An abrasive coating for a substrate including a metallic based bond coat layer; a top layer; and an intermediate layer between the metallic based bond coat layer and the top layer. A method of applying an abrasive coating including applying a metallic based bond coat layer onto a substrate; grading an intermediate layer into the metallic based bond coat layer to form a graded transition between the metallic based bond coat layer and the intermediate layer; and grading a top layer into the intermediate layer to form a graded transition between the intermediate layer and the top layer.

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.

Coated substrate comprising a substrate (1) comprising a metal substrate surface (11) coated with a coating system (7) consisting of or comprising a functional coating film (5), said functional coating film (5) consisting of or comprising at least one MCr Al—X coating layer, whereas ° the at least one MCr Al—X coating layer is deposited directly on the metal substrate (11), or ° the at least one MCr Al—X coating layer is deposited on an intermediate coating layer (3) that is formed of at least one substrate matching layer (31), wherein the at least one substrate matching layer (31) is deposited directly on the metal substrate surface (11), wherein the layer deposited directly on the metal substrate surface (11), it means respectively the MCr Al—X coating layer if it is deposited directly on the metal substrate surface (11) or the substrate matching layer (31) if it is deposited on the metal substrate surface (11) exhibits: ° epitaxial growth in part or totally, or ° heteroepitaxial growth in part or totally.

A coated substrate has a substrate and a coating system having one or more ceramic layers. At least a first layer of one of the one or more ceramic layers is a columnar layer having as-deposited columns and intercolumn gaps. The intercolumn gaps have a mean width at least one of: at least 4.0 micrometers; and at least 1.5% of a thickness of said first layer.

A coated component including a slotted ceramic coating with a reactive phase coating disposed thereon for improved resistance to environmental contaminant compositions, along with methods of its formation, is provided. The coated component may include a substrate defining a surface, a ceramic coating disposed on the surface of the substrate, and a reactive phase coating disposed on the layer of environmental contaminant compositions. The ceramic coating includes a plurality of slots disposed in the ceramic coating forming segments of ceramic coating material.

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.

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 disclosure provides a eutectic ceramic thermal barrier material and a preparation method thereof, which relates to the field of composite materials. The present disclosure provides a eutectic ceramic thermal barrier material comprising a nickel-based superalloy substrate, an intermediate binding layer and a eutectic ceramic cladding layer stacked sequentially; the intermediate binding layer comprises a NiCoCrAlY binding layer; the eutectic ceramic cladding layer comprises an Al.sub.2O.sub.3/GdAlO.sub.3 binary eutectic ceramic coating or an Al.sub.2O.sub.3/GdAlO.sub.3/ZrO.sub.2 ternary eutectic ceramic coating. The eutectic ceramic thermal barrier material provided by the present disclosure has good high temperature resistance, good oxidation resistance and excellent mechanical properties.

High temperature stable thermal barrier coatings useful for substrates that form component parts of engines such as a component from a gas turbine engine exposed to high temperatures are provided. The thermal barrier coatings include a multiphase composite and/or a multilayer coating comprised of two or more phases with at least one phase providing a low thermal conductivity and at least one phase providing mechanical and erosion durability. Such low thermal conductivity phase can include a rare earth zirconate and such mechanical durability phase can include a rare earth a rare earth aluminate. The different phases are thermochemically compatible even at high temperatures above about 1200° C.

A thermal barrier coated component, such as a turbine blade formed from a superalloy substrate, includes a thermal barrier coating applied onto the substrate. A metallic bond coat layer is on the substrate and includes rare-earth luminescent dopants. A ceramic top coat layer is on the bond coat layer. A temperature sensing thermally grown oxide (TGO) layer is formed at the interface of the bond coat layer and ceramic top coat layer. The temperature sensing TGO layer includes grown rare-earth luminescent ions migrated from the metallic bond coat layer in an amount sufficient to enable luminescence sensing of the TGO layer for real-time phosphor thermometry temperature measurements at the TGO layer.