Abstract: Nickel-base alloys suitable for use as a weld material to weld high-temperature components (10), such as turbine blades and vanes of gas turbine engines. The nickel-base alloys consist essentially of, by weight, 5 to 10 percent chromium, 3 to 14 percent cobalt, up to 4 percent molybdenum, 3 to 7 percent tungsten, 5 to 9 percent tantalum, 5 to 8 percent aluminum, 0.1 to 2 percent hafnium, 0.005 to 0.03 percent boron, up to 0.15 percent carbon, the balance being nickel and incidental impurities and/or residual elements. Welds (12) formed with the alloys are capable of exhibiting desirable levels of strength and oxidation resistance, while containing little if any rhenium.

Abstract: A restored or regenerated article including a residual substrate comprised of a first material and a restorative or regenerative layer of second material overlying at least a portion of the residual substrate. The second material is substantially similar in composition to the first material to promote an integral bond therebetween. The second material comprises the deposit of a suitable deposition process, i.e., vapor phase deposition, cathodic arc deposition, or sputtering. The restored/regenerated article includes an environmental coating at least partly diffused into the restorative or regenerative layer. The environmental coating comprises a deposit from a deposition process selected from vapor phase deposition, cathodic arc deposition, and combinations thereof. Heat treatments of about 2 hours or longer at temperatures between about 1500 ° F. to about 2300° F. (about 816° C. to about 1260° C.) to enhance the bond between the residual substrate and the restorative/regenerative layer.

Abstract: Coating system for a metallic substrate includes a strengthened bond coat including a bond coat inner layer and an aluminum-containing layer overlying the bond coat inner layer. The bond coat inner layer is formed by deposition of a bond coat composition including, in weight percent, 14-20% Cr, 5-8% Al, 8-12% Co, 3-7% Ta, 0.1-0.6% Hf, 0.1-0.5% Y, up to about 1% Si, 0.005-0.020% Zr, 0.04-0.08% C, 0.01-0.02% B, with a remainder including Ni and incidental impurities, wherein the bond coat composition is substantially free of rhenium. The coating system includes an optional thermal barrier coating which may be a yttria-stabilized zirconia.

Abstract: A method for restoring or regenerating an article, particularly a component for use in a gas turbine engine, includes providing a residual substrate comprised of a first material, evaluating a wall thickness of the residual substrate, and depositing a layer of a second material overlying at least a portion of the residual substrate. The second material is substantially similar in composition to the first material. The layer is deposited by vapor phase deposition, ion plasma deposition, cathodic arc deposition, sputtering, and combinations thereof. An environmental coating is deposited onto the component by vapor phase deposition, cathodic arc deposition, and combinations thereof. The method may include a heat treatment at temperatures between about 1500° F. to about 2300° F. (about 816° C. to about 1260° C.) for between about 2 to about 24 hours. The method may include a surface treatment such as grit blast polishing. Following use of the restored/regenerated component, the repair process may be repeated.

Abstract: A system for restoring or regenerating an article, such as turbine blade or vane for a gas turbine engine, includes a first cathode and a second cathode operably disposed in a deposition chamber. The first cathode includes a first deposition material substantially similar in composition to the material of a residual substrate. The second cathode includes a second deposition material able to form an environmental coating on a restored/regenerated component. The first and second cathodes may be sequentially operated without interrupting the vacuum conditions in the deposition chamber. A method for restoring or regenerating an article includes utilizing the first cathode to deposit a layer of first deposition material onto the residual substrate and subsequently applying the environmental coating utilizing a common deposition chamber, and without interrupting the vacuum conditions between depositions.