Abstract: Methods are provided for forming a thermal barrier coating having a non-linear compositional gradient and/or a non-linear porosity gradient, along with coated components formed therefrom. The method includes spraying a deposition mixture of a first composition and a second composition via a solution precursor plasma spray apparatus onto a surface of a substrate; while spraying the deposition mixture, adjusting at least one deposition parameter such that the thermal barrier coating is formed with the non-linear gradient.

Abstract: A coating system configured to be applied to a thermal barrier coating of an article includes an infiltration coating configured to be applied to the thermal barrier coating. The infiltration coating infiltrates at least some pores of the thermal barrier coating. The infiltration coating decomposes within the at least some pores of the thermal barrier coating to coat a portion of the at least some pores of the thermal barrier coating. The infiltration coating reduces a porosity of the thermal barrier coating. The coating system also includes a reactive phase spray formulation coat configured to be applied to the thermal barrier coating. The reactive phase spray formulation coating reacts with dust deposits on the thermal barrier coating.

Abstract: Coated components, along with methods of their formation, are provided. The coated component may include a substrate having a surface and a thermal barrier coating on the surface of the substrate. The thermal barrier coating includes a plurality of elongated surface-connected voids therein, and wherein the thermal barrier coating comprises a plurality of nonspherical particles within a thermal barrier material.

Abstract: A method for inspecting and repairing a surface of a component of a gas turbine engine, the method including: inserting an inspection and repair tool into an interior of the gas turbine engine; inspecting the surface of the component with the inspection and repair tool; performing a repair of the surface of the component with the inspection and repair tool from within the interior of the gas turbine engine, the inspection and repair tool remaining within the interior of the gas turbine engine between inspecting the component and performing the repair of the surface of the component.

Abstract: A method for inspecting and repairing a surface of a component of a gas turbine engine, the method including: inserting an inspection and repair tool into an interior of the gas turbine engine; inspecting the surface of the component with the inspection and repair tool; performing a repair of the surface of the component with the inspection and repair tool from within the interior of the gas turbine engine, the inspection and repair tool remaining within the interior of the gas turbine engine between inspecting the component and performing the repair of the surface of the component.

Abstract: A sprayable thermal barrier coating powder mixture for a gas turbine engine includes: a dry composition having a low surface area ceramic powder having a median particle size distribution greater than 5 microns and less than 50 microns, and a high surface area ceramic powder having a median particle size distribution smaller than 5 microns, wherein the low surface area ceramic powder makes up at least 50% by weight of the dry composition of the sprayable thermal barrier coating powder mixture.

Abstract: A coated component of a gas turbine engine includes a substrate defining a surface, a thermal barrier coating deposited on the surface of the substrate, a region of the component where the thermal barrier coating has spalled from the substrate, a layer of environmental contaminant compositions formed on one or more of the thermal barrier coating or the region of the component where the thermal barrier coating has spalled from the substrate in response to an initial exposure of the component to high operating temperatures of the gas turbine engine, and a thermal barrier coating (TBC) restoration coating deposited at least on the region of the component where there thermal barrier coating has spalled from the substrate.

Abstract: A reactive phase spray formulation coating is configured to be disposed on the thermal barrier coating of an article. The reactive phase spray formulation coating comprises a base material and a binder material. The base material has a compliance that is higher than a compliance of the binder material, the binder material has a cohesive strength that is greater than a cohesive strength of the base material, the binder material has an adhesive strength that is greater than an adhesive strength of the base material, and the binder material has a surface area of at least ten square-meters per gram that is greater than a surface area of the base material. The binder material is configured to improve a cohesive strength level, an adhesive strength level, and a compliance of the formulation coating of the thermal barrier coating relative to the formulation coating not including the binder material.

Abstract: A sprayable thermal barrier coating powder mixture for a gas turbine engine includes: a dry composition having a low surface area ceramic powder having a median particle size distribution greater than 5 microns and less than 50 microns, and a high surface area ceramic powder having a median particle size distribution smaller than 5 microns, wherein the low surface area ceramic powder makes up at least 50% by weight of the dry composition of the sprayable thermal barrier coating powder mixture.

Abstract: An insertion tool is provided for an engine defining an access opening and including a component defining at least in part a cavity. The insertion tool includes: an insertion tool arm having a plurality of segments, the insertion tool arm configured for insertion through the access opening into the cavity and the plurality of segments configured to be in a fixed position relative to one another within the cavity; and a base coupled to the insertion tool arm and configured to be positioned outside the cavity and to move the insertion tool arm along at least two degrees of freedom.

