A gas turbine engine includes an engine static structure extending circumferentially about an engine centerline axis; a compressor section, a combustor section, and a turbine section within the engine static structure. At least one of the compressor section and the turbine section includes at least one airfoil and at least one seal member adjacent to the at least one airfoil. A tip of the at least one airfoil is metal having a wear resistant coating and the at least one seal member is coated with an abradable coating. The wear resistant coating is formed as a layer in a base metal surface of the airfoil, has a thickness less than or equal to 10 mils (254 micrometers) and includes metal boride compounds.

A method can include coating a first surface of an additively manufactured article made of a base material with a coating material comprising at least two constituents, wherein a first constituent of the at least two constituents is configured to be at least partially transient liquid phase (TLP) diffused from the coating material into the base material at a first constituent diffusion temperature, and a second constituent of the at least two constituents is configured to not diffuse from the coating material at the first constituent diffusion temperature, heating the additively manufactured article to the first constituent diffusion temperature, TLP diffusing at least a portion of the first constituent from the coating and into the base material, leaving the second constituent of the coating material on the first surface, and forming a second surface that is smoother than the first surface.

A gas turbine engine includes an engine static structure extending circumferentially about an engine centerline axis; a compressor section, a combustor section, and a turbine section within the engine static structure. At least one of the compressor section and the turbine section includes at least one airfoil and at least one seal member adjacent to the at least one airfoil. A tip of the at least one airfoil is metal having a wear resistant coating and the at least one seal member is coated with an abradable coating. The wear resistant coating is formed as a layer in a base metal surface of the airfoil, has a thickness less than or equal to 10 mils (254 micrometers) and includes metal boride compounds.

A gas turbine engine includes an engine static structure extending circumferentially about an engine centerline axis; a compressor section, a combustor section, and a turbine section within the engine static structure. At least one of the compressor section and the turbine section includes at least one airfoil and at least one seal member adjacent to the at least one airfoil. A tip of the at least one airfoil is metal having a wear resistant coating and the at least one seal member is coated with an abradable coating. The wear resistant coating is formed as a layer in a base metal surface of the airfoil, has a thickness less than or equal to 10 mils (254 micrometers) and includes metal boride compounds.

A gas turbine engine includes: a turbine section including a casing extending circumferentially about a plurality of turbine blades and having at least one seal member coated with an abradable coating. At least one turbine blade has sides and a tip and at least one seal member is located adjacent to the tip of the at least one turbine blade. The tip of the at least one turbine blade has a wear resistant layer and an abrasive coating disposed on the wear resistant layer. The wear resistant layer has a thickness less than or equal to 10 mils (254 micrometers) and includes metal boride compounds.

A gas turbine engine includes: a turbine section including a casing extending circumferentially about a plurality of turbine blades and having at least one seal member coated with an abradable coating. At least one turbine blade has sides and a tip and at least one seal member is located adjacent to the tip of the at least one turbine blade. The tip of the at least one turbine blade has a wear resistant layer and an abrasive coating disposed on the wear resistant layer. The wear resistant layer has a thickness less than or equal to 10 mils (254 micrometers) and includes metal boride compounds.

The present disclosure provides a thermal spray alloy system that is more resistant to wear and/or corrosion than conventional alloy compositions. The disclosed alloys minimize or eliminate micro-cracks within the formed coating on the tool. The alloy comprises carbon, boron, and a fluxing agent selected from the group of aluminum, magnesium, or lithium. The alloy may also comprise titanium, silicon, manganese, molybdenum, nickel, and chromium, as well as other elements. The object to be coated may be any downhole component used in the oil and gas industry, or may be applied to any object or tool that needs an increased wear and/or corrosive protection layer including in diverse fields such as marine, chemical processing, and refining. A thermal spray coating with the disclosed alloy composition provides increased strength and resistance to spalling, breaking, cracking, deforming, and crack formation, as well as metallurgical bonding between the coating and the substrate.

A part includes a three-dimensional porous metallic workpiece printed via an additive manufacturing process and subsequently subjected to a diffusion-based process to convert at least a portion of the porous metallic workpiece to a ceramic workpiece or an intermetallic workpiece.

A part includes a three-dimensional porous metallic workpiece printed via an additive manufacturing process and subsequently subjected to a diffusion-based process to convert at least a portion of the porous metallic workpiece to a ceramic workpiece or an intermetallic workpiece.

A part includes a three-dimensional porous metallic workpiece printed via an additive manufacturing process and subsequently subjected to a diffusion-based process to convert at least a portion of the porous metallic workpiece to a ceramic workpiece or an intermetallic workpiece.