Abstract: An article having a thermal-spray coating thereon is prepared by thermally spraying a coating material onto a surface of a substrate article. The coated article is nondestructively tested by directing a transmitted ultrasonic signal into the coated article, receiving a received ultrasonic signal from the coated article, and evaluating a near-bondline region of the coated article located adjacent to the surface of the article using the received ultrasonic signal.

Abstract: An article having a thermal-spray coating thereon is prepared by thermally spraying a coating material onto a surface of a substrate article. The coated article is nondestructively tested by directing a transmitted ultrasonic signal into the coated article, receiving a received ultrasonic signal from the coated article, and evaluating a near-bondline region of the coated article located adjacent to the surface of the article using the received ultrasonic signal.

Abstract: A method for coating an article such as a turbine engine shroud with an environmental or bond coating, such as a MCrAlY composition, to produce a surface finish suitable for machining to predetermined dimensions and specifications. The method of applying an environmental or bond coating uses a thermal spray process such as hyper velocity oxygen fuel (“HVOF”) to produce a thick and reasonably uniform coating which can be machined to desired dimensions while still providing key quality characteristics required to protect the coated parts in a high temperature, oxidative and corrosive atmosphere and permitting application of long life thermal barrier topcoats.

Abstract: A method for coating an article such as a turbine engine shroud with an environmental or bond coating, such as a MCrAlY composition, to produce a surface finish suitable for machining to predetermined dimensions and specifications. The method of applying an environmental or bond coating uses a thermal spray process such as hyper velocity oxygen fuel (“HVOF”) to produce a thick and reasonably uniform coating which can be machined to desired dimensions while still providing key quality characteristics required to protect the coated parts in a high temperature, oxidative and corrosive atmosphere and permitting application of long life thermal barrier topcoats.

Abstract: An article comprising a substrate and an outer metallic layer, such as a coating, is provided with augmented heat transfer from the substrate through the combination of a layer thickness of about 0.003″ to about 0.017″, a layer surface roughness of at least about 500 micro inches Ra, a layer tensile bond strength of at least about 5 ksi, and a heat transfer augmentation of at least about 1.1. A method of making the article uses an electric arc wire thermal spray process in which the atomizing gas pressure is maintained within the range of about 20-80 psi.

Abstract: An article comprising a substrate and an outer metallic layer, such as a coating, is provided with augmented heat transfer from the substrate through the combination of a layer thickness of about 0.003″ to about 0.017″, a layer surface roughness of at least about 500 micro inches Ra, a layer tensile bond strength of at least about 5 ksi, and a heat transfer augmentation of at least about 1.1. A method of making the article uses an electric arc wire thermal spray process in which the atomizing gas pressure is maintained within the range of about 20-80 psi.

Abstract: A method of applying thermal barrier coating systems to a metal piece having a cooling hole extending along a central axis through the piece from a first surface of the piece to a second surface of the piece opposite the first surface. The method includes spraying a bond coat on the first surface of the piece and spraying a thermal barrier coating on the bond coat. Further, the method includes spraying a high pressure fluid jet from a nozzle toward the hole and in a direction generally parallel to the central axis of the hole. The fluid jet is substantially free of solid particulate thereby permitting the jet to remove the bond coat and the thermal barrier coating from the hole without removing metal from the piece.

Abstract: A method for preparing a heat-treated article made of a superalloy, such as a turbine disk preform, includes furnishing an article made of a superalloy that is prone to quench cracking, usually after forging the article, and thereafter covering at least a portion of the article with a quench cladding having a thickness of at least about 1/8 inch so that the quench cladding is in direct thermal contact with the article. The quench cladding may be conveniently applied to the article by thermal spraying, which produces direct thermal contact between the quench cladding and the article, or by placing the article into the envelope of the quench cladding material and hot isostatically pressing to achieve a direct thermal contact between the envelope and the article. After the quench cladding is in place, the clad article is heated to elevated temperature and quenched from the elevated temperature to a lower temperature, and the envelope is removed.