A process (20) for applying a thermal barrier coating (51) to a turbine component (50) including the step (34) of depsoiting a bond coating layer (56) by a cold spray process. The layer of bond coating material may have different depths (80, 82) in different areas of the component (50), and it may have different compositions (60, 62) across its depth. The precise control afforded by the cold spray material deposition step allows the surface of the bond coating material layer to be formed with a predetermined surface roughness or with a plurality of micro-ridges (86) in order to optimize its bond to the ovelying ceramic insulating layer (52).

Thermal barrier coating applied with cold spray technique

Disclosed herein are methods of treating an article surface. The method comprises removing a metal oxide surface from the metal substrate to expose a metal surface; and delivering particles comprising a dopant from at least one fluid jet to the metal surface to impregnate the surface of the article with the dopant. The method also comprises delivering substantially simultaneously a first set of particles comprising a dopant and a second set of particles comprising an abrasive from at least one fluid jet to a surface of an article to impregnate the surface of the article with the dopant.

Method of doping surfaces

A process ( 30 ) for the repair of a component part ( 36,66 ) incorporating a cold spray process step ( 50 ) for depositing material particles ( 54 ) to fill a discontinuity ( 40 ) in the part surface ( 42 ) or to create a desired surface geometry ( 78 ) on the part ( 66 ). The cold spray process may be controlled to provide a grit blasting effect prior to depositing the material in order to remove contaminants ( 48 ) from the surface of the part. The material deposited ( 56 ) by the cold spray process may form a joint ( 78 ) between an insert ( 72 ) and the part ( 66 ). The process may be used to repair parts made of directionally solidified (DS) or single crystal (SC) base material ( 44 ) without causing a re-crystallization of the base material. The process may further be used to deposit repair material ( 56 ) over a braze material ( 22 ).

Cold spray repair process

An abrasive coating and a process for forming the abrasive coating by co-depositing hard particles within a matrix material onto a substrate using a cold spray process. The cold sprayed combination of hard particles and matrix material provides a coating that is wear, erosion and oxidation resistant. The abrasive coating may have different compositions across its depth. The hard particles may be deposited at different densities across the thickness of the matrix material. A first layer of the abrasive coating proximate the surface of the substrate may be devoid of hard particles.

Mixed powder deposition of components for wear, erosion and abrasion resistant applications

A cold spray process (20) for applying an abradable coating (16) to a substrate material (12). A bond coat layer (14) and/or an abradable coating material layer (16) are applied to a substrate (12) by directing particles of the material toward the substrate surface at a velocity sufficiently high to cause the particles to deform and to adhere to the surface. Particles of the bond coat material may first be directed toward the substrate surface at a velocity sufficiently high to clean the surface (24) but not sufficiently high to cause the particles to deform and to adhere to the surface.

Abradable coating applied with cold spray technique

A method for coating a substrate with rapidly solidified metal which comprises spraying a mixture of rapidly solidified metal powder and small peening particles at high velocity against the substrate, said velocity being sufficient for the rapidly solidified metal powder and peening particles to impact the substrate and simultaneously bond the metal powder to the substrate. If the substrate is metallic, the method may provide the simultaneous mechanical working of the substrate surface.

Huai-Pu Chu

Papers

Method of coating a substrate with a rapidly solidified metal