Abstract: A method for inspecting and repairing a surface of a component of a gas turbine engine, the method including: inserting an inspection and repair tool into an interior of the gas turbine engine; inspecting the surface of the component with the inspection and repair tool; performing a repair of the surface of the component with the inspection and repair tool from within the interior of the gas turbine engine, the inspection and repair tool remaining within the interior of the gas turbine engine between inspecting the component and performing the repair of the surface of the component.

Abstract: A control system includes one or more processors configured to determine when to extend a life span of an engine by applying an additional restorative coating to the engine based on one or more monitored parameters of the engine. The monitored parameters include a condition of a previously applied restorative coating. The one or more processors are configured to determine the condition of the previously applied restorative coating based on an optical response of the previously applied restorative coating. The one or more processors also are configured to direct application of the additional restorative coating based on the one or more monitored parameters of the engine.

Abstract: A coating system configured to be applied to a thermal barrier coating of an article includes an infiltration coating configured to be applied to the thermal barrier coating. The infiltration coating infiltrates at least some pores of the thermal barrier coating. The infiltration coating decomposes within the at least some pores of the thermal barrier coating to coat a portion of the at least some pores of the thermal barrier coating. The infiltration coating reduces a porosity of the thermal barrier coating. The coating system also includes a reactive phase spray formulation coat configured to be applied to the thermal barrier coating.

Abstract: A method includes applying an infiltration coating on a thermal barrier coating of an article. The infiltration coating infiltrates at least some pores of the thermal barrier coating. The infiltration coating decomposes within the at least some pores of the thermal barrier coating to coat a portion of the at least some pores of the thermal barrier coating. The infiltration coating reduces a porosity of the thermal barrier coating. The method also includes applying a reactive phase spray formulation coating on the thermal barrier coating. The reactive phase spray formulation coating reacts with dust deposits on the thermal barrier coating.

Abstract: A coated component of a gas turbine engine includes a substrate defining a surface, a thermal barrier coating deposited on the surface of the substrate, a region of the component where the thermal barrier coating has spalled from the substrate, a layer of environmental contaminant compositions formed on one or more of the thermal barrier coating or the region of the component where the thermal barrier coating has spalled from the substrate in response to an initial exposure of the component to high operating temperatures of the gas turbine engine, and a thermal barrier coating (TBC) restoration coating deposited at least on the region of the component where there thermal barrier coating has spalled from the substrate.

Abstract: A coating analysis system and method inductively heat a component having a coating. Optionally, the component is heated while a cooling fluid flows through cooling holes extending through the component and the coating. The system and method measure rates of infrared radiation emission from the component and the coating at different locations on the component and the coating. The system and method determining bond qualities (e.g., tensile strengths of bonds) between the coating and the component at the different locations based on the rates of infrared radiation emission that are measured.

Abstract: An inspection system includes a light source, an imaging device, and one or more processors. The light source is configured to direct an illumination light having a controlled light characteristic towards a surface of a thermal barrier coating of a work piece. The imaging device is configured to capture image data of the surface of the thermal barrier coating by monitoring the illumination light reflected off the surface. The one or more processors are operably connected to the imaging device and configured to analyze the image data of the surface by comparing the image data to reference image data depicting a first designated microstructure. The first designated microstructure has an associated coating quality value. The one or more processors are configured to determine that the thermal barrier coating of the work piece has the first designated microstructure based on the analysis.

Abstract: A method includes applying an infiltration coating on a thermal barrier coating of an article. The infiltration coating infiltrates at least some pores of the thermal barrier coating. The infiltration coating decomposes within the at least some pores of the thermal barrier coating to coat a portion of the at least some pores of the thermal barrier coating. The infiltration coating reduces a porosity of the thermal barrier coating. The method also includes applying a reactive phase spray formulation coating on the thermal barrier coating. The reactive phase spray formulation coating reacts with dust deposits on the thermal barrier coating.

Abstract: An inspection system includes a light source, an imaging device, and one or more processors. The light source is configured to direct an illumination light having a controlled light characteristic towards a surface of a thermal barrier coating of a work piece. The imaging device is configured to capture image data of the surface of the thermal barrier coating by monitoring the illumination light reflected off the surface. The one or more processors are operably connected to the imaging device and configured to analyze the image data of the surface by comparing the image data to reference image data depicting a first designated microstructure. The first designated microstructure has an associated coating quality value. The one or more processors are configured to determine that the thermal barrier coating of the work piece has the first designated microstructure based on the analysis.

Abstract: A coating analysis system and method inductively heat a component having a coating. Optionally, the component is heated while a cooling fluid flows through cooling holes extending through the component and the coating. The system and method measure rates of infrared radiation emission from the component and the coating at different locations on the component and the coating. The system and method determining bond qualities (e.g., tensile strengths of bonds) between the coating and the component at the different locations based on the rates of infrared radiation emission that are measured.