Abstract: A beta-phase NiAl overlay coating containing a dispersion of ceramic particles and a process for depositing the overlay coating. If the coating is used to adhere a thermal barrier coating (TBC), the TBC exhibits improved spallation resistance as a result of the dispersion of ceramic particles having a dispersion-strengthening effect on the overlay coating. The overlay coating contains at least one reactive element and is deposited so that the some of the reactive element deposits as the ceramic particles dispersed in the overlay coating.

Abstract: A turbine engine component comprising a substrate made of a nickel-base or cobalt-base superalloy and a protective coating overlying the substrate, the coating formed by electroplating at least two platinum group metals selected from the group consisting of platinum, palladium, rhodium, ruthenium and iridium. The protective coating is typically heat treated to increase homogeneity of the coating and adherence with the substrate. The component typically further comprises a ceramic thermal barrier coating overlying the protective coating. Also disclosed are methods for forming the protective coating on the turbine engine component by electroplating the platinum group metals.

Abstract: A thermal barrier coating, or TBC, and method for forming the TBC. The TBC is formed of a thermal-insulating material that contains yttria-stabilized zirconia (YSZ) alloyed with at least a third oxide. The TBC is formed to also contain elemental carbon, and may potentially contain carbides and/or a carbon-containing gas that forms from the thermal decomposition of carbon. The TBC is characterized by lower density and thermal conductivity, high temperature stability and improved mechanical properties. To exhibit the desired effect, the third oxide is more particularly one that increases the lattice strain energy of the TBC microstructure as a result of having an ion size that is sufficiently different than a zirconium ion.

Abstract: A PVD process and apparatus (120) for depositing a coating (132) from multiple sources (110, 111) of different materials. The process and apparatus (120) are particulaity intended to deposit a beta-nickel aluminide coating (132) containing one or more elements whose vapor pressures are lower than NiAl. The PVD process and apparatus (120) entail feeding at least two materials (110, 111) into a coating chamber (122) and evaporating the materials (110, 111) at different rates from separate molten pools (114, 115) thereof. Articles (130) to be coated are suspended within the coating chamber (122), and transported with a support apparatus (118) relative to the two molten pools (114, 115) so as to deposit a coating (132) with a controlled composition that is a mixture of the first and second materials (110, 111).

Abstract: A turbine wall includes a metal substrate having front and back surfaces. A thermal barrier coating is bonded atop the front surface. A network of flow channels is laminated between the substrate and the coating for carrying an air coolant therebetween for cooling the thermal barrier coating.

Abstract: Zirconia-containing ceramic compositions having a c/a ratio of the zirconia lattice in the range of from about 1.005 to about 1.016. These compositions comprise a stabilizing amount up to about 10 mole % of the composition of a stabilizer component which comprises: (1) a first metal oxide selected from the group consisting of yttria, calcia, ceria, scandia, magnesia, india and mixtures thereof in an amount of from about 1.5 to about 6 mole % of the composition of; (2) a second metal oxide selected from the group consisting of lanthana, neodymia and mixtures thereof in an amount of from about 0.5 to about 4 mole % of the composition; and (3) optionally ytterbia in an amount of from about 0.5 to about 4 mole % of the composition. These compositions further comprise hafnia in an amount of from about 0.5 to about 15 mole % of the composition; and optionally tantala in an amount of from about 0.5 to about 1.5 mole % of the composition.

Abstract: A process and apparatus for depositing a ceramic coating on a component. The process involves a technique for evaporating an evaporation source containing multiple different oxide compounds, at least one of the oxide compounds having a vapor pressure that is higher than the remaining oxide compounds, to depositing a coating of the multiple oxide compounds. A high energy beam is projected onto the evaporation source to melt and form a vapor cloud of the oxide compounds of the evaporation source, while preventing the vapor cloud from contacting and condensing on the component during an initial phase in which the relative amount of the one oxide compound in the vapor cloud is greater than its relative amount in the evaporation source.

Abstract: A turbine engine rotor component, such as a compressor or turbine disk or seal element, is protected from corrosion by implanting aluminum or chromium ions, or mixtures thereof, on the surface of the component. Additional metal ions, such as rare earth and reactive elements, may also be implanted on the surface of the component. The component may be heated in a nonoxidizing atmosphere at a specified temperature and time to diffuse the ions into the surface. The component is typically then heated or maintained at an elevated temperature in the presence of oxygen to form an oxide coating on the surface of the component.

Abstract: A beta-phase nickel aluminide (NiAl) overlay coating (24) and method for modifying the grain structure of the coating (24) to improve its oxidation resistance. The coating (24) is deposited by a method that produces a grain structure characterized by grain boundaries (44) exposed at the outer coating surface (36). The grain boundaries (44) may also contain precipitates (40) as a result of the alloyed chemistry of the coating (24). During or after deposition, the overlay coating (24) is caused to form new grain boundaries (34) that, though open to the outer surface (36) of the coating (24), are free of precipitates or contain fewer precipitates (40) than the as-deposited grain boundaries (44). New grain boundaries (34) are preferably produced by causing the overlay coating (24) to recrystallize during coating deposition or after deposition as a result of a surface treatment followed by heat treatment.

Abstract: A process for forming a beta-phase nickel aluminide (NiAl) overlay coating that is suitable for use as a bond coat for a thermal barrier coating (TBC). The overlay coating is deposited by a method that produces a generally columnar grain structure in which grains extend through the coating such that at least some grain boundaries are open at the coating surface. The coating is then peened with a particulate media, followed by heating the overlay coating to a temperature sufficient to cause the overlay coating to recrystallize and form new grain boundaries that are not open to the outer surface of the coating and significantly less susceptible to accelerated oxidation than the original grain boundaries. The particulate media is formed of a composition containing nickel and aluminum, such that an oxide scale that forms on the surface of the coating after the peening operation is substantially free of deleterious oxide compounds, notably iron-containing spinels.

