A coated component, along with methods of its formation and use, is provided. The coated component may include a substrate having a surface, a first refractory layer on the surface of the substrate, a silicon-based bond coating on the first refractory layer, and an environmental barrier coating on the silicon-based bond coating. The silicon-based bond coating includes a silicon-phase contained within a refractory phase such that, when melted, the silicon-phase is contained within the refractory phase and between the surface of the substrate and an inner surface of the environmental barrier coating.

A method for coating a substrate includes spraying a combination of powders. The combination of powders includes: Hf.sub.0.5Si.sub.0.5O.sub.2; Zr.sub.0.5Si.sub.0.5O.sub.2; and, optionally, at least one of HfO.sub.2 and ZrO.sub.2. A molar ratio of said Hf.sub.0.5Si.sub.0.5O.sub.2 and HfO.sub.2 combined to said Zr.sub.0.5Si.sub.0.5O.sub.2 and ZrO.sub.2 combined is from 2:1 to 4:1. A molar ratio of said Hf.sub.0.5Si.sub.0.5O.sub.2 to said HfO.sub.2 is at least 1:3.

A method for coating a substrate includes spraying a combination of powders. The combination of powders includes: Hf.sub.0.5Si.sub.0.5O.sub.2; Zr.sub.0.5Si.sub.0.5O.sub.2; and, optionally, at least one of HfO.sub.2 and ZrO.sub.2. A molar ratio of said Hf.sub.0.5Si.sub.0.5O.sub.2 and HfO.sub.2 combined to said Zr.sub.0.5Si.sub.0.5O.sub.2 and ZrO.sub.2 combined is from 2:1 to 4:1. A molar ratio of said Hf.sub.0.5Si.sub.0.5O.sub.2 to said HfO.sub.2 is at least 1:3.

An airfoil includes an airfoil wall that defines a leading end, a trailing end, and suction and pressure sides that join the leading end and the trailing end. The airfoil wall is formed of a silicon-containing ceramic. A first environmental barrier topcoat is disposed on the suction side of the airfoil wall, and a second, different environmental barrier topcoat is disposed on the pressure side of the airfoil wall. The first topcoat is vaporization-resistant and the second topcoat is resistant to calcium-magnesium-aluminosilicate.

An airfoil includes an airfoil wall that defines a leading end, a trailing end, and suction and pressure sides that join the leading end and the trailing end. The airfoil wall is formed of a silicon-containing ceramic. A first environmental barrier topcoat is disposed on the suction side of the airfoil wall, and a second, different environmental barrier topcoat is disposed on the pressure side of the airfoil wall. The first topcoat is vaporization-resistant and the second topcoat is resistant to calcium-magnesium-aluminosilicate.

A coating according to an exemplary embodiment of this disclosure, among other possible things includes a bond coat including gettering particles and diffusive particles dispersed in a matrix, a top coat disposed over the bond coat, and an intermediate layer between the bond coat and the top coat. The intermediate layer includes non-silicate oxide particles dispersed in a matrix. An article and a method of protecting a ceramic-based substrate are also disclosed.

A coating according to an exemplary embodiment of this disclosure, among other possible things includes a bond coat including gettering particles and diffusive particles dispersed in a matrix, a top coat disposed over the bond coat, and an intermediate layer between the bond coat and the top coat. The intermediate layer includes non-silicate oxide particles dispersed in a matrix. An article and a method of protecting a ceramic-based substrate are also disclosed.

An airfoil includes an airfoil wall that defines a leading end, a trailing end, and suction and pressure sides that join the leading end and the trailing end. The airfoil wall is formed of a silicon-containing ceramic. A first environmental barrier topcoat is disposed on the suction side of the airfoil wall, and a second, different environmental barrier topcoat is disposed on the pressure side of the airfoil wall. The first topcoat is vaporization-resistant and the second topcoat is resistant to calcium-magnesium-aluminosilicate.

An airfoil includes an airfoil wall that defines a leading end, a trailing end, and suction and pressure sides that join the leading end and the trailing end. The airfoil wall is formed of a silicon-containing ceramic. A first environmental barrier topcoat is disposed on the suction side of the airfoil wall, and a second, different environmental barrier topcoat is disposed on the pressure side of the airfoil wall. The first topcoat is vaporization-resistant and the second topcoat is resistant to calcium-magnesium-aluminosilicate.

A process of coating a substrate containing silicon with an environmental barrier coating, comprising altering a surface of the substrate and applying an environmental barrier layer to the surface of the substrate.