Abstract: A vapor-based system and method for treating one or more components of a gas turbine engine. The system includes a treatment compound contained in a storage vessel. The storage vessel being operably coupled to a delivery module. The delivery module delivering the treatment compound at one or more locations of the gas turbine engine such that the treatment compound is a vapor when exposed to an engine air-path.

Abstract: A high purity yttria or ytterbia stabilized zirconia powder wherein a purity of the zirconia is at least 99.5 weight percent purity and with a maximum amount of specified oxide impurities.

Abstract: A high purity yttria or ytterbia stabilized zirconia powder wherein a purity of the zirconia is at least 99.5 weight percent purity and with a maximum amount of specified oxide impurities.

Abstract: A vapor-based system and method for treating one or more components of a gas turbine engine. The system includes a treatment compound contained in a storage vessel. The storage vessel being operably coupled to a delivery module. The delivery module delivering the treatment compound at one or more locations of the gas turbine engine such that the treatment compound is a vapor when exposed to an engine air-path.

Abstract: Thermal barrier coating made from a thermally sprayable powder that includes yttria stabilized zirconia and hafnia, from 6 to 9 weight percent yttria, and total impurities less than or equal to about 0.1 weight percent. The thermal barrier coating has from about 5 to 250 vertical macro cracks per 25.4 mm length measured along a coating surface and the macro cracks are oriented perpendicular to a surface of a substrate containing said coating.

Abstract: A high purity yttria or ytterbia stabilized zirconia powder wherein a purity of the zirconia is at least 99.5 weight percent purity and with a maximum amount of specified oxide impurities.

Abstract: A hybrid diffusion-brazing process and hybrid diffusion-brazed article are disclosed. The hybrid diffusion-brazing process includes providing a component having a temperature-tolerant region and a temperature-sensitive region, brazing a braze material to the temperature-tolerant region during a localized brazing cycle, then heating the component in a furnace during a diffusion cycle. The brazing and the heating diffusion-braze the braze material to the component, and the localized brazing cycle is performed independent of the diffusion cycle in the hybrid diffusion-brazing process. The hybrid diffusion-brazed article includes a component, and a braze material diffusion-brazed to the component with a filler material. The filler material has a melting temperature that is above a tolerance temperature of the component.

Abstract: The present disclosure is directed to a method for coating a component of a gas turbine engine. The method includes isolating a first portion of the component of the gas turbine engine from a second portion of the component. The method also includes simultaneously depositing a first coating material on the first portion of the component and a second coating material on the second portion of the component, wherein the first and second coating materials are different.

Abstract: A hybrid diffusion-brazing process and hybrid diffusion-brazed article are disclosed. The hybrid diffusion-brazing process includes providing a component having a temperature-tolerant region and a temperature-sensitive region, brazing a braze material to the temperature-tolerant region during a localized brazing cycle, then heating the component in a furnace during a diffusion cycle. The brazing and the heating diffusion-braze the braze material to the component, and the localized brazing cycle is performed independent of the diffusion cycle in the hybrid diffusion-brazing process. The hybrid diffusion-brazed article includes a component, and a braze material diffusion-brazed to the component with a filler material. The filler material has a melting temperature that is above a tolerance temperature of the component.

Abstract: The present invention provides a high-purity fused and crushed stabilized zirconia powder. The powder—with or without further processing, such as plasma spheroidization—is used in thermal spray applications of thermal barrier coatings (TBCs) and high-temperature abradables. The resulting coatings have a significantly improved high temperature sintering resistance, which will enhance the durability and thermal insulation effect of the coating.

Abstract: Thermal barrier coating made from a thermally sprayable powder that includes yttria stabilized zirconia and hafnia, from 6 to 9 weight percent yttria, and total impurities less than or equal to about 0.1 weight percent. The thermal barrier coating has from about 5 to 250 vertical macro cracks per 25.4 mm length measured along a coating surface and the macro cracks are oriented perpendicular to a surface of a substrate containing said coating.

Abstract: A metal oxide powder includes a powder feed material structured and arranged to form molten droplets when melted in a plasma stream. The molten droplets are structured and arranged to form frozen spherical droplets under free-fall conditions such that said molten droplets have ample time for complete in-flight solidification before reaching a collection chamber.

