Abstract: A coating system disposed on a surface of a substrate is provided. The coating system includes a bond coating on the surface of the substrate, a protective coating on the bond coating, a thermal barrier coating on the protective coating, and a protective agent disposed within at least some of the voids of the thermal barrier coating. The protective coating is constructed from a ceramic material, and the thermal barrier coating defines a plurality of elongated surface-connected voids. Methods are also generally provided for forming such a coating system.

Abstract: A system and methods for applying a ceramic coating to a component that includes first applying a coating material to a first portion of a component. A removal agent is then applied to a second portion of the component that has an overspray byproduct thereon, and then the ceramic coating material is applied to at least the second portion of the component.

Abstract: A coating system disposed on a surface of a substrate is provided. The coating system includes a bond coating on the surface of the substrate, a protective coating on the bond coating, a thermal barrier coating on the protective coating, and a protective agent disposed within at least some of the voids of the thermal barrier coating. The protective coating is constructed from a ceramic material, and the thermal barrier coating defines a plurality of elongated surface-connected voids. Methods are also generally provided for forming such a coating system.

Abstract: Methods and apparatuses by which an oxidized metallic surface can be prepared for a subsequent repair operation without excessive removal of parent metal material. At least one gas is supplied to a limited portion of a metallic surface of a component, and the limited portion is locally heated in the presence of the gas to a treatment temperature sufficient to cause the gas or a gas that forms therefrom to chemically remove oxides from the limited portion of the metallic surface. At least a second portion of the metallic surface is not locally heated to the treatment temperature.

Abstract: Methods and apparatuses by which an oxidized metallic surface can be prepared for a subsequent repair operation without excessive removal of parent metal material. At least one gas is supplied to a limited portion of a metallic surface of a component, and the limited portion is locally heated in the presence of the gas to a treatment temperature sufficient to cause the gas or a gas that forms therefrom to chemically remove oxides from the limited portion of the metallic surface. At least a second portion of the metallic surface is not locally heated to the treatment temperature.

Abstract: Methods and apparatuses by which an oxidized metallic surface can be prepared for a subsequent repair operation without excessive removal of parent metal material. At least one gas is supplied to a limited portion of a metallic surface of a component, and the limited portion is locally heated in the presence of the gas to a treatment temperature sufficient to cause the gas or a gas that forms therefrom to chemically remove oxides from the limited portion of the metallic surface. At least a second portion of the metallic surface is not locally heated to the treatment temperature.

Abstract: Systems for applying a thermal barrier coating to a superalloy substrate including at least one target for supplying a material for making the thermal barrier coating; at least one laser operably directed toward the target for liberating atomic particles from the target; and a plasma torch for generating a plasma for accelerating and depositing the atomic particles onto the superalloy substrate as the thermal barrier coating where the superalloy substrate is a nickel based superalloy or a cobalt based superalloy.

Abstract: Methods of laser assisted plasma coating at atmospheric pressure including providing a plasma, at least one target, at least one laser, and a superalloy substrate, operably directing the laser toward the target to liberate atomic particles from the target and feed the atomic particles into the plasma, and depositing the atomic particles onto the superalloy substrate using the plasma to produce a thermal barrier coating having a column width of from about 0.5 microns to about 60 microns, and an intra column porosity of from about 0% to about 9%.

Abstract: A method of forming a metal coating on surfaces of internal passages of a turbine blade includes, in an exemplary embodiment, the steps of positioning the turbine blade in a CVD chamber, coupling a reagent gas manifold to at least one internal passage inlet, and coating the surfaces of the at least one internal passage by a CVD process using metal coating reagent gases to form a metal coating on the surfaces of the at least one internal passage.

Abstract: A process for brazing components formed of superalloys that contain elements prone to oxidation during brazing. At least one braze tape is applied to at least one faying surface of at least a first of the components being joined by brazing. The braze tape comprises a braze tape alloy containing the base metal of the superalloys and a melting point suppressant, and is applied so as to substantially cover the faying surface. The braze tape is then bonded to the faying surface by heating the first component to a temperature not exceeding the brazing temperature required to join the components. Thereafter, the components are assembled so that the bonded braze tape are between the respective faying surfaces of the components. The components are then brazed together by applying and heating a braze alloy to the braze temperature.

Abstract: A method for processing a substrate article is provided. The method includes masking a first portion of the substrate article with a maskant that includes a formed graphite piece that overlays and contacts the first portion of the substrate such that a second portion of the substrate is not overlaid nor contacted by the maskant; and processing the substrate article such that a coating of material is deposited on the second portion of the substrate, and wherein the maskant facilitates preventing the coating from being deposited on the first portion of the substrate article.

