Abstract: Repair methods involving conductive heat resistance welding includes repairing a crack of a gas turbine engine component using a conductive heat resistance welding technique and a welding technique other than conductive heat resistance welding.

Abstract: A metallic coating for use in a high temperature application is created from a nickel base alloy containing from 5.0 to 10.5 wt % aluminum, from 4.0 to 15 wt % chromium, from 2.0 to 8.0 wt % tungsten, from 3.0 to 10 wt % tantalum, and the balance nickel. The metallic coating has particular utility in protecting single crystal superalloys used in high temperature applications such as turbine engine components.

Abstract: Repair methods involving conductive heat resistance welding includes repairing a crack of a gas turbine engine component using a conductive heat resistance welding technique and a welding technique other than conductive heat resistance welding.

Abstract: A refractory metal core for use in a casting system has a coating for providing oxidation resistance during shell fire and protection against reaction/dissolution during casting. In a first embodiment, the coating includes at least one oxide and a silicon containing material. In a second embodiment, the coating includes an oxide selected from the group of calcia, magnesia, alumina, zirconia, chromia, yttria, silica, hafnia, and mixtures thereof. In a third embodiment, the coating includes a nitride selected from the group of silicon nitride, sialon, titanium nitride, and mixtures thereof. Other coating embodiments are described in the disclosure.

Abstract: A refractory metal core for use in a casting system has a coating for providing oxidation resistance during shell fire and protection against reaction/dissolution during casting. In a first embodiment, the coating includes at least one oxide and a silicon containing material. In a second embodiment, the coating includes an oxide selected from the group of calcia, magnesia, alumina, zirconia, chromia, yttria, silica, hafnia, and mixtures thereof. In a third embodiment, the coating includes a nitride selected from the group of silicon nitride, sialon, titanium nitride, and mixtures thereof. Other coating embodiments are described in the disclosure.

Abstract: The present invention relates to an overlay coating which has improved strength properties. The overlay coating comprises a deposited layer of MCrAlY material containing discrete nitride particles therein. The nitride particles are present in a volume fraction in the range of 0.1% to 15.0% and have a particle size in the range of from 0.1 microns to 10.0 microns. The coating may also have oxide particles dispersed therein.

Abstract: A method and apparatus are provided for inspecting a coated substrate such as a multi-layer coating on a substrate of a turbine airfoil. At each of a number of locations along the airfoil a number of frequencies of alternating current are passed through the airfoil. At least one impedance parameter is measured. The measured impedance parameters are utilized to determine a condition of the coating.

Abstract: The present invention relates to an overlay coating which has improved strength properties. The overlay coating comprises a deposited layer of MCrAlY material containing discrete nitride particles therein. The nitride particles are present in a volume fraction in the range of 0.1% to 15.0% and have a particle size in the range of from 0.1 microns to 10.0 microns. The coating may also have oxide particles dispersed therein.

Abstract: The present invention relates to an overlay coating which has improved strength properties. The overlay coating comprises a deposited layer of MCrAlY material containing discrete nitride particles therein. The nitride particles are present in a volume fraction in the range of 0.1% to 15.0% and have a particle size in the range of from 0.1 microns to 10.0 microns. The coating may also have oxide particles dispersed therein.

Abstract: A method and apparatus are provided for inspecting a coated substrate such as a multi-layer coating on a substrate of a turbine airfoil. At each of a number of locations along the airfoil a number of frequencies of alternating current are passed through the airfoil. At least one impedance parameter is measured. The measured impedance parameters are utilized to determine a condition of the coating.

Abstract: A method of surface cleaning and controlled oxidation of superalloys is described. The method provides a thin homogeneous layer of relatively pure alpha alumina which is suited to receive and adhere to a subsequent vapor deposited coating.

Abstract: The present invention relates to a method for repairing turbine engine components, such as vanes and blades, which have airfoils. The method broadly comprises removing oxidation debris from portions of the component by blending areas exhibiting thermal barrier coating spall and/or oxidation damage, removing a ceramic insulating layer from the component, and blending surfaces of the component where nicks, dents, and/or cracks are located. If the component has a depleted aluminum zone, the depleted zone is either removed or replenished. Further, a tip portion of the component, if damaged, is restored and tip abrasives are applied to restore the component's cutting ability. Thereafter, a ceramic coating is applied to the component.

Abstract: The present invention relates to an overlay coating which has improved strength properties. The overlay coating comprises a deposited layer of MCrAlY material containing discrete nitride particles therein. The nitride particles are present in a volume fraction in the range of 0.1% to 15.0% and have a particle size in the range of from 0.1 microns to 10.0 microns. The coating may also have oxide particles dispersed therein.

