Abstract: A method of operating an EBPVD apparatus (10) to deposit a ceramic coating on an article (20), such that the thermal conductivity of the coating is both minimized and stabilized. More particularly, the EBPVD apparatus (10) is operated to perform multiple successive coating operations which together constitute a coating campaign. During the campaign, the surface temperatures of the articles (20) being coated do not exceed about 1000° C. as a result of the combined heat transfer from the coating chamber (14) to the articles (20) being reduced during the course of the campaign, even though the temperature within the coating chamber (14) continuously rises during successive coating operations of the campaign. Ceramic coatings deposited at such relatively low temperatures exhibit lower and more stable thermal conductivities.

Abstract: A method of operating an EBPVD apparatus (10) to deposit a ceramic coating on an article (20), such that the thermal conductivity of the coating is both minimized and stabilized. More particularly, the EBPVD apparatus (10) is operated to perform multiple successive coating operations which together constitute a coating campaign. During the campaign, the surface temperatures of the articles (20) being coated do not exceed about 1000° C. as a result of the combined heat transfer from the coating chamber (14) to the articles (20) being reduced during the course of the campaign, even though the temperature within the coating chamber (14) continuously rises during successive coating operations of the campaign. Ceramic coatings deposited at such relatively low temperatures exhibit lower and more stable thermal conductivities.

Abstract: A method of adjusting airflow through a plurality of cooling holes by depositing a thermal barrier coating on an exterior surface and/or an interior surface of the component by a physical vapor deposition process. The cooling holes are not masked. Thus, a portion of the thermal barrier coating partially obstructs airflow through the cooling holes and reduces airflow through the cooling holes. A predetermined pressure drop is developed across the cooling holes and airflow through the cooling holes is measured. The measured airflow is compared to a preselected range of desired cooling hole airflows and the steps of depositing the thermal barrier coating, developing the predetermined pressure drop, calculating airflow and comparing the measured airflow to the preselected range are repeated until the measured airflow is within the preselected range of desired cooling hole airflows.

Abstract: A method of depositing a ceramic thermal barrier coating on an article that will be subjected to a hostile environment, such as turbine, combustor and augmentor components of a gas turbine engine. The thermal barrier coating is deposited by electron beam physical vapor deposition (EBPVD) using process parameters that include an absolute pressure of greater than 0.010 mbar and an oxygen partial pressure of greater than 50%, preferably at or close to 100%. Under these conditions, the desired ceramic material is evaporated with an electron beam to produce a vapor that deposits on the component to form a thermal barrier coating of the ceramic material.