Abstract: A method and apparatus form a thermal barrier coating on a metal component. A molten thermal barrier coating powder is sprayed on the component in sweeping strokes. A plurality of overlapping solidified coating ribbons are deposited on the component and include a sequentially deposited surface ribbon forming sublayer ribbons therebelow. The surface ribbon is preheated at a spray site so that the sprayed molten powder remelts the surface ribbon at the spray site for sequentially welding the sequentially deposited surface ribbons to the sublayer ribbons.

Abstract: A method is provided for protecting thermal barrier coatings deposited on parts from the deleterious effects of environmental contaminants at operating temperatures. The method uses an impermeable barrier coating with the thermal barrier coating, where the impermeable barrier coating prevents environmental contaminants and resulting contaminant compositions from infiltrating openings in thermal barrier coatings during service at operating temperatures.

Abstract: A composite that protects thermal barrier coatings on parts from the deleterious effects of environmental contaminants at operating temperatures with an impermeable barrier coating is divulged. The thermal barrier coating composite decreases infiltration of molten contaminant compositions into openings in the thermal barrier coating to increase the life of the composite.

Abstract: An article having a spallation resistant TBC comprises a metal substrate, such as a high temperature superalloy, and a TBC, such as a coating of yttria stabilized zirconia. The TBC comprises a plurality of plasma-sprayed layers. The TBC has a coherent, continuous columnar grain microstructure, wherein at least one layer has a plurality of continuous columnar grains which have been extended by directional solidification into an adjacent layer. In a preferred embodiment, the coherent, continuous columnar microstructure comprises substantially all of the volume of TBC. A coherent, continuous columnar grain microstructure is also taught wherein at least some of the plurality of coherent, continuous columnar grains which comprise a TBC extend through essentially the entire thickness of the coating.

Abstract: A composite that protects thermal barrier coatings on parts from the deleterious effects of environmental contaminants at operating temperatures with a sacrificial oxide coating is divulged. The thermal barrier coating composite decreases infiltration of molten contaminant compositions into openings in the thermal barrier coating to increase the life of the composite.

Abstract: A method for protecting thermal barrier coatings deposited on engine parts from the deleterious effects of environmental contaminants at high temperatures is given. The method uses a sacrificially consumed oxide coating with the thermal barrier coating, where the consumption of the oxide coating increases the melting temperature of a contaminant composition above the surface temperature of the thermal barrier coating, or increases the viscosity of the contaminant composition to prevent its infiltration into the thermal barrier coating.