Abstract: Novel slurry formulations and processes for forming improved protective coatings used in the hot section components of gas turbine engines are provided. The process includes a unique two-step deposition methodology whereby the required concentration of reactive element within an improved reactive element doped aluminide coating can be consistently produced in a reproducible manner.

Abstract: A novel dual layer mask formulation is provided. In particular, the mask has a unique composition that protects the integrity of an underlying chromide coating, prevents chromium depletion from the chromide coating and prevents a subsequent aluminide coating from being deposited thereon.

Abstract: Unique and improved chromizing processes are disclosed. The processes involve forming localized chromizing coatings onto selected regions of a substrate. The chromium diffusion coatings are locally applied to selected regions of substrates in a controlled manner, in comparison to conventional chromizing processes, and further in a manner that produces less material waste and does not require diffusion-stop-off masking. Prior to or after a localized slurry chromizing process of the present invention, a layer of a platinum-group-metal (PGM) is applied to produce a PGM-modified chromium diffusion coating onto selected regions of a substrate. A second coating can be selectively applied onto other regions of the substrate.

Abstract: Unique and improved chromium coatings derived from modified chromium-containing slurry formulations are disclosed. The slurry formulation includes a combination of a selected halide activator and buffer material that synergistically interact with each other to form chromium diffusion coatings with improved microstructure in comparison to chromium diffusion coatings produced from conventional chromizing processes. The coatings may be locally applied in a controlled manner with accuracy onto various parts, including those having internal sections with complex geometries, without masking any portion thereof.

Abstract: Unique and improved chromium coatings derived from modified chromium-containing slurry formulations are disclosed. The slurry formulation includes a combination of a selected halide activator and buffer material that synergistically interact with each other to form chromium diffusion coatings with improved microstructure in comparison to chromium diffusion coatings produced from conventional chromizing processes. The coatings may be locally applied in a controlled manner with accuracy onto various parts, including those having internal sections with complex geometries, without masking any portion thereof.

Abstract: A method for applying an aluminide coating includes applying an aluminum-based slurry onto an elongated member. The elongate member is introduced through an opening of a component and positioned within a cavity of the component at a location that is spaced apart from the internal surfaces of the component. Heat is applied to generate vaporized aluminum which diffuses into the internal surfaces of the component. Aluminum reacts with the internal surfaces to form an aluminide coating.

Abstract: Unique and improved chromizing processes are disclosed. The processes involve forming localized chromizing coatings onto selected regions of a substrate. The chromium diffusion coatings are locally applied to selected regions of substrates in a controlled manner, in comparison to conventional chromizing processes, and further in a manner that produces less material waste and does not require diffusion-stop-off masking. Prior to or after a localized slurry chromizing process of the present invention, a layer of a platinum-group-metal (PGM) is applied to produce a PGM-modified chromium diffusion coating onto selected regions of a substrate. A second coating can be selectively applied onto other regions of the substrate.

Abstract: Unique and improved chromizing processes are disclosed. The processes involve forming localized chromizing coatings onto selected regions of a substrate. The chromium diffusion coatings are locally applied to selected regions of substrates in a controlled manner, in comparison to conventional chromizing processes, and further in a manner that produces less material waste and does not require masking. A second coating can be selectively applied onto other regions of the substrate.

Abstract: Novel slurry formulations and processes for forming improved protective coatings used in the hot section components of gas turbine engines are provided. The process includes a unique two-step deposition methodology whereby the required concentration of reactive element within an improved reactive element doped aluminide coating can be consistently produced in a reproducible manner.

Abstract: A novel dual layer mask formulation is provided. In particular, the mask has a unique composition that protects the integrity of an underlying chromide coating, prevents chromium depletion from the chromide coating and prevents a subsequent aluminide coating from being deposited thereon.

Abstract: Unique and improved chromizing processes are disclosed. The processes involve forming localized chromizing coatings onto selected regions of a substrate. The chromium diffusion coatings are locally applied to selected regions of substrates in a controlled manner, in comparison to conventional chromizing processes, and further in a manner that produces less material waste and does not require masking. A second coating can be selectively applied onto other regions of the substrate.

Abstract: Unique and improved chromium coatings derived from modified chromium-containing slurry formulations are disclosed. The slurry formulation includes a combination of a selected halide activator and buffer material that synergistically interact with each other to form chromium diffusion coatings with improved microstructure in comparison to chromium diffusion coatings produced from conventional chromizing processes. The coatings may be locally applied in a controlled manner with accuracy onto various parts, including those having internal sections with complex geometries, without masking any portion thereof.

Abstract: Unique and improved methods and coating apparatuses for applying diffusion aluminide materials onto internal sections of various parts are disclosed. The source material is coated onto an elongated member, such as a wire or rod, which is subsequently inserted at a specific location into a hollow cavity of the component to be coated. Improvements in the coating process and resultant coating include the ability to coat complex geometries and coat components with uniform thicknesses that do not require post-coating steps for removal of oxides and/or residual bisque.

Abstract: A method for coating a nickel- or cobalt-based superalloy surface by slurry deposition/heat diffusion. The method includes preparing a slurry of a metal coating powder mixed into an adhesive carrier that will burn off ash-free during a diffusion cycle, depositing the slurry onto the surface of a Ni- or Co-based superalloy material to form a coated surface, and heating the coated surface to a temperature of at least about 1600° F. to diffuse the metal coating powder into the metal substrate.

Abstract: A method for coating a nickel- or cobalt-based superalloy surface by slurry deposition/heat diffusion. The method includes preparing a slurry of a metal coating powder mixed into an adhesive carrier that will burn off ash-free during a diffusion cycle, depositing the slurry onto the surface of a Ni- or Co-based superalloy material to form a coated surface, and heating the coated surface to a temperature of at least about 1600° F. to diffuse the metal coating powder into the metal substrate.