Abstract: A method of fabricating a component for a gas turbine engine is provided. The method includes applying a bond coat to at least a portion of the component, applying a dense vertically cracked (DVC) thermal barrier coating to at least a portion of the bond coat using a spray mechanism positioned a first distance from the component, and overlying at least a portion of the DVC thermal barrier coating with a soft coat thermal barrier coating using a spray mechanism that is positioned a second distance away from the component, wherein the second distance is greater than the first distance to facilitate adherence of the soft coating thermal barrier coating to the DVC thermal barrier coating.

Abstract: A method of fabricating a component for a gas turbine engine is provided. The method includes applying a bond coat to at least a portion of the component, applying a dense vertically cracked (DVC) thermal barrier coating to at least a portion of the bond coat using a spray mechanism positioned a first distance from the component, and overlying at least a portion of the DVC thermal barrier coating with a soft coat thermal barrier coating using a spray mechanism that is positioned a second distance away from the component, wherein the second distance is greater than the first distance to facilitate adherence of the soft coating thermal barrier coating to the DVC thermal barrier coating.

Abstract: A method of repairing a thermal barrier coating (16) on a component (10) designed for use in a hostile thermal environment, such as turbine, combustor and augmentor components of a gas turbine engine. The method more particularly involves repairing a thermal barrier coating (16) on a component (10) that has suffered localized spallation (20) of the thermal barrier coating (16). After cleaning the surface area (22) of the component (10) exposed by the localized spallation (20), a ceramic paste (24) comprising a ceramic powder in a binder is applied to the surface area (22) of the component (10). The binder is then reacted to yield a ceramic-containing repair coating (26) that covers the surface area of the component and comprises the ceramic powder in a matrix of a material formed when the binder was reacted.

Abstract: A method of repairing a thermal barrier coating (16) on a component (10) designed for use in a hostile thermal environment, such as turbine, combustor and augmentor components of a gas turbine engine. The method more particularly involves repairing a thermal barrier coating (16) on a component (10) that has suffered localized spallation (20) of the thermal barrier coating (16). After cleaning the surface area (22) of the component (10) exposed by the localized spallation (20), a ceramic paste (24) comprising a ceramic powder in a binder is applied to the surface area (22) of the component (10). The binder is then reacted to yield a ceramic-containing repair coating (26) that covers the surface area of the component and comprises the ceramic powder in a matrix of a material formed when the binder was reacted.

Abstract: A protective coating and coating method for protecting a thermal barrier coating (TBC) on a component, such as a component of a gas turbine engine. The protective coating comprises alumina particles in a silica-containing matrix, and may be substantially homogeneous or formed of multiple layers having different compositions. The composition and relative amounts of alumina and matrix material in the protective coating enable the coating to react with molten compounds containing calcia, magnesia, alumina and/or silica (CMAS), forming a compound with a melting temperature that is significantly higher than CMAS. As such, infiltration of molten CMAS into the TBC is significantly reduced or entirely avoided.

Abstract: A tightly adherent anti-stick coating applied over coated turbine components of gas turbine engines. The tightly adherent coating is an oxide of at least one metal selected from the group consisting of Pt, W, group 4b and group 5b metals of the periodic table and Si, Ge and Sn of group 4a. The oxide is applied directly over existing environmental coatings, and thermal barrier coatings. It can also be applied directly to substrate material and to areas that are not within the combustion exhaust gases, such as platform portions and shank portions of airfoils including turbine blades. The oxide is conveniently applied to a uniform thickness of no greater than about 10 microns, and prevents the build-up of corrosion products and other products of combustion from the gases, thereby increasing the life expectancy of the component.

Abstract: A method of 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 more particularly involves repairing a thermal barrier coating on a component that has suffered localized spallation of the thermal barrier coating. After cleaning the surface area of the component exposed by the localized spallation, a ceramic paste comprising a ceramic powder in a binder is applied to the surface area of the component. The binder is then reacted to yield a ceramic-containing repair coating that covers the surface area of the component and 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, such that the repair coating has a ceramic matrix.

Abstract: A tightly adherent anti-stick coating applied over coated turbine components of gas turbine engines. The tightly adherent coating is an oxide of at least one metal selected from the group consisting of Pt, W, group 4b and group 5b metals of the periodic table and Si, Ge and Sn of group 4a. The oxide is applied directly over existing environmental coatings, and thermal barrier coatings. It can also be applied directly to substrate material and to areas that are not within the combustion exhaust gases, such as platform portions and shank portions of airfoils including turbine blades. The oxide is conveniently applied to a uniform thickness of no greater than about 10 microns, and prevents the build-up of corrosion products and other products of combustion from the gases, thereby increasing the life expectancy of the component.

Abstract: A coated article suitable for use at elevated temperature is formed of a substrate made from metal or a ceramic, a diffuse reflective barrier coating overlying the substrate, and a low-emissivity top coat covering the diffuse reflective barrier coating. The diffuse reflective barrier coating includes a transmissive medium having a transmissive-medium index of refraction, and a plurality of radiation-scattering centers distributed in the transmissive medium, the radiation-scattering centers having a scattering-center index of refraction different from the transmissive-medium index of refraction. The radiation scattering centers may be voids or second ceramic particles. The diffuse reflective barrier coating has a surface roughness of less than about 150 microinches RMS.

