Abstract: A chemical composition and method for repairing a thermal barrier coating on a component designed for use in a hostile thermal environment, such as turbine, combustor and augmentor components of a gas turbine engine. The method repairs a thermal barrier coating on a component that has suffered localized damage to the thermal barrier coating. After cleaning the surface area of the component exposed by the localized spallation, a mixture of a ceramic composition comprising a ceramic powder in a binder is applied, preferably by spraying, to the surface area of the component. The binder is then allowed to dry to form a dried coating. Upon subsequent heating, the dried coating reacts to produce a ceramic-containing repair coating, wherein the coating comprises the ceramic powder in a matrix of a material formed when the binder was reacted. The binder is preferably a ceramic precursor material that can be converted immediately to a ceramic or allowed to thermally decompose over time to form a ceramic.

Abstract: A method applies a heat-rejection coating directly on a substrate of a ceramic component. The steps include supplying a ceramic component, such as of a gas turbine engine, before applying a reflective-coating mixture onto the component, wherein the reflective-coating mixture comprises a metallic pigment and a reflective-coating-mixture carrier, and wherein the step of applying is accomplished by a method selected from the group consisting of air-assisted spraying, airless spraying, brushing, and decal transfer. The component having the reflective-coating mixture thereon is fired to form a reflective coating on the component.

Abstract: A heat-rejection coating is applied to a metallic component of a gas turbine engine, preferably made of a nickel-base superalloy. A component surface is preferably pre-treated, as by polishing the component surface, thereafter pre-oxidizing the component surface, and thereafter applying a ceramic barrier coating onto the component surface. A reflective-coating mixture is air sprayed onto the pre-treated component surface. The reflective-coating mixture includes a metallic pigment, such as platinum, gold, palladium, and alloys thereof, and a reflective-coating-mixture carrier. The component with the reflective-coating mixture sprayed thereon is fired.

Abstract: A differential thickness pattern can be induced in a coating that is sprayed on an aircraft engine part using a robotic system. The robotic system includes a spray mechanism with a triggering device to spray the coating on the aircraft engine part and a controller. The controller is used to move the spray mechanism along a predetermined path and to activate and deactivate the triggering device. To obtain the differential thickness pattern, a predetermined profile of the aircraft engine part corresponding to areas of the aircraft engine part requiring a thicker coating is integrated into a control program used by the controller. The controller uses the control program to activate and deactivate the triggering mechanism to limit the spraying of the coating to only those areas of the part in the predetermined profile to obtain a different coating thickness.

Abstract: A heat-rejection coating is applied to a metallic component of a gas turbine engine, preferably made of a nickel-base superalloy. A component surface is preferably pre-treated, as by polishing the component surface, thereafter pre-oxidizing the component surface, and thereafter applying a ceramic barrier coating onto the component surface. A reflective-coating mixture is air sprayed onto the pre-treated component surface. The reflective-coating mixture includes a metallic pigment, such as platinum, gold, palladium, and alloys thereof, and a reflective-coating-mixture carrier. The component with the reflective-coating mixture sprayed thereon is fired.

Abstract: A differential thickness pattern can be induced in a coating that is sprayed on an aircraft engine part using a robotic system. The robotic system includes a spray mechanism with a triggering device to spray the coating on the aircraft engine part and a controller. The controller is used to move the spray mechanism along a predetermined path and to activate and deactivate the triggering device. To obtain the differential thickness pattern, a predetermined profile of the aircraft engine part corresponding to areas of the aircraft engine part requiring a thicker coating is integrated into a control program used by the controller. The controller uses the control program to activate and deactivate the triggering mechanism to limit the spraying of the coating to only those areas of the part in the predetermined profile to obtain a different coating thickness.