Abstract: An automated system is provided. The system includes: a manipulator coupled to: an opening forming device configured to create an opening having a predefined geometry partially into a multilayer component at a selected location on a surface of the multilayer component, where the multilayer component includes a plurality of material layers including at least a substrate and a bond coat, and where the opening exposes each of the plurality of material layers; and an imaging device configured to create an image of the exposed plurality of material layers in the opening; and a processor configured to calculate at least a thickness of the bond coat of the exposed plurality of material layers from the image and based on the predefined geometry of the opening. Methods of using the system to analyze layer thickness of a multilayer component and repair a multilayer component are also provided.

Abstract: A system for analyzing layer thickness of a multilayer component is provided. The system includes: an opening forming device configured to create an opening having a predefined geometry partially into the multilayer component at a selected location on a surface of the multilayer component, where the multilayer component includes a plurality of material layers including a substrate and a bond coat and the opening exposes each of the plurality of material layers, and an imaging device configured to create an image of the exposed plurality of material layers in the opening. The system is configured to calculate at least a thickness of the bond coat of the exposed plurality of material layers from the image and based on the predefined geometry of the opening. The system may also include a repairing device configured to repair the opening, allowing the multilayer component to be used for an intended purpose.

Abstract: A method of analyzing layer thickness of a multilayer component is provided. The method includes: creating an opening having a predefined geometry partially into the multilayer component at a selected location on a surface of the multilayer component. The multilayer component includes a plurality of material layers including a substrate and a bond coat. The opening exposes each of the plurality of material layers including the substrate. Contrast of the exposed plurality of material layers can be increased. An image is created of the exposed layers in the opening using a digital microscope, and thickness of a bond coat, thickness of a depletion layer\ and/or thickness of an oxide layer is calculated from the image and based on the predefined geometry of the opening. Repairing the opening, allows the multilayer component to be used for an intended purpose after testing, e.g., re-installed and reused in a gas turbine.

Abstract: A method of analyzing layer thickness of a multilayer component is provided. The method includes: creating an opening having a predefined geometry partially into the multilayer component at a selected location on a surface of the multilayer component. The multilayer component includes a plurality of material layers including a substrate and a bond coat. The opening exposes each of the plurality of material layers including the substrate. Contrast of the exposed plurality of material layers can be increased. An image is created of the exposed layers in the opening using a digital microscope, and thickness of a bond coat, thickness of a depletion layer\ and/or thickness of an oxide layer is calculated from the image and based on the predefined geometry of the opening. Repairing the opening, allows the multilayer component to be used for an intended purpose after testing, e.g., re-installed and reused in a gas turbine.

Abstract: A method for generating coatings is disclosed. The method involves applying a flame spray technique. A metallic powder material is provided to the flame, and the process parameters of the flame spray process are chosen such as to achieve a metallic coating layer with a distinct surface roughness. In a subsequent process phase, a non-metallic material may be disposed on the rough metallic layer by flame spraying. The non-metallic layer effectively interlocks with the roughness of the metallic layer. The method may be carried out with hand-held equipment.

Abstract: The invention relates to a high temperature protective coating based on MCrAlY coating, with M at least one element out of the group of Ni, Co and Fe, for a component of a turbo machine, especially a gas turbine, the coating containing at least at least 1.75 vol.-% chromium borides and the coating consisting of the following chemical composition (in wt.-%): 10-27 Cr; 3-12 Al; 1-4 Si; 0.1-3 Ta; 0.01-3 Y; 0.1-3 B; 0-7 M, with M being a different element out of said group compared to the remainder, and the remainder being M and inevitable impurities. A preferred embodiment is a coating with the following chemical composition: 10-27 Cr; 3-12 Al; 1-4 Si; 0.1-3 Ta; 0.01-3 Y; 0.1-3 B; 0-7 Co and the remainder being Ni and inevitable impurities.