Abstract: The present invention relates to a method for repairing turbine engine components, such as vanes and blades, which have airfoils. The method broadly comprises removing oxidation debris from portions of the component by blending areas exhibiting thermal barrier coating spall and/or oxidation damage, removing a ceramic insulating layer from the component, and blending surfaces of the component where nicks, dents, and/or cracks are located. If the component has a depleted aluminum zone, the depleted zone is either removed or replenished. Further, a tip portion of the component, if damaged, is restored and tip abrasives are applied to restore the component's cutting ability. Thereafter, a ceramic coating is applied to the component.

Abstract: The present invention relates to high temperature composite materials formed from nano-sized powders suitable for use in the manufacture of jet engine components. The composite materials consist essentially of a matrix formed from a powdered material having a particle size in the range of from about 1 to about 100 nanometers and a plurality of reinforcing fibers embedded within the matrix and comprising from about 20% to about 40% by volume of the composite material. The method of manufacturing the composite materials broadly comprises the steps of mixing the powdered material with the reinforcing fibers and consolidating the mixture to form the composite material.

Abstract: A process is disclosed for forming an improved aluminide coating which includes one or more oxygen active elements. A metallic substrate is coated with an overlay coating, such as an MCrAl coating, including one or more oxygen active elements such as yttrium, hafnium and silicon, by a conventional overlay process such as low pressure plasma spray. A metal, preferably a Series VIII transition metal such as platinum, is applied to the substrate, for example by electroplating. The substrate is then aluminized, for example by chemical vapor deposition, and is preferably heat treated. A ceramic thermal barrier may also be applied. The present invention provides an active element containing aluminide coating having a more consistent composition and having improved durability, either as a standalone coating or as a bond coat for a subsequently-applied thermal barrier coating.

Abstract: A thermal barrier coating system for a superalloy substrate is disclosed. The superalloy is preferably of the type that is capable of forming an adherent alumina layer. A bond coat is applied to a local area of the substrate, so that a portion of the substrate remains exposed. The localized area is defined to be the area(s) at which a TBC typically fails first, e.g., the leading and trailing edges of an airfoil, or other area. An alumina layer is formed on the remaining portion of the substrate, and also on the bond coat. A ceramic layer is then applied on the alumina layer. Even if the ceramic material is removed, the localized bond coat remains, and reduces the rate at which the underlying substrate oxidizes. A coated article is also disclosed, as is a system that utilizes a conventional superalloy and aluminide coating with the localized bond coat.

Abstract: A thermal barrier coating system for a superalloy substrate is disclosed. The superalloy is preferably of the type that is capable of forming an adherent alumina layer. A bond coat is applied to a local area of the substrate, so that a portion of the substrate remains exposed. The localized area is defined to be the area(s) at which a TBC typically fails first, e.g., the leading and trailing edges of an airfoil, or other area. An alumina layer is formed on the remaining portion of the substrate, and also on the bond coat. A ceramic layer is then applied on the alumina layer. Even if the ceramic material is removed, the localized bond coat remains, and reduces the rate at which the underlying substrate oxidizes. A coated article is also disclosed, as is a system that utilizes a conventional superalloy and aluminide coating with the localized bond coat.

Abstract: A thermal barrier coating system for a superalloy substrate is disclosed. The superalloy is preferably of the type that is capable of forming an adherent alumina layer. A bond coat is applied to a local area of the substrate, so that a portion of the substrate remains exposed. The localized area is defined to be the area(s) at which a TBC typically fails first, e.g., the leading and trailing edges of an airfoil, or other area. An alumina layer is formed on the remaining portion of the substrate, and also on the bond coat. A ceramic layer is then applied on the alumina layer. Even if the ceramic material is removed, the localized bond coat remains, and reduces the rate at which the underlying substrate oxidizes. A coated article is also disclosed, as is a system that utilizes a conventional superalloy and aluminide coating with the localized bond coat.

Abstract: A thermal barrier coating system for a superalloy substrate is disclosed. The superalloy is preferably of the type that is capable of forming an adherent alumina layer. A bond coat is applied to a local area of the substrate, so that a portion of the substrate remains exposed. The localized area is defined to be the area(s) at which a TBC typically fails first, e.g., the leading and trailing edges of an airfoil, or other area. An alumina layer is formed on the remaining portion of the substrate, and also on the bond coat. A ceramic layer is then applied on the alumina layer. Even if the ceramic material is removed, the localized bond coat remains, and reduces the rate at which the underlying substrate oxidizes. A coated article is also disclosed, as is a system that utilizes a conventional superalloy and aluminide coating with the localized bond coat.