Abstract: One embodiment of the present invention is a unique engine hot section component having a coating system operative to reduce heat transfer to the hot section component. Another embodiment is a unique method for making a gas turbine engine hot section component with a coating system. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for gas turbine engines, hot section components and coating systems. Further embodiments, forms, features, aspects, benefits, and advantages of the present application shall become apparent from the description and figures provided herewith.

Abstract: A method, system and apparatus are disclosed for providing an anti-fret coating system to a component having a wear surface. The method includes applying a dry film lubrication system to a basecoat having a copper based material positioned on a substrate, wherein the dry film lubrication system includes: applying at least one intermediate coating layer having a calcium fluoride and barium fluoride material in a silicone binder over the basecoat; and applying a top coat layer having a molybdenum disulfide material over the at least one intermediate coating layer. The method can further include removing an existing intermediate coating layer and an existing top coat layer before said applying the dry film lubrication system; removing an existing top coat layer before said applying the dry film lubrication system; and removing an existing basecoat and applying another basecoat having a copper based material before said applying the dry film lubrication system.

Abstract: An article includes a substrate and an environmental barrier coating overlying the substrate. The environmental barrier coating includes a first dense layer, an intermediate layer overlying the first dense layer, and a second dense layer overlying the intermediate layer. The first dense layer includes at least one of a first rare earth silicate or barium strontium aluminosilicate and the second dense layer includes at least one of a second rare earth silicate or barium strontium aluminosilicate. Additionally, the intermediate layer includes at least one of a porous microstructure, a lamellar microstructure, or an absorptive material.

Abstract: One embodiment of the present invention is a unique engine hot section component having a coating system operative to reduce heat transfer to the hot section component. Another embodiment is a unique method for making a gas turbine engine hot section component with a coating system. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for gas turbine engines, hot section components and coating systems. Further embodiments, forms, features, aspects, benefits, and advantages of the present application shall become apparent from the description and figures provided herewith.

Abstract: A method of coating a substrate, the method including depositing mullite on the substrate during a first time period via thermal spraying to form a first layer, the mullite comprising mullite powder formed via at least one of a fused plus crush or sinter plus crush process; and depositing a second material on the first layer to form a second layer, wherein the substrate is at a temperature less than approximately 50 degrees Celsius at approximately a beginning of the first time period. In some embodiments, the method may further include depositing silicon to form a silicon bond layer between the substrate and mullite layer.

Abstract: Dry film lubricant coatings are provided by using a silicone resin binder, either as an aqueous emulsion or in a solvent-based system, to fix an alkaline earth metal fluoride to a substrate. The compositions used to apply the coatings may also include relatively minor amounts of xylene, ammonium benzoate, a wetting agent, and/or a porosity-inducing agent—although none of those additives remains in the cured coating. Multi-layer dry film lubricant coatings are also disclosed, with the multi-layer coating having a basecoat layer as described above, and a topcoat layer made of a layer-lattice solid such as graphite or molybdenum disulfide, and a silicone resin, aluminum phosphate or an alkali metal silicate binder.

Abstract: Dry film lubricant coatings are provided by using a silicone resin binder, either as an aqueous emulsion or in a solvent-based system, to fix an alkaline earth metal fluoride to a substrate. The compositions used to apply the coatings may also include relatively minor amounts of xylene, ammonium benzoate, a wetting agent, and/or a porosity-inducing agent—although none of those additives remains in the cured coating.

Abstract: A “one-step” method of forming diffused noble metal-aluminide coatings with or without minor incorporations of Si, Cr, Mn, Hf, La, and Y, is disclosed. With the inventive method, two or more powdered metals or metal alloys are applied and diffused into the metal substrate together, using a sequential multi-stage heating process. This method contrasts with the prior art technology where metals were applied and diffused into the substrate separately.

Abstract: A method of controlling the final coating thickness of a diffused aluminide coating on a metal substrate. The method includes: (a) depositing an alumina-doped platinum-silicon powder onto a metal substrate, (b) heating the coated substrate to diffuse the platinum-silicon powder into the substrate and removing the undiffused scale, (c) depositing an aluminum-bearing powder onto the platinum-silicon-enriched substrate, and (d) heating the coated substrate to diffuse the aluminum-bearing powder into the substrate and removing the undiffused scale. The depositions are preferably done electrophoretically, in which case the Pt--Si deposition bath is doped with alumina or some other inert particulate. Alternatively, slurry deposition may be used. The method may also be used to deposit Pd--Si coatings onto metal substrates.

Abstract: Nickel aluminide single crystal alloys having improved strength and ductility at elevated temperatures, produced by major elemental additions to strengthen the Ni.sub.3 Al phase by solid solutioning and/or secondary phase formation. The major elemental additions comprise (by weight) 7-20% Al, 0.5-9% molybedenum, 0.5-10% tungsten and 2-15% titanium. Optional minor elemental additions of boron, manganese, silcon and/or hafnium are preferred.

Abstract: Abradable wall structures for high temperature applications, such as in turbine housings and the like. The wall structures comprise a superalloy metal base plate supporting a superalloy metallic cellular structure, the cells of which are filled to a substantial extent with at least one ceramic core material providing high heat resistance, oxygen barrier and low thermal expansion properties. The invention involves the application of a porous or pore-forming surface composition to provide a corrosion-resistant, erosion-resistant abradable outer surface layer, the softness or porosity of which can be tailored to improve the abradability of the wall structure, while imparting oxidation-, corrosion- and erosion-resistance to the structure. The surface layer composition may comprise metal superalloy, ceramic or cermet base compositions containing fugitive or retained inert filler materials.

