A method for producing a thermal spray powder includes: a preparing step of preparing a powder mixture containing a first particle made from zirconia-based ceramic containing a first additive agent and a second particle made from zirconia-based ceramic containing a second additive agent, the powder mixture having a 10% cumulative particle diameter of more than 0 μm and not more than 10 μm; and a secondary-particle producing step of producing a plurality of secondary particles each of which includes the first particle and the second particle sintered with each other.

A ceramic material which contains yttrium oxide as stabilizers and at least one of the materials erbium oxide or ytterbium oxide provides a phase having sintering stability for a ceramic material for ceramic layers and a ceramic layer system which maintain the mechanical and thermal properties for a long time even when used at high temperatures.

An article may include a substrate defining at least one at least partially obstructed surface. The substrate includes at least one of a ceramic or a ceramic matrix composite. The article also may include a multilayer, multi-microstructure environmental barrier coating on the at least partially obstructed substrate. The multilayer, multi-microstructure environmental barrier coating includes a first layer comprising a rare earth disilicate and a substantially dense microstructure; and a second layer on the first layer. The second layer includes a columnar microstructure and at least one of a rare earth monosilicate or a thermal barrier coating composition comprising a base oxide comprising zirconia or hafnia; a primary dopant comprising ytterbia; a first co-dopant comprising samaria; and a second co-dopant comprising at least one of lutetia, scandia, ceria, gadolinia, neodymia, or europia.

Disclosed is a method of making a seal comprising fabricating a seal body that includes a first friction surface including nickel and cobalt. The first friction surface on the seal body is contacted with a metal counter-body surface including nickel. Pressure and heat is applied between the seal body and the counter-body, and motion is applied between the seal body and the counter-body with respect to each other in a direction parallel to the first friction surface, followed by separating the seal from the counter-body.

A method for forming a porous barrier coating on a substrate without substantial chemical segregation includes the steps of providing or obtaining a barrier coating material in powdered form and spraying the barrier coating material onto the substrate using air plasma spraying. The air plasma spraying is performed using an average homologous surface temperature of the depositing particles in a range of about 1.25 to about 1.5 and a particle velocity in a range of about 300 m/s to about 500 m/s. The depositing particles are fully molten.

A method of manufacturing a CMC structure includes infiltrating a porous substrate with a composite material and performing a first densification on the infiltrated porous substrate, forming a first densified porous substrate, wherein the first densification includes techniques selected from the group of techniques comprising photonic curing, photonic sintering, pulsed thermal heating, or combinations thereof.

The present disclosure discloses a rare earth tantalate ceramic resisting corrosion of a low melting point oxide. A general chemical formula of the ceramic is RETaO.sub.4. A method for preparing the ceramic includes: weighing RE.sub.2O.sub.3 powder and Ta.sub.2O.sub.5 powder and adding to a solvent to mix, and ball milling the mixed solution with a ball mill to obtain powder A; drying the powder A, and sieving the powder A for a first time to obtain powder B; placing the powder B in a mold for compaction, pre-sintering the powder B to form a block C, cooling the block C to room temperature, grounding the block C with a grinder, and sieving the block C for a second time to obtain powder D; and sintering the powder D to obtain the rare earth tantalate ceramic. The ceramic has high density and strong corrosion resistance to low melting point oxides.

A ceramic matrix composite (CMC) component includes at least one seal surface, the at least one seal surface disposed adjacent an interfacing surface for providing a seal therebetween; and a coating disposed on the seal surface. The coating includes an aluminum oxide and/or a silicon dioxide.

A blade (10) for a turbine engine that includes an internal cooling system (56) formed from at least one cavity (58) positioned within a generally elongated airfoil (12). A squealer tip (36) and at least one densified oxide dispersion strengthened layer (38) extend radially from a radially outer tip cap (70) of the blade (10), the tip cap (70) having a tip cap upper surface (50).

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.