Abstract: An article protected by a protective coating includes a substrate made of a first nickel-base superalloy substrate material that is susceptible to the formation of a secondary reaction zone when overlaid by a diffusion aluminide coating or an aluminide overlay coating. A protective coating including a deposited coating at the substrate surface. The deposited coating is a second nickel-base superalloy different from the first nickel-base superalloy and which does not produce a secondary reaction zone when interdiffused with the first nickel-base superalloy. In one version, the deposited coating has a nominal composition, in weight percent, of about 3.1 percent cobalt, about 7.6 percent chromium, about 7.8 percent aluminum, about 5.45 percent tantalum, about 3.85 percent tungsten, about 1.65 percent rhenium, about 0.02 percent carbon, about 0.016 percent hafnium, about 0.015 percent boron, about 0.5 percent silicon, balance nickel and incidental impurities.

Abstract: A single-crystal article having a thermal barrier coating on a surface thereof, and a method for processing the article so as to promote the life of the coating. As a result of its single-crystal microstructure, the article is characterized by having been unidirectionally solidified along a primary crystallographic direction, and secondary crystallographic directions that are normal to the primary crystallographic direction. Improved spallation resistance of the coating is achieved by selectively orienting the secondary crystallographic direction with respect to a direction normal to a life-limiting surface region of the thermal barrier coating.