Abstract: The invention includes a low activity localized aluminide coating for a metallic article made by positioning a coating material, preferably in the form of a tape, on a portion of the article. The coating material comprises a binder, a halide activator, an aluminum source, and an inert ceramic material. The coating material and the article are heated in an inert atmosphere between about 1800.degree. F. (982.degree. C.) and about 2050.degree. F. (1121.degree. C.) for between about four and about seven hours thereby producing a low activity localized aluminide coating having an outward diffusion aluminide coating microstructure characterized by two distinct zones, an inner diffusion zone and an outer zone including between about 20-28 percent, by weight, aluminum.

Abstract: The invention includes a low activity localized aluminide coating for a metallic article made by positioning a coating material, preferably in the form of a tape, on a portion of the article. The coating material comprises a binder, a halide activator, an aluminum source, and an inert ceramic material. The coating material and the article are heated in an inert atmosphere between about 1800.degree. F. (982.degree. C.) and about 2050.degree. F. (1121.degree. C.) for between about four and about seven hours thereby producing a low activity localized aluminide coating having an outward diffusion aluminide coating microstructure characterized by two distinct zones, an inner diffusion zone and an outer zone including between about 20-28 percent, by weight, aluminum.

Abstract: A gas turbine engine component coated with a thermal barrier coating that includes a metallic bond coat and a ceramic top coat is repaired by removing the ceramic top coat from an engine-run gas turbine engine component and inspecting the component. A metallic flash coat is applied to at least a portion of the component. A ceramic top coat is then applied over predetermined portions of the component, including the portion to which the metallic flash coat was applied.

Abstract: Variable polarity welding is used to repair coated articles, particularly gas turbine engine components. The variable polarity welding process is found to remove the coating during the welding process. This permits the elimination of costly steps which would otherwise be needed in the repair process.