Abstract: A masking tool for a turbine component configured to receive and cover a portion of the turbine component includes a first casing part and a second casing part configured to engage the first casing part to form a chamber configured to receive a portion of the turbine component. The first and second casing parts are configured to leave part of the turbine component exposed to atmosphere when the first and second casing parts are secured together and receive the turbine component. The first and second casing parts are configured to be compressed against each other when secured together. In addition, the first and second casing parts are configured to seal a space containing portions of the turbine component without an elastomeric seal.

Abstract: Methods for vapor depositing high temperature coatings on gas turbine components are provided, as are methods for producing pre-alloyed pucks for usage in vapor deposition processes. In one embodiment, the method includes the step of producing a pre-alloyed puck including a master alloy and a high vaporization temperature refractory metal, which has a vaporization temperature greater than each of the master alloy constituents. The pre-alloyed puck is placed over an ingot and heated to a temperature greater than the melt point of the pre-alloyed puck and less than the vaporization temperature of the high vaporization temperature refractory metal to transform the puck and a portion of the ingot into a molten pool and to produce a vapor stream containing the constituents of the master alloy and the ingot. The vapor stream is exposed to a gas turbine engine component to deposit the high temperature coating over at least one surface thereof.

Abstract: A coating is disclosed that consists essentially of, by weight, about 27.5% to about 31.5% aluminum, about 0.20% to about 0.60% hafnium, about 0.08% to about 0.30% zirconium, about 0.005% to about 0.100% of two or more reactive elements selected from a group consisting of yttrium, lanthanum, and cerium, and a balance of nickel. Turbine engine components including the coating and methods of applying the coating on such components are also disclosed.

Abstract: A turbine engine component includes an electron beam-physical vapor deposition thermal barrier coating covering at least a portion of a substrate. The thermal barrier coating includes an inner layer having a columnar-grained microstructure with inter-columnar gap porosity. The inner layer includes a stabilized ceramic material. The thermal barrier coating also includes a substantially non-porous outer layer, covering the inner layer and including the stabilized ceramic material. The outer layer is deposited with continuous line-of-sight exposure to the vapor source under oxygen deficient conditions. The outer layer may further comprise a dopant oxide that is more readily reducible than the stabilized ceramic material. During deposition, the outer layer may also have an oxygen deficient stoichiometry with respect to the inner layer. Oxygen stoichiometry in the outer layer may be restored by exposure of the coated component to an oxidizing environment.