Articles coated with a porous, segmented thermal barrier coating. The coating described has a density less than about 88% of the theoretical density. Multi-layer articles and methods of applying the thermal barrier coatings to an article are also described.

Articles coated with a porous, segmented thermal barrier coating. The coating described has a density less than about 88% of the theoretical density. Multi-layer articles and methods of applying the thermal barrier coatings to an article are also described.

A process comprising: (i) coating particles of silicon carbide, silicon nitride, boron carbide or boron nitride with a metal alloy or metal layer; (ii) agglomerating the particles of step (i); thermally spraying the agglomerated metal or metal alloy coated particles onto a substrate to provide a coating thereon.

A process comprising: (i) coating particles of silicon carbide, silicon nitride, boron carbide or boron nitride with a metal alloy or metal layer; (ii) agglomerating the particles of step (i); thermally spraying the agglomerated metal or metal alloy coated particles onto a substrate to provide a coating thereon.

Systems and methods are provided for braiding Metal Matrix Composite (MMC) tape. One method includes drawing multiple lanes of MMC tape, comprising a matrix of metal reinforced by fibers, from bobbins arranged around a mandrel. The method also includes braiding the multiple lanes to form a preform at the mandrel for an MMC part and consolidating the preform via application of heat and pressure.

Systems and methods are provided for braiding Metal Matrix Composite (MMC) tape. One method includes drawing multiple lanes of MMC tape, comprising a matrix of metal reinforced by fibers, from bobbins arranged around a mandrel. The method also includes braiding the multiple lanes to form a preform at the mandrel for an MMC part and consolidating the preform via application of heat and pressure.

A system and method are provided to create porous surface coatings. In use, a material layer includes synthesized carbon-containing composite materials, wherein the synthesized carbon-containing composite materials comprise a porosity characteristic, and at least one of: heat transfer characteristics, resistance to corrosion characteristics, or non-ablative erosion characteristics. Additionally, a bonding layer comprising at least some of the synthesized carbon-containing composite materials is bonded by at least one of, a carbon-to-carbon bond, or a metal-to-carbon bond to a substrate. Further, a surface interfacial layer comprising at least some of the synthesized carbon-containing composite materials is hydraulically smooth.

A system and method are provided to create porous surface coatings. In use, a material layer includes synthesized carbon-containing composite materials, wherein the synthesized carbon-containing composite materials comprise a porosity characteristic, and at least one of: heat transfer characteristics, resistance to corrosion characteristics, or non-ablative erosion characteristics. Additionally, a bonding layer comprising at least some of the synthesized carbon-containing composite materials is bonded by at least one of, a carbon-to-carbon bond, or a metal-to-carbon bond to a substrate. Further, a surface interfacial layer comprising at least some of the synthesized carbon-containing composite materials is hydraulically smooth.

A coated component of a gas turbine engine includes a substrate defining a surface, a thermal barrier coating deposited on the surface of the substrate, a region of the component where the thermal barrier coating has spalled from the substrate, a layer of environmental contaminant compositions formed on one or more of the thermal barrier coating or the region of the component where the thermal barrier coating has spalled from the substrate in response to an initial exposure of the component to high operating temperatures of the gas turbine engine, and a thermal barrier coating (TBC) restoration coating deposited at least on the region of the component where there thermal barrier coating has spalled from the substrate.

A coated component of a gas turbine engine includes a substrate defining a surface, a thermal barrier coating deposited on the surface of the substrate, a region of the component where the thermal barrier coating has spalled from the substrate, a layer of environmental contaminant compositions formed on one or more of the thermal barrier coating or the region of the component where the thermal barrier coating has spalled from the substrate in response to an initial exposure of the component to high operating temperatures of the gas turbine engine, and a thermal barrier coating (TBC) restoration coating deposited at least on the region of the component where there thermal barrier coating has spalled from the substrate.