Abstract: A process of coating an article includes the steps of (1) applying upon at least one surface of an article at least one graded layer of at least one ceramic based compound comprising at least one metal selected from the group consisting of lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, lutelium, indium, scandium, yttrium, zirconium, hafnium, titanium, and mixtures thereof; (2) optionally drying the coated article; and (3) optionally repeating steps (1) and (2).

Abstract: A system for applying a coating to a part has a crucible configured for receiving an ingot, a drive for feeding the ingot into the crucible, and an energy source for heating the ingot and melting a portion of the ingot such that it forms a molten pool and then evaporates. The system includes sensors that monitor the location of the molten pool within the crucible. The sensors are connected to a controller, which is also connected to the drive, such that the controller varies the feed rate of the ingot as a function of the sensed location of the molten pool.

Abstract: A method for applying a hybrid thermal barrier coating, comprising masking at least a portion of a first surface of a component with a first maskant; applying a first coating material to at least a portion of a second surface of said component; removing said first maskant; optionally masking at least a portion of said second surface of said component with a second maskant; applying a second coating material to at least a portion of said first surface of said component; and removing said second maskant.

Abstract: An article has a metallic substrate having a first emissivity. A thermal barrier coating atop the substrate may have an emissivity that is a substantial fraction of the first emissivity.

Abstract: A process for forming a coating on a substrate, such as a turbine engine component, is provided. The process comprises the steps of providing a rare earth oxide stabilized zirconia composition, blending the first rare earth oxide stabilized zirconia composition with at least one additional constituent selected from the group consisting of TiO2, Al2O3, a blend of Al2O3—TiO2, La2Zr2O7, and 20 wt % Yttria Stabilized Zirconia; and depositing the blended powder onto the substrate. Articles having the coating formed from the above process are also described.

Abstract: Probes for assessing a coating on a substrate via electrochemical impedance spectroscopy are described herein. Embodiments of theses probes comprise an electrolyte reservoir capable of containing a liquid electrolyte therein; a counter electrode disposed so as to be capable of being operatively coupled to the liquid electrolyte; at least one sealing device capable of retaining the liquid electrolyte within the electrolyte reservoir; and a delivery device operatively coupled to the electrolyte reservoir, the delivery device being capable of delivering a predetermined amount of the liquid electrolyte onto the coating on the substrate to operatively couple the coating to the counter electrode. These probes may also comprise a reference electrode. These small, handheld probes can be used to assess thermal barrier coatings on gas turbine engine components in production, repair and maintenance environments so that the remaining lifetime of the components can be easily and non-destructively determined.

Abstract: Integrated ceramic/metallic components and methods of making same are described herein. Embodiments of these integrated ceramic/metallic components comprise a metallic non-foam region; and a ceramic foam region comprising a gradient porosity therein, wherein the ceramic foam region and the metallic non-foam region are integrally formed together to create the integrated ceramic/metallic component. Embodiments of these integrated ceramic/metallic components comprise a metallic region; and a single piece ceramic foam construction comprising a plurality of ceramic foam regions therein, each ceramic foam region comprising a predetermined pore size and a predetermined volume percent porosity, wherein the single piece ceramic foam construction is integrally joined to the metallic region to form the integrated ceramic/metallic component. These components may be utilized in gas turbine engines.

Abstract: An article has a characteristic thermal-mechanical stress principal direction. The article has a single crystal substrate having a lowest modulus direction within a target alignment with the principal direction.