A method includes applying a material coating on a surface of a machine component using a thermal spray, wherein the material coating is formed from a combination of a hardfacing material and aluminum-containing particles. The method also includes thermally treating the material coating to generate an oxide layer comprising aluminum from the aluminum-containing particles, wherein the oxide layer is configured to reduce oxidation of the hardfacing material.

A method includes applying a material coating on a surface of a machine component using a thermal spray, wherein the material coating is formed from a combination of a hardfacing material and aluminum-containing particles. The method also includes thermally treating the material coating to generate an oxide layer comprising aluminum from the aluminum-containing particles, wherein the oxide layer is configured to reduce oxidation of the hardfacing material.

The present invention provides a thermal barrier coated component, monitoring or evaluation of the soundness of which is able to be adequately carried out on the basis of the thermal boundary conditions that are detected by a sensor. A thermal barrier coated component according to the present invention comprises: a base material; a first bond coat layer that is a metal bonding layer formed on the base material; a sensor unit that comprises a sensor and a conductive wire, which are formed on the first bond coat layer; a second bond coat layer that is formed on the first bond coat layer so as to cover at least the sensor unit, while having a surface roughness higher than that of the first bond coat layer; and a top coat layer that is formed on the second bond coat layer.

The present invention provides a thermal barrier coated component, monitoring or evaluation of the soundness of which is able to be adequately carried out on the basis of the thermal boundary conditions that are detected by a sensor. A thermal barrier coated component according to the present invention comprises: a base material; a first bond coat layer that is a metal bonding layer formed on the base material; a sensor unit that comprises a sensor and a conductive wire, which are formed on the first bond coat layer; a second bond coat layer that is formed on the first bond coat layer so as to cover at least the sensor unit, while having a surface roughness higher than that of the first bond coat layer; and a top coat layer that is formed on the second bond coat layer.

Turbine and compressor casing abradable components for turbine engines include abradable surfaces with a zonal system of forward (zone A) and rear or aft sections (zone B) surface features. The zone A surface profile comprises an array pattern of non-directional depression dimples, or upwardly projecting dimples, or both, in the abradable surface. The dimpled forward zone A surface features reduce surface solidity in a controlled manner, to help increase abradability during blade tip rubbing incidents, yet they provide sufficient material to resist incoming hot working fluid erosion of the abradable surface. In addition, the dimples provide generic forward section aerodynamic profiling to the abradable surface, compatible with different blade airfoil-camber profiles. The aft zone B surface features comprise an array pattern of ridges and grooves.

Alloy composition for the manufacture of protective coatings, comprising cobalt, nickel, chromium, aluminum, yttrium and iridium in amounts so as to obtain the phases α, β and σ, in particular for coating a super-alloy article. Preferably, such super-alloy article is a turbine component.

Alloy composition for the manufacture of protective coatings, comprising cobalt, nickel, chromium, aluminum, yttrium and iridium in amounts so as to obtain the phases α, β and σ, in particular for coating a super-alloy article. Preferably, such super-alloy article is a turbine component.

Yttria stabilized zirconia (YSZ) particles (40) form a thermal barrier layer (58) on a metal substrate (24). The YSZ particles have a porous interior (52, 54) and a fully melted and solidified outer shell (50). The thermal barrier layer may have porosity greater than 12%, including porosity within the particles and inter-particle gap porosity. Inter-particle gaps may be greater than 5 microns. The thermal barrier layer may exhibit elastic hysteresis and an average modulus of elasticity of 15-25 GPa. A bond coat (44A, 44B) may be applied between the substrate and the thermal barrier layer. The bond coat may have a first dense MCrAlY layer (44A) on the substrate and a second rough, porous MCrAlY layer (44B) on the first MCrAlY layer, the bond layers diffusion bonded to each other and to the substrate.

Yttria stabilized zirconia (YSZ) particles (40) form a thermal barrier layer (58) on a metal substrate (24). The YSZ particles have a porous interior (52, 54) and a fully melted and solidified outer shell (50). The thermal barrier layer may have porosity greater than 12%, including porosity within the particles and inter-particle gap porosity. Inter-particle gaps may be greater than 5 microns. The thermal barrier layer may exhibit elastic hysteresis and an average modulus of elasticity of 15-25 GPa. A bond coat (44A, 44B) may be applied between the substrate and the thermal barrier layer. The bond coat may have a first dense MCrAlY layer (44A) on the substrate and a second rough, porous MCrAlY layer (44B) on the first MCrAlY layer, the bond layers diffusion bonded to each other and to the substrate.

The metal ceramic powder with a particle size of 15-45 .Math.m and suitable for thermal spraying is prepared through a combination of mechanical ball milling, spray granulation, and vacuum sintering. The metal ceramic powder is sprayed on a surface of a steel substrate adopting the high velocity oxygen fuel (HVOF) technology with oxygen-propane as fuel and taking oxygen as a combustion improver, propane as fuel, nitrogen as powder feeding carrier gas, and air as a cooling medium to prepare and form the NiCrBSi—ZrB2 composite coating. The present disclosure solves the problem that ZrB.sub.2 ceramic is difficult to compact during sintering and improves powder bonding strength and fluidity. The preparation method is simple, has advantages of high coating deposition efficiency and convenient equipment operation, and is cost-effective. The preparation method can improve thermal corrosion resistance and high-temperature wear resistance of a surface of boiler, and prolonging lifetime of the boiler.