Abstract: A coated article comprises a substrate, an inner environmental resistant coating portion including Al on the substrate, and an outer heat energy reflecting and oxygen diffusion inhibiting coating portion outward of the inner portion. The outer coating portion is multi-layer, comprising 6-48 discrete stacked layers and a total outer coating portion thickness in the range of about 2.5-25 microns.

Abstract: A component for use in a high-temperature environment such as the coating chamber of a PVD apparatus. A reflective coating on the component serves as a barrier to radiant heat transfer to the component by reflecting thermal radiation. The coating comprises at least one pair of reflective layers, each layer being formed of a material that is essentially transparent to electromagnetic wavelengths of between 500 and 3000 nanometers (nm). In addition, the material of the outermost layer of the pair has a higher index of refraction than the material of the other layer of the pair.

Abstract: A heating apparatus and method for welding a superalloy article. In a preferred embodiment, the apparatus and method entail welding a superalloy article within an enclosure equipped with a thermal radiation-generating device that preheats the article to a temperature of at least 1500.degree. F. prior to welding. The invention more particularly provides a thermally-reflective coating on a reflector member positioned adjacent the thermal radiation-generating device for the purpose of reflecting thermal radiation emitted by the device into the enclosure. The device is then operated to heat the superalloy article to a suitable temperature, e.g., 1500.degree. F. or more, after which a welding operation is performed on the superalloy article.

Abstract: A superalloy component having a substrate article of a superalloy, and a strengthenable coating covering at least a portion of the substrate article. The coating exhibits thermal barrier characteristics and when cured formed a ceramic material. The component may further include a fiber layer between the substrate article and the coating, and the coating may be reinforced with fiber and the ceramic may be imbedded with inorganic particles. The coating is a foam obtained by reacting an admixture of (a) a silane polymer, (b) a silicone-vinyl resin and (c) a catalyst. The article is preferably a turbine blade. The component is useful as a gas turbine element.

Abstract: A metal or ceramic matrix composite part and corresponding method are provided exhibiting desired heat transfer characteristics. The part has a metal or ceramic matrix composite substrate and a multilayer dielectric coating. The coating has high reflectivity at wave lengths corresponding to radiation wavelengths of various combustion gases and has low reflectance at radiation wavelengths corresponding to the substrate. The multilayer coating allows the heat generated external of the part at wavelengths corresponding to combustion gases to be reflected from the part while permitting radiation wavelengths associated with the substrate to pass through the coating. The parts are useful for use in combustive gas atmospheres.

Abstract: A superalloy component having a substrate article of a superalloy, and a strengthenable coating covering at least a portion of the substrate article. The coating exhibits thermal barrier characteristics and when cured formed a ceramic material. The component may further include a fiber layer between the substrate article and the coating, and the coating may be reinforced with fiber and the ceramic may be imbedded with inorganic particles. The coating is a foam obtained by reacting an admixture of (a) a silane polymer, (b) a silicone-vinyl resin and (c) a catalyst. The article is preferably a turbine blade. The component is useful as a gas turbine element.

Abstract: A method is disclosed to deposit aluminum and a metal oxide on substrates for improved corrosion, oxidation, and erosion protection. Low temperature chemical vapor deposition is used. A homogeneous biphase coating may be deposited, as well as layers of aluminum and metal oxides.

Abstract: The invention relates to a type of proximity sensor. In one form, two sinusoidal signals travel along two transmission lines near an object. When the distance between one or both of the lines and the object changes, the speed of travel of one or both of the signals changes. There is a correlation between the speed change and the distance, thus allowing one to infer distance from speed change. One way to measure the speed change is to measure the phase relationship between the two signals. The invention can be used to measure clearances between turbine blades and turbine shrouds in gas turbine aircraft engines. Based on the measured clearance, other apparatus can direct hot or cold air upon the shroud to expand or shrink the shroud, thereby changing the clearance.

Abstract: Method for repelling sharks and the like by creating an electric field containing a zone about an anode and/or cathode electrodes submersed in salt water. A voltage gradient of sufficient magnitude to overstimulate the nervous system of a shark has been found. The applied voltage is insufficient to disturb most scaled fish and man. The electric field is determined by considering the free space solutions of Maxwell's electro-magnetic field equations. The d.c. square wave potential is applied to the electrodes for that period of time wherein electron flow from cathode to anode is continued. The square wave potential is maintained only long enough to allow nervecell response in a shark. It is turned on with a frequency near a shark's nervous system's normal frequency.

Abstract: Apparatus and method for reacting coal with hydrogen to provide hydrocarbon products. In a container having an anode and a cathode spaced therefrom, an electric potential about 200 to 1000 volts more positive than the potential at the cathode is applied to the anode to provide an electric arc at a current density of about 0.01 to 100 amperes per square centimeter in a reaction zone between them comprising hydrogen at a pressure of about 10 to 500 millimeters of mercury, and thus to maintain a plasma therein. A magnetic field of about 100 to 1000 gauss is provided approximately perpendicular to the arc. Hydrogen is directed into contact with the anode (as through passages therein) and from there into the reaction zone to ionize a substantial portion of the hydrogen positively, while coal is directed either in a slurry or as a fine powder, into contact with the cathode (as through passages therein) and from there into the reaction zone to charge a substantial portion of the coal with a negative potential.