Abstract: A process for modifying or repairing a metallic component, such as a combustion cap effusion plate for a gas turbine, is disclosed. The method includes generating a notch or groove in the metallic component and depositing a filler material in the notch or groove. A pulsed laser is applied to the filler material. The pulsed laser has a power, frequency, and pulse width sufficient to apply heat to the metallic component and to the filler material to make at least a portion of the metallic component and the filler material melt in order to weld the filler material to the metallic component and repair or modify the metallic component. Various operating parameters of the pulsed laser can be configured to reduce undesirable heating affects.

Abstract: The present invention provides a high-purity fused and crushed stabilized zirconia powder. The powder—with or without further processing, such as plasma spheroidization—is used in thermal spray applications of thermal barrier coatings (TBCs) and high-temperature abradables. The resulting coatings have a significantly improved high temperature sintering resistance, which will enhance the durability and thermal insulation effect of the coating.

Abstract: The invention is directed to a material and method for obtaining a ceramic abradable system for high temperature applications. High purity partially stabilized zirconia and/or hafnia base material has higher sintering resistance compared to conventional 6-9 weight percent yttria stabilized zirconia systems. The benefits of these systems are higher service lifetime and low thermal conductivity to achieve high operating temperatures. System includes a superalloy substrate, oxidation resistant bond coat and a thick ceramic abradable top coat. Total coating thickness is about 0.5-5 mm. In some applications an intermediate layer of high purity partially stabilized zirconia or a partially stabilized YSZ/MCrAlY cermet is applied over the oxidation resistant bond coat. In other applications an abradable system is applied on top of a grid. Additional benefits should be reduced blade wear at high operating conditions.

Abstract: The invention is directed to a material and method for obtaining a ceramic abradable system for high temperature applications. High purity partially stabilized zirconia and/or hafnia base material has higher sintering resistance compared to conventional 6-9 weight percent yttria stabilized zirconia systems. The benefits of these systems are higher service lifetime and low thermal conductivity to achieve high operating temperatures. System includes a superalloy substrate, oxidation resistant bond coat and a thick ceramic abradable top coat. Total coating thickness is about 0.5-5 mm. In some applications an intermediate layer of high purity partially stabilized zirconia or a partially stabilized YSZ/MCrAlY cermet is applied over the oxidation resistant bond coat. In other applications an abradable system is applied on top of a grid. Additional benefits should be reduced blade wear at high operating conditions.

Abstract: The invention is directed to a material and method for obtaining a ceramic abradable system for high temperature applications. High purity partially stabilized zirconia and/or hafnia base material has higher sintering resistance compared to conventional 6-9 weight percent yttria stabilized zirconia systems. The benefits of these systems are higher service lifetime and low thermal conductivity to achieve high operating temperatures. System includes a superalloy substrate, oxidation resistant bond coat and a thick ceramic abradable top coat. Total coating thickness is about 0.5-5 mm. In some applications an intermediate layer of high purity partially stabilized zirconia or a partially stabilized YSZ/MCrAlY cermet is applied over the oxidation resistant bond coat. In other applications an abradable system is applied on top of a grid. Additional benefits should be reduced blade wear at high operating conditions.

Abstract: The invention is directed to high purity zirconia-based and/or hafnia-based materials and coatings for high temperature cycling applications. Thermal barrier coatings made from the invention high purity material was found to have significantly improved sintering resistance relative to coatings made from current materials of lower purity. The invention materials are high purity zirconia and/or hafnia partially or fully stabilized by one or any combinations of the following stabilizers: yttria, ytterbia, scandia, lanthanide oxide and actinide oxide. Limits for impurity oxide, oxides other than the intended ingredients, that lead to significantly improved sintering resistance were discovered. High purity coating structures suitable for high temperature cycling applications and for application onto a substrate were provided. In one structure, the coating comprises a ceramic matrix, porosity and micro cracks. In another structure, the coating comprises a ceramic matrix, porosity, macro cracks and micro cracks.

Abstract: A metal oxide powder includes a powder feed material structured and arranged to form molten droplets when melted in a plasma stream. The molten droplets are structured and arranged to form frozen spherical droplets under free-fall conditions such that said molten droplets have ample time for complete in-flight solidification before reaching a collection chamber.

Abstract: According to aspects of the present invention, metal oxide powder, such as yttria and alumina powder (feed material), is processed using a plasma apparatus. The process generally consists of in-flight heating and melting of the feed material by the plasma apparatus. The plasma apparatus contains a plasma torch with required power supply and cooling systems, a powder feeder, a chamber to collect the powder and a dedusting system. The heated powder forms molten spherical droplets that are rapidly cooled under free fall conditions. The plasma densification process removes some impurity oxides, modifies the morphology of the particle and increases the apparent density of the powder.