Abstract: A non-destructive method of detecting subsurface defects in thermal barrier coatings applied to gas turbine engine components is provided. In an exemplary embodiment, the method includes positioning a evanescent microwave microscope probe adjacent a turbine component surface coated with a thermal barrier coating, and scanning the thermal barrier coating by moving at least one of the evanescent microwave microscope probe and the component surface in relation to one another in an x-y plane while maintaining a predetermined distance between the probe and the thermal barrier coating constant.

Abstract: A non-destructive method of detecting and measuring machining induced surface defects on gas turbine engine components is provided. In an exemplary embodiment, the method includes positioning an evanescent microwave microscope probe adjacent a turbine component surface, and scanning the turbine component surface by moving at least one of the evanescent microwave microscope probe and the component surface in an x-y plane while maintaining a predetermined distance between the probe and the component surface constant.

Abstract: A thermal barrier coating, or TBC (26), and method for forming the TBC (26). The TBC (26) is formed of a thermal-insulating material that contains yttria-stabilized zirconia (YSZ) alloyed with at least a third oxide. The TBC (26) is formed to also contain elemental carbon, and may potentially contain carbides and/or a carbon-containing gas that forms from the thermal decomposition of carbon. The TBC (26) is characterized by lower density and thermal conductivity, high temperature stability and improved mechanical properties. To exhibit the desired effect, the third oxide is more particularly one that increases the lattice strain energy of the TBC microstructure as a result of having an ion size that is sufficiently different than a zirconium ion.

Abstract: A beta-phase NiAl overlay coating containing a dispersion of ceramic particles and a process for depositing the overlay coating. If the coating is used to adhere a thermal barrier coating (TBC), the TBC exhibits improved spallation resistance as a result of the dispersion of ceramic particles having a dispersion-strengthening effect on the overlay coating. The overlay coating contains at least one reactive element and is deposited so that the some of the reactive element deposits as the ceramic particles dispersed in the overlay coating.

Abstract: A process for depositing a ceramic coating on a component. The process involves a technique for evaporating an evaporation source containing multiple different oxide compounds, at least one of the oxide compounds having a vapor pressure that is higher than the remaining oxide compounds, to deposit a coating of the multiple oxide compounds. A high energy beam is projected onto the evaporation source to melt and form a vapor cloud of the oxide compounds of the evaporation source, while preventing the vapor cloud from contacting and condensing on the component during an initial phase in which the relative amount of the one oxide compound in the vapor cloud is greater than its relative amount in the evaporation source. During a subsequent phase in which the relative amount of the one oxide compound in the vapor cloud has decreased to something approximately equal to its relative amount in the evaporation source, the vapor cloud is allowed to contact and condense on the component to form the coating.

Abstract: A coated article having a high resistance to particle-impact damage has a substrate, and a layered coating overlying the substrate. The layered coating includes a substantially continuous quasicrystalline layer, and a substantially continuous ductile metallic layer in facing contact with the quasicrystalline layer. The coated article is preferably used in applications where it is subjected to particle-impact conditions.

Abstract: A gas turbine engine component includes a perforate metal wall having pores extending therethrough. The wall has a first surface covered by a thermal barrier coating. The pores have first ends which are covered by the thermal barrier coating, and the pores are ventilated from an opposite second surface of the wall for cooling the thermal barrier coating.

Abstract: One exemplary embodiment of a turbine component (which may be a blade) comprises a substrate comprising a silicide-based material, a plurality of through holes disposed in the substrate, the holes being configured to receive an airflow, a silicide coating disposed at the surfaces of the substrate and the through holes, and a thermal barrier coating disposed at the silicide coating. In another exemplary embodiment the silicide coating may be replaced by a Laves phase-containing layer. In still another exemplary embodiment the silicide coating may be replaced by a diffusion barrier layer disposed at a surface of the substrate and a platinum group metal layer disposed at the diffusion barrier layer. One exemplary embodiment of a blade may comprise an airfoil comprising a silicide-based material and through holes disposed therein, a cooling plenum disposed in the airfoil, and a base configured to receive the airfoil in a dovetail fit, the base comprising a superalloy.

Abstract: A coated article having a high resistance to wear damage has a substrate, and a layered coating overlying the substrate. The layered coating includes a ductile metallic layer overlying and in facing contact with the substrate, and a protective layer overlying and in facing contact with the ductile metallic layer and including a mixture of a quasicrystalline metallic phase and a non-quasicrystalline ductile phase. The coated article is preferably used in applications where it is subjected to wear conditions.

Abstract: An article for use in a hot gas path of a gas turbine assembly, a metallic skin for such an article, and a method for making such an article are presented with, for example, the article comprising a spar, the spar providing mechanical support for the article and comprising a cooling fluid delivery system, a top end, and a bottom end; a standoff structure attached to the spar, the standoff structure comprising a plurality of spacing elements in a spaced-apart relation to each other, the spacing elements having first ends adjacent to the spar and second ends opposite to the first ends; a skin conformally surrounding the spar and the standoff structure, the skin comprising a top end and a bottom end, wherein the standoff structure separates the spar and the skin, wherein the plurality of spacing elements is disposed with an inner surface of the skin adjacent to the second ends of the spacing elements to form a plurality of plena between the spar and the skin, the plena in fluid communication with the cooling flu