General Electric Company

Deborah Anne Schorr

Ramgopal Darolia

Bangalore Aswatha Nagaraj

Irene T Spitsberg

Joseph David Rigney

William Scott Walston

Craig Douglas Young

Jeffrey Allan Pfaendtner

Raymond William Heidorn

Thomas John Tomlinson

David Allen Kastrup

Eva Zielonka Lanman

A method applying a thermal barrier coating to a metal substrate, or for repairing a thermal barrier coating previously applied by physical vapor deposition to an underlying aluminide diffusion coating that overlays the metal substrate. The aluminide diffusion coating is treated to make it more receptive to adherence of a plasma spray-applied overlay alloy bond coat layer. An overlay alloy bond coat material is then plasma sprayed on the treated aluminide diffusion coating to form an overlay alloy bond coat layer. A ceramic thermal barrier coating material is plasma sprayed on the overlay alloy bond coat layer to form the thermal barrier coating. In the repair embodiment of this method, the physical vapor deposition-applied thermal barrier coating is initially removed from the underlying aluminide diffusion coating.

Method for applying or repairing thermal barrier coatings

An article and TBC coating system thereon that in combination exhibit significantly improved spallation resistance. The article comprises a substrate formed of a metal alloy containing ruthenium and one or more refractory elements (e.g., tantalum, tungsten, molybdenum, rhenium, hafnium, etc.). The substrate is protected by a coating system comprising an aluminum-containing bond coat on the surface of the substrate and a ceramic coating bonded to the substrate by the bond coat. The bond coat, preferably an aluminide, is deposited so as to be substantially free of ruthenium, though ruthenium is present in the bond coat as a result of diffusion from the substrate into the bond coat.

Ni-base superalloy having a thermal barrier coating system

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Cincinnati, OH, United States of America

Deborah Anne Schorr