Embodiments of the present disclosure are directed to an article and methods of forming the article. The article includes a thermal barrier coating disposed on a substrate. The thermal barrier coating includes a thermal barrier material and partially filled surface-connected columnar voids. The partially filled surface-connected columnar voids are interspersed with the thermal barrier material in the thermal barrier coating. At least some of the partially filled surface-connected columnar voids include a calcium-magnesium-aluminum-silicon-oxide (CMAS)-reactive material disposed within, such that the CMAS-reactive material is physically separated from the substrate by a columnar cavity having an aspect ratio greater than 3.

A manufacturing method is provided. During this method, a preform component is provided for a turbine engine. The preform component includes a substrate. A meter section of a cooling aperture is formed in the substrate. An internal coating is applied onto a surface of the meter section. An external coating is applied over the substrate. A diffuser section of the cooling aperture is formed in the external coating and the substrate to provide the cooling aperture.

A manufacturing method is provided. During this method, a preform component is provided for a turbine engine. The preform component includes a substrate. A preform meter section and a preform diffuser section are formed in the substrate. An internal coating is applied to at least the preform meter section to provide a meter section of a cooling aperture. External coating material is applied over the substrate. The applying of the external coating material forms an external coating over the substrate. The applying of the external coating also builds up the external coating material within the preform diffuser section to form a diffuser section of the cooling aperture.

A method for coating a substrate having a cavity structure, in particular a cooling structure, inside the substrate, wherein the cavity structure includes openings in the surface of the substrate. At least one bonding layer, in particular a diffusion layer, or at least one metallic layer is applied onto the substrate, in particular onto the surface of the substrate, and subsequently at least one thermal protection layer is applied onto the at least one diffusion layer by using a plasma spray physical vapour deposition (PS-PVD) method, a hollow cathode sputtering method or a suspension plasma spray (SPS) method.

A blade for a gas turbine engine comprises a blade portion having a first end and a second end and an engagement portion including a first surface coupled to the second end of the blade portion and a second surface coupled to the second end of the blade portion, the first and second surfaces arranged to extend divergently away from one another. The engagement portion is adapted for coupling to a wheel included in a gas turbine engine wheel.

A method for applying a coating 1 to a surface 2 of a mullite material 3 is specified, which comprises pretreating the surface 2 of the mullite material 3 by means of a plasma-chemical process in which molecular hydrogen is excited in such a way that plasma-activated hydrogen is produced S1, and applying an aluminum oxide-containing layer 4 by means of a PVD process to the pretreated surface 2 of the mullite material 3 S2. Furthermore, a mullite material 3 with a coating and a gas turbine component with such a mullite material 3 are specified.

A composite bond coat may include a matrix and a reinforcing component. The matrix may be formed from silicon-based particles, and the reinforcing component includes silicon-based ceramic particles. The composite bond coat may be formed by introducing a precursor composition into a plume generated by a thermal spray gun to generate a thermal spray stream. The thermal spray stream may be directed at a major surface defined by a substrate of the component to form the composite bond coat. The precursor composition includes the matrix component and the reinforcing component.

A coating system for coating a part (10), such as a turbine blade or vane, has a mask (14) positioned adjacent to a first portion (16) of the part (10) to be coated and a mechanism (30) for moving the mask (14) relative to the part (10). The mechanism (30) may be a gear mechanism or a magnetic mechanism.

The thermal barrier coating includes reactive gadolinia in its microstructures and the embedded gadolinia effectively reacts with CMAS contaminant reducing the damage from CMAS. Moreover, a method to produce a CMAS resistant thermal barrier coating can include a post-treatment to the thermal barrier coating with the reactive gadolinia suspension in sol-gel state.

A method for manufacturing a blade (1) for a turbomachine, the blade having a hardfacing on its tip (4) and an erosion-protection coating (13) at least on its airfoil (3) is provided. Initially, a blade tip hardfacing is applied to the blade tip and, subsequently, a mask (10) is positioned in the region of the blade tip hardfacing, the mask covering the blade tip hardfacing, and, subsequently, the erosion-protection coating is deposited. The mask is removed after the erosion-protection coating is completed. A blade for a turbomachine, the blade having a hardfacing on its tip (4) and an erosion-protection coating (13) at least on its airfoil (3) is also provided. The erosion-protection coating at least partially covers the blade tip hardfacing, and the thickness of the erosion-protection coating decreases continuously in and/or toward the region of the blade tip hardfacing.