Abstract: A thermal spray system may include a thermal spray torch configured to produce an emission of material, at least one camera configured to capture an image of the emission of material emitted by the thermal spray torch, a diagnostic device communicatively coupled to the at least one camera, and a controller communicatively coupled to the diagnostic device. The camera may be configured to transmit an image of the emission of material to a diagnostic device that may be configured to determine a characteristic of the emission of material based on the image. The diagnostic device may transmit the characteristic to a controller that may control a position of the thermal spray torch based on the characteristic.

Abstract: A method of protecting a gas turbine component for operation in a high temperature environment that includes the gas turbine component including a substrate having a silicon-containing layer, wherein the gas turbine component has a curved surface; forming a flexible mask configured to cover the curved surface of the gas turbine component, the flexible mask including a plurality of slots disposed in a pattern; disposing the flexible mask in direct contact with the curved surface of the gas turbine component; applying a bondcoat onto the flexible mask and the gas turbine component, such that bondcoat fills the plurality of slots and contacts the curved surface; and removing the flexible mask by heat or chemical reaction, such that, after removing the flexible mask, the curved surface of the gas turbine component comprises a patterned bondcoat layer in the pattern defined by the flexible mask.

Abstract: A method for forming a coated turbine component and a coated turbine component is provided. The method includes a step of providing a component having a substrate including a trailing edge face. The method further includes a step of applying a thermal barrier coating or environmental barrier coating selectively to the substrate to form a discontinuous transition from a hot gas path surface at the trailing edge face to discourage hot gas flow along the trailing edge face.

Abstract: A coated ceramic matrix composite component and a gas turbine assembly are provided. The coated ceramic matrix composite component comprises a substrate comprising an endface surface and a hot gas path surface. The hot gas path surface is arranged and disposed to contact a hot gas path when the component is installed in the gas turbine assembly. The endface surface is disposed at an endface angle to the hot gas path surface and opposing at least one adjacent component when the component is installed in the gas turbine assembly. The coated ceramic matrix composite component further comprises an environmental barrier coating on at least a portion of the endface surface.

Abstract: A method for controlling the porosity parameter of porous thermal barrier coatings is presented. The method includes disposing a feedstock material on a substrate to form a porous thermal barrier coating. The feedstock material includes a gas-forming additive and a thermal barrier coating material. The disposing step further includes controlling the porosity parameter of the porous thermal barrier coating by controlling a feedstock material feed rate, an amount of the gas-forming additive in the feedstock material, a temperature of the disposed feedstock material on the substrate, or combinations thereof.

Abstract: A method for forming a coated turbine component and a coated turbine component is provided. The method includes a step of providing a component having a substrate comprising a trailing edge face. The method further includes a step of applying a thermal barrier coating or environmental barrier coating selectively to the substrate to form a discontinuous transition from a hot gas path surface at the trailing edge face to discourage hot gas flow along the trailing edge face.

Abstract: A coated ceramic matrix composite or metallic component and a gas turbine assembly is provided. The component comprises a substrate comprising a first surface and a hot gas path surface. The hot gas path surface is arranged and disposed to contact a hot gas flow when the component is installed in the gas turbine. The first surface is disposed at an angle to the hot gas path surface and opposes at least one adjacent component when the component is installed in the gas turbine. The component further comprises an angled or rounded feature extending from the first surface to the hot gas path surface. The component further comprises an environmental barrier coating or thermal barrier coating on at least a portion of the hot gas path surface. The angled or rounded feature reduces an incidence angle of the hot gas flow onto the first surface. The gas turbine assembly comprises a plurality of the coated components.

Abstract: A coated ceramic matrix composite component and a gas turbine assembly are provided. The coated ceramic matrix composite component comprises a substrate comprising an endface surface and a hot gas path surface. The hot gas path surface is arranged and disposed to contact a hot gas path when the component is installed in the gas turbine assembly. The endface surface is disposed at an endface angle to the hot gas path surface and opposing at least one adjacent component when the component is installed in the gas turbine assembly. The coated ceramic matrix composite component further comprises an environmental barrier coating on at least a portion of the endface surface.

Abstract: A process of forming a calcium-magnesium-aluminosilicate (CMAS) penetration resistant coating, and a CMAS penetration resistant coating are disclosed. The process includes providing a thermal barrier coating having a dopant, and exposing the thermal barrier coating to calcium-magnesium-aluminosilicate and gas turbine operating conditions. The exposing forming a calcium-magnesium-aluminosilicate penetration resistant layer. The coating includes a thermal barrier coating composition comprising a dopant selected from the group consisting of rare earth elements, non-rare earth element solutes, and combinations thereof. Additional or alternatively, the coating includes a thermal barrier coating and an impermeable barrier layer or a washable sacrificial layer positioned on an outer surface of the thermal barrier coating.

Abstract: A method of forming an article includes forming a plurality of channels and ridges in a silicon-containing layer on a surface of a substrate of the article using a mask placed on the surface of the substrate or the silicon-containing layer.

