Abstract: An oxidation resistant coating system for a turbine engine component includes a cathodic arc coating applied to a surface of the engine component, a thin APS metallic coating applied to a surface of the cathodic arc coating, and a ceramic top coating applied to a surface of the thin APS metallic coating to improve lifetime of the engine components.

Abstract: A plasma spray system including a turntable subsystem operable to position a multiple of work pieces on a respective multiple of workpiece mounts; a plasma spray subsystem operable to plasma spray the multiple of work pieces on said turntable subsystem; and an overspray wash subsystem operable to wash the multiple of work pieces on said turntable subsystem subsequent to plasma spray of the multiple of work pieces.

Abstract: A plasma spraying system is provided for coating a substrate. The plasma spraying system includes a plasma gun, a nozzle and a mounting system. The plasma gun is adapted to direct plasma towards the substrate. The nozzle is adapted to direct coating medium into the plasma. The mounting system is adapted to rotate the nozzle to change an angle of incidence between the coating medium and the plasma.

Abstract: An article such as a heat shield panel includes a substrate and a multi-layered coating supported on the substrate. The multi-layered coating can include alternating layers of different ceramic material compositions having individual thicknesses of less than 25 micrometers.

Abstract: A heat shield panel for a gas turbine engine includes a substrate layer having a first substrate surface and a second substrate surface opposite the first substrate surface. The first substrate surface and the second substrate surface define a substrate layer thickness therebetween. One or more thermally protective coating layers are applied to the first substrate surface of the substrate layer. The one or more coating layers have a constant coating layer thickness and the substrate layer thickness tapers along an axial length of the heat shield panel.

Abstract: A plasma spray gun has: a plasma outlet having an axis; and a plurality of liquid feedstock outlets having a non-uniform distribution about said axis.

Abstract: In a method for coating an airfoil member, the airfoil member comprises: a platform having a surface; and an airfoil having an end at the platform surface. The method comprises applying, via suspension plasma spray or solution plasma spray, a ceramic coating: to the airfoil with a first average coating thickness; and to the platform surface with a second average thickness at least 90% of the first average thickness.

Abstract: A heat shield panel for a gas turbine engine includes a substrate layer having a first substrate surface and a second substrate surface opposite the first substrate surface. The first substrate surface and the second substrate surface define a substrate layer thickness therebetween. One or more thermally protective coating layers are applied to the first substrate surface of the substrate layer. The one or more coating layers have a constant coating layer thickness and the substrate layer thickness tapers along an axial length of the heat shield panel.

Abstract: A plasma spray system including a turntable subsystem operable to position a multiple of work pieces on a respective multiple of workpiece mounts; a plasma spray subsystem operable to plasma spray the multiple of work pieces on said turntable subsystem; and an overspray wash subsystem operable to wash the multiple of work pieces on said turntable subsystem subsequent to plasma spray of the multiple of work pieces.

Abstract: A plasma spray system including a turntable subsystem operable to position a multiple of work pieces on a respective multiple of workpiece mounts; a plasma spray subsystem operable to plasma spray the multiple of work pieces on said turntable subsystem; and an overspray wash subsystem operable to wash the multiple of work pieces on said turntable subsystem subsequent to plasma spray of the multiple of work pieces.

Abstract: A plasma spray gun has: a plasma outlet having an axis; and a plurality of liquid feedstock outlets having a non-uniform distribution about said axis.

Abstract: An article such as a heat shield panel includes a substrate and a multi-layered coating supported on the substrate. The multi-layered coating can include alternating layers of different ceramic material compositions having individual thicknesses of less than 25 micrometers.

Abstract: In a method for coating an airfoil member, the airfoil member comprises: a platform having a surface; and an airfoil having an end at the platform surface. The method comprises applying, via suspension plasma spray or solution plasma spray, a ceramic coating: to the airfoil with a first average coating thickness; and to the platform surface with a second average thickness at least 90% of the first average thickness.

Abstract: An oxidation resistant coating system for a turbine engine component includes a cathodic arc coating applied to a surface of the engine component, a thin APS metallic coating applied to a surface of the cathodic arc coating, and a ceramic top coating applied to a surface of the thin APS metallic coating to improve lifetime of the engine components.

Abstract: A plasma spraying system is provided for coating a substrate. The plasma spraying system includes a plasma gun, a nozzle and a mounting system. The plasma gun is adapted to direct plasma towards the substrate. The nozzle is adapted to direct coating medium into the plasma. The mounting system is adapted to rotate the nozzle to change an angle of incidence between the coating medium and the plasma.

Abstract: A plasma spray system including a turntable subsystem operable to position a multiple of work pieces on a respective multiple of workpiece mounts; a plasma spray subsystem operable to plasma spray the multiple of work pieces on said turntable subsystem; and an overspray wash subsystem operable to wash the multiple of work pieces on said turntable subsystem subsequent to plasma spray of the multiple of work pieces.

Abstract: Systems and methods are disclosed for removing overspray from a substrate. A coating material may be plasma sprayed on a substrate utilizing Suspension Plasma Spray or Solution Precursor Plasma Spray. The plasma spray may deposit loosely adhered overspray on the substrate. A pressurized gas may be directed at the overspray to remove the overspray from the component.