Abstract: Disclosed are novel nickel base single crystal alloy compositions consisting essentially of, by weight, about 4.0-10.0% chromium, 1.5-6.0% cobalt, 1.0-12.0% molybdenum, 3.0-10.0% tungsten, 2.5-7.0% titanium, 2.5-7.0% aluminum, 3.0-10.0% tantalum, about 0.02%-1.5% of hafnium and/or about 0.02%-1.0% silicon, from about 0.02%-1.0% each of yttrium and/or lanthanum, from about 0.3% to about 8.0% rhenium; from about 0.2% to about 4.0% vanadium and/or from about 0.2% to about 4.0% niobium; from about 0.02% to about 3% platinum; from about 0 to about 1.0% boron, the balance nickel, and the balance nickel.Methods of thermal treatment and coating of the novel alloys to enhance their mechanical properties are also disclosed, as are articles produced by such methods.

Abstract: Abradable wall structures for high temperature applications, such as in turbine housings and the like. The wall structures comprise a superalloy metal base plate supporting a superalloy metallic cellular structure, the cells of which are filled to a substantial extent with at least one ceramic core material providing high heat resistance, oxygen barrier and low thermal expansion properties. The invention involves the application of a porous or pore-forming surface composition to provide a corrosion-resistant, erosion-resistant abradable outer surface layer, the softness or porosity of which can be tailored to improve the abradability of the wall structure, while imparting oxidation-, corrosion- and erosion-resistance to the structure. The surface layer composition may comprise metal superalloy, ceramic or cermet base compositions containing fugitive or retained inert filler materials.

Abstract: Erosion resistance is imparted to a metallic substrate without an attendant loss of fatigue life in the substrate by applying to the substrate a first layer comprising palladium, platinum or nickel in direct contact with the substrate and then applying a second layer which overcoats the first layer, the second layer being comprises of a tungsten-carbon alloy or a material formed of a tungsten matrix having dispersed tungsten-carbon compound phases therein. In another embodiment erosion resistance is imparted by employing a coating which comprises a first ductile layer on the substrate of palladium, platinum or nickel; a second layer comprising substantially pure tungsten; and a third layer comprising a material formed of a tungsten-carbon alloy or a material formed of a tungsten matrix having dispersed tungsten-carbon compound phases.

Abstract: Erosion resistance is imparted to a metallic substrate without an attendant loss of fatigue life in the substrate in one embodiment by applying to the substrate a first ductile layer comprising a metal from Group VI to Group VIII elements as well as the noble metal group of elements, and a second hard erosion-resistant layer applied on the first layer comprising a boride, carbide, nitride or oxide of a metal selected from Group III to Group VI elements, the first layer capable of retaining substrate integrity and preventing diffusion of material from the second layer into the substrate. Another embodiment defines another layer of a substantially pure metal from Group III to Group VI between the first and second layers. Still another embodiment defines that in the second layer the content of either the carbide, nitride, boride or oxide is graded, i.e.

Abstract: Disclosed are novel nickel base single crystal alloy compositions consisting essentially of, by weight, about 8.0-14.0% chromium, 1.5-6.0% cobalt, 0.5-2.0% molybdenum, 3.0-10% tungsten, 2.5-7.0% titanium, 2.5-7.0% aluminum, 3.0-6.0% tantalum, about 0.005% to about 1.0% each of hafnium and/or silicon, optional minor amounts of yttrium, lanthanum and/or manganese, and the balance nickel.Methods of thermal treatment and coating of the novel alloys to enhance their mechanical properties are also disclosed, as are articles produced by such methods.

Abstract: Erosion resistance is imparted to a metallic substrate without an attendant loss of fatigue life in the substrate in one embodiment by applying to the substrate a first ductile layer comprising a metal from Group VI to Group VIII elements as well as the noble metal group of elements, and a second hard erosion-resistant layer applied on the first layer comprising a boride, carbide, nitride or oxide of a metal selected from Group III to Group VI elements, the first layer capable of retaining substrate integrity and preventing diffusion of material from the second layer into the substrate. Another embodiment defines another layer of a substantially pure metal from Group III to Group VI between the first and second layers. Still another embodiment defines that in the second layer the content of either the carbide, nitride, boride or oxide is graded, i.e.

Abstract: Erosion resistance is imparted to a metallic substrate without an attendant loss of fatigue life in the substrate by applying to the substrate a first layer comprising palladium, platinum or nickel in direct contact with the substrate and then applying a second layer which overcoats the first layer, the second layer being comprised of a tungsten-carbon alloy or a material formed of a tungsten matrix having dispersed tungsten-carbon compound phases therein. In another embodiment erosion resistance is imparted by employing a coating which comprises a first ductile layer on the substrate of palladium, platinum or nickel; a second layer comprising substantially pure tungsten; and a third layer comprising a material formed of a tungsten-carbon alloy or a material formed of a tungsten matrix having dispersed tungsten-carbon compound phases.

Abstract: Disclosed is a novel high temperature coating system comprised of two successively deposited layers of different respective materials which may be applied to turbine engine components to provide improved oxidation and corrosion resistance. The second applied layer is a composition having the general formula MCrAlY wherein M is a solid solution of molybdenum in nickel, cobalt or nickel plus cobalt. The first applied layer or interlayer, which is applied directly to the turbine engine component, is an aluminum coating.

Abstract: Disclosed are novel nickel-base single crystal alloy compositions consisting essentially of, by weight, about 8.0-14.0% chromium, 1.5-6.0% cobalt, 0.5-2.0% molybdenum, 3.0-10.0% tungsten, 2.5-7.0% titanium, 2.5-7.0% aluminum, 3.0-6.0% tantalum and the balance nickel.A combination of thermal treatment and coating of the novel alloys to enhance their mechanical properties is also disclosed.