Abstract: The present disclosure is directed to a system for attaching an instrument lead to a gas turbine engine component. The system includes a gas turbine engine component that includes a surface. A first sleeve couples to the surface of the gas turbine engine component. The first sleeve defines a first sleeve passageway extending therethrough. An instrument lead extends through the first sleeve passageway. A first potting material couples the instrument lead to the first sleeve to prevent the instrument lead from moving longitudinally relative to the first sleeve.

Abstract: A method for fabricating thermal barrier coatings. The thermal barrier coatings are produced with a fine grain size by reverse co-precipitation of fine powders. The powders are then sprayed by a solution plasma spray that partially melts the fine powders while producing a fine grain size with dense vertical cracking. The coatings comprise at least one of 45%-65% Yb2O3 the balance zirconia (zirconium oxide), Yb/Y/Hf/Ta the balance zirconia (zirconium oxide) and 2.3-7.8% La, 1.4-5.1% Y and the balance zirconia (zirconium oxide) and are characterized by a thermal conductivity that is about 25-50% lower than that of thermal barrier coatings comprising YSZ. The thermal barrier coatings also are characterized by at least one of excellent erosion resistance, fracture toughness and abrasion resistance.

Abstract: Methods of making an environmental barrier coating (EBC) for a substrate are provided that include providing an EBC feedstock comprising a rare earth element composition, in which a portion of the composition produces a volatile species during an air plasma spray coating process, providing a first additive that comprises or produces the volatile species during the air plasma spray coating process, injecting the EBC feedstock into a plasma spray plume during the air plasma spray coating process; and injecting the first additive into at least one of the plasma spray plume and a plasma torch nozzle during the air plasma spray coating process, in which the EBC has a composition that is substantially similar to the composition of the EBC feedstock. Also provided are processes for air plasma spray coating an EBC onto a substrate.

Abstract: A composite wire for use with a wire arc spray system and related methods. The composite wire can include: a low melting point material at a core region thereof and a cladding including a metal surrounding the core region, the low metal point material having a melting point less than that of the metal, wherein the low melting point material includes a polymer in the form of a powder having particles having a size of from approximately 1 nanometer to approximately 100 nanometers.

Abstract: A coating process and coated article are disclosed. The coating process includes positioning an article relative to an inductor, heating the article with the inductor, then applying a coating material over the article to form a crystalline coating. The heating of the article increases a first temperature of a surface of the article to a second temperature favoring crystal formation. Another coating process includes positioning an article, uniformly heating a surface of the article to a second temperature favoring crystal formation, then applying an environmental barrier coating material over the surface of the article to form a crystalline environmental barrier coating. The application of the environmental barrier coating is performed through air plasma spray deposition. The coated article includes an article having a complex geometry, and a crystalline coating applied on a surface of the article. The crystalline coating includes increased resistant to delamination.

Abstract: A bond layer may be applied to the substrate of an article and a first layer may be applied to the bond layer by thermal spray. A second layer may be applied above the first layer by slurry coating.

Abstract: A process of fabricating a thermal barrier coating is disclosed. The process includes cold spraying a substrate with a feedstock to form a thermal barrier coating and concurrently oxidizing one or more of the substrate, the feedstock, and the thermal barrier coating. The cold spraying is in a region having an oxygen concentration of at least 10%. In another embodiment, the process includes heating a feedstock with a laser and cold spraying a substrate with the feedstock to form a thermal barrier coating. At least a portion of the feedstock is retained in the thermal barrier coating. In another embodiment, the process of fabricating a thermal barrier coating includes heating a substrate with a laser and cold spraying the substrate with a feedstock to form a thermal barrier coating.

Abstract: Various aspects of the present disclosure relate to a nozzle insert which may be used with a thermal spray gun apparatus. A nozzle insert according to the disclosure may include a body having an outer surface, the outer surface of the body being configured to circumferentially contact and transfer heat to an inner face of a thermal spray gun nozzle of a thermal spray gun. The body of the nozzle insert may be removed from the thermal spray gun nozzle without disassembling the thermal spray gun, and includes an axial passage configured to communicate a plasma discharge from the nozzle insert. A thermal spray gun apparatus and a thermal spray gun system including the nozzle insert are also disclosed.

Abstract: Methods of manufacturing turbine shrouds with an abradable coating that balance the apparently contradictory requirements of high flowpath solidity, low blade tip wear, and good durability in service. The methods include obtaining a shroud substrate. The methods may include obtaining a coating system on the shroud substrate. The methods include forming an abradable coating on a surface of the coating system so as to form a substantially smooth flowpath surface. Forming the abradable coating includes forming a relatively dense scaffold and relatively porous filler regions in-between the relatively dense abradable scaffold. The methods may also include machining the abradable so as to achieve a substantially smooth flowpath surface comprising a relatively porous abradable phase surrounded by a relatively dense, high-durability corrale phase.

Abstract: A ceramic powder and method of forming the ceramic powder capable of being used in coatings to allow components to survive in high temperatures environments, such as the hostile thermal environment of a gas turbine engine. The ceramic powder includes powder particles each having an inner core formed of a first material and an outer region formed of a second material. The inner core has a lower thermal conductivity than the outer region, and the outer region is more erosion resistance relative to the inner core.