Abstract: A wall panel assembly includes a first liner panel and a coating. The first liner panel has an inner first liner panel surface and a first liner panel outer surface each axially extending between a first liner panel first end and a first liner panel second end. The coating is disposed on at least one of the first liner panel inner surface and the first liner panel outer surface. The coating has an overall thickness that varies axially between the first liner panel first end and the first liner panel second end.

Abstract: A metal article includes a metallic substrate and a thermal barrier coating. A thermally grown mixed oxide layer between the metal substrate and the thermally grown mixed oxide layer enhances the spallation resistance of the thermal barrier coating on the metallic substrate of metal article. In an embodiment, the thermal barrier coating is about 51 weight percent gadolinia and about 49 weight percent yttria partially stabilized zirconia.

Abstract: A method of forming a spallation resistant thermal barrier coating on a metal substrate includes cleaning the substrate and preheating the substrate to a temperature suitable for the deposition of a thermal barrier coating according to a preheating schedule that allows a thermally grown mixed oxide layer to form on the substrate. A ceramic thermal barrier coating deposited on the thermally grown mixed oxide layer forms a spallation resistant coating.

Abstract: A wall panel assembly includes a first liner panel and a coating. The first liner panel has an inner first liner panel surface and a first liner panel outer surface each axially extending between a first liner panel first end and a first liner panel second end. The coating is disposed on at least one of the first liner panel inner surface and the first liner panel outer surface. The coating has an overall thickness that varies axially between the first liner panel first end and the first liner panel second end.

Abstract: A method of forming a thermal barrier coating on a metal part includes laser cleaning a surface of the metal part to remove undesirable oxides and residues from the surface of the part. It further includes depositing an aluminum containing bondcoat on the part and thermally interdiffusing the bondcoat and the part with a heat treatment. Laser cleaning a surface of the bondcoat to remove oxides and debris from the surface forms an alpha aluminum oxide layer on the bondcoat. A ceramic topcoat is then deposited on the alpha aluminum oxide layer at a temperature above 1800° F. (982° C.).

Abstract: A method of forming a thermal barrier coating on a metal part includes laser cleaning a surface of the metal part to remove undesirable oxides and residues from the surface of the part. It further includes depositing an aluminum containing bondcoat on the part and thermally interdiffusing the bondcoat and the part with a heat treatment. Laser cleaning a surface of the bondcoat to remove oxides and debris from the surface forms an alpha aluminum oxide layer on the bondcoat. A ceramic topcoat is then deposited on the alpha aluminum oxide layer at a temperature above 1800° F. (982° C.).

Abstract: A method of forming a thermal barrier coating on a metal part includes laser cleaning a surface of the metal part to remove undesirable oxides and residues from the surface of the part. It further includes depositing an aluminum containing bondcoat on the part and thermally interdiffusing the bondcoat and the part with a heat treatment. Laser cleaning a surface of the bondcoat to remove oxides and debris from the surface forms an alpha aluminum oxide layer on the bondcoat. A ceramic topcoat is then deposited on the alpha aluminum oxide layer at a temperature above 1800° F. (982° C.).

Abstract: A metal article includes a metallic substrate and a thermal barrier coating. A thermally grown mixed oxide layer between the metal substrate and the thermally grown mixed oxide layer enhances the spallation resistance of the thermal barrier coating on the metallic substrate of metal article. In an embodiment, the thermal barrier coating is about 51 weight percent gadolinia and about 49 weight percent yttria partially stabilized zirconia.

Abstract: A method of forming targets for cathodic arc deposition of alloy bond coats for turbine engines components consists of melting a base alloy containing aluminum and other metals, adding grain boundary strengthening alloy additions, and casting the melt to form a cylindrical billet that is subsequently sectioned into puck shaped targets. The grain boundary strengthening additions minimize intergranular fracture of the targets during high current operation of the arc coating process.

Abstract: A coating process includes preheating a workpiece having an aluminum-containing layer through a temperature range in a reducing atmosphere having hydrogen to limit formation of thermally grown oxides on the surface of the workpiece. A source of oxygen is introduced to establish an oxidizing atmosphere at a temperature above the temperature range to form a desired type of thermally grown oxide on the surfaces of the workpiece. A coating is then deposited on the desired type of thermally grown oxide.

Abstract: A process for coating a part comprises the steps of: loading a bond coated part into a load chamber; moving the bond coated part from the load chamber to a preheat chamber; subjecting the bond coated part to a preheat treatment with controlled conditions to promote a specific thermally grown oxide layer to form; and moving the bond coated part with the thermally grown oxide layer to a electron beam physical vapor coating chamber for ceramic coating.

Abstract: A method and apparatus for forming thermally grown alpha alumina oxide scale on a substrate is provided. The method includes the steps of: a) providing a heating chamber having a heat source and an oxidizing gas source selectively operable to provide a stream of oxidizing gas; b) providing at least one substrate disposed in the heating chamber, which substrate has a composition sufficient to permit formation of an alpha alumina scale on one or more surfaces; c) maintaining a vacuum in the heating chamber at a level that inhibits formation of one or more low temperature oxides on the one or more surfaces of the substrate; d) heating at least one of the one or more surfaces of the substrate to a predetermined temperature at or above 1800 degrees Fahrenheit; and e) directing the stream of oxidizing gas at a controlled rate toward one or more heated surfaces of the substrate.

Abstract: A method of forming targets for cathodic arc deposition of alloy bond coats for turbine engines components consists of melting a base alloy containing aluminum and other metals, adding grain boundary strengthening alloy additions, and casting the melt to form a cylindrical billet that is subsequently sectioned into puck shaped targets. The grain boundary strengthening additions minimize intergranular fracture of the targets during high current operation of the arc coating process.

Abstract: A grit blast free method of removing a ceramic thermal barrier layer from a turbine component is described. The method comprises removing the layer in an autoclave with a caustic medium followed by a low pressure water jet wash. The component is dried in a stream of hot dry nitrogen and a new thermal barrier coating is applied before the component reenters product flow.

Abstract: A method and apparatus for forming thermally grown alpha alumina oxide scale on a substrate is provided. The method includes the steps of: a) providing a heating chamber having a heat source and an oxidizing gas source selectively operable to provide a stream of oxidizing gas; b) providing at least one substrate disposed in the heating chamber, which substrate has a composition sufficient to permit formation of an alpha alumina scale on one or more surfaces; c) maintaining a vacuum in the heating chamber at a level that inhibits formation of one or more low temperature oxides on the one or more surfaces of the substrate; d) heating at least one of the one or more surfaces of the substrate to a predetermined temperature at or above 1800 degrees Fahrenheit; and e) directing the stream of oxidizing gas at a controlled rate toward one or more heated surfaces of the substrate.

Abstract: A coating process includes preheating a workpiece having an aluminum-containing layer through a temperature range in a reducing atmosphere having hydrogen to limit formation of thermally grown oxides on the surface of the workpiece. A source of oxygen is introduced to establish an oxidizing atmosphere at a temperature above the temperature range to form a desired type of thermally grown oxide on the surfaces of the workpiece. A coating is then deposited on the desired type of thermally grown oxide.