Abstract: A coated article has a metallic substrate with a substrate composition, and a metallic coating overlying and contacting the metallic substrate. The metallic coating has a metallic-coating composition different from the substrate composition. A protective coating overlies and contacts the metallic coating. The protective coating includes an aluminide layer overlying and contacting the metallic coating, and optionally a thermal barrier coating overlying and contacting the aluminide layer. This structure may be used to restore a key dimension of an article that has previously been in service and to protect the article as well.

Abstract: A method of forming a metal coating on surfaces of internal passages of a turbine blade includes, in an exemplary embodiment, the steps of positioning the turbine blade in a CVD chamber, coupling a reagent gas manifold to at least one internal passage inlet, and coating the surfaces of the at least one internal passage by a CVD process using metal coating reagent gases to form a metal coating on the surfaces of the at least one internal passage.

Abstract: A method comprising the following steps: (a) providing a turbine component comprising a metal substrate having an external surface; and (b) analyzing the external surface by laser plasma spectroscopy to determine whether a metallic coating is present on or absent from the external surface. If a metallic coating is determined to be present on the external surface, the elemental composition, elemental concentration and/or thickness of the metallic coating present on the external surface may be determined (qualitatively and/or quantitatively) by laser plasma spectroscopy. Another method comprises the following steps: (a) providing a turbine component comprising a metal substrate having an external surface which has been subjected to treatment to remove a metallic coating applied to the external surface; and (b) analyzing the treated external surface by laser plasma spectroscopy to determine the degree of removal of the metallic coating from the treated external surface.

Abstract: A process for forming diffusion aluminide coatings on an uncoated surface of a substrate, without interdiffusing a sufficient amount of aluminum into a coating layer to adversely affect the coating growth potential and mechanical properties of said coating layer. A metal substrate is provided comprising an external surface and an internal passage therein defined by an internal surface, at least a portion of the external surface of the substrate being coated with a coating layer selected from the group consisting of ?-NiAl-base, MCrAlX, a line-of-sight diffusion aluminide, a non-line-of-sight diffusion aluminide, a pack diffusion aluminide, and a slurry diffusion aluminide on said substrate. The metal substrate is subjected to an aluminum vapor phase deposition process.

Abstract: A method for processing a substrate article is provided. The method includes masking a first portion of the substrate article with a maskant that includes a formed graphite piece that overlays and contacts the first portion of the substrate such that a second portion of the substrate is not overlaid nor contacted by the maskant; and processing the substrate article such that a coating of material is deposited on the second portion of the substrate, and wherein the maskant facilitates preventing the coating from being deposited on the first portion of the substrate article.

Abstract: A coated article has a metallic substrate with a substrate composition, and a metallic coating overlying and contacting the metallic substrate. The metallic coating has a metallic-coating composition different from the substrate composition. A protective coating overlies and contacts the metallic coating. The protective coating includes a chromium aluminide layer overlying and contacting the metallic coating, and optionally a thermal barrier coating overlying and contacting the chromium aluminide layer. This structure may be used to restore a key dimension of an article that has previously been in service and to protect the article as well.

Abstract: A method for applying diffusion aluminide coating on a selective area of a turbine engine component and the coating produced by that method is disclosed. A quartz infrared lamp heats only substantially the localized area of the component to be coated, rather than the complete part. Either halide activated or non-activated tape is applied on the area to be coated and is held in place during coating using a high temperature dimensionally stable tape holder manufactured from graphite or ceramic. The quartz infrared lamp is used to heat only the desired area to a coating temperature of about 1800° F. to about 2000° F. under an inert atmosphere for about 3 to about 8 hours to achieve the desired aluminide coating thickness. No powder masking of the machined surface area is required. Due to the localized heating, aluminum vapor generated from the tape will only deposit aluminide coating on the taped area.

Abstract: A surface of an article is protected by coating the surface with a silicon-containing coating by preparing a coating mixture of silicon, a halide activator, and an oxide powder, positioning the surface of the article in gaseous communication with the coating mixture, and heating the surface of the article and the coating mixture to a coating temperature of from about 1150° F. to about 1500° F. The article is preferably a component of a gas turbine engine made of a nickel-base superalloy.

Abstract: A turbine engine rotor component, such as a compressor or turbine disk or seal element, is protected from corrosion by depositing an aluminum or chromium coating on the component. The deposition can be performed by a vapor deposition process, such as metal organic chemical vapor deposition (MOCVD), to a coating thickness of from about 0.2 to about 50 microns, typically from about 0.5 to about 3 microns. In one embodiment, the method is conducted in a vapor coating container having a hollow interior coating chamber, and includes the steps of loading the coating chamber with the component to be coated; and flowing a tri-alkyl aluminum or chromium carbonyl coating gas into the loaded coating chamber at a specified temperature, pressure, and time to deposit an aluminum or chromium coating on the surface of the component. The coated component is then heated in a nonoxidizing atmosphere to a specified temperature to form an aluminide or chromide coating on the surface.